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vsg-4111413 engine service manual

1. OVERHAUL Continued Front Bearing Installation Rear Bearing Recess Bearing installation is not the reverse of the removal procedure because the snap ring which retains the front bearing cannot be installed with the bearing in place on the rotor shaft 1 Seat the bearing in the front housing 2 Install the snap ring The rear bearing is not locked into its recess in the rear housing The outer race is prevented from turning by a snug fit in the recess plus the added friction of a rubber seal ring in a groove in the recess Replace the seal ring whenever the generator is disassembled Assembly 1 Resolder stator to rectifier Use a pair of pliers as a heat sink to reduce heat spread to diodes Pressing Front Bearing Onto Shaft 1 Using a suitable sleeve such as a 17mm 11 16 inch deep socket press the bearing with front housing onto the rotor shaft Apply force to the inner race only 2 Press the bearing on until the inner race touches the shoulder on the shaft STATOR CONNECTIONS 2 Position stator and rectifier assembly in rear housing and install retaining screws 3 Press rear bearing onto rotor shaft 4 Install front bearing into front housing Position retainer plate and install retaining screws 5 Install rotor to front housin
2. Column A Column B A RU wem UNE 66 84 N Alml l 2 11 12 1 E C2 N 1 Use column A to check the ECT sensor resistance at the sensor not through the harness 2 Use column B to check the ECT sensor resistance at Pin 4 of the ICM connector This value includes the 10 000 ohm series resistor in the harness gt e 220 002vect 1063 DV 002V 31 163 Gv 00 cVcl 1183 6 Nid OL SSINYVH 3NION3 SLIOA HOLO3NNOO 1109 SIO usn a eee aa HOLO3NNOO 3HL3AOW3H _ _ 9298 02 11 VcS8 991 1H 1H v0S8 A EU C NOLLINOI Vest 8 ct SINHO SSINHOLNBIHISIA LL d i CAR A es 07 qu CELI rw ASVHd Odd 1H 1H od GNNOUS SITOA NO HOLIMS NOILINOI J3ONVAQV 5 HF SINHO 3NVLOO 13S OL LNO Hot 3 212 1v SWHO 000 2 TIMO HOLO3NNOO S103 qu SO Ignition System Distributorless das H1V8 H3JVM 391 NI HOSN3S 3Y8NIVIANIL LNV 1OOO VvSt HOLO3NNOO SHA 792 HOSN3S NOILISOd ANVYO HOSN3S 3ONVLOfYI3U8 INAVIHVA SINHO 009 006 L HOLO3NNOO SSINYVH Nid DIAGNOSING AND TESTING DIS Continued 02 11 02 12 Ignition System Distributorless 02 12 DIAGNOSING AND TESTING DIS Continued WIRING HARNESS CIRCUIT IDENTIFICATION F4JL 14305 AA Stripe Color Gree
3. 08 1 CHARGING SYSTEM 04 1 SECTION 03 Fuel System SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION 03 3 ZENITH MODEL 33 CARBURETOR 03 7 General Description 03 3 Operation and Service 03 7 Identification 03 3 Fuel Supply System 03 7 DIAGNOSIS AND TESTING 03 4 Idle System 03 7 General Information 03 4 High Speed System 03 8 FUEL 03 5 Accelerating Pump System 03 9 Description 03 5 Disassembly 03 11 Diagnosis and Testing 03 5 Cleaning and Inspection 03 11 Pressure Tests 03 5 Assembly of Air Intake 03 11 Capacity Volume Test 03 5 Assembly of Fuel Bowl 03 11 REMOVAL AND INSTALLATION 03 6 Automatic Choke Operation 03 12 Fuel Pump Assembly 03 6 Choke Pull Off
4. 01 1 IGNITION SYSTEM DISTRIBUTORLESS 02 1 FUEL SYSTEM 03 1 EMISSION CONTROL SYSTEM 03A 1 CHARGING SYSTEM 04 1 SECTION TITLE PAGE STARTING SYSTEM 05 1 GOVERNOR 06 1 COOLING SYSTEM 07 1 SPECIFICATIONS 08 1 SUBJECT PAGE DESCRIPTION AND OPERATION 06 3 ADJUSTMENTS 06 4 Preliminary 06 4 Oil 06 4 Belt Tension 06 4 Throttle Control 06 4 RPM Adjustments 06 4 High Speed 06 4 Spread or Sensitivity 06 4 SUBJECT PAGE Increase Spread 06 4 Decrease Spread 06 5 Low 06 5 No Load Surge 06 5 REMOVAL AND INSTALLATION 06 6 ELECTRONIC DESCRIPTION AND OPERATION 06 7 ELECTRONIC DIAGNOSIS AND TESTING 06 8
5. 01 7 Camshaft End Play 01 7 OVERHAUL 01 8 Cylinder Head 01 8 Reaming Valve Guides 01 8 Refacing Valve Seats 01 8 Valves 01 8 Refacing Valves 01 8 Select Fitting Valves 01 9 Camshaft Repair 01 9 01 9 Refinishing Journals 01 9 Fitting Main or Connecting Rod Bearings With Plastigage 01 9 Pistons Pins and Rings 01 10 Fitting Pistons 01 10 Fitting Piston Rings 01 10 Fitting Piston 5 01 11 Valve Rocker Arm and or Shaft Assembly 01 11 Push 01 11 Cylinder Block 01 11 Refinishing Cylinder Walls 01 11 Repairing Sand Holes or Porous Engine 5 01 11 CLEANING AND INSPECTION 01 12 Intake 01 12 Exhaust Manifolds
6. ZENITH MODEL 33 CARBURETOR Operation and Service The Zenith model 33 carburetor is a singe downdraft unit of two piece construction consisting of a cast aluminum air intake and throttle body with a fuel bowl The single venturi is removable for easy adaptability to meet different size engine requirements The mounting flange holes are elongated to allow it to fit either the SAE 1 or 1 1 4 flange A vacuum operated accelerator pump is used Fuel Supply System The fuel supply system consists of the threaded fuel inlet connection and fuel valve seat fuel valve float and fuel chamber The fuel supply line is connected to the threaded inlet Gasoline passes through the connection through the fuel valve seat and past the fuel valve and into the fuel chamber The level of the fuel in the fuel chamber is regulated by the float through its control of the fuel valve The fuel valve does not open and close alternately It assumes a more or less fixed opening position as regulated by the float sufficient to maintain a proper level in the fuel chamber equal to the fuel demand of the engine according to its speed and load idle System The idle system supplies fuel to run the engine at curb idle and also slow speeds until sufficient velocity is built up in the main venturi to operate the main system This system consists of the idle discharge holes the idle adjusting needle the passage or channel between the
7. 06 9 06 2 Governor 06 2 a a a E 06 3 Governor 06 3 DESCRIPTION AND OPERATION A mechanical flyweight type governor and an electronic governor are available for this engine The mechanical governor is mounted on the right front of the engine and is belt driven from the engine accessory pulley A direct mechanical linkage from the governor throttle control lever to the carburetor throttle lever limits carburetor action to the governor setting As the engine speed increases the rotation of the governor shaft increases Centrifugal force causes the weights to move outward as the rotation of the governor shaft increases However a spring retards or limits the movement of the weights until centrifugal force overcomes the spring tension At this time the weights are forced outward closing the throttle plates through the linkage to the throttle shaft 06 4 Governor 06 4 EE GGG IC A S AR E ARS EN A EEE SE IEEE A E A A a ORE E ADJUSTMENTS Preliminary Checks Three preliminary checks must be made on the mechanical governor before attempting any repair adjustments These are the governor oil level drive belt tension and the throttle control rod length Oil Level Clean the body of the governor in the area of the fill plug Remove the oil level plug If oil drips out the level is full If oil doesn t drip out remove the oil fill plug and add 10W 30 or 10W 40 engine oil into the fill hole unt
8. 03 13 Automatic Choke Setup Procedure 03 13 Adjusting the Choke Pull Off 03 13 Adjusting the Thermostatic Spring 03 14 03 2 Fuel System 03 2 AN A een ee ee ee AA AAA BLANK 03 3 Fuel System 03 3 E al DESCRIPTION AND OPERATION General Description Identification The fuel system includes a permanently sealed single The carburetor is identified on the main body near the fuel action fuel pump operated by a lobe on the camshaft and inlet The basic part number for all carburetors is 9510 To a single barrel carburetor with either a manual choke or an procure parts it is necessary to know the part number automatic choke It also has a screen filter located in the prefix and suffix fuel inlet F6JL AA PART NO PREFIX PART NO SUFFIX 03 4 Fuel System 03 4 A A A A A A E o A NEN DIAGNOSIS AND TESTING General Information Water and dirt that accumulate in the fuel tank can cause a restricted fuel line or filter and malfunction of the fuel pump or carburetor Condensation which is the greatest source of water entering the fuel tank is formed by moisture in the air when it strikes the cold interior walls of the fuel tank If the accumulation of dirt and water in the filter is excessive the fuel tank should be removed and flushed and the line from the fuel pump to the tank should be blown out Air leakage in the fuel inlet line can cause lo
9. 01 12 Valve Rocker Arm and or Shaft Assembly 01 12 Push 01 12 SUBJECT PAGE Cylinder 01 12 01 14 Timing Chain SprocketS 01 14 Camshaft 01 14 Camshaft Bores 01 14 01 14 01 15 Connecting 01 15 Pistons Pins and Rings 01 16 Main and Connecting Rod Bearings 01 16 Cylinder Block 01 16 Oil Pan 01 17 Oil Pump 01 17 REMOVAL AND INSTALLATION 01 19 Valve Rocker Arm Cover Rocker Arm and or Shaft 01 19 Intake Manifold 01 19 Exhaust Manifold 01 19 Cylinder Head 01 20 Valve Spring Retainer and Stem Seal 01 21 Cylinder Head Removed 01 21 Cylinder Head Installed 01 21 Water 01 22 Cylinder Front Cover an
10. 01 31 Basic Engine DISASSEMBLY AND ASSEMBLY Continued 13 14 15 16 17 Install a new oil seal to the front cover using tool 21 046 Install the oil slinger on the crankshaft and position the front cover gasket in place using oil resistant sealer Locate the front cover aligning the seal to the crankshaft with pulley Tighten the bolts evenly to specification Install a new oil seal in the rear oil seal carrier using tool 21 059A Position a new gasket on the rear oil seal carrier using oil resistant sealer Secure the carrier to the cylinder block Tighten the bolts evenly to specification Assemble the respective pistons to their connecting rods Be sure the F or front on the rod and the arrow on the top of the piston face the same side Push the piston pin into the piston and rod and install the two piston pin snap rings on service pistons only 18 Install the rings on the piston starting with the oil ring then the second compression ring and the top compression ring Position the gaps as shown OIL RING PIN BORE PISTON COMPRESSION COMPRESSION RING RING FRONT OF ENGINE 19 20 21 22 23 24 25 26 27 28 29 01 31 Rotate the engine in the stand so that the front end is up Oil the piston rings and cylinder bores with engine oil Compress the rings using a universal piston ring compressor Install the piston and connecting rod a
11. A vacuum line connects the transducer to the engine intake manifold The engine vacuum is proportional to its load Engine Temperature The Engine Coolant Temperature ECT Sensor sends engine temperature information to the ICM The ECT sensor is located in the intake manifold water jacket Fuel Octane Level Adjustment This input to the ICM retards the spark according to the Spark Timing table on page 13 This input is not usually used in the U S The ICM module outputs are Ignition Coil Driver The ICM switches two ignition coils on and off at the correct times to give the desired spark advance Sensor Fail safe If the ICM identifies a failure of any of its inputs other than the engine speed position sensor it will substitute a fixed value for that input until such time that the fault on the input is rectified A failed sensor is defined as the instantaneous reading of a sensor being made that is either above or below the maximum or minimum reading as defined by the system constants below Pressure maximum 101 kPa Engine Coolant minimum 39 C 38 F Temperature maximum 112 C 234 F Manifold Absolute minimum 21 kPa 6 22 Hg 29 91 Hg Ignition timing is adjusted constantly by the ICM Many factors including all the sensors affect the final ignition setting Cranking Mode Cranking mode is the area of engine operating speed within which the ignition timing is at a static position The static
12. Flywheel Face Runout Install a dial indicator so that the indicator point bears against the flywheel face Turn the flywheel making sure that it is full forward or rearward so that the crankshaft end play will not be indicated as flywheel runout If the clutch face runout exceeds specifications remove the flywheel and check for burrs between the flywheel and the face of the crankshaft mounting flange If no burrs exist check the runout of the crankshaft mounting flange Replace the flywheel or machine the crankshaft flywheel mounting face sufficiently to true up the surface if the mounting flange runout exceeds specifications Replace it or reinstall it on the flywheel Minimum Maximum Minimum kPa PSI kPa PSI kPa PSI kPa PSI 696 903 Maximum Minimum kPa PSI 910 917 931 938 952 965 972 979 993 1000 1014 1020 1034 1041 1055 1062 1076 1083 1089 CA1005 A Camshaft End Play Push the camshaft toward the rear of the engine Install a dial indicator so that the indicator point is on the camshaft sprocket attaching screw or gear hub Zero the dial indicator Position a large screwdriver between the camshaft sprocket and the cylinder head Pull the camshaft forward and release it Compare the dial indicator reading with specifications If the end play is excessive replace the thrust plate retaining the camshaft Remove the dial indicator 01 8 Basic Engine 01 8 OVERHAUL Cylinder Head Replace the he
13. Intake Cold 0 22 mm 0 009 in Exhaust Cold 0 32 mm 0 013 in Stem Diameter Intake Exhaust 7 025 7 043 mm 0 2766 0 2772 in 6 999 7 017 mm 0 2756 0 2762 in Stem to Guide Clearance Intake 0 021 0 069 mm 0 0008 0 0027 in Exhaust 1 1L 0 046 0 095 mm 0 0018 0 0037 in 1 3L 0 043 0 091 mm 0 0017 0 0036 in Length Intake Exhaust Head Diameter 1 1L Intake 103 70 104 40 mm 4 083 4 110 in 104 02 104 72 mm 4 096 4 122 in 32 90 33 10 mm 1 296 1 303 in Exhaust 28 90 29 10 mm 1 138 1 145 in Head Diameter 1 3L Intake 34 40 34 60 mm 1 355 1 362 in Exhaust 28 90 29 10 mm 1 138 1 145 in 270 newions 607 b Tappet Diameter 13 081 13 094 mm 0 5150 0 5155 in 13 110 13 143 mm 0 5162 0 5174 in 0 016 0 062 mm 0 007 0 0024 in 15 82 15 85 mm 0 6229 0 6240 in 15 875 15 913 mm 0 6250 0 6264 in Block Bore Lubrication Oil Type Motorcraft Super Engine Oil API SG Oil Capacity With Filter FL 400 3 25 Liters 3 5 qts 2 75 Liters 2 9 qts Oil Pressure Hot at 2000 rpm minimum 1 5 Bars 22 psi Relief Valve Opens 2 41 2 75 Bars 35 40 psi Without Filter Oil Pump Outer Rotor to Housing Clearance 0 14 0 26 mm 0 006 0 010 in Inner to Outer Rotor Gap 0 051 0 127 mm 0 002 0 005 in End Play Rotors to Pump Cover 0 025 0 06 mm 0 0010 0 0023 in All specifications are in millimeters inches For Conversion Factors see page 8 08 7 Specifica
14. Pump Weight Jet Assembly Accelerator Washer Accelerator Jet Tube Idle Jet Plug Vacuum Channel Screw Choke Cable Screw Choke Swivel Lever amp Shaft Choke O Ring Washer Washer Pump Spacer Optional Washer Disassembly 4 Install choke plate 2 in air intake and start screws Disassembly consists of separating the carburetor into two 1 Note that edges are beveled to fit agains nal basic groups air intake and fuel bowl throttle body and the then closed On plates including poppet valve the disassembly of each of these groups Use exploded spring should face the top Hold choke plate closed illustration as a guide for disassembly and reassembly with finger and tighten screws 5 Turn air intake upside down and insert vacuum power Cleaning and Inspection piston 6 into cylinder making sure it will move freely Thoroughly clean all metal parts in solvent or Deepclene Hold in place and stake casting with punch at three Blow out all parts and channels with air pressure Inspect points to retain piston assembly for damage excessive wear burrs or warpage DO NOT 6 Press well filler tube 7 into casting to shoulder Do CLEAN NON METALLIC PARTS in solvent or Deepclene not bend or distort NOTE The following assembly instructions and the 7 Press idle tube 49 into casting with rolled down exploded illustration are generalized and include all parts possibly found in the carburetor at this time Ther
15. Tighten the main bearing cap JOURNAL MARKING bolts evenly to specifications and check crankshaft rotation 7 Check the crankshaft end play 8 Install the tappets into their respective bores 9 Oil the camshaft journals with heavy engine oil and The standard diameter connecting rod journals are apply Lubriplate or equivalent to all lobes and then unmarked Where the connecting rod journals are 0 25 mm carefully slide it through the bearings 010 inch undersize the crankshaft is marked with a 10 Position the camshaft thrust plate and tighten the green paint spot on the web next to the connecting rod attaching bolts to specifications Check the camshaft bearing journal number one as shown end play Bend the locking tabs to secure the bolts 11 Install the camshaft sprocket and timing chain aligning the timing marks on the camshaft and crankshaft sprockets Tighten the attaching bolts to specification and bend up the locking plate tabs CONNECTING 12 Position the timing chain tensioner arm on the pivot ROD JOURNAL MARKING The standard main bearing and connecting rod bearing inserts have no color marking Bearing inserts for undersize u s crankshafts or oversize 0 s cylinder blocks have corresponding inscriptions on the back When new bearing inserts are selected they should be measured to ensure that they are the appropriate size Be sure that the specified tolerances are adhered to by pin and install the tensioner
16. design tolerances 1 Remove the air cleaner assembly Disconnect the fuel inlet line or the fuel filter at the carburetor Use care to prevent combustion due to fuel spillage 2 Connect pressure gauge restrictor and flexible hose between the fuel filter and carburetor NOTE Inside diameter of smallest passage in test flow circuit must not be smaller than 5 59 mm 0 220 in 3 Position the flexible fuel outlet hose and the restrictor so the fuel can be discharged into the graduated container FUEL OUTLET HOSE HOSE RESTRICTOR FUEL FILTER FUEL INLET FUEL INLET LINE TO CARBURETOR FUEL CONTAINER FA8RICATEO ADAPTER FITTING HOSE IN LINE FUEL FILTER 82630 18 4 Before taking a pressure reading operate the engine at the specified idle rom and vent the system into the container by opening the hose restrictor momentarily 5 Close the hose restrictor allow the pressure to stabilize and note the reading If the pump pressure is not within specifications with temperatures normalized at idle speed and in neutral and the fuel lines and filter are in satisfactory condition the pump is worn or damaged and should be replaced If the pump pressure is within specifications perform the tests for fuel capacity volume Capacity Volume Test With the fuel pump pressure within specifications test the capacity volume as follows 1 Operate the engine at the specified idle rpm 2 Open the hose restrictor and e
17. 03A 1 SPECIFICATIONS 55 vo rara aia 08 1 CHARGING SYSTEM 04 1 SECTION 04 Charging System SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION 04 3 Regulator Input Test 04 9 Generator currere RR REA di 04 3 Generator Brush 04 10 DIAGNOSIS AND TESTING 04 5 Field Ground and Open Tests 04 10 Preliminary Information 04 5 Field Voltage Test 04 10 Isolating the Problem 04 5 Overcharglhid ees ir ai 04 11 Battery Testing 04 5 Generator Disassembly 04 11 Capacity Test 04 5 ADJUSTMENTS wies eee amas px CR 04 12 System Connections 04 6 Belt Adjustments 04 12 Generator Connections 04 6 REMOVAL AND INSTALLATION 04 13 Electrical Testing Precautions 04 6 cR Ad CEN RR DNA ARS 04 14 Output Voltage Test 04 6 Disassembly 04 14 Regulator Bypass Test 04 7 Releasing Fron
18. 1 1L 71 826 71 852 mm 2 8278 2 8288 in 77 086 77 112 mm 3 0349 3 0359 in Deck Height Oil Pan Rail to Head Deck 1 1L 194 6 0 065 mm 7 6614 0 0026 in 4 of Crankshaft Above Oil Pan Rail 1 1L amp 1 3L 2 578 0 115 mm 0 1015 0 0045 in All specifications are in millimeters inches For Conversion Factors see page 5 08 4 Specifications 08 4 SPECIFICATIONS Continued ENGINE MODEL YEARS 1993 Crankshaft Main Bearing Journal Dia 1 1L Standard 56 99 57 00 mm 2 2437 2 2441 in 56 98 56 99 mm 2 2433 2 2437 in Main Bearing Journal Dia 1 3L Standard 56 980 57 000 mm 2 2433 2 2441 in Main Bearing Clearance 1 1L 0 009 0 046 mm 0 0004 0 0018 in Main Bearing Clearance 1 3L 0 009 0 056 mm 0 0004 0 0022 in Rod Bearing Journal Dia 1 1L Standard 40 99 41 01 mm 1 6138 1 6145 in 40 74 40 76 mm 1 6039 1 6047 in Rod Bearing Journal Dia 1 3L Standard 42 99 43 01 mm 1 6926 1 6933 in 42 74 42 76 mm 1 6827 1 6834 in Rod Bearing Clearance 1 1L and 1 3L 0 006 0 060 mm 0 0003 0 0023 in End Play 1 1L and 1 3L 0 075 0 285 mm 0 003 0 011 in Journal Diameter 1 1L and 1 3L 39 615 39 636 mm 1 5596 1 5605 in Bearing 1 0 1 1L and 1 3L 39 662 39 713 mm 1 5615 1 5635 in Bearing Clearance Standard Bearing 1 1 and 1 3L 0 026 0 067 mm 0 001 0 002 in Wear Limit 0 0762 mm 0 003 in Camshaft Thrust Plate Thickness 1 1L and 1 3L 4 457 4 508 mm 0 1754 0 1774 in End Play 0 02 0 19
19. Basic Engine 01 11 A A E A MCI A A A SD sos A Mc Se Sm OVERHAUL Continued Fitting Piston Pins The piston pins are selected to give the correct fit in the piston pin bore and bushing in the connecting rod Pistons are only supplied in service complete with the piston pin to ensure the correct fit The piston pins should not be interchanged Valve Rocker Arm and or Shaft Assembly Dress up minor surface defects on the rocker arm shaft and in the rocker arm bore with a hone If the pad at the valve end of the rocker arm has a grooved radius replace the rocker arm Do not attempt to true this surface by grinding Push Rods Following the procedures under Push Rod Inspection check the push rods for straightness If the runout exceeds the maximum limit at any point discard the rod Do not attempt to straighten push rods Cylinder Block Refinishing Cylinder Walls Honing is recommended for refinishing cylinder walls only when the walls have minor scuffs or scratches or for fitting pistons to the specified clearance The grade of hone to be used is determined by the amount of metal to be removed Follow the instructions of the hone manufacturer If coarse stones are used to start the honing operation leave enough material so that all hone marks can be removed with the finishing hone which is used to obtain the proper piston clearance Cylinder walls that are severely marred and or worn beyond the specified limits should be
20. Black White Black ICM Pin 8 to Splice Green ICM Spark Retard 2 OS1 Brown ICM Spark Retard 4 OS2 Brown 354 ICM to Resistor Brown White 265 ICM to Crankshaft Position Sensor Green White Terminal Strip to Generator Mounted Regulator Yellow Carburetor Solenoid Blue Temperature Gauge to Temp Sending Unit 264 ICM to Crankshaft Position Sensor CKP 152 Aa fos oa a la CO 170 39 White 31 Oil Pressure Indicator Light to Oil Pressure Switch White 57T Ground Circuit Temperature Gauge Black 38 GEN BATT Terminal to Starter Solenoid BATT Terminal Black 32 Ignition Switch to Starter Motor Relay Blue a O 21 Starter Solenoid Battery Terminal to Ignition Switch Feed Yellow 02 15 Ignition System Distributorless 02 15 DIAGNOSING AND TESTING DIS Continued GENERATOR 7 c V d Nd 277439 ML 5 TERMINAL USER NOTES NOTE THE WIRE LOOP FROM UESC PIN 6 TO PIN 7 IF THE ENGINE IS OPERATED WITH LOW OCTANE FUEL IT MAY BE NECESSARY TO RETARD THE SPARK THIS MAY BE DONE BY CUTTING OPEN THE LOOP AND GROUNDING THE WIRE WHICH GOES TO PIN 6 TO PIN 7 OR BOTH TO RETARD 4 GROUND WIRE TO PIN 7 ENGINE TEMP TO RETARD 10 GROUND WIRE TO PIN 6 GROUND SENDER TO RETARD 18 GROUND WIRE TO PIN 6 amp 7 THE UESC MODULE MUST BE MOUNTED SOMEWHAT ABOVE THE LEVEL OF THE I
21. Cylinder No 3 rocking adjust cylinder No 2 Cylinder No 1 rocking adjust cylinder No 4 Cylinder No 2 rocking adjust cylinder No 3 01 24 REMOVAL AND INSTALLATION Continued Crankshaft Front Oil Seal Removal ls Loosen alternator and adjusting bracket bolts and remove fan belt Remove crankshaft pulley bolt and remove pulley by hand Remove oil seal from front cover using special service tool 21 096 NOTE Use short end of tool on this seal Installation 1 Lubricate the sealing lip of the new seal with engine oil and push new seal into front cover using tool 21 046 crankshaft pulley bolt and washer Remove special service tool and reinstall crankshaft pulley Torque bolt to specification Install fan belt and adjust the tension of the belts to specification using Tool T63L 8620 A Tighten alternator and adjusting bracket bolts CRANKSHAFT TOOL 21 046 PULLEY Basic Engine 01 24 Camshaft and or Valve Lifters Removal 1 10 11 12 13 14 15 Remove the engine assembly and mount the engine on a stand Drain the crankcase Disconnect the fuel line at the fuel pump Loosen the generator and governor adjustment bolts and remove the belts Remove the fan and water pump pulley Remove the oil and fuel pumps from the cylinder block Disconnect the spark plug wires from the plugs Remove the rocker arm cover attaching screws and rocker cover Clean
22. IGNITION SYSTEM e WHEN CARRYING OUT SERVICE OPERATIONS ON AN ENGINE EQUIPPED WITH DISTRIBUTORLESS IGNITION IT IS IMPORTANT TO BE AWARE OF THE ABOVE POINT AS WELL AS ALL THE USUAL SAFETY MEASURES TO PREVENT THE POSSIBILITY OF ELECTRIC SHOCKS The purpose of an engine s ignition system is to ignite the fuel air mixture at the correct time and sequence based upon the input it receives The Distributorless Ignition System DIS used on the VSG 411 413 engines is a state of the art ignition system The brain of this system is the Ignition Control Module ICM also known as the Universal Electronic Spark Control UESC module This module normally receives four inputs e Crankshaft position e Crankshaft speed e Engine temperature e Engine vacuum load From these inputs the ICM computes spark strategy spark advance to obtain optimum engine performance for correct input conditions With this system the electronic control module monitors the engine load speed and operating temperature and decides what degree of spark advance is correct for all of the operating conditions This system maximizes the benefits of the high compression swirl design 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 fixed a
23. System 03A 1 SECTION TITLE PAGE STARTING SYSTEM oia 05 1 GOVERNOR usas aaa lia caos pa dani 06 1 COOLING SYSTEM is nane 07 1 SPECIFICATIONS viso dr E erra ese a 08 1 SECTION 03A Emission Control System SUBJECT PAGE DESCRIPTION AND OPERATION 03A 3 Exhaust Gas Recirculation EGR Valve 03A 3 Crankcase Emission Control System 03A 6 DIAGNOSIS AND TESTING 03A 7 Symptoms of EGR System Malfunctions 03A 7 alel o ai lell arca iS 03A 7 Surge Stall or Won t Start 03A 7 Detonation Spark Knock 03A 7 Poor Fuel Economy 03A 7 SUBJECT PAGE EGR System Gas Flow Test 03A 7 Diaphragm Leak Test 03A 7 EGR Valve Leakage Check 03A 8 Testing for EGR Source Vacuum 03A 8 Tesing the 2 Port PVS Valve 03A 8 REMOVAL AND INSTALLATION 03A 9 03A 2 Emission Control System 03A 2 A AAA NESSES GE A A A 03A 3 Emission Control System 03A 3 A IMe VM RIR RES AR A NR A A Ea A DESCRIPTION AND OPERATION Exhaust Gas Recirculation EGR Valve cylinders to reduce the combustion temperature This The exhaust gas recirculation EGR system feeds a reduces the formation of an atmospheric pollutant known contro
24. VACUUM LINE INTO THE MODULE DURING OPERATION OR STORAGE 4 WIRE 354 CONTAINS A 10 SERIES RESISTOR FROM THE RESISTOR TO THE ECT SENSOR CONNECTOR THIS CIRCUIT IS CALLED 354A STARTER RELAY 850A 16C 852A TO E DISTRIBUTORLESS am y SYSTEM 354A TO ENGINE RA A COOLANT As TEMPERATURE SENSOR BATTERY xX s TERMINAL A Se ANO NT TS N N o CARB N OLENOID TACH B GOV NNO 850 TACH FT AT O VOLTMETER OSITION t NS CT 67 675 on CKP 0 SENSOR S gt 10KO NOS xS 730 RESISTOR NN LOCATION N 9 5606 on ON CENAS ox TO 7 SG RELAY 579 Gre GAUGE MODULE as Grp TEMP GAUGE 264 265 354 6 6 16M 57 359 850 852 677 TO IGNITION CONTROL 02 14 Ignition System Distributorless 02 14 DIAGNOSING AND TESTING DIS Continued WIRING HARNESS CIRCUIT IDENTIFICATION F4JL 14305 BA Circuit Description Base Color Stripe Color 16l 852B 852A Ignition Switch to Splice Splice to Electronic Governor or Tachometer Yellow oplice to DIS Coil 2 Yellow Splice to Electronic Governor or Tachometer Yellow Splice to DIS Coil 1 Yellow Resistor to ECT Sensor Brown DIS Coil to Splice ICM Ignition Control Module or UESC to Splice Yellow ICM to Splice Yellow 359 ICM to ECT Sensor Ground Green 57 ICM to Battery Ground 16M Green White 00 White 850B Black 850A Black 354A 16C 852 850 White Green White 00
25. a certain point a thermostatic switch closes and the heater circuit is complete Electric current supplied by circuit now flows through the coil heater Its electrical resistance to current flow generates the necessary heat Choke Pull Off After the engine is started air flow into the carburetor will open the choke plate a small amount against the tension of the thermostatic coil The choke plate will open this slight amount because it is mounted off center on the choke shaft This slight opening of the choke plate is necessary to prevent an overly rich mixture after the engine starts Because the velocity of the air entering the carburetor will vary with engine speed the choke plate is linked to a vacuum operated piston that provides a positive pull against the closing tension of the thermostatic coil THERMOSTATIC COIL The action of the piston is called choke pull off and its purpose is two fold e it helps open the choke after the engine starts e it controls the position of the choke plate depending on engine load When the throttle is opened to accelerate the air fuel mixture has to be enriched The action of the accelerator pump provides momentary enrichment but additional richness is required since the engine is cold This added richness is provided by the action of the pull off system The opening of the throttle valve causes a drop in intake manifold vacuum which is transmitted to the diaphragm or piston Wi
26. and bolts and move governor towards engine to loosen drive belt 4 Remove drive belt from governor pulley 5 Remove governor to bracket attaching bolts and remove governor Installation 1 Position the governor to the mounting bracket and install the attaching bolts snugly Position drive belt to governor pulley and move the governor away from the engine to tighten the belt Tighten the attaching bolts Adiust the belt tension Connect the governor to carburetor throttle control rod Adjust the rod as described previously Connect hand throttle cable to governor variable speed lever Adjust cable as necessary to permit operation from idle to maximum speed 06 7 Governor 06 7 ELECTRONIC DESCRIPTION AND OPERATION The Barber Colman electronic governor consists of three main components e acontroller e an actuator e acarburetor The controller is a Barber Colman model 10851 digital unit This controller allows up to four engine speeds to be used on one application The operator changes the engine speeds via a run speed select switch mounted on the control panel of the machine These governors are isochronous in operation these is no governor droop The governor maintains the same engine speed from no load to full load operation Each controller BAT BAT DIS IGN DIS IGN ACTUATOR ACTUATOR SPDSELA SPD SELB can be programmed with up to four separate engine speeds The ca
27. are out of tolerance replace actuator Il Engine 1 Incorrect engine With the engine running connect battery power to pin H This will select doesn t Speed Run 2 If Run 2 is set a higher speed than Run 1 and the speed does not change change replace the controller Contact OEM for speed settings speeds With the engine running connect battery power to pin G This will select Run 3 If Run 3 is set higher than the previous speed and the speed does not change replace the controller Contact OEM for speed settings With the engine running connect battery power to pins G amp H This will select Run 4 If Run 4 is set higher than the previous speed and the speed does not change replace the controller Contact OEM for speed settings 06 9 Governor 06 9 ELECTRONIC DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE SOURCE ACTION I Engine is 1 Engine is misfiring Disconnect the connector from the controller The governor is now hunting due to idle mixture disabled and a warm engine should be running at a mechanical idle of mis adjustment This approximately 600 RPM causes engine hunt at no load condition If the engine is not running at the mechanical idle and is governed by an integrated carburetor loosen the three actuator fasteners and rotate the actuator to achieve an idle of 600 RPM If the engine is governed by a linear actuator adjust the idle speed screw to achieve 600 RPM Slowly rotate the idle mixture scr
28. as necessary using a wire brush or professional spark plug cleaner follow manufacturer s instructions Inspect the firing tip Refer to Spark Plug Inspection Chart Replace spark plugs if they are worn or damaged Ignition Coil Wipe the coil towers with a clean cloth dampened with soap and water Remove any soap film and dry with compressed air Inspect for cracks carbon tracking and dirt Ignition Wires Wipe the spark plug wire set with a clean damp cloth before inspecting it Without removing the spark plug wire set from the spark plugs or ignition coil inspect the wire set for visible damage such as cuts pinches or cracked or torn boots Refer to Ignition Wires Removal and Installation in this section and replace as necessary 02 9 Ignition System Distributorless DIAGNOSING AND TESTING DIS Continued Spark Plug Inspection Chart GAP BRIDGED IDENTIFIED BY DEPOSIT BUILD UP CLOSING GAP BETWEEN ELECTRODES CAUSED BY OIL OR CARBON FOULING REPLACE PLUG OH IF DEPOSITS ARE NOT EXCESSIVE THE PLUG CAN BE CLEANED IDENTIFIED BY SEVERELY ERODED OR WORN ELECTRODES CAUSED BY NORMAL WEAR SHOULD BE REPLACED PRE IGNITION E IDENTIFIEO 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 OIL FOULED ID
29. assembly from armature shaft use a suitably dimensioned tube to separate thrust collar from over C clip Remove C clip from its groove and slide thrust collar and drive pinion assembly off armature shaft THRUST COLLAR Cleaning and Inspection 1 Do not wash the drive because the solvent will wash out the lubricant causing the drive to slip Use a brush or compressed air to clean the drive field coils armature commutator armature shaft front end plate and rear end housing Wash all other parts in solvent and dry the parts Inspect the armature windings for broken or burned insulation and unsoldered connections Check the armature for open circuits and grounds Inspect the armature shaft and the two bearings for scoring and excessive wear If the commutator is rough turn it Check the brush holders for broken springs and the insulated holder for shorts to ground Replace the brushes if worn Check the brush spring tension Inspect the field coils for burned or broken insulation and continuity Check the field brush connections and lead insulation A brush kit is available All other assemblies are to be replaced rather than repaired Examine the wear pattern on the starter drive teeth The pinion teeth must penetrate to a depth greater than 1 2 the ring gear tooth depth to eliminate premature ring gear and starter drive failure Heplace starter drives and ring gears that have milled pitted or broken teeth or
30. cause of undercharging it may be due to low regulator output when the system is operating under load 4 Engine ON 5 While running the engine at 1600 rpm measure the F terminal voltage Field voltage should be 10 5 to 11 5 volts initially and quickly taper off to 7 5 to 8 5 volts as the starting discharge is re charged If the voltage is low or fluctuating the regulator is defective In that case replace the regulator Overcharging If the output voltage test indicates on overcharging condition greater than 14 4 volts it usually indicates a defective regulator but not always If the regulator sense voltage at the terminal is lower than the output voltage by more than 0 5 volt due to a defective diode trio a good regulator will increase field current and generator output in an effort to bring the sense voltage up to regulating value Whether and to what extent the system will overcharge will depend on the nature and degree of the field diode failure as field current must pass through the field diodes Generator Disassembly If the foregoing series of on equipment tests has not identified the cause of charging system malfunctions remove and disassemble the generator for further tests See Overhaul in this section If specialized test equipment is available for checking diodes and stator windings under operating load conditions follow the equipment manufacturer s instructions If this equipment is not
31. from vacuum plate is opened slightly off idle Vacuum is then available At wide open throttle EGR vacuum is weak to zero and to the EGR control valve Vacuum level decreases as the will cause the EGR valve to close for maximum engine throttle plate opens power Note that at idle when EGR vacuum is off the EGR system is least needed because NOx formation is at a minimum Under certain circumstances the EGR valve will usually be off These include 1 Atidle when the engine needs a richer mixture 2 When the engine is cold OT NN id FE 3 When there is a heavy load wide open throttle res HIGH VACUUM At idle and at wide open throttle there is no vacuum at the FLOW TO EGR i i SYSTEMS EGR vacuum port To control EGR at various engine temperatures a port vacuum switch PVS is used HIGH INTAKE MANIFOLD VACUUM VACUUM 03A 6 Emission Control System 03A 6 A A A A Sa ee UR UM a A a DESCRIPTION AND OPERATION Continued COLD ENGINE WARM ENGINE O RING IS UNSEATED 2727777 22227777 O RING IS HELD SEATED TO BLOCK VACUUM E PORT IS OUTLET gt VACUUM FLOW THROUGH VALVE 77 4 5 PORT CONNECTED TO VACUUM SOURCE ADO A 4 COOLANT TEMPERATURE 2 Hn Nit men N NO R q CAMA MM TS 9 y y La 2 IN AN NN AAA N N N N Dno n f VE 1 2 22 XV EN
32. gasket 8 lfanew manifold is to be installed transfer all necessary components to the new manifold Installation 1 Apply a water resistant sealer to both sides of the gasket around the water port and position it on the cylinder head 2 Install the intake manifold and tighten the nuts and bolts evenly to specifications 3 Connect the water hose and the crankcase ventilation hose to the intake manifold 4 Connect the distributor vacuum line and the fuel supply line to the carburetor 5 Connect the throttle rod 6 Install the air cleaner 7 Refill the cooling system with the recommended coolant Exhaust Manifold Removal 1 Remove the exhaust pipe retaining nuts and exhaust pipe Remove the eight exhaust manifold retaining nuts 3 Remove the exhaust manifold 4 Remove the four exhaust gaskets and discard them 01 20 Basic Engine 01 20 REMOVAL AND INSTALLATION Continued Installation 1 Install four new exhaust manifold gaskets onto the studs 2 Install the exhaust manifold and torque the nuts to specification in the sequence shown 3 Install the exhaust pipe and torque the retaining nuts to specification FRONT OF ENGINE 5 1 4 8 3 2 Cylinder Head Removal 1 Hemove the air cleaner 2 Disconnect the fuel line at the fuel pump and carburetor 3 Drain the coolant 4 Disconnect the spark plug leads remove them from the clip on the rocker cover and position out
33. going to be used 3 Push the ring down into the bore area where normal ring wear is not encountered bearings Bearing clearance must be within specified 4 Use the head of a piston to position the ring in the limits If 0 05 mm 0 002 inch undersize main bore so that the ring is square with the cylinder wall bearings are used on more than one journal be sure Use caution to avoid damage to the ring or they are all installed in cylinder block side of bearing cylinder bore If standard and 0 05 mm 0 002 inch undersize 5 Measure the gap between the ends of the ring with a bearings do not bring clearance within desired limits feeler gauge If the ring gap is less or greater than the refinish crankshaft journal then install undersize specified limits try another ring set bearings 7 After bearing has been fitted remove Plastigage apply light coat of engine oil to journal and bearings Install bearing cap Torque cap bolts to specifications 8 Repeat procedure for remaining bearings that require replacement Pistons Pins and Rings Fitting Pistons Pistons are available for service in standard sizes and the oversizes shown in the parts list Measure the piston diameter to ensure that the specified clearance is obtained It may be necessary periodically to use another piston that is either slightly larger or smaller to A8515 B achieve the specified clearance If none can be fitted refinish the cylinder to provide the proper c
34. idle jet and the discharge holes the idle air bleed and the idle jet and pickup tubes At idling speeds manifold vacuum is transmitted through the primary idle discharge hole to the idle jet through a passage running through the throttle and air intake bodies Fuel from the fuel bowl flows through the main jet into the fuel well where it is picked up by the pickup tube to be metered by the idle jet As the fuel leaves the idle jet it is mixed with air from the idle air bleed which is located just above the jet in the air intake therefore a fuel and air mixture is provided just before the passage to the idle discharge holes This air bleed calibration ts to provide better control of the fuel delivery and to prevent the fuel in the bowl from being siphoned into the intake manifold through the idle system when the engine is shut off IDLE AIR BLEED LLL LLL SOD ANAND SECONDARY IDLE DISCHARGE HOLE IDLE SYSTEM The discharge of the idle fuel into the air stream at curb idle is controlled by the idle adjusting needle in the primary idle discharge hole Turning the needle in clockwise O L L LL L A A a cd cl cl lle 2 Z ys 2 JE ta Y y S IDLE JET AND PICK UP TUBE a HIS EE A IDLE ADJUSTING NEEDLE O El 9 OT restricts the primary discharge hole to provide a l
35. imperfections with an oil stone Replace all expansion type plugs that show evidence of leakage Inspect the cylinder walls for scoring roughness or other signs of wear Check the cylinder bore for out of round and taper Measure the bore with an accurate bore gauge following the instructions of the manufacturer Measure the diameter of each cylinder bore at the top middle and bottom with the gauge placed at right angles and parallel to the centerline of the engine Use only the measurements obtained at 90 degrees to the engine centerline when calculating the piston to cylinder bore clearance Am CENTER LINE OF ENGINE N 1 OUT OF ROUND DIFFERENCE BETWEEN A 2 TAPER DIFFERENCE BETWEEN THE A MEASUREMENT AT TOP OF CYLINDER BORE AND THE A MEASUREMENT AT BOTTOM OF CYLINDER BORE A2905 1A Refinish cylinders that are deeply scored and or when out of round and or taper exceed the wear limits If the cylinder walls have minor surface imperfections but the out of round and taper are within limits it may be possible to remove the imperfections by honing the cylinder walls and installing new service piston rings providing the piston clearance is within specified limits Oil Pan Cleaning Scrape any dirt or metal particles from the inside of the pan Scrape all old gasket material from the gasket surface Wash the pan in a solvent and dry it thoroughly Be sure all foreign particles are removed from below t
36. intake valves be ground or the valves lapped in as this will remove the diffused aluminum coating and reduce the valves wear and heat resistant properties If the valve faces are worn or pitted it will be necessary to install new valves and to resurface the valve seats or alternatively lap the seats using dummy valves The exhaust valves may be lapped in or the faces ground if required If the valve face runout is excessive and or to remove pits and grooves reface the valves to a true 44 degree angle Hemove only enough stock to correct the runout or to clean up the pits and grooves If the edge of the valve head is less than 0 8 mm 1 32 inch thick after grinding replace the valve as the valve will run too hot in the engine The interference fit of the valve and seat should not be lapped out Remove all grooves or score marks from the end of the valve stem and chamfer it as necessary Do not remove more than 0 25 mm 0 010 inch from the end of the valve stem FOR DIMENSIONS CHECK FOR REFER TO BENT STEM SPECIFICATIONS DIAMETER VALVE VALVE FACE MARGIN FACE ANGLE 1 32 MINIMUM EDGE OF VALVE HEAD THIS LINE PARALLEL WITH VALVE HEAD 10090 1 If the valve and or valve seat has been refaced it will be necessary to check the clearance between the rocker arm pad and the valve stem with the valve train assembly installed in the engine Select Fitting Valves If the valve stem to valve guide clearance exceeds the w
37. necessary and the end seal on the front cover with an oil resistant sealer at the ends Install the front cover and align the seal by installing the crankshaft pulley Tighten the attaching bolts evenly to specification Basic Engine 10 11 12 01 23 Install and torque crankshaft pulley retaining bolt Install the water pump and torque the attaching bolts to specification Install the water pump pulley and fan Install the governor and fan belts and adjust the tension of the belts to specifications using Tool T63L 8620 A Install the radiator Install the radiator upper and lower hoses and tighten the clamps Refill the radiator Start engine and check for oil and water leaks Adjusting Valve Clearances 1 Only turn the crankshaft belt pulley clockwise while adjusting the valve clearances and start by aligning the mark on the belt pulley with the O mark on the front cover If belt pulley is now turned to and fro slightly valves of cylinder No 1 or 4 will be rocking i e the two rockers and push rods move in opposite directions When valves in cylinder No 4 are rocking No 1 cylinder valve clearances should be adjusted Then rotate belt pulley a further half turn In this position valves of cylinder No 3 will rock and valve clearances of cylinder No 2 can be adjusted and so on according to firing order See Technical Data for settings Cylinder No 4 rocking adjust cylinder No 1
38. numbers when seeking information or ordering replacement parts for this engine SERIAL NUMBER Power Products MODEL NUMBER VSG 411 6005 E S O OPTIONS MODEL CODE 1425 A SERIAL NUMBER ENGINE CODE C ENGINE BUILD DATE The engine code will begin with a G This will indicate that itis a 1 1 liter engine The engine build date follows the corporate system Example 4K26 The first number indicates the year The letter indicates the month in alphabetical sequence A January B February etc omitting The last two numbers are the day of the month 01 4 DESCRIPTION The engine is a water cooled 4 cylinder 4 stroke in line gasoline engine The cylinder head in which the combustion chambers are located is of a cross flow type the fresh fuel air mixture is drawn in on one side and burnt gases are passed into the exhaust system on the opposite side The valves are suspended in the cylinder head and are operated by means of tappets pushrods and rocker arms The valves are disposed in an alternating pattern in the cylinder head starting with an exhaust valve by the thermostat housing The three bearing camshaft is located on the right side of the cylinder block and driven by roller chain from the crankshaft The common driving gear shared by the distributor and oil pump is located behind the second cam on the camshaft the eccentric cam driving the fuel pump is located between the sixth and seventh cams Basi
39. of the way 5 Disconnect the water outlet and crankcase ventilation hoses at the intake manifold 6 Disconnect the wire from the temperature gauge sending unit 7 Detach the exhaust pipe Disconnect the throttle rod choke cable and the distributor vacuum advance hose from the carburetor 9 Disconnect the throttle linkage at the governor and position out of the way 10 Remove the governor mounting bolts and remove governor 11 Remove the thermostat housing pull to one side and remove the thermostat 12 Remove the rocker arm cover and gasket 13 Remove the rocker arm shaft bolts evenly and lift off the rocker arm shaft assembly 14 Lift out the push rods from their locations and keep them in their correct order 15 Remove the cylinder head bolts and lift off the cylinder head and gasket Do not lay the cylinder head flat on its face as damage to the spark plugs or gasket surface can occur Installation 1 Clean all gasket material from the mating surfaces and position the cylinder head gasket on the cylinder block using pilot studs 2 Position the cylinder head remove pilot studs and install the cylinder head bolts Tighten the bolts down evenly in sequence and in four steps to specifications 3 Lubricate both ends of the push rods with Lubriplate or equivalent and install them in their respective bores 4 Install the rocker arm shaft assembly to the cylinder head locating the push rods on the adju
40. open the choke plate by rotating the choke shaft 2 Allow the thermostatic spring inside the choke assembly to slowly close the choke plate When the choke housing is at 21 C 70 F the choke plate i should be within 0 8 mm 1 32 inch of but not 6 touching the choke bore 0 8 MM 1 32 03 14 If the choke plate does not meet this dimension loosen the three cover plate screws to rotate the cover as necessary and repeat steps 1 and 2 If the carburetor temperature is other than 21 C 70 F make the following correction e Setthe choke plate as described in steps 2 and 3 e Readjust the cover plate to compensate for the deviation from 21 C 70 F Each mark on the cover plate denotes a 2 8 C 5 F change in the setting For example if the actual carburetor temperature is 27 C 80 F when the choke plate is adjusted rotate the cover two marks in the LEAN direction Likewise if the carburetor temperature is 10 C 50 F rotate the cover four marks in the RICH direction Tighten the three cover screws Check the rotation of the choke shaft to be sure there is no sticking or binding before installing the carburetor 03A 1 SECTION TITLE PAGE BASIC ENGINE concisa dar 01 1 IGNITION SYSTEM DISTRIBUTORLESS 02 1 FUEL SYSTEM cosita Ea e ERA XE EUN a 03 1 EMISSION CONTROL SYSTEM 03A 1 CHARGING SYSTEM 04 1 Emission Control
41. or to which they were fitted The connecting rods and bearing caps are numbered from 1 to 4 beginning at the front of the engine The number on the connecting rod and bearing cap must be on the same side of rod when installing in the cylinder bore If a connecting rod is ever transferred from one cylinder block to another or from one cylinder to another new bearings should be fitted and the connecting rod should be re numbered to correspond with the new cylinder number 4 Make sure the ring gaps are properly spaced around the circumference of the piston Oil the rings then install a piston ring compressor on the piston Make sure that the arrow in the dome of piston is toward the front then push the piston into its bore with the handle end of a hammer until it is slightly below the top of the cylinder Be sure to guide the connecting rods to avoid damaging the crankshaft journals 01 28 Basic Engine 01 28 REMOVAL AND INSTALLATION Continued 5 Check the clearance of each bearing following the procedure under Overhaul in this section OIL RING 6 After the bearings have been fitted apply a light coat of engine oil to the journals and bearings 7 Turn the crankshaft throw to the bottom of its stroke then push the piston all the way down until the connecting rod bearing seats on the crankshaft journal Install the connecting rod cap Tighten the nuts to specification 8 After the piston and connecting rod assemblies
42. point below the level of fuel in the well Introducing air into the well tube below the level of fuel reduces the surface tension of the fuel and helps fuel flow at low suction This bleed also restricts fuel flow through the main jet under high suctions WELL VENT DISCHARGE TUBE 4 AHA ZZ j 7 2 gt IWS 2 Lao ANN MAIN SYSTEM When the throttle plate is opened to a point just above the idle position enough air passes through the carburetor to lower the pressure at the discharge tube The float chamber is open to atmospheric pressure consequently f WELL TUBE TNA Cee PRN SRL gt 7 h 7 0 ERAN E A ANE e E E S 772 29 4 E EN MAIN JET Air admitted through bleed holes in the well tube an amount measured by the well vent is mixed with the fuel This mixture of fuel from the main well tube passes through the discharge tube in the venturi and is added to the air stream in the venturi This mixture then passes into the intake manifold the greater pressure in the float chamber will cause the fuel to flow from the fuel bowl through the main jet into the main well and well tube 03 9 ZENITH MODEL 433 CARBURETOR Continued Accelerating Pump System The accelerating pump controls the amount of fuel that is discharged into the air stream on sudden thrott
43. properly adjusted at all times A loose drive belt can cause improper generator fan and water pump operation A belt that is too tight places a severe strain on the water pump and the generator bearings A properly tensioned drive belt minimizes noise and also prolongs the service life of the belt Therefore it is recommended that a belt tension gauge be used to check and adjust the belt tension Any belt that has been operated for a minimum of 10 minutes is considered a used belt and when adjusted it must be adjusted to the used tension shown in the specifications 07 4 Belt Tension 1 Install the belt tension tool on the drive belt and check the tension 2 If adjustment is necessary loosen the generator mounting and adjusting arm bolts Move the generator toward or away from the engine until the correct tension is obtained Remove the gauge 3 Tighten the generator adjusting arm and mounting bolts Install the tension gauge and recheck the belt tension BELT TENSION GAUGE T63L 8620 A V BELT OR 021 00019 V RIBBED BELTS Q1039 1G 08 1 Specifications 08 1 EE ASSES EE A SECTION TITLE PAGE SECTION TITLE PAGE BASIC ENGINE 2 dao 01 1 STARTING SYSTEM ip iS 05 1 IGNITION SYSTEM DISTRIBUTORLESS 02 1 522 Rer ERREUR REA es 06 1 FUEE SYSTEM as 03 1 COOLING SYSTEM i o RR PE RE RR RES 07 1 EMISSION CONTROL SYSTEM 03A 1 SPECIFIC
44. that show evidence of inadequate engagement 05 9 Starting System 05 9 E nn e OVERHAUL Continued Starter motor Brush spring Bolt Brush end bushing Solenoid Through bolt kit Bushing Armature insstallation kit Brush set Drive assembly Brushholder Bushing 05 10 OVERHAUL Continued e Los p lt A SE NORMAL WEAR PATTERN SMALL WEAR PATTERN Assembly 1 Slide drive pinion assembly and thrust collar on to armature shaft Fit C clip into its groove in armature shaft and then draw thrust collar over C clip Connect actuating arm on to drive pinion flange Align armature and actuating arm to drive end housing and couple up components Install actuating arm pin and secure with retaining nut Install rubber insert into drive end housing Guide frame over armature and abut to drive end housing and tap home Position brush holder over end of armature Align location cut out in brush holder with loop in field windings Brush will be positively located when through bolts are installed Position four brushes in their respective brush holder locations and retain with brush springs Guide commutator end housing into position sliding rubber insulator into commutator housing cut out and locating two through bolts through housing holes Secure commutator end housing with two nuts and washers or two through bolts as applicable Slide armature in its bearings to obtain maximum possible protr
45. withdraw the valve Installation Lubricate all valves valve stems and valve guides with heavy engine oil SAE 50 weight 1 Install each valve in the valve guide hole from which it was removed or to which a new valve is to be used Cover the valve grooves with plastic tape slide the new seal onto the valve stem remove the tape NOTE The exhaust valves are fitted with umbrella type seals The intake valves have the positive guide mounted seals which must be pressed on with a special service tool Positive type seals may only be installed on intake valves not having the Ford oval on the stem EXHAUST VALVE SEAL Install valve spring and damper assembly over the valve then install spring retainer Compress spring and install retainer key locks Measure the assembled height of the valve spring from the underside of the spring to the underside of the spring retainer If the assembled height is not within specification valve spring load loss may be excessive Shim spring to specification Basic Engine 01 21 INTAKE VALVE SEAL Cylinder Head Installed Removal 1 Remove the air cleaner 2 Disconnect the spark plug leads remove them from the clip on the rocker cover and position out of the Way 3 Remove the rocker arm cover and gasket 4 Remove the rocker arm shaft bolts evenly and lift off the rocker arm shaft assembly 5 Lift the push rods from their locations and keep them in their correct orde
46. 059 00006 OR EQUIVALENT This timing light uses an inductive pickup for convenience and safety on 12 volt systems This timing light includes a tachometer which reads from zero to 3000 RPM DIS Diagnosing This check will test the engine harness connectors and sensors for both continuity amp resistance 1 Remove the 12 pin ICM harness plug from the ICM module Pins 1 and 5 are not used and therefore do not have female connectors in the 12 pin harness connector plug 2 Check the following circuits with the volt ohmmeter with the sensors connected per the chart on page 12 with reference to the wiring diagram on page 14 Ifthe DIS Engine Harness checks are not to the chart specifications page 12 complete the following e Remove the wire harness connector to the ICM e Remove each sensor or component from the harness e Using a high impedance digital volt ohmmeter DVOM check each wire for continuity or resistance e f the wire harness has open circuits or resistance higher than specifications repair or replace the harness e f the wire harness checks to specifications reconnect each sensor and component and complete another DIS Engine Harness check e if the same sensor or component circuit does not test to specifications replace that sensor or coil e lfthe engine will not start and or run install a new module and make a normal start DIS Cleaning and Inspection Spark Plugs Clean spark plugs
47. 2 1 GOVERNOR AS 06 1 FUEL SYSTEM cats did 03 1 COOLING SYSTEM 07 1 EMISSION CONTROL SYSTEM 03A 1 SPECIFICATIONS 2 ais 08 1 CHARGING SYSTEM 04 1 SECTION 07 Cooling System SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION 07 3 ADJUSTMENTS ocur 07 4 Drive Senda as saca 07 4 07 2 Cooling System 07 2 RENAS A RE A A EE 07 3 Cooling System 07 3 DESCRIPTION AND OPERATION The system is of the full flow type with a centrifugal pump The thermostat located in the cylinder head controls the flow through the system maintaining the proper temperature The coolant flow is from the bottom of the radiator to the pump which delivers it to the cylinder block It then flows through the cored passages to cool the entire length of each cylinder wall Upon reaching the rear of the cylinder block the coolant is directed upward into the cylinder head where it cools the combustion chambers valves and valve Seats The coolant from the cylinder head flows past the thermostat if it is open through the coolant outlet housing and into the top of the radiator Another passage in the head routes the warm coolant through the intake manifold to help atomize the fuel mixture and then through a hose to the inlet hose of the water pump 07 4 Cooling System ADJUSTMENTS Drive Belt The fan drive belt should be
48. ATIONS eerta RERO a a 08 1 CHARGING SYSTEM i eer ER ERI RES 04 1 SECTION 08 Specifications SUBJECT PAGE SUBJECT PAGE SPECIFICATIONS cosida iras 08 3 Special Service Tools 08 8 Engine Model Years 1993 08 3 Conversion Factors 08 8 Torque Specifications 08 8 08 2 Specifications 08 2 a a BLANK 08 3 Specifications 08 3 SPECIFICATIONS ENGINE MODEL YEARS 1993 General Specifications VSG 411 VSG 413 Bore and Stroke 1 1L 68 68 and 75 48 mm 2 704 and 2 971 in 73 96 and 75 48 mm 2 912 and 2 971 in 1 2 4 3 700 800 rpm Full Load 2800 rpm No Load 3050 rpm 4 Cylinder 1 1 Liter 4 Cylinder 1 3 Liter Firing Order Idle Speed Rated Engine Speed Maximum Cylinder Block Number of Main Bearings Cast Marks 1 1L 93BM 6015 AA 89BM 6015 FA Cylinder Bore Diameter 1 1L 68 680 68 710 mm 2 7039 2 7051 in 73 94 73 97 mm 2 9110 2 9122 in Out of Round Maximum 0 038 mm 0 0015 in Wear Limit 0 127 mm 0 005 in Taper 0 0254 mm 0 0010 in Wear Limit 0 254 mm 0 010 in Main Bearing Bore Standard 60 623 60 636 mm 2 3868 2 3872 in Oversize 61 003 61 016 mm 2 4017 2 4022 in Camshaft Bearing Bore Standard 42 888 42 918 mm 1 6886 1 6896 in Oversize 43 396 43 420 mm 1 7086 1 7094 in Cylinder Block Liner Bore Diameter
49. DIS ENGINE HARNESS CHECKS ICM HARNESS CONNECTOR REMOVED ALL SENSORS CONNECTED TO HARNESS Connector DVOM PIN Nos Reading 200 3000 Engine RPM amp Crank Position Wires 264 265 amp CKP Sensor 105 000 92 2 4 to 10 at 0 C 32 F C ntin it ICM Spark Advance A single wire connects Pins 6 and 7 in a closed loop 3 6to7 0 Q y Cutting and grounding this wire changes the spark advance See the following table for values 11 to 12 E Check for continuity in the DIS coil circuit Wires 850 850A to 852 852A 14 000 Remove the four spark plug wires and measure the secondary resistance from 5 Secondaries E t 5 1 to 4 1 to 4 CON 14 000 Q Remove the four spark plug wires and measure the secondary resistance from Secondaries D 42 to 3 5 2 to 3 SPARK TIMING ENGINE COOLANT TEMPERATURE SENSOR CHARACTERISTICS Effect on Sensor Ohms Sensor amp Harness Loop between Pins 6 and 7 MEM 5 Ohms 5 sicud pal 481 000 491 000 Ground Pin 7 Retard Base Spark 271 200 281 200 essi a 158 000 168 000 Ground Pin 6 Retard Base Spark by 2 4 degrees Ground Pins 6 and 7 Retard Base Spark by 6 8 degrees 95 000 105 000 58 750 68 750 37 300 47 300 NOTE For generator set application the vacuum line between the intake manifold and the ignition module may be disconnected Harness Description of Circuit Wires Checked amp Circuit Function Eng Coolant Temp Sensor Wires 354 354A and 359
50. ENTIFIED BY WET BLACK DEP OSITS ON THE INSULATOR SHELL BORE ELECTRODES CAUSED BY EXCESSIVE OIL ENTERING COMBUS TION CHAMBER THROUGH WORN RINGS AND PISTONS EXCESSIVE CLEARANCE BETWEEN VALVE GUIDES AND STEMS OR WORN OR LOOSE BEARINGS REPLACE THE PLUG IF ENGINE IS NOT REPAIRED USE A HOTTER PLUG NORMAL IDENTIFIED BY LIGHT TAN OR GRAY DEPOSITS ON THE FIRING TIP OVERHEATING IDENTIFIED BY A WHITE OR LIGHT GRAY INSULATOR WITH SMALL BLACK OR GRAY BROWN SPOTS AND WITH BLUISH BURNT APPEAR ANCE OF ELECTRODES CAUSEO BY ENGINE OVERHEATING WRONG TYPE OF FUEL LOOSE SPARK PLUGS TOO HOT A PLUG LOW FUEL PUMP PRESSURE OR INCOR RECT IGNITION TIMING REPLACE THE PLUG 02 9 CARBON FOULED IDENTIFIED BY BLACK DRY FLUFFY CARBON DEPOSITS ON INSULATOR TIPS EXPOSED SHELL SURFACES AND ELECTRODES CAUSED BY TOO COLD A PLUG WEAK IGNITION DIRTY AIR CLEANER DEFECTIVE FUEL PUMP TOO RICH A FUEL MIXTURE IMPROPERLY OPERATING HEAT RISER OR EXCESSIVE IDLING CAN BE CLEANED LEAD FOULED IDENTIFIED BY DARK GRAY BLACK YELLOW OR TAN DEPOSITS OR A FUSED GLAZED COATING ON THE INSULATOR TIP CAUSED BY HIGHLY LEADED GASOLINE REPLACE THE PLUG FUSED SPOT DEPOSIT IDENTIFIED BY MELTEO OR SPOTTY DEPOSITS RESEMBLING BUBBLES OR BLISTERS CAUSEO BY SUDDEN ACCELERATION CAN BE CLEANED IF NOT EXCESSIVE OTHERWISE REPLACE PLUG 02 10 Ignition System Distributorless 02 10 DIAGNOSING AND TESTING DIS Continued
51. GINE COOLANT S DA 7 Y 4 2 WHEN ENGINE WARMS SENSOR EXPANDS TO PUSH PLUNGER UP The two port PVS senses engine coolant temperature so Crankcase Emission Control System that it can cut off vacuum to the EGR valve when the The Crankcase Emission Control System consists of an oil engine is cold and connect vacuum to the EGR valve filler cap including PCV valve with two connecting hoses when the engine is warm one of which passes to the inlet manifold and the other to the air cleaner The result is a closed ventilation system in which the fumes from the crankcase pass back via the inlet manifold into the cylinders for combustion 03A 7 Emission Control System 03A 7 A NE DIAGNOSIS AND TESTING Symptoms of EGR System Malfunctions Many problems of poor engine performance are incorrectly diagnosed as being related to the EGR valve or EGR system Therefore it is important to know what engine symptoms can be EGR related and how to test the system Rough Idle This can be caused by an EGR valve stuck open by dirt on the valve seat or by loose mounting bolts Loose mounting will cause a vacuum leak and a hissing noise A stuck valve can be diagnosed by a functional test and by visual inspection Surge Stall or Won t Start Can be caused by the valve stuck open Detonation Spark Knock Any condition that prevents poor EGR gas flow can cause detonation This includes a valve s
52. NTAKE MANIFOLD THIS IS SO THAT FUEL OR CONDENSED FUEL VAPORS CANNOT DRAIN THRU THE VACUUM LINE INTO THE MODULE q DURING OPERATION OR STORAGE STARTER N WIRE 354 CONTAINS A 10 KQ SERIES RESISTOR FROM RELAY THE RESISTOR TO THE SENSOR CONNECTOR THIS CIRCUIT IS CALLED 354A o Se Ee em o gt fas 850A 16C 852A NX TO WEEK DISTRIBUTORLESS her ji IGNITION C system rm 354A ENGINE COOLANT IN TEMPERATURE SENSOR BATTERY SS 250 TERMINAL lt A OS N BEN OIL PRESS h SWITCH CARB SOLENOID 852 TACH B onGov at 850 TACH TO XO 904 CRANKSHAFT A GEN POSITION CKP gt 9 SENSOR cx 31 PRESS 10KQ RESISTOR ado TEMP LOCATION CONNECTS TO CLO Il STATION TERMINAL STRIP XO ST Y 152 CTO ad H IGN TO Lu e ni YA Y MED IGNITION Co 00080 DOGO O CONTROL 2 esc NEN 677 GND 264 265 354 6 6 16M 57 359 850 852 03 1 Fuel System 03 1 E no SECTION TITLE PAGE SECTION TITLE PAGE BASIC 01 1 STARTING SYSTEM 05 1 IGNITION SYSTEM DISTRIBUTORLESS 02 1 GOVERNOR 06 1 FUEL SYSTEM 03 1 COOLING SYSTEM 07 1 EMISSION CONTROL SYSTEM 03A 1 SPECIFICATIONS
53. SING A BATTERY IN AN ENCLOSED SPACE ALWAYS PROVIDE VENTILATION AND SHIELD YOUR EYES WARNING BATTERIES ARE HEAVY WEIGHING 30 LBS OR MORE LIFT THEM WITH YOUR LEGS RATHER THAN YOUR BACK TO PREVENT MUSCLE STRAINS AND BE CAREFUL NOT TO DROP THEM POSSIBLE BREAKAGE OR TO SPILL THE CONTENTS SULFURIC ACID CAUTION 12 volt starting motors can be damaged beyond repair if connected to a 24 volt power supply two 12 volt batteries in series or a 24 volt motor generator set even when cranking loads are relatively light Extensive starting motor damage is more likely if the starter is connected to a 24 volt supply while being subjected to prolonged heavy cranking loads such as attempting to start an engine in subzero temperature Tests are made on a battery to determine the state of charge and also its capacity or ability to crank an engine The ultimate result of these tests is to show that the battery is good needs recharging or must be replaced Before attempting to test a battery it is important to give it a thorough examination to determine if it has been damaged Remove battery cable clamps negative terminal first Check for dirty or corroded connections and loose battery posts Remove hold downs and heat shields and inspect for a broken or cracked case or cover If the battery is worn or damaged if there is a loose or broken post or if there is a cracked case or cover replace the battery The battery capacity test sh
54. STEM ree rra lee 05 1 IGNITION SYSTEM DISTRIBUTORLESS 02 1 GOVERNOR ses nan wate ata deii RR 06 1 FUEL SYSTEM kei Ed as 03 1 COOLING SYSTEM 2 2222 ass 07 1 EMISSION CONTROL SYSTEM 03A 1 SPECIFICATIONS RIS E CEU CER 08 1 CHARGING SYSTEM 04 1 SECTION 05 Starting System SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION 05 3 REMOVAL AND INSTALLATION 05 7 TESTING iras 05 4 OVERHAUL 2 pun Eus SPP MESS 05 8 Hoad SerVICO oes A 05 4 Disassembly ai 05 8 On Engine 05 4 Cleaning and Inspection 05 8 Starter Cranking Circuit Test 05 4 Assembly 2 22122 a dae De mE ES 05 10 Starter Load 1 05 5 Permanent Magnet Starter 05 11 Starter Solenoid Test 05 5 eU nr ads o 05 11 Benen Tests Ex 05 5 Disassembly 05 11 Starter No Load Test L 05 5 ASSOMDIV ss Td ad 05 12 Armature Open Circuit Test 05 6 Armature and Field Grounded Circuit Test 05 6 05 2 Starting System 05 2 A A A 222252 2225220 BLANK 05 3 Starting System 05 3 DESCRIPTION AND OPERATION There are
55. VSG 411 413 ENGINE SERVICE MANUAL For Engines Produced 1993 and Later The Source for Power Worldwide IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe reliable operation of all motor vehicles as well as the personal safety of the individual doing the work This Shop Manual provides general direc tions for accomplishing service and repair work with tested effective techniques Following them will help assure reliability There are numerous variations in procedures techniques tools and parts for servicing vehicles as well as in the skill of the individual doing the work This Manual cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly anyone who departs from the instructions provided in this Manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods tools or parts NOTES CAUTIONS AND WARNINGS As you read through the procedures you will come across NOTES CAUTIONS and WARNINGS Each one is there for a specific purpose NOTES give you added information that will help you to complete a particular proce dure CAUTIONS are given to prevent you from making an error that could damage the vehicle WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury The following list contains some general WARNINGS th
56. act surfaces or sticky movement 6 Clean and free up the brushes or replace the assembly 7 While the brush holder is out release belt tension to allow free rotation of the rotor and clean the slip rings with crocus cloth or fine abrasive Field Ground and Open Tests This test uses an ohmmeter to check for opens or shorts to ground in the field 1 Touch the meter probes to either of the slip rings and to ground If the meter shows continuity or low resistance there is a grounded condition In that case replace the rotor o VOLTMETER 2 Measure the resistance from one slip ring to the other Field coil resistance should be 4 to 5 ohms If the ohmmeter indicates a high resistance between the slip rings the field is partially open In that case replace the rotor Field Voltage Test With the slip rings clean and known good brushes installed repeat the field excitation voltage test at the F terminal 1 KeyON 2 Release belt tension to allow the rotor to spin freely 3 While spinning the rotor by hand to assure good brush contact probe the F terminal and observe the voltage If it still does not fall within the 1 5 to 3 0 volt range the field coil resistance is incorrect In that case replace the rotor GENERATOR VOLTMETER 04 11 Charging System 04 11 A A ES OA AAA AA M A Ea ETUR O DIAGNOSIS AND TESTING Continued If the foregoing test sequence does not identify the
57. ad if it is cracked Do not plane or grind more than 0 25 mm 0 010 inch from the cylinder head gasket surface Remove all burrs or scratches with an oil stone Reaming Valve Guides If it becomes necessary to ream the valve guide to an oversize valve always use the reamer in sequence Always reface the valve seat after the valve guide has been reamed and use a suitable scraper to break the sharp corner ID at the top of the valve guide Y U d a BREAK SHARP Refacing Valve Seats Refacing of the valve seat should be closely coordinated with the refacing of the valve face so that the finished seat and valve face will be concentric and the specified interference fit will be maintained This is important so that the valve and seat will have a compression tight fit Be sure that the refaced grinding wheels are properly dressed Grind the valve seats to a true 45 degree angle Remove only enough stock to clean up pits and grooves or to correct the valve seat runout After the seat has been refaced use a seat width scale or a machinist scale to measure the seat width Narrow the seat if necessary to bring it within specifications If the valve seat width exceeds the maximum limit remove enough stock from the top edge and or bottom edge of the seat to reduce the width to specifications On the valve seats of all engines use a 60 degree angle grinding wheel to remove stock from the bottom of the seats raise the seats an
58. age drop in the circuit will be indicated by the voltmeter 0 to 2 volt range Maximum allowable voltage drop should be 1 With the voltmeter negative lead connected to the starter terminal and the positive lead connected to the battery positive terminal Connection No 1 0 5 volt 2 With the voltmeter negative lead connected to the starter terminal and the positive lead connected to the battery terminal of the starter solenoid Connection No 2 0 3 volt E iri s DECR 3 With the voltmeter negative lead connected to the battery terminal of the starter solenoid and the positive lead connected to the positive terminal of the battery Connection No 3 0 2 volt 4 With the voltmeter negative lead connected to the negative terminal of the battery and the positive lead connected to the engine ground Connection No 4 0 1 volt 05 5 Starting System 05 5 AA AA CM MM A NECI SEO A CN IC ER c c ESSE TESTING Continued Starter Load Test the ignition coil and by connecting a jumper from the Connect the test equipment as shown Be sure that no battery terminal of the starter solenoid to the ignition switch current is flowing through the ammeter and heavy duty S terminal of the solenoid carbon pile rheostat portion of the circuit rheostat at Stop cranking the engine and adjust the load of the carbon maximum counterclockwise position pile until the voltmeter indicates the same reading as that Crank the engin
59. all gasket material from rocker arm cover and cylinder head Remove the rocker arm shaft support bolts evenly and lift off the rocker arm shaft Lift the push rods from their locations in the cylinder block taking care to keep them in their correct order Invert the engine on the stand and remove the oil pan and gaskets Remove the crankshaft pulley the front cover and oil slinger Hemove the timing chain tensioner assembly Remove the camshaft sprocket and timing chain With the engine inverted remove the camshaft thrust plate and remove the camshaft If necessary remove the tappets from their locations in the cylinder block and keep them in the correct order Installation Install a new front cover oil seal using Tool 21 046 Install the tappets if removed Install the camshaft and fit the thrust plate in the camshaft groove Tighten the attaching bolts to specification and bend up the locking tabs 01 25 Basic Engine 01 25 EES REMOVAL AND INSTALLATION Continued 4 Check the camshaft end play 9 Locate the timing chain on the camshaft sprocket and install the camshaft sprocket with the timing mark aligned with the one on the crankshaft sprocket Tighten the attaching bolts to specification and bend up the locking tabs 6 Locate the tensioner arm on the pivot pin and install the timing chain tensioner 7 Install the oil slinger on the crankshaft 8 Position the gasket on the front cove
60. are limits are 2 mm 5 64 inch Follow the same procedure to check new valve springs before installation Make certain the proper spring color coded is installed NOT MORE CLOSED 7 COIL END DOWNWARD Tappets Cleaning Thoroughly clean the tappets in cleaning solvent and wipe them with a clean lint free cloth Inspection Check tha tappets for wear or scores Check the bottom end of tappet to make sure that it has a slight convex Replace tappets that are scored worn or if the bottom is not smooth If the bottom surface is worn flat it may be used with the original camshaft only Timing Chain and Sprockets Cleaning Clean a parts in solvent and dry them with compressed air Lubricate the timing chain with engine oil before installing it on the sprockets Inspection Inspect the chain for broken links Inspect the sprockets for cracks and worn or damaged teeth Replace all the components of the timing chain and sprocket assembly if any oae item needs replacement Camshaft Cleaning Clean the camshaft in solvent and wipe it dry Inspection Inspect the camshaft lobes for scoring and signs of abnormal wear Lobe pitting except in the ceneral area of the lobe toe is not detrimental to the operation of the camshaft therefore the camshaft should not be replaced unless the lobe lift loss has exceeded specifications or _ pitting has occurred in the lobe lift area The lift of the camshaft lobes can be
61. arning light indication while running or a no voltage indication on the voltmeter This test will check the generator output to verify that the problem is in the charging system and not in the instrument circuit If the regulator is hot do not perform this test until the regulator has cooled down The regulator will respond to and regulate at a lower voltage as the temperature rises This offsets the tendency toward battery overcharging in warm weather This built in temperature compensation reduces generator output by about one volt per 55 C 100 F temperature rise 1 Key OFF 2 Check the voltage at the generator output terminal It should be battery voltage 3 Start the engine 4 With the engine running at 1000 to 1200 rpm check the voltage at the generator output terminal The voltage should rise to 13 6 to 14 4 volts as soon as the starting discharge has been restored GENERATOR VOLTMETER 5 After the voltage stabilizes turn on any accessories one by one while observing the output voltage If it stays above battery voltage under load but the warning light is on or if the voltmeter indicates no voltage the cause may be a blown fuse feeding the instrument circuit 04 7 Charging System 04 7 A AAA AA A AAA A 52 2 422 544222 2 A DIAGNOSIS AND TESTING Continued Regulator Bypass Test Key Off Check Perform this test if the Output Voltage Test indicates less 1 Key OFF 1 Key OFF ter
62. at you should follow when you work on a vehicle e Always wear safety glasses for eye protection e Use safety stands whenever a procedure requires you to be under the vehicle e Be sure that the ignition switch is always in the OFF position unless otherwise required by the procedure e Set the parking brake when working on the vehicle If you have an automatic transmission set it in PARK unless instructed otherwise for a specific operation If you have a manual transmission it should be in REVERSE engine OFF or NEUTRAL engine ON unless instructed otherwise for a specific operation Place wood blocks 4 x 4 or larger to the front and rear surfaces of the tires to provide further restraint from inad vertent vehicle movement e Operate the engine only in a well ventilated area to avoid the danger of carbon monoxide e Keep yourself and your clothing away from moving parts when the engine is running especially the fan and belts e To prevent serious burns avoid contact with hot metal parts such as the radiator exhaust manifold tail pipe catalytic converter and muffler e Do not smoke while working on the vehicle To avoid injury always remove rings watches loose hanging jewelry and loose clothing before beginning to work on a vehicle Tie long hair securely behind the head e Keep hands and other objects clear of the radiator fan blades Electric cooling fans can start to operate at any time by an increase in underhood temp
63. ations Position a new gasket to the fuel pump flange and insert the rocker arm through the slot in the block so that the arm lies on the camshaft lobe Install the mounting bolts and tighten evenly to specification 01 32 DISASSEMBLY AND ASSEMBLY Continued 30 31 32 33 34 35 36 37 38 39 40 Position the cylinder head gasket on the cylinder block using pilot studs Position the cylinder head remove the pilot studs and install the cylinder bolts Tighten the bolts down evenly in sequence and in three steps to specification Lubricate both ends of the push rods with Lubriplate or equivalent and install them in their respective bores Install the rocker arm shaft assembly to the cylinder head locating the push rods on the adjusting screws Tighten the bolts evenly to specification Adjust the valve clearances Install the rocker cover Locate the thermostat in its bore in the cylinder head and install the gasket and thermostat housing Connect the wire to the temperature gauge sending unit Connect primary wires to coil Install dipstick and tube Position governor and install mounting bolts Connect the throttle rod to the carburetor Connect the water outlet and crankcase ventilation hoses at the intake manifold Connect the leads to the spark plugs Connect the fuel line at the fuel pump and carburetor Basic Engine 01 32 41 Install remaining generator adjusting arm mount
64. available refer the job to the nearest Authorized Service Station 04 12 ADJUSTMENTS Belt Adjustments 1 Check the belt tension with Tool T63L 8620 A The belt should be within specifications Specifications Section If the belt is not within specification loosen the generator mounting bolt to a snug position and loosen the adjusting arm bolts Charging System 04 12 Apply pressure on the generator front housing only and tighten the adjusting arm to generator bolt Check the belt tension using Tool T63L 8620 A Adjust the belt for specified tension Tighten all mounting bolts 04 13 Charging System 04 13 REMOVAL AND INSTALLATION Removal Installation 1 Disconnect the battery ground cable 1 Install the generator wiring connector Position the 2 Loosen the generator mounting bolts and remove the generator to the engine and install the spacer bolt only finger tight 3 Remove the electrical connector from the generator l 2 Install the adjustment arm to generator attaching bolt 4 Disengage the generator belt Remove the generator tension using Tool T63L 8620 A Apply pressure on the generator front housing only when tightening the belt Tighten the adjusting arm bolt and the mounting bolt 4 Connect the battery ground cable 04 14 Charging System 04 14 n_n OVERHAUL Disassembly Releasing Front Bearing Retainer 1 Mark both end housings and the stator with a scribe To remove the fr
65. c Engine 01 4 The oil pump is bolted onto the outside of the cylinder block below the distributor The full flow oil filter is angled downwards and mounted directly on the oil pump The crankshaft is mounted in five bearings The crankshaft end play is determined by thrust half rings at the center main bearing The front crankshaft journal is sealed by means of an oil seal installed in the timing cover The rear crankshaft journal is sealed by means of an oil seal pressed into an oil seal carrier The timing cover has cast ignition timing degree marks or a TDC reference pointer A notch on the crankshaft belt pulley is used in conjunction with either the degree or TDC reference points when installing the distributor and checking timing They are visible on the front left side of the engine A no ma ee a en T eo W D 01 5 Basic Engine 01 5 ee DESCRIPTION Continued The spark plugs have a tapered seat without a sealing ring Engine Ventilation The ventilation system consists of an oil filler cap with two connecting hoses one of which passes to the inlet manifold and the other to the air cleaner A VENTILATION AT IDLE SPEED AND HALF THROTTLE B VENTILATION AT FULL THROTTLE Lubrication Circuit An eccentric twin rotor oil pump draws oil via a strainer from the sump and forces it into the full flow oil filter Oil pressure is regulated by a relief valv
66. checked with the camshaft installed in the engine or on centers Refer to Camshaft Lobe Lift To measure the camshaft lobe lift proceed as follows 1 Measure distance between the major A A and minor B B diameters of each cam lobe with a Vernier caliper and record the readings The difference in the readings on each cam diameter is the lobe lift 1 4 NO PITTING 6 35 MM 6 35 MM ALLOWED IN 1 4 THIS AREA DIMENSION A MINUS DIMENSION B EQUALS THE CAM LOBE LIFT 2 If the readings do not meet specification replace the camshaft Camshaft Bores Inspection Check camshaft bores for size taper roundness runout and finish If any of these dimensions exceeds the limits given in Specifications install new camshaft bearings Crankshaft Cleaning Handle the crankshaft with care to avoid possible fractures or damage to the finished surfaces Clean the crankshaft with solvent then blow out all oil passages with compressed air Inspection Inspect the main and connecting rod journals for cracks scratches grooves or scores Inspect the crankshaft oil seal surface for nicks sharp edges or burrs that might damage the oil seal during installation or cause premature seal wear Measure the diameter of each journal in at least four places to determine an out of round taper or undersize condition 01 15 Basic Engine 01 15 A A AA A A A SS CLEANING AND INSPECTION Co
67. ct battery and start engine Allow engine to warm to normal operating temperature Check and if necessary add coolant 02 8 Ignition System Distributorless 02 8 e cc end DIAGNOSING AND TESTING DIS DIS Diagnosis Equipment To accurately diagnose DIS certain diagnostic equipment and tools are required In addition the suggested diagnostic equipment may make the job easier and more convenient Prior to diagnosing DIS obtain the following test equipment or equivalent e SPARK TESTER NEON BULB TYPE CHAMPION CT 436 OR EQUIVALENT There is no need to disconnect a plug wire just place this spark tester on a spark plug wire to determine if spark is being provided to the plug This is especially useful for those hard to reach plug wires e SPARK TESTER GAP TYPE SPECIAL SERVICE TOOL D81P 6666 A OR EQUIVALENT Connect this gap type spark tester between any spark plug wire and engine ground to instantly determine if spark is being provided to the plug A spark plug with a broken side electrode is not sufficient to check for spark and may lead to incorrect results e VOLT OHMMETER ROTUNDA 014 00575 OR EQUIVALENT A volt ohmmeter is essential for gathering system operating data during diagnosis testing and engine servicing procedures A digital volt ohmmeter DVOM can also be used for general purpose electrical troubleshooting on conventional starting and charging systems e 12 14 VOLT TEST LAMP TIMING LIGHT ROTUNDA
68. cuum replace the PVS valve 1 03A 9 Emission Control System REMOVAL AND INSTALLATION Removal 1 Remove the vacuum hose that goes to the PVS valve 2 Remove the EGR hose 2 REQUIRED nstallation Seat the EGR restrictor into the spacer block A small amount of grease may be applied to the EGR restrictor prior to installation This will ensure that the EGR restrictor does not become dislodged during the installation of the EGR valve gasket and the EGR valve Do not allow grease to block the hole in the EGR restrictor 2 REQUIRED Ao eo Remove the two EGR valve mounting bolts Remove the EGR valve gasket Remove the EGR restrictor CARBURETOR PORT VACUUM SWITCH PVS SPACER EGR VALVE EGR GASKET RESTRICTOR GASKET EGR SPACER TOmmoou 2 REQUIRED Install the EGR valve gasket Install the EGR valve Install the two EGR valve mounting bolts Tighten to 16 20 Nem 12 15 ft Ibs Install the EGR hose Tighten to 34 47 Nem 25 35 ft lbs Attach the vacuum hose that comes from the PVS valve 03A 9 04 1 Charging System 04 1 NU SECTION TITLE PAGE SECTION TITLE PAGE BASIC 01 1 STARTING SYSTEM ccend ERE ds 05 1 IGNITION SYSTEM DISTRIBUTORLESS 02 1 GOVERNOR cesar ea Mores 06 1 FUEL SYSTEM cutis ERE GSM TET dE 03 1 COOLING SYSTEM eh ae da ER ELE 07 1 EMISSION CONTROL SYSTEM
69. d Timing Chain or Crankshaft 01 22 Adjusting Valve Clearances 01 23 Crankshaft Front Oil Seal 01 24 Camshaft and or Valve Lifters 01 24 Camshaft Bearings 01 25 Oil Pump 01 26 Oil Pan 01 26 Flywheel Ring 01 26 Crankshaft Rear Oil Seal 01 27 Pistons and Connecting Rods 01 27 Oil Filter 01 28 DISASSEMBLY AND ASSEMBLY 01 29 Engine Assembly 01 29 Oil Pump 01 32 01 2 Basic Engine 01 2 E O 01 3 Basic Engine 01 3 A eel IDENTIFICATION An Identification Decal is affixed to the left side of the Identification of the cylinder block and therefore of the basic rocker cover of each engine The decal contains the engine engine type can be made by reference to the stampings on serial number which identifies this unit from all others Next the left rear top edge of the cylinder block is the engine displacement which determines the engine specifications then the model number and S O or special options which determine the parts or components required on this unit Use all
70. d in a suitable solvent and dry it with compressed air Inspection Inspect the manifold for cracks damaged gasket surfaces or other defects that would make it unfit for further service Replace all studs that are stripped or otherwise damaged Remove all filings and foreign matter that may have entered the manifold as a result of repairs Exhaust Manifolds Cleaning Remove all gasket material from the manifolds Inspection Inspect the cylinder head joining flanges of the exhaust manifold for evidence of exhaust gas leaks Inspect the manifolds for cracks damaged gasket surfaces or other defects that would make them unfit for further service Valve Rocker Arm and or Shaft Assembly Cleaning Clean all the parts thoroughly Make sure all oil passages are open Make sure the oil passage in the rocker arm is open Inspection On rocker arm shaft assemblies check the clearance between each rocker arm and the shaft by checking the ID of the rocker arm bore and the OD of the shaft If the clearance between any rocker arm and the shaft exceeds the wear limit replace the shaft and or the rocker arm Inspect the shaft and the rocker arm bore for nicks scratches scores or scuffs Inspect the pad at the valve end of the rocker arm for indications of scuffing or abnormal wear If the pad is grooved replace the rocker arm Do not attempt to true this surface by grinding Check the adjusting nut s torque If not within s
71. d use a 30 degree angle wheel to remove stock from the top of the seats lower the seats TO REMOVE STOCK FROM TOP OF SEAT USE 30 WHEEL TO REMOVE STOCK FROM BOTTOM OF SEAT USE 60 WHEEL VALVE SEAT WIDTH A7382 14 The finished valve seat should contact the approximate center of the valve face It is good practice to determine where the valve seat contacts the face To do this coat the seat with Prussian blue and set the valve in place Rotate the valve with light pressure If the blue is transferred to the center of the valve face the contact is satisfactory If the blue is transferred to the top edge of the valve face lower the valve seat If the blue is transferred to the bottom edge of the valve face raise the valve seat uy WY NO SEAT WIDTH SCALE Valves Minor pits grooves etc may be removed Discard valves that are severely damagea if the face runout cannot be corrected by refinishing or stem clearance exceeds specifications Discard any excessively worn or damaged valve train parts Refacing Valves The valve refacing operation should be closely coordinated with the valve seat refacing operations so that the finished angles of the valve face and of the valve seat will be to specifications and provide a compression tight fit Be sure that the refaced grinding wheels are properly dressed 01 9 Basic Engine 01 9 E nn nn nn A OVERHAUL Continued Under no circumstances should the faces of aluminized
72. ded in body with the float needle sticking into the threaded opening 12 Install the fuel valve seat 19 and washer 18 making sure that the fuel valve enters the seat properly the valve will enter the seat more easily if Although the thermostatic coil unwinds as the engine the float is held in the up position and tighten warms up the actual unwinding of the coil is assisted by securely an electric heater 13 Insert float axle clip 11 in slot to bear against axle ends Holding axle in place raise float by applying light finger pressure to the float bracket Float pontoons should be approximately level when the valve is seated If not bend tab to carefully adjust 14 Install O ring 54 on venturi skirt and place venturi 10 into recess provided in body making sure that the nozzle 9 lines up with the notch in the fuel well 15 Place intake gasket 8 in position on body NOTE If you have an older model unit with removable accelerator jet after intake gasket 8 is in place an additional washer 55 will be assembled over the accelerator jet tube 47 and set inside the large hole in the intake gasket 8 and on top of the T m smaller washer 48 Lower air intake carefully onto bow and fasten securely and evenly using attaching screws 5 03 13 Fuel System 03 13 AA AAA A A A A A A A A AA E ut A A AAA 2 2 2725 2242 22704 ZENITH MODEL 33 CARBURETOR Continued When the temperature drops below
73. dge cutter Follow the instructions furnished by the tool manufacturer Never cut into the ring travel area in excess of 0 8 mm 1 32 inch when removing ridge Invert the engine on the stand and remove the oil pan and gaskets Remove the oil pick up tube and screen Remove the flywheel and tear engine plate Remove the tear bearing retainer Remove the timing chain tensioner Remove the camshaft sprocket and timing chain Basic Engine 27 28 29 30 01 29 Remove the camshaft thrush plate and the camshaft Remove the tappets keeping them in their correct order Make sure all connecting rods and caps are marked so that they can be installed in their original locations Partially loosen the connecting rod bolts several turns and tap them to release the bearing caps Remove the bolts completely and remove the caps Push the pistons out of the bores and remove the assemblies Remove the main bearing caps bolts evenly and lift off each cap Lift out the crankshaft and handle with care to avoid possible fracture or damage to finished surfaces 31 Remove the main bearings from block and cap Remove the thrust washers 32 Disassemble the piston and connecting rod assemblies Remove the piston rings and the two piston pin snap rings Push the piston pin out of each piston 33 Remove the coolant drain plug and oil pressure sending unit from the block 34 Remove the block from the stand Assembly When installin
74. dvance for service checking 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 which is coupled with improved warm up and a new carburetor The spark plugs are paired so that one plug fires during the compression stroke and its companion plug fires during the exhaust stroke The next time that coil is fired the plug that was on exhaust will be on compression and the one that was on compression will be on exhaust The spark in the exhaust cylinder is wasted but little of the coil energy is lost The spark strategy is based on sensors and manifold vacuum input to the ICM module which include the following inputs AJ av 4 l EAN e ia WAY N COMPRESSION EXHAUST STROKE STROKE Engine Speed and C S Position The crankshaft position and speed information comes to the ICM from the Crankshaft Position Sensor CKP also known as the Variable Reluctance Sensor VRS The CKP is triggered by teeth cast into the engine side of the flywheel The 36 1 teeth spaced 10 apart indicate to the ICM the crankshaft speed The missing tooth indicates crankshaft position 02 4 Ignition System Distributorless 02 4 DESCRIPTION AND OPERATION Continued Engine Load The engine load information is processed into the ICM s electronics by a pressure transducer located within the ICM
75. e cylinder block Disconnect the radiator hoses at the engine Remove the radiator Remove the governor and fan belts and then remove the fan and the water pump pulley Remove the water pump Remove the crankshaft pulley Remove the oil pan to cylinder front cover and front cover to block attaching bolts Use a thin knife to cut the oil pan gasket flush with cylinder block face prior to separating the cover from the cylinder block Remove the front cover Remove the crankshaft oil slinger Remove the camshaft sprocket retainer and bolts Remove the timing chain tensioner arm Remove the camshaft sprocket and disconnect the timing chain If crankshaft sprocket is to be removed use a standard two jaw puller 01 23 REMOVAL AND INSTALLATION Continued Installation 1 If crankshaft sprocket was removed install using the pulley bolt and washer The timing mark on the sprocket must face the end of the crankshaft Position the timing chain over the camshaft and crankshaft sprockets so that the timing marks are aligned when the sprocket is installed The number 4 cylinder is on top dead center when using the gear marks as reference Tighten the bolts to specification then bend up the locking tabs TIMING MARKS Locate the tensioner arm on the pivot pin while holding the tensioner cam in the released position Install the oil slinger on the crankshaft Position the gasket portions of oil pan gasket if
76. e inside the pump The filtered oil passes through the center of the filter element then along a short passage right hand side of the engine to the oil pressure switch and through a transverse bore to the main oil gallery left hand side of the engine The crankshaft main bearings are fed directly from the main oil gallery and the camshaft bearings are linked in turn for their lubrication with the front center and rear main bearings Each of the rod journals are supplied with oil by the nearest main bearing through oblique passages An oil hole in the connecting rod ensures splash lubrication of the piston pins and the trailing side of the cylinders Timing chain and sprockets are also lubricated via a splash hole The camshaft front bearing journal has a machined groove through which oil is intermittently forced to the rocker shaft via passages in cylinder block and cylinder head The result is a closed ventilation system in which the fumes from the crankcase pass back via the inlet manifold into the cylinders for combustion Gas flow is regulated by a calibrated orifice in the oil filler cap HOSE CONNECTION TO AIR CLEANER PRESS IN ORIFICE HOSE CONNECTION TO INTAKE MANIFOLD VACUUM FITTING LUBRICATION CIRCUIT 01 6 Basic Engine 01 6 DIAGNOSIS AND TESTING Camshaft Lobe Lift Check the lift of each lobe in consecutive order and make a note of the readings 1 Remove the air cleaner and the valve rocker ar
77. e the hoses If the source vacuum is not okay check for an has excessive leakage and should be replaced obstruction in the carburetor or for a vacuum leak caused by loose mounting CARBURETOR REMOVE EGR VACUUM HOSE EGR PORT ATTACH A VACUUM GAUGE DIRECTLY TO THE EGR VACUUM SUPPLY PORT CHECK FOR VACUUM Testing the 2 Port PVS Valve WARNING LET THE ENGINE COOL AND RELEASE The 2 port PVS valve is okay if it blocks vacuum from the COOLING SYSTEM PRESSURE BEFORE REMOVING EGR valve when the engine is cold and allows a vacuum THE VALVE OR YOU COULD BE BURNED IT ALSO to get to the valve when the engine is hot MAY BE NECESSARY TO DRAIN OUT SOME OF THE COOLANT REMOVE HOSES CONNECT VACUUM APPLY 10 INCHES GAUGE TO ONE PORT VACUUM TO VALVE AND REMOTE VACUUM SUPPLY OTHER COLOR CODE IS A VACUUM READING ON THIS GAUGE VALVE SETTING O OPERATE ENGINE UNTIL SEE IF THERE COOLANT WARMS ABOVE 1 Remove both hoses from the PVS valve 4 Run the engine until the coolant is warmer than the PVS 2 Connect a vacuum gauge to one port of the PVS valve setting PVS valves are color coded This engine valve and connect a vacuum pump to the other has a black PVS valve that opens at 38 C 100 F port 5 See if there is a vacuum reading on the gauge that is 3 Apply 10 inches of vacuum to the PVS valve connected directly to the PVS valve There should be a vacuum reading on the gauge If there is no va
78. e the voltage from the battery negative terminal to ground It should be zero If it is more than 0 2 volt check the ground circuit The following connections must be clean and tight e Generator mounting bolts e Generator and engine mounting surfaces e Ground cable connections to the engine and battery Field Voltage Test This test checks for initial excitation voltage at the F terminal Perform this test if the output voltage did not rise above battery voltage in the output voltage test but did rise with the regulator bypassed 1 Make sure the field lead is connected 2 Key ON 3 Measure the field voltage by carefully probing the F terminal GENERATOR VOLTMETER CAUTION To avoid grounding the field and causing component damage use a taped probe or connect the field lead through a jumper to provide meter probe access to the terminal A reading of 1 5 to 3 0 volts is normal A zero volt reading indicates an open in the initial excitation circuit either in the regulator or in the circuit between the battery and the regulator If battery voltage appears at the F terminal an open is present in the field circuit either in the coil or in the brushes The meaning of voltage readings between these extremes depends on the specific equipment being tested 04 9 Charging System 04 9 ERES A GN MM Om I EE CL MEC A A RS O 22 A RS MINUTES DIAGNOSIS AND TESTING Continued Initial Excitat
79. e with the ignition OFF and determine the obtained while the starter cranked the engine The exact reading on the voltmeter This test is accomplished ammeter will indicate the starter current draw under load by disconnecting and grounding the high tension lead from STARTER LOAD TEST BATTERY STARTER TESTER CARBON PILE RHEOSTAT VOL TMETER AMMETER REMOTE CONTROL STARTER SWITCH SOLENOID TO IGNITION SWITCH POSITIVE LEAD STARTER SOLENOID ICE PICK STARTER CONTRO NTROL STARTER SOSA STARTER TM SWITCH Starter Solenoid Test Disconnect the starter from the battery and adjust the If the solenoid does not pull in in the Starter Load Test load of the rheostat until the voltmeter indicates the same measure the voltage between the starter mounted solenoid reading as that obtained while the starter was running switch terminal and ground with the ignition switch closed The ammeter will indicate the starter no load current draw If the voltage is 10 or more volts a worn or damaged solenoid is indicated Remove the starter assembly for STARTER NO LOAD BENCH TEST solenoid replacement BATTERY Bench Tests STARTER TESTER Starter No Load Test The starter no load test will uncover such faults as open or shorted windings rubbing armature and bent armature shaft The starter can be tested at no load on the test bench only Make the test connections as shown The starter will run at no load Be sure
80. eaner mixture Turning the needle out counterclockwise allows a richer mixture 03 8 Fuel System 03 8 E E ZENITH MODEL 33 CARBURETOR Continued As the throttle plate opens extra fuel is discharged from the secondary idle discharge holes as the throttle plate passes them This hole is precisely located from the closed throttle plate with the size and location depending on fuel requirements As the throttle plate is opened wider the idle system gradually ceases to function The delivery of fuel through the high speed system increases as the throttle plate is advanced Although the delivery of fuel through the idle system diminishes as the throttle plate approaches the wide open position it continues to deliver a small volume of fuel contributing to the fuel delivered by the high speed system It cannot be said that the idle system ceases to deliver fuel entirely at wide open throttle but it must be made clear that the amount of fuel delivered from the idle system at wide open throttle is minute and relatively unimportant High Speed System The high speed system consists of a venturi a main jet a well vent and a well tube This system also controls the mixture at part throttle speed The main jet controls fuel delivery from about one quarter to three quarters throttle opening To maintain a proper mixture ratio a small amount of air is admitted through the well vent There are also air bleed holes located in the well tube at a
81. ear limit ream the valve guide for the next oversize valve stem Valves with oversize stem diameter are available for service Always reface the valve seat after the guide has been reamed Refer to Reaming Valve Guides Camshaft Repair Remove light scuffs scores or nicks from the camshaft machined surfaces with a smooth oil stone Crankshaft Dress minor scores with an oil stone If the journals are severely marred or exceed the wear limit they should be refinished to size for the next undersize bearing Refinishing Journals Refinish the journals to give the proper clearance with the next undersize bearing If the journal will not clean up to maximum undersize bearing available replace the crankshaft Always reproduce the same journal shoulder radius that existed originally Too small a radius will result in fatigue failure of the crankshaft Too large a radius will result in bearing failure due to radius ride of the bearing After refinishing the journals chamfer the oil holes then polish the journal with a No 320 grit polishing cloth and engine oil Crocus cloth may also be used as a polishing agent Fitting Main or Connecting Rod Bearings With Plastigage 1 Clean crankshaft journals Inspect journals and thrust faces thrust bearing for nicks burrs or bearing pickup that would cause premature bearing wear When replacing standard bearings with new bearings it is good practice to fit the bearing to minimum sp
82. ecified clearance If the desired clearance cannot be obtained with a standard bearing try a 0 05 mm 0 002 inch undersize in combination with a standard bearing to obtain the proper clearance 2 If fitting a main bearing in the chassis position a jack under the counterweight adjoining bearing which is being checked Support crankshaft with jack so its weight will not compress Plastigage and provide an erroneous reading 3 Place a piece of Plastigage on bearing surface across full width of bearing cap and about 6 4 mm 1 4 inch off center PLACE PLASTIGAGE FULL WIDTH OF JOURNAL ABOUT 1 4 INCH OFF CENTER ZA MEASURING era S PLASTIGAGE IN 0 0015 INCH PLASTIGAGE CLEARANCE CHECK WIDTH OF PLASTIGAGE A2868 B 01 10 Basic Engine 01 10 OVERHAUL Continued 4 Install cap and torque bolts to specifications Do not Fitting Piston Rings turn crankshaft while Plastigage is in place Three piston rings are fitted two compression and one oil 5 Remove cap Using Plastigage scale check width of control ring Plastigage at widest point to get minimum clearance 1 Select the proper ring set for the size cylinder bore Check at narrowest point to get maximum clearance Difference between readings is taper of journals 6 If clearance exceeds specified limits on the connecting rod bearings try a 0 05 mm 0 002 inch undersize bearing in combination with the standard 2 Position the ring in the cylinder bore in which it is
83. econds If it holds vacuum the diaphragm is okay Proceed to the Source Vacuum test If the diaphragm won t hold vacuum replace the EGR valve APPLY 8 INCHES VACUUM 4 VACUUM AND TRAP WATCH WITH SECOND HAND 03A 8 Emission Control System 03A 8 E nn e DIAGNOSIS AND TESTING Continued EGR Valve Leakage Check Testing for EGR Source Vacuum Perform this test if the engine stalls idles roughly or runs Occasionally the EGR system may fail to operate because poorly the vacuum port on the carburetor is plugged or because 1 Remove and cap the EGR valve vacuum hose Start of a vacuum leak To test for source vacuum the engine If the engine idle quality improves 1 Remove the EGR supply vacuum hose from its noticeably double check the vacuum hose routing connection at the carburetor because the valve may have a vacuum supply at idle 2 Attach a vacuum gauge to the source 2 the engine idle quality does not improve remove 3 Start the engine and watch the gauge as you momen the EGR valve from the spacer Block the EGR tarily accelerate to half throttle 3000 rpm maximum passages with a plate or install a known good EGR The vacuum should rise at off idle decrease at half valve Start the engine If the idle quality is still bad throttle and go to zero at closed throttle the problem is elsewhere Reinstall the EGR valve If If the source vacuum is okay test the PVS and inspect the idle quality improves noticeably the EGR valv
84. eed loosen the locknuts and adjust the screw to rarely requires adjustment If necessary this adjustment move the spring towards the lever hub Tighten the can be used to prevent hunting and surging and no load locknuts speeds provided the rpm spread adjustment is set 2 Recheck governor operation under load and no load properly conditions 1 the adjustment with the tachometer installed 3 Readjust the governor high speed stop screw to Increase the engine speed with the hand throttle or maintain the correct high speed under load variable speed lever to 75 rpm lower than the Low Speed maximum no load desired control rpm 2 Loosen the no load surge adjustment screw locknut and turn the screw inward until the rpm increases to the desired control rpm CAUTION Do not turn the screw in all the way It will interfere with proper governor operation and prevent the governor from returning the engine to idle speed 3 Readjust the governor high speed stop screw to maintain the correct high speed under load 1 Attach a tachometer and move the hand throttle or variable speed lever to the closed position 2 Adjust the carburetor idle speed screw to obtain the desired idle speed 06 6 Governor 06 6 REMOVAL AND INSTALLATION Removal 1 Disconnect hand throttle connection at governor variable speed lever 2 Disconnect governor to carburetor throttle control rod at governor 3 Loosen governor mounting nuts
85. efore all of the parts shown and mentioned may not be included in the particular assembly being worked on Assembly of Air Intake 1 Drive channel plug 50 into vacuum channel flush with surface 2 Drive cup plug 4 into end of choke shaft hole opposite choke lever 3 Insert choke shaft 53 with milled flat toward top orifice into casting until the bottom end is 31 8 mm 1 25 inches from the cast surface Do not bend or distort Assembly of Fuel Bowl 1 Install the following parts as needed not normally removed for service a Cup plug 17 in shaft hole flush b Fuel channel plug 23 flush c Welch plug 24 over idle port d Idle channel plug 25 flush 03 12 Fuel System 03 12 E noo ZENITH MODEL 33 CARBURETOR Continued e Welch plug 31 over spark vacuum port 16 Place accelerator pump diaphragm 37 in place on f Spark vacuum tube 32 to approximately 14 mm body with bagged section into cavity Insert 9 16 inch from casting diaphragm protector 38 into end of spring 39 and install spring with protector against diaphragm 17 Place cover 40 over spring and compress Insert screws 41 and tighten evenly and securely NOTE Pump spacer 57 will install into cover before assembly if required g Throttle body plug 36 flush h Pump check valve 42 flush using tool C151 53 i Well tube 44 making sure that end openings align with notch in casting at top and fuel channel at bott
86. en thoroughly rinse the bore s with clean water to remove the soap or detergent and wipe the bore s dry with a clean lint free cloth Finally wipe the bore s with a clean cloth dipped in engine oil If these procedures are not followed rusting of the cylinder bore s may occur 01 17 Basic Engine 01 17 AA A A A A EC MMC A A A E A A e A a CLEANING AND INSPECTION Continued If the engine is disassembled thoroughly clean the block with solvent Remove old gasket material from all machined surfaces Remove all pipe plugs that seal oil passages then clean out all the passages Blow out all passages bolt holes etc with compressed air Make sure the threads in the cylinder head bolt holes are clean Dirt in the threads may cause binding and result in a false torque reading Use a tap to true up threads and to remove any deposits Thoroughly clean the grooves in the crankshaft bearing and bearing retainers Inspection After the block has been thoroughly cleaned check it for cracks Minute cracks not visible to the naked eye may be detected by coating the suspected area with a mixture of 25 kerosene and 75 light engine oil Wipe the part dry and immediately apply a coating of zinc oxide dissolved in wood alcohol If cracks are present the coating will become discolored at the defective area Replace the block if it is cracked Check all machined gasket surfaces for burrs nicks scratches and scores Remove minor
87. er from the oil pump 3 Remove the three bolts attaching the oil pump and remove the assembly Installation 1 Ensure the mating surfaces are clean of old gasket material then install the oil pump assembly on the cylinder block using a new gasket together with an oil resistant sealer and secure with the three bolts Tighten the bolts to specifications 2 Install the oil filter to the oil pump assembly 3 Checkthe oil level and add oil if necessary Start the engine and check for oil leaks Cil Pan Removal 1 Drain the crankcase 2 Remove the oil level dipstick 3 Remove the three bolts and remove the starter motor 4 Remove the oil pan attaching bolts and remove the pan and gasket Installation 1 Clean the oil pump inlet tube and screen assembly 2 Clean the gasket surfaces of the block and oil pan Be sure to clean the seal retainer grooves in the cylinder front cover and the rear seal retainer The oil pan has a two piece gasket Coat the block surface and the oil pan gasket surface with oil resistant sealer Position the oil pan gaskets on the cylinder block 3 Position the end seals with the chamfered ends into the grooves again using an oil resistant sealer Position the oil pan and tighten the bolts evenly to specifications following first the alphabetical then the numerical sequences shown 4 Clean and install the starter motor securing it with the three bolts 5 Refill the oil pan with the cor
88. er head gasket surface for conformance to specifications If necessary to refinish the cylinder head gasket surface do not plane or grind off more than 0 25 mm 0 010 inch DOCHECK DIAGONALLY CHECK ACROSS CENTER 01 13 Basic Engine 01 13 1 CLEANING AND INSPECTION Continued Check the valve seat runout with an accurate gauge Follow the instructions of the gauge manufacturer If the runout exceeds the wear limit reface the valve and valve seat Measure the valve seat width Reface any valve seat whose width is not within specifications RUNOUT GAUGE Inspect the valve face and the edge of the valve head for pits grooves scores or other damage Inspect the stem for a bent condition and the end of the valve head for pits grooves scores or other wear Inspect the stem for a bent condition and the end of the stem for grooves or scores Check the valve head for signs of burning erosion warpage and cracking Minor pits grooves etc may be removed Discard valves that are severely damaged Inspect the valve spring valve spring retainers locks and sleeves for wear or damage Discard any visually damaged parts Check the valve stem to valve guide clearance of each valve in its respective valve guide with the tool shown below or its equivalent Use a flat end indicator point With the cylinder head gasket face up slide a new standard intake or exhaust valve into the valve guide to be checked until the tip of the val
89. eratures 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 A WARNING A The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Introduction In general this manual covers the servicing of the engine and asso ciated standard equipment In many cases engines are supplied with accessories and equipment that are unique to the application If service information is ever required on such unique accessories or equipment it is suggested that Power Products Division GRI be con tacted The proper information will either be forwarded or the Ser vice Technician will be advised where it can be obtained The information in this manual is grouped in sections according to the type of work being performed The various sections are indi cated in the index In addition each section is subdivided to include topics such as diagnosis and testing cleaning and inspection over haul removal and installation procedures disassembly and assem bly procedures and service specifications Power Products POWER PRODUCTS DIVISION GRI The Source for Power 28333 TELEGRAPH ROAD 300 Worldwide SOUTHFIELD MICHIGAN 48034 The descriptions and specifications contained in this manual were in effect at the time the book was released f
90. ew clockwise CW until the engine speed begins to decrease Slowly tur the idle mixture screw counterclockwise CCW until the engine speed begins to decrease Now turn the idle mixture screw clockwise CW until maximum idle speed is achieved The idle mixture is now adjusted 2 Engine is misfiring Disconnect the connector from the controller and consult the engine repair manual NAMEPLATE 219 012 5 56 3 9 07 8103 gal allay 1127 1 0 SPD SEL 4 437 040 ASD BUS TOTmMOODD 4 06 6 160 024 219 016 41g 5 56 4 1 65 gt MAX 219 016 146 1 10 5 75 040 Calibration 512K of conventional RAM must be available Also Initial speed settings as well as other parameters can be required is a 1 44 Meg High Density floppy drive and a set using a special interface connector and an IBM VGA graphic display Programming of the controller is compatible PC 286 minimum with 640K RAM of which covered in a separate publication 06 10 Governor 06 10 AA O A A RG RE DS A a A e a E NRO ELECTRONIC DIAGNOSIS AND TESTING Continued B BATTERY ACTUATOR SPEED SELECT TACH LEAD SPEED SELECT TACH LEAD CONNECTOR 07 1 Cooling System 07 1 E SRS RREO 2252 SR 222220 SECTION TITLE PAGE SECTION TITLE PAGE BASIC ENGINE user riadas 01 1 STARTING SYSTEM 225225252222 560581 05 1 IGNITION SYSTEM DISTRIBUTORLESS 0
91. g 6 Position the rear housing and stator assembly over the rotor and align the scribe marks made during disassembly Seat the machined portion of the stator core into the step in both end housings Install the housing through bolts 7 Install the fan spacer fan dished washer spacer pulley spacer lockwasher and nut Tighten nut 04 16 Charging System 04 16 FE SN AME CK A AA a A A A A A A a A DM ME DENEN OVERHAUL Continued NOTE Dished washer must be fitted correctly with the outer circumference pressing against the fan In this way it GENERATOR acts as a vibration damper and prevents fatigue failures Output Voltage Test If possible check the generator on a bench tester before re installing After bench testing or if bench testing is not available re install the generator to the engine 1 Install and connect the generator Apply proper tension to the drive belt Make sure the battery cable connections are tight Key ON With the engine running at 1000 to 1200 rpm VOLTMETER measure the voltage from the output terminal to ground OF q oo 6 Gradually increase the electrical load while observing the voltage reading If voltage stays between 13 6 and 14 4 volts under all but extreme load conditions the charging system is working properly 05 1 Starting System 05 1 Lu DSG EE SNS A SECTION TITLE PAGE SECTION TITLE PAGE BASIC ENGINE assess EUER EE HE Rma RM EE 01 1 STARTING SY
92. g nuts or bolts that must be tightened refer to the torque specifications oil the threads with light weight engine oil Do not oil threads that require oil resistant or water resistant sealer Start the assembly by examining the block and crankshaft to determine the bearings to be used The block with standard main bearing bores is unmarked With 0 38 mm 0 015 inch oversized main bearing bores the bearing caps are marked with white paint MAIN BEARING CAP MARKINGS 01 30 Basic Engine 01 30 DISASSEMBLY AND ASSEMBLY Continued The crankshaft main bearing journals of standard diameter measuring bearing journals and block bores individually came in two size categories and are either unmarked or with the bearing inserts installed have a yellow paint mark on the first counterweight See 1 Mount the block in the stand inverted specifications for dimensions 2 Install the coolant drain plug and oil pressure sending unit 3 Place the upper main bearing inserts in position in the bore with the tang fitting in the slot provided 4 Install the lower main bearing inserts in the bearing caps 5 Carefully lower the crankshaft into place Be careful not to damage the bearing surfaces Check the clearance of each main bearing following the procedures in the Overhaul Section 6 Install the thrust washers to the center main Apply alight coat of oil to the journals and bearings Install MAIN BEARING the main bearing caps
93. ge T63L 8620 A Model 210019 or equivalent and tighten to specification if necessary Isolating the Problem Battery starting system and light systems problems can be caused by poor charging system performance It is also possible to suspect the charging system because of an overload in another area of the electrical system To avoid guesswork it is necessary to isolate the battery the charging system and the electrical circuits to correctly identify the area where the difficulty lies The best method to do this is to check the battery first before any electrical system diagnosis The battery must be in proper state of charge The battery must be operating properly before the other areas of the electrical system can perform normally Battery Testing WARNING KEEP BATTERIES OUT OF REACH OF CHILDREN BATTERIES CONTAIN SULFURIC ACID AVOID CONTACT WITH SKIN EYES OR CLOTHING ALSO SHIELD YOUR EYES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION IN CASE OF ACID CONTACT WITH 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 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 U
94. ging System 04 6 E nn ER DIAGNOSIS AND TESTING Continued BATTERY DISCHARGE RATES 200 TEMPERATURE CORRECTION CHART ALL BATTERIES Minimum Acceptable Load Voltage Temperature System Connections Check that all charging system connections cables and wires are sound clean and tight This includes Battery cables Battery connections Starter solenoid connections Starter ground Regulator terminal connections Generator wiring harness Generator Connections 1 Check all the harness connections to the generator Make sure they are clean and tight 2 Inspect the soldered connections to the output diode and the ground diode These connections are visible through the ventilation holes in the rear housing of the generator Electrical Testing Precautions Observe the following precautions to avoid permanent damage to the regulator or to the generator diodes 1 Do not disconnect the generator output lead the ground lead or the battery cable while the engine is running 2 Do not disconnect the generator field terminal or the regulator connection while the engine is running 3 Do not short the generator field terminal or field lead to ground 4 Disconnect the battery ground terminal before removing the generator or the generator brush holder assembly 5 Never reverse polarity when charging or replacing the battery Output Voltage Test Perform this test if the trouble symptom is a w
95. han the maximum speed threshold then the spark events are terminated until the instantaneous engine speed falls below 6375 RPM During this time all other ICM calculations are performed as normal 02 5 Ignition System Distributorless 02 5 ESENTIUM DM MEAM A A E A IE SERVICE ADJUSTMENTS AND CHECKS 1 Each 400 hours of engine operation remove the spark plugs and clean amp adjust the electrode 2 Clean and visually check spark plug high tension leads and check for secure fit replace if necessary The ICM must be mounted above the intake manifold vacuum fitting to prevent fuel from entering the ICM chamber The connecting rubber hose must be compatible with gasoline and be as short as possible It is recommended that a fuel vapor trap be used in line in the connecting hose 02 6 Ignition System Distributorless 02 6 ra REMOVAL AND INSTALLATION Ignition Coil Removal 4 Remove three screws and detach coil assembly 1 Disconnect battery ground lead 2 Disconnect ignition coil multiplug IGNITION COIL RETAINING SCREWS AA ZI su MA gt NES mM N 3 Compress 2 lugs and disconnect HT leads at coil Installation 1 Position coil assembly secure with three screws 2 Connect HT leads at coil ensuring that locking tabs snap into position NOTE HT connections at coil are marked 1 to 4 It is important that each HT lead is connected in correct sequence 3 Connect ignition coil multi
96. have been installed check the connecting rod side clearance on each crankshaft journal 9 Install the oil pan and related parts Follow procedures in this Section 10 Refer to Cylinder Head Installation and install the cylinder head and related parts Adjust the valve PISTON Y clearance as described in this Section COMPRESSION i COMPRESSION 11 Fill and bleed the cooling system Fill the crankcase RING FRONT OF RING 12 Start the engine and check for oil pressure Operate ENGINE the engine at fast idle and check for oil and coolant leaks 13 Operate the engine until engine temperatures have stabilized Check and adjust the ignition timing Adjust the engine idle speed and fuel mixture to the specifications Cil Filter Removal Place a drip pan under the filter Unscrew the filter from the adapter fitting Clean the adapter filter recess Installation 1 Coat the gasket on the replacement filter with oil Position the filter on the adapter fitting Hand tighten the filter until the gasket contacts the adapter face then advance it 1 2 turn 2 Operate the engine at fast idle and check for oil leaks If oil leaks are evident perform the necessary repairs to correct the leakage Check the oil level and fill the crankcase as required 01 29 DISASSEMBLY AND ASSEMBLY Engine Assembly Disassembly 1 2 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Mount t
97. he baffle plate Inspection Check the pan for cracks holes damaged drain plug threads and a loose baffle or a damaged gasket surface Inspect for damage uneven surface at the bolt holes caused by over torquing the bolts Straighten surfaces as required Repair any damage or replace the pan if repairs cannot be made satisfactorily Oil Pump Cleaning Wash all parts in a solvent and dry them thoroughly with compressed air Use a brush to clean the inside of the pump housing and the pressure relief valve chamber Be sure all dirt and metal particles are removed inspection Refer to the specifications for clearances and wear limits Check the inside of the pump housing and the outer race and rotor for damage or excessive wear Check the mating surface of the pump cover for wear If the cover mating surface is worn scored or grooved replace the cover Measure the outer race to housing clearance Then check the clearance between the outer race and the rotor lobes 01 18 Basic Engine 01 18 CLEANING AND INSPECTION Continued measuring the OD of the shaft and the ID of the housing bearing Inspect the relief valve spring for a collapsed or worn condition Check the relief valve spring tension If the spring is worn or damaged replace the spring Check the relief valve piston for scores and free operation in the bore STRAIGHT EDGE With the rotor assembly installed in the housing place a straight edge over the
98. he engine on a stand and drain crankcase Disconnect the fuel line at the fuel pump and carburetor Disconnect the spark plug leads remove them from the clip on the rocker cover and position out of the Way Disconnect the water outlet and crankcase ventilation hoses at the intake manifold Disconnect the wire from the temperature gauge sending unit Disconnect the throttle rod from the carburetor Remove the governor mounting bolts and remove governor and drive belt Remove the thermostat housing and thermostat Hemove the rocker arm cover and gasket Remove the rocker arm shaft bolts evenly and lift off the rocker arm shaft assembly Lift out the push rods from their locations and keep them in their correct order Remove the cylinder head bolts and lift off the cylinder head and gasket Do not lay the cylinder head flat on its face as damage to the spark plugs or gasket surface can occur Remove the fuel pump and oil pump Remove the dipstick and tube Remove the secondary wiring Remove fan spacer pulley and generator belt Remove the generator mounting and adjusting bracket bolts Remove generator Remove crankshaft pulley Remove tne water pump front cover and crankshaft oil slinger Remove any ridge and or carbon deposits from the upper end of the cylinder bores Move the piston to the bottom of its travel and place a cloth on the piston head to collect the cuttings Remove the cylinder ridge with a ri
99. he valve clearances to specification 17 Install the rocker arm cover and a new gasket and secure with attaching screws and torque to specifications 18 Connect the vacuum advance line to the carburetor 19 Connect wires to spark plugs 20 Install the water pump pulley and fan Position the generator and governor drive belts on the pulley and adjust the belt tension to specifications Connect the fuel line from the carburetor to the fuel pump 21 Remove engine from stand 22 Install the engine assembly in the unit 23 Start the engine and check for oil and water leaks 24 Install the air cleaner assembly 25 Start engine adjust the ignition timing if necessary 26 Adjust the carburetor idle speed and fuel air mixture to specifications Check governor operation Camshaft Bearings The service bearings for the camshaft are pre sized and require no machining after installation When one bearing requires replacement it is advisable to replace all three as camshaft alignment may be affected if only one bearing is changed The camshaft front and rear bearing are both approximately 19 mm 3 4 inch wide the front one having an additional oil hole for the rocker arm shaft oil feed and the center bearing approximately 16 mm 5 8 inch wide Install the bearings using a replacer in addition to the adapters previously used Make sure that the oil holes in the bearings and cylinder block are correctly aligned before installati
100. ickness 1 1L and 1 3L 2 978 2 990 mm 0 1172 0 1177 in Oil Ring Side Clearance 1 1L and 1 3L 0 032 mm 0 0 0012 in Top Compression Ring Standard Bore Ring Gap P 0 25 0 45 mm 0 010 0 017 in Bottom Compression Ring Standard Bore Ring Gap 0 25 0 45 mm 0 010 0 017 in Oil Ring Standard Bore Ring Gap P 0 20 0 40 mm 0 008 0 015 in Cylinder Head Maximum permissible cylinder head distortion 1 1L and 1 3L Measured over a distance of 26 mm 0 04 mm 0 0015 in Measured over a distance of 152 mm 0 08 mm 0 003 in Measured over the entire length 0 15 mm 0 006 in Valve Stem Bore 1 1L and 1 3L 7 063 7 094 0 2781 0 2793 in Valve Seat Angle 45 Valve Seat Insert Exhaust Outside Diameter 1 1L and 1 3L 31 500 31 515 mm 1 2402 1 2407 in Combustion Chamber Volume 1 1L 27 24 29 24 cc 4 22 4 53 cu in 31 79 33 79 cc 4 93 5 24 cu in Reface cylinder head mating surface The following minimum combustion chamber depth must be left after skimming 1 1L and 1 3L 14 4 mm 0 15 mm 0 567 in 0 006 in All specifications are in millimeters inches For Conversion Factors see page 8 b Ring Gap may exceed these specifications by 0 15 0 006 in when measurement is made in the block Insert must be chilled in liquid nitrogen or dry ice prior to assembly 08 6 Specifications 08 o SPECIFICATIONS Continued ENGINE MODEL YEARS 1993 Valve Mechanism Lash
101. il is starts dripping out of the oil level hole Install the oil level and oil fill plugs Belt Tension Belt tension should be checked on a cold belt only 1 Install belt tension tool T63L 8620 A on the drive belt and check the tension BELT TENSION 95 Nem 70 Ib ft 68 Nem 50 Ib ft A used belt is one that has been in operation for 10 minutes or more 2 If adjustment is required loosen the governor adjusting bolts and move the governor until the correct tension is obtained 3 Remove the gauge Tighten the governor adjusting bolts Install the tension gauge and recheck the belt tension Throttle Control Rod 1 Manually move the governor throttle lever to the maximum open throttle with spring tension on the governor 2 Checkthe gap between the carburetor throttle shaft lever and its maximum open position stop It should be 0 8 1 6mm 1 32 to 1 16 inch wide 3 If adjustment is necessary loosen the control rod ball joint locknuts remove the rod from the carburetor throttle lever and adjust the length of the rod with the ball joints 4 Install the throttle control rod on the carburetor throttle lever and recheck the gap Tighten the locknuts CAUTION Be sure the throttle control rod is properly installed with the long end at the governor to prevent binding on the ignition wires RPM Adjustments High Speed First attach a tachometer to the engine then run the engine until it reaches normal ope
102. indicate low compression pressures and squirting oil on the pistons does not increase the compression the cause may bea cylinder head gasket leak between the cylinders Engine oil and or coolant in the cylinders could result from this problem It is recommended the following quick reference chart be used when checking cylinder compression pressures The chart has been calculated so that the lowest reading number is 75 of the highest reading Example After checking the compression pressures in all cylinders it was found that the highest reading obtained was 196 psi The lowest pressure reading was 155 psi The engine is within specifications and the compression is considered satisfactory 01 7 Basic Engine DIAGNOSIS AND TESTING Continued Maximum kPa PSI 101 703 102 717 104 724 105 738 107 745 108 758 110 765 111 779 113 786 114 793 115 807 117 814 118 827 120 834 121 848 123 855 124 869 126 876 127 889 129 Crankshaft End Play 1 Force the crankshaft toward the rear of the engine 2 Install a dial indicator so that the contact point rests against the crankshaft flange and the indicator axis is parallel to the crankshaft axis 3 Zero the dial indicator Push the crankshaft forward and note the reading on the dial 4 fthe end play exceeds the wear limit replace the thrust washers If the end play is less than the minimum limit inspect the thrust bearing faces for scratches burrs nicks or dirt
103. ing bolts Loosen generator and governor adjusting bolts 42 Install water pump pulley spacer and fan Install generator and governor drive belts Adjust both belts to specifications 43 Remove engine from stand Oil Pump Disassembly Remove the filter Remove the end plate and withdraw the rubber O ring from the groove in the pump body If itis necessary to replace the rotor assembly remove the outer rotor then drive out the retaining pin securing the gear to the shaft and pull off the gear Remove the inner rotor and shaft Drill a small hole and insert a self threading sheet metal screw of the proper diameter into the oil pressure relief valve chamber cap and pull the cap out of the chamber Remove the spring and plunger Assembly Oil all parts thoroughly Install the oil pressure relief valve plunger spring and new cap Install the inner rotor and shaft assembly in the pump body Press the gear onto the shaft supporting the shaft at the rotor end on a suitable spacer until the far end of the gear teeth are 57 2 mm 2 1 4 inches from the mounting flange If a new shaft and or gear are used drill a 3 2 mm 1 8 inch hole at right angles to the shaft through the gear shoulder 33 3 mm 1 5 16 inches from the mounting flange Replace the gear retaining pin and peen over the ends securely Install the outer rotor with its chamfered side facing inward toward the pump body Place a new rubber O ring in the groo
104. ion Circuits GENERATOR REGULATOR EXCITATION Seis GENERATOR WARNING LIGHT RECTIFIER INSTRUMENTS BRIDGE IF EQUIPPED GENERATOR INSTRUMENT FIELD FUSE FUSE IF EQUIPPED IGNITION SWITCH BATTERY Initial excitation voltage reaches the field terminal through 1 Key ON an excitation lead from the ignition switch to the regulator o and an excitation resistor inside the regulator If the circuit is equipped with a voltmeter this is the only path If the circuit is equipped with a generator warning light the warning light provides an alternate path in parallel with the excitation resistor This excitation function of the warning Senne light is an incidental result of its being positioned in the RESISTOR LEAD circuit so as to compare battery and output voltages but it we is important because it can mask an open in the excitation circuit Normally initial excitation current is drawn through both paths but either one will pass sufficient current if the other is open If the excitation resistor is open or higher in value than it should be there will still be excitation current to magnetize the field at startup but the voltage at the field terminal will be lower because of the larger voltage drop through the increased resistance Likewise if the warning light bulb is burned out the excitation resistor will provide field current but also at reduced voltage A burned out bulb is easily detected if it fails to ligh
105. l Seal Carrier 16 to 20 12 15 1 Step One Torque to 4 Nem 3 Ft lbs Step Two Turn 90 more TORQUE SPECIFICATIONS Continued Nm Fus 100 to 120 73 4 88 73 4 88 Timing Cover Water Pump Crankshaft Pulley 1 1 and 1 3L 89 M Y and later Water Pump Pulley Starter Motor Fuel Pump Distributor Retaining Bolt Distributor Clamp Bolt Oil Pump Oil Pump Cover Oil Pump Pickup Tube Bracket Oil Pan Step 1 Alphabetical Step 2 Numerical Step 3 Alphabetical Retorque after engine has warmed up 15 minutes at 1000 rpm Oil Pan Plug 15 20 Oil Pressure Switch 10 11 40 to 46 30 34 STEP 1 30 22 STEP 90 More 2 Turn STEP 90 More 3 Turn 12 5 15 12 5 15 Temperature Sender Rocker Shaft Pedestals Cylinder Head Bolts Step 1 Step 2 Step 3 Rocker Cover Exhaust Manifold Inlet Manifold Carburetor Thermostat Housing Spark Plugs EGR Valve Bolts EGR Hose gt
106. le openings When the throttle is opened suddenly air rushes through the carburetor into the intake manifold and to the engine This air is lighter than the liquid fuel and gets into motion q N N N qu SPRING WEIGHT au BALL mor Seen E IN PA y gt A NIE RE SPRING VACUUM CHANNEL Tual AN Fuel System 42222227 03 9 more quickly That means that the air reaches the cylinders of the engine before the first charge of fuel supplied by the high speed system A lean mixture would result momentarily in this case and to counteract the condition additional fuel must be supplied instantly The supply of that extra fuel is the job of the accelerating pump system MENS ZZ A mpm Yue EN CANIS AS S D q LS 35 n le ULL Lez sem SOS B WA UNA UNA am d ma A 2 2 4 2 ACCELERATING SYSTEM The accelerating system consists of the pump diaphragm assembly accelerating jet intake check valve and three parts making up the refill check The pump is vacuum operated In this system the pump diaphragm is pulled against the pump spring by the engine manifold vacuum When the throttle is opened the pull on the diaphragm drops allowing the spring to push the diaphragm against the fuel causing it to discharge through the accelerator jet This amount may be varied b
107. learance for the piston When a piston has been fitted mark it for assembly in the cylinder to which it was fitted If the taper out of round and piston to cylinder bore 6 Check the ring side clearance of the compression clearance conditions of the cylinder bore are within rings with a feeler gauge inserted between the ring specified limits new piston rings will give satisfactory and its lower land The gauge should slide freely service If new rings are to be installed in a used around the entire ring circumference without binding cylinder that has not been refinished remove the Any wear that occurs will form a step at the inner cylinder wall glaze Refer to Cylinder Block portion of the lower land If the lower lands have Refinishing Cylinder Walls Be sure to clean the high steps the piston should be replaced cylinder bore thoroughly 1 Calculate the size piston to be used by taking a cylinder bore check Follow the procedures outlined under Cleaning and Inspection 2 Select the proper size piston to provide the desired clearance refer to the specifications The piston should be measured 57 2 mm 2 1 4 inches below the dome and at 90 to the piston pin bore 3 Make sure the piston and cylinder block are at room temperature 21 degrees C 70 degrees F After any refinishing operation allow the cylinder bore to cool and make sure the piston and bore are clean and dry before the piston fit is checked A8514 B 01 11
108. lled amount of exhaust gas back through the as oxides of nitrogen NOx A CARBURETOR B SPACER C EGR VALVE D EGR TUBE E INTAKE MANIFOLD The EGR valve is a vacuum operated flow control valve Between the EGR valve adapter and the carburetor is a It is attached to the carburetor by an EGR valve adapter spacer which has gaskets on both sides 03A 4 Emission Control System 03A 4 DESCRIPTION AND OPERATION Continued 2 REQUIRED 2 REQUIRED CARBURETOR PORT VACUUM SWITCH PVS SPACER EGR VALVE EGR GASKET RESTRICTOR GASKET EGR SPACER TOnmmOOOUD gt 2 REQUIRED The EGR valve is operated by a vacuum signal from the spring the valve is opened allowing EGR flow The carburetor which actuates the valve diaphragm As the amount of flow is dependent on the location of a tapered vacuum increases sufficiently to overcome the diaphragm pintle which is a direct result of the vacuum signal 03A 5 Emission Control System 03A 5 SERES DS IMEEM IM EROS TETERA MN MM UR EM MEE FCIRE EK AAA DESCRIPTION AND OPERATION Continued EGR VALVE CLOSED DIAPHRAGM SPRING VACUUM NIPPLE PINTLE INTAKE MANIFOLD EXHAUST GAS MANIFOLD VACUUM PINTLE SEAT DIAPHRAGM DIAPHRAGM SPRING TO VACUUM PINTLE INTAKE MANIFOLD EXHAUST GAS MANIFOLD VACUUM PINTLE SEAT DIAPHRAGM gt EGR vacuum port is open to vacuum when the throttle At closed throttle the EGR port is blocked
109. m cover 2 Remove the valve rocker arm shaft assembly as detailed in the pertinent section 3 Make sure the push rod is in the valve lifter socket Install a dial indicator in such a manner as to have the ball socket adapter of the indicator on the end of the push rod and in the same plane as the push rod movement DIAL INDICATOR 4 Connect an auxiliary starter switch in the starting circuit Crank the engine with the ignition switch OFF Bump the crankshaft over until the tappet or lifter is on the base circle of the camshaft lobe At this point the push rod will be in its lowest position 5 Zero the dial indicator Continue to rotate the crankshaft slowly until the push rod is in the fully raised position highest indicator reading 6 Compare the total lift recorded on the indicator with specifications 7 check the accuracy of the original indicator reading continue to rotate the crankshaft until the indicator reads zero If the lift on any lobe is below specified wear limits the camshaft and the valve lifters operating on the worn lobe s must be replaced 8 Remove the dial indicator and auxiliary starter switch 9 Install the rocker arm shaft assembly as detailed under Removal and Installation 10 Install the valve rocker arm cover and the air cleaner Compression Test Compression Gauge Check 1 Be sure the crankcase is at the proper level and the battery is properly charged Operate the engine f
110. me side as the adjusting screw in the rocker arm The oil holes must point downward and the flat on the shaft to the front of engine The rocker arms are right and left handed the rocker pads being inclined towards the support Install the cotter pins with the heads upwards and bend over the legs to secure 3 Lubricate the valve stem tips rocker arm pads and the push rod ends with Lubriplate or equivalent Position the rocker shaft assembly on the cylinder head engaging the push rods with the adjusting screws Install and tighten the bolts evenly to specifications 4 Adjust the valve clearance to specifications 5 Ensure that the mating surfaces on the cylinder head and rocker cover are free from all traces of the old gasket material 6 Position the rocker cover and gasket on the cylinder head and secure with the attaching screws Torque the screws to specifications 7 Locate the spark plug leads in the rocker cover clip and reconnect them to their respective plugs 8 Install the air cleaner Intake Manifold Removal 1 Partially drain the cooling system 2 Remove the air cleaner 3 Disconnect the throttle rod from the carburetor throttle lever 4 Disconnect the fuel line and the distributor vacuum line from the carburetor 5 Disconnect the water outlet hose and the crankcase ventilation hose from the intake manifold 6 Remove the attaching nut and bolts and remove the intake manifold 7 Remove the
111. minals if present 2 Disconnect the field lead from the F terminal 3 Connect the field lead to the F terminal if it is not 3 Connect a jumper from the F terminal to the R already corrected terminal 4 Check the voltage at the R terminal If any voltage is 4 Start the engine present it indicates a shorted output diode or diodes This causes undercharging and also allows the battery to discharge through the regulator and field with the engine stopped CAUTION Be sure to keep the rpm low as an unregulated generator can produce voltage high enough to cause damage 5 With the engine running at idle check the output voltage GENERATOR GENERATOR VOLTMETER VOLTMETER Regulator Sense Voltage 1 Start the engine e Ifthe output voltage is still low the problem is in 2 With the engine running at 1000 to 1200 rpm check the generator the voltage from the O terminal to ground e If the output voltage rises above 13 6 volts with the regulator bypassed check the regulator circuit for low output although the problem may still be partly or entirely in the generator Possible generator GENERATOR problems include Defective output or field diodes Excessresistance in the field circuit which includes the regulator Excess resistance in the charging circuit external to the generator VOLTMETER 04 8 Charging System 04 8 DIAGNOSIS AND TESTING Conti
112. mm 0 0008 0 0075 in Cam Lift 1 1L Intake 5 15 mm 0 203 in Exhaust 4 92 mm 0 194 in Camshaft Lift 1 3L Intake 5 70 mm 0 224 in Exhaust 5 76 mm 0 227 in Drive 1 1L and 1 3L Connecting Rod Piston Pin Bore 1 1L and 1 3L 17 990 18 010 mm 0 7083 0 7091 in Rod Bearing Bore 1 1L and 1 3L 43 990 44 010 mm 1 7319 1 7327 in Maximum Twist or Bend 20 10 mm 0 004 in End Play 1 1 and 1 3L 0 10 0 25 mm 0 004 0 010 in Chain Diameter 1 1L 68 670 68 700 mm 2 7035 2 7047 in Diameter 1 3L 73 930 73 955 mm 2 9107 2 9116 in Piston to Bore Clearance 0 015 0 050 mm 0 0006 0 0019 in All specifications are in millimeters inches For Conversion Factors see page 8 08 5 Specifications 08 5 De 3222 ICD A DE E A A a Ee VEMM M UCM a KG A A aC SPECIFICATIONS Continued ENGINE MODEL YEARS 1993 18 026 18 029 mm 0 7097 0 7098 in 14L 58 6 59 4 mm 2 31 2 33 in Interference Fit in Rod at 21 C 1 1L and 1 3L Clearance in Piston at 21 C 1 1L and 1 3L 0 008 0 014 mm 0 0003 0 0006 in Piston Rings Top Compression Ring Thickness 1 1L and 1 3L 1 503 1 505 mm 0 05918 0 05925 in Bottom Compression Ring Thickness 1 1L and 1 3L 1 728 1 740 mm 0 0680 0 0685 in Top Compression Ring Side Clearance 1 1L and 1 3L 013 027 mm 0 0005 0 0011 in Bottom Compression Ring Side Clearance 1 1L and 1 3L 005 042 mm 0 0002 0 0017 in Compression Ring Side Clearance Wear Limit 0 15 mm 0 006 in Oil Ring Th
113. n White White Black Black White 852 ICM Ignition Control Module or UESC to Splice Yellow 152 ACC Terminal of Ign Sw to Generator Mounted Regulator Yellow Green White Black White Green Brown Brown White ala a dO 2 2 850 359 57 354 65 64 730 7P 5 Ground Circuit Pressure Gauge Black 575 Ground Circuit Switch Gauge Relay Black 9 T Ground Circuit Temperature Gauge Black 57V Ground Circuit Voltmeter Black 38 GEN BATT Terminal to Starter Solenoid BATT Terminal Black 32 Ignition Switch to Starter Motor Relay 21 Starter Solenoid Battery Terminal to Ignition Switch Feed Yellow a o O Blue 02 13 Ignition System Distributorless 02 13 E PULILIIAALMAIIUULLLLUILAAIHLALALLULLLLLLLLSILLLLILuLILzgLLu DDLAGLSLLLILLILLLLII DIAGNOSING AND TESTING DIS Continued USER NOTES IF THE ENGINE IS OPERATED WITH LOW OCTANE FUEL IT MAY NECESSARY RETARD THE SPARK THIS MAY BE DONE BY CUTTING OPEN THE LOOP AND GROUNDING THE WIRE WHICH GOES TO PIN 6 TO PIN 7 OR BOTH X TO RETARD 4 GROUND WIRE TO PIN 7 Vo TO RETARD 10 GROUND WIRE TO PIN 6 X d TO RETARD 18 GROUND WIRE TO PIN6 amp 7 5 TERMINAL Vi 38 GENERATOR NOTE THE WIRE LOOP FROM UESC PIN 6 TO PIN 7 THE UESC MODULE MUST BE MOUNTED SOMEWHAT ABOVE THE LEVEL OF THE INTAKE MANIFOLD THIS IS SO THAT FUEL OR CONDENSED FUEL VAPORS CANNOT DRAIN THRU THE
114. n the piston Replace any piston pin or piston that is not within specifications Heplace all rings that are scored broken chipped or cracked Check the end gap and side clearance Rings should not be transferred from one piston to another regardless of mileage or hours Main and Connecting Rod Bearings Cleaning Clean the bearing inserts and caps thoroughly in solvent and dry them with compressed air Do not scrape gum or varnish deposits from the bearing shells BRIGHT POLISHED CRATERS OR POCKETS SECTIONS FATIGUE FAILURE IMPROPER SEATING SCRATCHES OVERLAY WIPED OUT DIRT IMBEDDED INTO BEARING MATERIAL LACK OF OIL OR IMPROPER CLEARANCE AS Q SCRATCHED BY DIRT OVERLAY GONE RADIUS RIDE FROM ENTIRE SURFACE TAPERED JOURNAL OR CRANKSHAFT RADIUS RIDE A10095 1A HOURGLASSING Inspection Inspect each bearing carefully Bearings that have a scored chipped or worn surface should be replaced The copper lead bearing base may be visible through the bearing overlay This does not mean that the bearing is worn It is not necessary to replace the bearing if the bearing clearance is within recommended limits Check the clearance of bearings that appear to be satisfactory with Plastigage as detailed under Overhaul Main and Connecting Rod Bearings Cylinder Block Cleaning After any cylinder bore repair operation such as honing or deglazing clean the bore s with soap or detergent and water Th
115. n bright metal surface Chamfer or undercut the hole or porosity to a greater depth than the rest of the cleaned surface Solid metal must surround the hole Openings larger than 6 4 mm 1 4 inch should not be repaired using metallic plastic Openings in excess of 6 4 mm 1 4 inch can be drilled tapped and plugged using common tools Clean the repair area thoroughly Metallic plastic will not stick to a dirty or oily surface 2 Mixthe metallic plastic base and hardener as directed on the container Stir thoroughly until uniform 3 Apply the repair mixture with a suitable clean tool putty knife wood spoon etc forcing the epoxy into the hole or porosity 4 Allow the repair mixture to harden This can be accomplished by two methods heat cure with a 121 degrees C 250 degrees F lamp placed 254 mm 10 inches from the repaired surface or air dry for 10 12 hours at temperatures above 10 degrees C 50 degrees F 5 Sandor grind the repaired area to blend with the general contour of the surrounding surface 6 Paint the surface to match the rest of the block 01 12 Basic Engine 01 12 E cono CLEANING AND INSPECTION The cleaning and inspection procedures are for a complete engine overhaul therefore for partial engine overhaul or parts replacement follow the pertinent cleaning or inspection procedure Intake Manifold Cleaning Remove all gasket material from the machined surfaces of the manifold Clean the manifol
116. ng causes the shift lever to disengage the starter drive from the engine flywheel ring gear The starting motor is protected from excessive speed by an overrunning clutch incorporated in the starter drive assembly The overrunning clutch permits the drive pinion gear to rotate faster than the armature thus disengaging itself from the engine flywheel ring gear when the engine starts 05 4 Starting System TESTING Road Service On road service calls connect a booster battery to the system for cases of a starter that will not crank the engine or a starter that cranks the engine very slowly If the starter does not turn the engine over even with the booster battery attached refer to the following tests Be certain that correct battery polarity is observed when using a booster battery positive to positive and negative to negative connection of the auxiliary cables 05 4 On Engine Testing Starter Cranking Circuit Test These tests will determine whether or not there is excessive resistance in the cranking circuit Make each test connection as shown While cranking the engine observe the voltage drop reading for each test Disconnect and ground the high tension lead from the ignition coil to prevent the engine from starting Connect a remote control switch between the battery terminal of the starter relay and the S terminal of the relay STARTER CRANKING CIRCUIT TEST GROUND BATTERY STARTER SOLENOID 18 al The volt
117. nt is supplied the battery REGULATOR FIELD TERMINAL TERMINAL INSIDE REGULATOR COVER a OUTPUT TERMINAL REGULATOR AC TAP NOT USED EXCITATION RESISTOR PIGTAIL GROUND TO IGNITION SWITCH TERMINAL FIELD TERMINAL REGULATOR REGULATOR TERMINAL GROUND TERMINAL EXCITATION OUTPUT RESISTOR PIGTAIL TERMINAL TO IGNITION SWITCH 04 4 Charging System 04 4 DESCRIPTION AND OPERATION Continued FIELD WIRE GREEN REGULATOR GENERATOR SENSE WIRE RED EXCITATION RESISTOR WIRE YELLOW 04 5 Charging System 04 5 E PP PP DIAGNOSIS AND TESTING Preliminary Information Before performing charging system tests on the engine note the complaint such as slow cranking battery dead or using an excessive amount of water top of battery wet ammeter shows charge at all times and or no charge generator warning lamp does not come on and or never goes out voltmeter shows above or below open circuit nominal voltage This information will aid in isolating the part of the system causing the symptom Next visually inspect as follows 1 Check battery posts and battery cable terminals for clean and tight connections Remove the battery cables if corroded clean and install them securely 2 Check for clean and tight wiring connections at the generator regulator and engine Inspect for evidence of arcing 3 Check the generator belt tension using belt tension gau
118. nting plate and start the mounting bolts Snug the starting motor mounting bolts while holding the starter squarely against the mounting surface and fully inserted into the pilot hole Tighten the mounting bolts Connect the cable and wires to the terminals on the solenoid Connect the battery ground cable 05 8 Starting System OVERHAUL Disassembly 1 2 3 Clamp starter motor in vise fitted with protective soft jaws Remove nut and washer retaining field winding cable to solenoid and remove cable from stud Remove solenoid by removing three screws Remove two screws retaining commutator end housing cap remove cap and rubber seal RETAINING SCREW HOUSING CAP SCREWDRIVER SHIMS C CLIP ARMATURE SHAFT Wipe grease from armature shaft and remove C clip and shims from armature end Remove through bolts or two nuts and washers and lift off commutator end housing Remove brushes from brush holder assembly by carefully lifting brush retaining tensioning springs clear and sliding brushes from their holder Remove brush holder assembly Separate drive end housing and armature assembly from frame by tapping apart Remove rubber insert from drive end housing Remove actuating arm pivot retaining nut and slide pivot pin from housing Withdraw armature assembly complete with actuating arm from drive end housing Unhook actuating arm from drive pinion flange 10 05 8 To remove drive pinion
119. ntinued A VS B VERTICAL TAPER C VS D HORIZONTAL TAPER A VS C AND B VS D OUT OF ROUND CHECK FOR OUT OF ROUND AT EACH END OF JOURNAL Flywheel Inspection Inspect the flywheel for cracks heat check or other damage that would make it unfit for further service Machine the friction surface of the flywheel if it is scored or worn If it is necessary to remove more than 1 14 mm 0 045 inch of stock from the original thickness replace the flywheel Inspect the ring gear for worn chipped or cracked teeth If the teeth are damaged replace the ring gear With the flywheel installed on the crankshaft check the flywheel face runout following the procedure under Diagnosis and Testing Connecting Rods Cleaning Removing the bearing from the rod and cap Identify the hearing if they are to be used again Clean the connecting rod in solvent including the rod bore and the back of the inserts Do not use a caustic cleaning solution Blow out all passages with compressed air Inspection The connecting rods and related parts should be carefully inspected and checked for conformance to specifications Various forms of engine wear caused by these parts can be readily identified A shiny surface on either pin boss side of the piston usually indicates that a connecting rod is bent Abnormal connecting rod bearing wear can be caused by either a bent connecting rod worn or damaged crankpin or a tapered connecting r
120. nued 3 With the engine running at 1000 to 1200 rpm check the voltage from the R terminal to ground GENERATOR VOLTMETER Even if the output voltage is low the R terminal voltage should be within 0 5 volt of the O terminal voltage If the R terminal voltage is higher than the output voltage it indicates an open diode or diodes and the higher R voltage would signal the regulator to reduce output before normal charging voltage could be built up This causes an undercharging condition If the voltage at the R terminal is more than 0 5 volt lower than the output voltage one or more of the field diodes is defective In this condition the regulator would normally increase the generator output to bring the sense voltage up to the regulating value and an overcharging condition would result 4 Continue with External Circuit Tests External Circuit Tests This test checks the circuit between the generator and the battery by measuring the voltage from each battery terminal to ground 1 With the engine running at 1000 to 1200 rpm measure the voltage from the positive battery terminal to ground Voltage at the positive terminal should be the same as the generator output voltage If itis lower by more than 0 2 volt excess resistance is present in the generator output lead or in the battery positive cable or connections Check for wire or cable damage or for loose or dirty connections 2 Measur
121. od bore Twisted connecting rods will not create an identifiable wear pattern but badly twisted rods will disturb the action of the entire piston rings and connecting rod assembly and may be the cause of excessive oil consumption Inspect the connecting rods for signs of fractures and the bearing bores for out of round and taper If the bore exceeds the recommended limits and or if the connecting rod is fractured it should be replaced Check the ID of the connecting rod piston pin bore If the pin bore in the connecting rod is larger than specifications install a 0 05 mm 0 002 inch oversize piston pin First prefit the oversize piston pin to the piston pin bore by reaming or honing the piston Then assemble the piston piston pin and connecting rod following the procedures for assembly It is not necessary to ream or hone the pin bore in the connecting rod Replace damaged connecting rod nuts and bolts Check the connecting rods for bend or twist on a suitable alignment fixture Follow the instructions of the fixture manufacturer If the bend and or twist exceeds specifications the connecting rod must be straightened or replaced 01 16 Basic Engine 01 16 A A AAA A A A 54 A 425 IM cc A A A CLEANING AND INSPECTION Continued Pistons Pins and Rings Cleaning Remove deposits from the piston surfaces Clean gum or varnish from the piston skirt piston pins and rings with solvent Do not use a caustic cleaning solution o
122. om 2 Slide seal 33 over throttle shaft with lip toward lever Automatic Choke Operation and install shaft in body When the engine is cranked a rich mixture is delivered to 3 Back out throttle stop screw 35 and pace body on the engine When the engine starts air movement into the bench with mounting flange up carburetor causes the choke plate to open slightly against the thermostatic spring pressure As the engine warms up the thermostatic coil unwinds and the choke plate gradually opens 4 With milled flat up install throttle plate 30 with short side toward idle port and start screws 28 Make sure beveled sides of plate are next to throttle body bore Tap the plate lightly plate held closed to center it and tighten screws 5 While holding throttle closed screw idle stop screw 35 in until it touches the casting then screw in an additional 3 4 turn 6 Install idle needle 27 washer 56 and spring 26 and screw in to gently touch the seat Back screw out approximately one turn 7 nstall power jet valve 14 using C161 9 wrench No gasket required 8 Install main jet 22 and seat firmly with screwdriver THERMOSTATIC No gasket required 9 Install main jet plug 20 and washer 21 and tighten securely If main jet adjustment or solenoid shutoff are used install in place of plug 10 Turn body right side up Insert float axle 13 into holes in float 12 11 Lower float axle and float into slot provi
123. on and that the splits in the bearings are upwards and outwards at 45 degrees to the vertical Removal Hemove camshaft following the appropriate procedures in this section 1 Remove the flywheel Remove the crankshaft rear oil seal carrier Remove the camshaft bearings Check all the oil passages to make sure that they are clear Apply an oil resistant sealer to the oil gallery plugs prior to installation 01 26 Basic Engine 01 26 A SE A AR A A A A A A A A A A Ria REMOVAL AND INSTALLATION Continued Installation 1 Install new camshaft bearings Make sure that the oil holes in the bearings and cylinder block are aligned The splits in the bearings should be upwards and outwards at 45 degrees to the vertical CAMSHAFT BEARING 2 Install a new crankshaft rear oil seal using Tool 21 0594 3 Position a new gasket to the rear oil seal carrier using an oil resistant sealer at the ends Install the carrier on the cylinder block and tighten the bolts evenly to specification 4 Locate the flywheel squarely on the crankshaft flange Tighten the attaching bolts to specification 5 Install the camshaft and related parts following the appropriate procedures in this section Oil Pump The oil pump and filter assembly is bolted to the right side of the cylinder block and can be removed with the engine in place Removal 1 Place a drain pan under the oil pump 2 Remove the oil filt
124. ont bearing which is pressed on the rotor mark for assembly shaft it must first be removed from the front housing It is 2 Remove retaining nut lockwasher spacer pulley retained in the housing by a snap ring which is accessible spacer dish washer fan and fan spacer from the front when the pulley and fan are removed NOTE Observe position and direction of spacer and 1 With a pair of snap ring pliers squeeze the ears of the dished washer between pulley and fan snap ring together 3 Remove regulator and brush holder 2 Rock the snap ring out of its groove Remove four through bolts 5 Separate the front housing and rotor from the stator and rear housing 6 Press rotor out of front housing 7 Remove front bearing retainer and bearing 8 Support rear bearing with a large washer incorporating a cut out to accommodate the rotor shaft and press bearing from shaft 9 Remove rectifier diode assembly retaining screws and lift out stator and rectifier assembly 10 Unsolder stator to rectifier connections using a pair of pliers as a heat sink to reduce heat spread to diodes 3 Press or tap the rotor shaft and bearing out of the front housing e QA Front or Rear Bearing Removal CONNECTIONS Remove the bearing from the shaft with a suitable puller and adapter 04 15 Charging System 04 15
125. or a minimum of 30 minutes at 1200 rpm or until the engine is at normal operating temperature Turn the ignition switch off then remove all the spark plugs 2 Setthe carburetor throttle plates and choke plate in the wide open position 3 Install a compression gauge in No 1 cylinder 4 nstall an auxiliary starter switch in the starting circuit Using the auxiliary starter switch crank the engine with the ignition switch off at least 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 as was required to obtain the highest reading on the No 1 cylinder Test Conclusion The indicated compression pressures are considered normal if the lowest reading cylinder is within 7596 of the highest Refer to the following example Seventy five percent of 140 the highest cylinder reading is 105 Therefore cylinder No 7 being less than 75 of cylinder No 3 indicates an improperly seated valve or worn or broken piston rings If one or more cylinders read low squirt approximately 15 ml one tablespoon of engine oil on top of the pistons in the low reading cylinders Repeat compression pressure check on these cylinders 1 If compression improves considerably the piston rings are at fault 2 f compression does not improve valves are sticking or seat ing poorly 3 If two adjacent cylinders
126. or printing Power Products Division GRI reserves the right to discontinue models at any time or change specifications or design without notice and without incurring obligation NOTE The recommendations and suggestions contained in this 01 1 Basic Engine 01 1 E IL UILEILLLT ILLIVLIUILLLUSU AXDL E cBUL GLeELLGCLECL ELACPNULLILULULIULILIULt tuuuo4M 1 BuU L GAtU UIdAGUUoreUv ie SECTION TITLE PAGE BASIC 01 1 IGNITION SYSTEM DISTRIBUTORLESS 02 1 FUEL SYSTEM 03 1 EMISSION CONTROL SYSTEM 03A 1 CHARGING SYSTEM 04 1 SECTION TITLE PAGE STARTING SYSTEM 05 1 GOVERNOR 06 1 COOLING SYSTEM 07 1 SPECIFICATIONS 08 1 SECTION 01 Basic Engine SUBJECT PAGE IDENTIFICATION 01 3 DESCRIPTION 01 4 DIAGNOSIS AND TESTING 01 6 Camshaft Lobe Lift 01 6 Compression Test 01 6 Compression Gauge Check 01 6 Test Conclusion 01 6 Crankshaft End 01 7 Flywheel Face Runout
127. ould be run next to remove any surface charge prior to determining the state of charge of a maintenance free battery Capacity Test A high rate discharge tester Rotunda Battery Starter Tester 02 0204 or equivalent in conjunction with a voltmeter is used for this test 1 Turn the control knob on the Battery Starter Tester to the OFF position 2 Turn the voltmeter selector switch to the 20 volt position and test selector switch to AMP 3 Connect both positive test leads to the positive battery post and both negative leads to the negative battery post The voltmeter clips must contact the battery posts and not the high rate discharge tester clips Unless this is done the actual battery terminal voltage will not be indicated 4 Turn the load control knob in a clockwise direction until the ammeter reaches the applicable discharge rate specified in the discharge rate table 5 With the ammeter reading the required load for 15 seconds note the voltmeter reading Avoid leaving the high discharge load on the battery for periods longer than 15 seconds If the voltmeter reading is above the minimum specified in the table with the test equipment for that temperature the battery has a good output capacity and will readily accept a charge if required Check the state of charge If the voltage reading obtained during the capacity test is below the minimum specified in the table check the state of charge 04 6 Char
128. park 06 02 8 Ignition Coil Driver 02 4 Ignition 02 8 Sensor 02 4 Ignition Wires 7 02 8 Cranking Mode 02 4 Spark Plug Inspection Chart 02 9 Run Mode 02 4 DIS Engine Harness Checks 02 10 Transient 02 4 Spark 02 10 Overspeed Mode 02 4 Engine Coolant Temperature SERVICE ADJUSTMENTS AND CHECKS 02 5 Sensor Characteristics 02 10 REMOVAL AND INSTALLATION 02 6 Wiring Harness Circuit Ignition 02 6 Identification F4JL 14305 AA 02 12 Engine Speed Sensor 02 6 Wiring Harness Circuit Engine Coolant Temperature Sensor 02 7 Identification F4JL 14305 BA 02 14 02 2 Ignition System Distributorless 02 2 A A A E A a A BLANK 02 3 Ignition System Distributorless 02 3 DESCRIPTION AND OPERATION WARNING e HIGH VOLTAGE PRODUCED BY A DISTRIBUTORLESS IGNITION SYSTEM IS HIGHER THAN FOR A CONVENTIONAL
129. pecifications replace the nut s Check the rocker arm pad and fulcrum seat for excessive wear cracks nicks or burrs Push Rods Cleaning Clean the push rods in a suitable solvent Blow dry the push rod with compressed air Inspection Check the ends of the push rods for nicks grooves roughness or excessive wear The push rods can be visually checked for straightness while they are installed in the engine by rotating them with the valve closed They also can be checked with a dial indicator If the push rod is visibly bent it should be replaced Cylinder Heads Cleaning With the valves installed to protect the valve seats remove deposits from the combustion chambers and valve heads with a scraper and a wire brush Be careful not to damage the cylinder head gasket surface After the valves are removed clean the valve guide bores with a valve guide cleaning tool Use cleaning solvent to remove dirt grease and other deposits Clean all bolt holes Remove all deposits from the valves with a fine wire brush or buffing wheel Inspection Check the cylinder head for cracks and inspect the gasket surface for burrs and nicks Replace the head if it is cracked The following inspection procedures are for a cylinder head that is to be completely overhauled For individual repair operations use only the pertinent inspection procedure When a cylinder head is removed because of gasket leaks check the flatness of the cylind
130. plug 4 Connect battery ground lead Start engine and check Coil operation Engine Speed Sensor Removal 1 Disconnect battery ground cable 2 Disconnect multiplug from sensor Remove engine speed sensor one screw MULTIPLUG LH RETAINING BOLT UY TE Q 02 7 Ignition System Distributorless 02 7 REMOVAL AND INSTALLATION Continued Installation 1 2 3 Fit engine speed sensor and secure with screw Refit sensor multiplug Connect battery ground cable Engine Coolant Temperature Sensor Removal 1 Disconnect battery and release cooling system pressure WARNING WHEN RELEASING SYSTEM PRESSURE COVER CAP WITH A THICK CLOTH TO PREVENT COOLANT SCALDING Place a clean drain tray below engine under radiator drain plug and remove drain plug To assist draining remove radiator cap Remove temperature sensor multiplug located below the intake manifold To remove multiplug pull on multiplug do not pull on wiring Unscrew sensor from intake manifold Installation 1 Install sensor into inlet manifold do not overtighten sensor Connect multiplug ensuring that locking tabs snap into position Replace radiator drain plug and refill system with correct solution Remove rubber blanking cap on water outlet When coolant is evident refit blanking cap Fill container to maximum mark allowing time for air in system to bubble through Install radiator cap Conne
131. r 6 Remove the spark plugs 7 Suitably support the appropriate valve with air pressure 8 Compress the valve spring using special service tool Remove the valve spring retainer locks Release the spring compressor remove the valve spring retainer and the valve stem oil seal 01 22 REMOVAL AND INSTALLATION Continued Installation 1 Cover the valve grooves with plastic tape slide the new seal onto the valve stem remove the tape NOTE The exhaust valves are fitted with umbrella type seals The intake valves have the positive guide mounted seals which must be pressed on with a special service tool 2 Position the valve spring and retainer over the valve stem 3 Compress the valve spring using the special service tool Position the valve spring retainer locks in the valve stem grooves and slowly release the spring to engage the locks in the retainer Remove the air hose and adapter 4 Lubricate both ends of the push rods with Lubriplate or equivalent and install them in their respective bores Install the rocker arm shaft assembly to the cylinder head locating the push rods on the adjusting screws Tighten the bolts evenly to specifications 5 Adjust valve clearances to specification 6 Install the rocker cover with a new gasket and torque the attaching screws to specification 7 Install the spark plugs 8 Locate the spark plug leads in the rocker cover clip and reconnect them to their respec
132. r a wire brush to clean pistons Clean the ring grooves with a ring groove cleaner Make sure the oil ring slots or holes are clean PISTON RING GROOVE CLEANER Inspection Carefully inspect the pistons for fractures at the ring lands skirts and pin bosses and for scuffed rough or scored skirts If the lower inner portion of the ring grooves has a high step replace the piston The step will interfere with ring operation and cause excessive ring side clearance opongy eroded areas near the edge of the top of the piston are usually caused by detonation or pre ignition A shiny surface on the thrust surface of the piston offset from the centerline between the piston pin holes can be caused by a bent connecting rod Replace pistons that show signs of excessive wear wavy ring lands or fractures or damage from detonation or pre ignition Check the piston to cylinder bore clearance by measuring the piston and bore diameters Refer to the specifications for the proper clearance Refer to Cylinder Block Inspection for the bore measurement procedure Measure the OD of the piston with micrometers approximately 57 2 mm 2 1 4 inches below the dome and at 90 degrees to the piston pin bore Check the ring side clearance Replace piston pins showing signs of fracture etching or wear Check the piston pin fit in the piston and rod Refer to Piston and Connecting Rod Assembly Check the OD of the piston pin and the ID of the pin bore i
133. r with an oil resistant sealer at the ends align the front cover with the crankshaft pulley and tighten the bolts evenly to specification 9 Position a new gasket on the block flange using an oil resistant sealer compound at each end Position the end seals chamfered ends into the groove again using an oil resistant sealer at the ends and install the oil pan Tighten the oil pan bolts to the correct torque FOLLOWING FIRST THE ALPHABETICAL THEN THE NUMERICAL SEQUENCES SHOWN 10 Install the dipstick 11 Install the crankshaft pulley aligning the pulley slot with the crankshaft key Tighten the pulley attaching bolt to specification 12 Right the engine on stand 19 Position a new gasket on the oil pump mounting flange and install the oil pump and filter assembly Tighten the attaching bolts to specification 14 Position a new gasket to the fuel pump flange and insert the rocker arm through the slot in the block wall so that the arm lies on the camshaft eccentric Secure the fuel pump to the cylinder block with two washers and bolts tightening the bolts evenly to specifications 15 Lubricate push rod ends valve stem tips and rocker pads with Lubriplate or equivalent Install the push rods in their respective bores and install the rocker arm shaft assembly making sure that the cupped ends of the push rods engage the adjusting screws Tighten the rocker arm shaft attaching bolts evenly to specification 16 Adjust t
134. rating temperature 1 Loosen the locknut on the high speed stop screw 2 Disengage engine load 3 Slowly pull the throttle to desired maximum engine speed 4 Adjust the high speed stop screw on the governor to attain the desired maximum engine speed Do not exceed the recommended maximum rpm 5 Tighten the locknut Spread or Sensitivity Proper governor operation requires a difference between full load and no load governed speed Too small an rpm spread between the two speeds will cause governor hunting and surging Too large a spread will cause low response For this governor normal rpm spread is approximately 250 rpm with the full load speed range of 2000 2800 rpm Increase Spread 1 With the engine running under no load at maximum governed speed loosen the locknuts and adjust the screw to move the spring away from the lever hub Tighten the locknuts 2 Recheck governor operation under full load and no load conditions to determine if operation is stabilized and sensitivity is satisfactory 3 Readjust the governor high speed stop screw to maintain the correct high speed under load 06 5 Governor 06 5 ADJUSTMENTS Continued HIGH SPEED SPREAD ADJUSTMENT ADJUSTMENT GOVERNOR THROTTLE SE LEVER a8 Ve LOW SPEED ADJUSTMENT NO LOAD SURGE ADJUSTMENT SCREW Decrease Spread No Load Surge 1 With the engine under no load at maximum governed The no load surge adjustment is set at the factory and sp
135. rburetor and actuator are integrated into one unit The carburetor is a Zenith model 33 offered with either a manual or automatic choke It is spring loaded to keep carburetor at its minimum fuel position when no power is applied The feature causes the carburetor to go fully closed in the event of governor power failure The rotary actuator is mounted directly to the end of the throttle shaft This feature eliminates any need for throttle linkage The actuator is electrically connected to the controller through a two wire Packard connector If the governor is used with any other fuel system such as LPG then a linear actuator is available 06 8 Governor 06 8 ELECTRONIC DIAGNOSIS AND TESTING This governor system is comprised of three major components the carburetor actuator and controller The objective of this document is to help a technician identify which component is creating a problem so it can be fixed or replaced CONDITION POSSIBLE SOURCE ACTION l Governor 1 Battery power is not Remove the connector from the controller and with a voltmeter check for appears supplied to controller battery power across pins A amp B of the wiring harness connector dead If battery power is not present check wiring to the controller 2 Controller is not If the controller is connected to an engine with a distributor pins C amp D receiving the speed should both be connected to the negative side of the coil or the signal tachome
136. rect grade of engine oil and install the dipstick 6 Start the engine and check for oil leaks Flywheel Ring Gear The flywheel ring gear is located in a retention groove and can be removed by cutting between two adjacent teeth with a hacksaw and splitting the gear with a chisel In no circumstances should pressure be applied in an attempt to remove the ring gear for repositioning on the flywheel 01 27 Basic Engine 01 27 lt REMOVAL AND INSTALLATION Continued When installing the ring gear it must be heated evenly to a temperature of 260 to 280 C 500 535 F Do not exceed 290 C 554 F as the ring gear wear resistant properties will be destroyed If the ring gear is to be heated by direct flame place the ring gear on a metal plate approximately 2 to 3 mm 079 118 in thick and heat plate from below in the area of the ring gear until it reaches the required temperature The correct temperature can be detected by using a special type of temperature sensitive crayon Fit the ring gear with the chamfers on the leading faces of the gear teeth relative to the direction of rotation Allow the ring gear to cool naturally in air Do not quench Crankshaft Rear Oil Seal Removal 1 Remove the P T O or transmission clutch amp pressure plate 2 Remove the flywheel 3 Remove the rear oil seal using tool 21 096 Installation 1 Lubricate the sealing lip of the new seal with engine oil and push new seal in
137. refinished Before any cylinder is refinished all main bearing caps must be in place and tightened to the proper torque so that the crankshaft bearing bores will not become distorted from there finishing operation Hefinish only the cylinder or cylinders that require it All pistons are the same weight both standard and oversize therefore various sizes of pistons can be used without upsetting engine balance Refinish the cylinder with the most wear first to determine the maximum oversize If the cylinder will not clean up when refinished for the maximum oversize piston recommended replace the block Refinish the cylinder to within approximately 0 04 mm 0 0015 inch of the required oversize diameter This will allow enough Stock for the final step of honing so that the correct surface finish and pattern are obtained For the proper use of the refinishing equipment follow the instructions of the manufacturer Only experienced personnel should be allowed to perform this work Use a motor driven spring pressure type hone at a speed of 300 500 rpm Hones of grit sizes 180 220 will normally provide the desired bore surface finish of 15 32 RMS When honing the cylinder bores use a lubricant mixture of equal parts of kerosene and SAE No 20 motor oil Operate the hone in such a way to produce a cross hatch finish on the cylinder bore The cross hatch pattern should be at an angle of approximately 30 degrees to the cylinder bore After the final opera
138. rotor assembly and the housing Measure the clearance rotor end play between the straight edge and the rotor and outer race The outer race shaft and rotor are replaceable only as an assembly Check the drive shaft to housing bearing clearance by 01 19 Basic Engine 01 19 A DEE EE A A A a cc cc su i 7 CAE E e AS REMOVAL AND INSTALLATION Valve Rocker Arm Cover Rocker Arm and or Shaft Removal 1 Remove the air cleaner from the carburetor 2 Disconnect the spark plug leads remove them from the clip on the rocker cover and position aside 3 Remove the rocker cover attaching screws remove the rocker cover and discard the gasket 4 Remove the rocker arm shaft attaching bolts evenly and lift off the rocker arm shaft assembly 5 Remove the cotter pin from one end of the shaft and slip the flat washer crimped washer and second flat washer off the shaft The rocker arm shaft supports rocker arms and springs can now be removed from the shaft 6 Remove the plugs from the rocker shaft ends by drilling a hole in one plug Insert a long rod through the drilled plug and knock the opposite plug out of the shaft Remove the drilled plug in the same manner 7 Clean the component parts of the shaft assembly in any suitable degreasing fluid OIL HOLE FLAT Installation 1 Refit new plugs to the rocker shaft ends 2 Assemble the rocker arm shaft The bolt hole in the rocker arm shaft support must be on the sa
139. spark advance is fixed at 10 degrees BTDC up to 250 RPM Run Mode In this mode the RPM is above 250 and the spark advance is calculated in three main sections which are added together The ICM sections are Base Spark Advance BSA plus Spark Advance Offset Temperature SAOT plus Spark Advance Offset Detonation ECT SAODE The final spark advance is then corrected for propagation delays and finally the spark advance is limited by the System ranges and the spark slew rate limited The Base Spark Advance BSA is calculated by the ICM looking at speed and load inputs The Spark Advance Offset Temperature SAOT will change ignition timing from the function of Engine Coolant Temperature ECT This allows the spark advance to be altered during cold engine conditions to improve starting and operation Spark Advance Offset Detonation ECT SAODE the ignition timing Is offset as a function of Engine Coolant Temperature ECT This allows the spark advance to be reduced during hot engine conditions to avoid detonation and allow base spark advance to be calibrated near to the best performance curve Transient Mode This function is to provide detonation protection when the engine load is increased rapidly by fast opening of the throttle plate Rapid increases in engine load are determined by large changes in consecutive Manifold Absolute Pressure MAP values to the ICM Overspeed Mode If the instantaneous engine speed is greater t
140. ssemblies into their respective bores with the arrow on top of the piston pointing toward the front of the block Install the connecting rod bearings and check the clearances as detailed in the Overhaul Section Oil the hearings and journals with engine oil and install the connecting rod bearing caps Tighten the bolts to specification Check the connecting rod side clearance Rotate the engine to the inverted position Replace the oil pump pick up tube and screen Press the tubes to the full depth of the counter bored holes Position the flywheel squarely on the crankshaft flange Tighten the attaching bolts evenly to specification Install the crankshaft pulley and torque the bolt to specification Coat the block surface and the oil pan gasket surface with oil resistant sealer Position the oil pan gaskets on the cylinder block Position the end seals with the chamfered ends into the grooves again using an oil resistant sealer at the mating areas Position the oil pan and tighten the bolts evenly to specification following first the alphabetical then the numerical sequences shown Right the engine in the stand Position a new gasket on the water pump and install the pump on the block Position the generator and brackets to the block and install mounting bolts Position a new oil pump mounting gasket to the block using oil resistant sealer Position the pump to the block install the mounting bolts and torque to specific
141. sting screws Tighten the bolts evenly to specifications Adjust the valve clearances Install the rocker arm cover Connect the exhaust pipe Connect the distributor vacuum advance line the throttle rod and choke cable to the carburetor 9 Connect the wire to the temperature gauge sender unit NO q 10 Connect the water outlet and crankcase ventilation hoses to the intake manifold 11 Locate the thermostat in its bore in the cylinder head and install the gasket and thermostat housing 12 Refill the cooling system 13 Position governor and mounting bracket to cylinder head and install bolts 14 Loosen governor adjusting bolts and position drive belt to governor Adjust belt to specification and tighten bolts 15 Connect the throttle linkage to the governor 16 Install the alternator bracket mounting bolt to cylinder head 17 Connect the ignition wires to the spark plugs in the correct firing order 18 Install the air cleaner to the carburetor 19 Adjust the carburetor idle speed and mixture settings 20 Check governor operation adjust as required 01 21 REMOVAL AND INSTALLATION Continued Valve Spring Retainer and Stem Seal Cylinder Head Removed Removal 1 Remove the exhaust manifold and the spark plugs 2 Compress the valve spring with a valve spring compressor Remove the valve spring retainer locks release the spring and remove the spring and retainer 3 Remove the seal and
142. t Bearing Retainer 04 14 Key Oll Check ou ovra saa os 6 04 7 Front or Rear Bearing Removal 04 14 Regulator Sense Voltage 04 7 Front Bearing Installation 04 15 External Circuit Tests 04 8 Pressing Front Bearing Onto Shaft 04 15 Field Voltage Test 04 8 ASSOmbDIV iaa 04 15 Initial Excitation Circuits 04 9 Output Voltage Test 04 16 04 2 Charging System 04 2 04 3 Charging System 04 3 A A MEME A A A nc RES A Ga A GUESS DESCRIPTION AND OPERATION Generator from the generator regulator system to the rotating field of The generator charging system is a negative ground the generator through two brushes to two slip rings System and consists of an generator a regulator a charge The generator produces power in the form of alternating indicator a storage battery and associated wiring current The alternating current is rectified to direct current The present VSG range uses a Prestolite 37 amp or by six diodes The generator regulator automatically 51 amp generator These units have a self contained adjusts the generator field current to maintain the generator regulator mounted directly to the generator case The output voltage within prescribed limits to correctly charge generator is belt driven from the engine Curre
143. t when the key is turned Carefully probe the yellow wire terminal in the pigtail connector for the regulator excitation lead Battery voltage should be present ON and the other warning lights and gauges respond normally 2 Regulator Input Test VOLTMETER This test measures excitation supply voltage to the regulator Perform this test if the field terminal voltage is less than 1 5 volts 04 10 Charging System 04 10 E e DIAGNOSIS AND TESTING Continued 3 If battery voltage is not present check the circuit from the ignition switch through the alternator field fuse If so equipped to the pigtail connector for the regulator excitation lead If battery voltage is present at the yellow regulator lead but the regulator output is low replace the regulator Generator Brush Check If the field terminal voltage is more than 3 0 volts undercharging may be caused by high resistance in the generator field circuit even though generator output was increased in the regulator bypass test Even if field circuit resistance is normal it may be a combination of low field coil resistance due to a partially shorted coil and high brush resistance 1 Disconnect the battery ground cable at the battery 2 Remove the regulator housing 3 Remove the field wire from the field terminal 4 Remove the generator brush holder assembly BRUSH ASSEMBLY 5 Inspect the brushes for abnormal wear damage dirty cont
144. ter output NOTE This controller If the controller is connected to an engine with a DIS ignition pin C should receives its speed signal be connected to one of the two tachometer outputs and pin D should be from the ignition connected to the other tachometer output The DIS ignition utilizes two coils NOTE Do not short the tach leads doing so could damage the spark controller Using an ohmmeter check continuity from pins C amp D to the termination points If continuity is not present repair the wiring 3 Actuator fails to Remove the 2 pin connector at the actuator With a DC voltmeter check operate between the purple wire and chassis battery ground The voltmeter should read 12 volts 2 volts If the voltage is low disconnect the 8 pin connector from the controller and check continuity between the wiring harness pins E amp F to their respective actuator terminals If there is no continuity check for openings in the wires Using a voltmeter check for battery voltage from controller terminal E to chassis battery ground If battery power is not found replace the controller and check the actuator and actuator wiring for grounds and shorts NOTE Check wiring before replacing controller Bad wiring might destroy the new controller Check continuity across actuator wires 2 ohms 5 ohm should be measured Check the continuity of actuator wires to the case The ohms measured should be 1M or greater If these values
145. th the lower vacuum signal the choke coil is able to move the choke valve towards the closed position The amount it is closed depends on how much vacuum drop occurs during acceleration Automatic Choke Setup Procedure The automatic choke assembly contains a bimetallic thermostatic coil spring which regulates the choke plate opening at different temperatures and a vacuum piston which regulates choke pull off The piston exerts a pull against the closing action of the thermostatic spring This helps to open the choke after the engine starts and controls the position of the choke plate depending on engine load Adjusting the Choke Pull Off 1 Remove the choke housing cover 2 Remove the cork insulation strip 3 Remove the inner plate 4 Position the sliding pin in the slip link slot away from the piston 5 Place a 9 52 mm 0 375 inch gage pin between the top of the choke plate and the inside of the air intake SET OPENING TO 9 52 MM 0 375 INCH GAUGE PIN 03 14 Fuel System ZENITH MODEL 33 CARBURETOR Continued 6 Adjust the stop screw until the slip link starts to move 2 away from the SLIDING PIN 7 Tighten the lock nut to 0 9 1 4 Nem 8 12 Ib in to limit the travel of the piston so that the choke plate is pulled to the gage dimension 8 Install the inner plate 9 Install the cork insulation strip 10 Install the choke housing cover Adjusting the Thermostatic Spring 1 Manualiy
146. that no current is flowing through the ammeter rheostat at maximum counterclockwise position Determine the exact reading on the voltmeter BATTERY BENCH TEST 05 6 Starting System 05 6 TESTING Continued Armature Open Circuit Test An open circuit armature may sometimes be detected by ARMATURE GROUNDED CIRCUIT TEST examining the commutator for evidence of burning A spot burned on the commutator is caused by an arc formed every time the commutator segment connected to the open circuit winding passes under a brush Armature and Field Grounded Circuit Test The test will determine if the winding insulation has failed permitting a conductor to touch the frame or armature core To determine if the armature windings are grounded make the connection as shown If the voltmeter indicates any voltage the windings are grounded Grounded field windings can be detected by first disconnecting the grounded end of the winding where it terminates at the frame then making the connections as shown If the voltmeter indicates any voltage the field windings are grounded FIELD GROUNDED CIRCUIT TEST 05 7 Starting System REMOVAL AND INSTALLATION Removal 1 Disconnect the battery ground cable 2 Disconnect the cable and wires at the terminals on the solenoid 3 Remove the starter mounting bolts and remove the starter assembly 05 7 Installation 1 Position the starter assembly to the starter mou
147. the flywheel and back to its original position Overhaul Disassembly A ARMATURE B ARMATURE RETURN SPRING C SOLENOID BODY 1 Remove the hex nut 2 Remove the flat washer 3 Remove the spring 05 12 Starting System 05 12 e A A A A A AA A A A AS OVERHAUL Continued Remove the spring retainer If the armature has been partially or totally removed Remove the pinion from the starter body make sure the brushes are properly seated before re installing the armature Remove the through bolts Remove the drive end plate 5429 gU BRUSHES NOT SEATED PROPERLY Assembly 1 Install the drive end plate onto the starter body Make sure the notch in the drive end plate matches the raised crimp on the inside edge of the starter body This alignment is also shown on the outside of the starter by a raised line on the drive end plate and a corresponding mark on the starter body BRUSHES IN PLACE 05 13 Starting System 05 13 OVERHAUL Continued 2 Install the through bolts Install the pinion Install the spring retainer Install the spring Install the flat washer Install the hex nut DU Qr Oy P coe NOTE The through bolts pass between two powerful magnets and will be attracted to them A firm side to side wiggle near the heads of the bolts may be necessary in order to engage the bolts with their threaded holes 06 1 Governor 06 1 A SECTION TITLE PAGE BASIC ENGINE
148. tion in either of the two refinishing methods described and prior to checking the piston fit thoroughly clean and oil the cylinder walls Mark the pistons to correspond to the cylinders in which they are to be installed When the refinishing of all cylinders that require it has been completed and all pistons are fitted thoroughly clean the entire block and oil the cylinder walls Repairing Sand Holes or Porous Engine Castings Porosity or sand hole s which will cause oil seepage or leakage can occur with modern casting processes A complete inspection of engine and transmission should be made If the leak is attributed to the porous condition of the cylinder block or sand hole s repairs can be made with metallic plastic part No 6 2 19554 Do not repair cracks with this material Repairs with this metallic plastic must be confined to those cast iron engine component surfaces where the inner wall surface is not exposed to engine coolant pressure or oil pressure For example 1 Oylinder block surfaces extending along the length of the block upward from the oil pan rail to the cylinder water jacket but not including machined areas 2 Lower rear face of the cylinder block 3 Intake manifold casting 4 Cylinder head along the rocker arm cover gasket surface The following procedure should be used to repair porous areas or sand holes in cast iron 1 Clean the surface to be repaired by grinding or rotary filing to a clea
149. tions 08 7 SPECIFICATIONS Continued ENGINE MODEL YEARS 1993 Ignition System Firing Order 1 2 4 3 DIS Y with 87 Octane Unleaded Gasoline 1 1L and 1 3L Fixed Spark Plugs AGRF 22 C1 Gap 1 0 mm 0 040 in Distributorless Type Coil Type High Output DIS Coil Coil Output 37 0 KV Minimum Primary Resistance at the Coil Tower 0 50 1 00 Ohm High Tension Leads 30 000 Ohms Max per Lead Belt Tension Alternator New 351 449 N 79 101 lbs Used Reset Minimum 249 334 56 75 lbs Governor New 334 N 75 lbs Used Reset Minimum 222 N 50 lbs Fuel System 1 1L and 1 3L Unleaded 1986 87 Octane Pump Delivery Pressure 0 24 0 38 Bar 3 5 5 5 psi Starter Current Draw Normal Engine Cranking 175 amps Maximum Load at Stall 410 amps No Load 35 to 55 amps All specifications are in millimeters inches For Conversion Factors see page 8 9 Distributorless Ignition System 08 8 Specifications 08 8 SPECIFICATIONS Continued SPECIAL SERVICE TOOLS Installer Valve Stem Seal Intake 21 007 Installer Crankshaft Seal Front 21 046 Timing Cover Installer Rear Crankshaft Seal 21 059A Remover Crankshaft Oil Seals 21 096 Valve Spring Compressor T81P 6513 A Call Owatonna Tool Company 1 800 533 5338 Ask for Ford Order Desk CONVERSION FACTORS Kilogram Force x 2 2046 Ft lbs Torque TORQUE SPECIFICATIONS Connecting Rod Bolts x HE Rear Oi
150. tive plugs 9 Install the air cleaner assembly Water Pump Removal 1 Drain the cooling system 2 Loosen the governor adjusting bolts and remove drive belt 3 Loosen the alternator adjusting and mounting bolts Pivot the alternator towards the engine and remove the drive belt 4 Remove the fan and pulley attaching bolts Remove the fan and pulley 5 Loosen the clamps and remove the lower hose from the water pump 6 Remove bolts securing water pump to cylinder block and remove the pump and gasket Installation 1 Make sure that the mating faces of cylinder block and pump are clean 2 Position the pump and gasket on the cylinder block and secure with the attaching bolts 3 Position lower hose on water pump and tighten the clamp 4 Position the pulley and fan and secure with bolts Torque the bolts to specification Basic Engine 01 22 Position drive belt over crankshaft fan and alternator pulley and adjust the belt tension to specifications using Tool No T63L 8620 A Tighten the alternator mounting and adjusting bolt to specifications Position the governor drive belt to governor and fan pulley Adjust the belt to specification Tighten adjusting bolts Refill radiator and install cap Start the engine and check for leaks Cylinder Front Cover and Timing Chain or Crankshaft Sprockets Removal 1 Drain the engine coolant by opening the drain cock on the radiator and removing the drain plug in th
151. to seal carrier using tool 21 059A 2 Locate the flywheel squarely on the crankshaft flange Tighten the bolts evenly to specification 3 Install the P T O or transmission clutch and pressure plate Pistons and Connecting Rods Removal 1 Drain the cooling system and the crankcase 2 Refer to Cylinder Head Removal in this Section and remove the cylinder head and related parts 3 Remove the oil pan following the procedure under Oil Pan Removal in this Section 4 Turn the crankshaft until the piston to be removed is at the bottom of the stroke and place a cloth on the piston dome to collect the cuttings Remove any ridge and or deposits from the upper end of the cylinder bore with a ridge cutter Follow the instructions furnished by the tool manufacturer Never cut into the ring travel area in excess of 0 8 mm 1 32 inch when removing ridges 5 sure all the connecting rod caps are marked so that they can be installed in their original positions Remove the connecting rod cap 6 Push the connecting rod and piston assembly out the top of the cylinder with the handle end of a hammer Avoid damage to the crankshaft journal or the cylinder wall when removing the piston and rod Installation 1 Referto Cylinder Block Refinishing in this Section 2 Oil the piston rings pistons and cylinder walls with light engine oil 3 Be sure to install the pistons in the same cylinders from which they were removed
152. tuck closed leaking valve diaphragm restrictions in flow passages EGR disconnected or a problem in the vacuum source On engines with high spark advance detonation is serious enough to destroy an engine Diagnose the condition by performing the tests in this section HAND VACUUM CAUTION Improper use of leaded gasoline can plug up an EGR valve with deposits that restrict flow Poor Fuel Economy This is an EGR condition only if it is related to detonation or some other symptom of restricted or zero EGR flow EGR System Gas Flow Test The exhaust gas flow test must be made with the engine idling and hot It tells you if the gas flow passages are open 1 Remove the vacuum line from the valve diaphragm Plug the line to prevent a vacuum leak or dirt entry 2 Attach a hand vacuum pump to the valve diaphragm 3 Apply 15 inches of vacuum to the valve a little at a time If the gas flow is okay the engine will begin to idle roughly at some point or it may stall If the idle doesn t change there is a restricted passage in the valve or the spacer Remove the valve for inspection If the valve diaphragm fails to hold vacuum install a new EGR valve Diaphragm Leak Test The diaphragm leak test can be performed with the engine off 1 Attach a hand vacuum pump to the vacuum nipple of the EGR valve 2 Apply eight inches of vacuum and trap hold it The diaphragm must hold 7 8 inches of vacuum for at least 30 s
153. two starters available in the VSG range Most engines are equipped with the Bosch electromagnetic field starter which is detailed in this section Some engines are equipped with the United Technologies permanent magnet starter This starter features an inertially actuated pinion gear which is described later in this section The electromagnetic field starter is a four pole four brush motor with a series field and a solenoid operated roller clutch drive The solenoid assembly is mounted to a flange on the starter drive housing The entire shift lever mechanism and the solenoid plunger are enclosed in the drive housing thus protecting them from exposure to dirt and road splash The solenoid incorporates two windings a pull in winding and a hold in winding Together they provide sufficient magnetic attraction to pull the solenoid plunger into the solenoid Engine cranking occurs when the starter solenoid on the starter is energized through the starter control ignition switch When energized the solenoid shifts the starting motor pinion into mesh with the engine flywheel ring gear Simultaneously the main contacts of the solenoid are closed and battery current is directed to the starting motor causing the armature to rotate After the engine starts the starter drive is disengaged when the ignition switch is returned from the start to the ON or RUN position This opens the circuit to the starter solenoid and the solenoid return spri
154. usion of armature shaft at commutator bearing end Install sufficient shims on armature end play when C clip is in place Fit C clip Starting System 05 10 PINION AND RING GEAR WEAR PATTERNS MILLED CONDITION EXCESSIVE WEAR ON 2 OR 3 TEETH MILLED TOOTH METAL BUILD UP WILL NOT PERMIT ENGAGEMENT MILLED GEARS Place bearing cap seal in position on commutator housing smear a small quantity of lithium based grease on end of armature shaft and refit bearing cap securing with two screws FIELD WINDING LOOPS 10 LOCATION CUT OUTS Smear lithium based grease onto solenoid armature hook and then locate hook onto actuating arm in drive end housing Ensure solenoid armature return spring is correctly positioned and then guide solenoid body over armature Align body with drive end housing and install retaining screws 05 11 Starting System 05 11 OVERHAUL Continued 11 Reconnect field winding cable to solenoid and install Permanent Magnet Starter retaining nut Some engines in the VSG range are equipped with the United Technologies permanent magnet starter This starter has a pinion gear which is actuated by inertial force in place of a starter solenoid When the starter is energized inertia causes the pinion gear to move out along a spirally threaded shaft and engage the flywheel When the engine has started the starter motor is de energized and spring tension causes the pinion gear to move away from
155. ve in the pump body Position the end plate with the machined face toward the rotors and install the retaining bolts Coat the gasket on the oil filter with engine oil Position the filter to the pump housing Hand tighten the filter until the gasket contacts the face then advance it 1 2 turn 02 1 ignition System Distributorless 02 1 O PPP SECTION TITLE PAGE SECTION TITLE PAGE BASIC ENGINE 01 1 STARTING SYSTEM 05 1 IGNITION SYSTEM DISTRIBUTORLESS 02 1 GOVERNOR 06 1 FUEL SYSTEM 03 1 COOLING SYSTEM 07 1 EMISSION CONTROL SYSTEM 03A 1 SPECIFICATIONS 08 1 CHARGING SYSTEM 04 1 SECTION 02 Ignition System Distributorless SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION 02 3 DIAGNOSING AND TESTING DIS 02 8 Engine Speed and C S Position 02 3 DIS Diagnosis Equipment 02 8 Engine Load 02 4 DIS Diagnosing 02 8 Engine Temperature 02 4 DIS Cleaning and Inspection 02 8 Fuel Octane Level Adjustment 02 4 S
156. ve stem is flush with the top of the valve guide Mount a dial test indicator on the cylinder head by the valve to be checked Position the plunger of the dial test indicator on the edge of the valve head and measure the valve head movement by applying lateral pressure to the valve If the valve head movement is greater than the values given below the valve guide in question must be reamed using the appropriate reamer and a new oversize valve installed Maximum permissible valve head movement values for the above test procedure Intake valve Exhaust valve 0 50 mm 0 020 in 0 60 mm 0 024 in Check the springs for proper pressure at the specified spring lengths Tool 6513 DD Manually rotating the valve spring assemblies while installed in the engine must not be used to determine good and or bad valve springs Weak valve springs cause poor engine performance Replace any spring not within specifications APPLY TORQUE UNTIL CLICK 1S HEARD READ TORQUE WRENCH AND MULTIPLY READING VALVE CLUTCH SPRING TESTER TOOL 6513 DD VALVE SPRING SET KNOB TO SPRING A9077 1C 01 14 Basic Engine 01 14 O CLEANING AND INSPECTION Continued Check each spring for squareness using a steel square and a flat surface Stand the spring and square on end on the flat surface Slide the spring up to the square Revolve the spring slowly and observe the space between the top coil of the spring and the square The out of squ
157. w fuel pump pressure and volume A restricted fuel tank vent can cause low fuel pump pressure and volume and can result in collapsed inlet hoses or a collapsed fuel tank High or low pressure are the two most likely fuel pump troubles that will affect engine performance Low pressure will cause a lean mixture and fuel starvation at high speeds and excessive pressure will cause high fuel consumption and carburetor flooding Dirt accumulation in the fuel and air passages improper idle adjustments and improper fuel level are the major sources of carburetor troubles 03 5 Fuel System 03 5 FUEL PUMP Description A single action mechanical fuel pump is standard on this engine It is located on the right side of the engine and is driven by a lobe on the camshaft The pump is permanently sealed and is serviced by replacing the entire unit Diagnosis and Testing To determine that the fuel pump is in satisfactory operating condition tests for both fuel pump pressure and fuel pump capacity volume should be performed The tests are performed with the fuel pump installed on the engine and the engine at normal operating temperature at idle speed Before the tests make sure the replaceable fuel filter has been changed within the recommended maintenance mileage interval When in doubt install a new filter Pressure Tests Refer to the fuel pump specification and note the fuel pump pressure and capacity volume
158. xpel the fuel into the container while observing the time required to expel 0 5 liters one pint Close the restrictor 0 5 liters one pint or more of fuel should be expelled within the specified time limit 25 sec If the pump volume is below specifications repeat the test using an auxiliary fuel supply and a new fuel filter If the pump volume meets specifications while using the auxiliary fuel supply check for a restriction in the fuel supply from the tank and for the tank not venting properly 03 6 Fuel System REMOVAL AND INSTALLATION Fuel Pump Assembly 2 Removal 1 Disconnect the inlet and outlet lines at the fuel pump 2 Remove the pump attaching screws then remove the pump and the gasket Discard the gasket 3 Installation 1 Remove all the gasket material from the mounting 4 pad and pump flange Apply oil resistant sealer to both sides of a new gasket and to the threads on the 5 attaching bolts 03 6 Position the new gasket on the pump flange and hold the pump in position against the mounting pad Make sure the rocker arm is riding on the camshaft eccentric Turn engine over until the fuel pump eccentric is on the low side of the stroke Press the pump tight against the pad install the attaching screws and alternately tighten them to specification Connect the fuel inlet and outlet lines Operate the engine and check for leaks 03 7 Fuel System 03 7 A
159. y adjusting the travel of the pump spring Such adjustment is made possible by changing the length of the diaphragm protector in the end of the pump spring 03 10 Fuel System 03 10 ZENITH MODEL 33 CARBURETOR Continued 03 11 Fuel System 03 11 E ZENITH MODEL 33 CARBURETOR Continued Jon Screw amp L Washer Choke Plate Plate Choke Body Air Intake Cup Plug Shaft Hole Screw Intake Assembly Piston Vacuum Power Tube Well Filler Gasket Intake to Body Tube Discharge Venturi Hetainer Float Axle Assembly Float Axle Float Valve Power Jet Body Throttle Valve Fuel Cup Plug Shaft Hole Washer Main Jet Plug Seat Fuel Valve Plug Main Jet Washer Main Jet Plug Jet Main Plug Fuel Channel Welch Plug Idle Port Plug Idle Channel Spring Idle Adjusting Screw Screw Idle Adjusting Screw amp L Washer Throttle Plate Gasket Manifold Flange Not normally removed for service Dm 30 Plate Throttle Welch Plug Vacuum Spark Tube Vacuum Spark Seal Throttle Shaft Lever Shaft Throttle Screw Idle Stop Plug Throttle Body Gasket Pump Diaphragm Protector Diaphragm Spring Accelerator Pump Cover Accelerator Pump Screw Pump Cover 4 Required Assembly Check Valve Ball Pump Discharge Tube Well Weight Pump Ball Spring

vsg-4111413 engine service manual

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