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DSG-423 Service Manual - Coulson Compression & Measurement

1. Crankshaft Pulley Crankshaft Front Seal Crankshaft Front Seal Engine Front Cover 2 41 111 1 ea Engine Front Cover enne enne Timing Drive Components eee en nenne enne nennen nns Timing Drive Components Installation Valve Spring e Engine Front Cover 2 1 1 Engine Front Cover 1 eene nennen nennen nnn Timing Drive Components nnns Timing Drive Components Installation Valve Spring Removal eec decet no qued go d anth Valve Spring Recreo vn eap nee oe ead ce u
2. 01 3 Battery Handling and Chargirig EHE re ede ed e digo 01 4 EOPWald aont nter ete 01 5 Engine ERES 01 5 Parts And Service in nio RD RERUM OREL US 01 5 Descriptioncand Operation p E i Ee eet ehe ee Pe d hd 01 5 Diagnosis and Testing 00186 2 LE 01 6 Inspection and Verification 01 7 m S 01 7 PCV System Malf rnctlon erai niter deckt ___________ 01 10 Engine Oil 01 10 op eb oe oie p tede i TE Test io dde aero 01 12 Cylinder Leakage Detection 22 2 24114 4 1 ieai sene innen neben E anne ada 01 13 Intake Manifold Vacuum 01 13 Excessive Engine Oil CONSUMPTION 01 15 Oil Pressure Pra erect p en bd 01 16 Valve Train Analysis Static aiii ne teet cede bee ende de ee ed de de eaa Ene dea 01 17 Valve Train Analysis 01 17 Camshaft Lobe iei diede ceu dd cle dee dae edd aa 01 18 Hydraulic Valve Lash 7 01 20 General Servic
3. 01 35 eee lada 01 35 iit t iip EUM iip p IMG 01 36 Cylinder Bore d Le RC nde te ts 01 36 Cylinder Block Repair Cast Iron Porosity 01 37 Cylinder Block Core Plug eee enne enne enne 01 37 Cylinder Head DISTOFtIOn 1i rime UM 01 37 Spark Plug ener e tae 01 39 Exhaust Manifold 01 40 uwiellfe EiS 01 41 01 2 DSG 423 GENERAL INFORMATION GENERAL INFORMATION Introduction This section covers various engine tests adjustments service procedures and cleaning inspection procedures Engine assembly and service specifications appear at the end of the Section 02 For engine disassembly assembly installation adjustment procedures and specifications refer to Section 02 This engine incorporates a closed type crankcase ventilation system To maintain the required performance level the fuel System ignition system an
4. 05 8 Thermostat Operational 05 8 General Service Procedurses caneret tenere exe de sant cvecs veg ceeecenacesexedevuctevecssueveuseedecteveessneetes 05 9 Draining the Cooling 05 9 Flushing the Cooling SyStem o ette te e d vei cota 05 9 Filling the Cooling 05 9 Removal and Installation sii iic c cccececcccessecteccessstceeeesssecneceenseeceescessctereeeuesecesedensecteeseasecterseessseceerendeceesaveseeceeids 05 10 Drive Removal M 05 10 Drive Belt Installatigri eue eere 05 10 Belt Tensioner 05 10 Idler Pulley 05 10 Radiator Hose Removal seeria AEA e dete gii ett ik na uite ae aee dei Le 05 11 Radiator Hose 05 11 Thermostat Housing 05 12 Coolant Pump 05 13 Olitlet Pipe Replacement icai cerra
5. Oil Level Indicator amp Tube Oil Pan Removal e de est teme ae adap ined e ad aa deans Oil Par Installation cz o oet ton dp d nidi Oil Pickup Tube caste vans eaten ete ee ee Oil Pump Installation eoi aei nl cade due ro us ee ere T dare Rae dde eda rides de ERE ee ee Flywheel Flexplate Oil Pickup Tube DSG 423 ENGINE INDEX Subject Removal And Installation Oil Pump Removal E E e DRE RR RUE Oil Pump sInstallation xot He een Mee tetas las Flywheel Flexplate Crankshaft Rear Seal Retainer Crankshaft Rear Seal Retainer Installation 02 Disassembly amp Assembly Engine Disassembly er e Lu e ER r aid RU Cylinder Head 1 1 1
6. 04 31 Spring Lock Coupling Type 04 32 Spring Lock Coupling Type 04 32 Quick Connect Coupling Type 04 33 Quick Connect Coupling Type 04 33 Quick Connect Coupling Type Il 04 33 Quick Connect Coupling Type 04 34 Removal and Installation 1 Ice ede rene cdeacedtueevanunducese anni rete 04 35 Fuel Rail amp Injectors 04 35 Actuators REMOVAL euh 04 36 Actuator Installatiori 2 eL e ee Dee 04 36 SPOCIPICACIONS pee mE 04 37 04 1 DSG 423 FUEL SYSTEM CAUTIONS amp WARNINGS WARNING DO SMOKE OR CARRY LIGHTED OPEN FLAME WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
7. 01 26 EHE 01 27 Piston Ring End Gap t 01 27 Piston Ring to Groove Clearance 2 01 28 Crankshaft Connecting Rod Journal 01 28 Crankshaft Connecting Rod Journal 01 28 Connecting Rod Cleaning dea ne de aene dada 01 28 Connecting Rod Larger End 01 29 Piston Pin Diamieter e ere eee 01 29 Connecting Rod Bushing 01 29 Connecting Rod Bend 01 29 01 1 DSG 423 GENERAL INFORMATION INDEX CONT Subject Page General Service Procedures Gonnectirigi Od TWISE c Ee teet CR ede E eR UR 01 29 Connecting Rod Piston Pin Side 01 30 Connecting Rod Journal 01 30 Bearing Inspection etg ere ten tee teer tbe ce tede ld i Ep ide aed ug 01 31 Roller Follower 01 31 Hydraulic Eash
8. eruere mM Cylinder Head Assembly eee eiie ee iade one aenean seda da acne Engine Assembly RERUM mt msn reset eos Adjustments Malve Gleararice Gheck Specifications 02 2 DSG 423 ENGINE GENERAL INFORMATION Engine The DSG 423 is a 4 valve per cylinder dual overhead cam engine The engine block is cast aluminum with iron cylinder liners Connecting rods are made of sintered metal the crankshaft is nodular iron with five main bearings The cam cover oil pan and front cover are also made of aluminum The dual camshafts are chain driven with an automatic tensioning system The valve train components are alternate fuel ready Spark is delivered by an individual coil on plug ignition system A broadband knock sensor is calibrated for individual cylinder use All fuels are controlled in closed loop Gasoline is delivered by sequential port fuel injection The electronic engine management system has built in engine protection against detonation high coolant temperature low oil pressure engine overspeed starter engagement while engine is running NOTE A set of metric wrenches are required to service the DSG 423 engine WARNING TO AVOID THE PO
9. 8H 8L 8 J0j259uuo JojeJouoc 8 zm cru EL 71 VOL VS esnd 459 c4 MSA 23 Ee llle cuml d e e O vL Bury f eyeg 08 17 DSG 423 ENGINE CONTROLS Engine Controls Sensors 1 of 2 doo NLA l NLY AS IXIAS 1 JULIO XueJ2 194 s PEDEM MIU Rep TEC DE SZ 02 50 8 8L aaa qu A9 ist e qu A9 ist 300 10d suan 013611 ooejoju v Josuag auljoses 9 gt 01 8 105 5 1050 105 LH2 duie uonisod uonisod yeusuie AD dVINL ejnssaJg 2 08 18 DSG 423 ENGINE CONTROLS Engine Controls Sensors 2 of 2 439 TH eit Vi Vit 9 5 914 due 093 O93 9 E eL er ae 6 ec 02 29 S 8L 8 9 8 uuo3 cv o 01 on onsouBeiq ol 68 HN 9G 8 Josueg 105 5 SZOH
10. i manu m Neve 1 VOL VOL 54 v3 4 3 ld 1 MEM PER EM ERES e ome 4 je 3e Es 4 siu Asayeg NENNEN db 08 14 DSG 423 ENGINE CONTROLS Ignition System d29 109 9 gz VI 105 yseds yseds penc Ee Nie UR NE MEME D Rcs CR 8L QN 3A 8L 1A 9Q 8L M8 3A 84 1 1 z 1 1 4 105 105 _ 1 1 3 Uuonub J 9b 9b qu 9b qu 9b 9 9 qu 9b quU 9b qu 9b jeueg E mc 08 15 DSG 423 ENGINE CONTROLS Starting System 1 uuo doo ugs EI ue _ bL XM x SL 6 24 Md HM 9b Md 81 9 28 18 69 EET PUE 5 D E i d 98 91 3 8L 1 9L Bury 84 8L Le WS 74 Elec J uoniub 08 16 DSG 423 ENGINE CONTROLS Charging System Aejoy 1eyejs jan 98 98 p L
11. 03550 Valve Spring Out of Square Measure the out of square on each valve spring Turn the valve spring and observe the space FPPO3548 between the top of the valve spring and the square Replace the valve spring if out of specification 2 Reface the valve seat 3 Clean the sharp edges left by reaming 03551 01 33 DSG 423 GENERAL INFORMATION Valve Spring Compression Pressure Special Tool s Valve Clutch Spring Tester TOOL 6513 DD or Equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 FPP10035 e Use the Valve Clutch Spring Tester to check the valve springs for proper strength at the specified valve spring length FPP03552 Valve and Seat Refacing Measurements NOTE After grinding valves or valve seats check valve clearance e Check the valve seat and valve angles Valve Seat Width e Measure the valve seat width If necessary grind the valve seat to specification 03554 Valve Seat Runout Usethe Valve Seat Runout Gauge to check valve seat runout 03555 03553 01 34 DSG 423 GENERAL INFORMATION Flywheel Inspection Oil Pump Rotor Inspection Special Tool s Inspect the oil pump rotor tips for damage or wear Dial Indicator with Bracketry NES TOOL 4201 C
12. NE 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 NOM Rt NOM TEMP TEMP OHMS VOLTS 40 40 925 021 4 54 35 81 673 787 4 50 80 22 496 051 4 46 25 13 368 896 4 41 20 4 276 959 4 34 15 5 209 816 4 25 10 14 160 313 4 15 5 23 123 485 4 02 0 32 95 851 3 88 5 41 74 914 3 71 10 50 58 987 3 52 15 59 46 774 3 32 20 68 37 340 3 09 25 77 30 000 2 86 30 86 24 253 2 62 85 95 19 716 2 39 40 104 16 113 2 15 45 118 13 236 1 98 50 122 10 926 1 72 55 131 9 061 1 52 60 140 7 548 1 34 65 149 6 332 1 18 70 158 5 335 1 04 75 167 4 515 91 80 176 3 837 79 85 185 3 274 70 90 194 2 804 61 95 203 2 411 53 100 212 2 080 47 105 221 1 801 41 110 230 1 564 36 115 239 1 363 32 120 248 1 191 28 125 257 1 044 25 130 266 918 22 135 275 809 19 140 284 715 17 145 293 633 15 150 302 563 14 Voltage values calculated for VREF 5 volts may vary 15 due to sensor and VREF variations 08 5 DSG 423 ENGINE CONTROLS Cylinder Head Temperature
13. mod desta Pn Deor duet uae nte aet en 06 11 Voltage Regulator Replacement 06 11 Generator Pulley 06 12 Battery cete a cte e iei M Eee ETE MISERE neal Gee et na ERA 06 13 Battery Installation Teri a untere capte 06 13 rdg aM 06 14 06 1 DSG 423 CHARGING SYSTEM CAUTIONS amp WARNINGS SHIELD EYES EXPLOSIVE EVITER LES ETINCELLES o DANGERIPOISON Ke SULPHURI FPP01101 The handling and correct use of lead acid batteries is not as hazardous provided that sensible precautions are observed and that operatives have been trained in their use and are adequately supervised It is important that all labeling on the battery is carefully read understood and complied with The format of the following symbols and labels is common to most brands of lead acid battery FIRE AND OR BURN HAZARD Could result in death or serious injury Close contact can cause serious burns or fire Allow Catalyst to cool completely before servicing CAUTION Observe all manufacturers instructions when using charging equipment WARNING BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES WHICH CAN CAUSE PERSONAL INJURY THEREFORE DO NOT ALLOW FLAMES SPARKS OR ANY IGNITED OBJECT TO COME NEAR THE BATTERY WHEN CHARGING OR WORKING NEAR A BATTERY
14. CAUTION Only turn the engine in the normal direction of rotation Installing the special tool in this next step will prevent the engine from being rotated in the clockwise direction However the engine can still be rotated in the counterclockwise direction 3 Install special tool 303 507 4 Position the oil pump assembly and tighten the bolts in the sequence shown in 2 stages Stage 1 Tighten to 10 Nm 89 Ib in Stage 2 Tighten to 20 Nm 15 Ib ft 5 Position a new oil pump pickup tube gasket and the pickup tube and tighten 4 bolts in the sequence shown e Tighten to 10 Nm 89 Ib in 02 36 DSG 423 ENGINE 6 Using special tool 303 328 install a new crankshaft rear seal and retainer plate assembly Tighten bolts in the sequence shown Tighten to 10 Nm 89 Ib in NOTE If oil pan is not secured within 4 minutes the sealant must be removed and the sealing area recleaned Refer to Engine Cleaning on page 34 of this section 7 Apply a 2 5 mm 0 1 in bead of silicone gasket and sealant to the oil pan Install the oil pan and bolts Tighten in the sequence shown e Tighten to 25 Nm 18 lb ft 2 4 ENT 43 8 Install cylinder head alignment dowels until fully seated in block NOTE If cylinder head is not secured within 4 minutes the sealant must be removed and the sealing ar
15. Crankthe engine and observe the amount of measured No vacuum Is the measured vacuum outside the specifications Refer to Diagnostic Aids below Diagnostic Aids Fuel Lock Solenoid The fuel lock is an electronic solenoid that is opened to allow fuel flow when the key is turned ON High temperatures may cause the solenoid to become intermittent not opening to supply sufficient fuel pressure Fuel Filter There is a filter element located in the inlet of the fuel lock which may become clogged and limit fuel flow especially at low tank pressures Check the filter and replace or clean as necessary Fuel Line Restrictions The vehicle specifications table specifies the fuel line to be a certain size If the fuel line from the tank to the fuel lock is not the proper size or any valves or fittings with flow restrictive characteristics are used the fuel flow will not be sufficient to the converter with low tank pressure Correct any fuel line or fitting restrictions Mixer Assembly Carburetor It is possible that a backfire may have caused the fuel valve to partially come off of it s retainer and restrict fuel check the mixer fuel valves see section 475 1 for disassembly Regulator Assembly Converter If no other problems have been identified replace the fuel management assembly with a known good part of the same pressure range Retest 04 13 DSG 423 FUEL SYSTEM The pinpoint tests below should be performed after t
16. Engine related problem Refer to Section 01 Diagnosis and Testing Starter cranks slowly Low Battery Charge or replace battery refer to section 6 High resistance or loose connections in starter solenoid battery feed or ground circuit Check that all connections are secure Ring gear runout excessive Replace ring gear Defective starter Replace starter motor Starter remains engaged and runs with engine Shorted ignition switch Replace ignition switch Battery cable touching solenoid S terminal defective or mispositioned cable Replace or relocate cable Defective starter Replace starter motor Starter clicks and engages but engine will not crank Hydrolocked cylinder Remove all plugs one at a time while checking for fluid in cylinders Seized main or rod bearing Repair as needed Refer to Section 01 07 6 DSG 423 STARTER Motor Feed Circuit Voltage Drop Test Slow cranking is often caused by high resistance in the battery cables or connections especially in cold weather After all batteries check good and terminals are clean and tight check the starter motor feed circuit 1 Connect a remote starter switch between the starter S terminal and the battery positive 4 terminal 2 Connect a digital multimeter positive lead to the battery positive post Connect negative lead to the starter solenoid M terminal Remote Start Swit
17. 08 43 Camshaft Position CMP Sensor Replacement enne nnns 08 43 Crankshaft Position Sensor 08 43 Crankshaft Position Sensor 08 44 Cylinder Head Temperature CHT Sensor 08 45 Engine Coolant Temperature ECT Sensor Replacement sss 08 45 Heated Oxygen Sensor 25 07 08 45 Knock Sensor KS 08 46 Temperature Manifold Absolute Pressure TMAP Sensor 08 46 Actuator Throttle Position TP Sensor Replacement sss 08 46 SPECIFICATIONS AM 08 47 08 1 DSG 423 ENGINE CONTROLS GENERAL INFORMATION GCP and Sensors CMP Sensor CKP Sensor TMAP Sensor HO2S Sensor KS Sensor ECT Sensor Actuator Fuel Injector 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 temp
18. Exhaust Gas Recirculation Diagnostic Valve EGR Diagnostic EGR Diagnostic Valve Exhaust Gas Recirculation System EGR System EGR System Exhaust Gas Recirculation Temperature EGRT EGR Temperature Exhaust Gas Recirculation Temperature Sensor EGRT Sensor Recirculated Exhaust Gas Temperature Sensor REGTS Exhaust Gas Recirculation Thermal Vacuum Valve EGR TVV EGR Thermal Vacuum Valve EGR TVV Exhaust Gas Recirculation Vacuum Regulator Solenoid EGR Vacuum Regulator Solenoid EGR Vacuum Regulator Solenoid EVR Solenoid Exhaust Gas Recirculation Vacuum Regulator Valve EGR Vacuum Regulator Valve EGR Vacuum Regulator Valve EVRV Exhaust Gas Recirculation Valve EGR Valve EGR Valve EGRV Exhaust Gas Recirculation Valve Control EGR Valve Control EGR Valve Control EGRVC Exhaust Gas Recirculation Valve Position Sensor EGR Valve Position Sensor EGR Valve Position Sensor EVP Sensor Fan Control FC Electro Drive Fan Control EDF Control Engine Coolant Fan Control High Electro Drive Fan Control HEDF Control Radiator Fan Control Fan Control Module FC Module Fan Control Module 09 9 DSG 423 METRICS New Term New Acronym Old Terms Acronyms Fan Control Relay FC Relay Fan Motor Control Relay Radiator Fan Relay Feedback Pressure Exhaust Gas Recirculation Feedback Pressure EGR Pressure
19. Remove spark plugs and mark location using a piece of masking tape Inspect condition of spark plug Refer to Spark Plug Inspection on page 7 of this section Spark Plug Installation 1 03 6 Apply a few drops of engine oil to spark plug threads near tip Adjust spark plug gap to 1 25 1 35 mm 0 049 0 053 in Install spark plugs to original locations and tighten to 11 Ib ft 15 Nm Install coil Refer to Ignition Coil Replacement on page 6 of this section DSG 423 IGNITION SYSTEM SPECIFICATIONS GENERAL SPECIFICATIONS Firing Order 1 3 4 2 Spark Plug Type AGSF32YPC Gap 1 25 1 35 mm 0 049 0 053 in Silicone Brake Caliper Grease ESE M1C171 A and Dielectric Compound XG TORQUE SPECIFICATIONS Description Nm Ib ft Ib in Spark plugs 15 11 132 Coil bolts 8 6 71 03 7 DSG 423 FUEL SYSTEM INDEX Subject Page Cautions amp ices vsc sci TR 04 2 General Information 04 3 DESCrIPUON x En 04 3 Gir n 04 4 Fuel System 04 4 Wiring 8 04 5 General Information Dry 04 7 Descriptions ceo tede itis Eat
20. 090423 An identification Decal is affixed to valve cover of the engine The decal contains the engine serial number which identifies this unit from all others Use all numbers when seeking information or ordering replacement parts for this engine Parts and Service Replacement parts can be obtained through your local EDI Distributor listed in the back portion of this manual They also may be found in the yellow pages under Engines or contact EDI directly at 1 800 220 2700 EDI Distributors are equipped to perform major and minor repairs They are anxious to see that all of your maintenance and service needs are quickly and courteously completed Description and Operation Section 01 of this manual covers general procedures and diagnosis of the engine system including base engine repair procedures that would be common to most engines Refer to Section 02 for more specific service information on the DSG 423 engine The DSG 423 engine incorporates a closed positive crankcase ventilation system and an exhaust emission control system The engine s fuel ignition emissions system and exhaust system all affect exhaust emission levels and must be maintained according to the maintenance schedule Refer to the Maintenance and Operator s Handbook or contact your nearest EDI distributor listed
21. 2 Remove or disconnect any component to allow access and removal of the knock sensor Disconnect KS serisor electrical connector 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 Remove bolt and TMAP Sensor 5 Reverse procedure to install 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 4 ritis gt Actuator Throttle Position TP Sensor Replacement need procedure 08 46 DSG 423 ENGINE CONTROLS SPECIFICATIONS GENERAL SPECIFICATIONS TORQUE SPECIFICATIONS Description Nm Ib ft Ib in CHT Sensor 12 9 CMP Sensor 7 62 CKP Sensor 7 62 ECT Sensor HO2S Sensor 40 30 Knock Sensor 20 15 TMAP Sensor SPECIAL TOOLS HO2S Removal Tool 303 476 08 47 DSG 423 METRICS INDEX Subject Page Miro ducto enrio 09 2 Nomenclature for BoRS m 09 2 Bolt Strength 09 3 Hex Nut Strength Identification eene enne nennen nnne nent nnne nenn
22. 5 2 5 o 5 LI lI lc E e BK WH Grounding Ring 04 9 18 DG VT 14 15 CAN1 1 DSG 423 FUEL SYSTEM DIAGNOSIS AND TESTING LPG Symptom Chart Symptom Go to Engine Cranking But Will Not Start Page 12 Engine Starts But Has Rough Idle Page 14 Engine Idles with Rough Acceleration at Load Page 16 Engine Is Unable To Reach Full Power Page 18 Overall Power Loss Page 12 Engine Misses Page 20 Backfire Page 22 Emissions Failure Rich Mixture Page 24 Emissions Failure Lean Mixture Page 25 Engine Overheats Page 27 Engine Stops Running Dies Page 28 04 10 DSG 423 FUEL SYSTEM Preliminary Test This Pinpoint Test checklist is your guide to the most probable causes of an engine performance complaint when the malfunction is due to the fuel system Test Step Result Action to Take 1 Inspect installation Yes Go to Step 2 Check fuel hose for kings No Repair as necessary Check fuel hose lengths orientation and presence of parts Is everything OK 2 Inspect Fuel System for Supply Leaks Yes Repair the leak e Key OFF No Go to Step 3 e Check for leaks or damaged supply lines from the fuel tank to the fuel lockoff Are there any leaks present 3 Inspect the Fuel System for any loose wires or Yes Repair or Replace as Necessary hoses Key OFF No Go to Step 4
23. Engine Stops Running Dies Continued Test Step Result Action to Take 6 Check air valve operation Yes Refer to section 475 1 for servicing the carburetor Using the WTK 1 test kit connect the vacuum gauge between the carburetor and the FCV valve to measure the carburetor air valve vacuum AVV Service the carburetor see section e With the engine at idle and accelerating observe the No 475 1 and retest aoe to the amount of measured vacuum Diagnostic Aids below Is the measured vacuum non linear and outside the specifications Diagnostic Aids Fuel Lock Solenoid The fuel lock is an electronic solenoid that is opened to allow fuel flow when the key is turned ON High temperatures may cause the solenoid to become intermittent not opening to supply sufficient fuel pressure Fuel Filter There is a filter element located in the inlet of the fuel lock which may become clogged and limit fuel flow especially at low tank pressures Check the filter and replace as necessary Fuel Line Restrictions The vehicle specifications table specifies the fuel line to be a certain size If the fuel line from the tank to the fuel lock is not the proper size or any valves or fittings with flow restrictive characteristics are used the fuel flow will not be sufficient to the converter with low tank pressure Correct any fuel line or fitting restrictions Mixer Assembly Carburetor It is possible that
24. FPP03537 01 29 DSG 423 GENERAL INFORMATION Connecting Rod Piston Pin Side Clearance 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 Measure the clearance between the connecting rod and the piston Verify the measurement is within specification FPP03538 03540 Connecting Rod Journal Clearance Special Tool s Plastigage amp D81L 6002 B or Equivalent Special Service Tools called for by the procedures can be obtained by calling FPRTQ0SE 1 800 ROTUNDA 1 800 768 8632 NOTE The crankshaft connecting rod journals must be within specifications to check the connecting rod bearing journal clearances 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 01 30 DSG 423 GENERAL INFORMATION Bearing Inspection Inspect bearings for the following defects Possible causes are shown Cratering fatigue failure A Spot polishing improper seating B Scratchi
25. SO 1001 199 OL SIML gsr 8L 91 90 8 Lh r fe k 84 NV NVO Xi XL NLH 9d 9d AS YNY HWNS SLI 9 9q g1j 8L 81 8 5 eyeq 2 S is l v _ 9 emoJur yosog 04 6 DSG 423 FUEL SYSTEM GENERAL INFORMATION DRY FUEL Liquid Propane Line Carburetor as Vapor Propane Description the throat and hence on the top of the diaphragm When the pressure on the top of the diaphragm is low enough the diaphragm overcomes the spring force holding it down and lifts and allows fuel to be drawn from the fuel port into the air flow into the engine This engine with the proper fuel equipment can also operate on dry fuel such as LPG Grade 5 and natural gas 1050 BTU ft Natural Gas fuel specification must meet or exceed 38 7 MJ m UK 39 0 MJ m USA Differential in Vaporized propane is introduced into the engine with a pressure on each DIAPHRAGM Vapor Carburetor Pressure is regulated by an overcomes mespina Ln THROTTLE Electronic Pressure Regulator EPR which is controlled ipa ES by the GCP Coolant is circulated through EPR AIR INLET 14 3psi FUEL INLET Operation The dry fuel vapor carburetor is a device by which fuel can be added to passing air flow
26. Block Heater Replacement 1 Drain the cooling system Refer to Draining the Cooling System on page 9 of this section 2 Disconnect the block heater electrical connector Electrical Connector NOTE Do not loosen the screw more than necessary for removal 3 Loosen the block heater screw and twist and slide the block heater to release the retainer clip Discard the retainer clip and remove the block heater 4 Reverse procedure to install 05 14 DSG 423 COOLING SYSTEM Coolant Bypass Replacement 2 Remove or disconnect components as necessary to gain access to the bypass hose 1 Drain the cooling system Refer to Draining the 3 Detach coolant bypass hose from the routing clip Cooling System on page 9 in this section Retainer 4 Disconnect the coolant bypass hose trom the tubes 5 Reverse procedure to install 05 15 SPECIFICATIONS DSG 423 COOLING SYSTEM GENERAL SPECIFICATIONS Coolant Water Mixture 50 50 Pressure Relief Cap Opening Pressure kPa psi 89 124 kPa 13 18 psi Radiator Pressure Test 138 kPa 20 psi Thermostat start to open temperature 90 C 194 Thermostat full open temperature 97 106 C 206 2229 F Coolant Specification WSS M97B51 A1 Motorcraft Premium Gold Engine Coolant TORQUE SPECIFICATIONS Description Nm Ib ft Ib in Block heater 2 18 screw Coolant 25 18
27. Cylinder Head Temperature CHT Sensor Fan Assembly Radiator and Cap Thermostat and Housing Degas Bottle Engine Block Heater e Coolant pump Coolant Walter C Avrea the owner of patents 3 601 181 and RE27 965 has granted Ford Motor Company rights with respect to cooling systems covered by these patents The ECT Sensor is used by the GCP to obtain coolant temperature information Refer to Section 8 for further information on this sensor The coolant fan blade can either draw or push air through the radiator to help cool the system coolant The fan clutch is a thermostatic controlled clutch that controls the fan drive The radiator allows excess heat to be transferred to the air The radiator tanks can not be repaired The radiator cap maintains system pressure This pressure raises the boiling point of the coolant and helps prevent vapor locks in the engine block and cooling system The thermostat prevents coolant flow until it reaches a specified temperature At this temperature it will open and allow coolant flow through the engine and radiator The thermostat and housing are serviced as a unit The radiator degas bottle holds a surplus coolant when the engine is hot It also replenishes coolant back to the System as it cools The degas bottle allows air separation during operation which reduces engine hot spots Coolant Pump The coolant pump circulates the coolant through the engine block and c
28. High Energy Ignition HEI Remote Mount Thick Film Ignition Remote Mount Thick Film Ignition TFI Distributor Ignition Capacitor DI Capacitor Condenser Distributor Ignition Control Module Distributor ICM Electronic Distributor Ignition System Module EDIS Module Distributor Ignition System DI System Electronic Distributor Ignition System EDIS Early Fuel Evaporation EFE Early Fuel Evaporation EFE Electrically Erasable Programmable Read Only EEPROM Electrically Erasable Programmable Read Only Memory Memory E2PROM Electronic Continuous Fuel Injection System Electronic CFI System Continuous Injection System Electronic Continuous Injection System E CIS E Electronic engine Control Electronic EC Electronic Engine Control EEC Electronic Ignition Computer Controlled Coil Ignition Distributorless Ignition DLI Electronic Ignition without distributor Integrated Direct Ignition IDI Electronic Ignition System EI System Direct Ignition System DIS Distributorless Ignition System DIS Electronic Distributorless Ignition System EDIS Engine Control EC Electronic Engine Control EEC Engine Control Module ECM Engine Control Module ECM 09 8 DSG 423 METRICS New Term New Acronym Old Terms Acronyms Engine Coolant Level ECL Engine Coolant Level EC
29. mounted near the crankshaft pulley The CKP Sensor is triggered by teeth on a trigger wheel located on the crankshaft pulley The pulse frequency indicates crankshaft speed and a missing tooth indicates crankshaft position Exhaust Stroke Engine Temperature The Engine Coolant Temperature ECT Sensor sends engine temperature information to the GCP It is located in the rear coolant outlet pipe Fuel Octane Level Adjustment In the event that the engine is operated on dry fuels such as natural gas compressed natural gas CNG or liquefied petroleum gas LGP timing can be modified by GCP Fuel Ignition Coil Driver The GCP switches 4 individual ignition coils on and off at the correct times to give the desired spark advance Ignition timing is adjusted constantly by the GCP Many factors including all the sensor inputs affect the final ignition setting Run Mode The GCP interprets engine speed above 200 rpm as Run Mode The Base Spark advance BSA is calculated by the GCP processing the engine speed input Transient Mode This function is to provide detonation protection when the engine load is increased rapidly by fast opening of the throttle plate Overspeed Mode If the engine speed exceeds 4000 rpm the dwell will be reduced until the speed drops below 4000 rpm 03 3 DSG 423 IGNITION SYSTEM iagram D iring aL 105 8
30. uabAxo pojeoH Josueg 4 gt L e Josuasg SZOH EAT u b xo ea L poakejay 20 20UM QN 3A 81 1001 Jed SUIN OL 3SI QN 3A 81 yoouy 8 08 19 DSG 423 ENGINE CONTROLS Fuel Injectors 429 57 c 57 S1 v S1 L 10 fu 10 fu cue 99 59 29 v9 9 9 9 9L NL 9 eu Vi 4032efu J03oefu 9b Sd Lou 6 n J9MOd 9b 9b 9b 049 08 20 DSG 423 ENGINE CONTROLS Engine Controls Actuator Data Link Connector DLC 429 0 XM XL Z SdL BE LL ee E E DD EE 4 SL v 96 66 28 08 8v Lv LA DGJ 8 1001 199 OL 97 90 sb HWNS 8l SO 1001 199 OL SIML gsr 8L 91 90 8 Lh r fe k 84 NV NVO Xi XL NLH 9d 9d AS HWNS SLI 9 9q g1j 8L 81 8 5 eyeq 2 S is l v _ 9 emoJur yosog 08 21 DSG 423 ENGINE CONTROLS Engine Controls Dry Fuel EPR I
31. 01 40 DSG 423 GENERAL INFORMATION SPECIFICATIONS GENERAL SPECIFICATIONS Epoxy Sealer M3D35 A E Threadlock 262 WSK M2G351 A6 E2FZ 19554 B Super Premium SAESW20 WSS M2C930 A NOTE Ford engines are designed to perform with engine oils that are licensed by the American Petroleum Institute API and oils carrying the most current API classification SJ or greater must be used 01 41 DSG 423 ENGINE NOTE INDEX Subject General Information ead iun AE ase Crankcase Ventilation Engine Cooling System iio eo en iade en Lubrication System een estet ai La RO USER ID Drive Belt SyStem ci eet Ed eio ede em e t i eU id Ignition a eerte ose certe te i need artes e e e E ete ae E IRE be ee ees Eel SVSter itr tette eret Con dee ede ite n et ene ee fex MER iat Removal And Installation Intake Manifold 9 Intake Manifold Camshaft Cover 0 Camshaft Cover 2 n en enne Crankshaft Pulley
32. 1 Clean the oil pump and block mating surface with metal surface prep WARNING OBSERVE ALL WARNINGS AND CAUTIONS AND FOLLOW ALL APPLICATION DIRECTIONS CONTAINED ON THE PACKAGING OF THE SILICONE GASKET REMOVER AND METAL SURFACE PREP 02 26 Install oil pump and 4 bolts in sequence shown in 2 stages Stage 1 Tighten to 10 Nm 89 Ib in Stage 2 Tighten to 20 Nm 15 Ib ft Tightening Sequence Install sprocket and bolt e Tighten to 25 18 Ib ft 4 Install the chain onto the sprockets 5 Install guide and 2 bolts Tighten to 10 Nm 89 Ib in 6 Install tensioner and bolt e Hook tensioner spring around the shoulder bolt Tighten to 10 Nm 89 Ib in Install pickup tube Refer to Oil Pickup Tube Replacement on page 25 of this section Install oil pan Refer to Oil Pan Installation on page 25 of this section Install engine front cover Refer to Engine Front Cover Installation on page 12 of this section 10 Install or reconnect any other component that was removed or disconnected DSG 423 ENGINE Flywheel Flexplate Replacement 1 Remove any components necessary to gain access 1 to the flywheel flexplate 2 Remove the transmission or PTO 3 Remove the pressure plate and clutch if equipped 4 Remove bolts using tool 303 103 CAUTION Special bolts are used for installation Do not use standard bolts
33. 546875 13 891 150 110 6 110 149 1 9 16 5625 14 288 160 118 0 120 162 7 37 64 578125 14 684 170 1254 130 176 3 19 32 59375 15 081 180 132 8 140 189 8 39 64 609375 15 478 5 8 625 15 875 190 140 1 150 203 4 41 64 640625 16 272 200 147 5 160 216 9 21 32 65625 16 669 225 166 0 170 230 5 43 64 671875 17 066 250 1844 180 244 0 11 16 6875 17 463 45 64 1703125 17 859 23 32 171875 18 256 47164 1734375 18 653 3 4 750 19 05 49 64 1765625 19 447 25 32 178125 19 844 51 64 1796875 20 241 13 16 8125 20 638 53 64 828125 21 034 27 32 84375 21 431 55 64 859375 21 828 7 8 875 22 225 57 64 890625 22 622 29 32 90625 23 019 59 64 921875 23 416 15 16 9375 23 813 61 64 953125 24 209 31 32 96875 24 606 63 64 984375 25 003 1 1 00 254 09 6 DSG 423 METRICS 41930 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 New Term New Acronym Old Terms Acronyms Accelerator Pedal AP Accelerator Air Cleaner ACL Thermac Air Cleaner Air Cleaner Element ACL Element Air Cleaner Element ACL Element Air Cleaner Housing ACL Housing Air Cleaner Housing ACH Air Cleaner Housing Cover ACL Housing Cover Air Cleaner Housing Cover ACL Housing Cover Air Conditioning Air Conditioning Air Conditioning Cl
34. Condition Possible Source Action Difficult Starting Damaged starting system Refer to Section 07 Damaged charging system battery Refer to Section 06 Burnt valve Replace valve Worn piston Replace piston and pin Worn piston rings or worn cylinder Repair or replace cylinder blocks Damaged cylinder head gasket Replace cylinder head gasket Damaged fuel system Refer to Section 04 Damaged ignition system Refer to Section 03 Spark plugs gapped incorrectly Check plug gap Damaged hydraulic tappet or hydraulic lash adjuster Replace tappet or lash adjuster Poor Idling Damaged hydraulic lash adjuster or hydraulic lash Replace hydraulic lash adjuster or hydraulic lash adjuster Damaged hydraulic lash adjuster guide or hydraulic lash adjuster Replace hydraulic lash adjuster guide or hydraulic lash adjuster Improper valve to valve seat contact Replace valve or valve seat Damaged cylinder head gasket Replace cylinder head gasket Malfunctioning or damaged fuel system Refer to Section 04 of this manual Malfunctioning or damaged ignition system Refer to Section 03 of this manual Spark plugs gapped incorrectly Check plug gap Malfunctioning or damaged IAC motor or system Refer to Section 03 of this manual Abnormal combustion Damaged hydraulic lash adjuster or hydraulic lash adjuster Replace hydraulic lash adjuster or hydraulic lash adjuster Damaged hydraulic
35. DSG 423 COOLING SYSTEM DIAGNOSIS AND TESTING WARNING REFER CAUTIONS AND WARNINGS AT THE BEGINNING OF THIS SECTION Begin diagnosis by verifying the customer s concern by operating the engine to duplicate the condition The most frequent cooling system complaints are leakage and overheating Either of these problems will soon render the engine inoperable Perform a visual inspection If the inspection reveals an obvious concern that can be readily identified repair as necessary If the concern remains after the inspection determine the symptom s and go to the Symptom Chart The Symptom Chart lists cooling system problems their possible cause and recommended correction Visual Inspection Check for leaks or damage at all hoses connections and hose clamps radiator seams core and drain petcock all block core plugs and drain plugs edges of all cooling system gaskets transmission oil cooler if equipped coolant pump shaft and bushing thermostat head and intake manifold gaskets coolant pump e degas bottle e heater core if equipped and fan clutch e engine coolant temperature sensor and wiring drive belt NOTE A small amount of antifreeze coming out the coolant pump weep hole may be considered normal Examine oil dipstick for evidence of coolant contaminated engine oil white milky appearance check radiator for evidences of oil in coolant leakage at transmission oil c
36. DSG 423 FUEL SYSTEM Engine Misses Continued Test Step Result Action to Take 4 Check carburetor air valve for binding Yes Refer to section 475 1 for servicing the carburetor With the air cleaner removed pull the air valve piston upwards to ensure free movement of the carburetor air valve Is the air valve binding No Go to Step 5 5 Check air valve operation Yes Refer to section 475 1 for servicing the carburetor Using the WTK 1 test kit connect the vacuum gauge between the carburetor and the FCV valve to measure the carburetor air valve vacuum AVV No Refer to Diagnostic Aids Below With the engine at idle and accelerating observe the amount of measured vacuum Is the measured vacuum outside the specifications Diagnostic Aids Fuel Lock Solenoid The fuel lock is an electronic solenoid that is opened to allow fuel flow when the key is turned ON High temperatures may cause the solenoid to become intermittent not opening to supply sufficient fuel pressure Fuel Filter There may be a strainer element located in the inlet of the fuel lock which may become clogged and limit fuel flow especially at low tank pressures Check the filter and replace as necessary Fuel Line Restrictions The vehicle specifications table specifies the fuel line to be a certain size If the fuel line from the tank to the fuel lock is not the proper size or any valves or fittings
37. DSG 423 GENERAL INFORMATION Crankshaft Main Bearing Journal Diameter Crankshaft Main Bearing Journal Taper Measure each of the crankshaft main bearing journal e Measure each ofthe crankshaft main bearing journal diameters in at least two directions diameters in at least two directions at each end of E T the main bearing journal e fitis out of specification replace as necessary e fitis out of specifications replace as necessary T FPP03513 FPP03514 01 23 DSG 423 GENERAL INFORMATION Crankshaft Main Bearing Journal Clearance Special Tool s Plastigage amp D81L 6002 B or Equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 FPP10031 NOTE Crankshaft main bearing journals must be within specifications before checking journal clearance 1 Remove the crankshaft main bearing caps and bearings 2 Lay a piece of Plastigage across the face of each crankshaft main surface FPP03515 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 Ifitis out of specification replace as necessary FPP03516 Bearing Inspection Inspect bearings for the following defects Possible causes are shown Cratering fatigue failure A Spot polishing
38. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY WARNING WHEN WORKING THE AREA OF THE STARTER MOTOR BE CAREFUL TO AVOID TOUCHING HOT EXHAUST COMPONENTS FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY CAUTION A protective cap or boot is provided over the battery input terminal and must be reinstalled after removal CAUTION Be sure to disconnect the battery ground cable before repairing the starter motor WARNING HYDROGEN 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 WARNING TO AVOID INJURY USE PARTICULAR CARE WHEN CONNECTING A BOOSTER BATTERY TO A DISCHARGED BATTERY 07 2 DSG 423 STARTER GENERAL INFORMATION Description The starter motor provides the ro
39. 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 dis charge damage follow these guidelines Do not touch the GCP connector pins or soldered components on the GCP board 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 Ifthe part has been han
40. Idler Pulley Belt NOTE If a major component of the cooling system is renewed such as the radiator water pump etc the system should be flushed and re filled with a 50 solution of Motorcraft Premium Gold engine coolant or equivalent and clean water Refer to Flushing the Cooling System on page 9 of this section Drive Belt Removal NOTE Note belt routing for installation purposes 1 Rotate tensioner counterclockwise to relieve belt tension 2 Remove belt 3 Inspect belt and pulleys Refer to Visual Inspection on page 5 in this section Drive Belt Installation 1 Rotate tensioner counterclockwise to relieve tension 2 Route belt correctly and release tensioner onto belt 3 Run engine for a minute and then turn off 4 Recheck belt routing and groove alignment Belt Tensioner Replacement 1 Remove drive belt Refer to Drive Belt Removal Tensioner on page 10 of this section 2 Remove bolt Remove belt tensioner 4 Reverse procedure to install Tighten bolt to 47 Nm 35 Ib ft e Idler Pulley Replacement 1 Remove drive belt Refer to Drive Belt Removal on page 10 of this section 2 Remove belt idler pulley assembly 3 Reverse procedure to install e Tighten to 47 Nm 35 Ib ft 05 10 DSG 423 COOLING SYSTEM Radiator Hose Removal Radiator Hose Installation 1 Position the clamps at least 1 8 inch from each end of the hose WARNING REFE
41. Oillevel indicator tube connection Oil pressure sensor Leakage Points Under Engine e Oil pan gaskets oil sealer oil pan rear seal engine front cover gasket 01 10 DSG 423 GENERAL INFORMATION crankshaft front seal crankshaft rear oil seal Leakage Points with Flywheel Removed NOTE Air leakage in the area around a crankshaft rear oil seal does not necessarily indicate a crankshaft rear 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 rear main bearing cap and seals e flywheel mounting bolt holes with flywheel installed e camshaft rear bearing covers or pipe plugs at the end of oil passages except for overhead cam Oil leaks at crimped seams in sheet metal parts and cracks in cast or stamped parts can be detected when pressurizing the crankcase 01 11 DSG 423 GENERAL INFORMATION Compression Tests Compression Gauge Check 1 Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly charged Operate until the 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 Te
42. PERSONAL INJURY WARNING FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL CAUSING A FIRE HAZARD FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY A WARNING DO NOT CARRY PERSONAL ELECTRONIC DEVICES SUCH AS CELL PHONES PAGERS OR AUDIO EQUIPMENT OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY WARNING THESE PROCEDURES INVOLVE FUEL HANDLING BE PREPARED FOR FUEL SPILLAGE AT ALL TIMES AND ALWAYS OBSERVE FUEL HANDLING PRECAUTIONS FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY CAUTION If the liquid or vapor tube is damaged torn holes or delaminated a new tube assembly must be installed Do not use aftermarket sleeving Do not re adhere loose sleeving material CAUTION Fuel injection equipment is manufactured to very precise tolerances and fine clearances It is therefore essential that absolute cleanliness is observed when working with these components Always cap off any open orifices or tubes CAUTION When reusing liquid or vapor tube connectors make sure to use compressed air to remove any foreign material from the connector retaining clip area
43. and location of the leak must be positively identified prior to service Prior to performing this procedure clean the cylinder block cylinder heads valve covers oil pan and flywheel with a suitable solvent to remove all traces of oil Oil Leak Detector Y112 R0021 Fluorescent Oil Additive Method Use a 12 Volt Master UV Diagnostic Inspection Kit such as the Rotunda Oil Leak Detector 112 0021 or equivalent to perform the following procedure for oil leak diagnosis 1 Clean the engine with a suitable solvent to remove all traces of oil 2 Drain engine oil crankcase and refill with recommended oil premixed with Diesel Engine Dye 164 R3705 meeting Ford specification ESE M9C103 B1 or equivalent Use a minimum 14 8 ml 0 5 ounce to a maximum 29 6 ml 1 ounce of fluorescent additive to all engines If the oil is not premixed fluorescent additive must first be added to crankcase 3 Run the engine for 15 minutes Stop the engine and inspect all seal and gasket areas for leaks using the 12 Volt Master UV diagnostic Inspection Kit A clear bright yellow or orange area will identify the leak For extremely small leaks several hours may be required for the leak to appear 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 m
44. 352 Fuel Pump High Side Shorted to Power 08 41 DSG 423 ENGINE CONTROLS DTC Charts need charts 08 42 DSG 423 ENGINE CONTROLS REMOVAL AND INSTALLATION 5 Install special tool 303 507 and turn the crankshaft pulley bolt to position the No 1 cylinder at top dead Camshaft Position CMP Sensor center IDG Replacement CMP Sensor 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 Usea new o ring seal Lubricate o ring with clean engine oil prior to in stallation e Tighten bolt to 7 Nm 62 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 08 43 DSG 423 ENGINE CONTROLS Crankshaft Position CKP Sensor 6 Install the plug Installation Tighten to 10 Nm 89 Ib in 1 Position CKP sensor and loosely install the 2 bolts NOTE The sensor alignment tool is supplied with the new sensor and is not available separately y P 7 Reconnect or install any other component that was removed 8 Reconnect battery cable refer to se
45. 4 109 uous _ gz 109 105 8L sapurAg uoniub L L 4 8b 8L 17 31 Eun 4 5 105 105 uous uous 9L 9 9b qu 9 9b qu 9b quU 9b pc poakejay iem 95 4 tm esce 03 4 DSG 423 IGNITION SYSTEM DIAGNOSIS AND TESTING Spark Plug Inspection Inspect the spark plug tip as in the chart below GAP BRIDGED OIL FOULED IDENTIFIED BY DEPOSIT BUILD UP CLOSING GAP BETWEEN ELECTRODES CAUSED BY OIL OR CARBON FOULING REPLACE PLUG OR IF DEPOSITS ARE NOT EXCESSIVE THE PLUG CAN BE CLEANED CARBON FOULED IDENTIFIED BY BLACK DRY FLUFFY CARBON DEPOSITS ON INSULATOR TIPS EXPOSED SHELL SURFACES AND ELECTRODES CAUSED BY TOO COLD A PLUG DIRTY AIR CLEANER DEFECTIVE FUEL PUMP TOO RICH A FUEL MIXTURE IMPROPERLY OPERATING HEAT RISER OR EXCESSIVE IDLING CAN BE CLEANED OVERHEATING IDENTIFIED BY A WHITE OR LIGHT GRAY INSULATOR WITH SMALL BLACK OR GRAY BROWN SPOTS AND WITH BLUISH BURNT APPEARANCE OF ELECTRODES CAUSED BY ENGINE OVER HEATING WRONG TYPE OF FUEL LOOSE SPARK PLUGS TOO HOT A PLUG LOW FUEL PUMP PRESSURE OR INCORRECT IGNITION TIMING REPLACE THE PLUG IDENTIFIED BY LIGHT TAN OR GRAY DEPOSITS ON THE FIRING TIP IDENTIFIED BY WET BLACK DEPOSITS
46. 4 Diagnosis and Testing tm 03 5 Spark Pl g Inspectign ei edi ao sedo e et o idt edat ee re 03 5 Removal and Installation 1 deret tee oet Re cR Renate 03 6 ignition Goil Replacement a nete tdt de eret E pide uev tetas 03 6 Spark Plug Removals oed te eee tl tette ecd se A 03 6 Spark 03 6 Jeep ml EL 03 7 03 1 DSG 423 IGNITION SYSTEM GENERAL INFORMATION Camshaft Position CMP Sensor Crankshaft Position CKP Sensor Ignition Coil Description The DSG 423 engine is equipped with an individual coil on plug electronic ignition system The brain of this system is the Electronic Engine Control GCP Module which receives inputs from the following Crankshaft Position CKP Sensor e Camshaft Position CMP Sensor Engine Temperature Sensor From these inputs the GCP module computes spark strategy spark advance to obtain optimum engine performance for correct input conditions through the following outputs Spark Plug Engine Coolant Temp ECT Sensor e Ignition Coils Spark Plugs A WARNING HIGH TENSION VOLTAGE PRODUCED BY A DISTRIBUTORLESS IGNITION SYSTEM IS HIGHER THAN FOR A CONVENTIONAL IGNITION SYSTEM WHEN CARRYIN
47. 44135 PENNSYLVANIA Auto Electric 1241 Freedom Road 724 778 8200 Cranberry Twp PA 16066 WASHINGTON Pacific Torque 18060 Des Moines Memorial 206 241 8300 Drive Burien WA 98148 Appendix 1 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
48. 6 Reverse procedure to install Tighten bolts in sequence shown in three stages Stage 1 Tighten to 50 Nm 37 Ib ft Stage 2 Tighten to 80 Nm 59 Ib ft Stage 3 Tighten to 112 Nm 83 Ib ft 02 27 1 2 Crankshaft Rear Seal Retainer Removal Remove and or disconnect components to allow access and removal of the rear seal Label if necessary to allow for correct reinstallation 2 Remove flywheel or flexplate Refer to Flywheel Flexplate Replacement on page 27 of this section Remove oil pan Refer to Oil Pan Removal on page 24 of this section Remove bolts and retainer plate Crankshaft Rear Seal Retainer Installation Using special tool 303 328 position rear oil seal with retainer plate onto crankshaft Install 6 bolts in the sequence shown Tighten to 10 Nm 89 Ib in DSG 423 ENGINE 3 Install oil pan Refer to Oil Pan Installation on 6 Remove generator and bracket assembly page 25 of this section 4 Install flywheel or flexplate Refer to Flywheel Flexplate Replacement on page 27 of this section 5 Install or connect any other component removed or disconnected DISASSEMBLY amp ASSEMBLY Engine Disassembly CAUTION During engine repair procedures cleanliness is extremely important Any foreign material including any material created while cleaning gasket surfaces can enter the oil passages coolant
49. 7 ACTION Inspect wash gasket and test Replace only if cap will not hold pressure to specification Pressure test system Inspect hose hose connection radiator edges of cooling system gaskets core plugs and drain plugs transmission oil cooler lines water pump heater system components Repair or replace as required Disassembly engine as necessary check for cracked intake manifold blown head gaskets warped head or block gasket surfaces cracked cylinder head or engine block Fill as required Check for coolant loss Adjust Test Replace if necessary Remove bugs leaves etc Test Replace if necessary Test replace if necessary Check timing and advance Adjust as required Check electrical circuits and repair as required Check water pump block for blockage 1 2 water and 1 2 permanent anti freeze mixture Test replace if necessary Check electrical circuits and repair as required DSG 423 COOLING SYSTEM Cooling System Pressure Test Pressure Tester WARNING REFER TO CAUTIONS AND WARNINGS AT THE BEGINNING OF THIS SECTION 1 Remove the radiator cap from the radiator filler neck CAUTION Do not pressurize the cooling system be yond 138 kPa 20 psi 2 Fill the radiator as needed 3 Fit the pressure tester to the radiator neck 4 Pump the cooling system to a maximum of 138 kPa 20 psi and hold for 2 minutes 5 the pressure drops within this time inspect for leaks and repair as nec
50. 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 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 timing according to the incoming air density CHT Sensor 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 25 indicates whether the air fuel ratio is rich or lean with respect to stoichiometry The sign
51. Check the Fuel Lockoff connection and FCV valve connection Check the vacuum hoses to the FCV valve and carburetor for any damage or leakage Is there any damaged or loose wires or vacuum hoses 4 Check for fuel system leaks Yes Repair the Leak Key ON e Check the fuel system for leaks ne Key OFF Are there any leaks present 5 Check Carburetor air inlet for obstructions Yes Remove the obstruction re install the aircleaner and attempt to start e Remove the air cleaner 8 m Proceed to appropriate Are there any obstructions in the air inlet of the Troubleshooting Section carburetor No 04 11 DSG 423 FUEL SYSTEM Diagnostic Charts Perform the preliminary test before proceeding Engine Cranking But Will Not Start Test Step Result Action to Take 1 Check fuel tank Yes Fill or replace the fuel tank Do not exceed 80 of liquid capacity Is fuel tank empty No Go to Step 2 2 Check fuel valve Yes Slowly Open the Fuel Valve Is liquid fuel valve closed No Go to Step 3 3 Check the excess flow valve Yes Reset excess flow safety valve Is excess flow valve tripped and closed Close the main fuel valve Wait for a clicking sound from the excess flow valve indicating the valve has reset Slowly open the main fuel valve No Perform Preliminary Test before proceeding to Step 4 4 Check fuelock supply voltage Yes 12
52. Feedback Exhaust Gas Recirculation Feedback Pressure Exhaust Gas Recirculation Feedback Pressure Pressure Feedback Exhaust Gas Recirculation Sensor EGR Sensor PFE Sensor Flash Electrically Erasable Programmable Read FEEPROM Flash EEPROM Only Memory Flash Erasable Programmable Read Only Memory FEPROM Flash EPROM Flexible Fuel FF Flexible Fuel FF Flexible Fuel Sensor FF Sensor Alcohol Concentration Sensor Fuel Concentration Sensor Fuel Quality Sensor Percent Alcohol Sensor Variable Fuel Sensor Forth Gear 4GR Fourth Gear 4GR Fuel Level Sensor Fuel Level Sensor Fuel Sensor Fuel Pressure Fuel Pressure Fuel Pressure Fuel Pressure Regulator Fuel Pressure Fuel Regulator Regulator Fuel Pump FP Fuel Pump FP Fuel Pump Module FP Module Fuel Module Fuel Sender Fuel Tank Unit In Tank Module Fuel Pump Relay FP Relay Fuel Pump Relay Fuel Trim FT Adaptive Fuel Strategy Generator GEN Alternator ALT Governor Governor Governor Governor Control Module GCM Governor Electronic Module GEM Ground GND Ground GRD Heated Oxygen Sensor HO2S Heated Exhaust Gas Oxygen Sensor HEGO Sensor Heated Oxygen Sensor HOS High Speed Fan Control Switch High Speed FC Switch High speed Fan Control Switch High Speed FC Switch Idle Air Control IAC Idle Air Bypass Control Idle speed Control ISC Idle Speed Control B
53. 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 25 located in the exhaust system The 25 tells the GCP how much oxygen is in the exhaust gas The GCP changes the air fuel ratio to the engine by controlling the amount of time that the fuel injector is ON The best mixture to minimize exhaust emissions is 14 7 parts of air to 1 part of gasoline by weight which provides the most efficient combustion Because of the constant measuring and adjusting of the air fuel ratio the fuel injection system is called a closed loop system
54. Install the crankshaft pulley Refer to Crankshaft Pulley Installation on page 9 of this section 8 Position a new CKP Sensor and loosely install the 2 bolts 02 13 DSG 423 ENGINE 9 Adjust the with the alignment tool supplied with 4 Remove the right timing chain guide the new sensor The tool must engage a tooth of the vibration damper Tighten 2 bolts e Tighten to 7 Nm 62 Ib in E RE SE 10 Connect CKP Sensor connector 11 Connect battery negative cable refer to Section 6 12 Install or reconnect any other component removed or disconnected Timing Drive Components Removal CAUTION The crankshaft the crankshaft sprocket and the pulley are fitted together by friction with diamond washers between the flange faces on each part For that reason the crankshaft sprocket is also unfastened if you loosen the pulley Therefore the engine must be retimed each time the damper is removed Otherwise severe damage can occur 1 Remove and or disconnect components to allow access and removal of the timing drive components Label if necessary to allow for correct reinstallation 2 Remove the engine front cover Refer to Engine Front Cover Removal on page 11 of this section 3 Compress the timing chain tensioner and insert a paper clip into the hole Remove the 2 bolts and the timing chain tensioner CAUTION Do not rely on the Camshaft Alignment Pl
55. 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 re set 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 08 33 DSG 423 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 word Normal will change to the Injector you have selected The injector driver can be re enabled by selecting again If the engine is running below 1000 RPM the injector driver will stay disabled for 15 seconds and then re set If the engine is running above 1000 RPM the injector 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
56. ON THE INSULATOR SHELL BORE ELECTRODES CAUSED BY EXCESSIVE OIL ENTERING COMBUSTION CHAMBER THROUGH WORN RINGS AND PISTONS EXCESSIVE CLEARANCE BETWEEN VALVE GUIDES AND STEMS OR WORN OR LOOSE BEARINGS CORRECT OIL PROBLEM REPLACE THE PLUG PRE IGNITION IDENTIFIED BY MELTED ELECTRODES AND POSSIBLY BLISTERED INSULATOR METALLIC DEPOSITS ON INSULATOR INDICATE ENGINE DAMAGE CAUSED BY WRONG TYPE OF FUEL INCORRECT IGNITION TIMING OR ADVANCE TOO HOT A PLUG BURNT VALVES OR ENGINE OVERHEATING REPLACE THE PLUG FUSED SPOT DEPOSIT IDENTIFIED BY MELTED OR SPOTTY DEPOSITS RESEMBLING BUBBLES OR BLISTERS CAUSED BY SUDDEN ACCELERATION CAN BE CLEANED IF NOT EXCESSIVE OTHERWISE REPLACE PLUG 03 5 DSG 423 IGNITION SYSTEM REMOVAL AND INSTALLATION Ignition Coil Replacement aA wh Bolt Ignition Remove and or disconnect components to allow access and removal of the ignition coil Label if necessary to allow for correct reinstallation Disconnect electrical connector Remove bolt Remove ignition coil Reverse procedure to install Inspect for cracks carbon tracking or dirt Apply silicone dielectric compound to the inside of coil Spark Plug Removal Spark Plug Remove ignition coil Refer to Ignition Coil Replacement on page 6 of this section Loosen spark plugs and remove any dirt or foreign material from spark plug areas of cylinder head with compressed air
57. Position CKP Sensor connector amp Pulley 7 Remove the three bolts and the coolant pump pulley 8 Remove three bolts and power steering pump and set aside Power Steering CAUTION A new CKP Sensor must be installed whenever the old sensor is removed 5 Remove the CKP Sensor and discard 6 Remove bolt and accessory drive tensioner CAUTION There is one bolt behind the cooling fan drive pulley This bolt can be accessed by lining up one of the holes in the pulley with the bolt NOTE The next step is only necessary if a new front cover is being installed 02 11 DSG 423 ENGINE 9 Using a 3 jaw puller remove the fan drive pulley Engine Front Cover Installation 10 Remove bolts and engine front cover Front Cover 9899 1 NOTE This step is needed only if a new front cover is being installed Install the fan drive pulley using a nut and bolt with flat washers as shown below Bolt NS 0 NOTE If not secured within 4 minutes the sealant must 2 be removed and the sealing area recleaned as before Refer to previous CAUTION 8 WARNING 2 Apply a 2 5 mm 0 1 in bead of silicone gasket and 0 0 O k 4 CNN CAUTION Do not use metal scrapers wire brushes power abrasive discs or other abrasive mean
58. Start engine with good battery Run engine at a moderate speed 6 Start engine with discharged battery Follow starting instructions in the Operator handbook 7 Completely discharged batteries may require an electrical load to initialize charging 8 Remove cables in exact REVERSE sequence Begin by removing negative cable from engine that had discharged battery If the starter does not turn the engine over even with the booster battery attached refer to Diagnosis 07 8 DSG 423 STARTER REMOVAL AND INSTALLATION WARNING REFER TO CAUTIONS amp WARNINGS WARNING WHEN SERVICING STARTER OR THE BEGINNING OF THIS SECTION PERFORMING OTHER WORK IN THE VICINITY OF THE STARTER BE AWARE THAT THE HEAVY Starter Motor Replacement GAUGE BATTERY INPUT LEAD AT THE STARTER P SOLENOID IS ELECTRICALLY HOT AT ALL TIMES B Terminal M Terminal Starter Motor 5 Reverse procedure to install WARNING REFER TO CAUTIONS amp WARNINGS AT Tighten and M nuts to 12 Nm 9 lb ft THE BEGINNING OF THIS SECTION Tighten S nut to 5 Nm 44 Ib in Tighten mount bolts to 25 Nm 18 lb ft 1 Disconnect negative battery cable 2 Remove any component to allow access and removal of the starter motor 3 Remove terminal cover and nuts 4 Remove starter mount bolts 07 9 SPECIFICATIONS DSG 423 STARTER GENERAL SPECIFICATIONS Current draw NO load 60
59. TDC can result in damage to the engine Turn the engine in the normal direction of rotation only CAUTION The crankshaft the crankshaft sprocket and the pulley are fitted together by friction with diamond washers between the flange faces on each part For that reason the crankshaft sprocket is also unfastened if you loosen the pulley Therefore the engine must be retimed each time the damper is removed Otherwise severe damage can occur 22 Using the crankshaft pulley bolt turn the crankshaft clockwise to position the No 1 piston at TDC CAUTION The special tool 303 465 is for camshaft alignment only Using this tool to prevent engine rotation can result in engine damage NOTE The camshaft timing slots are offset If the special tool cannot be installed rotate the crankshaft one complete revolution clockwise to correctly position the camshafts 23 Install special tool 303 465 in the slots on the rear of both camshafts 02 30 DSG 423 ENGINE 24 Install special tools 205 126 amp 205 072 02 205 072 02 CAUTION Failure to hold the crankshaft pulley in place during bolt loosening can cause damage to the engine 25 Using the special tools remove bolt washer and crankshaft pulley Discard the bolt CAUTION There is one front cover bolt behind the cooling fan drive pulley 26 bolt behind cooling fan drive pulley throu
60. 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 DONOT SMOKE WHILE WORKING ON THE EQUIPMENT e ALWAYS REMOVE RINGS WATCHES LOOSE HANGING JEWELRY AND LOOSE CLOTHING BEFORE BEGINNING TO WORK ON THE EQUIPMENT TIE LONG HAIR SECURELY BEHIND THE HEAD KEEPHANDS AND OTHER OBJECTS CLEAR OF THE RADIATOR FAN BLADES ELECTRIC COOLING FANS CAN START TO OPERATE AT ANY TIME BY AN INCREASE IN UNDERHOOD TEMPERATURES EVEN THOUGH THE IGNITION IS IN THE OFF POSITION THEREFORE CARE SHOULD BE TAKEN TO ENSURE THAT THE ELECTRIC COOLING FAN IS COMPLETELY DISCONNECTED WHEN WORKING UNDER THE HOOD 01 3 DSG 423 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 SHIELD EYES GASES CAN EXPLOSIVE SPARKS BLINDNESS NG SE PROTEEGER LES EVITER LES ETINCELLES ET LES FLAMMES RENDRE AVEUGLE DFENSE DE FUMER KEEP OUT OF REACH OF CHILDREN DAN 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 GER POISON FLUSH EYES SULPHURIC ACID CAN CAUSE IMMEDIATELY BLINDNESS OR SEVE
61. The GCP monitors signals from several sensors in order to determine the fuel needs of the engine Fuel is delivered under one of several conditions called modes modes are controlled by the 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 Fuel Injector 08 8 DSG 423 ENGINE CONTROLS Fuel Filter The fuel filter is an inline filter assembly Refer to Section 4 for information on relieving fuel pressure disconnecting fuel lines and fuel filter replacement Fuel Filter 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 wit
62. Valve Spring Installation CAUTION Check that there is no dirt or particles within the valve stem grooves Check the seating of the valve collets 1 Install the valve spring and retainer 2 Using special tools compress valve spring and install the valve retainer keys 3 Release spring and check that keys are seated properly 4 Remove air supply and all special tools 5 Install the valve tappets Refer to Valve Tappet Replacement on page 18 of this section 6 Install spark plug Tighten to 15 Nm 11 Ib ft 02 16 DSG 423 ENGINE Valve Seal Removal CAUTION During engine repair procedures cleanliness is extremely important Any foreign material including any material created while cleaning gasket surfaces that enters the oil passages coolant passages or the oil pan can cause engine failure 1 Remove camshafts Refer to Camshafts Removal on page 18 of this section CAUTION If the camshafts and valve tappets are to be reused mark the location of the valve tappets to make sure they are assembled in their original positions NOTE The number on the valve tappets only reflects the digits that follow the decimal For example a tappet with the number 0 650 has the thickness of 3 650 mm 2 Remove the valve tappets Refer to Valve Tappet Replacement on page 18 of this section 3 Remove valve spring assembly Refer to Valve Spring Removal on page 16 of this section 4 Usi
63. Valve stem diameter 5 470 5 485 mm Piston intake 0 2153 0 2159 in Diameter 1 87 5 87 51 mm Valve stem diameter 5 465 5 480 mm exhaust 0 2151 0 2157 in 02 46 DSG 423 ENGINE General Specifications Continued General Specifications Continued Item Specification Item Specification Valve stem to guide 0 0027 mm 0 0009 in Tappet to valve clearance 0 22 0 28 mm learance intake intake 0 008 0 011 Valve stem to guide 0 0029 mm 0 0011 in Tappet to valve clearance 0 27 0 33 mm learance exhaust exhaust 0 010 0 013 in Valve face runout 0 05 mm 0 001 in Tappet to bore clearance 0 02 0 06 mm Valve face angle Valve Spring Compress 45 degrees ion Pressure Camshaft 0 0007 0 0023 in Lobe lift intake 8 24999 mm 0 324 in Lobe lift exhaust Runout 7 80007 mm 0 307 in 0 03 mm 0 001 in Thrust clearance Intake and exhaust 38 667 lbs installed Intake valve open 8 9 97 032 165 mm 0 35 in of lift Exhaust valve open 7 4 93 338 ibs mm of lift 0 09 0 24 mm 0 003 0 009 in Journal diameter Free length 44 92 mm 1 768 in 24 96 24 98 mm 0 982 0 983 in Assembled height Crankshaft 37 9 mm 1 492 in Main bearing journal diameter Production repair 51 980 52 000 mm 2 046 2 047 51 730 51 750 mm 2 036 2 03
64. a backfire may have caused the fuel valve to partially come off of it s retainer and restrict fuel check the mixer fuel valves see section 475 1 for disassembly Also check the mixer adapter plates for leakage past the carburetor Regulator Assembly Converter amp FCV If no other problems have been identified replace the fuel management assembly with a known good part of the same pressure range Retest 04 29 DSG 423 FUEL SYSTEM DIAGNOSIS AND TESTING GASOLINE NOTE For diagnosis of Electronic Engine Control refer to Section 08 Visual Inspection Check for dirt or water in the fuel tank Water and dirt that accumulate in the fuel tank can cause a restricted fuel line filter or a malfunction of the fuel pump Condensation which is the greatest source of water entering the fuel tank is formed by moisture in the air when it strikes the cold interior walls of the fuel tank Water Falls to Bottom in the filter is excessive the fuel tank should be removed and flushed and the line from the fuel pump to the tank should be blown out Check fuel lines for damage Air leakage in the fuel inlet line can cause low fuel pump pressure and volume Check fuel tank vent A restricted fuel tank vent can cause low fuel pump pressure and volume and can result in collapsed inlet hoses or a collapsed fuel tank High or low pressure are the two most likely fuel pump troubles that will affect engine performance Low pressu
65. a battery needs the proper tools Using the right tools will prevent damage to the battery battery cables and battery hold down clamp Tools and equipment manufactured for servicing batteries have parts insulated to help prevent arcing should the tool be dropped or placed accidentally between a terminal and some other contact surface Clamp Puller Use a clamp puller to remove a cable clamp from the battery terminal With the jaws gripping the underside of the cable clamp pull the clamp up by means of pressure exerted against the top of the battery terminal Proper use of this tool avoids the damaging lateral or twisting forces that result when using a pry bar or pliers Battery Clamp Spreader The spreader is used to expand the cable clamp after it has been removed from the terminal and the clamp bolt has been loosened The cable clamp can then be easily placed in its correct position completely on the terminal Terminal Cleaning Brush The terminal cleaning brush is designed with units to clean both tapered battery terminal and the mating surface of the cable clamp Carrier WARNING GRIPPING THE END WALLS ON THE PLASTIC CASED BATTERY COULD CAUSE ELECTROLYTE TO SPEW FROM SOME OF THE CELLS RESULTING IN PERSONAL INJURY AND POSSIBLY CAUSE DAMAGE TO SOME OF THE INTERNAL COMPONENTS Use a suitable battery carrier for lifting and transporting the battery The illustration shows a clamp type carrier used to grip the sidewalls of
66. assist with unit diagnosis Diagnostic Connector 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 08 25 DSG 423 ENGINE CONTROLS KOER operation a DTC is stored the MIL will illuminate and remain on steady if the code is active MIL Bulb Test The MIL bulb test occurs KOEO with the STI connector not grounded The MIL bulb will stay on and remain on if no DTCs are present If DTCs are present except DTC 123 the MIL bulb will blink If the MIL bulb does not illuminate when 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 extracti
67. 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 component through a process of logical decisions The tests and charts are prepared with the requirement that the engine functioned correctly at the time of assembly and that there were not multiple faults present There is a continuous self diagnosis on certain control functions This diagnostic capability is complimented by the diagnostic procedures contained in this section The language for communicating the source of the malfunction is a system of diagnostic trouble codes When a malfunction is detected by the Engine Control Module GCP a 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 Diagnos
68. 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 08 34 DSG 423 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 key will toggle to the last screen you were on 08 35 DSG 423 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 en
69. be used year round with temperatures above 34 4 C 30 F If recycled coolant is used it must meet Ford specification ESE M97B44 A or WSS M97B44 D CAUTION Not all coolant recycling processes pro duce coolant which meets Ford specification ESE 97 44 or WSS M97B44 D Use of coolant that does not meet specifications may harm engine and cooling system components The engine cooling system is filled with Motorcraft Premium Gold Engine Coolant Always refill the cooling system with the same coolant that was drained from the system Do not mix coolant types CAUTION Do not use alcohol type antifreeze alka line brine solutions or 100 000 mile red in color antifreeze This may cause serious engine cooling system damage NOTE The use of stop leak may change the color of the coolant 1 Make sure the radiator drain cock is completely closed 2 Fill the system with the proper coolant mix 3 Start engine and hold at 2 500 rpm engine speed for approximately 8 minutes until thermostat opens 4 Maintain 2 500 rpm for an additional 3 minutes Add coolant as necessary 5 Increase engine speed to 4000 rpm and hold for 5 seconds 6 Return engine speed to 2 500 rpm and hold for an additional 3 minutes 7 Stop the engine and check for leaks 8 Verify correct fluid level after engine cools for 20 minutes Top off the degas bottle to line 05 9 DSG 423 COOLING SYSTEM REMOVAL AND INSTALLATION
70. by elbow which connects the vacuum line from the converter pass port to the FCV valve Is this bypass closed with dirt or debris No Go to Step 8 8 Check for stuck primer button Yes Try and free the primer button If you cannot reseat the primer then see Key Off section 475R 1 for servicing the Press the primer button on the converter once to assure converter the primer is not sticking open A small amount of fuel that is trapped between the fuel lock and the converter should No Go to Step 9 pass through to the carburetor Is the primer button stuck in the depressed position 6 Check regulator operation Yes The Regulator is malfunctioning See E section 475R 1 for service of the Using Woodward WTK 1 test kit install the secondary converter pressure gauge as described in section G 1 note the secondary spring color and pressure range Crank the engine No Go to Step 7 Is the pressure less than X psi 7 Check carburetor air valve for binding Yes Refer to section 475 1 for servicing the carburetor With the air cleaner removed pull the air valve piston upwards to ensure free movement of the carburetor air valve Is the air valve binding No Go to Step 8 8 Check air valve operation Yes Replace the carburetor and retest Using the WTK 1 test kit connect the vacuum gauge between the carburetor and the FCV valve to measure the carburetor air valve vacuum AVV
71. by friction with diamond washers between the flange faces on each part The diamond washers must be installed correctly or severe engine damage can result 13 Install washers and oil pump chain and sprockets Oil Pump Sprocket Washers NOTE The crankshaft sprocket flange must be facing away from the engine block Engine Block Side 14 Holding the oil pump chain sprocket in place tighten oil pump sprocket bolt Tighten to 25 Nm 18 Ib ft 15 Install oil pump chain guide and shoulder bolt Tighten to 10 Nm 89 Ib in 16 Install oil pump chain tensioner Hook spring around shoulder bolt and tighten Tighten to 10 Nm 89 Ib in NOTE Sprockets must turn freely on the camshafts 17 Position camshaft sprockets and loosely install bolts CAUTION Do not compress the ratchet assembly This will damage the ratchet assembly 18 Using the edge of a vise compress the timing chain tensioner plunger 02 38 DSG 423 ENGINE 19 Using a small pick push back and hold the ratchet 23 Position timing chain guides and install guide bolts mechanism Tighten to 10 Nm 89 Ib in 20 While holding the ratchet mechanism push the ratchet arm back into the tensioner housing the paper clip to apply tension to chain Tighten to 10 Nm 89 Ib in 21 Install a paper clip into the hole in the tensioner housing to hold the ratchet a
72. cable terminals and battery hold down clamp with a wire brush Replace all cables or parts that are worn or frayed 2 Clean battery tray with a wire brush and scraper 3 Place battery in battery tray with positive and negative cables in same position as when removed 4 Assemble and tighten battery hold down clamp so battery is secure Do not tighten excessively 5 Secure cables to proper terminals Tighten to 6 Nm 53 Ib in Apply petroleum jelly to terminals Ford Motor Company strongly recommends that lead acid batteries be returned to an authorized recycling WARNING WHEN LIFTING PLASTIC CASED BATTERY EXCESSIVE PRESSURE ON THE END WALLS COULD CAUSE ACID TO SPEW THROUGH THE VENT CAPS RESULTING IN PERSONAL INJURY DAMAGE TO THE EQUIPMENT OR BATTERY LIFT WITH A BATTERY CARRIER OR WITH YOUR HANDS ON OPPOSITE CORNERS WARNING KEEP OUT REACH OF CHILDREN BATTERIES CONTAIN SULFURIC ACID AVOID CONTACT WITH SKIN EYES OR CLOTHING ALSO SHIELD YOUR EYES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION IN CASE OF ACID CONTACT WITH SKIN OR EYES FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF 15 MINUTES AND GET PROMPT MEDICAL ATTENTION IF ACID IS SWALLOWED DRINK LARGE QUANTITIES OF MILK OR WATER FOLLOWED BY MILK OF MAGNESIA A BEATEN EGG OR VEGETABLE OIL CALL A PHYSICIAN IMMEDIATELY CAUTION Care should be taken when removing or replacing the cable clamp bolts so tha
73. cct A edes deest e eee 04 7 PRI HU IE E 04 7 Fuel System Requiremients te doe be E uet Et rta egent 04 7 Wining te peii ia nats RR ENERO 04 9 Diagnosis and Testing ceci creciente dne conne cre cete reo cene eda Dre 04 8 Diagnosis and Testing E PG eene nette trier ri irr erii verc cien p 04 10 Sy MPO cip M DEED 04 10 Preliminary Testa ee mee teu coe ente te de e fene nt 04 11 Diagnostic Sc 04 12 Diagnosis and Testing 2 4 1 1 aaie asas 04 30 pier bun Ip Imper 04 30 Symptom Charts E ED 04 31 Fuel Pressure Check ed odd sed HER Fue e HIE he pate tasa 04 30 General Service Procedures eese ener nent nn nnn entr nn neni anni nsns an nnns intr nnn nnns 04 31 Fuel Pressure Relief e hem nte e eene datae ett 04 31 Spring Lock Coupling Type 04 31 Spring Lock Coupling Type
74. chain guide 10 89 bolt Engine wire harness 10 89 bulkhead connector Power steering pump 25 18 bolt ju bolts M EGR outlet 55 4l Er Power steering pressure 20 15 tube to cylinder head tube nut EN E fitting Powertrain control 6 53 Exhaust 40 30 e module PCM manifold to exhaust electrical connector inlet pipe nuts bolt Engine support 102 75 PCM harness ground 10 89 insulator nuts cable nut Engine to transmission 48 35 Starter motor bolts 25 18 bolts Transmission access 10 Engine front cover bolts Timing peg plug 20 15 Engine lifting eye bolts 45 33 Torque 35 26 ES EGR valve bolts 25 18 converter to fly wheel nuts Exhaust 17 13 manifold to cylinder Transmission lines 28 21 head studs bracket bolt E Exhaust 54 40 Timing chain guide 10 89 manifold to cylinder bolts 02 48 DSG 423 ENGINE Torque Specifications Continued Description Timing chain tensioner bolts Valve cover bolts a Refer to the procedure in this section 02 49 DSG 423 IGNITION SYSTEM INDEX Subject Page General IMFOrMAation 03 2 C EE 03 2 Operati 03 3 Winrng DIagram seti p tr RE ERR RM 03
75. filter necessary Start the engine and re check emission levels Has the rich emission failure been eliminated No Goto Step 2 2 Check carburetor air valve for binding Yes Refer to section 475 1 for servicing the carburetor e With the air cleaner removed pull the air valve piston upwards to ensure free movement of the carburetor air valve Goto Step 3 Is the air valve binding 3 Check air valve operation Yes Refer to section 475 1 for servicing the carburetor Using the WTK 1 test kit connect the vacuum gauge between the carburetor and the FCV valve to measure the carburetor air valve vacuum AVV With the engine at idle and accelerating observe the amount of measured vacuum Go to Step 4 Is the measured vacuum outside the specifications 4 Check regulator operation Yes The Regulator is functioning properly and the problem is with the FCV valve Using a secondary pressure gauge described in section or vacuum hoses Inspect the vacuum 475G 1 note the secondary spring color and pressure hoses and fittings replace as range necessary Replace the FCV valve Start the engine and retest Is the pressure constant and at 1 5 inches of w c as specified No The Regulator is malfunctioning See section 475R 1 for service of the regulator Diagnostic Aids Regulator Assembly Converter amp FCV If no other problems have been identified replace the fuel managemen
76. 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 filter and refill with one quart less than the recommended amount 6 Run the engine for three minutes 10 minutes if cold and allow the oil to drain back for at least five minutes with the engine vehicle on a level surface 7 Remove oil level dipstick and wipe clean CAUTION Do not wipe with anything contaminated with silicone compounds 8 Reinstall the oil level dipstick being sure to seat it firmly in the oil level indicator tube Remove the oil level dipstick and draw a mark on the back unmarked surface at the indicated oil level This level should be about the same as the ADD mark on the face of the oil level dipstick 9 Add one quart of oil Restart the engine and allow to idle for at least two minutes Shut off the engine and allow the oil to drain back for at least five minutes Mark the oil level dipstick using the procedure above This level may range from slightly below the top of the cross hatched area to slightly below the letter F in FULL 10 Record the vehicle mileage or hours 01 15 DSG 423 GENERAL INFORMATION 11 Instruct the customer to run engine as usual and perform the following e Check the oil level r
77. improper seating Scratching dirty C Base exposed poor lubrication D e Both edges worn journal damaged E One edge worn journal tapered or bearing not seated F 03517 01 24 DSG 423 GENERAL INFORMATION Crankshaft End Play Special Tool s Dial Indicator with Bracketry TOOL 4201 C or Equivalent m _ M S FPP10026 Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 1 Measure the crankshaft end play Use the Dial Indicator with Bracketry to measure crankshaft end play 2 Position the crankshaft to the rear of the cylinder block 3 Zero the Dial Indicator with Bracketry FPP03518 4 Move the crankshaft to the front of the cylinder block Note and record the camshaft end play If camshaft end play exceeds specifications re place the crankshaft thrust washers or thrust bearing Crankshaft Runout Special Tool s Use the Dial Indicator with Bracketry to measure the crankshaft runout e Rotate the crankshaft and subtract the lowest dial indicator reading from the highest dial indicator reading to figure the crankshaft runout If it is out of specification replace as necessary 03519 Cylinder Bore Taper Measure the cylinder bore at the top and bottom Verify the cylinder bore is within the wear limit The difference indicates
78. is in most cases a temporary aid for production start up and color will generally revert to normal black or bright after start up English or Metric system fasteners are available through your Ford Parts and Service operation NOMENCLATURE FOR BOLTS English System Bolt 1 2 13 x 1 Metric System Bolt M12 1 75 x 25 ERE D MORES FPP03570 FPP03571 Grade Marking bolt strength L Length inches T Thread Pitch thread inch D Nominal Diameter inches P Property Class bolt strength L Length millimeters T Thread Pitch thread width crest to crest mm D lt Nominal Diameter millimeters The Property class is an Arabic numeral distinguishable from the slash SAE English grade system The length of all bolts is measured from the underside of the head to the end 09 2 DSG 423 METRICS BOLT STRENGTH IDENTIFICATION English System Grade 8 03572 Grade 1 or 2 English inch bolts Identification marks correspond to bolt strength increasing number of slashes represent increasing strength Metric System 03573 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 English System Grade I
79. is the difference between fuel vapor pressure and the air inlet pressure This has been calibrated for all speeds and loads There is a sensor internal to the EPR that measures the actual Delta P of the delivered fuel The actuator of the EPR will then drive the diaphragm of the vaporizer to adjust the fuel pressure to the carburetor so that the actual Delta P matches the Delta P command from the GCP This provides an extremely accurate open loop type of fuel control There is also a dry fuel temperature sensor for increased pressure command accuracy After a preset time has passed the engine will go into closed loop control using information from the pre and post oxygen sensors to allow further adjustement to meet emissions regulations 04 8 DSG 423 FUEL SYSTEM Wiring Diagrams Revision Level The following wiring schematics are taken from the wiring diagram labeled below This draming m property ef E amp antrela Inc and ia subject EDI FORD 2 3L W GCP to retum upan request ond nok to copied or reproduced Hurmbar Rew without permimsian All rights mb E z 1782000 F Daka Beis anes By J SUTTON ECONTROLS INC 17B2ObBF mrh Sheet 1 of 1 G H Engine Controls Dry Fuel EPR ata s a 1 25 2 x M 6 o eum bod a 6 9 x 51 e 2 gt 5 Y Is 2
80. 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 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 overload any circuit Whentesting 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 e 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 Discharge Damage for more information Use of Circuit Testing Tools Do not use a test light to diagnose the engine electrical systems unless specifically instructed by the diagnostic procedures A test light can put an excessive load on a GCP circuit and result in component damage
81. must also be mounted in packed foam CAUTION The electric fuel pump MUST NOT be mounted directly on the engine assembly as en gine vibration will shorten the life of the pump 04 4 DSG 423 FUEL SYSTEM Wiring Diagrams Revision Level The following wiring schematics are taken from the wiring diagram labeled below The dreaming khe preparty 6 of EGartrela Inc and subject EDI FORD 2 3L W GCP to ratum upan request ond nok to cepied or reproduced Slza Hurnbar iud DE All rights D 17828008 F Daka Beis anes By J SUTTON ECONTROLS INC 17B2ODBF ech Sheet 1 of 1 G H Fuel Injectors Injector 4 16 BN LB a x o 25 gt 5 a 2 2 Y o TN I z e a Da g 8 E z e a c T 16 Relayed Power 04 5 a eo SI 5 EMI Tg T TEN ga 82 T 1 o 33 511 E 1 1 1 T 9 Am T 1 1 T 1 L LI DSG 423 FUEL SYSTEM Actuator Data Link Connector DLC 429 0 XM XL Z SdL BE a C Er DD EE 4 SL v 96 66 28 08 8v Lv LA DGJ 8 1001 199 OL 97 90 sb HWNS 8l
82. on page 24 of this section 3 Install drain plug e Tighten to 28 Nm 21 lb ft 4 Fill engine with clean engine oil 5 Install or reconnect any other component that was removed or disconnected Oil Pickup Tube Replacement 1 Remove the oil pan Refer to Oil Pan Removal on page 24 of this section 2 Remove bolts and oil pickup tube Pickup Tube 3 Remove gasket and discard 4 Clean the sealing surface with metal surface prep WARNING OBSERVE ALL WARNINGS AND CAUTIONS AND FOLLOW ALL APPLICATION DIRECTIONS CONTAINED ON THE PACKAGING OF THE SILICONE GASKET REMOVER AND METAL SURFACE PREP 5 Reverse procedure to install Usea new gasket Tighten bolts to 10 Nm 89 Ib in 02 25 DSG 423 ENGINE Oil Pump Removal 1 Remove and or disconnect components to allow access and removal of the oil pump Label if necessary to allow for correct reinstallation Remove engine front cover Refer to Engine Front Cover Removal on page 11 of this section Remove oil pan Refer to Oil Pan Removal page 24 of this section Remove oil pickup tube Refer to Oil Pickup Tube Replacement on page 25 of this section Release the tension on the tensioner spring and remove the bolt and tensioner 6 Remove 2 bolts and oil pump chain guide 7 Remove oil pump chain 8 9 Remove 4 bolts and oil pump Remove bolt and oil pump sprocket Oil Pump Installation
83. on page 24 of this section 7 Remove generator support bracket refer to Section 6 8 Remove nuts exhaust manifold and gasket discard nuts and gasket Gasket Exhaust Manifold 9 Remove and discard exhaust manifold studs 10 Inspect manifold for flatness refer to Section 1 CAUTION Do not use metal scrapers wire brushes power abrasive discs or other abrasive means to clean the sealing surfaces These tools cause scratches and gouges which make leak paths Use a plastic scraping tool to remove all traces of old sealant 11 Clean the sealing surface with silicone gasket remover and metal surface prep WARNING OBSERVE ALL WARNINGS AND CAUTIONS AND FOLLOW ALL APPLICATION DIRECTIONS CONTAINED ON THE PACKAGING OF THE SILICONE GASKET REMOVER AND METAL SURFACE PREP Exhaust Manifold Installation 1 Install new studs Tighten to 17 Nm 13 Ib ft 2 Install new gasket 3 Position exhaust manifold and install nuts Tighten to 54 Nm 40 Ib ft Gasket Exhaust Manifold 6 5 Install oil level indicator Refer to Oil Level Indicator amp Tube Replacement on page 24 of this section 02 19 DSG 423 ENGINE 6 Install exhaust pipe to manifold 7 Install accessory drive belt refer to Section 6 8 Connect battery negative cable refer to Section 6 9 Install or reconnect any other components removed or disconnected Cylinder Head Removal CAUTION
84. 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 Ib load Test the lash adjusters as follows Leakdown Testing NOTE Do not mix parts from different hydraulic lash adjusters Parts are select fit and are not interchangeable 1 Clean the lash adjuster to remove all traces of engine oil NOTE Lash adjusters can
85. pump pulley bolts Coolant 10 89 pump to block bolts Draincock 2 18 Thermostat 10 89 housing bolts 05 16 DSG 423 CHARGING SYSTEM INDEX Subject Page General Informati om E e 06 3 Begin pe UM 06 3 06 3 Diagram uses etti iR tr RE PH AER 06 4 Diagnosis Testing 06 5 Preliminary eie co 06 5 Warning Indicator Check erac ce Ee ted aro oe de e a uae ge de Rap e Nut e ety ede 06 5 e 06 6 Battery PE 06 7 Battery Load TeSt ies 06 7 Generator Output Test iioc ade Ae edet 06 8 Generator Voltage Test 1 06 8 General Service 06 9 Battery Cleaning and aer Bec Eres eI ivre Be 06 9 erum 06 9 Battery snot eere eee Cie ar ted aep 06 10 Removal and Installationen eite edere nier terere cedro cio rides etin Le 06 11 Generator
86. resistance in I circuit Burned out bulb Poor ground S circuit shorted to Voltage regulator Generator Accessory drive belt Accessory brackets Bent generator pulley Generator Other components Lamp circuit shorted to B Improper lamp circuit wiring Repair as necessary Repair as necessary Repair as necessary 06 6 DSG 423 CHARGING SYSTEM Battery Drain Test A WARNING REFER TO CAUTIONS amp WARNINGS AT THE BEGINNING OF THIS SECTION A defective component or wiring defect may be causing a small current drain that is less than the fuse rating for the circuit so the fuse does not open Perform the following to determine if an excessive drain is occurring NOTE Batteries should be fully charged for the following test A WARNING DO NOT ATTEMPT THIS TEST ON A LEAD ACID BATTERY THAT HAS RECENTLY BEEN RECHARGED EXPLOSIVE GASES MAY CAUSE PERSONAL INJURY FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY CAUTION To prevent damage to the meter do not crank engine or operate accessories that draw more than 10A 1 Allow the engine to sit with the ignition off for at least 40 minutes to allow the GCP to power down 2 Connect a fused 10A jumper wire between the negative battery cable and post to prevent the GCP from resetting and to catch capacitive drains 3 Disconnect the negative battery cable without breaking the connection of the jumper wire NOT
87. rpm adjust the VAT 40 or equivalent load bank to determine the output of the generator Generator output should be greater than values given in the graph below AMPS 100 65 AMPS MIN 80 2000 RPM 60 40 20 O 500 1000 1500 2000 2500 ENGINE SPEED RPM Generator Voltage Test WARNING REFER TO CAUTIONS amp WARNINGS THE BEGINNING OF THIS SECTION 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 06 8 DSG 423 CHARGING SYSTEM GENERAL SERVICE PROCEDURES IN WARNING REFER TO CAUTIONS amp WARNINGS AT THE BEGINNING OF THIS SECTION Battery Cleaning and Inspection Keeping the battery top clean and dry reduces the need for service and extends battery life Also make certain the cable clamps are tightly fastened to the battery posts If corrosion is found disconnect the cables and clean clamps and posts with a wire brush Neutralize the corrosion with a solution of baking soda and water After installing cables apply a small quantity of Premium Long Life Grease XG 1 C or K or equivalent grease meeting Ford specification ESA M1C75 B to each battery post to help prevent corrosion Battery Tools Anyone working with
88. the cylinder bore taper Bore the cylinder to the next oversize gt i 1 i 1 1 1 1 amp FPP03520 Dial Indicator with Bracketry TOOL 4201 C or Equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 FPP10026 NOTE Crankshaft main bearing journals must be within specifications before checking runout 01 25 DSG 423 GENERAL INFORMATION Cylinder Bore Out of Round Make sure the oil ring holes are clean 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 7A V V N A FPP03523 ODDO Loe Piston Diameter Measure piston skirt diameter Piston Inspection Special Tool s Piston Ring Groove Cleaner D81L 6002 D or Equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA FPP03524 1 800 768 8632 FPP10032 CAUTION Do not use a caustic cleaning solutionor Piston to Cylinder Bore Clearance a wire brush to clean the pistons or possible dam age can occur E P Subtract the piston diameter from the cylinder bore diameter to find the piston to cylinder bore clearance 1 Clean and inspect the ring lan
89. 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 03545 Valve Inspection Inspect the following valve areas The end of the stem for grooves or scoring The valve face and the edge for pits grooves or scores The valve head for signs of burning erosion warpage and cracking Minor pits grooves and other abrasions may be removed The valve head thickness for wear Valve Stem Valve Head Thickness Y Valve Face 03546 01 32 DSG 423 GENERAL INFORMATION Valve Guide Inner Diameter Valve Spring Installed Length 1 Measure the inner diameter of the valve guides in Measure the installed length of each valve spring 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 J i ni 03549 C Valve Spring Free Length Measure the free length of each valve spring 03547 Valve Guide Reaming 1 Use a hand reaming kit to ream the valve guide
90. to 2222292 04 16 DSG 423 FUEL SYSTEM Engine Idles With Rough Acceleration At Load Continued at the harness connector Is the voltage less than 11 5 volts Test Step Result Action to Take 6 Check FCV operation Yes This would indicate the engine is too lean Possible causes e Accelerate engine to induce symptom Plugged bypass port go to Step 7 Disconnect the vacuum hose from the FCV valve to the regulator FCV valve connection go to Does the engine accelerate smooth with the hose disconnected fault Go to Step 9 7 Check FCV vacuum fitting bypass port Yes Clean out bypass with a 050 size pin or drill bit and retest The bypass port is located on the back of the 90 degree CAUTION Do not enlarge the by elbow which connects the vacuum line from the converter pass port to the FCV valve Is this bypass partially closed with dirt or debris No Go to Step 8 8 Check FCV supply voltage Yes 12 volt FCV circuit is open shorted to ground or the GCP module is faulty Key OFF Check wiring connectors and fuses Disconnect connector from harness for possible cause With engine at idle and upon acceleration Using a high impedance DVOM check for 12 volt supply No Referto section 475 1 for servicing the carburetor Also refer to the Diagnostic Aids below Diagnostic Aids Fuel Line Restrictions The
91. to measure the carburetor air valve vacuum AVV No With the engine at idle and accelerating observe the Check the adapter plates between the amount of measured vacuum mixer and the manifold for leaks If none can be found service the carburetor see section 475 1 and retest If the failure is still present replace the FCV valve Is the measured vacuum non linear and outside the specifications Diagnostic Aids Regulator Assembly Converter amp FCV Check the regulator primer button for slight sticking or a small leak around the seat This may be enriching the mixture enough for a failure If a leak is found see section 475R 1 for servicing the regulator If no other problems have been identified replace the fuel management assembly with a known good part of the same pressure range Retest 04 26 DSG 423 FUEL SYSTEM The pinpoint tests below should be performed after the preliminary tests and Engine Cranks but Will Not Start chart Steps 1 3 Any electrical diagnostics should have been performed to eliminate any sensor GCP or solenoid valve problems before proceeding Engine Overheats Test Step Result Action to Take 1 Check for icing or freezing of the Regulator Yes The presence of ice on the converter with the engine running indicates the With the Engine at Idle possibility of a coolant supply problem Check for ice or frost build up on the converter casing a
92. vehicle specifications table specifies the fuel to be a certain size If the fuel line from the tank to the fuel lock is not the proper size or any valves or fittings with flow restrictive characteristics are used the fuel flow will not be sufficient to the converter with low tank pressure Correct any fuel line or fitting restrictions Mixer Assembly Carburetor It is possible that a backfire may have caused the fuel valve to partially come off of it s retainer and restrict fuel check the mixer fuel valves see section 475 1 for disassembly If no other problems have been identified and the mixer has been serviced replace the fuel management assembly with a known good part of the same pressure range Retest 04 17 DSG 423 FUEL SYSTEM The pinpoint tests below should be performed after the preliminary tests and Engine Cranks but Will Not Start chart Steps 1 3 Any electrical diagnostics should have been performed to eliminate any sensor GCP or solenoid valve problems before proceeding Engine Is Unable To Reach Full Power Test Step Result Action to Take 1 Check carburetor air valve for binding Yes Referto section 475 1 for servicing the carburetor e With the air cleaner removed pull the air valve piston upwards to ensure free movement of the carburetor air valve Is the air valve binding No 2 Check air valve operation Yes Referto section 47
93. volt fuelock activation circuit is open shorted to ground or the GCP Key OFF module is faulty Check wiring connectors and fuses for possible Disconnect Fuelock connector from harness cause Key ON pene No Go to Step 5 Using a high impedance DVOM check for 12 volt supply at the harness connector Is the voltage less than 11 5 volts 5 Check primary fuel pressure to regulator Yes Fuel filter element may be clogged inspect and or replace the fuel filter as Using Woodward WTK 1 test kit install the primary described in section 475F 1 Repeat pressure gauge as described in section 475G 1 test steps 4 5 if pressure is still less e Kev than specified the fuelock is faulty EY NN Replace the fuel lock Is the pressure less than X psi No Go to Step 6 5 Check for icing or freezing of the Regulator Yes The presence of ice on the converter without the engine cranking indicates Key ON the possibility of a fuel leak past the rg for ice or frost build up on the converter casing and RomA eee outlet port converter Key OFF i No Go to Step 6 Is ice present 04 12 DSG 423 FUEL SYSTEM Engine Cranking But Will Not Start Continued Test Step Result Action to Take 7 Check FCV vacuum fitting bypass port Yes Clean out bypass with a 050 size pin or drill bit and retest The bypass port is located on the back of the 90 degree CAUTION Do not enlarge the
94. 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 or Engine Performance No Load illuminate 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 SYMPTOM POSSIBLE CAUSE Engine Runs Briefly and Shuts Down Loss of Spark Frozen Fuel Regulator Dry Fuel Low Fuel Pressure Air Inlet Restriction Wiring Failure GCP Failure Engine Cranks But No Start Faulty OEM Drivers Safety Shut Off Seat Switch Coil Power Loss GCP Ground Loss GCP Power Loss Severe Vacuum Leak Dry Fuel Air Inlet Restriction Air Inlet Leak Dry Fuel Fuel Lock Off Inoperative Dry Fuel Wiring Failure Low Fuel Pressure Ancillary Components Binding Engine Runs Poorly High Fuel Pressure Low Fuel Pressure Contaminated Fuel Incorrect Fuel Select Table Selected Wrong GCP Installed Actuator Air Blockage Map Sensor Leak Fuel Contaminated Noise Suppression Capacitor Failure Improper PCV Routing Valve Timing Low Cylinder Compression Engine Cranks Slowly Excessive Engine Load Hydraulic Pump Failing Binding Ancillary Drive Comp
95. when repairs are required but also for regular maintenance Distributors are listed at the back of this manual Engines manufactured by Ford Motor Company are available through EDI Distributors When in need of parts or service contact your local Authorized Distributor In overseas territories in the event of difficulties communicate directly with the supervising EDI affiliated Company in your area whose address appears at the end of this book Where the terms Right or Left occur in this publication they refer to the respective sides of the engine when viewed from the rear or flywheel end Pistons and valves are numbered from the front or timing cover end of the engine commencing at No 1 You may find that your engine assembly includes optional equipment not specifically covered in the following text Nevertheless the service procedures outlined in this book still apply to your engine Engine Identification Because Ford Power Products markets such a wide range of industrial gasoline and diesel engines manufactured both in the U S and overseas it is important that you have as complete identification of the engine as possible in order to provide the correct replacement parts Review the list in the back of this book for an EDI distributor in your area You can obtain a standard parts listing describing the parts It remains a distributor function to identify the part number 19 DISTRIBUTORS INC Model
96. 5 1 for servicing the carburetor Using the WTK 1 test kit connect the vacuum gauge between the carburetor and the FCV valve to measure the carburetor air valve vacuum AVV Goto Step 3 With the engine accelerating observe the amount of measured vacuum Is the measured vacuum non linear and outside the specifications 2 Check regulator fuel supply Yes The fuel filter may be restricting flow or the fuel lock may be intermittent Go Using Woodward WTK 1 test kit install the primary to Step 3 pressure gauge as described in section 475G 1 e Accelerate to induce symptom No Go to Step 4 Is the primary pressure less than X psi or fluctuating 3 Check fuelock supply voltage Yes 12 volt fuelock activation circuit is open shorted to ground or the GCP Key OFF module is faulty Check wiring e Disconnect Fuelock connector from harness connectors and fuses for possible cause Key ON Fuel filter element may be clogged Using a high impedance DVOM check for 12 volt supply inspect and or replace the fuel filter as at the harness connector described in section 475F 1 Repeat Is the voltage less than 11 5 volts test Step 2 if pressure is still less than specified replace the fuel lock and re test before moving to Step 4 4 Check regulator operation Yes Remove the vacuum hose from the FCV valve to the regulator If the Using Woodward WTK 1 test kit install the primary and pressure is not 1 5 inche
97. 6 3871 in mm 16387 0 in iter 0 016387 yard m 0 7646 pint us iter 0 47318 pint uk iter 0 56826 quart us iter 0 94635 gallon us iter 3 7854 gallon uk iter 4 5461 83 iter 28 3168 3 m 0 02832 Mass Oz g 28 3495 Ib kg 0 45359 ton kg 907 18 ton US tonne 0 90718 ton UK tonne 1 01605 Density Force Ibf Newton N 4 44822 kilogram Newton N 9 807 ounce Newton N 0 2780 Pressure amp Stress 1000 kpa Bar 1000 Ibt in psi kPa 6 895 Ibffin psi N M 6894 76 Ibf in psi Bar 0 0689 Ibf in psi N mm 0 00689 Ibf m psi mmHg 51 715 H20 kPa 0 2491 H20 mmH20 25 4 Hg mmHG 25 4 ton 05 N mm 13 7894 ton UK in2 N mm 15 4443 Velocity ft sec m s 0 3048 ft sec km h 1 09728 miles h m s 0 44694 miles h km h 1 609 Acceleration 2 m s 0 0254 ft sec m s 0 3048 Light foot candle lumens sq meter 10 764 09 5 TO CONVERT FROM TO MULTIPLY BY TO FROM DIVIDE BY Energy kW h Joules J 3 600 000 Ib ft Joules J 1 3558 Btu Joules J 1055 06 Kcal Joules J 4186 8 HP h kW h 0 7457 PS h kW h 0 7355 Temperature degree Farenheit F degree Celsius C F 32 x 0 556 Torque Ib ft Nm 1 35582 Ib in Nm 0 11298 Power HP kW 0 7457 PS kw 0 7355 HP PS 1 01387 Specific Fuel Consumption Ib hp h g kW h 608 277 miles gal kilometers liter km L 0 4251 gal miles liters kilometer L km 2 3527 DSG 423 METR
98. 7 in Journal to bore clearance 0 035 0 080 mm 0 001 0 003 in Connecting Rod Bearing clearance 0 027 0 052 0 001 0 002 in Bearing thickness Main bearing clearance 0 019 0 035 mm 0 0007 0 0013 in 1 496 1 520 mm 0 058 0 059 in Crank bore diameter Connecting rod journal diameter 49 980 50 000 mm Production repair 49 730 49 750 mm 1 957 1 958 in 1 967 1 968 in 53 025 53 045 mm 2 087 2 088 in Pin bore diameter Length center to center 20 965 20 985 mm 0 825 0 826 in 154 8 mm 6 094 in End play 0 22 0 43 mm Side clearance 1 95 3 05 mm 0 008 0 016 in 0 076 0 120 in Rings Axial clearance 0 14 0 36 mm Width top 1 17 1 185 mm 0 0460 0 0466 No 3 Journal Supported by No and No 5 Width 2nd 1 197 1 199 mm Journals 0 0471 0 0472 in Width oil 238 245 mm dimensions are in mm unless noted 0 093 0 096 in NE Torque Specifications Ring gap in bore top 0 16 0 31 mm 0 006 0 012 in Description Nm lb ft Ib in Ring gap in bore 2nd 0 33 0 48 mm Accelerator control 8 71 0 012 0 018 in splash shield Ring gap in bore oil 0 2 0 7 mm A C manifold tube bolt 20 15 OPE A C compressor bolts 25 18 Valve Tappet Camshaft sprocket bolt 65 48 Diameter 30 97 30 98 mm Cunsliati beanna ca
99. 8 1338 1000 1154 1158 134 101 164 123 194 146 224 168 938 703 1145 855 1351 1014 1558 1165 136 102 166 124 196 147 226 169 952 717 1158 869 1365 1020 1572 1179 138 104 168 126 198 148 228 171 965 724 1172 876 1379 1034 1586 1186 140 106 170 127 200 150 230 172 979 738 1186 889 1303 1041 1600 1200 142 107 172 129 202 151 232 174 933 745 1200 903 1407 1055 1055 1207 144 109 174 131 204 153 153 175 1007 758 1214 910 1420 1062 1627 1220 146 110 176 132 206 154 154 177 1020 765 1227 917 1434 1075 1641 1227 148 111 178 133 208 156 238 178 1034 779 1241 931 1448 1083 1655 1241 150 113 180 135 210 157 240 180 1048 786 1225 936 1462 1089 1669 1248 152 114 182 136 212 158 242 181 1062 793 1269 952 1476 1103 1682 1262 154 115 184 138 214 160 244 183 1076 807 1282 965 1489 1117 1696 1269 156 117 186 140 216 162 246 184 1089 814 1296 972 1503 1124 1710 1202 158 118 188 141 218 163 248 186 1103 872 1310 979 1517 1138 1724 1289 160 120 190 142 220 165 250 187 1110 834 1324 993 1631 1145 161 121 192 144 222 166 Interpreting Compression Readings 1 If compression improves considerably with the add
100. 80 AMPS Current draw NORMAL load Current draw MAX load 800 AMPS Minumum stall torque 5 volts 14 7 Nm 16 Ib ft Cranking speed 140 220 RPM Max voltage drop normal operating temp TORQUE SPECIFICATIONS Description Nm Ib ft Ib in Mounting bolts nuts studs 27 20 Battery cable nuts 6 53 Solenoid terminal nut 5 44 Solenoid terminal nut 12 9 SPECIAL TOOLS VAT 40 Starting charging 078 00005 Tester 07 10 DSG 423 ENGINE CONTROLS Subject Page General nformation 5 nere epe niente 08 2 GOP Al saat boas dE TE 08 2 Fuel System Components 9 08 8 Goil onspl g lghitlOD oon ae eae ea vae ce v al oles e A EAE EAS 08 9 Open Loop and Closed Loop 08 10 Adaptive tie e t ig RED RR 08 10 GCP Se rvice Precautiolis cete denn ee ah e Pee ende ete hanes 08 10 Use of Circuit Testing 06 08 10 Electrostatic Discharge Damage ott eee dive eg bv ete 08 10 Diagrams and 5 08 11 Engine
101. ALWAYS SHIELD YOUR EYES ALWAYS PROVIDE VENTILATION AN WARNING WHEN LIFTING A BATTERY ALWAYS LIFT WITH A BATTERY CARRIER OR WITH YOUR HANDS ON OPPOSITE CORNERS EXCESSIVE PRESSURE ON THE END WALLS COULD CAUSE ACID TO SPEW THROUGH THE VENT CAPS RESULTING IN PERSONAL INJURY WARNING IT IS ESSENTIAL THAT THE WIRING CONNECTIONS TO THE GENERATOR ARE NOT REMOVED WHILE THE ENGINE IS RUNNING AS THIS WILL RESULT IN DAMAGE TO THE REGULATOR OR PERSONAL INJURY WARNING KEEP BATTERIES OUT OF THE REACH OF CHILDREN BATTERIES CONTAIN SULFURIC ACID AVOID CONTACT WITH SKIN EYES OR CLOTHING ALSO SHIELD YOUR EYES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION IN CASE OF ACID CONTACT WITH THE SKIN OR EYES FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF 15 MINUTES AND GET PROMPT MEDICAL ATTENTION IF ACID IS SWALLOWED CALL A PHYSICIAN IMMEDIATELY FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY NOTE Battery posts and cable clamps must be clean and tight for accurate meter indications CAUTION Always remove the negative cable first to prevent possible arcing possibly damaging other electrical components 06 2 DSG 423 CHARGING SYSTEM GENERAL INFORMATION Bracket Generator Voltage Regulator Description WARNING REFER TO CAUTIONS amp WARNINGS AT THE BEGINNING OF THIS SECTION The charging system consists of a generator voltage regu
102. AND MAY BE IGNITED Bolts 2 Fuel Retainer Clips 4 A Lo S Electrical A 2 y Connector x Fuel Injectors 2 1 Disconnect the battery ground cable 7 If necessary remove the retaining clips and 2 Remove and or disconnect components to allow IOS Tetra access and removal of the fuel rail injectors Label if necessary to allow for correct reinstallation ioa Use o ring seals that are made of special uel resistance material The use of ordinary o rint CAUTION After disconnecting fuel lines plug the seals can cause the fuel system to leak Do not i ends to prevent fuel leakage use the o ring seals 3 Disconnect fuel lines Refer to General Service Procedures on page 310f this section 4 Disconnect injector electrical connectors 5 Remove bolts Tighten fuel rail bolts to 25 Nm 18 lb ft 6 Carefully remove the fuel rail and injector assembly 8 Reverse procedure to install Lubricate new o rings with clean engine oil 04 35 DSG 423 FUEL SYSTEM Actuator Removal 1 Remove and or disconnect components to allow access and removal of the actuator Label if necessary to allow for correct reinstallation Actuator Installation 1 2 3 Disconnect air cleaner components from actuator Disconnect accelerator cable Disconnect electrical connectors Remove nuts Remove actuator and gasket NOs 04 36 Inspect gas
103. AND NO LIST CAN BE EXHAUSTIVE ALWAYS BE CAUTIOUS TO AVIOD POTENTIAL SAFETY RISKS The following recommendations are for general guidance 1 Always wear correctly fitting protective clothing which should be laundered regularly Loose or baggy clothing can be extremely dangerous when working on running engines or machinery Clothing which becomes impregnated with oil or other substances can constitute a health hazard due to prolonged contact with the skin even through underclothing 2 So far as practicable work on or close to engines or machinery only when they are stopped If this is not practicable remember to keep tools test equipment and all parts of the body well away from the moving parts of the engine or equipment fans drive belts and pulleys are particularly dangerous The electric cooling fan used on some installations is actuated automatically when the coolant reaches a specified temperature For this reason care should be taken to ensure that the ignition isolating switch is OFF when working in the vicinity of the fan as an increase in coolant temperature may cause the fan suddenly to operate 3 Avoid contact with exhaust pipes exhaust manifolds and silencers when an engine is or has recently been running these can be very hot and can cause severe burns 4 Many liquids used in engines or vehicles are harmful if taken internally or splashed into the eyes In the event of accidentally swallowing gasoline petrol oil diesel fue
104. Adjuster Inspectlon e ntt tb e 01 31 Valve Stem 01 32 Valve Stem to Valve Guide 01 32 MalVe Inspections etait Segre Re et ha cade MEE UE 01 32 Valve Guide Inner Diameter 2 Donc E RE Me c td aces o qal 01 33 Valve Guide ROAMING tp PD EC RE HUI RELIER HR CER es eee 01 33 Valve Spring Installed Eengthi rere treten t HE te ee eee d beu e 01 33 Valve Spring Free Length iae RD MT HERB ERRARE EA 01 33 Spririg Outsof Square d 01 33 Valve Spring Compression Pressure 01 34 Valve and Seat Refacing 01 34 Malve Seat eau nu ULM tetur E 01 34 Malve Seat T 01 34 Elywheel Inspection iiie RR Og EAR Med 01 35 Oil Pump Gear Radial Clearance ants tent Tene da bates 01 35 Oil Pump Rotor
105. Component Locator 08 23 Connector End 08 16 Diagnosis 08 24 Diagnostic Approach te anu aane ee en ee gan 08 24 GCP Diagnostic OvefVieWis imeri iein idle ree dut cde t Fato qe tup ds oe DELL oo e RD QE Dh adus 08 24 On Board Diagnostics iaa eerte ed kae caer ped 08 24 Engine Control Module GCP Limp Home Mode 08 24 Intermittent iioc trt e D ree cease ated anced rodea onte 08 25 Malfunction Indicator Lamp MIL DTC Retrieval 08 25 Diagnosis Using a Personal 08 26 Visual Inspectiori eicit e eee eee eee te De DE ne 08 36 IntcuanucnSuee nce 08 36 Symptom Ghants rdv o euge c Mette headin ene beaded 08 37 Engine Control Module GCP Diagnostic Trouble 08 40 Removal and Installation 55 rre Dee
106. DSG 423 ENGINE DISTRIBUTORS 2 3 LITER INDUSTRIAL ENGINE SERVICE MANUAL Powertrain Assemblies amp Components Provided By Ford Component Sales GE EDI 1060040 AUG 2007 Section Index Reproduction in any manner in whole or in part is prohibited without the express permission in writing from Engine Distributors Inc EDI EDI policy is one of continuous improvement and while every effort is made to ensure that this publication is up to date and correct in all respects the right to change prices specifications and equipment at any time without notice is reserved Accordingly this publication is not to be regarded as a final description of any individual engine Section 01 Kel Section 02 Section 03 Section 04 MIB Section 05 04010 NG Section 06 C HARG G Section 07 Section 08 emote E Section 09 24 64 Section 10 lt gt HEALTH 8 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
107. 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 Gasoline 14 1072 08 30 DSG 423 ENGINE CONTROLS Flight Data Recorder Data Stream Reading Sensor amp Actuator Values 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 is an example of a flight Data Recorder Data window 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 e Manifold Absolute Pressure MAP Engine Coolant Temperature ECT The FAULTS screen shows the following Intake Air Temperature IAT Fault Access Throttle Position TP System States Foot Pedal Position FPP DBW Variables Battery Voltage Closed Loop Contr
108. E Honing should be done when fitting new piston rings or to remove minor surface e 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 FPP03560 Cylinder Bore Cleaning CAUTION If these procedures are not followed rusting of the cylinder bores may occur 1 Clean the cylinder bores with soap or detergent and water 2 Thoroughly rinse with clean water and wipe dry with a clean lint free cloth 3 Use clean lint free cloth and lubricate the cylinder bores Use Engine Oil XO 10W30 QSP or DSP or equivalent meeting Ford specification ESE M2C153 E 01 36 DSG 423 GENERAL INFORMATION Cylinder Block Repair Cast Iron Porosity Defects CAUTION Do not attempt to repair cracks areas where temperature will exceed 260 500 or eas exposed to engine coolant or oil These areas will not repair and could cause future failure FPP03561 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
109. E It is very important that continuity between the negative battery cable and post is not broken If it is the entire procedure must be repeated so the GCP can power down again 4 Connect an ammeter between the negative battery cable and post The meter should have a 10 amp capability NOTE If after this next step the meter settings need to be switched or the test leads need to be moved to another jack the jumper wire must be reinstalled to avoid breaking continuity 5 Remove the jumper wire and note the amperage draw There should not be any more than 50 mA 0 050 amp draw If excessive remove fuses one at a time until the circuit with the excessive draw is located Usethe wiring diagram to locate any circuits that do not pass through the fuse box Disconnect the generator connections to check for an internal short causing an excessive draw Battery Load Test AN WARNING REFER TO CAUTIONS amp WARNINGS AT THE BEGINNING OF THIS SECTION 1 Disconnect both battery terminal cables Check the battery visually 2 Examine the hydrometer eye if no eye go to next step Eye shows green go to step 4 Eye shows dark recharge then go to step 4 Eye shows yellow replace battery 3 Apply a 300 amp load for 15 seconds Turn off load and wait one minute f 12 4 volts or more go to step 4 Ifless than 12 4 volts recharge then repeat step 3 4 Apply a test load equal to 50 of the batter
110. ER TO WARNINGS AT THE BEGINNING OF THIS SECTION 1 Relieve the fuel system pressure Refer to Fuel Pressure Relief on page 31 of this section 2 Disconnect the safety clip from the male hose n 4 Pull on the fitting to make sure it is fully engaged 3 Install the fuel tube disconnect tool 310 5039 and 04 32 DSG 423 FUEL SYSTEM then install safety clip Quick Connect Coupling Type Disconnect WARNING REFER TO WARNINGS AT THE BEGINNING OF THIS SECTION CAUTION Do not use any tools Use of tools may cause a deformity in the coupling components which can cause fuel leaks 1 Relieve the fuel system pressure Refer to Fuel Pressure Relief on page 31 of this section 2 Press the fuel tube quick connect coupling button and pull fuel tube to disconnect Wr Quick Connect Coupling Type 1 Connect 1 Inspect for damage and clean fittings CAUTION Make sure the fuel tube clicks into place when installing the tube To make sure that the fuel tube is fully seated pull on the tube 2 Lubricate the o ring seals with clean engine oil 3 Install the quick connect coupling onto the tube until it is fully seated 4 Pull on the fitting to make sure it is fully engaged Quick Connect Coupling Type Il Disconnect WARNING REFER WARNINGS THE BEGINNING OF THIS SECTION CAUTION Do not use any tools Use of tools may cause a defor
111. ETABLE OIL CALL A PHYSICIAN IMMEDIATELY CAUTION Do not disconnect the battery of the en gine to be started Disconnecting the battery could damage the equipment s electronic system WARNING MAKING THE FINAL CABLE CONNECTION COULD CAUSE AN ELECTRICAL SPARK NEAR THE BATTERY AND COULD CAUSE AN EXPLOSION REFER TO WARNING AT THE BEGINNING OF THE JUMP STARTING PROCEDURE 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 WARNING TO AVOID INJURY USE PARTICULAR CARE WHEN CONNECTING A BOOSTER BATTERY TO A DISCHARGED BATTERY 1 Position equipment so jumper cables will reach being careful that equipment does not touch each other Negative Jumper Lead Positive Jumper Lead FPP01112 Discharged Battery NOTE Be sure to disconnect battery negative cable before servicing starter 2 Connect one end of positive red jumper cable 1 to positive terminal of discharged battery and other end to positive terminal of booster battery 3 Connect one end of negative black jumper cable 3 to negative terminal of booster battery Connect other end to an engine bolthead or good metallic contact spot on engine of equipment to be started NOT TO NEGATIVE BATTERY TERMINAL 4 Make sure jumper cables are not in way of moving engine parts 5
112. G WARNING REFER CAUTIONS amp WARNINGS THE BEGINNING OF THIS SECTION NOTE When the battery is disconnected and connected some abnormal symptoms may occur while the GCP relearns its adaptive strategy The engine may need to run to relearn its strategy Preliminary Checks Before beginning test procedures check battery cables and generator wiring especially grounds for clean tight connections Wires and connectors should not be damaged or corroded Perform the following checks before any testing Looseor corroded connections at battery grounded starter motor cutout relay or engine e Inspect all connectors for loose or damaged pins wires etc Make sure the batteries are at 75 state of charge SOC or higher This represents an open circuit voltage OCV of 12 4 volts Batteries with an OCV of 12 volts or less are either completely discharged or have a dead cell e Check the generator drive belt tension This will cause low generator output e Check any light or indicator lamp filaments that are suspected of being open burned out This is done to avoid unnecessary extensive circuit checks e fuse is blown locate the cause of the overload condition and repair it The common procedure is as follows isolate sections of the circuit by disconnecting connectors and measure the resistance to ground to find the circuit that is shorted to ground Then locate the damaged spot in the wire or
113. G OUT SERVICE OPERATIONS ON AN ENGINE EQUIPPED WITH DISTRIBUTORLESS IGNITION IT IS IMPORTANT TO BE AWARE OF THE ABOVE POINT AS WELL AS ALL THE USUAL SAFETY MEASURES TO PREVENT THE POSSIBILITY OF ELECTRIC SHOCKS 03 2 DSG 423 IGNITION SYSTEM Compression Stroke Operation With this system the GCP monitors the engine speed and operating temperature and decides what degree of spark advance is correct for all of the operating conditions Because timing is set for life inherently in the design of 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 in the warm up mode The spark plugs are paired so that one plug fires during the compression stroke and its companion plug fires during the exhaust stroke The next time that coil is fired the plug that was on exhaust will be on compression and the one that was on compression will be on exhaust The spark in the exhaust cylinder is wasted referred to as the waste spark but little of the coil energy is lost Engine Speed and Crankshaft Position The crankshaft position and speed information comes to the GCP from the Crankshaft Position CKP Sensor
114. ICS DECIMAL AND METRIC EQUIVALENTS TORQUE CONVERSION Newton Pound Newton Pound EE 93125 E Meters Feet Meters Feet Nm Ib ft Nm Ib ft 3 64 046875 1 191 116 0625 1588 1 0 7376 1 1 356 5 64 1078125 1 984 2 1 5 2 2 7 3 32 09375 2 381 3 22 3 4 0 7 64 109375 2 778 4 3 0 4 54 1 8 125 3 175 5 37 5 68 9 64 140625 3 572 5 32 15625 3 969 6 44 6 8 1 11 64 171875 4 366 7 5 2 7 95 3 16 1875 4 763 8 59 8 10 8 13 64 203125 5 159 9 6 6 9 122 7 32 21875 5 556 10 74 10 136 15 64 234375 5 953 250 635 15 11 1 15 20 3 17 64 265625 6 747 20 14 8 20 27 1 9 32 28125 7 144 25 184 25 33 9 19 64 296875 7 54 30 224 30 40 7 5 16 3125 7 938 35 258 35 775 21 64 328125 8 334 11 32 34375 8 731 40 29 5 40 54 2 23 64 359375 9 128 50 36 9 45 61 0 3 8 375 9 525 60 44 3 50 67 8 25 64 390625 9 922 70 51 6 55 74 6 13 32 40625 10 319 80 59 0 60 812 27 64 421875 10 716 7 16 4375 11 113 90 66 4 65 88 1 29 64 453125 11 509 100 73 8 70 94 9 15 32 46875 11 906 110 81 1 75 101 7 31 64 484375 12 303 120 88 5 80 108 5 a 130 95 9 90 122 0 33 64 515625 13 097 17 32 53125 13 494 140 103 3 100 135 6 35 64
115. INFORMATION Valve Train Analysis Static With engine off and valve cover removed check for damaged or severely worn parts and correct assembly Make sure correct parts are used with the static engine analysis as follows Rocker Arm e Check for loose mounting bolts studs and nuts e Check for plugged oil feed in the rocker arms or cylinder head Camshaft Roller Followers and Hydraulic Lash Adjusters Check for loose mounting bolts on camshaft carriers e Check for plugged oil feed in the camshaft roller followers hydraulic lash adjusters HLA or cylinder heads Camshaft e Check for broken or damaged parts Check the bolts on the intake manifold Push Rods if equipped e Check for bent push rods and restricted oil passage Valve Springs e Check for broken or damaged parts Valve Spring Retainer and Valve Spring Retainer Keys 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 e Check for plugged oil drain back holes e Check for worn or damaged valve tips e Check for missing or damaged guide mounted valve stem seal e Check collapsed lash adjuster gap e Check installed valve spring height e Check for missing or worn valve spring seats Check for plugged oil metering orifice in cylin
116. L Engine Coolant Level Indicator ECL Indicator Engine Coolant Level Indicator Engine Coolant Temperature ECT Engine Coolant Temperature ECT Engine Coolant Temperature Sensor ECT Sensor Coolant Temperature Sensor CTS Engine Coolant Temperature Sender ECT Sender Engine Coolant Temperature Switch ECT Switch Coolant Temperature Switch CTS Engine Speed RPM Crankshaft Speed Revolutions Per Minute RPM Engine Speed Sensor RPM Sensor Crankshaft Speed Sensor Erasable Programmable Read Only Memory EPROM Erasable Programmable Read Only Memory EPROM Evaporative Emission EVAP Evaporative Emission EVAP Evaporative Emission Canister EVAP Canister Canister Charcoal Canister Evaporative Emission Canister Purge EVAP Canister Purge EVAP CANP Canister Purge CANP Evaporative Emission Canister Purge Valve EVAP Canister Purge Valve Canister Purge Valve Canister Purge Vacuum Switching Valve Canister Purge VSV Duty Solenoid for Purge Valve Evaporative Emission Purge Valve EVAP Purge Valve Vacuum Solenoid Valve Canister VSV Vacuum Solenoid Valve EVAP VSV Evaporative Emission System EVAP System Evaporation Emission Control System EECS Exhaust Gas Recirculation EGR Digital Exhaust Gas Recirculation Digital EGR Exhaust Gas Recirculation Backpressure Transducer EGR Backpressure Transducer Backpressure Transducer
117. NVO LNV SL vL lA 9QJ 8b 1001 199 SUIN OL SIML 91 90 81 1001 10d SUIN OL SIML 97 90 81 8 Bury L 4 1 n age NVO HMMA L qaa 9 HME 81 o p q voL 13 4 08 22 DSG 423 ENGINE CONTROLS Engine Component Locator View CMP Sensor TMAP Sensor Actuator with Throttle Position Sensor TP GCP CHT Sensor ECT Sensor HO2S Sensor 08 23 DSG 423 ENGINE CONTROLS DIAGNOSIS AND TESTING Diagnostic Approach Use the following step by step approach when diagnosing an engine performance problem 1 Verify the concern and determine if it is a deviation from normal operation 2 Once the concern has been verified preliminary checks can be done Conduct a thorough visual inspection be alert for unusual sounds or odors and gather diagnostic trouble code DTC information 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 an
118. Pressure Higher than Expected DTC 112 HO2S Open Inactive Bank 1 DTC 354 MegaJector Delivery Pressure Lower than Expected DTC 113 HO2S Open Inactive Bank 2 DTC 355 MegaJector Communication Lost DTC 121 Closed Loop Multiplier High Bank 1 Gasoline DTC 361 MegaJector Voltage Supply High DTC 122 Closed Loop Multiplier Low Gank 1 Gasoline DTC 362 MegaJector Voltage Supply Low DTC 124 Closed Loop Multiplier Low LPG DTC 363 MegaJector Internal Actuator Fault Detection DTC 125 Closed Loop Multiplier High Natural Gas DTC 364 Megavector Internal Circuitry Fault Detection DTC 126 Closed Loop Multiplier Low Natural Gas DTC 365 MegaJector Internal Communication Fault Detection DTC 131 Closed Loop Multiplier High Bank 2 Gasoline DTC 411 Coil Driver 1 Open DTC 132 Closed Loop Multiplier Low Bank 2 Gasoline DTC 412 Coil Driver 1 Shorted DTC 141 Adaptive Lean Fault High Limit Gasoline DTC 413 Coil Driver 2 Open DTC 142 Adaptive Rich Fault Low Limit Gasoline DTC 414 Coil Driver 2 Shorted DTC 143 Adaptive Learn High LPG DTC 511 FPP1 High Voltage DTC 144 Adaptive Learn Low LPG DTC 512 FPP1 Low Voltage 145 Adaptive Learn High Natural Gas 513 FPP1 Higher Than IVS Limit DTC 146 Adaptive Learn Low Natural Gas DTC 514 FPP1 Lower Than IVS Limit DTC 161 System Voltage Low DTC 521 FPP2 High Voltage DTC 162 System Voltage High DTC 522 FPP2 Low Voltage DTC 211 High Voltage DTC 531 TPS1 Signal Voltage High DTC 212 IA
119. R TO CAUTIONS AND WARNINGS AT THE BEGINNING OF THIS SECTION 2 Coat the connection areas with an approved water resistant sealer and slide the hose on the 1 Drain the cooling system Refer to Draining the connection Cooling System on page 9 of this section NOTE Make sure the clamps are beyond the bead and 2 Loosen the clamps at each end of the hose to be placed in the center of the clamping surface of the removed connections 3 Slide the hose off the radiator connection and the 3 Tighten the clamps engine water outlet connection 4 Fill the system with coolant Refer to Filling the Cooling System on page 9 of this section 5 Operate the engine for several minutes then check the hoses and connections for leaks Upper Hose Lower Hose 05 11 DSG 423 COOLING SYSTEM Thermostat amp Housing Replacement 1 A 5 WARNING REFER TO CAUTIONS AND WARNINGS AT THE BEGINNING OF THIS SECTION Allow the engine to cool down until the coolant has lowered in temperature to below 110 F Drain the radiator so coolant level is below the thermostat Refer to Draining the Cooling System on page 9 of this section 3 Remove or disconnect components as necessary to thermostat and housing are serviced as an gain access to the thermostat housing 4 Disconnect the lower radiator hose Thermostat amp Housing 4 Radiator Hose Bolt 5 Remove bolts and thermostat ho
120. RE BURNS WITH WATER GET MEDICAL SULFURIQUE HELP RAST PEUT CAUSER LA 5 1 LES YEUX CECITE CU DES SE RINCER LES YEUX A L EAU IHLEDIATEMENT DRUCURES GRAVES CONSULTER UN MEDECIN RAPIDEMENT TENIR HORS DE LA PORTEE DES ENFANTS 01101 Typical Battery Labelling Explosive gases Read relevant L 1 instructions Eye protection must Keep away from 6 children be WORN Do not dispose of as NS CZ household waste CN gt No smoking or naked flames Pb 5 gt recognized disposal RECYCLE Flush eyes immediately when contacted with acid Electrical current may cause injury to personnel Caution important notice NOTE Observe all manufacturers instructions when using charging equipment CAUTION Batteries should not be charged in the vehicle or equipment May damage electrical com ponents DSG 423 GENERAL INFORMATION Forward This book contains service information for the engine s listed on the title page The life of your engine unit and the delivery of the high performance built into it will depend on the care it receives throughout its life It is the operator s responsibility to ensure that the engine is correctly operated We consider it to be in your interests to enlist the aid of an authorized EDI Distributor not only
121. RSONS USING ANTIFREEZE ARE RECOMMENDED TO ADHERE TO THE FOLLOWING PRECAUTIONS ANTIFREEZE MUST NEVER BE TAKEN INTERNALLY IF ANTIFREEZE IS SWALLOWED ACCIDENTALLY MEDICAL ADVICE SHOULD BE SOUGHT IMMEDIATELY PRECAUTIONS SHOULD BE TAKEN TO AVOID SKIN CONTACT WITH ANTIFREEZE IN THE EVENT OF ACCIDENTAL SPILLAGE ONTO THE SKIN ANTIFREEZE SHOULD BE WASHED OFF AS SOON AS PRACTICABLE IF CLOTHING IS SPLASHED WITH ANTIFREEZE IT SHOULD BE REMOVED AND WASHED BEFORE BEING WORN AGAIN TO AVOID PROLONGED SKIN CONTACT FORREGULAR AND FREQUENT HANDLING OF ANTIFREEZE PROTECTIVE CLOTHING PLASTIC OR RUBBER GLOVES BOOTS AND IMPERVIOUS OVERALLS OR APRONS MUST BE USED TO MINIMIZE SKIN CONTACT CAUTION Under no circumstances should the en gine be started without liquid in the cooling system This may cause permanent damage to the engine CAUTION The use of straight water as a coolant will cause permanent damage to the engine CAUTION Never use a cold coolant mixture to top up the radiator or degas tank of a hot engine if the coolant level is very low this could cause serious engine damage CAUTION In territories where freezing conditions may occur the coolant should consist of a mixture of 50 plain water and 50 Motorcraft Premium Gold coolant or equivalent This antifreeze con tains additional corrosion inhibitors designed to provide lasting protection for the engine CAUTION Only this antifreeze or proprietary anti fre
122. SSIBILITY OF PERSONAL INJURY OR DAMAGE DO NOT OPERATE THE ENGINE UNTIL THE FAN BLADE HAS BEEN FIRST EXAMINED FOR POSSIBLE CRACKS OR SEPARATION Positive Crankcase Ventilation System This engine is equipped with a positive closed type crankcase ventilation system which recycles crankcase vapors to the intake manifold Engine Cooling System The 2 3L engine is liquid cooled using an engine mounted coolant pump and external radiator This is a full flow system regulated by a thermostat located behind the water outlet connection The thermostat controls and maintains engine temperature Refer to Section 05 of this manual for more information on the cooling system 02 3 DSG 423 ENGINE 02 4 DSG 423 ENGINE Lubrication System The engine lubrication system consists of Oil pan e pump screen cover and tube Oil pump Oil filter Passageways in the cylinder block crankshaft camshaft and cylinder head The oil pan is pressure cast aluminum and serves as both an oil reservoir and engine bottom cover The oil pan has reinforcing ribs which strengthen the pan reduce engine noise transmission and aid in oil cooling The oil pump is mounted to the engine block and is driven by chain from the crankshaft Oil cooling jets spray to the underside of the piston skirt Oil Pump Drive Belt System Engine accessories such as the generator and water pump are driven by a single serpentine belt T
123. Setup Destination Folder Select a folder where the application will be installed Click next You will now see a screen telling you it is ready to install the software i FPP Display Setup Ready to Install the Application Click Next to begin installation Click next 08 28 DSG 423 ENGINE CONTROLS You will see an Installation Success screen when the software is finished installing ie FPP Display Setup FPP Display has been successfully installed Click the Finish button to exit this installation Click Finish A screen will pop up asking if it is ok to reboot your system Installer Information 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 FPP Display FPP Display as shown FPP Display 4 00 gt Type in the Password which can be found on the label of the CD ROM Enter Password Clear Password Paste Password J Single Serial Number Access im Save password and S N m Place the ignition key in the ON position The FORD system Gauge screen should now appear and a green banner in the upper left hand
124. T Low Voltage DTC 532 TPS1 Signal Voltage Low DTC 213 IAT Higher Than Expected 1 DTC 533 TPS2 Signal Voltage High DTC 214 IAT Higher Than Expected 2 DTC 534 TPS2 Signal Voltage Low DTC 215 Oil Pressure Low DTC 535 TPS1 Higher Than TPS2 DTC 221 CHT ECT High Voltage DTC 536 TPS1 Lower Than TPS2 DTC 222 CHT ECT Low Voltage DTC 537 Throttle Unable to Open DTC 223 CHT Higher Than Expected 1 DTC 538 Throttle Unable to Close DTC 224 CHT Higher Than Expected 2 DTC 545 Governor Interlock Failure DTC 231 MAP High Pressure DTC 551 Max Govern Speed Override DTC 232 MAP Low Voltage DTC 552 Fuel Rev Limit DTC 234 BP High Pressure DTC 553 Spark Rev Limit DTC 235 BP Low Pressure DTC 611 COP Failure DTC 242 Crank Sync Noise DTC 612 Invalid Interrupt DTC 243 Never Crank Synced At Start DTC 613 A D Loss DTC 244 Camshaft Sensor Loss DTC 614 RTI 1 Loss DTC 245 Camshaft Sensor Noise DTC 615 Flash Checksum Invalid DTC 253 Knock Sensor Open DTC 616 RAM Failure DTC 254 Excessive Knock Signal DTC 631 External 5V Ref Lower Than Expected DTC 311 Injector Driver 1 Open DTC 632 External 5V Ref Higher Than Expected DTC 312 Injector Driver 1 Shorted DTC 655 RTI 2 Loss DTC 313 Injector Driver 2 Open DTC 656 RTI 3 Loss DTC 314 Injector Driver 2 Shorted DTC 315 Injector Driver 3 Open DTC 316 Injector Driver 3 Shorted DTC 321 Injector Driver 44 Open DTC 322 Injector Driver 4 Shorted 351 Fuel Pump Loop Open or High Side Short to Ground DTC
125. The amount of fuel P di added is related to the amount of air passing through the carburetor 7psi The greater the airflow into the engine the greater the ideni ENGINE OFF ab ces pressure drop across the diaphragm and the more lift CE occurs on the fuel valve This allows more fuel to be AIR INLET 14 3psi f FUEL INLET 14 3psi FUEL VALVE 14 3psi The variable venturi carburetor controls fuel flow based on a differential pressure across the diaphragm The more air the engine demands the lower the pressure in 04 7 DSG 423 FUEL SYSTEM drawn into the engine Greater pressure DIAPHRAGM differential means greater diaphragm WIDE OPEN THROTTLE and valve lift N 9psi AIRINLET 14 3 FUEL INLET 13 9psi 13 9psi While the carburetor is designed to mix the fuel and air and adjust fuel to match the speed and load of the engine it has only ballpark accuracy This accuracy is not fine enough to achieve emissions targets To achieve accurate fueling the air inlet pressure to the carburetor is controlled by an Electronic Pressure Regulator EPR The EPR serves two functions to vaporize the liquid propane and to control the vapor pressure to the mixer As the propane vaporizes the EPR monitors and controls the vapor pressure to the mixer in reference to the inlet air pressure to the carburetor The receives a pressure command from the called Delta P which
126. The crankshaft the crankshaft sprocket and the pulley are fitted together by friction with diamond washers between the flange faces on each part For that reason the crankshaft sprocket is also unfastened if you loosen the pulley Therefore the engine must be retimed each time the damper is removed Otherwise severe damage can occur 1 Disconnect negative battery cable refer to Section 6 2 Remove and or disconnect components to allow access and removal of the cylinder head Label if necessary to allow for correct reinstallation 3 Remove camshaft cover Refer to Camshaft Cover Removal on page 6 of this section 4 Remove the camshafts Refer to Camshafts Removal on page 18 of this section 5 Remove exhaust manifold Refer to Exhaust Manifold Removal on page 19 of this section 6 Remove fuel rail refer to Section 4 7 Remove and discard cylinder head bolts Bolt 8 Remove and discard gasket 9 Inspect mating surfaces refer to Section 1 Cylinder Head Installation CAUTION Do not use metal scrapers wire brushes power abrasive discs or other abrasive means to clean the sealing surfaces These tools cause scratches and gouges which make leak paths Use a plastic scraping tool to remove all traces of old head gasket 1 Cleanthe mating surface of cylinder head and block with silicone gasket remover and metal surface prep Remove all traces of gasket sealant oil and coola
127. WARNINGS AT THE BEGINNING OF THIS SECTION 1 Relieve the fuel system pressure Refer to Fuel Pressure Relief on page 31 of this section 2 If equipped remove the fuel tube clip 3 Install special tool 310 0005 as shown 4 Close and push the special tool into the open side of the cage 310 D005 310 D005 Spring Lock Coupling Type I Connect 1 Inspect and clean both the coupling ends and install new o ring seals and garter springs if necessary 04 31 DSG 423 FUEL SYSTEM 2 Lubricate o ring seals with clean engine oil push into fitting 310 5039 ac di CAUTION Make sure the fuel tube clicks into place 4 Separate the fitting when installing the tube To make sure that the fuel tube is fully seated pull on the tube 3 Fitthe male fitting into female end and push until the garter spring snaps over the flared end of the female 310 5039 fitting Spring Lock Coupling Type Il Connect 1 Inspect for damage and clean fittings CAUTION Make sure the fuel tube clicks into place P when installing the tube To make sure that the fuel 4 Make sure the coupling is engaged by pulling on the tube is fully seated pull on the tube lines and install the safety clip 2 Lubricate the tube end with clean engine oil to ease Spring Lock Coupling Type Il Disconnect assembly 3 Align and push the tube into the fitting until you hear A a click WARNING REF
128. 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 FPP10000 Impact Slide Hammer T50T 100 A Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 1 Use a slide hammer or tools suitable to remove the cylinder block core plug FPPO4161 2 Inspect the cylinder block plug bore for any damage that would interfered with the proper sealing of the plug If the cylinder block plug bore is damaged bore for the next oversize plug NOTE Oversize plugs are identified by the OS stamped in the flat located on the cup side of the plug 3 Coat 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 Straightedge 303 D039 D83L 4201 A or equivalent 10036 Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 Useastraight edge and a feeler gauge to inspect the cylinder head for flatness Compare with specifications If the cylinder head is distorted install a new oylinder head Strai
129. a eds Valve Seal Installation 2 eee t i ae die RR are Valve Tappet Camshafts da heit t e ue E ER RETE ger ea PEU ARR Camshafts Installation ime hee drea as dde e e unu P eaae dde ele dee ane Exhaust Manifold Exhaust Manifold Cylinder Head Removal m Exhaust Manifold Exhaust Manifold Cylinder Head ho etie idee dua Lee ede ade odore edd dae eens Cylinder Head Oil Filter Adapter Oil Filter Adapter Oil Pressure Sender
130. acce ech Sheet 1 G H Starting System So eet les O I 1 x tot a 555 a 21846 2 5 I z 3 x a gt GE Bow o 15 61 2 2 a gt 6 a 6 ale 72 72 2 c 5 ols o 5 T T T T MM o mee y 3 1 No le 9 5 E eu Le 4 25 07 4 DSG 423 STARTER DIAGNOSIS AND TESTING IN WARNING REFER TO CAUTIONS amp WARNINGS AT THE BEGINNING OF THIS SECTION NOTE When testing with a meter always make connections with the component terminal rather than at the wiring end connector Making connection with the wiring end connector can result in a false reading because the meter will not pick up any high resistance between the wiring connector and the component Visual Inspection CAUTION Be sure to disconnect battery negative cable before servicing starter e Verify the concern by operating the starting system to duplicate the conditions Inspect starting system for loose connections e Check the wear patterns on the starter drive and the flywheel ring gear If the starter drive gear and the flywheel ring gear are not fully meshing or the gears are milled or damaged replace the starter motor and if n
131. acement 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 e Check for excessive bearing clearance Repair as required 20 Perform the oil consumption test to confirm the oil consumption concern has been resolved 01 16 Cil Pressure Test 1 Disconnect and remove the oil pressure sensor from the engine Connect the Engine Oil Pressure Gauge and Transmission Test Adapter to the oil pressure sender oil gallery port Run the engine until normal operating temperature is reached Run the engine at 3000 rpm and record the gauge reading The oil pressure should be within specifications 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 DSG 423 GENERAL
132. aintain exhaust emission levels to government mandated standards while providing excellent operation and fuel efficiency The GCP monitors numerous engine functions via electronic sensors such as the throttle position TP sensor and the heated oxygen sensor 25 GCP Inputs operating conditions read Engine Coolant Temperature e Crankshaft Position Exhaust Oxygen Content Manifold Absolute Pressure Battery Voltage Throttle Position Electronic Actuator Fuel Pump Voltage Intake Air Temperature e 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 08 3 DSG 423 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 calculate RPM and crankshaft position Camshaft Position CMP Sensor The Camshaft Position CMP Sensor uses a variable reluctor sensor to detect camshaft position The CMP signal is created as piston 1 is a pre determined number of degrees after top dead center on the power stroke The Camshaft Position CMP Sensor sends a CMP signal to the GCP The GCP uses this signal as a sync pulse to trigger the injectors i
133. al 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 08 6 Accuracy of measurement 1 5 Operating Temp Range 350 C to 850 C sensor tip Sensor Response Time 300 1500 msec Heater Current Draw 1 A steady state Voltage Output 0 450 mV lean exhaust gas 450 1000 mV rich exhaust gas DSG 423 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 cha
134. an 07 3 Beg pwec ee di ce a Oa A E ENEA 07 3 Geil Lm 07 3 Wiring Diagrams ii ere dtc e cen d Ro de Uoc Ope be E RUD Re De DX el 07 4 Diagnosis and ERE A ree 07 5 Misual InSpectiOn UNDE OUR AURATA DEP in 07 5 Symptom Ghar a oe Lo edat ida ua laters Cites 07 6 Motor Feed Circuit Voltage Drop 07 7 Starter Motor Ground Circuit 07 7 General Service Procedures eese 07 8 JUMP Stantingi s aa a e eee e Ee age DA FEE ce EE OR decr dos 07 8 Removaliand Installation 5 eter erect eter iren En AP LEREN 07 9 Starter Relay 07 9 Starter Motor Replacement eia ete ani eee bete E at 07 9 erreur 07 10 07 1 DSG 423 STARTER CAUTIONS amp WARNINGS WARNING WHEN SERVICING STARTER OR PERFORMING OTHER WORK IN THE VICINITY OF THE STARTER BE AWARE THAT THE HEAVY GAUGE BATTERY INPUT LEAD AT THE STARTER SOLENOID IS ELECTRICALLY HOT AT ALL TIMES
135. ant is lost through the fuel path Refer to section 457R 1 for servicing the regulator If no other problems have been identified replace the fuel management assembly with a known good part of the same pressure range Retest 04 27 DSG 423 FUEL SYSTEM The pinpoint tests below should be performed after the preliminary tests and Engine Cranks but Will Not Start chart Steps 1 3 Any electrical diagnostics should Engine Stops Running Dies have been performed to eliminate any sensor GCP or solenoid valve problems before proceeding Test Step Result Action to Take 1 Check for icing or freezing of the regulator Yes The presence of ice on the converter with the engine running indicates the With the Engine at Idle possibility of a coolant supply problem Check for ice or frost build up on the converter casing and Check Coolant level and the coolant outlet port system for leaks Check for proper Is ice present coolant type No Go to Step 2 2 Check FCV vacuum fitting bypass port Yes Clean out bypass with a 050 size pin or drill bit and retest The bypass port is located on the back of the 90 degree CAUTION Do not enlarge the by elbow which connects the vacuum line from the converter pass port to the FCV valve Is this bypass partially closed with dirt or debris NO Go to Step 3 3 Check regulator fuel supply Yes The fuel filter may be restricting flow or the f
136. ar downscale flicking can mean one or more valves are not seating 8 WORN VALVE GUIDES When the needle oscillates swings back and forth over about a 13 kPa 4 in Hg range at idle speed the valve guides could be worn As engine speed increases the needle will become steady if guides are responsible 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 approx 33 50 kPa 10 15 in Hg 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 pipe or other concerns will cause the needle to 1 NORMAL READING Needle between 51 74 kPa slowly drop to 0 kPa 0 in Hg The needle then may 15 22 in Hg and holding steady slowly ri
137. asket install the oil filter adapter and 4 bolts Tighten to 25 Nm 18 Ib ft 3 Install a new oil filter 4 Apply thread sealant with PTFE to the oil pressure sender threads and install the sender Tighten to 15 Nm 11 Ib ft Connect oil pressure sender connector Fill the engine with clean engine oil Run the engine and check for leaks 0 00 ODOT Install or reconnect any other component that was removed or disconnected Oil Pressure Sender Replacement 1 Disconnect negative battery cable refer to Section 6 2 Remove and or disconnect components to allow access and removal of the oil pressure sender Label if necessary to allow for correct reinstallation 3 Disconnect the oil pressure sender connector 4 Remove the oil pressure sender 5 Apply thread sealant with PTFE to the oil pressure sender threads and install the sender 6 Tighten to 15 Nm 11 Ib ft 7 Connect oil pressure sender connector 02 23 DSG 423 ENGINE Oil Level Indicator amp Tube Replacement 1 Remove and or disconnect components to allow access and removal of the oil level indicator amp tube Label if necessary to allow for correct reinstallation 2 Remove the oil level indicator Indicator Bolt O Ring 3 Remove the 2 bolts and tube 4 Remove and discard the o ring 5 Reverse procedure to install Install a new o ring Apply clean engine oil to o ring Tighten bo
138. ate to prevent camshaft rotation Damage to the tool or the camshaft can occur 02 14 DSG 423 ENGINE 7 f necessary remove the bolts and the camshaft 3 Install the timing chain sprockets NOTE Use the flats on the camshaft to prevent 2 camshaft rotation Timing Drive Components Installation CAUTION Do not rotate the camshafts Damage to the valves and pistons can occur CAUTION Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation Damage to the tool or the camshaft can occur NOTE If the camshaft sprockets were not removed use the flats on the camshafts to prevent camshaft rotation and loosen the sprocket bolts 5 Position the timing chain tensioner and install the 2 bolts Tighten to 10 Nm 89 Ib in Remove the paper clip to release the piston 1 If removed install the camshaft sprockets and the bolts finger tight 2 Install the left timing chain guide and 2 bolts 6 Tighten to 10 Nm 89 Ib in 02 15 DSG 423 ENGINE CAUTION Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation Damage to the tool or the camshaft can occur 7 Using the flats on the camshaft to prevent camshaft rotation tighten the sprocket bolts Tighten to 65 Nm 48 lb ft 9 8 Install the front cover Refer to Engine Front Cover Installation on page 12 of this s
139. aterials are required to fabricate the tool to be used e air supply and air hose e air pressure gauge that registers pressure in 4 kPa 1 psi increments airline shutoff valve appropriate fittings to attach the above parts to oil fill grommet hole and crankcase ventilation tube appropriate plugs to seal any openings leading to the crankcase asolution of liquid detergent and water to be applied with a suitable applicator such as a squirt bottle or brush Fabricate the air supply hose to include the air line shutoff valve and the appropriate adapter to permit the airto enter the engine through the crankcase ventilation tube Fabricate the air pressure gauge to a suitable adapter for installation on the engine at the oil filler opening CAUTION Use extreme caution when pressurizing crankcase Applying air pressure above specified pressure risks damage to seals gaskets and core plugs Under no circumstances should pressure be allowed to exceed 27 kPa 4 psi Testing Procedure Open air supply valve until the pressure gauge maintains 20 kPa 3 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 Above Engine Examine the following areas for oil leakage valve cover gaskets intake manifold gaskets cylinder head gaskets e filter Oil pump if external
140. ature Sensor IATS Manifold Air Temperature Sensor MATS Keep Alive Random Access Memory Keep Alive RAM Keep Alive memory KAM Knock Sensor KS Detonation Sensor DS Long Term Fuel Trim Long Term FT Block Learn Matrix BLM Block Learn Memory BLM Block Learn Multiplier BLM Low Speed Fan Control Switch Low Speed FC Switch Low Speed Fan Control Switch Low Speed FC Switch Malfunction Indicator Lamp MIL Check Engine Service Engine Soon Manifold Absolute Pressure MAP Manifold Absolute Pressure MAP Manifold Absolute Pressure Sensor MAP Sensor Intake Manifold Absolute Pressure Sensor Manifold Absolute Pressure Sensor MAPS Pressure Sensor P Sensor Manifold Differential Pressure MDP Manifold Differential Pressure MDP Manifold Differential Pressure Sensor MDP Sensor Vacuum Sensor VAC Sensor Manifold Surface Temperature MST Manifold Surface Temperature MST Manifold Vacuum Zone MVZ Manifold Vacuum Zone MVZ Manifold Vacuum Zone Switch MVZ Switch Vacuum Switches Mass Air Flow MAF Air Flow Control AFC Air Flow Meter Mass Air Flow Sensor MAF Sensor Air Flow Meter Air Flow Sensor AFS Hot Wire Anemometer Mixture Control MC Feed Back Control FBC Mixture Control M C Mixture Control Solenoid MC Solenoid Mixture Control Solenoid MCS 09 11 DSG 423 METRICS New Term New Acronym Old Terms Acronym
141. 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 511 FPP1 high voltage DTC 512 FPP1 low voltage DTC 521 FPP2 high voltage e DTC 522 FPP2 low voltage DTC 513 FPP1 higher than IVS limit DTC 514 FPP1 lower than IVS limit DTC 523 FPP2 higher than IVS limit e DTC 524 FPP2 lower than IVS limit DTC 515 FPP1 higher than FPP2 DTC 516 FPP1 lower than FPP2 Intermittent MIL Conditions that are only present from time to time are called intermittents To resolve intermittents perform the following steps 1 Evaluate the history of DTC s observed with this particular engine 2 Evaluate the symptoms and conditions described by the customer 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 Pilote using the optional serial interface available Refer to Equipment Setup for information about using a personal computer to
142. before separating from the tube Apply clean engine oil to the end of the tube before inserting the tube into the connector CAUTION To ensure absolute cleanliness is observed when working with fuel system components always cap off any open orifices or tubes 04 2 DSG 423 FUEL SYSTEM GENERAL INFORMATION GASOLINE Camshaft Position CMP Sensor Actuator Description The fuel system delivers fuel by an electronic fuel pump A fuel pressure regulator controls fuel pressure and also contains a fuel filter The Electronic Control Module GCP uses information from various sensors and controls fuel delivery to the cylinders by individual fuel injectors mounted in the cylinder head near each intake valve Air delivery is controlled by an actuator Fuel Rail The fuel rail is mounted to the top of the engine and distributes fuel to the individual injectors Fuel is delivered to the fuel inlet tube of the fuel rail by the fuel lines and hoses Fuel Injector The fuel injector is a solenoid operated device mounted to the cylinder head The GCP energizes the solenoid which opens a valve to allow fuel delivery into the cylinder Engine Coolant Temperature ECT Sensor Fuel Rail Injectors Camshaft Position CMP Sensor The Camshaft Position CMP Sensor is mounted in the camshaft cover This signal is sent to the GCP which uses it to indicate the position of t
143. bolt east iit Washer Bolt AN CAUTION Only hand tighten crankshaft pulley bolt or damage to front cover can occur NOTE This next step will correctly align crankshaft pulley to crankshaft 02 40 DSG 423 ENGINE 30 Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover 31 Rotate the crankshaft pulley as necessary to align the bolt holes CAUTION Failure to hold the crankshaft pulley in place during bolt tightening can cause damage to the engine front cover 32 Using special tools 205 072 02 and 205 126 hold crankshaft pulley in place and tighten crankshaft pulley bolt in 2 stages Stage 1 Tighten to 100 Nm 74 Ib ft Stage 2 Rotate an additional 90 degrees ANN 33 Remove all special tools 205 072 02 205 126 303 507 303 465 and 6mm bolt CAUTION Only turn engine in the normal direction of rotation 34 Turn the engine 2 complete revolutions then continue turning in same direction until the No 1 piston is at top dead center TDC 35 Install special tool 303 507 N 303 507 VERS CAUTION Only hand tighten the bolt in this next step or damage to the front cover can occur 36 Using a 6mm x 18 mm bolt check the position of the crankshaft pulley If it is not possible to install the 37 Using special tool 303 465 check the position of the camshafts If it is not possible to install the special tool correct th
144. ch Voltmeter 3 Engage the remote starter switch Read and record the voltage The voltage reading should be 0 5 volt or less f0 5 volt or less refer to starter motor ground circuit test If greater than 0 5 volt indicating excessive resis tance move the negative lead to the B terminal as shown and repeat the test If voltage reading at the B terminal is lower that 0 5 volt the con cern is either in the connections at the starter so lenoid or in the solenoid contacts By moving the lead toward the battery and checking each me chanical connection point the excessive voltage drop can be located When the high reading dis appears the last mechanical point that was checked is the concern Clean or repair as nec essary Starter Motor Ground Circuit Check A slow cranking condition can be caused by resistance in the ground or return portion of the cranking circuit Check the voltage drop in the ground circuit as follows 1 Connect a remote starter switch between the starter solenoid S termingal and the battery positive post Remote Start Switch Voltmeter Starter Casing 2 Connect a digital multimeter positive lead to the starter motor housing the connection must be clean and free of rust or grease 3 Connect the negative lead of the voltmeter to the negative battery terminal 4 Engage the remote starter switch and crank the engine Read and record the volta
145. ck signal typically half the battery voltage is used to turn off the warning indicator With the system functioning normally the generator output current is determined and compared to a set voltage internal to the regulator and the regulator controls the generator field current to maintain the correct generator output The set voltage varies with temperature and typically is higher in cold temperatures and lower in warm temperatures This allows for better battery recharge in the winter and reduces the chance of overcharging in the summer 06 3 DSG 423 CHARGING SYSTEM Wiring Diagram Revision Level The following wiring schematics are taken from the wiring diagram labeled below m droping m pre Vena FORD 2 3L W GCP to retum upan request ond nok to copied or reproduced Humber Rew without permimsian All rights 1782000 F Daka punica By J SUTTON ECONTROLS INC hina 17B2ODBF mh Sheet 1 of 1 G H Charging System 5 a3 oc c 9 e oo Lu 5 n gt 9 ols o c Msi 1 5 B T c d x a 8 2 2 N amp a gt EE a a c L E gt e a c e o 06 4 DSG 423 CHARGING SYSTEM DIAGNOSIS AND TESTIN
146. connector and repair Excessive battery drain due to lamps left on damaged or misadjusted switch accessories left on etc Warning Indicator Check Check the operation of the charging system warning indicator as follows e Ignition OFF Indicator should be OFF e Ignition ON Engine OFF Indicator should be ON e Ignition ON Engine ON Indicator should be OFF 06 5 Symptom Chart CONDITION Dead battery Battery will not stay charged Slow crank Low battery voltage No generator output Indicator lamp on with engine running Indicator lamp flickers or intermittent Battery over charging battery voltage greater than 15 5 volts Key off battery drain Open voltage drop in B circuit Open voltage drop in A circuit Open high resistance in circuit Voltage regulator Generator Open circuit Shorted I circuit Open shigh resistance in S circuit Voltage regulator Generator Loose connection to generator voltage regulator or battery Loose fuse or poor connection in A circuit Loose brush holder screw Voltage regulator Generator Voltage drop in A circuit Voltage drop in I circuit Poor ground Voltage regulator Generator DSG 423 CHARGING SYSTEM Repair as necessary Repair as necessary Repair as necessary Repair as necessary Indicator lamp off key on engine not running Generator noisy Indicator lamp on key off Open shigh
147. corner will read Connected 08 29 DSG 423 ENGINE CONTROLS Diagnostic Trouble Codes The System Fault screen is used to view and clear DTC s which have been set pz E nd 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 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 Ifthe fault occurred during the current key cycle Ifthe fault caused current engine shutdown How many key cycles since the 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 Historic Fault Information DTC 315 Injector 3 in firing order circuit loop open low side shorted to ground Snap Shot Data The Snap Shot
148. cting rod Heat damaged connecting rod bearing Replace connecting rod bearing Damaged connecting rod bushing Replace connecting rod bushing Worn cylinder Repair or replace cylinder blocks Worn piston or piston pin Replace piston or piston pin Damaged piston rings Replace piston rings Bent connecting rod Replace connecting rod Malfunctioning hydraulic lash adjuster or hydraulic lash adjuster Replace hydraulic lash adjuster or hydraulic lash adjuster Excessive hydraulic lash adjuster or hydraulic lash adjuster clearance Adjust clearance or replace hydraulic lash adjuster guide or hydraulic lash adjuster Broken valve spring Replace valve spring Excessive valve guide clearance Repair clearance or replace valve guide stem Malfunctioning or damaged cooling system Refer to Section 05 Malfunctioning or damaged fuel system Refer to Section 04 Leaking exhaust system Repair exhaust leakage Improper drive belt tension Refer to Section 05 Malfunctioning generator bearing Refer to Section 06 for diagnosis and testing of the generator Loose timing chain belt Adjust or replace timing chain belt Damaged timing belt tensioner Replace timing belt tensioner Malfunctioning water pump bearing Replace water pump Insufficient Power Malfunctioning hydraulic lash adjuster or hydraulic la
149. ction 6 2 Adjust the CKP sensor with the alignment tool and tighten 2 bolts Tighten to 7 Nm 62 Ib in 3 Connect CKP sensor electrical connector 4 Remove the M6 bolt 08 44 DSG 423 ENGINE CONTROLS Cylinder Head Temperature CHT Sensor gt Heated Oxygen Sensor HO2S Replacement Replacement Boot CHT wr 1 Disconnect battery ground cable refer to section 6 2 Remove or disconnect any component to allow 1 Disconnect battery ground cable refer to section 6 access and removal of the CHT Sensor 2 Remove or disconnect any component to allow 3 Pull back the CHT sensor cover and disconnect access and removal of th HO2S Sensor electrical connector 4 Remove the CHT Sensor 5 Reverse procedure to install Tighten CHT sensor to 12 Nm 9 lb ft 4 Remove HO2S sensor using special tool 303 476 3 Disconnect HO2S electrical connector NOTE Use penetrating oil to assist in removal Engine Coolant Temperature ECT Sensor Replacement need 303 476 5 Reverse procedure to install Apply a light coat of anti seize lubricant to the threads of the sensor Tighten sensor to 40 Nm 30 Ib ft 08 45 DSG 423 ENGINE CONTROLS Knock Sensor KS Replacement Temperature Manifold Absolute Pressure TMAP Sensor Replacement Knock Sensor TMAP Sensor 1 Disconnect battery ground cable refer to section 6
150. ctrical 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 e Poor terminal to wire connections This requires removing the terminal from the connector body to check Improperly installed aftermarket equipment accessories Operate the engine with accessories OFF and a suitable multimeter connected to the suspected circuit An abnormal voltage when the malfunction occurs is a good indication that there is a fault in the circuit being monitored To check GCP for loss of diagnostic code memory disconnect the MAP sensor connector and idle the engine until the MIL illuminates Perform MIL DTC retrieval procedure DTC should be stored and kept in memory when the ignition is turned OFF If not the GCP is faulty When this test is completed make sure that you clear the DTC from memory An intermittent MIL with no stored DTC may be caused by the following e Ignition coil shorted to ground and arcing at plugs MIL circuit to GCP shorted to ground Poor GCP grounds 08 36 DSG 423 ENGINE CONTROLS Symptom Charts NOTE If you have a symptom of the pedal not working and no is set go to the voltage screen and check pedal
151. cuum non linear and outside the specifications 3 Check regulator fuel supply Yes The fuel filter may be restricting flow or the fuel lock may be intermittent Go Using Woodward WTK 1 test kit install the primary to Step 4 pressure gauge as described in section 475G 1 e Accelerate to induce symptom No Go to Step 5 Is the primary pressure less than X psi or fluctuating 4 Check fuelock supply voltage Yes 12 volt fuelock activation circuit is open shorted to ground or the GCP Key OFF module is faulty Check wiring Disconnect Fuelock connector from harness connectors and fuses for possible cause Key ON ore No Fuel filter element may be clogged Using a high impedance DVOM check for 12 volt supply inspect and or replace the fuel filter as at the harness connector described in section 475F 1 Repeat Is the voltage less than 11 5 volts test Step 3 if pressure is still less than specified replace the fuel lock and re test before moving to Step 5 5 Check regulator operation Yes Remove the vacuum hose from the valve to the regulator If the Using Woodward WTK 1 test kit install the primary and pressure is not 1 5 inches of w c secondary pressure gauge as described in section 475G the Regulator is malfunctioning See 1 note the secondary spring color and pressure range section 475R 1 for service of the Accelerate to induce symptom regulator Are the pressures less than X specified Hs Go
152. d 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 procedures can contribute to engine damage and wear Airborne debris and abrasive grit from the grinding disc may enter the engine through exposed cavities causing premature wear and eventual engine damage Engine Distributors Inc EDI does not recommend using abrasive grinding discs to remove engine gasket material Use manual gasket scrapers for removing gasket material from the engine sealing surfaces Take added care to prevent scratching or gouging aluminum sealing surfaces Safety Notice There are numerous variations in procedures techniques tools and parts for servicing equipment as well as in the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly anyone who departs from the instructions provided in this Manual must first establish that neither personal safety nor equip
153. d repair history 6 Some diagnostic charts contain diagnostic aids which give additional information about a system Be sure to use all of the information that is available to you GCP Diagnostic Overview FORD Diagnostic Trouble Codes are set when the FORD system GCP runs a diagnostic self test and the test fails When a DTC is set the FORD system GCP will illuminate the Malfunction Indicator Lamp MIL on the instrument panel and save the code in memory The FORD system GCP will continue to run the self test unless the DTC is an oxygen sensor lean oxygen sensor rich or a GCP related DTC If the system continues to fail the test the lamp will stay illuminated and the DTC is current ACTIVE 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 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
154. dentification Metric System Class Identification HEX NUT HEX NUT HEX NUT HEX NUT Grade 5 Grade 8 Property Class 9 Property Class 10 3 dots 6 dots Arabic 9 Arabic 10 FPP03574 575 Increasing dots represent increasing strength May also have blue finish or paint daub on hex flat Increasing numbers represent increasing strength 09 3 DSG 423 METRICS OTHER TYPES OF PARTS Metric identification schemes vary by type of part most often a variation of that used of bolts and nuts Note that many types of English and Metric fasteners carry no special identification if they are otherwise unique s 03576 f S N 2 03577 Stamped U Nuts Tapping thread forming and certain other case hardened screws gt 27 Studs Large studs may carry the property class number Smaller studs use a geometric code on the end CLASS 10 9 CLASS 9 8 CLASS 8 8 03578 09 4 DSG 423 METRICS ENGLISH METRIC CONVERSION TO CONVERT FROM TO MULTIPLY BY TO FROM DIVIDE BY Distance inches mm 25 4 inches m 0 0254 feet mm 304 8 feet m 0 3048 yards m 0 9144 mile km 1 609 Area in mm 645 16 ft m 0 0929 2 2 6 45 yds m 0 8361 Volume in 1
155. der 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 e Check for plugged oil in the rocker arms or cylinder head e Check for proper overhead valve train lubrication If insufficient oiling is suspected accelerate the engine to 1200 rpm 100 rpm with the PTO in NEUTRAL load removed and the engine at normal operating temperature Oil should spurt from the rocker arm oil holes such that valve tips and rocker arms are well oiled or with the valve covers off oil splash may overshoot the rocker arms If oiling is insufficient for this to occur check oil passages for blockage Push Rods if equipped e Check for bent push rods and restriction in oil passage Positive Rotator and Valve Spring Retainer Keys Check for proper operation of positive rotator Valves and Cylinder Head Check for plugged oil drain back holes Check for missing or damaged valve stem seals or guide mounted valve stem seals If insufficient oiling is suspected check oil passages for blockage then accelerate the engine to 1200 rpm with the PTO in NEUTRAL or load removed and the engine at normal operating temperature Oil should spurt from the rocker arm oil holes such that valve tips and camshaft roller followers are well o
156. dled 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 08 10 DSG 423 ENGINE CONTROLS Diagrams and Schematics Symbols doo jueuieje esnj Aieyneg eunyejeduue 10 9155019 1 10 101515 16 peaj 0 jueuoduioo 2 M9J9S jueuoduio5 punoJ8 jo jejaw eseo jusuodwoy jueuodujoo Wed jueuoduijoo 4JOJOSUUOD e euJe 0 punoJ5 uonoeuuoo ple Esc Pes St 2 eoids 08 11 GCP Power Distribution Box DSG 423 ENGINE CONTROLS Part of 5250010 Wiring Harness Fuel pump Relay Power Relay Fuse Amps Circuits protected 1 10 Battery Voltage to EPR 2 5 Ignition Voltage to GCP and Relays 3 10 Battery Voltage to GCP 4 15 Fuel pump 5 15 Battery Vol
157. ds skirts pin bosses and the tops of the pistons If wear marks or polishing is found on the piston skirt check for a bent or twisted connecting rod Top of Piston Ring Lands Skirts Pin Bosses 03522 2 Use the Piston Ring Groove Cleaner to clean the piston ring grooves 01 26 DSG 423 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 the cylinder bore 03525 NOTE For precision fit new pistons 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 FPP03526 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 Feeler Gauge D81L 4201 A or Equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 FPP10033 CAUTION Use care when fitting piston rings to avoid possible damage to the piston ring or the cyl inder bore CAUTION Piston rings should not be transferred from one piston to another to prevent damage to cylinde
158. dude crap nde d eaa dia sida Ro n das eda pae ces pa dee 05 14 Block Heater Replacement dil eee deed de deae dee 05 14 Coolant Bypass 05 15 Specificatiohs inneren RE rau ee FRE EH M ein ale e cua RE IER 05 16 05 1 DSG 423 COOLING SYSTEM CAUTIONS amp WARNINGS WARNING THE RADIATOR OR DEGAS TANK IS EQUIPPED WITH A PRESSURE CAP IT IS DANGEROUS TO REMOVE THIS WHEN THE SYSTEM IS VERY HOT WARNING NEVER REMOVE THE PRESSURE RELIEF CAP WHILE THE ENGINE IS OPERATING OR WHEN THE COOLING SYSTEM IS HOT MAY CAUSE PERSONAL INJURY OR DAMAGE TO COOLING SYSTEM OR ENGINE TO REDUCE THE RISK OF HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE DEGAS BOTTLE WHEN REMOVING THE PRESSURE RELIEF CAP WAIT UNTIL THE ENGINE HAS COOLED DOWN TO AT LEAST 40 110 F 1 Wrapathick 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 WARNING ANTIFREEZE CONTAINS ETHYLENE GLYCOL AND OTHER CONSTITUENTS WHICH ARE TOXIC IF TAKEN INTERNALLY AND CAN BE ABSORBED IN TOXIC AMOUNTS ON REPEATED OR PROLONGED SKIN CONTACT PE
159. e Procedures Camshaft Journal Diameltoer et EE bad qe 01 21 Camshaft Journal Clearance eiie ener nennen tnn anna penna 01 21 Gamshatt Lobe Surface cen ome peer PR D E P 01 21 Camshattsobe 7 E Ee 01 22 RUNGU Em 01 22 Camshaft End Play iuto 01 22 Crankshaft Main Bearing Journal 01 23 Crankshaft Main Bearing Journal 01 23 Crankshaft Main Bearing Journal 22 2 004 01 24 Bearing eei cer ERR HERRERA te ll cem iR Dea ie Ioui E 01 24 Grankshatt End Plays ded eR ene Ree eee perte e a dre 01 25 Grankslaft eie enmt Ripe p tei m 01 25 Gylinder Bore 01 25 Cylinder Bore A G retener 01 26 Piston 1 ERES 01 26 Piston TEL 01 26 Piston to Cylinder Bore
160. e Regulator is functioning properly and the problem is with the FCV valve Using Woodward WTK 1 secondary pressure gauge as vacuum hoses or carburetor Go to described in section 475G 1 note the secondary spring Step 4 color and pressure range Remove the vacuum hose from the FCV valve to the regulator No The Regulator is malfunctioning See Start the engine section 475R 1 for service of the Is the pressure constant and at 1 5 inches of w c as regulator Repair or replace as specified necessary 4 Check FCV vacuum fitting bypass port Yes Clean out bypass with a 050 size pin or drill bit and retest The bypass port is located on the back of the 90 degree CAUTION Do not enlarge the by elbow which connects the vacuum line from the converter pass port to the FCV valve Is this bypass partially closed with dirt or debris No Go to Step 5 4 Check carburetor air valve for binding Yes Refer to section 475 1 for servicing the carburetor With the air cleaner removed pull the air valve piston upwards to ensure free movement of the carburetor air valve No Go to Step 5 Is the air valve binding 04 25 DSG 423 FUEL SYSTEM Emission Failure Lean Mixture Continued Test Step Result Action to Take 5 Check air valve operation Yes Refer to section 475 1 for servicing the carburetor Using the WTK 1 test kit connect the vacuum gauge between the carburetor and the FCV valve
161. e engine timing 38 Remove all special tools 303 507 303 465 and 6mm bolt 02 41 DSG 423 ENGINE 39 Install the plug bolt e Tighten to 20 Nm 15 lb ft 40 Position a new crankshaft position CKP sensor and loosely install 2 bolts Bolts EU 41 Using alignment tool that came with new sensor adjust CKP alignment The tool must engage a tooth of the damper then tighten bolts Tighten to 7 Nm 62 Ib in NOTE If camshaft cover is not secured within 4 minutes the sealant must be removed and the sealing area recleaned Refer to Engine Cleaning on page 34 of this section 42 Apply silicone gasket and sealant to the locations shown 43 Install camshaft cover and tighten bolts in sequence show Tighten to 10 Nm 89 Ib in 11 10 13 9 14 44 Install camshaft position CMP sensor and bolt Tighten to 7 Nm 62 Ib in 45 Install cylinder head temperature CHT sensor Tighten to 12 Nm 9 Ib ft 46 Install spark plugs Tighten to 15 Nm 11 Ib ft CHT Sensor CMP Sensor ZAN 2 SZ 9 jo E 4 W ORS 1 dr S E E eZ FF NG Spark Plugs 02 42 DSG 423 ENGINE 47 Lubricate a new coolant pump o ring seal with clean engi
162. e fuel lock which may become clogged and limit fuel flow especially at low tank pressures Check the filter and replace as necessary Fuel Line Restrictions The vehicle specifications table specifies the fuel line to be a certain size If the fuel line from the tank to the fuel lock is not the proper size or any valves or fittings with flow restrictive characteristics are used the fuel flow will not be sufficient to the converter with low tank pressure Correct any fuel line or fitting restrictions Mixer Assembly Carburetor It is possible that a backfire may have caused the fuel valve to partially come off of it s retainer and restrict fuel check the mixer fuel valves see section 475 1 for disassembly Also check the mixer adapter plates for leakage past the carburetor Regulator Assembly If no other problems have been identified replace the fuel management assembly with a known good part of the same pressure range Retest 04 23 DSG 423 FUEL SYSTEM The pinpoint tests below should be performed after the preliminary tests and Engine Cranks but Will Not Start chart Steps 1 3 Any electrical diagnostics should have been performed to eliminate any sensor GCP or solenoid valve problems before proceeding Emission Failure Rich Mixture Test Step Result Action to Take 1 Check for clogged or restricted air filter Yes This would indicate a clogged air E cleaner as the cause Replace as Remove the air
163. e run smooth with the hose disconnected GCP fault No Go to Step 6 4 Check FCV vacuum fitting bypass port Yes Clean out bypass with a 050 size pin or drill bit and retest The bypass port is located on the back of the 90 degree CAUTION Do not enlarge the by elbow which connects the vacuum line from the converter pass port to the FCV valve Is this bypass partially closed with dirt or debris No Go to Step 5 5 Check FCV supply voltage Yes 12 volt FCV circuit is open shorted to ground or the GCP module is faulty Key OFF Check wiring connectors and fuses Disconnect connector from harness for possible cause With the engine at idle No Go to Step 6 Using a high impedance DVOM check for 12 volt supply at the harness connector Is the voltage less than 11 5 volts 04 14 DSG 423 FUEL SYSTEM Engine Starts But Has Rough Idle Continued Test Step Result Action to Take 2 Check regulator operation Yes The Regulator is malfunctioning See E section 475R 1 for service of the Using Woodward WTK 1 test kit install the primary and converter secondary pressure gauge as described in section 475G 1 note the secondary spring color and pressure range With the engine at idle Are the pressures less than X psi No Go to Step 3 3 Check carburetor air valve for binding Yes Refer to section 475 1 for servicing the carburetor With the air c
164. e should read between 51 74 kPa 15 22 in Hg depending upon the engine condition and the altitude at which the test is performed Subtract 5 5 kPa 1 in Hg from the specified reading for every 500 meters 1 000 feet of elevation above sea level The reading should be quite steady If necessary adjust the gauge damper control where used if the needle is fluttering rapidly Adjust the damper until the needle moves easily without excessive flutter 01 13 DSG 423 GENERAL INFORMATION Interpreting Vacuum Gauge Readings 4 WORN RINGS OR DILUTED OIL When the engine is accelerated dotted needle the needle drops to 0 A careful study of the vacuum gauge reading while the kPa 0 in Hg Upon deceleration the needle runs engine is idling will help pinpoint trouble areas Always slightly above 74 kPa 22 in Hg conduct other appropriate tests before arriving at a final readings although remains steady at a normal vacuum but occasionally SIR MUSE OE ICA flicks sharp fast movement down and back about Most vacuum gauges have a normal band indicated on 13 kPa 4 in Hg one or more valves may be the gauge face sticking 6 BURNED OR WARPED VALVES A regular evenly spaced downscale flicking of the needle indicates one or more burned or warped valves Insufficient hydraulic lash adjuster or hydraulic lash adjuster HLA clearance will also cause this reaction 7 POOR VALVE SEATING A small but regul
165. e that a backfire may have caused the fuel valve to partially come off of it s retainer and restrict fuel check the mixer fuel valves see section 475 1 for disassembly Idle Mixture Adjustment The idle mixture adjustment is pre set at the factory with a tamper proof seal installed Regulator Assembly If no other problems have been identified replace the fuel management assembly with a known good part of the same pressure range Retest 04 15 DSG 423 FUEL SYSTEM The pinpoint tests below should be performed after the preliminary tests and Engine Cranks but Will Not Start chart Steps 1 3 Any electrical diagnostics should have been performed to eliminate any sensor GCP or solenoid valve problems before proceeding Engine Idles With Rough Acceleration At Load Test Step Result Action to Take 1 Check carburetor air valve for binding Yes Referto section 475 1 for servicing the carburetor e With the air cleaner removed pull the air valve piston upwards to ensure free movement of the carburetor air valve Is the air valve binding No Go to Step 2 2 Check air valve operation Yes Referto section 475 1 for servicing the carburetor Using the WTK 1 test kit connect the vacuum gauge between the carburetor and the FCV valve to measure the carburetor air valve vacuum AVV Go to Step 3 e With the engine accelerating observe the amount of measured vacuum Is the measured va
166. ea recleaned Refer to Engine Cleaning on page 34 of this section 9 Apply silicone gasket and sealant to the locations shown 10 Install a new gasket and position cylinder head CAUTION Do not reuse cylinder head bolts 11 Lubricate new bolts and install in the sequence shown in 5 stages Stage 1 Tighten to 5 Nm 44 Ib in Stage 2 Tighten to 15 Nm 11 Ib ft Stage 3 Tighten to 45 Nm 33 Ib ft Stage 4 Tighten an additional 90 degrees 1 4 turn Stage 5 Tighten an additional 90 degrees 1 4 turn CAUTION Install the camshafts with alignment slots in the camshaft lined up so the camshaft alignment plate can be installed without rotating the camshafts Make sure the lobes on the No 1 cylinder are in the same position as noted in the disassembly procedure Rotating the camshafts or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons NOTE Lubricate camshaft journals and bearing caps with clean engine oil 02 37 DSG 423 ENGINE 12 Install the camshafts and bearing caps Tighten bolts in sequence shown in three stages Stage 1 Tighten finger tight e Stage 2 Tighten to 7 Nm 62 Ib in Stage 3 Tighten to 16 Nm 12 Ib ft o 3 r TN UST CAUTION The crankshaft the crankshaft sprocket and the pulley are fitted together
167. ecessary replace flywheel ring gear Flywheel Ring Gear Q Starter Teeth If the inspection reveals an obvious concern that can be readily identified repair as necessary If the concern remains after the inspection note condition and continue diagnosis using the symptom chart 07 5 Symptom Chart DSG 423 STARTER CONDITION POSSIBLE SOURCE ACTION Starter does not crank audible click may or may not be heard Open fuse Check fuse continuity Low battery Refer to battery diagnosis in section 6 Defective remote relay Check relay Open circuit or high resistance in external feed circuit to starter solenoid Check starter wiring Defective starter Replace starter motor Defective neutral park switch Replace switch Unusual starter noise Starter not mounted flush cocked Realign starter on transmission bell housing or SAE housing Noise from other components Investigate other powertrain accessory noise contributors Ring gear tooth damage or excessive ring gear runout Replace flywheel ring gear Defective starter Replace starter motor Starter spins but the engine does not crank Starter not mounted flush cocked Realign starter on transmission bell housing or SAE housing Ring gear tooth damage Replace flywheel ring gear Starter cranks but engine does not start Problem in fuel system Refer to fuel system section 4
168. ection 9 Install or reconnect any other component removed or disconnected Valve Spring Removal CAUTION The crankshaft the crankshaft sprocket and the pulley are fitted together by friction with diamond washers between the flange faces on each part For that reason the crankshaft sprocket is also unfastened if you loosen the pulley Therefore the engine must be retimed each time the damper is removed Otherwise severe damage can occur 1 Remove the valve tappets Refer to Valve Tappet Replacement on page 18 of this section WARNING ALWAYS WEAR PROTECTIVE GOGGLES WHEN WORKING WITH COMPRESSED AIR THIS CAN PREVENT INJURY FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY CAUTION Use compressed air at 7 10 bars 100 150 psi Do not disconnect the compressed air from the cylinder until the valve spring valve retainer and valve spring retainer keys are installed 1 Remove spark plug of the cylinder being serviced 2 Using special tools apply compressed air to the cylinder of the valve spring being removed 3 Using special tools 303 350 303 300 and 303 472 compress valve spring and remove the retainer keys using some grease and a small screwdriver i 303 472 4 Remove the valve spring retainer and valve spring NOTE Place all parts in order to one side CAUTION Keep air pressure in cylinder until valve spring is reinstalled
169. ed 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 01 18 DSG 423 GENERAL INFORMATION 8 Compare the total lift recorded on the dial indicator with specifications 9 To check the accuracy of the original dial indicator reading continue to rotate the crankshaft until the indicator reads zero 10 Remove the dial indicator adapter and auxiliary starter switch 11 Reinstall components as necessary CAUTION Do not rotate the crankshaft until lash adjusters have had sufficient time to bleed down To do otherwise may cause serious valve damage Manually bleeding down lash adjusters will reduce waiting time 01 19 DSG 423 GENERAL INFORMATION Hydraulic Valve Lash Adjuster Hydraulic lash adjuster noise can be caused by any of the following excessively collapsed lash adjuster gap e sticking lash adjuster plunger lash adjuster check valve not functioning properly airin lubrication system e leakdown rate too rapid excessive valve guide wear Excessive collapsed lash adjuster gap can be caused by loose rocker arm seat bolts nuts incorrect initial adjustment or wear of lash adjuster face or worn roller lash adjusters push rod rocker arm rocker arm seat or valve tip With lash adjuster collapsed check gap between the valve tip and the rocker arm to determine if any other valve train
170. egularly 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 emer gency 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 UP PER 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 the oil test by the re sult This quantity is the approximate oil con sumption 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 Refer to Compression Tests on page 12 or perform a cylinder leak detection test with Engine Cylinder Leak Detection Air Pressurization Kit Refer to Cylinder Leakage Detection on page 13 This can help determine the source of oil consumption such as valves piston rings or other areas NOTE After determining if worn parts should be replaced make sure correct repl
171. el lock and re test before moving to Step 3 3 Check regulator operation Yes Remove the vacuum hose from the valve to the regulator If the Using Woodward WTK 1 test kit install the primary and pressure is not 1 5 inches of W C secondary pressure gauge as described in section 475G the Regulator is malfunctioning See 1 note the secondary spring color and pressure range Section 475R 1 for service of the At Idle or accelerate to induce symptom regulator Are the pressures less than X specified No Go to Step 4 4 Check FCV operation Yes This would indicate the engine is experiencing momentary mixture e At Idle or accelerate Engine to induce symptom change Possible causes Disconnect the vacuum hose from the valve to the e Faulty FCV valve connection or regulator vacuum leaks go to Step 5 Does the engine continue to miss with the hose GCP fault disconnected Go to Step 6 5 Check FCV supply voltage Yes 12 volt FCV circuit is open shorted to ground or the GCP module is faulty Key OFF Check wiring connectors and fuses Disconnect FCV connector from harness for possible cause With engine at idle and upon acceleration 2 Refer to section 475 1 for servicing the e Using a high impedance DVOM check for 12 volt supply at the harness connector Is the voltage less than 11 5 volts carburetor Also refer to the Diagnostic Aids below 04 20
172. en to yield designed and cannot be reused 41 Remove and discard cylinder head bolts 42 Remove cylinder head 43 Remove and discard the gasket 02 32 DSG 423 ENGINE 44 Remove the cylinder head alignment dowels 47 Remove bolts oil pump pickup tube and discard 46 Remove bolts and rear seal retainer plate 49 Remove and discard oil pump gasket Cylinder Head Disassembly 1 Remove rear lifting eye and front bracket 02 33 DSG 423 ENGINE 2 Remove cylinder head temperature CHT sensor CHT Sensor T diis Plug 3 Remove coolant outlet pipe 4 Remove spark plugs and discard CAUTION Note location of the tappets prior to removal 5 Remove 16 valve tappets 6 Using special tools 303 350 303 300 amp 303 472 compress valve spring and remove valve spring retainer keys retainers and springs 303 350 7 Remove all special tools CAUTION Note location of valves if they are to be reused 8 Remove valves 9 Using special tools 303 005 and 303 468 remove and discard valve stem seals 10 Inspect valve valve springs retainers and keys refer to Section 1 Engine Cleaning During engine repair procedures cleanliness is extremely important Any foreign material including any material created while cleaning gasket surfaces can enter the oil passages coolant passages or the oil pan and cau
173. ension is automatically adjusted by a tensioner Power Idler Steering Generator Coolant Pump Tensioner Crankshaft Ignition System The ignition used on the 2 3L engine is an Electronic Distributorless Ignition System EDIS Individual ignition coils are located directly above each spark plug and are used to ignite the fuel in the cylinders Refer to Section 03 of this manual for more information on the ignition system Fuel System The fuel system includes a remote mounted electric fuel pump The pump regulates and maintains fuel flow through an in line fuel filter to the electronic actuator mounted on the intake manifold The engine can be adapted for dry fuel use Refer to Section 04 of this manual for more information on the fuel system 02 5 DSG 423 ENGINE REMOVAL amp INSTALLATION Intake Manifold Removal 1 Drain the engine cooling system Refer to Section 5 2 Remove and or disconnect components to allow access and removal of the intake manifold Label if necessary to allow for correct reinstallation CAUTION Relieve fuel system pressure before disconnecting fuel supply lines refer to Section 4 3 Remove fuel supply connections refer to Section 4 Intake Manifold 4 Remove 5 bolts and the intake manifold CAUTION Do not use metal scrapers wire brushes power abrasive discs or other abrasive means to clean the sealing surfaces These tools cause scratches and gouges
174. er than FPP2 DTC 516 FPP1 lower than FPP2 DTC 353 MegaJector delivery pressure higher than expected e DTC 354 delivery pressure lower than expected DTC 355 MegaJector communication lost DTC 363 MegaJector internal actuator fault detection DTC 364 MegaJector internal circuitry fault detection DTC 365 MegaJector internal communication fault detection e DTC 611 COP failure Internal GCP failure e DTC 614 RTI 1 loss internal GCP failure DTC 655 RTI 2 loss internal GCP failure DTC 656 RTI loss internal GCP failure DTC 613 A D loss internal GCP failure DTC 612 Invalid interrupt internal GCP failure e DTC 615 Flash checksum invalid internal GCP failure DTC 616 RAM failure internal GCP failure Fault Low 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 511 FPP1 high voltage DTC 512 FPP1 low voltage DTC 513 FPP1 higher than IVS limit DTC 514 FPP1 lower than IVS limit DTC 523 FPP2 higher than IVS limit DTC 524 FPP2 lower than IVS limit DTC 515 FPP1 higher than FPP2 DTC 516 FPP1 lower than FPP2 DTC 545 IVS Brake interlock failure Force to Idle The engine RPM will
175. erature low oil pressure etc e Starter lockout e Auto crank Programmable overspeed protection e Automatic altitude compensation Sequential port fuel injection gasoline with pressure regulator to precisely control fuel delivery Dry fuel lockout controlled by the GCP produces reliable transition when switching fuels Certified closed loop dry fuel control Ignition Coil Configurable inputs available based on customer requirements Configurable outputs available based on ECT RPM or MAP signals and customer requirements 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 also be set up to run on a variety of electronic governing be programmed to provide up to four specific speeds with use of a matching toggle switch be programmed to provide an infinite variety of 08 2 DSG 423 ENGINE CONTROLS speeds with customer specified minimum and maximum based on a variable signal input e be an electronic replacement for a thro
176. essary Radiator Cap Pressure Test WARNING REFER TO CAUTIONS AND WARNINGS AT THE BEGINNING OF THIS SECTION 1 Inspect radiator cap and seals for damage or deterioration replace as necessary 2 Fit the radiator cap to the pressure tester using an adapter Pressure Tester Adapter Cap NOTE If the plunger of the pressure tester is depressed too fast an incorrect pressure reading will result 3 Slowly pump the pressure tester until the gauge stops increasing and note the highest pressure reading 4 Release the pressure and repeat the test 5 Install a new radiator cap if the pressure is not 124 kPa 18 psi Thermostat Operational Check 1 Hold thermostat up to the light 2 Visually check the valve to be sure it is air tight Leakage of light all around the valve at room temperature indicates a bad thermostat Aslightleakage of light at one or two locations on the perimeter of the valve is normal 3 Place the thermostat and a thermometer in water 4 Gradually increase the water temperature 5 Replace thermostat if it does not open at the specified temperatures Starts to open 90 C 194 F Fully open 97 106 C 206 6 222 8 05 8 DSG 423 COOLING SYSTEM GENERAL SERVICE PROCEDURES Draining the Cooling System WARNING REFER CAUTIONS AND WARNINGS AT THE BEGINNING OF THIS SECTION 1 Remove radiator cap CAUTION The coolant must be recovered in a suit ab
177. essure to Yes Fuel filter element may be clogged regulator inspect and or replace the fuel filter as described in section 475F 1 Repeat With the primary pressure gauge installed as described in test if pressure is still less than section 475G 1 measure the supply pressure specified the fuelock is faulty Running Replace the fuel lock Is the pressure less than X psi No Go to Step 3 3 With engine running check regulator operation Yes Remove the vacuum hose from the valve to the regulator If the Using Woodward WTK 1 test kit install the primary and pressure is not 1 5 inches of W C secondary pressure gauge as described in section 475G the Regulator is malfunctioning See 1 note the secondary spring color and pressure range section 475R 1 for service of the With the engine at idle or accelerate to induce symptom regulator Are the pressures less than X specified N 4 4 Check FCV operation Yes This would indicate the engine is experiencing a momentary mixture Atidle or accelerate Engine to induce symptom change Possible causes Disconnect the vacuum hose from the FCV valve to the Faulty FCV valve connection or regulator vacuum leaks go to Step 5 Is the backfire present with the hose disconnected GCP fault Go to Step 6 5 Check FCV Supply Voltage Yes 12 volt FCV circuit is open shorted to ground or the GCP module is fa
178. eze meeting Ford specification WSS M97B51 A1 should be used when topping up or re filling the cooling system Do not mix coolant types CAUTION Do not add or mix an orange colored ex tended life coolant such as Motorcraft Specialty Or ange engine coolant with factory filled coolant WSS M97B44 D Mixing Motorcraft Specialty Or ange engine coolant or any orange colored extend ed life product with factory filled coolant can result in degraded corrosion protection CAUTION If there is engine coolant in the engine oil or transmission fluid the cause must be corrected and oil fluid changed or major component damage can occur CAUTION When removing coolant the coolant must be recovered in a suitable clean container for reuse If the coolant is contaminated it must be re cycled or disposed of correctly WARNING DO NOT STAND INLINE WITH OR NEAR THE ENGINE COOLING FAN BLADE WHEN REVVING THE ENGINE FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY CAUTION Under no circumstances should the drive belt tensioner or pulleys be lubricated as po tential damage to the belt material and tensioner dampening mechanism will occur Do not apply any fluids or belt dressing to the drive belt or pulleys 05 2 DSG 423 COOLING SYSTEM GENERAL INFORMATION Upper Hose Degas Bottle NN Lower Hose Description The cooling system consists of the following Engine Coolant Temperature ECT Sensor
179. ff Catalyst Wide Open Throttle WOT Full Throttle Wide Open Throttle Switch WOT Switch Wide Open Throttle Switch WOTS 09 14 EDI DISTRIBUTORS North America Canada ONTARIO M K Power 5641 McAdam Road 905 890 5323 QUEBEC Products Corp Mississauga Ontario MONITOBA Canada LAZ 1N9 ALBERTA Industrial Engines 14355 120th Avenue 780 484 6213 SASKATCHEWAN Ltd Edmonton Alberta Canada T5L 2R8 North America United States ALABAMA Ford 30762 State Highway 181 800 633 1834 Daphne AL 36526 CALIFORNIA Powertech 2933 E Hamilton Avenue 559 264 1776 Engines Inc Fresno CA 93721 FLORIDA Engine 259 Ellis Rd South 800 342 3576 Distributors Inc Jacksonville FL 32254 Engine 2917 S W Second Ave 800 257 6605 Distributors Inc Fort Lauderdale FL 33315 MICHIGAN Engine Center Inc 2351 Hilton Road 800 726 8870 Ferndale MI 48220 MISSOURI Power 1100 Research Blvd 314 868 8620 Products St Louis MO 63132 NEBRASKA Anderson 5532 Center Street 402 558 8700 Industrial Engines Omaha NE 68106 Co NEW JERSEY Engine 400 University Court 800 220 2700 Distributors Inc Blackwood NJ 08012 NORTH Engine 303 Interstate Drive 800 220 7080 CAROLINA Distributors Inc Archdale NC 27263 3148 OHIO Graham Ford Inc 707 Broad St 614 464 6000 Columbus OH 43222 North Coast Ford 11885 Bellaire Road 216 251 5800 Industrial Cleveland OH
180. ge reading Areading of 0 2 volt or less indicates a good ground connection freading is more than 0 2 volts clean all ground connections and retest If still too high replace battery negative cable NOTE If the voltage reading is less than 0 2 volt and the engine still cranks slowly install a new starter motor 07 7 DSG 423 STARTER GENERAL SERVICE PROCEDURES WARNING REFER TO CAUTIONS amp WARNINGS AT THE BEGINNING OF THIS SECTION Jump Starting For cases of a starter that cranks the engine very slowly connect a 12 volt booster battery to the system To avoid damage to the equipment and battery or the possibility of personal injury follow these instructions and precautions 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 VEG
181. gh one of access holes 27 Remove all front cover bolts and front cover 28 Compress the timing chain tensioner and insert a paper clip into the hole 29 Remove 2 bolts and tensioner 30 Remove right timing chain guide ANN 02 31 DSG 423 ENGINE CAUTION Do not rely on camshaft alignment plate to prevent camshaft rotation Damage to the tool or the camshaft can occur 33 Using a wrench on the camshaft flats remove bolts washers and sprockets Oil Pump Sprocket Washers 36 Remove bolts and guide 37 Holding oil pump sprocket in place remove bolt chain sprockets and diamond washers 38 Remove special tool 303 465 CAUTION Failure to follow the camshaft loosening procedure can result in damage to the camshafts NOTE Note the position of the lobes on the number one cylinder before removing the camshafts for assembly reference 39 Remove the camshaft bearing caps as follows Loosen the camshaft bearing cap bolts in the se quence shown one turn at a time Repeat until all the tension is released from the camshaft bearing caps Remove the bearing caps 40 Remove the camshafts Camshafts removing it from the engine Cylinder head warpage can result if a warm or hot cylinder head is removed CAUTION The cylinder head bolts must be discarded and new bolts must be installed They are tight
182. ght Edge FPP04065 01 37 DSG 423 GENERAL INFORMATION Cylinder Block Core Plug Cup Type CAUTION Do not contact the flange when installing a cup type cylinder block core plug as this could damage the sealing edge and result in leakage NOTE When installed the flanged edge must be below the chamfered edge of the bore to effectively seal the bore e Use a fabricated tool to seat the cup type cylinder block core plug 03563 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 01 38 DSG 423 GENERAL INFORMATION Spark Plug Thread Repair Special Tool s 2 Startthe 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 Tapersert Installation Kit 107 0921 or Equivalent 9 FPP10038 Feeler Gauge D81L 4201 A or Equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 10033 1 800 768 8632 CAUTION The cylinder head must removed from the engine before installing a tapersert If this pro cedure is done with the cylinder head on the engine the cylinder walls can be damaged by metal ch
183. gine 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 nspect 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 e Inspect GCP sensors and actuators for physical damage nspect GCP grounds for cleanliness tightness and proper location Inspect fuel system for adequate fuel level and fuel quality concerns such as proper octane contamination winter summer blend Inspect intake air system and air filter for restrictions Inspect battery condition and starter current draw If no evidence of a problem is found after visual inspection has been performed proceed to Diagnostic System 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 ele
184. he 1 piston during its power stroke The GCP uses the CMP signal as a sync pulse to trigger the injectors in the proper sequence This allows the GCP to calculate true sequential fuel injection SFI mode of operation Engine Coolant Temperature ECT Sensor The Engine Coolant Temperature ECT Sensor is a thermistor mounted in the engine coolant stream in the rear coolant outlet pipe The GCP uses this information to calculate the correct air fuel mixture which varies with engine temperature Actuator The actuator controls air delivery into the cylinders An integral Throttle Position TP Sensor sends a signal to the GCP indicating throttle position The GCP calculates fuel delivery based on throttle valve angle operator demand 04 3 DSG 423 FUEL SYSTEM Fuel Pump Fuel Pressure Fuel Injectors Sensor 7 Pd Fuel Filter 0 9 e 5 Return to Tank Put From Tank Operation The fuel delivery system starts with the fuel in the tank Fuel is drawn up to the fuel pump through a pre filter The electric fuel pump then delivers the fuel to the fuel rail and injectors The GCP controls the fuel pump to deliver fuel pressure required by the injectors The GCP monitors system pressure through a fuel pressure sensor Fuel is injected under pressure in a conical spray pattern at the opening of the intake valve There is a return line to the tank with a small orifice to
185. he preliminary tests and Engine Cranks but Will Not Start chart Steps 1 3 Any electrical diagnostics should have been performed to eliminate any sensor GCP or solenoid valve problems before proceeding Engine Starts But Has Rough Idle Test Step Result Action to Take 1 Check for icing or freezing of the Regulator Yes The presence of ice on the converter with the engine running indicates the With the Engine at Idle possibility of a coolant supply problem Check for ice or frost build up on the converter casing and Check Coolant level and the coolant outlet port System for leaks Check for proper coolant type Is ice present No Go to Step 2 2 Check stuck primer button Yes Try and free the primer button If you cannot reseat the primer then see e Key Off section 475R 1 for servicing the Press the primer button on the converter once to ensure converter the primer is not sticking open A small amount of fuel that is trapped between the fuel lock and the converter should No Go to Step 3 pass through to the carburetor Is the primer button stuck in depressed position 3 Check FCV for operation Yes This would indicate the engine is too lean at idle Possible causes e With the Engine at Idle Plugged bypass port go to Step 4 e Disconnect the vacuum hose from the FCV valve to the FCV valve connection to Does the idl
186. hich has been completely discharged may be slow to accept a charge initially and in some cases may not accept charge at the normal charger setting When batteries are in this condition charging can be started by use of the dead battery switch on chargers so equipped To determine whether a battery is accepting a charge follow charger manufacturer s instructions for use of dead battery switch If switch is the spring loaded type it should be held in the ON position for up to three minutes After releasing switch and with charger still on measure battery voltage If it shows 12 volts or higher the battery is accepting a charge and is capable of being recharged However it may require up to two hours of charging with batteries colder than 5 C 41 F before charging rate is high enough to show on the charger ammeter It has been found that all non damaged batteries can be charged by this procedure If a battery cannot be charged by this procedure it should be replaced A rapid recharge procedure has been developed for recharging batteries that only need a quick recharge This can be due to battery in service no start battery failures engine will not crank due to low battery state of charge or battery discharged due to key off loads The battery can be rapidly recharged by using either of the following methods 06 10 Perform a two hour charge using 20A constant current manual setting on charger Perform a two hour charge
187. hin 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 mechanical load on the engine More coil cooldown time between firing events Elimination of mechanical timing adjustments Increased available ignition coil saturation time Elimination of high tension wires Ignition Coil coil on plug The coil on plug design has individual coils mounted directly over each spark plug Each cylinder is paired with its opposing cylinder in the firing order so that one cylinder on compression fires simultaneously with the opposing cylinder on exhaust The spark that occurs in the cylinder on the exhaust stroke is referred
188. ic Single Point Injection SPI Throttle Position TP Throttle Position TP Throttle Position Sensor TP Sensor Throttle Position Sensor TP Throttle Potentiometer Throttle Position Switch TP Switch Throttle Position Switch TPS Torque Converter Clutch TCC Converter Clutch Control CCC Converter Clutch Override CCO Viscous Converter Clutch VCC 09 13 DSG 423 METRICS New Term New Acronym Old Terms Acronyms Torque Converter Clutch Relay TCC Relay Lock Up Relay Torque Converter Clutch Solenoid Valve TCC Solenoid Valve Lock Up Solenoid Valve LUS Transmission Control Module TCM Transmission Control Module Transmission Range TR Park Reverse Neutral Drive Low PRNDL Selection Lever Position SLP Transmission Range Selection TRS Transmission Range Sensor TR Sensor Manual Lever Position Sensor MLP Sensor Transmission Range Switch TR Switch Manual Range Position Switch MRPS Transmission Position Switch Transmission Range Selection Switch TRSS Turbocharger TC Turbo Vehicle Speed Sensor VSS Distance Sensor Pulse Generator PG Voltage Regulator VR voltage Regulator VR Volume Air Flow VAF Air Flow Control AFC Air Flow Meter Vane Air Flow Volume Air Flow Sensor VAF Sensor Air Flow Meter Air Flow Sensor AFS Warm Up Oxidation Catalytic Converter WU OC Light Off Catalyst Warm Up Three Way Catalytic Converter WU TWC Light O
189. iled With the valve covers off some oil splash may overshoot camshaft roller followers 01 17 DSG 423 GENERAL INFORMATION Camshaft Lobe Lift Check the lift of each lobe in consecutive order and make a note of the readings 1 Remove the valve covers 2 Remove the rocker arm seat bolts rocker arm seat and rocker arms if equipped D T Dial Indicator Cup Shaped 2 A e Adapter 03504 Typical Engine with Push Rods 3 Make sure the lash adjuster is seated against camshaft Install the dial Indicator with Bracketry so the ball socket adapter of the indicator is on top of the hydraulic lash adjuster or the Cup Shaped Adapter is on top of the push rod and in the same plane as the lash adjuster push rod movement 4 On engines with overhead cam install the dial Indicator with Bracketry so the plunger is on top of the camshaft lobe and in the same plane as the camshaft lobe movement FPP03511 5 Remove the spark plugs 6 Connect an auxiliary starter switch in the starting circuit Crank the engine with the ignition switch in the OFF position Bump the crankshaft over until the indicator is measuring on the base circle of the camshaft lobe in its lowest position If checking during engine assembly turn the crankshaft using a socket or ratchet 7 Zero the dial indicator Continue to rotate the crankshaft slowly until the camshaft lobe is in the fully rais
190. in the back of this manual 01 5 DSG 423 GENERAL DIAGNOSIS AND TESTING Special Tools INFORMATION FPP10023 Commercially Available Leakdown Tester V Compression Tester 014 00707 or Equivalent Cup Shaped Adapter TOOL 6565 AB or Equivalent m __ M S FPP10026 Dial Indicator with Bracketry TOOL 4201 C or Equivalent Engine Cylinder Leak Detection Air Pressurization Kit 014 00705 or Equivalent 10028 Engine Pressure Gauge T73L 6600 A FPP10029 12 Volt Master UV Diagnostic Inspection Kit 164 R0756 or Equivalent 2 iG ho FPP10030 Vacuum Pressure Tester 164 R0253 or Equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 01 6 DSG 423 GENERAL INFORMATION Inspection and Verification Loose mounting bolts studs and nuts 1 Verify the customer concern by operating the engine to duplicate the condition 2 Visually inspect for obvious signs of mechanical and electrical damage 4 Engine coolant leaks Engine oil leaks Fuelleaks Damaged or severely worn pads Symptom Chart 3 If the inspection reveals obvious concerns that can be readily identified repair as required If the concerns remain after the inspection determine the symptoms and go to the symptom chart adjuster
191. ing valve clearance DSG 423 GENERAL INFORMATION GENERAL SERVICE PROCEDURES WARNING AVOID THE POSSIBILITY PERSONAL INJURY OR DAMAGE TO THE EQUIPMENT DO NOT OPERATE THE ENGINE UNTIL THE FAN BLADE HAS BEEN EXAMINED FOR POSSIBLE CRACKS AND SEPARATION NOTE Illustrations are typical and may not reflect your particular engine Specifications show the expected minimum or maximum condition NOTE If a component fails to meet the specifications it is necessary to replace or refinish If the component can be refinished wear limits are provided as an aid to making a decision Any component that fails to meet specifications and cannot be refinished must be replaced Camshaft Journal Diameter Measure each camshaft journal diameter in two directions e fitis out of specification replace as necessary 03508 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 FPP04126 Camshaft Lobe Surface Inspect camshaft lobes for pitting or damage in the active area Minor pitting is acceptable outside the active area Active Area i Jie 6 MU 01 21 DSG 423 GENERAL INFORMATION Camshaft Lobe Lift Special Tool s Camshaft Runou
192. ips 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 FPP03564 8882828 03565 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 threads of the mandrel with cutting oil Thread the tapersert onto the mandrel until one thread of the mandrel extends beyond the tapersert 03566 NOTE properly installed tapersert will be either flush with or 1 0 mm 0 039 inch below the spark plug gasket seat 01 39 DSG 423 GENERAL INFORMATION 6 Tighten the tapersert into the spark plug hole Exhaust Manifold Straightness 03567 Special Tool s ssi FPP10036 Straightedge 303 D039 D83L 4201 A or equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 7 Turn the mandrel body approximately one half turn manifold counterclockwise and remove e Place the Straightedge across the exhaust manifold flanges and check for warping with a feeler gauge NOTE The exhaust manifold shown is a typical exhaust 03568 03569
193. is for information regarding performing GCP and engine control system diagnosis Engine Control Module GCP Limp Home Mode Strategy The GCP has four settings for limp home mode Depending on what Diagnostic Trouble Code DTC is set one or more of the limp home modes will be in effect The four limp home modes are as follows Power Derate 1 The actuator is limited to a maximum opening of 50 If Power Derate 1 is active it will remain active until the active DTC goes away The following DTC s will cause Power Derate 1 to take affect e DTC 223 CHT ECT higher than expected 1 CHT ECT is greater than 240 F DTC213 IAT higher than expected 1 IAT is greater than 200 F 253 Knock sensor open 1 6L 4 2L only DTC 254 Excessive knock signal 1 6L and 4 2L only DTC 511 FPP1 high voltage DTC 512 FPP1 low voltage DTC 521 FPP2 high voltage DTC 522 FPP2 low voltage DTC 545 IVS Brake interlock failure Power 2 08 24 DSG 423 ENGINE CONTROLS The actuator is limited to a maximum opening of 2096 If Power Derate 2 is active it will remain active until the active DTC goes away and the ignition input to the GCP usually the ignition switch is cycled DTC 513 FPP1 higher than IVS limit DTC 514 FPP1 lower than IVS limit DTC 523 FPP2 higher than IVS limit e DTC 524 FPP2 lower than IVS limit DTC 515 FPP1 high
194. ition 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 oil on each piston does not increase compression the head gasket may be leaking between cylinders Engine oil or coolant in cylinders could result from this condition Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest reading is within 75 percent of the highest reading 01 12 DSG 423 GENERAL INFORMATION Cylinder Leakage Detection When a cylinder produces a low reading use of the Engine Cylinder Leak Detection Air Pressurization Kit such as the Rotunda Pressurization Kit 014 00705 or equivalent will be helpful in pinpointing the exact cause Rotunda Pressurization Kit 014 00705 The leakage detector is inserted in the spark plug hole the piston is brought up to dead center on the compression stroke and compressed air is admitted Once the combustion chamber is pressurized a special gauge included in the kit will read the percentage of leakage Leakage exceeding 20 percent is excessive While the air pressure is retained in the cylinder listen for the hiss of escaping air A leak atthe 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 ventila
195. ket and install a new one if necessary Position actuator onto studs Install nuts e Tighten to Reconnect electrical connectors Reconnect accelerator cable Reconnect air cleaner components to actuator Install or connect any other component removed or disconnected SPECIFICATIONS DSG 423 FUEL SYSTEM GENERAL SPECIFICATIONS Fuel pressure 414 448 kPa 60 65 psi Motorcraft SAE 5W20 Super Premium WSS M2C930 A TORQUE SPECIFICATIONS Description Nm Ib ft Ib in Fuel rail bolts 25 18 04 37 DSG 423 COOLING SYSTEM INDEX Subject Page General IMFOrMation 05 3 s EE 05 3 Diagnosis and Testing tcn tret cte Era eorr A KNR oL kno o 05 5 Visual Inspection etre Prem eem tus iier uet bii uera rip rr 05 5 Goolant Inspection ett etd du ett e d Ue tue eels deduc eap fue Ure vede 05 5 Coolant Range Gheck 2 aii dit e e etd e dh a ccr rd ede aude a t nadie cen 05 5 Drive Belt Inspection icri 05 6 Symptom Ghart iore Ieri rear Pete e Ru e Mp Pec d tom donee vi 05 7 Cooling System Pressure 05 8 Radiator Cap Pressure
196. l antifreeze battery acid etc do NOT encourage vomiting and OBTAIN QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY Wear protective goggles when handling liquids which are harmful to the eyes these include ammonia and battery acid If any of these substances are splashed in the eyes wash out thoroughly with clean water and OBTAIN QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY WARNING WARNING ENGINE EXHAUST SOME OF ITS CONSTITUENTS AND CERTAIN VEHICLE COMPONENTS CONTAIN OR EMIT CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER AND BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM IN ADDITION CERTAIN FLUIDS CONTAINED IN VEHICLES AND CERTAIN PRODUCTS OF COMPONENT WEAR CONTAIN OR EMIT CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER AND BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe reliable operation of all industrial engines as well as the personal safety of the individual doing the work This Service Manual provides general directions for accomplishing service and repair work with tested effective techniques Following them will help assure reliability DSG 423 GENERAL INFORMATION INDEX Subject Page General Information Introductionis tet i ue D tae i eid da erase tuit S 01 3 S WANsisre 01 3 Notes Cautions and
197. lash adjuster guide or hydraulic lash adjuster Replace hydraulic lash adjuster guide or hydraulic lash adjuster Burnt or sticking valve Repair or replace valve Weak or broken valve spring Replace valve spring Carbon accumulation in combustion chamber Eliminate carbon buildup Malfunctioning or damaged fuel system Refer to Section 04 of this manual Malfunctioning or damaged ignition system Refer to Section 03 of this manual 01 7 DSG 423 GENERAL INFORMATION Condition Possible Source Action Excessive Oil Worn piston ring groove Replace piston and pin Consumption Sticking piston rings Repair or replace piston rings Worn piston or cylinders Repair or replace piston or cylinder blocks Worn valve stem seal Replace valve stem seal Worn valve stem or valve guide Replace valve stem and guide Leaking oil Repair oil leakage Worn piston rings Replace piston rings Plugged PCV system Service PCV system 01 8 DSG 423 GENERAL INFORMATION Condition Possible Source Action Engine Noise Excessive main bearing oil clearance Adjust clearance or replace main bearing Seized or heat damaged main bearing Replace main bearing Excessive crankshaft end play Replace crankshaft thrust main bearing Excessive connecting rod bearing oil clearance Replace conne
198. lator and battery A serpentine belt drives the generator from the crankshaft pulley refer to Section 5 for information on the drive belt The generator produces alternating current which is subsequently converted to direct current The charging rate is adjusted automatically by the built in regulator to provide sufficient electric current to keep the battery fully charged under normal operating conditions Battery power The battery is a 12 volt DC source connected in a negative ground system There are three main functions of the battery Tosupply powerto the starter and ignition system so the engine can be cranked and started Tosupply extra power required when the equipment load requirements exceed the supply from the charging system To actas a voltage stabilizer by smoothing out or reducing temporary high voltages within the electrical system Operation With the ignition on voltage is applied to the voltage regulator This turns the regulator on allowing current to flow from the battery to the generator field coil When the engine is started the generator begins to generate alternating current AC which is internally converted to direct current DC This current is then supplied to the equipment electrical system through the terminal of the generator Once the generator begins generating current a voltage signal is taken from the generator stator and fed back to the regulator This voltage feedba
199. le clean container for reuse If the coolant is con taminated it must be recycled or disposed of correctly 2 Open drain cock at radiator and drain old coolant from engine into a suitable container Close the drain cock when finished Radiator Drain Cock 3 If necessary remove the lower radiator hose to completely drain the system Reinstall when finished 4 If rust sludge or other foreign material are present in the old coolant system should be flushed Refer to Flushing the Cooling System on page 9 of this section Flushing the Cooling System To remove rust sludge and other foreign material from the cooling system use Rotunda Cooling System Cleanser Removal of such material restores cooling efficiency and avoids overheating Always remove the thermostat prior to pressure flushing A pulsating or reversed direction of flushing water flow will loosen sediment more quickly than a steady flow in the normal direction of coolant flow In severe cases where cleaning solvents will not properly clean the cooling system for efficient operation it will be necessary to use the pressure flushing method Various types of flushing equipment are available Follow manufacturer s operating instructions Filling the Cooling System WARNING REFER TO CAUTIONS AND WARNINGS AT THE BEGINNING OF THIS SECTION Coolant is made up of a 50 50 mix of ethylene glycol permanent antifreeze and distilled water This mixture is to
200. leaner removed pull the air valve piston upwards to ensure free movement of the carburetor air valve Is the air valve binding No Go to Step 4 4 Check air valve operation Yes Refer to section 475 1 for servicing the carburetor Using the WTK 1 test kit connect the vacuum gauge between the carburetor and the FCV valve to measure the carburetor air valve vacuum AVV With the engine at idle observe the amount of measured No The Idle mixture may be mis adjusted vacuum Is the measured vacuum outside the specifications Refer to Diagnostic Aids Below Diagnostic Aids Fuel Lock Solenoid The fuel lock is an electronic solenoid that is opened to allow fuel flow when the key is turned ON High temperatures may cause the solenoid to become intermittent not opening to supply sufficient fuel pressure Fuel Filter There is a filter element located in the inlet of the fuel lock which may become clogged and limit fuel flow especially at low tank pressures Check the filter and replace as necessary Fuel Line Restrictions The vehicle specifications table specifies the fuel line to be a certain size If the fuel line from the tank to the fuel lock is not the proper size or any valves or fittings with flow restrictive characteristics are used the fuel flow will not be sufficient to the converter with low tank pressure Correct any fuel line or fitting restrictions Mixer Assembly Carburetor It is possibl
201. lts to 10 Nm 89 Ib in Oil Pan Removal CAUTION Failure to follow this procedure can cause future oil leakage 1 Remove and or disconnect components to allow access and removal of the oil pan Label if necessary to allow for correct reinstallation 2 Drain the engine oil 3 Remove oil level indicator amp tube Refer to Oil Level Indicator amp Tube Replacement on page 24 of this section E rn Drain Plug f Bolt CAUTION Do not use metal scrapers wire brushes power abrasive discs or other abrasive means to clean the sealing surfaces These tools cause scratches and gouges which make leak paths Use a plastic scraping tool to remove all traces of old sealant 5 Clean the mating surface of oil pan and block with silicone gasket remover and metal surface prep WARNING OBSERVE ALL WARNINGS AND CAUTIONS AND FOLLOW ALL APPLICATION DIRECTIONS CONTAINED ON THE PACKAGING OF THE SILICONE GASKET REMOVER AND METAL SURFACE PREP 02 24 DSG 423 ENGINE Oil Pan Installation NOTE If not secured within 4 minutes the sealant must be removed and the sealing area recleaned as before Refer to previous CAUTION amp WARNING 1 Apply a 2 5 mm 0 1 in bead of silicone gasket and sealant to the oil pan Install the oil pan and bolts in sequence shown e Tighten to 25 Nm 18 lb ft 2 Install oil level indicator and tube Refer to Oil Level Indicator amp Tube Replacement
202. ment integrity are compromised by the choice of methods tools or parts Notes Cautions and Warnings As you read through the procedures you will come across NOTES CAUTIONS and WARNINGS Each one is there for a specific purpose NOTES gives you added information that will help you to complete a particular procedure CAUTIONS are given to prevent you from making an error that could damage the equipment WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury The following list contains some general WARNINGS that you should follow when you work on the equipment GENERAL WARNINGS TO HELP AVOID INJURY ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION USESAFETY STANDS WHENEVER A PROCEDURE REQUIRES YOU TO BE UNDER THE EQUIPMENT BESURE 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
203. mity in the coupling components which can cause fuel leaks 1 Relieve the fuel system pressure Refer to Fuel Pressure Relief on page 31 of this section 2 Release the locking tab on the quick connect coupling 3 Separate the quick connect coupling from the fitting j um 04 33 DSG 423 FUEL SYSTEM Quick Connect Coupling Type Il Connect 1 Inspect for damage and clean fittings CAUTION Make sure the fuel tube clicks into place when installing the tube To make sure that the fuel tube is fully seated pull on the tube 2 Lubricate the o ring seals with clean engine oil 3 Release the locking tab and install the quick connect coupling onto the fitting 4 Position the locking tab into the latched position 5 Pull on the fitting to make sure it is fully engaged 04 34 DSG 423 FUEL SYSTEM REMOVAL AND INSTALLATION RESULTING IN POSSIBLE PERSONAL INJURY Fuel Rail amp Injectors Replacement WARNING FUEL IN THE FUEL SYSTEM REMAINS AN AS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR WARNING DO NOT SMOKE OR CARRY LIGHTED FUEL SYSTEM COMPONENTS THE FUEL SYSTEM TOBACCO OR OPEN FLAME OF ANY TYPE WHEN PRESSURE MUST BE RELIEVED FAILURE TO WORKING ON OR NEAR ANY FUEL RELATED COMPONENT HIGHLY FLAMMABLE MIXTURES BCREGNALIMIUR ARE ALWAYS PRESENT
204. mshafts Failure to measure all clearances prior to removing camshafts will necessitate repeated removal and installation and wasted labor time 3 Select tappets and mark location using the following formula tappet thickness measured clearance plus base tappet thickness minus most desirable thickness NOTE If any tappets do not measure within specifications install new tappets in those locations Refer to Valve Tappet Replacement on page 18 of this section 02 45 DSG 423 ENGINE SPECIFICATIONS General Specifications Continued Specification General Specifications Diameter 2 87 51 87 52 mm Specification 3 4452 3 4456 in Motorcraft Metal Surface Diameter 3 87 52 87 53 mm Prep ZC 31 3 444 3 446 in Silicone Gasket Remover Piston to bore clearance 0 025 0 045 mm ZC 30 0 0009 0 0017 in Silicone Gasket and WSE M4G323 A4 Ring groove width top 1 203 1 205 mm Sealant TA 30 0 0473 0 0474 in Motorcraft SAE 5W 20 WSS M2C930 A Ring groove width 2nd 1 17 1 19 mm Premium Synthetic Blend 0 0 460 0 0468 in Motor Ring groove width oil 2 501 2 503 mm in Canada Motorcraft 0 0984 0 0985 i SAE 5W 20 Super 0 0984 0 0985 in Premium Motor Oil Piston skirt coating 0 008 0 020 mm CXO 5W20 LSP12 or thick
205. n 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 CMP Sensor 08 4 DSG 423 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 40 F High temperature causes a low resistance of 70 ohms at 130 C 266 F The GCP supplies a 5 volt signal to the ECT sensor through resistors in the 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
206. nd Check Coolant level and the coolant outlet port system for leaks Check for proper Is ice present conlant type No Go to Step 2 2 Check regulator operation Yes The Regulator is functioning properly and the problem may be with the FCV Using Woodward WTK 1 secondary pressure gauge as valve vacuum hoses or carburetor described in section 475G 1 note the secondary spring Go to J3 color and pressure range Startthe engine No The Regulator is malfunctioning See Is the pressure constant and at 1 5 inches of w c as section 475R 1 for service of the specified regulator Repair or replace as necessary 3 Check valve operation Yes Refer to section 475 1 for servicing the carburetor Using the WTK 1 test kit connect the vacuum gauge between the carburetor and the FCV valve to measure the carburetor air valve vacuum AVV e With the engine at idle and accelerating observe the Ne amount of measured vacuum Service the carburetor see section Is the measured vacuum non linear and outside the 1 to the specifications agnosie Foe Diagnostic Aids Regulator Assembly Converter amp FCV Overheating is typically related to a cooling or coolant problem There is a possibility of a gasket leak inside the regulator which would allow coolant to pass through to the fuel supply This may effect the emissions if large enough In this situation the coolant level should consistently drop as cool
207. ne 1 2192 1 2196 in m Coolant outlet pipe 10 89 bolts 02 47 Torque Specifications Continued DSG 423 ENGINE Torque Specifications Continued head nuts Description Nm Ib ft Ib in Description Nm Ib ft Ib in pump pulley 25 18 Shroud bolts 7 62 bolts te Flywheel bolt Coolant thermostat 10 89 G bol 25 18 _ bolts enerator bolts Generator A C 48 35 Coolant pump bolts 10 89 compressor s ppoit Coolant outlet front 25 18 bracket bolts Intake manifold bolts 18 13 ie 9 Knock sensor 20 15 Cylin der head bole EP a3 Oil pressure sensor 15 11 Oil level indicator tube 10 89 Crankshaft pulley bolt bolt m pump sprocket bolt 25 18 Crankshaft oil seal eae Oil pump pickup tube 10 x 89 and screen bolts ground 10 89 Oil drain plug alle 28 21 cable to cylinder head Oil filter adaptor bolts 25 18 e E bolt Oil pan bolts Exhaust gas 10 89 Oil 4o evlind 20 15 recirculation EGR ea Ea E 54 tube bracket bolt zm il pump chain 10 EGR outlet 20 15 t bolt tube to intake manifold i flange bolts Oil pump
208. ne at idle and upon acceleration Using a high impedance DVOM check for 12 volt supply No Refer to section 475 1 for servicing the at the harness connector carburetor Also refer to the Diagnostic Is the voltage less than 11 5 volts Aids below 9 Check FCV operation Yes This would indicate the engine is too lean Possible causes e Accelerate Engine to induce symptom e Plugged bypass port go to Step 7 e Disconnect the vacuum hose from the FCV valve to the regulator Faulty t Does engine accelerate to full power with hose disconnected fault Refer to section 475 1 for servicing the carburetor Also refer to the Diagnostic Aids below Diagnostic Aids Fuel Line Restrictions The vehicle specifications table specifies the fuel line to be a certain size If the fuel line from the tank to the fuel lock is not the proper size or any valves or fittings with flow restrictive characteristics are used the fuel flow will not be sufficient to the converter with low tank pressure Correct any fuel line or fitting restrictions Mixer Assembly Carburetor It is possible that a backfire may have caused the fuel valve to partially come off of it s retainer and restrict fuel check the mixer fuel valves see section 475 1 for disassembly If no other problems have been identified and the mixer has been serviced replace the fuel management assembly with a known good part
209. ne coolant and install coolant pump and 3 bolts Tighten to 10 Nm 89 Ib in Coolant Pump Bolts Coolant Pump Pulley NOTE Lubricate new fuel injector o ring seals with clean engine oil prior to installation 49 Using new o ring seals install fuel rail assembly and bolts Tighten to 25 Nm 18 Ib ft Injector CAUTION The knock sensor KS must not touch the engine vent cover 50 Install knock sensor e Tighten to 20 Nm 15 Ib ft 51 Install engine vent cover and bolts Tighten to 10 Nm 89 Ib in Hose PCV Valve 52 Using a new gasket install thermostat housing and 3 bolts Tighten to 10 Nm 89 Ib in Thermostat amp Housing ane Q Q Q NOTE Apply silicone dielectric compound to inside of spark plug boot area prior to installation of coils 53 Install coils over spark plugs and tighten bolts Tighten to 222222222222222229 54 Make any connections that will not be accessible after intake manifold is installed 55 Inspect and install new intake manifold gaskets if necessary 02 43 DSG 423 ENGINE 56 Install intake manifold and bolts 59 Install 7 new exhaust manifold studs Tighten to 18 Nm 13 Ib ft T Tighten to 17 Nm 13 Ib ft Exhaust Manifold Manifold Bolt 60 Position a new gasket and install exhaust manifold and 7 new nuts Tighten to 54 Nm 40 Ib ft 61 Install generator and support bracke
210. ness 0 0003 0 0007 in equivalent zi Piston Pin Motorcraft Premium Gold WSS M97B51 A1 Diameter 20 995 21 0 mm Engine Coolant 7 0 8266 0 8268 in in California Oregon and i New Mexico 7 in Length 59 6 60 4 mm Canada 7 2 346 2 377 in equivalent yellow color Piston to pin clearance 0 008 0 016 mm Multi Purpose Grease ESB M1C93 B 0 0003 0 0006 in XG 4 and or XL 5 Pin to rod clearance zi Press fit Sealant with PTFE WSK M2G350 A2 Cylinder Head Exhaust valve lift in 7 4 mm 0 2913 in Displacement 2 3L zero lash Nogofeylinders i Intake valve lift in 7 9 mm 0 3110 in Bore stroke 87 5 94 0 zero lash Firing order 1 3 4 2 Valve guide diameter 5 509 5 539 mm Oil pressure hot 2000 29 39 psi 216 02 18 rpm 200 268 kPa Valve seat width 0 99 1 84 mm Oil capacity 3 5 qts 0 5 qt with intake exhaust 0 038 0 072 in filter Valve seat angle 45 degrees Cylinder Block Valve seat runout 0 075 mm 0 0029 in Cylinder bore diameter 87 5 87 53 mm Valve lash adjustor bore 31 00 31 03 mm 3 444 3 445 in diameter 1 220 1 221 in Out of round 0 008 mm Cam bore diameter 25 015 25 040 mm 0 0003 in 0 984 0 985 in Main bearing bore 57 020 57 038 mm Valve diameter ZAS IN Valve head diameter 34 85 35 15 mm Head face flatness 0 1 mm general intake 1 372 1 383 in EE a 5 Valve head diameter 29 85 30 15 mm HVEEM haust 1 175 1 187 i 0 0019 in 7 87 x 7 87 00
211. ng dirty C Base exposed poor lubrication D Both edges worn journal damaged E One edge worn journal tapered or bearing not seated F 517 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 4 FPP03541 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 4 FPP03541 01 31 DSG 423 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 111 FPP03544 Valve Stem to Valve Guide Clearance Special Tool s Dial Indicator with Bracketry TOOL 4201 C or Equivalent FPP10026 Valve Stem Clearance Tool TOOL 6505 E or Equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 NOTE Valve stem diameter must be within specifications before checking valve stem to valve guide clearance NOTE If necessary use a magnetic base 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
212. ng DTCs via the MIL the following apply e The flashing MIL is on for 0 4 second and off for 0 4 second e 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 Upto 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 Using 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 e Kit for laptop part PN 2U1L 6K947 AA Kit for PDA or laptop part PN 2U1E 6K947 AA The required software is available from your local EDI distributor or you can download it from web fpp ford com Laptop Requirements Serial port 800 x 600 dpi screen Windows 95 or newer operating system e No speed minimum e 32 MB of RAM PDA Requirements Palm OS 3 0 software 64K 08 26 DSG 423 ENGINE CONTROLS Interface Hook up laptop computer Connect interface cable to serial For connection to a laptop use kit PN 2U1L 6K947 AA cable Connect interface cable to the 4
213. ng special tools 307 005 and 303 468 remove and discard the valve seal Valve Seal Installation 1 Install the valve stem seal installation sleeve i Installation Sleeve 2 Using special tool 303 470 install a new valve seal 3 Install valve spring Refer to Valve Spring Installation on page 16 of this section 4 Install tappets Refer to Valve Tappet Replacement on page 18 of this section CAUTION If reusing tappets install in original locations 5 Install camshafts Refer to Camshafts Installation on page 18 of this section 6 Repeat for each cylinder being serviced 02 17 DSG 423 ENGINE Valve Tappet Replacement CAUTION During engine repair procedures cleanliness is extremely important Any foreign material including any material created while cleaning gasket surfaces that enters the oil passages coolant passages or the oil pan can cause engine failure NOTE Valve tappets are select fit and the valve clearance must be checked before removing the tappets Refer to Valve Clearance Check on page 45 of this section 1 Remove camshafts Refer to Camshafts Removal on page 18 of this section CAUTION If the camshafts and valve tappets are to be reused mark the location of the valve tappets to make sure they are assembled in their original positions NOTE The number on the valve tappets only reflects the digi
214. nges 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 TMAP Sensor lt 2 AN A 2 Ou A AC Su SUC 1 MEL 5 Su S Cm SEM NN gt NI 4 1 lt imm NS NN XA YN S du TN N NY Qu N N NY U EN EN x Wht EN 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 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 sen
215. not be checked with engine oil in them Use only testing fluid New hydraulic lash adjusters are already filled with testing fluid 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 lash adjuster and compress 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 Leakdown Tester Lash Adjuster 03542 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 03543 Pointer 4 01 20 A satisfactory lash adjuster must have a leakdown rate time in seconds within specified minimum and maximum limits Ifthe lash adjuster is not within specification replace it with a new lash adjuster Do not disassemble and clean new lash adjusters before testing because oil contained in the new lash adjuster is test fluid Remove the fluid from the cup and bleed the fluid from the lash adjuster by working the plunger up and down This step will aid in depressing the lash adjuster plungers when check
216. nt WARNING OBSERVE ALL WARNINGS AND CAUTIONS AND FOLLOW ALL APPLICATION DIRECTIONS CONTAINED ON THE PACKAGING OF THE SILICONE GASKET REMOVER AND METAL SURFACE PREP CAUTION Failure to follow this procedure can cause future oil leakage NOTE Do not attempt to make the metal shiny Some staining of the metal surfaces is normal 02 20 DSG 423 ENGINE 2 Apply silicone gasket and sealant to the locations shown V NOTE If not secured within 4 minutes the sealant must be removed and the sealing area recleaned as before Refer to previous CAUTION amp WARNING 3 Install a new cylinder head gasket 4 Lubricate new cylinder head bolts with clean engine oil CAUTION Cylinder head bolts are torque to yield and must not be reused New bolts must be installed 5 Install cylinder head carefully Bolt 2 Coolant Pipes Gasket 02 21 DSG 423 ENGINE 6 Tighten bolts in sequence shown in 5 stages Stage 1 Tighten to 5 Nm 44 Ib in Stage 2 Tighten to 15 Nm 11 Ib ft Stage 3 Tighten to 45 Nm 33 Ib ft Stage 4 Tighten an additional 90 degrees Stage 5 Tighten an additional 90 degrees T Install fuel rail refer to Section 4 8 Install exhaust manifold Refer to Exhaust Manifold Installation on page 19 of this section 9 Install camshafts Refer to Camshafts Installation on page 18 of this
217. oat valve stems and guides with clean engine oil 5 Install 16 valve tappets and install into cylinder head amp Install new CHT Sensor Tighten to 12 Nm 9 Ib ft 7 Install 4 new spark plugs properly gapped CAUTION Use protector provided with replacement kit to prevent damage to the valve seals 2 Using special tool 303 470 install valve seals onto Tighten to 15 Nm 11 Ib ft the guides 8 Using a new gasket install coolant outlet pipe and 4 bolts Tighten to 10 Nm 89 Ib in 9 Install rear lifting eye and front lifting eye bracket Tighten to 45 Nm 33 Ib ft 4 Using special tools 303 350 303 300 and 303 472 compress valve spring and install retainer keys 303 350 02 35 DSG 423 ENGINE Engine Assembly CAUTION The crankshaft the crankshaft sprocket and the pulley are fitted together by friction with diamond washers between the flange faces on each part For that reason the crankshaft sprocket is also unfastened if you loosen the pulley Therefore the engine must be retimed each time the damper is removed Otherwise severe damage can occur CAUTION Failure to position the No 1 piston at top dead center TDC can result in damage to the engine Turn the engine in the normal direction of rotation only 1 Using the crankshaft pulley bolt turn the crankshaft clockwise to position the No 1 piston on gt
218. of the same pressure range Retest Overall Power Loss After performing the Preliminary Test refer to Unable to reach Full Power Chart 04 19 DSG 423 FUEL SYSTEM The pinpoint tests below should be performed after the preliminary tests and Engine Cranks but Will Not Start chart Steps 1 3 Any electrical diagnostics should have been performed to eliminate any sensor GCP or solenoid valve problems before proceeding Engine Misses Test Step Result Action to Take 1 Check regulator fuel supply Yes The fuel filter may be restricting flow or the fuel lock may be intermittent Go Using Woodward WTK 1 test kit install the primary to Step 2 pressure gauge as described in section 475G 1 With the Engine at Idle or on acceleration to induce No Go to Step 3 symptom Is the primary pressure less than X psi or fluctuating 2 Check fuelock supply voltage Yes 12 volt fuelock activation circuit is open shorted to ground or the GCP Key OFF module is faulty Check wiring Disconnect Fuelock connector from harness connectors and fuses for possible cause Key ON Using a high impedance DVOM check for 12 volt supply No Fuel filter element may be clogged at the harness connector inspect and or replace the fuel filter as Is the voltage less than 11 5 volts described in section 475F 1 Repeat test step 1 if pressure is still less than specified replace the fu
219. ol Engine speed RPM Digital Input Voltages Exhaust Gas Oxygen HO2S Diagnostic Modes Hour meter Historic Faults Number of continuous starts Active Faults Run mode power mode and fuel type Use the keys at the upper left corner Use the keys at the upper left corner or the page command to toggle the three main or the page command to toggle the three main screens GAUGES FAULTS AND RAW VOLTS screens GAUGES FAULTS AND RAW VOLTS NOTE F9 key will toggle to the last screen you were on 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 08 31 DSG 423 ENGINE CONTROLS Plotting and Data Logging Recording the values and voltages can be a very useful 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 Dis software In order to record variables the FPP Dis software must be Connected to the GCP Plotting To plot a variable you must fir
220. on with diamond washers between the flange faces on each part For that reason the crankshaft sprocket is also unfastened if you loosen the pulley Therefore the engine must be retimed each time the damper is removed Otherwise severe damage can occur 1 Remove and or disconnect components to allow access and removal of the crankshaft pulley Label if necessary to allow for correct reinstallation 2 Remove the drive belt refer to Section 6 3 Remove the camshaft cover Refer to Camshaft Cover Removal on page 6 of this section CAUTION Failure to position the No 1 piston at top dead center TDC can result in damage to the engine Turn the engine in the normal direction of rotation only 4 Using the crankshaft pulley bolt turn the crankshaft clockwise to position the No 1 piston at TDC CAUTION The special tool 303 465 is for camshaft alignment only Using this tool to prevent engine rotation can result in engine damage 5 Install special tool 303 465 in the slots on the rear of both camshafts 9 NOTE Camshaft timing slots are offset If special tool cannot be installed rotate crankshaft one complete revolution clockwise to correctly position camshafts 6 Remove plug bolt CAUTION Installing special tool in this next step will prevent engine from being rotated in the clockwise direction However the engine can
221. onents Low Battery Voltage Incorrect Battery Specifications Incorrect Battery Cable Size Starter Relay Starter Failure Excessive Drain Engine Does Not Crank Dead Battery Ground Loss Ancillary Components Binding or Seized OEM Shutdown Level Safety Starter Lockout Relay Failure Ignition Switch Failure Bad Starter Crank Control Wire Failure Loose Connection or Corrosion 08 37 DSG 423 ENGINE CONTROLS Engine Performance While Under Load SYMPTOM POSSIBLE CAUSE Engine Stalls Quits Faulty OEM Drivers Safety Shut off Seat Switch Low Battery Voltage Low Fuel Pressure OEM Safety Shutdowns Bad MAP Sensor Air Restriction Coil Failure Fuel Mixer Binding Dry Fuel Runs Rough Ground Loss Misrouted Spark Plug Wires Fuel System Failure Vacuum Leak Wiring Failure Low Fuel Pressure Spark Plugs Fouled Incorrect Valve Timing Misses Fuel System Failure Misrouted Spark Plug Wires Spark Plug Gap Too High Spark Plugs Fouled Cracked Spark Plug Insulator Incorrect Valve Timing Compression Loss Hesitation Stumble Low Fuel Pressure Spark Plugs Fouled MAP Sensor Vacuum Signal Loss Surge Low Fuel Pressure Map Sensor Failure Application or Ancillary System Momentarily Binding During Load or Unload Backfires Faulty OEM Drivers Safety Shut off Seat Switch Fouled Spark Plugs Spark Plug Wire Broke GCP Momentary Ground Loss Excess Lean Condi
222. ontrol Valve AIR Control Valve Air Control Valve Secondary Air Check Valve SACV Secondary Air Injection Diverter AIR Diverter Air Management2 AM2 Secondary Air Injection Diverter AIRD Thermactor Air Diverter TAD Secondary Air Injection Pump AIR Pump Air Injection Pump AIP Secondary Air Injection Switching Valve AIR Switching Valve Secondary Air Switching Valve SASV Sequential Multiport Fuel Injection SFI Fuel Injection Sequential Electronic Fuel Injection SEFI Sequential Fuel Injection Service Reminder Indicator SRI Check Engine Engine Maintenance Reminder EMR Oxygen Sensor Indicator OXS Service Engine Soon Short Term Fuel Trim Short Term FT Integrator INT Smoke Puff Limiter SPL Smoke Puff Limiter SPL Supercharger SC Supercharger SC Supercharger Bypass SCB Supercharger Bypass SCB Supercharger Bypass Solenoid SCB Solenoid Supercharger Bypass Solenoid SBS System Readiness Test SRT System Readiness Test SRT Thermal Vacuum Valve TVV Thermal Vacuum Switch TVS Third Gear 3GR Third Gear 3GR Three Way Catalytic Converter TWC Three Way Catalytic Converter TWC Three Way Oxidation Catalytic Converter TWC OC Dual Bed Throttle Body TB Fuel Charging Station Throttle Body Fuel Injection TBI Central Fuel Injection CFI Electronic Fuel Injection EFI Fuel Injection Monotron
223. ooler if equipped Some engines use an ethylene glycol base antifreeze solution to which the manufacturers have added a dye color The dye color makes the antifreeze solution an excellent leak detector If this type of solution is not being used in the cooling system a vegetable dye may be added to aid in locating external leakage Coolant Inspection A WARNING REFER TO CAUTIONS AND WARNINGS AT THE BEGINNING OF THIS SECTION Check level and condition of coolant A dark brown color could indicate a stop leak was used light or reddish brown color indicates that rust may be present in the cooling system Flush the system and refill with the correct mixture of dis tilled water and premium engine coolant Aniridescent sheen on top of the coolant could indicate a trace of oil is entering the system Amilky brown color may indicate that either en gine oil or transmission fluid is entering the cool ing system If transmission fluid is suspected it may be entering through the transmission cooler in the radiator If engine oil is suspected the cause may an internal leak in the engine Coolant Range Check If the engine coolant appearance is acceptable test the engine coolant freezing point and concentration level The antifreeze concentration in a cooling system can be determined by using a suitable hydrometer or a battery antifreeze tester The freezing point should be in the range 45 C to 23 C 50 F
224. or Equivalent __ gt Special Service Tools called for CSS 22 by procedures be oO E obtained by calling 1 800 ROTUNDA 1 800 768 8632 FPP10026 1 Inspect the flywheel for Cracks A FPP03558 Worn ring gear teeth B Chipped or cracked ring gear teeth C Oil Pump Side Clearance 2 Inspect the flywheel ring gear runout Special Tool s Feeler Gauge D81L 4201 A or Equivalent FPP10033 Straight Edge D83L 4201 A or Equivalent Special Service Tools called for by the procedures can be Cil Pump Gear Radial Clearance RPE 10086 obtained by calling 1 800 ROTUNDA Measure the clearance between the rotor and 1 800 768 8632 pump housing 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 FPP03557 03559 01 35 DSG 423 GENERAL INFORMATION Cylinder Bore Honing Special Tool s Engine Cylinder Hone Set T73L 6011 A Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 FPP10037 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 NOT
225. 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 oylinder block cylinder walls pistons piston pins and rings intake and exhaust valve stems intake and exhaust valve guides allinternal engine components When the pistons move downward a thin film of oil is left on the cylinder walls As the engine is operated some oil is also drawn into the combustion chambers past the intake and exhaust valve stem seals and burned The following is a partial list of conditions that can affect oil consumption rates 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 percei
226. passages or the oil pan and cause engine failure CAUTION Due to the precision fit and timing of the balancer shaft assembly it cannot be removed from the engine block 1 Remove engine from equipment and mount on an engine stand Refer to Flywheel Flexplate Replacement on page 27 of this section 2 Remove the drivebelt Exhaust Manifold 8 Remove and discard exhaust manifold gasket and studs 9 Inspect exhaust manifold for flatness refer to Section 1 10 If equipped remove block heater 4 Remove all coolant pipes and hoses 5 Remove A C compressor if equipped 02 28 DSG 423 ENGINE Power Steering Knock Sensor Bolt 4 2 3 lt 2 SA 2 lt 2 o D o lt 5 GO TAC lt W PCV Valve PCV Hose 17 Remove fuel rail and injectors Discard o rings 13 Remove ignition coils 14 Remove 3 bolts and thermostat housing Fuel Rail Injector t M 7 y D ANS f 4 S MS AN SS 5 Water Pump Pulley Bolt 02 29 DSG 423 ENGINE 19 Remove 3 bolts and coolant pump Discard the o Coolant Pump 20 Remove camshaft cover Bolt a Camshaft Cover Gasket CAUTION Failure to position the No 1 piston at top dead center
227. pin diagnostic Connect serial cable to RS232 port on the back of the Laptop Computer Serial Communication Cable Interface Cable To Diagnostic Connector For connection to a PDA use kit PN 2U1E 6K947 AA Connect as shown below PDA To Diagnostic Connector HotSync Cable Interface Cable 08 27 DSG 423 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 technicians EPM software Display msi Windows Installer Package instmsi setup DistFile a Double click FPP Display icon You will now see a welcome screen is FPP Display Setup Click next Welcome to the FPP Display Installation Wizard It is strongly recommended that you exit all Windows programs before running this setup program Click Cancel to quit the setup program then close any programs you have running Click Next to continue the installation WARNING This program is protected by copyright law and international treaties Unauthorized reproduction or distribution of this program or any portion of it may result in severe civil and criminal penalties and will be prosecuted to the maximum extent possible under law A screen will pop up telling you the name of the destination folder i FPP Display
228. prevent vapor lock in the pump An actuator controls air supply to the intake manifold Governor settings are not adjustable They can only be programmed by authorized personnel only Contact your local EDI Distributor listed in the back of this manual for further information CAUTION Do not force the throttle plate open This may cause permanent damage to the actuator A pressure relief valve is located on the fuel rail This is used to read fuel pressure and also to relieve fuel pressure prior to component replacement The GCP controls the amount of fuel air delivery refer to Section 8 for further information on Electronic Engine Control Fuel System Requirements Fuel Tanks The DOEM or OEM supplies the tanks There must be a fuel outlet and a fuel inlet The gas cap must also be vented Wet Fuels The following fuels must all be unleaded and clean Gasoline petrol This engine is designed to operate on unleaded 87 or 89 octane gasoline Gasohol Ethanol A mixture of gasoline and ethanol grain alcohol containing up to 1096 ethanol by volume with properly formulated cosolvents and other necessary additives Blends index of 87 or 89 Gasohol Methanol A mixture of gasoline and alcohol wood alcohol etc containing up to 5 methanol by volume with properly formulated cosolvents and other necessary additives Blends index of 87 or 89 Fuel Pump The fuel pump must be mounted on the frame rail not on the engine It
229. pulley Refer to Crankshaft Pulley Removal on page 8 of this section CAUTION Use care not to damage the engine front cover or the crankshaft when removing the seal 3 Using special tool 303 409 remove the crankshaft front seal Crankshaft Front Seal Installation 1 Lubricate the new crankshaft front seal with clean engine oil prior to installation 2 Using special tool 303 096 install the crankshaft front seal 3 Install the crankshaft pulley Refer to Crankshaft Front Seal Installation on page 10 of this section 4 Install or reconnect any other components that were removed or disconnected 02 10 DSG 423 ENGINE Engine Front Cover Removal 1 Disconnect the negative battery cable refer to Tensioner Section 6 CAUTION The crankshaft the crankshaft sprocket and the pulley are fitted together by friction with diamond washers between the flange faces on each part For that reason the crankshaft sprocket is also unfastened if you loosen the pulley Therefore the engine must be retimed each time the damper is removed Otherwise severe damage can occur 4 2 Ug 2 2 Remove and or disconnect components to allow access and removal of the engine front cover Label if necessary to allow for correct reinstallation 3 Remove the crankshaft pulley Refer to Crankshaft Pulley Removal on page 8 of this section 4 Disconnect Crankshaft
230. r 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 L A bes 2 Use a feeler gauge to measure the top piston ring end gap and the second piston ring end gap 03528 01 27 DSG 423 GENERAL INFORMATION Piston Ring to Groove Clearance Special Tool s Feeler Gauge D81L 4201 A or Equivalent Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 FPP10033 1 Inspect for a stop in the grooves 2 Measure the piston to groove clearance 03529 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 specification gt 03530 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 FPP03531 Connecting Rod Cleaning CAUTION Do not use a cau
231. re will cause a lean mixture and fuel starvation at high speeds and excessive pressure will cause high fuel consumption and possible flooding Fuel Pressure Check A WARNING REFER TO WARNINGS AT THE BEGINNING OF THIS SECTION 1 Remove the Schrader valve cap and attach a fuel pressure gauge 2 Bleed air from guage line into a suitable container 3 Fuel pressure should be as follows e Key Engine off 414 448 kPa 60 65 psi Engine running 414 448 kPa 60 65 psi Fuel Pressure Gauge 310 012 Schrader Valve If fuel pressure is insufficient check for a clogged pump filter screen or fuel filter Also check for a break or restriction in the fuel lines If fuel pump is inoperative check for damaged or loose ground or improper wiring Make sure fuel lines connections area tight and not leaking 04 30 DSG 423 FUEL SYSTEM GENERAL SERVICE PROCEDURES Fuel Pressure Relief WARNING REFER WARNINGS THE BEGINNING OF THIS SECTION 1 Disconnect the negative battery cable refer to Section 6 2 Remove the Schrader valve cap and attach a fuel pressure gauge Fuel Pressure Gauge 310 012 Schrader Valve WARNING OPEN MANUAL VALVE SLOWLY RELIEVE SYSTEM PRESSURE 3 Open the manual valve on the pressure gauge and drain some fuel into a suitable container 4 Fuel pressure is now relieved from system Spring Lock Coupling Type Disconnect WARNING REFER TO
232. ry The GCP is also equipped with multiple safety and protection devices that protect the user and engine from hazards such as over speed e over temperature over voltage low oil pressure unauthorized tampering over cranking starter motor The GCP controls the following Fuel metering system e Ignition timing e On board diagnostics for engine functions The GCP constantly observes the information from various sensors The GCP controls the systems that affect engine performance The GCP performs the diagnostic function of the system It can recognize operational problems alert the operator through the Malfunction Indicator Lamp MIL and store diagnostic trouble codes DTC s DTC s identify the problem areas to aid the technician in making repairs The GCP 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 voltmeter will not give an accurate reading because its resistance is too low Therefore a digital voltmeter with at least 10 meg ohms 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 m
233. s Multiport Fuel Injection MFI D Jetronic Digital Fuel Injection EFI Electronic Fuel Injection EFI Fuel Injection L Jetronic LH Jetronic Motronic Multipoint Injection MPI Multiport Injection MPI Port Fuel Injection Programmed Fuel Injection PGM FI Tuned Port Injection Nonvolatile Random Access Memory NVRAM Keep Alive Memory KAM Nonvolatile Memory NVM Oil Pressure Sensor Oil Pressure Sensor Oil Pressure Sender Oil Pressure Switch Oil Pressure Switch Oil Pressure Switch On Board Diagnostic OBD Self Test Open Loop OL Open Loop OL Oxidation Catalytic Converter Continuous Oxidation Catalyst Oxidation Catalyst OC Oxygen Sensor 025 Exhaust Gas Oxygen Sensor EGO Sensor EGOS Exhaust Gas Sensor EGS Exhaust Oxygen Sensor EOS Lambda Oxygen Sensor O2 Sensor OS Park Neutral Position PNP Park Neutral P N Park Neutral Position Switch PNP Switch Neutral Drive Switch NDS Neutral Gear Switch NGS Neutral Position Switch NPS Neutral Safety Switch Periodic Trap Oxidizer PTOX Trap Oxidizer Periodic TOP Positive Crankcase Ventilation PCV Positive Crankcase Ventilation PCV Positive Crankcase Ventilation Valve PCV Valve Positive Crankcase Ventilation PCV valve Power Steering Pressure PSP Power Steering Pressure PSP Power Steering Press
234. s of w c secondary pressure gauge as described in section 475G the Regulator is malfunctioning See 1 note the secondary spring color and pressure range section 475R 1 for service of the Accelerate to induce symptom regulator Are the pressures less than X specified Ma Go to 22222222 04 18 DSG 423 FUEL SYSTEM Engine Is Unable To Reach Full Power Continued Test Step Result Action to Take 6 Check FCV operation Yes This would indicate the engine is too lean Possible causes e Accelerate engine to induce symptom e Plugged bypass port go to Step 7 e Disconnect the vacuum hose from the FCV valve to the regulator e Faulty FCV valve connection or vacuum leaks go to Step 8 Does the engine accelerate to full power with the hose disconnected fault Go to Step 9 7 Check FCV vacuum fitting bypass port Yes Clean out bypass with a 050 size pin or drill bit and retest The bypass port is located on the back of the 90 degree CAUTION Do not enlarge the by elbow which connects the vacuum line from the converter pass port to the FCV valve Is this bypass partially closed with dirt or debris No Go to Step 8 8 Check FCV supply voltage Yes 12 volt FCV circuit is open shorted to ground or the GCP module is faulty Key OFF Check wiring connectors and fuses Disconnect connector from harness for possible cause With engi
235. s to clean the sealing surfaces These tools cause scratches and gouges which make leak paths Use a plastic scraping tool to remove all traces of old sealant 11 Clean the sealing surface with silicone gasket remover and metal surface prep WARNING OBSERVE ALL WARNINGS AND CAUTIONS AND FOLLOW ALL APPLICATION DIRECTIONS CONTAINED ON THE PACKAGING OF THE SILICONE GASKET REMOVER AND METAL SURFACE PREP sealant to the cylinder head and oil pan joint areas and also to front cover as shown below 02 12 DSG 423 ENGINE 3 Install the front cover and tighten the bolts in the 5 Position the coolant pump pulley and install the 3 sequence shown to the following specifications bolts Tighten 8 mm bolts to 10 Nm 89 Ib in e Tighten to 25 Nm 18 Ib ft Tighten 10 mm bolts to 25 Nm 18 Ib ft Tighten 13 mm bolts to 48 Nm 35 Ib ft Tensioner e Coolant Pump Pulley 6 Install the accessory drive belt tensioner and the bolt 4 Position the power steering pump and install the _ Tighten to 50 Nm 37 lb ft bolts CAUTION The crankshaft the crankshaft sprocket and the pulley are fitted together by friction with Tighten to 25 Nm 18 Ib ft diamond washers between the flange faces on each part For that reason the crankshaft sprocket is also unfastened if you loosen the pulley Therefore the engine must be retimed each time the damper is removed Otherwise severe damage can occur 7
236. se Excessive exhaust clogging will cause the needle to drop to a low point even if the engine 2 NORMAL READING DURING RAPID is only idling ACCELERATION AND DEACCELERATION When m the engine is rapidly accelerated dotted needle the When vacuum leaks are indicated search out and needle will drop to a low reading not to zero When correct the cause Excess air leaking into the system 5 STICKING VALVES When the needle dotted The following are potential gauge readings Some are normal others should be investigated further 1 4 4 H 7 10 3 1 15 03503 the throttle is suddenly released the needle will will upset the fuel mixture and cause concerns such as snap back up to a higher than normal figure rough idle missing on acceleration or burned valves If 3 NORMAL FOR HIGH LIFT CAMSHAFT WITH the leak exists in an accessory unit such as the power LARGE OVERLAP The needle will register as low brake booster the unit will not function correctly Always as 51 kPa 15 in Hg but will be relatively steady fix vacuum leaks Some oscillation is normal 01 14 DSG 423 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
237. se engine failure Place clean shop towels over exposed engine cavities Carefully remove the towels so foreign material is not dropped into the engine CAUTION Do not use metal scrapers wire brushes power abrasive discs or other abrasive means to clean the sealing surfaces These tools cause scratches and gouges that make leak paths Use a plastic scraping tool to remove all traces of the gasket material and sealant CAUTION Aluminum surfaces are soft and can be scratched easily Never place the cylinder head gasket surface unprotected on a bench surface To clean residual sealant oil coolant and gasket material from sealing area use silicone gasket remover and metal surface prep A second application may be required if traces of silicone or gasket material remain Allow to dry until there is no sign of wetness or 4 minutes whichever is longer Failure to follow this procedure can cause future oil leakage WARNING OBSERVE ALL WARNINGS AND CAUTIONS AND FOLLOW ALL APPLICATION DIRECTIONS CONTAINED ON THE PACKAGING OF THE SILICONE GASKET REMOVER AND METAL SURFACE PREP NOTE Do not attempt to make metal shiny Some staining of metal surfaces is normal 02 34 DSG 423 ENGINE Cylinder Head Assembly NOTE Make sure keys are seated properly CAUTION If installing original valves make sure CAUTION Be sure to install tappets in the same they are installed in the same position as removed location as removed 1 C
238. se metal scrapers wire brushes power abrasive discs or other abrasive means to clean the sealing surfaces These tools cause scratches and gouges which make leak paths Use a plastic scraping tool to remove all traces of old sealant 11 Clean the sealing surface of the cylinder head with silicone gasket remover and metal surface prep WARNING OBSERVE ALL WARNINGS AND CAUTIONS AND FOLLOW ALL APPLICATION DIRECTIONS CONTAINED ON THE PACKAGING OF THE SILICONE GASKET REMOVER AND METAL SURFACE PREP Camshaft Cover Installation 1 2 Position camshaft cover and install bolts in sequence shown Tighten to 10 Nm 89 Ib in Install new gaskets D 2 10 Qo 005 5 z 14 Tightening Sequence 3 Reconnect crankcase ventilation tube NOTE Apply clean engine oil to CMP sensor o ring seal prior to installation 4 Install CMP sensor and bolt Tighten to 7 Nm 62 Ib in Reconnect CMP sensor ignition coil and CHT Sensor connectors Reinstall or connect any other components that were removed or disconnected Install intake manifold Refer to Intake Manifold Installation on page 6 of this section Reconnect negative battery cable refer to Section 6 02 7 DSG 423 ENGINE Crankshaft Pulley Removal CAUTION The crankshaft the crankshaft sprocket and the pulley are fitted together by fricti
239. section 10 Install camshaft cover Refer to Camshaft Cover Installation on page 7 of this section 11 Install or reconnect any other component that was removed or disconnected 12 Reconnect negative battery cable refer to Section 6 02 22 DSG 423 ENGINE Filter Adapter Removal x Disconnect negative battery cable refer to Section 6 2 Remove and or disconnect components to allow access and removal of the oil filter adapter Label if necessary to allow for correct reinstallation Drain the engine oil A Disconnect the oil pressure sender connector e Remove the oil pressure sender Refer to Oil Pressure Sender Replacement on page 23 of this section Filter 2 Pressure Sender 6 Remove and discard the oil filter 7 Remove 4 bolts and oil filter adapter 8 Remove and discard the gasket Filter Adapter Installation CAUTION Do not use metal scrapers wire brushes power abrasive discs or other abrasive means to clean the sealing surfaces These tools cause scratches and gouges which make leak paths Use a plastic scraping tool to remove all traces of old sealant 1 Clean the mating surface of adapter and block with silicone gasket remover and metal surface prep WARNING OBSERVE ALL WARNINGS AND CAUTIONS AND FOLLOW ALL APPLICATION DIRECTIONS CONTAINED ON THE PACKAGING OF THE SILICONE GASKET REMOVER AND METAL SURFACE PREP 2 Using a new g
240. sh adjuster Replace hydraulic lash adjuster or hydraulic lash adjuster Damaged hydraulic lash adjuster guide or hydraulic lash adjuster Replace hydraulic lash adjuster guide or hydraulic lash adjuster Compression leakage at valve seat Repair or replace valve valve seat or cylinder head Seized valve stem Replace valve stem Weak or broken valve spring Replace valve spring Damaged cylinder head gasket Replace cylinder head gasket Cracked or distorted cylinder head Replace cylinder head Damaged worn or sticking piston ring s Repair or replace piston ring s Worn or damaged piston Replace piston Malfunctioning or damaged fuel system Refer to Section 04 Malfunctioning or damaged ignition system Refer to Section 03 Damaged or plugged exhaust system Repair or replace exhaust system 01 9 DSG 423 GENERAL INFORMATION PCV System Malfunction A malfunctioning Positive Crankcase Ventilation System closed type may be indicated by loping or rough engine idle Do not attempt to compensate for this idle condition by disconnecting the PCV system and making an air bypass or idle speed adjustment CAUTION The removal of the PCV system from the engine will adversely affect fuel economy and engine crankcase ventilation with resultant shortening of engine life Engine Oil Leaks NOTE When diagnosing engine oil leaks the source
241. sor 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 TP DTC is set the GCP will shut down the engine immediately Specifications e Range of Measurement 0 85 angular Measurement Accuracy 2 of VREF Resolution 0 5 max 08 7 DSG 423 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
242. ssembly and the plunger in during installation alignment only Using this tool to prevent engine rotation can result in engine damage 22 Install the timing chain 25 Install special tool 303 465 in the timing slots on rear Por rper of both camshafts Timing slots are offset from the centerline of the camshaft 02 39 DSG 423 ENGINE 28 Install the front cover and bolts Tighten in the NOTE Use a wrench on the flats between cylinders sequence shown in 3 stages No 1 and No 2 to hold the camshafts in place Stage 1 Tighten 8mm bolts to 10 nm 89 Ib in Stage 2 Tighten 10 mm bolts to 25 Nm 18 Ib ft Stage 3 Tighten 13 mm bolts to 48 Nm 35 Ib ft 20 Je gt 9 14 12 5 9 8 e 5 26 camshaft sprocket bolts 2 587 U 6 Tighten to 65 Nm 48 lb ft V A NOTE If front cover is not secured within 4 minutes the Gi Qe sealant must be removed and the sealing area recleaned Refer to Engine Cleaning on page 34 of 50 3 15 this section 27 2 5 mm 0 1 in bead of silicone gasket and i 9 2 sealant to front cover and to block as shown 19 T 46 17 CAUTION Do not reuse crankshaft pulley bolt NOTE Apply clean engine oil to crankshaft front seal area prior to installing 29 Install crankshaft pulley and hand tighten
243. st 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 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
244. ster such as Rotunda Compression Tester 059 0009 or equivalent in the No 1 cylinder 4 Install an auxiliary starter switch in the starting circuit With the ignition switch in the OFF position and using the auxiliary starter switch crank the engine a minimum of five compression strokes and record the highest reading Note the approximate number of compression strokes required to obtain the highest reading 5 Repeat the test on each cylinder cranking the engine approximately the same number of compression strokes Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading Refer to the Compression Pressure Limit Chart If one or more cylinders reads low squirt approximately one tablespoon of clean engine oil meeting Ford specification ESE M2C153 E on top of the pistons in the low reading cylinders Repeat the compression pressure check on these cylinders Example Readings If after checking the compression pressures in all cylinders it was found that the highest reading obtained was 1351 kPa 196 psi and the lowest pressure reading was 1069 kPa 155 psi the engine is within specification and the compression is considered satisfactory Compression Pressure Limit Chart MAX MIN MAX MIN MAX MIN MAX MIN kPa psi kPa psi kPa psi kPa psi 924 696 1131 84
245. stic cleaning solution or damage to connecting rods can occur NOTE The connecting rod large end is mechanically split or cracked to produce a unique parting face This produces a locking joint Parts are not interchangeable e Mark and separate the parts and clean with solvent Clean the oil passages 03532 01 28 DSG 423 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 out of round is within specification FPP03533 Piston Pin Diameter Measure the piston pin diameter in two directions at the points shown Verify the diameter is within specifications 03534 Connecting Rod Bushing Diameter Measure the inner diameter of the connecting rod bushing Verify the diameter is within specification 03535 Connecting Rod Bend Measure the connecting rod bend on a suitable alignment fixture Follow the instructions of the fixture manufacturer Verify the bend measurement is within specification 03536 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
246. still be rotated in the counterclockwise direction Only turn the engine in the normal direction of rotation 7 Install special tool 303 507 2 4 6 ASSN CAUTION Failure to hold the crankshaft pulley in place during bolt loosening can cause damage to the engine 02 8 DSG 423 ENGINE 9 Remove bolt washer and pulley Discard crankshaft pulley bolt Bolt Washer Crankshaft Pulley Installation CAUTION Do not reuse the crankshaft pulley bolt 1 Apply clean engine oil on the crankshaft front seal and install crankshaft pulley washer and hand tighten new bolt CAUTION Only hand tighten the bolt or damage to the front cover can occur NOTE This next step will correctly align the crankshaft pulley to the crankshaft 2 Install a standard x 18mm bolt as shown and thread it into the front cover NOTE Rotate the crankshaft pulley as necessary to align the bolt hole CAUTION Failure to hold the crankshaft pulley in place during bolt tightening can cause damage to the engine front cover 3 Using special tools 205 126 and 205 072 02 to hold the crankshaft pulley in place tighten the crankshaft pulley bolt in 2 stages Stage 1 Tighten to 100 Nm 74 Ib ft Stage 2 Rotate an additional 90 degrees 4 Remove all special tools and 6 mm bolt CAUTION Only turn the engine in the normal direction of rotation 5 Turn the engine 2 complete revolutions then continue to
247. t 57 Install power steering pump and bolts 62 Tighten bolts in the sequence shown in 2 stages Stage 1 Tighten finger tight Stage 2 Tighten to 47 Nm 935 Ib ft 63 Install A C compressor if equipped and bolts Tighten to 25 Nm 18 Ib ft 02 44 DSG 423 ENGINE 64 Install oil level indicator tube Tighten to 10 Nm 89 Ib in Oil Level Indicator p O ring 65 Install accessory drive belt Power Steering Tensioner Coolant Pump Crankshaft 66 Install any tubes hoses or components removed or disconnected 67 Remove engine from engine stand and install flywheel or flexplate 68 Using special tool tighten bolts in the sequence shown in 3 stages Stage 1 Tighten to 50 Nm 37 Ib ft Stage 2 Tighten to 80 Nm 59 Ib ft Stage 3 Tighten to 112 Nm 83 Ib ft 69 Lubricate transmission input shaft pilot bearing with grease ADJUSTMENTS Valve Clearance Check 1 Remove camshaft cover Refer to Camshaft Cover Removal on page 6 of this section CAUTION Turn the engine clockwise only and use the crankshaft bolt only 2 Use a feeler gauge to measure each valve s clearance and record its location A mid range clearance is most desirable Intake 0 22 0 28 mm 0 008 0 011 inch Exhaust 0 27 0 33 mm 0 010 0 013 inch NOTE Measure each valve s clearance at base circle with lobe pointed away from the tappet before removing ca
248. t Special Tool s Dial Indicator with Bracketry TOOL 4201 C or Equivalent m _ M S FPP10026 Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 Dial Indicator with Bracketry TOOL 4201 C or Equivalent m S FPP10026 Special Service Tools called for by the procedures can be obtained by calling 1 800 ROTUNDA 1 800 768 8632 1 Use the Dial Indicator with Bracketry to measure camshaft intake lobe lift FPP03511 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 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 gut V 03512 Camshaft End Play Move camshaft to the rear Zero dial indicator Move camshaft to the front Compare end play with specifications Dial Indicator 04127 01 22
249. t assembly with a known good part of the same pressure range Retest 04 24 DSG 423 FUEL SYSTEM The pinpoint tests below should be performed after the preliminary tests and Engine Cranks but Will Not Start chart Steps 1 3 Any electrical diagnostics should have been performed to eliminate any sensor GCP or solenoid valve problems before proceeding Emission Failure Lean Mixture Test Step Result Action to Take 1 Check regulator fuel supply Yes The fuel filter may be restricting flow or the fuel lock may be intermittent Go Using Woodward WTK 1 test kit install the primary to Step 2 pressure gauge as described in section 475G 1 Start the engine to induce the failure No Go to Step 3 Is the primary pressure less than X psi or fluctuating 2 Check fuelock supply voltage Yes 12 volt fuelock activation circuit is open shorted to ground or the GCP Key OFF module is faulty Check wiring Disconnect Fuelock connector from harness connectors and fuses for possible cause Key ON Using a high impedance DVOM check for 12 volt supply No Fuel filter element may be clogged at the harness connector inspect and or replace the fuel filter as Is the voltage less than 11 5 volts described in section 475F 1 Repeat test step Step 1 if pressure is still less than specified replace the fuel lock and re test before moving to Step 3 3 Check regulator operation Yes Th
250. t nnne tenni nnne 09 3 Other Types of Parts eene iu scrunch etauerdcbersstecerersssccdceseesquurceequuecedveuscedeerers stores 09 4 English Metric conversion crece rennen a pana ck Rua 09 5 Decimal and Metric Eg ivalentS 2225200 09 6 NIRE 09 6 41930 Terminology List iere err erret terree auia se erac 09 7 DSG 423 METRICS INTRODUCTION Most threaded fasteners are covered by specifications that define required mechanical properties such as tensile strength yield strength proof load and hardness These specifications are carefully considered in initial selection of fasteners for a given application To ensure continued satisfactory vehicle performance replacement fasteners used should be of the correct strength as well as the correct nominal diameter thread pitch length and finish Most original equipment fasteners English or Metric system are identified with markings or numbers indicating the strength of the fastener These markings are described in the pages that follow Attention to these markings is important to ensure that the proper replacement fasteners are used Further some metric fasteners especially nuts are colored blue This metric blue identification
251. t the battery terminal is not subjected to any excessive lateral or twisting forces Such forces could cause major damage to the internal components of the battery and leakage at the terminals 1 Remove battery cables from battery terminals battery ground cable first 2 Remove battery hold down components CAUTION When lifting a plastic cased battery ex cessive pressure on the end walls could cause acid to spew through the vent caps resulting in personal injury damage to the equipment or battery Lift with a battery carrier or with your hands on opposite cor ners 3 Remove battery from equipment 06 13 facility for disposal RECYCLE DSG 423 CHARGING SYSTEM SPECIFICATIONS GENERAL SPECIFICATIONS Generator output 65 110 max amps 9 1800 6000 generator rpm approx 500 2000 engine rpm Battery Motorcraft 12 Volt 540 CCA at 18 C 0 F 58 amp hr Battery Charging Voltage 13 15 5 volts TORQUE SPECIFICATIONS Description Nm lb ft Ib in Generator mounting bolts 25 18 Regulator attachment screws 3 27 Battery cable nuts 6 53 Generator pulley nut 109 80 Generator wiring nuts 8 71 SPECIAL TOOLS VAT 40 Starting charging 078 00005 Tester 06 14 DSG 423 STARTER INDEX Subject Page Cautions amp Warmnihg Tm 07 2 General Information esena eee er
252. tage out of Power Relay 6 Not used 08 12 DSG 423 ENGINE CONTROLS Wire Colors Symbol Color BK BLACK BN BROWN BU BLUE DB DARK BLUE DG DARK GREEN GN GREEN GY GRAY LB LIGHT BLUE LG LIGHT GREEN NA NATURAL OG ORANGE PK PINK RD RED SR SILVER TN TAN VT VIOLET WH WHITE YE YELLOW Revision Level The following wiring schematics are taken from the wiring diagram labeled below need umet EDI FORD 2 3L W GCP te return upan request ond nok tn copied reproduced Humber Rew issiam Al right rig z 1 Dremm By J SUTTON 5 INC Filename 1 mh Sheet 1 of 1 G H 08 13 DSG 423 ENGINE CONTROLS Power Distribution 409 1224 jan4 MSA 09 fez v 4 9 9L Mad 91 L NL GH 8 cT 5 NL GS 4 rin L 1 18 oe 9L 9L Mad 9L L 98 5105 uous oL pH Rejoy 5 iem qs a el 5 L Ium e L 9L 8L 8L gas 9b jaued esnJ
253. tation of the engine crankshaft through the flywheel that is needed to start the engine The starter system consists of Starter motor Starter Motor Operation When the ignition is turned to the start position the starter relay switches power to the starter solenoid causing the starter motor to engage transmission must be in PARK or NEUTRAL Battery power is always present at the starter motor M Terminal starter solenoid Starter relay battery The starter motor is a permanent magnet gear reduction type It runs on 12 volts DC current The starter solenoid is integral to the motor and a relay is also used Refer to section 6 for information on the battery B Terminal terminal The starter motor relay when energized sends current to the starter motor S terminal which causes the motor s shaft to rotate When the starter Switch is released a spring returns the solenoid to the released position 2215 there any info on a starter lockout circuit 07 3 DSG 423 STARTER Wiring Diagram Revision Level The following wiring schematics are taken from the wiring diagram labeled below m drowing m m nne Weed ume FORD 2 3L W GCP te return request ond nok tn copied reproduced Humber Rew pmermimminn All rights 1782000 F Data 5 ING
254. tch Compact Disc Read Only memory CDROM Compact Disc Read Only Memory CDROM 09 7 DSG 423 METRICS New Term New Acronym Old Terms Acronyms Continuous Fuel Injection CFI Continuous Injection System CIS Continuous Injection System Electronic continuous Injection System E CIS E Fuel Injection Fl K Jetronic KE Jetronic KE Motronic Continuous Fuel Injection system CFI System Continuous Injection System CIS Continuous Trap Oxidizer CTOX Continuous Trap Oxidizer CTO Trap Oxidizer Continuous TOC Crankshaft Position CKP Crankshaft Position CP Position Indicator Pulse PIP Crankshaft Position Sensor CKP Sensor Crankshaft Position Sensor CPS Crank Angle Sensor Data Link Connector DLC Assembly Line Communication Link ALCL Assembly Line Diagnostic Link ALDL Self Test Connector Vehicle in Process Connector VIP Connector Diagnostic Test Mode DTM Modes Diagnostic Trouble Code DTC Self Test Codes Differential Pressure Feedback Gas Recirculation System Differential Pressure Feedback EGR System Differential Pressure Feedback EGR System Direct Fuel Injection DFI Direct Injection DI Direct Injection Diesel DID Fuel Injection Distributor Ignition DI Capacitive Discharge Ignition CDI Closed Bowl Distributor Electronic Ignition with Distributor Electronic Spark Advance Control ESAC
255. th the diagnos tic software the DTC terminal can NOT be ground ed CAUTION Removing battery power before access ing diagnostic program will erase all codes record ed This section contains circuit description information and troubleshooting charts on all the DTC s obtained by diagnostic software or a Malfunction Indicator Lamp MIL When diagnostic trouble codes are obtained by a Malfunction Indicator Lamp MIL the following sequence will be flashed e 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 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 08 40 DSG 423 ENGINE CONTROLS Diagnostic Trouble Code DTC Diagnostic Trouble Code DTC DTC 111 Closed Loop Multiplier High LPG DTC 353 MegaJector Delivery
256. the camshaft alignment plate can be installed without rotating the camshafts Make sure the lobes on the No 1 cylinder are in the same position as noted in the removal procedure Rotating the camshafts when the timing chain is removed or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons NOTE Lubricate the camshaft journals and bearing caps with clean engine oil prior to installation 1 Install the camshafts and bearing caps Tighten bolts in the sequence shown in 3 stages Stage 1 Tighten one turn at a time until tight Stage 2 Tighten bolts to 7 Nm 62 Ib in Stage 3 Tighten bolts to 16 Nm 12 Ib ft DM S7 US Y 4 0 02 18 DSG 423 ENGINE 2 Install timing chain and sprockets Refer to Timing Drive Components Installation on page 15 of this section 3 Install or reconnect any other components removed or disconnected Exhaust Manifold Removal 1 Disconnect negative battery cable refer to Section 6 2 Remove and or disconnect components to allow access and removal of the exhaust manifold Label if necessary to allow for correct reinstallation 3 Remove accessory drive belt refer to Section 6 4 Drain the engine cooling system refer to Section 5 5 Disconnect exhaust pipe from manifold 6 Remove oil level indicator Refer to Oil Level Indicator amp Tube Replacement
257. the container just below the lip of the cover The carrier is used on the sidewalls rather than the end walls since the sidewalls have additional strength from the inner cell partitions This is particularly important with the plastic cased battery which has end walls that are flexible 06 9 DSG 423 CHARGING SYSTEM Battery Charging WARNING REFER TO CAUTIONS amp WARNINGS AT THE BEGINNING OF THIS SECTION NOTE excessive gassing or electrolyte spewing occurs during the charge discontinue charging The battery has reached serviceable charge If the battery will not accept at least 5A after 20 minutes of charging replace the battery A WARNING WEAR SAFETY GLASSES BATTERY CHARGING CAN BE DANGEROUS WHILE BEING CHARGED THE BATTERY PRODUCES A POTENTIALLY EXPLOSIVE MIXTURE OF HYDROGEN AND OXYGEN GASSES KEEP SPARKS FLAMES AND LIGHTED CIGARETTES AWAY FROM BATTERIES IN CASE OF ACID CONTACT WITH SKIN EYES OR CLOTHING FLUSH IMMEDIATELY WITH LARGE AMOUNTS OF WATER GET MEDICAL ATTENTION Inspect and service any of the following pre existing conditions before recharging a discharged battery Refer to Preliminary Checks on page 5 of this section Cold batteries will not readily accept a charge Therefore batteries should be allowed to warm up to approximately 5 C 41 F before charging This may require four to eight hours at room temperature depending on the initial temperature and battery size A battery w
258. tion connection If air is passing through a blown head gasket to an adjacent cylinder the noise will be evident at the spark plug hole of the cylinder into which the air is leaking Cracks in the cylinder blocks or gasket leakage into the cooling system may be detected by a stream of bubbles in the radiator Oil Leak and Valve Stem Seal Test The oylinder 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 a Vacuum Pressure Tester such as Rotunda Vacuum Pressure Tester 059 00008 or equivalent to the intake manifold Run the engine at the specified idle Speed Vacuum Pressure Tester 059 00008 The vacuum gaug
259. tion Fuel Lock Off Leaking Dry Fuel Intake Manifold Leak Bad Intake Valve Lack of Power Ancillary Components Binding Intake Air Restriction Crossed Spark Plug Wires Spark Plugs Fouled Fuel System Failure Low Fuel Pressure Low Cylinder Compression Spark Knock Poor Quality or Contaminated Fuel Carbon Build up Wrong Spark Plugs Too High Heat Range Fuel Delivery System PCV System Fuel Selection Timing Cylinder Hot Spots 08 38 DSG 423 ENGINE CONTROLS Engine Concerns SYMPTOM POSSIBLE CAUSE Oil System Concerns High Oil Consumption Positive Crankcase Ventilation PCV System Oil Viscosity External Leaks Improper Oil Dipstick Valve Seals Cylinder Wall Taper Excessive Worn Piston Rings Cooling System Concerns Trapped Air Worn Drive Belt Worn Water Pump Stuck Thermostat Plugged Radiator Internal amp External Dry Fuel System Running Rich Exhaust System Concerns visible smoke Black Smoke Blue Smoke Ignition System Fuel Delivery System Sticking Fuel Injector High Fuel Pressure System Worn Piston Rings Worn Valve Guides Fuel System Concerns Leaky Lines Contaminated Fuel Excessive Alcohol in Fuel Incorrect Octane Rating Engine Noise Low Oil Pressure Oil Filter Restriction 08 39 DSG 423 ENGINE CONTROLS Engine Control Module GCP Diagnostic Trouble Codes CAUTION When checking codes wi
260. to 10 F If the equipment is run in cold climates colder than 36 34 F it may be necessary to increase the coolant concentration to get adequate freeze protection Maximum coolant concentration is 6096 coolant to 4096 distilled water If coolant tests too strong remove some of the coolant and ad distilled water until the readings are acceptable Minimum coolant concentration is 4096 coolant to 6096 distilled water If coolant tests too weak drain some coolant out and add straight coolant until readings are acceptable 05 5 DSG 423 COOLING SYSTEM Drive Belt Inspection Longer deposits building up to 50 of the rib height is also not a concern except it can result in WARNING REFER TO CAUTIONS AND WARNINGS AT THE BEGINNING OF THIS SECTION With engine running observe the belt movement It Medium should respond when engine is accelerated rapidly Piling tensioner moves excessively without rapid acceleration Install a new belt If excessive movement still exists install a new tensioner Visually inspect the belt for obvious signs of damage e Upto 15 cracks in a rib over a distance of 100 mm 4 0 in can be considered acceptable e f heavy deposits are apparent resulting in noise and belt instability install a new belt Heavy Piling e If cracks are beyond acceptable or any chunks are found to be missing from the ribs a new belt must be installed Drive belt sq
261. to as a waste spark waste spark Power Stroke Exhaust Stroke The primary coils in the coil pack are triggered by the ignition coil feed 1 and ignition coil feed 2 signals from the GCP 08 9 DSG 423 ENGINE CONTROLS Open Loop and Closed Loop Operation NOTE No DTC will be set unless engine has operated in closed loop status for more than 6 seconds The GCP will operate in the following two modes e Open loop Closed loop When the engine is first started the system is in 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 e 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 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
262. ts that follow the decimal For example a tappet with the number 0 650 has the thickness of 3 650 mm 2 Remove and inspect valve tappets 3 Reverse procedure to install NOTE Coat valve tappets with clean engine oil prior to installation Camshafts Removal CAUTION The crankshaft the crankshaft sprocket and the pulley are fitted together by friction with diamond washers between the flange faces on each part For that reason the crankshaft sprocket is also unfastened if you loosen the pulley Therefore the engine must be retimed each time the damper is removed Otherwise severe damage can occur 1 Remove and or disconnect components to allow access and removal of the timing drive components Label if necessary to allow for correct reinstallation 2 Remove timing chain and sprockets Refer to Timing Drive Components Removal on page 14 of this section CAUTION Failure to follow the camshaft loosening procedure can result in damage to the camshafts NOTE Note the position of the lobes on the No 1 cylinder before removing the camshafts for assembly reference 3 Loosen the camshaft bearing cap bolts in sequence shown one turn at a time 4 Repeat until all tension is released from the camshaft bearing caps 5 Remove bearing caps and camshafts Camshafts Installation CAUTION Install the camshafts with the alignment slots in the camshafts lined up so
263. ttle cable with maximum speed governing throttle by wire Orit 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 e when it happened if the fault still exists e alist of essential engine data from the time of the fault It can also display a 10 second graph of critical engine data from 8 seconds before the fault occurred to two seconds after 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 control modules through a Controller Area Network CAN link with messages written in the J1939 protocol This allows large amounts of data to move throughout the machine through only two wires and can be used to run some module based gauge packages The GCP also carries auxiliary features that can be programmed to control OEM devices allowing the OEM to eliminate components from their machine
264. turn until piston is at TDC 6 Install special tool 303 507 CAUTION Only hand tighten the bolt in the next step or damage to the front cover can occur 7 Using the 6mm x 18 mm bolt check the position of the crankshaft pulley If itis not possible to install this bolt correct the engine timing 02 9 DSG 423 ENGINE 8 Using special tool 303 465 check the position of the camshaft If it is not possible to install the special tool correct the engine timing 9 Remove all special tools and 6mm bolt 10 Install the plug bolt Tighten to 20 Nm 15 Ib ft 11 Install camshaft cover Refer to Camshaft Cover Installation on page 7 of this section 12 Install accessory drive belt refer to Section 6 13 Install or reconnect any other components that were removed or disconnected Crankshaft Front Seal Removal CAUTION The crankshaft the crankshaft sprocket and the pulley are fitted together by friction with diamond washers between the flange faces on each part For that reason the crankshaft sprocket is also unfastened if you loosen the pulley Therefore the engine must be retimed each time the damper is removed Otherwise severe damage can occur 1 Remove and or disconnect components to allow access and removal of the crankshaft front seal Label if necessary to allow for correct reinstallation 2 Remove crankshaft
265. ueal that is short and intermittent is expected and considered normal Constant or reoccurring drive belt squeal can occur with a damaged pulley bearing fluid contamination or a loose belt Also check for belt misalignment which can cause chirping noise If misalignment is found check the tensioner for damage especially the mounting pad surface Check for a damaged pulley that wobbles Check mounting brackets for tightness and for any interference Small scatted deposits of rubber material known as piling is not a concern Small Piling e Check tensioner with a suitable release tool that it moves without sticking or binding e With belt off check that all pulleys rotate freely without binding CAUTION Incorrect drive belt installation will cause excessive drive belt wear and can cause the belt to come off the pulleys 05 6 Symptom Chart Refer to the following Diagnosis Chart for cooling system problems their possible cause and recommended correction CONDITION Loss of coolant Engine Overheats Engine fails to reach normal operating temperature DSG 423 COOLING SYSTEM POSSIBLE SOURCE Pressure cap and gasket Leakage External leakage Internal leakage Low coolant level Loose fan belt Pressure cap Radiator obstruction Closed thermostat Fan drive clutch Ignition Temp gauge or cold light Engine Coolant mixture Open thermostat Temperature gauge or cold light 05
266. uel lock may be intermittent Go Using Woodward WTK 1 test kit install the primary to Step 4 pressure gauge as described in section 475G 1 e Start the engine to induce the failure Is the primary pressure less than X psi or fluctuating No Go to Step 5 4 Check fuelock supply voltage Yes 12 volt fuelock activation circuit is open shorted to ground or the GCP Key OFF module is faulty Check wiring Disconnect Fuelock connector from harness connectors and fuses for possible cause Key ON Using a high impedance DVOM check for 12 volt supply No Fuel filter element may be clogged at the harness connector inspect and or replace the fuel filter as Is the voltage less than 11 5 volts described in section 475F 1 Repeat test Step 3 if pressure is still less than specified replace the fuel lock and re test before moving to Step 5 5 Check regulator operation Yes The Regulator is functioning properly and the problem may be with the FCV Using Woodward WTK 1 secondary pressure gauge as valve vacuum hoses or carburetor described in section 475G 1 note the secondary spring Go to Step 6 color and pressure range Remove the vacuum hose from the FCV valve to the regulator No The Regulator is malfunctioning See Startthe engine Is the pressure constant and at 1 5 inches of w c as specified section 475R 1 for service of the regulator Repair or replace as necessary 04 28 DSG 423 FUEL SYSTEM
267. ulty Key OFF Check wiring connectors and fuses Disconnect connector from harness for possible cause With engine at idle Go to Step 6 Using a high impedance DVOM check for 12 volt supply at the harness connector Is the voltage less than 11 5 volts 04 22 DSG 423 FUEL SYSTEM Engine Backfires Continued Test Step Result Action to Take 4 Check carburetor air valve for binding Yes Refer to section 475 1 for servicing the carburetor Key ON Engine Running With the air cleaner removed pull the air valve piston upwards to ensure free movement of the carburetor air No Go to 222222222 valve Is the air valve binding 7 Check air valve operation Yes Refer to section 475 1 for servicing the carburetor Using the WTK 1 test kit connect the vacuum gauge between the carburetor and the FCV valve to measure the ET carburetor air valve vacuum AVV No Refer to Diagnostic Aids Below With the engine at idle and accelerating observe the amount of measured vacuum Is the measured vacuum outside the specifications Diagnostic Aids Fuel Lock Solenoid The fuel lock is an electronic solenoid that is opened to allow fuel flow when the key is turned ON High temperatures may cause the solenoid to become intermittent not opening to supply sufficient fuel pressure Fuel Filter There is a filter element located in the inlet of th
268. 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 08 32 DSG 423 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 will lock into the position it was in when the test mode was entered If the Spark System Test mode is selected with the engine running above 1000 RPM the throttle will continue to operate normally 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
269. ure Switch PSP Switch Power Steering Pressure Switch P S Pressure Switch PSPS Powertrain Control Module PCM Electronic Control Assembly ECA Electronic Control Unit 4 ECUA Electronic Engine Control Processor EEC Processor Microprocessor Control Unit MCU Single Board Engine Control SBEC Single Module Engine Control SMEC Pressure Transducer Exhaust Gas Recirculation Pressure Transducer Pressure Transducer EGR System System EGR System Programmable Read Only Memory PROM Programmable Read Only memory PROM Pulsed Secondary Air Injection PAIR Air Injection Reactor AIR Air Injection Valve AIV Pulsair Thermactor II Pulsed Secondary Air Injection Valve PAIR Valve Reed Valve Random Access Memory RAM Random Access Memory RAM Read Only memory ROM Read Only Memory ROM 09 12 DSG 423 METRICS New Term New Acronym Old Terms Acronyms Relay Module RM Integrated Relay Module Scan Tool ST Scan Tool Secondary Air Injection AIR Air Injection AI Air Injection Reactor AIR Thermac Thermactor Secondary Air Injection Bypass AIR Bypass Air Management 1 AM1 Secondary Air Injection Bypass AIRB Thermactor Air Bypass TAB Secondary Air Injection Bypass Valve AIR Bypass Valve Secondary Air Bypass Valve SABV Secondary Air Injection Check Valve AIR Check Valve Secondary Air Check Valve Secondary Air Injection C
270. using 6 Reverse procedure to install Clean and inspect gasket install a new gasket if necessary e Tighten bolts to 10 Nm 89 Gasket 05 12 DSG 423 COOLING SYSTEM Coolant Pump Replacement Cooling System on page 9 of this section 2 Remove or disconnect components as necessary to N gain access to the coolant pump WARNING REFER TO CAUTIONS AND WARNINGS 3 Remove the drive belt Refer to Drive Belt AT THE BEGINNING OF THIS SECTION Installation on page 10 of this section 4 Remove 3 bolts and coolant pump pulley 1 Drain the cooling system Refer to Draining the 5 Remove 3 bolts and coolant pump Coolant PUmp Pulley 6 Heverse proceaure to install Lubricate coolant pump o ring with clean coolant Tighten coolant pump bolts to 10 Nm 89 Ib in Tighten pulley bolts to 25 Nm 18 Ib ft 05 13 DSG 423 COOLING SYSTEM Outlet Pipe Replacement A WARNING REFER TO CAUTIONS AND WARNINGS AT THE BEGINNING OF THIS SECTION 1 Drain the cooling system Refer to Draining the Cooling System on page 9 of this section 2 Remove or disconnect components as necessary to gain access to the outlet pipe Disconnect hoses from outlet pipe Disconnect electrical connector at ECT Sensor Remove bolts and outlet pipe Reverse procedure to install e Clean gasket mating surfaces Install new gasket e Tighten bolts to 10 Nm 89 Doar w
271. using a constant potential automatic setting on charger DSG 423 CHARGING SYSTEM REMOVAL AND INSTALLATION Generator Bolts Drive Belt Generator Replacement 1 N O Voltage Regulator Replacement 1 Remove the generator Refer to Generator Replacement on page 11 of this section 2 Remove 4 screws and voltage regulator includes brush and holder f Voltage Regulator Insertion Hole Screws 3 Reverse procedure to install Insert a wire into the insertion hole to hold the brushes during assembly Remove wire when done e Tighten screws to Nm 27 Ib in Disconnect battery negative cable Refer to Battery Cleaning and Inspection on page 9 of this section Remove or disconnect any component to allow access and removal of generator Remove drive belt refer to Section 5 Remove 2 bolts and position the generator aside Disconnect electrical connector Remove generator Reverse procedure to install Tighten generator bolts to 25 Nm 18 Ib ft Tighten terminal to 8 Nm 71 Ib in 06 11 DSG 423 CHARGING SYSTEM Generator Pulley Replacement 1 Remove generator assembly Refer to Generator Replacement on page 11 of this section 2 Remove nut 3 Remove pulley 4 Reverse procedure to install Tighten nut to 109 Nm 80 Ib ft 06 12 DSG 423 CHARGING SYSTEM Battery Removal Battery Installation 1 Clean
272. utch Clutch Air Conditioning Clutch ACC Air Conditioning Cycling Switch Cycling Switch Air Conditioning Cycling Switch ACCS Air Conditioning Sensor A C Sensor Air Conditioning Sensor A C Sensor Air Conditioning System A C System Air Conditioning System SCS Automatic Transaxle Electronic Automatic Transaxle EATX Automatic Transmission Electronic Automatic Transmission Barometric Pressure BARO Barometric Pressure BARO Barometric Pressure Sensor BARO Sensor Absolute Pressure Sensor APS Barometric Pressure Sensor BP Sensor Battery Positive Voltage Battery Positive Voltage Camshaft Position CMP Sync Pickup Camshaft Position Sensor CMP Sensor Camshaft Position Sensor CPS Camshaft Sensor Oylinder Identification Sensor Cylinder ID Sensor CID Canister Canister Canister Carburetor CARB Feed Back Carburetor FBC Central Multiport Fuel Injection Central MFI Central Multiport Fuel Injection Fuel Injection Charge Air Cooler CAC After Cooler Inter Cooler Closed Loop CL Closed Loop System CLS Closed Throttle Position CTP Closed Throttle Position CTP Closed Throttle Position Switch CTP Switch Closed Throttle Switch Clutch Pedal Position CPP Clutch Pedal Position CPP Clutch Pedal Position Switch CPP Switch Clutch Engage Switch CES Clutch Start Switch Clutch Swi
273. ved 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 engine oil is changed at the intervals specified Refer to the Engine Operator s handbook Oil Consumption Test The following diagnostic procedure is used to determine the source of excessive internal oil consumption NOTE Oil use is normally greater during the first 300 hours of service As hours increase oil use generally decreases Engines in normal service should get at least 31 7 hours per quart 900 miles per quart after 300 hours of service High speeds heavy loads high ambient temperature and other factors may result in greater oil use 1 Determine customer s engine load habits such as sustained high speed operation extended idle heavy work loads and other considerations 2 Verify that the engine has no external oil leak as described under Engine Oil Leaks in the Diagnosis and Testing portion of this section 3 Verify that the engine has the correct oil level dipstick 4 Verify that the engine is not being run in an overfilled condition Check the oil level at least five minutes after a
274. which make leak paths Use a plastic scraping tool to remove all traces of old sealant 5 Clean the sealing surface of the cylinder head with silicone gasket remover and metal surface prep A WARNING OBSERVE ALL WARNINGS AND CAUTIONS AND FOLLOW ALL APPLICATION DIRECTIONS CONTAINED ON THE PACKAGING OF THE SILICONE GASKET REMOVER AND METAL SURFACE PREP 6 Remove and discard intake manifold gaskets Intake Manifold Installation 1 Install new intake gaskets 2 Position intake manifold and install 5 bolts Tighten to 18 Nm 13 Ib ft 3 Reconnect fuel supply connections refer to Section 4 4 Reinstall or connect any components that were removed or disconnected 5 Fill and bleed the engine cooling system refer to Section 5 Camshaft Cover Removal 1 Disconnect negative battery cable refer to Section 6 2 Remove intake manifold Refer to Intake Manifold Removal on page 6 of this section 3 Remove and or disconnect components to allow access and removal of the camshaft cover Label if necessary to allow for correct reinstallation CMP CHT Sensor Cover 4 Disconnect CHT sensor connector 5 Disconnect ignition coil connectors 6 Disconnect Camshaft Position CMP Sensor connector 7T Remove CMP Sensor 8 Disconnect crankcase ventilation tube quick connect coupling 02 6 DSG 423 ENGINE 9 Remove bolts and camshaft cover Capacitor CAUTION Do not u
275. with flow restrictive characteristics are used the fuel flow will not be sufficient to the converter with low tank pressure Correct any fuel line or fitting restrictions Mixer Assembly Carburetor It is possible that a backfire may have caused the fuel valve to partially come off of it s retainer and restrict fuel check the mixer fuel valves see section 475 1 for disassembly Also check the mixer adapter plates for leakage past the carburetor Regulator Assembly If no other problems have been identified replace the fuel management assembly with a known good part of the same pressure range Retest 04 21 DSG 423 FUEL SYSTEM The pinpoint tests below should be performed after the preliminary tests and Engine Cranks but Will Not Start chart Steps 1 3 Any electrical diagnostics should have been performed to eliminate any sensor GCP or solenoid valve problems before proceeding Engine Backfires Test Step Result Action to Take 1 During Start up check for fuel lock leakage not Yes This would indicate the fuel lock is not closing closing and allowing fuel to pass in the OFF position Replace the Fuel Lock Close the tanks main fuel valve Using Woodward WTK 1 test kit install the primary No Go to Step 2 pressure gauge as described in section 475G 1 P Key OFF Slowly open the main fuel valve Do you measure any fuel pressure 2 With engine running check primary fuel pr
276. y CCA rating at 17 8 C 0 After 15 seconds with the load still applied measure and record terminal voltage Turn the load OFF 5 Estimate the battery temperature If measured voltage does not meet or exceed the value shown in the following table replace the battery Temp C 21 1 10 1 1 9 4 17 8 Temp F 70 50 30 15 0 Min Volts 9 6 9 4 9 1 8 8 8 5 6 Clean all cable ends and terminals of the battery with a wire brush 06 7 DSG 423 CHARGING SYSTEM Generator Output Test WARNING REFER CAUTIONS amp WARNINGS THE BEGINNING OF THIS SECTION CAUTION To prevent damage to the generator do not make jumper wire connections except as direct ed CAUTION Do not allow any metal object to come in contact with the housing and the internal diode cooling fins with the ignition on or off A short cir cuit may result and burn out the diodes In order to check the generator the use of rotunda Starting and charging System Tester 078 00005 VAT 40 or equivalent is recommended NOTE Refer to the test equipment user s manual for complete directions on examining the charging system NOTE Turn off all lamps and accessories 1 Switch the tester to ammeter function 2 Connectthe positive and negative leads of the tester to the battery 3 Connect current probe to generator terminal to measure generator output 4 With the engine running at 2000
277. ylinder heads to the thermostat If the thermostat is closed the coolant returns to the coolant pump through a bypass hose Once the coolant reaches a specified temperature the thermostat will open allowing the coolant to flow to the radiator for heat transfer and back to the coolant pump inlet Engine coolant provides freeze and boil protection to the engine and cooling components In order to obtain these protections the engine coolant must be maintained at the correct concentration and fluid level in the degas bottle or coolant expansion tank The engine block heater is an optional electrical heating element installed in the core plug opening It uses a standard 110 volt electrical supply The heater keeps engine coolant warm during cold weather Coolant is made up of a 50 50 mix of ethylene glycol permanent antifreeze and water This mixture is to be used year round with temperatures above 34 4 C 30 F If recycled coolant is used it must meet Ford specification ESE M97B44 A or WSS M97B44 D 05 3 DSG 423 COOLING SYSTEM CAUTION Not all coolant recycling processes pro duce coolant which meets Ford specification ESE 97 44 or WSS M97B44 D Use of coolant that does not meet specifications may harm engine and cooling system components CAUTION Do not use alcohol type antifreeze alka line brine solutions or 100 000 mile red in color an tifreeze This may cause serious engine cooling system damage 05 4
278. ypass air ISC BPA Idle Air Control Thermal Valve IAC Thermal Valve Fast Idle Thermo Valve Idle Air Control Valve IAC Valve Air Valve Fast Idle Thermo Valve Idle Air Control Valve IACV Idle Speed Control ISC Throttle Opener Idle Speed Control Actuator ISC Actuator Idle Speed Control Actuator ISC Actuator Idle Speed Control Solenoid Vacuum ISC Solenoid Vacuum Valve Throttle Opener Vacuum Switching Valve Throttle Opener VSV Vacuum Solenoid Valve Throttle VSV 09 10 DSG 423 METRICS New Term New Acronym Old Terms Acronyms Ignition Control IC Electronic Spark Advance ESA Electronic spark Timing EST Ignition Control Module ICM Distributorless Ignition System Module DIS Module Thick Film Ignition Module TFI Module Indirect Fuel Injection IFI Fuel Injection Indirect Fuel Injection Indirect Diesel Injection IDI Inertia Fuel Shutoff IFS Inertia Fuel Shutoff IFS Inertia Fuel Shutoff Switch IFS Switch Inertia Switch Inertia Fuel Shutoff Switch Intake Air Intake Air Intake Air Duct IA Duct Intake Air Duct Intake Air System IA System Air Intake System Intake Air Temperature Air Charge Temperature ACT Manifold Air Temperature MAT Throttle Body Temperature TBT Vane Air Temperature VAT Intake Air Temperature Sensor IAT Sensor Air Temperature Sensor ATS Intake Air Temper

DSG-423 Service Manual - Coulson Compression & Measurement

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DSG-423 Service Manual - Coulson Compression &amp; Measurement

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DSG-423 Service Manual - Coulson Compression & Measurement