194-303 LRG425 Service Manual

LRG-425
2.5 LITER
(153 CID)
INDUSTRIAL ENGINE SERVICE MANUAL
IMPORTANT SAFETY NOTICE

Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all
industrial engines as well as the personal safety of the individual doing the work. This Service Manual provides
general directions for accomplishing service and repair work with tested, effective techniques. Following them will
help assure reliability.
There are numerous variations in procedures, techniques, tools and parts for servicing equipment, as well as in the
skill of the individual doing the work. This Manual cannot possibly anticipate all such variations and provide advice
or cautions as to each. Accordingly, anyone who departs from the instructions provided in this Manual must first
establish that he compromises neither his personal safety nor the equipment integrity by his choice of methods, tools
or parts.
NOTES, CAUTIONS, AND WARNINGS

As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is
there for a specific purpose. NOTES give you added information that will help you to complete a particular
procedure. CAUTIONS are given to prevent you from making an error that could damage the equipment.
WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury. The
following list contains some general WARNINGS that you should follow when you work on the equipment.
Always wear safety glasses for eye protection.

Use safety stands whenever a procedure requires you to be under the equipment.
Be sure that the ignition switch is always in the OFF position, unless otherwise required by the
procedure.
Set the parking brake (if equipped) when working on the equipment. If you have an automatic
transmission, set it in PARK REVERSE (engine off) or NEUTRAL (engine on) unless instructed
otherwise for a specific operation. Place wood blocks (4 x 4 or larger) to the front and rear
surfaces of the tires to provide further restraint from inadvertent equipment movement.
Operate the engine only in a well ventilated area to avoid the danger of carbon monoxide.
Keep yourself and your clothing away from moving parts when the engine is running, especially the
fan and belts.
To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold,
tail pipe, catalytic converter and muffler.
Do not smoke while working on the equipment.
To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before
beginning to work on the equipment. Tie long hair securely behind the head.
Keep hands and other objects clear of the radiator fan blades. Electric cooling fans can start to
operate at any time by an increase in underhood temperatures, even through the ignition is in the
OFF position. Therefore, care should be taken to ensure that the electric cooling fan is completely
disconnected when working under the hood.
Introduction
In general, this manual covers the servicing of the engine and
associated standard equipment. In many cases, engines are
supplied with accessories and equipment that are unique to the
application. If service information is ever required on such unique
accessories or equipment it is suggested that Ford Power Products
be contacted. The proper information will either be forwarded or the
Service Technician will be advised where it can be obtained.
The information in this manual is grouped in sections according to
the type of work being performed. The various sections are indicated
in the index. In addition, each section is subdivided to include
topics such as diagnosis and testing, cleaning and inspection,
overhaul, removal and installation procedures, disassembly and
assembly procedures, and service specifications.
Special service tools called for by the procedures can be obtained by
calling:
1-800-ROTUNDA (1-800-768-8632).
The descriptions and specifications contained in this manual were in

effect at the time the book was released for printing. Ford Power
Products reserves the right to discontinue models at any time, or
change specifications or design, without notice and without incurring
obligation.
NOTE: The recommendations and suggestions contained in this
publication are made to assist the distributor in improving his
distributorship parts and/or service department operations. These
recommendations and suggestions do not supersede or override the
provisions of the Warranty and Policy Manual and in any cases
where there may be a conflict, the provisions of the Warranty and
Policy Manual shall govern.
Reroduction in any manner, in whole or in part, is prohibited without

The express permission in writing from:
Ford Power Products, Marketing Department.
TABLE OF CONTENTS
SECTION TITLE
PAGE
ENGINE SERVICE - GENERAL ................................................................................................01

ENGINE SERVICE 2.5L .........................................................................................................02
IGNITION SYSTEM ...................................................................................................................03
FUEL PUMP ..............................................................................................................................04
CARBURETOR..........................................................................................................................05
STARTER MOTOR ....................................................................................................................06
GOVERNOR ..............................................................................................................................07
COOLING SYSTEM...................................................................................................................08
GENERATOR ............................................................................................................................09
01-1
Engine Service - General
SECTION TITLE
01-1
PAGE
ENGINE SERVICE - General ................................................................................................................................ 01-01

ENGINE SERVICE - 2.5L ...................................................................................................................................... 02-01
IGNITION SYSTEM ............................................................................................................................................... 03-01
FUEL PUMP ......................................................................................................................................................... 04-01
CARBURETOR...................................................................................................................................................... 05-01
STARTER MOTOR................................................................................................................................................ 06-01
GOVERNOR.......................................................................................................................................................... 07-01
COOLING SYSTEM .............................................................................................................................................. 08-01
GENERATOR ........................................................................................................................................................ 09-01
SECTION 01 - Engine Service - General

SUBJECT
PAGE
DESCRIPTION ............................................................................................................................................................. 2
Introduction .............................................................................................................................................................. 2
Engine Identification Nameplate .............................................................................................................................. 2
DIAGNOSIS.................................................................................................................................................................. 3
Inspection................................................................................................................................................................. 3
Symptom Chart........................................................................................................................................................ 3
PCV System Malfunction ......................................................................................................................................... 5
Engine Oil Leak Check ............................................................................................................................................ 5
Compression Test.................................................................................................................................................... 7
Cylinder Leakage Test............................................................................................................................................. 8
Oil Leak and Valve Guide Seal Test........................................................................................................................ 8
Intake Manifold Vacuum Test .................................................................................................................................. 8
Oil Consumption Test ............................................................................................................................................ 10
Oil Pressure Test ................................................................................................................................................... 11
SERVICE PROCEDURES.......................................................................................................................................... 12
Camshaft Service................................................................................................................................................... 12
Connecting Rod Service ........................................................................................................................................ 14
Crankshaft Bearing Service ................................................................................................................................... 15
Crankshaft Service................................................................................................................................................. 18
Cylinder Block Service........................................................................................................................................... 20
Cylinder Head Service ........................................................................................................................................... 23
Engine Block Plug Service..................................................................................................................................... 31
Exhaust Manifold Service ...................................................................................................................................... 32
Hydraulic Valve Tappet/Adjuster Service............................................................................................................... 32
Intake Manifold Service.......................................................................................................................................... 34
Oil Pan Service ...................................................................................................................................................... 34
Piston Service........................................................................................................................................................ 34
SPECIAL TOOLS ....................................................................................................................................................... 38
01-2
01-2
Take added care to prevent scratching or gouging
DESCRIPTION
Introduction
This section covers various engine tests, adjustments,
service
procedures
and
cleaning/inspection
procedures.
Engine assembly and service
specifications appear at the end of Section 02.
For engine disassembly, assembly, installation,
adjustment procedures and specifications, refer to
Section 02.
Most Ford Power Product engines incorporate a
closed-type crankcase ventilation system. Other than
the crankcase ventilation system there are no exhaust
emission controls or engine/emission control systems
used with industrial versions of these engines.
aluminum sealing surfaces.
To maintain the required performance level, the fuel

system, ignition system and engine must be kept in
good operating condition and meet recommended
adjustment specifications.
Before replacing damaged or worn engine
components such as the crankshaft, cylinder head,
valve guide, valves, camshaft or cylinder block, make
sure part(s) is not serviceable.
WARNING: TO AVOID THE POSSIBILITY OF

PERSONAL INJURY OR DAMAGE, DO NOT
OPERATE THE ENGINE UNTIL THE FAN BLADE
HAS FIRST BEEN EXAMINED FOR POSSIBLE
CRACKS OR SEPARATION.
Engine Identification Nameplate

For quick engine identification, refer to the Engine
Identification Nameplate. The nameplate lists engine
information required for proper servicing of the
engine. The Engine Identification Nameplate and
identification label provide information pertaining to
engine displacement, serial number, model number,
S.O./Options, and model code.
An engine code decal is attached to the engine front
cover. The symbol code on the decal identifies each
engine for determining parts usage.
CAUTION: Use of abrasive grinding discs to

remove gasket material from the engine sealing
surfaces during repair procedures can contribute
to engine damage and wear. Airborne debris and
abrasive grit from the grinding disc may enter the
engine through exposed cavities causing
premature wear and eventual engine damage.
Ford Power Products does not recommend using
abrasive grinding discs to remove engine gasket
material. Use manual gasket scrapers for removing
gasket material from the engine sealing surfaces.
DESCRIPTION
01-3
01-3
DIAGNOSIS
Inspection
Inspect to determine if any of the following mechanical concerns apply:
Engine oil leaks.
Damaged and/or severely worn parts.
Loose mounting bolts, studs and nuts.

CONDITION
DIFFICULT
STARTING
POSSIBLE SOURCE
Burnt valve.
Replace valve.
Worn piston.
Replace piston.
Worn piston ring(s).
Replace piston ring(s).
Worn cylinder.
Service or replace cylinder block.
Damaged cylinder head gasket.
Replace cylinder head gasket.
Malfunctioning or damaged fuel system.
Refer to section on fuel system.
Malfunctioning or damaged ignition system.
Refer to section on ignition system.
Damaged hydraulic valve tappet.
Replace hydraulic valve tappet.
Damaged hydraulic valve tappet guide.
Replace hydraulic valve tappet

guide.
Improper valve to valve seat contact.
Replace valve and/or valve seat.
Refer to section on Fuel system.
Damaged hydraulic valve tappet.
Damaged hydraulic valve tappet bore.
Replace cylinder block.
Burnt or sticking valve.
Service or replace valve.
Weak or broken valve spring.
Replace valve spring.
Carbon accumulation in combustion chamber.
Eliminate carbon buildup.
Worn piston ring groove.
Replace piston.
Sticking piston ring(s).
Service or replace piston ring (s).
Worn piston or cylinder.
Service or replace piston or cylinder

block.
Worn valve stem seal.
Replace valve stem seal.
Worn valve stem or valve guides.
Replace valve stem and guide.
Leaking oil.
Service oil leak.
Worn piston rings.
Replace piston rings.
Plugged pcv system.
Service PCV system.
POOR IDLING
ABNORMAL
COMBUSTION
EXCESSIVE OIL
CONSUMPTION
ACTION
DIAGNOSIS
01-4
CONDITION
ENGINE NOISE
POSSIBLE SOURCE
Excessive main bearing oil clearance.
Seized or heat damaged crankshaft main

bearing.
Excessive crankshaft end play.
Excessive connecting rod bearing oil

clearance.
Heat damaged connecting rod bearing.
Damaged connecting rod bushing.
Worn cylinder.
Worn piston or piston pin.
Damaged piston ring(s).
Bent connecting rod.
Malfunctioning hydraulic valve tappet.
Excessive hydraulic valve tappet clearance.
Broken valve spring.

Excessive valve guide clearance.
Malfunctioning or damaged cooling system.

Leaking exhaust system.
Improper drive belt tension.
Malfunctioning generator bearing.
Loose riming belt.

Damaged timing belt tensioner.
Malfunctioning water pump bearing.
Malfunctioning hydraulic valve tappet.
Damaged hydraulic valve tappet bore.
Seized valve stem.
Weak or broken valve spring.

Cracked or distorted cylinder head.
Damaged, worn or sticking piston ring(s).
Worn or damaged piston.
INSUFFICIENT
POWER
ACTION
DIAGNOSIS
01-4
Adjust clearance or replace

crankshaft main bearing.
Replace crankshaft main bearing.
Adjust end play or replace
crankshaft.
connecting rod.
Replace connecting rod bearing.
Replace connecting rod bushing.
Service or replace cylinder block.
Replace piston or piston pin.
Replace piston ring(s).
Replace connecting rod.
hydraulic valve tappet.
Service clearance or replace valve
guide/stem.
Refer to section on cooling system.
Service exhaust leakage.
Refer to section on accessory
drivebelts.
Refer to section on charging system.
Adjust or replace timing belt.
Replace timing belt tensioner.
Refer to section on cooling system.

Replace cylinder block.
Service or replace valve, valve seat
and/or cylinder head.
Replace cylinder head.
Service or replace piston ring(s).
Replace piston.
01-5
01-5
Fluorescent Oil Additive Method
PCV System Malfunction

A malfunctioning Positive Crankcase Ventilation
System (closed type) may be indicated by loping or
rough engine idle. Do not attempt to compensate for
this idle condition by disconnecting the crankcase
ventilation system and making an air bypass or idle
speed adjustment. The removal of the crankcase
ventilation system from the engine will adversely
affect fuel economy and engine crankcase
ventilation with resultant shortening of engine
life.
To perform oil leak diagnosis using Rotunda Oil Leak

Detector Kit 112-R0030, or equivalent, perform the
following procedure.
Engine Oil Leak Check

When diagnosing engine oil leaks, it is important that
the source and location of the leak be positively
identified prior to service.
NOTE: Due to their remote location, rear engine
oil leaks may be very difficult to pinpoint. This
area is also very difficult to clean. Make sure to
eliminate all other possibilities before removing
the engine to repair a suspected leak in this area.
There are two methods of diagnosing engine oil leaks.
The following procedure has been found to be very
effective and requires only a minimum of equipment.
Prior to using this procedure, it is important to clean
the cylinder block, cylinder heads, valve covers, oil
pan and flywheel housing areas with a suitable
solvent to remove all traces of oil.
1.
Clean engine with a suitable solvent to remove all

traces of oil.
2.
Drain engine oil from crankcase and refill with

recommended oil, premixed with Rotunda
Fluorescent Oil Additive 112-R0015,
or
equivalent.
Use 29.6ml (1 fluid once) of
fluorescent additive.
If oil is not premixed,
fluorescent additive must be added to crankcase
first.
3.
Run engine for 15 minutes. Stop engine and

inspect all seal and gasket areas for leaks using
Rotunda Oil Leak Detector Y112-R0021 (part of
112-R0030 kit) Lamp or equivalent. A clear bright
yellow or orange area will identify leak. For
extremely small leaks, several hours may be
required for the leak to appear.
4.
If necessary, pressurize main oil gallery system to

locate leaks due to improperly sealed, loose or
cocked plugs. If flywheel bolts leak oil, look for
sealer on threads.
5.
Service all leaks as required.
DIAGNOSIS
01-6
01-6
Pressure Method
Oil pressure sensor
As an alternative testing procedure, the crankcase

can be pressurized, not to exceed 27 kPa (4 psi), to
locate oil leaks. The following materials are required
to fabricate the tool to be used:
Cup plugs and/or pipe plugs at end of oil

passages
Oil pan gasket
Oil pan front and rear end seals
Oil pan front and rear end seals
Air supply and air hose.
Air pressure gauge that registers pressure in

increments of one psi.
Air line shutoff valve.
Crankshaft front seal
Appropriate fittings to attach the above parts to oil

fill, PCV grommet holes and PCV fresh air hose
tube.
Crankshaft rear oil seal
Oil pump
Crankshaft rear oil seal
Appropriate plugs to seal any openings leading to

crankcase.
A solution of liquid detergent and water to be
applied with a suitable type applicator such as a
squirt bottle or brush.
Fabricate the air supply hose to include the air line

shutoff valve and the appropriate adapter to permit
the air to enter the engine through the rocker arm
cover tube. Fabricate the air pressure gauge to a
suitable adapter for installation on the engine at the oil
fill opening.
Air leakage in area around a crankshaft rear oil seal

does not necessarily indicate a rear seal leak.
However, if no other cause can be found for oil
leakage, it can be assumed that rear seal is the cause
of the oil leakage:
Rear main bearing cap parting line.
Rear main bearing cap and seals.
Flywheel mounting bolt holes.
Rear cup plugs and/or pipe plugs at the end of oil

passages.
Oil leaks at crimped seams in sheet metal parts and

cracks in cast or stamped parts can be detected when
pressurizing the crankcase.
CAUTION:
Use
extreme
caution
when
pressurizing crankcase. Applying air pressure
above specified pressure risks damage to seals,
gaskets and core plugs. Under no circumstances
should pressure be allowed to exceed 27 kPa (4
psi).
1.
Open air supply valve until pressure gauge

maintains 20 kPa (3 psi).
2.
Inspect sealed and/or gasketed areas for leaks

by applying a solution of liquid detergent and
water over areas for formation of bubbles, which
indicates leakage.
3.
Examine the following areas for oil leakage:
Rocker cover sealant or gaskets
Intake manifold gaskets/end seals
Cylinder head gaskets
Oil bypass filter
Oil level indicator (dipstick) tube connection
Light foaming equally around rocker arm cover bolts

and crankshaft seals is not detrimental and no
corrections are required in such cases.
DIAGNOSIS
01-7
01-7
Compression Test
1.
Make sure oil in crankcase is of the correct

viscosity and at proper level, and battery is
properly charged. Operate the engine until it is at
normal operating temperature. Turn off ignition
switch, then remove all spark plugs .
2.
Set throttle plates in wide-open position.
3.
Install a compression gauge such as Rotunda

Compression Tester 059-R0009, or equivalent, in
No. 1 cylinder.
Example Readings
If, after checking the compression pressures in all
cylinders, it was found that the highest reading
obtained was 1351 kPa (196 psi) and the lowest
pressure reading was 1069 kPa (155 psi), the engine
is within specification and the compression is
considered satisfactory.
Compression Pressure Limit Chart (MAX - MIN)
134 - 101
136 - 102
138 - 104
140 - 105
142 - 107
144 - 108
146 - 110
148 - 111
150 - 113
152 - 114
154 - 115
156 - 117
158 - 118
160 - 120
162 - 121
164 - 123
166 - 124
168 - 126
170 - 127
172 - 129
174 - 131
176 - 132
178 - 133
180 - 135
182 - 136
184 - 138
186 - 140
188 - 141
190 - 142
192 - 144
194 - 145
196 - 147
The indicated compression pressures are considered

within specification if the lowest reading cylinder is
within 75 percent of the highest (refer to chart ).
198 - 148
200 - 150
202 - 151
204 - 153
206 - 154
208 - 156
210 - 157
212 - 158
If one or more cylinders reads low, squirt

approximately one tablespoon of SAE 50 weight, or
equivalent, engine oil on top of the pistons in the low
reading cylinders. Repeat compression pressure
check on these cylinders.
214 - 160
216 - 162
218 - 163
220 - 165
222 - 166
224 - 168
226 - 169
228 - 171
230 - 172
232 - 174
234 - 175
236 - 177
238 - 178
240 - 180
242 - 181
244 - 183
246 - 184
248 - 186
250 - 187
4.
5.
Install an auxiliary starter switch in staring circuit.

With ignition switching the OFF position, and
using auxiliary starter switch, crank engine at
least five compression strokes and record highest
reading.
Note the approximate number of
compression strokes required to obtain the
highest reading.
Repeat test on each cylinder, cranking the engine
approximately the same number of compression
strokes.
1.
If compression improves considerably, piston

rings are at fault.
2.
If compression does not improve, valves are

sticking or seating poorly.
3.
If two adjacent cylinders indicate low compression

pressures and squirting oil on pistons does not
increase compression, cause may be a cylinder
head gasket leak between cylinders. Engine oil
and/or coolant in cylinders could result from this
problem.
DIAGNOSIS
01-8
01-8
Oil Leak and Valve Guide Seal Test

The cylinder leakage detector can be used to test for
engine oil leaks and to check the valve seals for
leakage.
1.
Plug all crankcase openings except the one used

for connecting the leakage detector.
2.
Connect the detector to a crankcase opening.

The oil level indicator tube is convenient. Adjust
the air pressure to approximately 34 kPa (5 psi).
3.
Using a solution of liquid soap and water, brush

the solution along the gasket sealing surfaces
and bearing seals. Look for bubbles or foam.
4.
Remove the spark plugs and rotate the engine

slowly with a wrench. Check for large amounts of
air escaping into the cylinders as each intake and
exhaust valve opens.
The spark plugs on the leaking cylinders will probably

show deposits of burned oil.
Intake Manifold Vacuum Test

Cylinder Leakage Test
When a cylinder produces a low reading, the use of
Rotunda Pressurization Kit 014-00705, or equivalent,
will be helpful in pinpointing the exact cause.
Bring the engine to normal operating temperature.

Connect Rotunda Vacuum/Pressure Tester 05900008, or equivalent, to the intake manifold. Run the
engine at the specified idle speed.
The leakage detector is inserted in the spark plug

hole, the piston is brought up to top dead center on
the compression stroke, and compressed air is
admitted.
Once the combustion chamber is pressurized, a
special gauge will read the percentage of leakage.
Leakage exceeding 20 percent is considered
excessive.
While the air pressure is retained in the cylinder, listen
for the hiss of escaping air. A leak by the intake valve
will be audible in the carburetor. A leak by the
exhaust valve can be head at the exhaust pipe.
Leakage past the rings will be audible at the positive
crankcase ventilation (PCV) connection. If air is
passing through a blown gasket to an adjacent
cylinder, the noise will be evident at the spark plug
hole of the cylinder block, or gasket leakage into the
cooling system may be detected by a stream of
bubbles in the radiator.
The vacuum gauge should read between -51 and -74

kPa (15 and 22 in-Hg) depending upon the engine
condition and the altitude at which the test is
performed.
Subtract 5.5 kpa from the specified reading for every
500 meters (1 in-hg for every 1,000 feet) of elevation
above sea level.
DIAGNOSIS
01-9
01-9
The reading should be quite steady. It may be

necessary to adjust the gauge damper control (where
used) if the needle is fluttering rapidly. Adjust damper
until needle moves easily without excessive flutter.
3.
NORMAL FOR HIGH LIFT CAM WITH LARGE

OVERLAP: Needle will register as low as -50 kPa
(15 in-Hg) but will be relatively steady. Some
oscillation is normal.
A careful study of the vacuum gauge reading while

the engine is idling will help pinpoint trouble areas.
Always conduct other appropriate tests before arriving
at a final diagnostic decision.
Remember that
vacuum gauge readings, although helpful, must be
interpreted with care.
4.
WORN RINGS OR DILUTED OIL: When engine

is accelerated (dotted needle), needle drops to 0
kPa (0 in-Hg). Upon deceleration, needle runs
slightly above 74 kPa (22 in-Hg).
5.
STICKING VALVE(S): When the needle (dotted)

remains steady at a normal vacuum but
occasionally flicks (sharp, fast movement) down
and back about 13 kPa (4 in-Hg), one or more
valves may be sticking.
6.
BURNED OR WARPED VALVES: A regular,

evenly spaced, downscale flicking of the needle
indicates one or more burned or warped valves.
Insufficient hydraulic lash adjuster clearance will
also cause this action.
7.
POOR VALVE SEATING: A small but regular

downscale flicking can mean one or more valves
are not seating.
8.
WORN VALVE SPRINGS: When the needle

oscillates (swings back and forth) over a 13 kPa
(4 in-Hg) range at idle speed, the valve guides
could be worn. As engine speed is increased, the
needle will become steady if the guides are
responsible.
9.
WEAK VALVE SPRINGS: When the needle

oscillation becomes more violent as engine rpm is
increased, weak valve springs are indicated. The
reading at idle could be relatively steady.
Most vacuum gauges have a normal band indicated

on the gauge face. The following are potential gauge
readings, compare with the corresponding text.
10. LATE VALVE TIMING: A steady but low reading

could be caused by late valve timing.
11. IGNITION TIMING RETARDING: Retarded
ignition timing will produce a steady but low
reading.
1.
NORMAL READING: Needle between -51 and 75 kPa (15 and 20 in-Hg) and holding steady.
2.
NORMAL
READING
DURING
RAPID
ACCELERATION AND DECELERATION: When
engine is rapidly accelerated (dotted needle),
needle will drop to a low (not to 0) reading. When
throttle is suddenly released, the needle will snap
back up to a higher than normal figure.
When
12. INSUFFICIENT SPARK PLUG GAP:
plugs are gapped too close, a regular, small
pulsation of the needle can occur.
13. INTAKE LEAK: A low, steady reading can be
caused by an intake manifold or carburetor
mounting flange gasket leak.
14. BLOWN HEAD GASKET: A regular drop of
approximately 33-50 kPa (10-15 in-Hg) can be
caused by a blown head gasket or warped headto-block mounting surface.
DIAGNOSIS
01-10
15. RESTRICTED EXHAUST SYSTEM: When the

engine is first started and idled, the reading may
be normal. But as the engine rpm is increased,
back pressure caused by a clogged exhaust pipe,
etc., will cause the needle to slowly drop to 0.
The needle then may slowly rise. Excessive
exhaust clogging will cause the needle to drop to
a low point even if the engine is only idled.
When vacuum leaks are indicated, search out and
correct the condition. Excess air leaking into the
system will upset the fuel mixture and cause
conditions such as rough idle, missing, or burned
valves. ALWAYS SERVICE VACUUM LEAKS.
Verify that the engine is not being run in an overfilled

condition. Check the oil level at least five minutes
after a hot shutdown (engine must be level). Under
no circumstances should the oil level be above the
FULL line. If a significant overfill is indicated, perform
Steps 1 through 4 to verify the dipstick calibration. If
the dipstick calibration checks OK, instruct the
operator to avoid overfilling the engine and return the
engine to service. To verify the engines actual oil
consumption, perform Steps 5 and 6 only after the
dipstick has been calibrated.
Perform engine oil consumption test as follows:
1.
Drain engine oil. Remove and replace oil filter.

Using 0.95 liter (1 U.S. quart) less than
recommended,
refill
crankcase
with
recommended quality of oil.
2.
Run the engine for three minutes (10 minutes if

cold), then turn engine off. Allow oil to drain into
the oil pan for an additional five minutes (engine
should be level).
3.
Remove oil level dipstick and wipe clean. Do not

wipe using anything contaminated with silicone
compounds. Reinstall oil level dipstick being
sure to seat the oil level dipstick firmly in the oil
level indicator tube. Remove the oil level dipstick
and scribe a mark on the back (unmarked)
surface at the indicated oil level. This should be
about the same level as the ADD mark on the
face of the oil level dipstick .
4.
Add 0.95 liter (1 U.S. quart) of oil. Restart the

engine and allow it to idle for at least two minutes.
Shut down and allow oil to drain back for at least
five minutes.
Mark the dipstick using the
procedure above. This level may range from
slightly below the top of the cross-hatched area to
slightly below the letter F in FULL.
5.
Instruct the operator to run the engine as usual

and :
Oil Consumption Test

The following diagnostic procedure is intended to be
used to determine the source of excessive internal oil
consumption.
Determine what is considered to be excessive oil
consumption. Note hours of engine service and the
following observations:
How many hours of engine use per 0.95 liter (1

U.S. quart) of oil used?
How is the engine being used (e.g., sustained

high-speed operation, heavy loads, high ambient
temperature, etc.)?
What is the expected normal oil consumption?
Verify that the engine has no external oil leak as

described under Engine Oil Leaks in this section.
Verify that the oil level dipstick and oil level indicator
tube are unmodified and in good condition. Verify that
the oil level indicator tube is properly seated in the
block, and the dipstick seats properly in the oil level
indicator tube .
01-10
Check the oil level regularly at intervals of

three to five hours.
Call for service when the oil level drops below

the lower (ADD) mark previously scribed on
the dipstick.
In an emergency, add only 0.95 liter (1 U.S.

quart) of the same oil and note the engine
hours at which the oil was added.
DIAGNOSIS
01-11
6.
Check the oil level under the same conditions as

in Steps 3 and 4, reading the back of the dipstick
where the scribe marks are located.
Measure the distance from the oil level to the

upper scribe mark on the dipstick and record
the measurement.
01-11
If internal oil consumption still persists, proceed as

follows:
1.
Remove intake manifold(s), cylinder heads, oil

pan and oil pump.
2.
Check piston ring clearance, ring gap and ring

orientation as outlined in this section. Service as
required.
Measure the distance between the two scribe

marks and record the measurement.
3.
Divide the first measurement by the second.

Add one to this total for every 0.95 liters (1
U.S. quart) added by the customer as
instructed in Step 5.
Check for excessive bearing clearance

outlined in this section. Service as required.
4.
Perform Oil Consumption Test again to verify that

the oil consumption concern has been resolved.
Divide the engine hours operated during the

oil test by the result. This quantity is the
approximate oil consumption rate in hours per
quart.
Oil Pressure Test
7.
If the calculated oil consumption

unacceptable, proceed as follows.
rate
Special Tool Required
is
Engine Oil Pressure Gauge
Check PCV system. Make sure system is not

plugged.
Check for plugged oil drain-back holes in

cylinder heads and cylinder block.
If condition still exists, perform a cylinder

compression test as described in this section,
and/or perform a cylinder leak detection test
with Rotunda Pressurization Kit 014-00705, or
equivalent. This can be helpful in determining
the source of oil consumption, as an example,
valves, piston rings, etc.
as
Check valve guides for excessive clearance.

Replace all valve stem seals after correct
valve guide clearance has been verified.
NOTE: After checking for worn parts, if it is

determined parts should be replaced, make sure
correct replacement parts are used. Worn or
damaged internal engine components can cause
excessive oil consumption. Small deposits of oil
on tip of spark plugs can be a clue to internal oil
consumption.
T73L-6600-A
1.
Disconnect and remove the oil pressure sensor

from the engine.
2.
Connect an Engine Oil Pressure Gauge T73L6600-A, or equivalent, to the oil pressure sensor
screw port.
3.
Run the engine until

temperature is reached.
4.
Run the engine at 3,000 rpm and record the

gauge reading.
normal
operating
The oil pressure should be 250-490 kPa (3671 psi) at 3,000 rpm.
If the pressure is not within specification, check

the following possible sources:
5.
Insufficient oil
Oil leakage
Worn or damaged oil pump
Clogged oil pump screen cover and tube
Excessive main bearing clearance
Excessive connecting rod bearing clearance
DIAGNOSIS
01-12
5. Using suitable bore gauge or inside micrometer,

measure each bearing, 90 degrees apart, to
determine bearing size and out-of-round.
Double-check by measuring twice.
SERVICE PROCEDURES
Camshaft Service
Camshaft End Play
CAUTION: Prying against
sprocket with valve train
camshaft, can break or
camshaft sprocket. Remove load
prior to checking end play.
01-12
the camshaft
load on the
damage the
on camshaft
6. Check results against specifications in the

specification section. If bearings are out of
specifications, they will have to be replaced.
Check camshaft journals before replacing
bearings to determine if undersize bearings are
required.
7. If necessary, replace the bearings.
Cleaning
Camshaft Bearing Journals
1. Remove camshaft from engine
1. Measure each journal twice, 90 degrees apart, to

determine journal wear, size, and out-of-round.
2. Remove sprocket.
3. Clean the camshaft in an appropriate solvent.
4. Wipe it dry with a clean lint free cloth.
5. Remove light scuffs, scores, or nicks from the
camshaft machined surfaces with an oil stone.
Inspection
2. Check measurements against specifications in

the specification section.
3. If journals are excessively out-of-round or worn,
regrind to a standard undersize. Refer to Master
Parts Catalogue.
4. If journals are too worn to be refinished to an
available undersize, replace camshaft.
Inspect the camshaft journals and lobes for

scoring and signs of abnormal wear.
Lobe pitting, except in the general area of the

lobe toe, is not detrimental to the operation of the
camshaft. The camshaft should not be replaced
unless lobe lift loss has exceeded the
specifications or pitting has occurred in the lobe
lift area. Refer to Cam Lobes in this section.
Camshaft Journals Oil Clearance
Inspect camshaft sprocket for worn or broken

teeth. If necessary, remove and replace.
3. Check clearance against

specification section.
Camshaft Bearings
1. Wipe bearing bore clean with a clean rag and
solvent.
1. Measure camshaft bearings and camshaft

bearing journals as outlined in this section.
2. Subtract size of journal from the size of its
bearing.
specifications
in
4. If clearance is excessive, but camshaft journals

are within specifications, simply install new
bearings.
5. If both bearings and journals are worn, turn
camshaft journals to a standard undersize and
install new undersize bearings.
2. Dry with a clean rag.

3. Inspect for scoring and visible wear.
4. Inspect bearings for excessive wear. If visibly
worn or damaged, replace bearings. If one of the
center bearings is worn significantly more than
the end bearings, check camshaft for excessive
runout.
SERVICE PROCEDURES
01-13
Camshaft Runout
NOTE: Check camshaft journals for out-of-round
before checking for runout. An out-of-round
condition on the center journal could be confused
for an excess runout condition. Set suitable Vblocks on surface plate. Support outer camshaft
journals on V-blocks.
1. Set up TOOL-4201-C, or equivalent, Dial

Indicator with bracketry to check center bearing
journal.
2. Zero dial indicator.
3. Slowly rotate camshaft to determine overall
runout. If runout exceeds 0.03mm (0.0012 in.),
replace camshaft.
01-13
5. Check the lobe lift for each cam lobe against the
Specifications .
6. If any cam lobe is worn excessively, replace the
camshaft and tappets.
Cam Lobe Lift (with dial indicator)

1. Clean and inspect the camshaft as outlined in this
section.
2. Install the camshaft on a lathe or camshaft
grinder centers.
3. Position the machines dial indicator at the heel of
the cam lobe you are going to check.
4. Zero the dial indicator.
Cam Lobe Lift Measurement

There are two ways of measuring cam lobe lift:
5. Slowly turn the camshaft until the point of the dial

indicator is on the tip of the cam lobe.
micrometer
6. Read the dial indicator. This is your cam lobe lift.
dial indicator (more accurate)
7. Check the lobe lift against the specifications in the

specifications section. If any cam is excessively
worn, replace the camshaft and tappets.
Cam Lobe Lift (with micrometer)

1. Inspect camshaft bearing as outlined in this
section.
2. Measure the distance of each cam lobe at the
major diameter.
3. Measure the distance of each cam lobe at the
minor diameter.
4. For each cam lobe, subtract the minor diameter
from the major diameter. The result for each lobe
is the lobe lift.
SERVICE PROCEDURES
01-14
01-14
Inspection
Connecting Rod Service

Connecting Rod Side Clearance
1. Install Rotunda Dial Indicator with Bracketry
TOOL-4201-C, or equivalent so that the contact
point rests against the connecting rod cap.
2. Pull cap toward front of engine and zero the dial
indicator.
3. Push cap toward rear of engine and observe
amount of side clearance on dial indicator.
4. If side clearance exceeds specification, replace
connecting rod and cap.
Refer to the
If side clearance is less than specification, remove rod
and cap and inspect for scratches, burrs, nicks or dirt
between crankshaft and connecting rod.
Cleaning
Remove the bearings from the rod and cap. Identify
each bearing location if they are to be 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.
The connecting rods and related parts should be

carefully inspected and checked for conformance to
specifications. Refer to the specifications section.
Various forms of engine wear caused by these parts
can be readily identified.
A shiny surface on either pin boss inside of the piston
usually indicates that a connecting rod is bent.
Abnormal connecting rod bearing wear can be
caused by either a bent connecting rod, worn or
damaged piston pin, or a tapered connecting rod
crankshaft pin.
Twisted connecting rods can create an identifiable
piston skirt wear pattern, but badly twisted rods will
disturb the action of the entire piston, rings, and
connecting rod assembly and may be the cause of
excessive oil consumption.
Check the connecting rods for bend or twist on a
suitable alignment fixture. Follow the instructions of
the fixture manufacturer. If the bend and/or twist
exceeds specification, the connecting rod must be
replaced.
Inspect the connecting rods for signs of fractures and
the rod bearing bores for out-of-round and taper. If
the bore exceeds the recommended limits and/or if
the connecting rod is fractured, it should be replaced.
SERVICE PROCEDURES
01-15
01-15
Crankshaft Bearing Service

Main Bearing Bore Alignment
Main bearing bore misalignment may be suspected in
cases of premature bearing wear if one bearing wears
considerably more that the others or bearings wear
cone-shaped.
NOTE: Bearings are not available with oversize
outside diameters to allow line boring.
If bearing misalignment is suspected:
1. Acquire a gauge bar the same diameter as the
crankshaft journals and straight within 0.076mm
(0.003 in.).
2. Put a thin coating of Prussian Blue or similar die
on gauge bar.
3. Insert good bearings in block.
4. Insert gauge bar in bearings and rotate one turn.
5. Remove gauge bar.
6. Inspect bearings. Blue die should be deposited
evenly on all bearings. If die appears on only one
side or bottom of bearing or not at all, block is
distorted and should be replaced.
Cleaning
NOTE: Do not scrape gum or varnish deposits
from the bearing shells.
Bearings that are to be reused should be identified so
they can be installed in their original locations.
Clean the bearing inserts and caps thoroughly in
solvent, and dry them with compressed air.
Inspection
Inspect each bearing carefully. Bearings that have a
scored, chipped or worn surface should be replaced.
Typical examples of unsatisfactory bearings and their
causes are shown in the illustration. The copper lead
bearing base may be visible through the bearing
overlay. If the base showing is less than 20 percent
of the total area, the bearing is not excessively 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 described in this
section.
ITEM
DESCRIPTION
Connecting Rod Bearing
Fatigue Failure - Craters or Pockets
Improper Seating - Bright (polished)

Sections
Dirt Scratching, Imbedding
Overlay Wiped Out - Lack of Oil or Improper

Clearance
Hourglass - Overlay Gone from Edges
Radius Ride
Overlay Gone from Mating Edge, One Side

Only. Rod Cap Shift.
SERVICE PROCEDURES
01-16
01-16
7. If bearing clearance exceeds the specified limits,
Crankshaft Bearing Clearance

(Plastigage Method)
1. Clean crankshaft journals.
2. Inspect journals and thrust faces for nicks, burrs
or roughness that would cause premature bearing
wear.
When replacing standard bearings with new
bearings, it is good practice to fit bearing to
minimum specified clearance.
If desired
clearance cannot be obtained with a standard
bearing, try a 0.050 mm (0.002-inch) undersize
bearing set to obtain proper clearance.
CAUTION: Do not position jack under

crankshaft pulley. Crankshaft post
damage will result.
try using one of the various combinations of

undersize bearings as directed by the
accompanying table. Use of any other bearing
combination is not recommended.
Bearing
clearance must be within specified limits. Refer
to specifications in specification section for main
and connecting rod bearing clearance limits. If
use of these bearing combinations does not bring
clearance to the desired limits, refinish the crank
journal to a standard undersize, and use the
appropriate undersize bearing.
3. If fitting main bearing in-equipment, position a

jack under counterweight adjoining bearing which
is being checked. Support crankshaft with jack
so its weight will not compress Plastigage and
cause an incorrect reading.
4. Place a piece of Plastigage D81L-6002-B, or
equivalent, on bearing surface across full width of
bearing cup and about 6.35mm (1/4 inch) off
center.
5. Install cap and tighten bolts to specification. Do
not turn crankshaft while Plastigage is in place.
6. Remove cap. Using Plastigage scale, check
width of Plastigage at widest point to get
minimum clearance. Check at narrowest point to
get maximum clearance. Difference between
reading is taper of journals.
8. After bearing has been fitted and cleaned, apply a

light coat of engine oil to journal and bearings.
9. Install bearing cap.
Tighten cap bolts to
specifications found in the specifications section.
10. Repeat procedure for remaining bearings that
require replacement.
For This Amount of
Use This Bearing Size
Bearing Clearance Excess
Upper Bearing
Lower Bearing
mm
inch
mm
inch
mm
inch
0-.013
0-.0005
.025
.001
Standard
Standard
.013-.026
.0005-.0010
.025
.001
.025
.001
.026-.039
.0010-.0015
.050
.002
.025
.001
.039-.052
.0015-.0020
.050
.002
.050
.002
SERVICE PROCEDURES
01-17
Crankshaft Bearing Clearance

(Bore Gauge Method)
1. Install bearings in the cylinder block
2. Install bearing caps.
3. Install crankshaft and tighten main bearing cap
bolts to the specified torque .
4. Remove bearing caps and crankshaft.
5. Reinstall bearing caps with bearings still installed
in cylinder block and caps.
6. Tighten bearing cap bolts to torque specified.
7. Using micrometer, measure main bearing journals
as outlined in this section.
8. Using bore gauge, measure the inside diameter
of each bearing assembly. It may be necessary
to measure the outer bearings first, then remove
those caps and measure the inner bearings.
9. Subtract the maximum measurement for each
journal from the minimum measurement of each
bearing to determine the minimum oil clearance.
Compare with specifications.
SERVICE PROCEDURES
01-17
01-18
Crankshaft Service
01-18
Cleaning
Crankshaft End Play

Crankshaft must be installed in block with the
bearings that will be used, but without connecting
rods, pistons, or flywheel installed to check end play.
1. Install Dial Indicator with Bracketry TOOL-4201C, or equivalent, so contact point rests against
the end of the crankshaft post and indicator axis
is parallel to crankshaft axis.
2. Force crankshaft toward rear of engine.
CAUTION: Handle the crankshaft with

care to avoid possible damage to the
finished surfaces.
Clean the crankshaft with solvent, then blow out all oil
passages with compresses air.
Inspection
Measure the diameter of each journal in at least four
places to determine an out-of-round, taper or
undersize condition. For specifications, refer to the
Inspect crankshaft sprocket for chipped, broken, or
excessively worn teeth. Remove and replace as
outlined in Section 02 if necessary.
Crankshaft Runout
NOTE: Check crankshaft journals for out-of-round
before checking runout,.
An out-of-round
condition on the center journal could be confused
as excess runout.
1. Set V-blocks on surface plate and set crankshaft
on V-blocks supported on the outer two main
bearing journals.
2. Set up TOOL-4201-C, or equivalent, Dial
Indicator with Bracketry to measure runout on
3. Zero dial indicator. Push crankshaft forward and

note reading on dial.
4. If the end play exceeds the wear limit listed in the
specification section, replace the thrust bearing.
Inspect the crankshaft for damage to the thrust
face before installing the new bearing. If the end
play is less than the minimum limit, inspect the
thrust bearing faces for scratches, burrs, nicks, or
dirt. If the thrust faces are not damaged or dirty,
the main thrust bearing may not be aligned
properly. Lubricate and install the thrust bearing
and align the faces, following Main Bearing
Replacement procedure in the appropriate engine
section. Re-check crankshaft end play.
center main bearing journal.

3. Zero dial indicator.
4. Slowly rotate crankshaft one revolution and
record highest and lowest readings.
5. Crankshaft runout should not exceed 0.050 mm
(0.002 in.). If crankshaft runout is excessive,
replace crankshaft.
SERVICE PROCEDURES
01-19
01-19
Crankshaft Journals
Journal Refinishing
Inspect the main journal and crankpin journal

diameters. Measure the diameter of each journal at
two different points in the directions as shown.
NOTE: Polish direction is clockwise as viewed

from the front of the crankshaft.
Dress minor imperfections such as scores, nicks or
burrs with an oil stone.
If journals are severely marred or exceed service
limits for wear, taper, or out-of-round, they should be
refinished to size for the next undersize crankshaft
main bearing.
Follow crankshaft lathe manufacturers instructions for
refinishing crankshaft.
If the journals will not clean up to less than the
maximum undersize bearing available, replace the
crankshaft.
Always reproduce the same journal shoulder radius
that existed originally. Too small a radius will result in
fatigue failure of the crankshaft. Too large a radius
will result in bearing failure due to radius ride of the
crankshaft bearing.
Refer to Section
specifications.
02
for
crankshaft
journal
After refinishing the journals, chamfer the oil holes.

Polish the journals with a No. 500 grit polishing cloth
and engine oil (crocus cloth may also be used as a
polishing agent) to obtain a smooth finish.
SERVICE PROCEDURES
01-20
01-20
Cylinder Block Service

Cylinder Walls, Refinishing
Cleaning and Inspection
If the engine has been removed and disassembled,
remove all core plugs and pipe plugs. Clean the
cylinder block using solvent, preferably in a hot tank.
Follow all safety an environmental precautions with
regard to the solvent. Make sure all oil and dirt is
cleaned from the cylinder block.
Make sure all oil passageways are clean.
cleaning brush is useful for this purpose.
A rifle-
Use a long, thin screwdriver to scrape the bottom of

the water jackets through the openings in the top deck
to make sure all scale and deposits are removed.
Most engines have a dead spot at the back of the
block where the coolant makes a U-turn and drops
any deposits. If the water jackets are not thoroughly
cleaned, overheating will result.
If the entire engine has NOT been disassembled,

clean the individual cylinder bore(s) with a cloth
soaked in solvent. Dry with a clean, lint-free cloth.
If the entire engine HAS been disassembled, refer to
Cleaning and Inspection in this section.
After any cylinder bore service operation, such as
honing or deglazing, clean the bore(s) with soap or
detergent and water. Then thoroughly rinse the
bore(s) with clean water to remove the soap or
detergent, and wipe the bore(s) dry with a clean lintfree cloth.
Finally wipe the bore(s) with a clean cloth dipped in
XO-10W30-QSP or -DSP, or equivalent, motor oil
meeting Ford specification ESE-M2C153-E.
Before removing the piston:
Cylinder Block Distortion
1. Check the amount of ridge at the top of the bore.

A thick ridge is a sign of considerable wear.
Cylinder block distortion is rare because cylinder

blocks are normalized after casting, and before
machining, to relieve internal stresses from the
casting process.
2. Look for signs of coolant in the bore, especially

rust on the bore surface indicating possible
leaking head gasket or a crack in the cylinder
bore.
The most probable cause of cylinder block distortion

would be extreme overheating which would probably
be accompanied by other damage such as scored
bearings or cylinder walls, warped cylinder heads,
and possible cylinder block cracks.
3. Check the top of the piston for possible oversize.

If oversize pistons have been installed, the
oversize will be stamped in the top of the piston.
Cylinder Head Deck Flatness
4. Look for scoring. These are parallel gouges

usually on the piston thrust side, that is, at right
angles to the piston pin. If scored, the cylinder
will have to be refinished.
Place a straightedge across the cylinder head deck in

three positions and check for any gaps between the
straightedge and the deck with a feeler gauge.
The deck should be flat within 0.76 mm (0.003 in.)
over 152 mm (6 inches) and 0.152mm (0.006 in.)
overall. If necessary, resurface or replace cylinder
block.
After the piston is removed and the bore cleaned:
5. Look for cracks. If unsure about a crack, tiny

cracks may be detected by coating the bore with
a mixture of 25 percent kerosene and 75 percent
light engine oil.
Wipe the bore dry and
immediately apply a coating of zinc oxide
dissolved in wood alcohol. Do not use rubbing
alcohol as a substitute. If cracks are present, the
coating will be become discolored at the
damaged area. Replace the cylinder block if it is
cracked. Magnafluxing may also be used.
SERVICE PROCEDURES
01-21
01-21
6. Check for cylinder wall glazing. When refinished,

the cylinder bore is given a slightly rough finish
with a cylinder hone to help seat the new piston
rings. This finish is worn away as the rings and
cylinder bore mate and the bore becomes
glassy smooth. If the engine has been run
enough for this to have happened, the cylinder
will at least have to be honed to seat the new
rings on the piston.
7. New rings should be installed when the piston is
removed and reinstalled because piston rings are
given a special finish by the factory to help them
wear-in and seat. In seating, the special finish is
worn off. Reusing piston rings will result in high
oil consumption.
Cylinder Bore Diameter

Make sure cylinder bore is clean and dry before
measuring.
Cylinder Bore Taper
Using a suitable cylinder bore micrometer or gauge,

measure the cylinder bore(s) in the X and Y directions
(90 degrees apart) at points A, B, and C. The X
direction is parallel to the piston pin. The Y direction
is perpendicular to the piston pin and is the direction
of piston thrust.
Subtract the micrometer or gauge reading from point

C direction Y from point A direction Y. Also from point
C direction X from point A direction X.
Each
difference should be less than 0.127mm (0.005 inch).
If taper exceeds this specification, cylinder will have to
be refinished.
Cylinder Out-of-Round
Subtract the reading in direction X (non-thrust) from
direction Y (thrust side) at all points A, B, and C. All
readings should be less than 0.127mm (0.005 inch).
If out-of-round exceeds this specification, cylinder will
have to be refinished.
SERVICE PROCEDURES
01-22
Cylinder Bore Clearance
01-22
Cylinder Wall Honing
1. Measure the diameter of the piston on the thrust

side at right angles to the piston pin--25.4mm
(1.00 inch) below the oil ring groove.
Hone the cylinder bore:
When reinstalling a piston with new rings.
To resize a cylinder to accept a service parts

piston going into it.
1. Measure the diameter of the piston on the thrust

side at right angles to the piston pin -- 25.4mm
(1.00 inch) below the oil ring groove.
2. Measure the cylinder bore diameter at right
angles to the piston pin at points A, B, and C as
described under cylinder taper.
3. Subtract the piston diameter from the maximum
cylinder bore diameter to determine the maximum
amount of material that can be removed.
2. Measure the cylinder bore diameter at right
angles to the piston pin at points A, B, and C as
described under cylinder taper.
3. Subtract the piston diameter from the cylinder
bore diameter. The difference should not exceed
the maximum piston-to-bore clearance found in
Specifications in Section 02.
4. Hone the cylinder according to the hone

manufacturers instructions to obtain the proper
bore surface finish of 18-38 RMS.
5. Keep the hone moving up and down to achieve
the proper crosshatch pattern.
6. Measure frequently to make sure that you do not
remove too much of the cylinder wall, creating
excess clearance.
SERVICE PROCEDURES
01-23
01-23
Cylinder Head Service

On Engine Inspection
CAUTION: The overuse of cleaning fluids
may cause engine damage not covered
under warranty.
Check for loose mounting bolts, studs and nuts.
Check for a plugged oil feed in the rocker arm, or

cylinder head.
Check for broken or damaged valve springs.
Check for proper seating of valve spring retainer

keys on valve stem and in valve spring retainer.
Check for signs of improper head gasket

installation, such as the shape of the head and
block and shape of the gasket not matching .
Check for signs of cylinder head gasket leakage

such as coolant or oil leaking between the
cylinder block and cylinder head.
1. Perform engine inspection of vacuum lines and

wiring.
Check for plugged oil drain-back holes.
2. Perform normal engine diagnostics. Check fuel

and ignition systems.
Check for worn or damaged valve tips.
Check for missing or damaged intake and

exhaust valve stem seals.
3. If normal diagnostics have not resolved the

engine performance concerns, proceed with the
following IVD inspection steps.
Check valve clearance.
4. Remove any two spark plugs.
Check installed spring height.
Check for missing or worn valve spring seats, if

equipped.
On Engine Valve Cleaning

The intake valve cleaning procedure is to be used if
there is a concern with engine hesitation, rough idle,
long crank times, and stall at idle and engine
engagement after cold starts.
Many fluids are available to clean carburetors. Some
cleaning fluids also claim to remove intake valve
deposits (IVD). Engineering evaluation of these fluids
indicates no ability to remove the intake valve
deposits. If engine performance concerns have been
affected by cleaning fluids, it is most likely due to
cleanup of carburetor deposits. IVD is more difficult
to remove than carburetor deposits. IVD must be
COMPLETELY removed to restore cold start and
normal engine performance.
CAUTION: Only walnut shell blasting

using Rotunda 014-00975 Carbon Blaster
and
Automotive
Borescope,
or
equivalent is recommended for removing carbon
from engine valves with the engine assembled.
Other abrasives may cause engine damage on
start-up if not completely removed.
CAUTION: Do not bump the engine

with the remote starter switch or
ignition switch with the borescope in
the spark plug hole or attempt to view the
valve while rotating the engine. Damage to
the borescope or engine may result.
5. Use a remote starter switch to bump the engine
over until the intake valve is fully open in the
cylinder to be inspected.
CAUTION: Do not power the

borescope light source from a
vehicle battery while it is being
charged.
For example, if the engine is
running or the battery is connected to a
charger, the lamp may fail.
SERVICE PROCEDURES
01-24
6. Using the Rotunda Carbon Blaster and

Automotive Borescope 014-00975, or equivalent
automotive borescope, inspect the backside of
the intake valves through the spark plug holes for
the presence of carbon deposits. Compare the
deposits with the deposit rating system chart. If
any of the intake valves appear to have a carbon
deposit level of 7 or less (lower number rating),
intake valve cleaning is required. If no carbon
deposits are seen or the deposit level is 8 or
cleaner, the drive concern may be the result of
low volatility fuel.
Cleaning
With the valves installed to protect the valve seats,
remove deposits from the combustion chambers and
valve heads with a scraper and a wire brush. Be
careful not to damage the cylinder head gasket
surface. After the valves are removed, clean the
valve guide bores. Use cleaning solvent to remove
dirt, grease and other deposits from the valves with a
fine wire brush or buffing wheel.
CAUTION: Do not plane or grind more

than 0.25mm (0.010") from original
cylinder head gasket surface.
7. Remove the intake manifold assembly as outlined

in Section 02.
8. Remove flex hose and manifold adapter form the
hand-held vacuum included with the Rotunda
014-00975 Carbon Blaster and Automotive
Borescope. Insert tapered end of vacuum hose
into intake port of cylinder head using a twisting
motion to ensure a tight fit.
NOTE: Detailed written instructions and a procedural
video tape are included with the Rotunda 014-00975
Carbon Blaster and Automotive Borescope. Perform
the intake valve carbon cleaning procedure, using the
Rotunda 014-00975 Carbon Blaster or equivalent.
The intake valves should be in the closed position.
Cleaning takes approximately 1 to 1 minutes per
valve.
01-24
Inspection
Inspect the cylinder head for cracks or

excessively burned areas in the exhaust outlet
ports. Replace the cylinder head if it is cracked.
Check the cylinder head gasket surface for burrs

and nicks. Small imperfections of this type can be
dressed down using an oil stone.
9. Confirm the intake valve is clean using Rotunda

014-00975, or equivalent automotive borescope.
10. Using a remote starter switch, bump the engine
over until the remaining intake valves to be
cleaned, are in the closed position, and clean
them as outlined above.
11. Install the intake manifold as outlined in Section
02.
SERVICE PROCEDURES
01-25
01-25
Spark Plug Thread Service

NOTE: The use of power or air driven tools is not
approved for the installation of tapersets.
3. Remove tap. Remove all metal chips using

compressed air.
Damaged spark plug threads in the cylinder head can

be serviced using Rotunda Taperset Installation Kit
107-R0901, or equivalent.
4. Coat threads of mandrel with cutting oil. Thread

taperset onto mandrel until one thread of mandrel
extends beyond taperset.

NOTE: A properly installed taperset will be flush
to one millimeter below spark plug gasket seat.
5. Thread taperset into tapped spark plug hole using
a torque wrench. Continue tightening mandrel
until torque wrench indicates 61 N-m (45 lb-ft).
The procedure involves cutting new threads in the
spark plug hole. After rethreading operation, a
tapered sleeve will be installed in the cylinder head.
The sleeve is threaded on the inside and outside.
The outside threads into the cylinder head while the
inside provides new threads for the spark plug.
6. To loosen mandrel for removal, hold mandrel

stationary and turn mandrel body approximately
on-half turn. Remove mandrel.
The service is permanent and will have no effect on

cylinder head or spark plug life.
CAUTION: The cylinder head must be

removed from the engine before
installing a taperset.
The service
procedure includes a thread cutting process
which produces metal chips. Performing this
procedure while the cylinder head is on the
engine will cause metal chips to fall into the
cylinder. Once in the cylinder, these chips can
damage the cylinder wall when the engine is
started.
1. Thoroughly clean spark plug counter bore, seat
and threads of all dirt or other foreign material.
2. Start tap into spark plug hole being careful to
keep it properly aligned. As tap begins cutting
new threads, apply oil to tap. Continue cutting
threads and applying oil until stop ring bottoms
against spark plug seat.
SERVICE PROCEDURES
01-26
01-26
Cylinder Head Flatness
Valve Stem-to- Guide Clearance
NOTE: Do not plane or grind off more than

0.254mm (0.010 inch).
1. Check the valve stem-to-guide clearance of each

valve in its respective valve guide with Valve
Stem Clearance Tool TOOL-6505-E, or
equivalent. Use a flat-end indicator point.
When a cylinder head is removed because of gasket

leaks, check the flatness of the cylinder head gasket
surface for conformance to specification.
If
necessary, refinish the cylinder head gasket surface.
2. Install TOOL-6505-E to cylinder head. Permit the

valve to drop away from its seat 9.55mm (0.375
inch). Contact tip of valve stem with dial indicator
and tighten clamping knob.
Valve Seat Runout

Check the valve seat runout with Valve Seat Runout
Gauge D81P-6002-E, or equivalent, as illustrated
below.
Follow the instructions of the gauge manufacturer. If
the runout exceeds the wear limit, reface the valve
and valve seat. For specifications, refer to Section
02.
3. Position the dial indicator with its flat tip against
the center portion of the tools spherical section at
approximately 90 degrees to the valve stem axis.
4. Move the valve stem back and forth in line with
the indicator stem.
5. Take a reading on the dial indicator without
removing the tool from the valve guide upper
surface.
6. Divide the reading by two, the division factor for
the tool.
7. If valve stem-to-guide clearance exceeds the
wear limit, ream the valve guide for the next
oversize valve stem as described in this section.
SERVICE PROCEDURES
01-27
Valves, Select Fitting

If the valve stem-to-guide clearance exceeds the
service clearance, ream the valve guide for the next
oversize valve stem. Valves with oversize stem
diameters are available for service. Refer to Master
Parts Catalogue for available sizes. Always reface
the valve seat after the valve guide has been
reamed. Refer to Valve Guide Reaming.
In the case of valve stem-to-guide clearance, the
service clearance is intended as an aid to diagnosing
engine noise only, and does not constitute a failure or
indicate need for service.
However, when
overhauling or reconditioning a cylinder head, the
service clearance should be regarded as a practical
working value, and used as a determinant for
installing the next oversize valve to make sure service
life is extended.
Valve Guide Reaming

If it becomes necessary to ream a valve guide to
install a valve with an oversize stem, a hand reaming
kit is available which contains the following reamer
and pilot combinations:
0.38mm (0.015-inch) OS reamer with a 0.076mm

(0.003-inch) OS pilot.
0.76mm (0.030-inch) reamer with a 0.38mm

(0.015-inch) OS pilot.
01-27
NOTE: If oversize valve stems and oversize stem

seals are not available, bore out original valve
guide and install service bushing (if available).
Ream inside diameter for specified clearance for
standard size valve.
Reface valve seat, as
required. Install standard size valve stem oil seal.
When replacing a standard size valve with an
oversize valve, always use the reamer in sequence
(smallest oversize first, and then the next smallest,
etc.) so as not to overload the reamers. Always
reface the valve seat after the valve guide has
been reamed, and use a suitable scraper to break
the sharp corner (inside diameter) at the top of
the valve guide.
NOTE: The interference angle of the valve and
seat should not be lapped out. Remove all
grooves or score marks from the end of the valve
stem and chamfer it as necessary. Do not remove
more than 0.254mm (0.010 inch) from the end of
the valve stem.
If the valve face runout is excessive and/or to remove
pits and grooves, reface the valves to a true 45
degree angle. Remove only enough stock to correct
the runout or to clean up the pits and grooves. If the
edge of the valve head is less than 0.0794mm (1/32
inch) thick after grinding, replace the valve as the
valve will run too hot in the engine.
If the valve and/or valve seat has been refaced, it will
be necessary to check the clearance between the
rocker arm pad and the valve stem with the valve train
assembly installed in the engine.
SERVICE PROCEDURES
01-28
01-28
Grind the valve seats of all engines to a true 45degree 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
specification.
Item
Description
Valve
Valve Seat Angle
Seat Width and Proper Location on Valve
Bottom Narrowing Angle 75 degrees
Top Narrowing Angle 30 degrees
Valve Face Angle
Valve Margin
If the valve seat width exceeds the maximum limit,

remove enough stock from the top edge and/or
bottom edge of the seat to reduce the width to
specification.
On the intake and exhaust seats, use a 60-degree
angle grinding wheel to remove stock from the bottom
of the seat (raise the seats). A 30-degree angle
wheel is used to remove stock from the top of the
seats (lower the seats).
Valve Seats, Refacing

Measure the valve seat width. Reface the valve
seat(s) if the width is not within specifications. Refer
to the specifications section.
Refer to Engine Service in the Rotunda Tool catalog
for a description of the various types of valve seat
grinders and cutters available.
Refacing the valve seat should be closely coordinated
with the refacing of the valve face so that the finished
seat and valve face will be concentric and the
specified interference angle will be maintained. This
is important so that the valve and seat will have a
compression-tight fit. Make sure refacer grinding
wheels are properly dressed.
The finished valve seat should contact the

approximate center of the valve face. It is good
practice to determine where the valve seat contacts
the face.
To do this, coat the seat with Prussian Blue and set
the valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of the
valve face, the contact is satisfactory. If the blue is
transferred to the top edge of the valve face, lower
the valve seat. If the blue is transferred to the bottom
edge of the valve face, raise the valve seat.
SERVICE PROCEDURES
01-29
01-29
Valve Inspection
Valves, Refacing
Inspect the valve stem for bends, and the end of

the stem for grooves or scoring.
NOTE: Discard any excessively worn or damaged

valve train parts.
Inspect the valve face and the edge of the valve

head for pits, grooves or scores.
Minor pits or grooves may be removed.
Inspect the stem for a bend condition and the end

of the stem for grooves or scores.
Check the valve head for signs of burning or

erosion, warpage and cracking.
Minor pits,
grooves, etc., may be removed. Discard severely
damaged valves.
Discard valves that are severely damaged if the

face runout cannot be corrected by refinishing or
if stem clearance exceeds specification. Refer to
specifications section for valve specifications.
Refer to Engine Service in the Rotunda Tool

catalog for a description of the various types of
valve resurfacing equipment.
The valve refacing operation should be closely

coordinated with the valve seat refacing
operations so that the finished angles of the valve
face and valve seat will be to specifications and
provide a compression-tight fit.
Make sure refacer grinding wheels are properly

dressed.
Inspect the valve spring, valve spring retainer,

valve spring retainer keys and discard any
visually damaged parts.
SERVICE PROCEDURES
01-30
01-30
Valve Spring Tension
Valve Spring Squareness
Inspect the valve spring, valve spring retainers, and

keys for wear or damage. Discard any damaged
parts.
Check each valve spring for squareness using a steel

square and a flat surface. Stand the valve spring and
square on end of the flat surface. Slide the valve
spring up to the square. Revolve the valve spring
slowly and observe the space between the top coil of
the valve spring and the square.
Check the valve springs for proper pressure at the

specified spring lengths using Valve/Clutch Spring
Tester TOOL-6513-DD, or equivalent.
Apply torque until click is heard, read torque wrench

and multiply reading by two. Weak valve springs
cause poor engine performance. Replace any valve
spring not within specification.
Refer to the
specification section. Manually rotating the valve
spring assemblies while installed in the engine will not
determine condition of valve springs.
CAUTION: Make sure the valve springs

are reassembled to their own original
dampers by pushing damper on the
spring. Do not open damper with any kind of tool
in order to reassemble.
Refer to specifications for out-of-square limits. Follow

this same procedure for new valve springs before
installation. Make sure the proper valve spring (colorcoded) is installed.
CAUTION: Make sure the valve springs

are reassembled to their own original
dampers by pushing damper on the
valve spring. Do not open damper with any kind
of tool in order to reassemble.
SERVICE PROCEDURES
01-31
01-31
If the core plug replacing tool has a depth seating

surface, do not seat the tool against a non-machined
(casting) surface.
Engine Block Plug Service

Special Tools
Cup-Type
Impact Slide Hammer
T59L-100-B
Impact Slide Hammer
T50T-100-A
Removal and Installation

To remove a large core plug, drill a 12.70mm (1/2
inch) hole in the center of the plug and remove with
an Impact Slide Hammer T59L-100-B or T50T-100-A
or pry it out with a large drift punch. On a small core
plug, drill a 6.35mm (1/4 inch) hole in the center of the
plug and pry it out with a small pin punch. Clean and
inspect the plug bore.
Prior to installing a core plug, the plug bore should be
inspected for any damage that would interfere with
the proper sealing of the plug. If the bore is
damaged, it will be necessary to true the surface by
boring for the next specified oversize plug.
Cup-type core plugs are installed with the flanged

edge outward. The maximum diameter of this plug is
located at the outer edge of the flange. The flange on
cup-type plugs flare outward with the largest diameter
of the outer (sealing) edge.
CAUTION: It is imperative to pull the plug

into the machined bore by using a
properly designed tool.
Under no
circumstances is the plug to be driven into the
bore using a tool that contacts the flange. This
method will damage the sealing edge and will
result in leakage and/or plug blowout.
Oversize plugs are identified by the OS stamped in

the flat located on the cup side of the plug.
Coat the plug and/or bore lightly with an oil-resistant
(oil galley) Stud and Bearing Mount E0AZ-19554-BA,
or equivalent, meeting Ford specification WSKM2G349-A1 or Threadlock 262 E2FZ-19554-B, or
equivalent, meeting Ford specification WSK-M2G351A6, and install it following the procedure for cup-type
or expansion-type below:
Expansion-Type
Expansion-type core plugs are installed with the
flange edge inward. The maximum diameter of this
plug is located at the base of the flange with the
flange flaring inward.
CAUTION: It is imperative to push or

drive the plug into the machined bore
using a properly designed tool. Under
no circumstances is the plug to be driven using a
tool that contacts the crowned portion of the
plug. This method will expand the plug prior to
installation and may damage the plug and/or plug
bore.
The flanged (trailing) edge must be below the

chamfered edge of the bore to effectively seal the
plugged bore.
When installed, the trailing (maximum) diameter must

be below the chamfered edge of the bore to
effectively seal the plugged bore.
SERVICE PROCEDURES
01-32
Exhaust Manifold Service

Cleaning
Remove all gasket or foreign material from all inlet
and outlet sealing surfaces of the exhaust manifold.
Inspection
Inspect the cylinder head joining flanges of the

exhaust manifold for evidence of exhaust gas
leaks.
Inspect the exhaust manifold for cracks, damaged

gasket surfaces, or other damage that would
make it unfit for further service.
A warped or cracked exhaust manifold must be

replaced.
Hydraulic Valve Tappet/Adjuster Service

The hydraulic lash adjusters used in overhead cam
engines are zero-lash hydraulic devices similar in
construction and operation to the hydraulic valve
tappets used on push rod engines. They are cleaned,
inspected and checked in the same manner as
hydraulic valve tappets. The instructions below apply
equally to the lash adjuster and the valve tappet.
Hydraulic tappet noise may be caused by any of the
following:
1. Excessive collapsed tappet gap
A tappet check valve that is not functional may be

caused by an obstruction such as dirt or chips
preventing it from closing when operated, or it may be
caused by broken check valve spring within the
tappet.
Air bubbles in the lubrication system will prevent the
valve tappet from supporting the valve spring load
and may be caused by an oil level that is too high or
too low, or by air being drawn into the system through
a hole, crack or leaking gasket on the oil pump screen
cover and tube.
If the leakdown time is below the specified time for
used valve tappets, noisy operation may result. If no
other cause for noisy valve tappets can be found, the
leakdown rate should be checked, and any outside
the specification should be replaced.
Valve tappet assemblies should be kept in proper
sequence so that they can be installed in their original
position.
Inspect and test each valve tappet
separately. Do not intermix tappet positions. If any
part of the tappet assembly is worn or otherwise
damaged, replace the entire assembly.
Cleaning
Thoroughly clean all parts in clean solvent and wipe
them with a clean, lint-free cloth.
Inspection
Inspect the parts and discard the entire

tappet/lash adjuster assembly if any part shows
pitting, scoring or excessive wear.
Replace the entire assembly if the plunger is not

free in the body. The plunger should drop to the
bottom of the body by its own weight when
assembled dry and check ball assembly removed.
Assemble the hydraulic tappet/lash adjuster

assembly and check for freeness of operation by
pressing down on the plunger.
The lash adjusters can also be checked with a

hydraulic tester to test the leakdown rate. Follow
the instructions of the test unit manufacturer or
Leakdown Testing in this section.
2. Sticking tappet plunger

3. Tappet check valve not functioning properly
4. Air in lubrication system
5. Leak-down rate too rapid
6. Excessive valve guide wear
Excessive collapsed tappet gap may be caused by
loose valve train parts such as wear of tappet face,
worn roller finger follower, or worn valve tip. With
valve tappet collapsed, check gap between valve tip
and roller finger follower to determine if any other
valve train parts are damaged, or worn. Replace any
worn or damaged parts.
01-32
A sticking tappet plunger may be caused by dirt,

chips, or varnish inside the tappet. The sticking can
be corrected by disassembling the valve tappet and
removing the dirt, chips or varnish that are causing
the condition.
SERVICE PROCEDURES
01-33
Leakdown Testing
Assembled valve tappets can be tested with Hydraulic
Tappet Leakdown Tester TOOL-6500-E, or
equivalent, to check the leakdown rate.
The
leakdown rate specification is the time in seconds for
the plunger to move a specified distance of its travel
while under a 22.7 kg (50 lb.) load. Test the valve
tappets as follows:
01-33
5. Use mark on pointer scale as Stop Timing point

instead of original Stop Timing mark at top of
scale.
6. Allow ram and weight to force tappet plunger
downward. Measure exact time it takes for
pointer to travel from Start Timing to Stop Timing
marks of tester.
NOTE: Do not mix parts from different valve

tappets. Parts are select-fitted and are not
interchangeable.
NOTE: Tappets cannot be checked with engine oil
in them.
Only testing fluid can be used.
Disassemble and clean valve tappet to remove all
traces of engine oil.
7. A valve tappet that is satisfactory must have a

leakdown rate (time in seconds) within minimum
and maximum limits specified in Section 02.
8. Remove fluid from cup and bleed fluid from tappet
by working plunger up and down. This step will
aid in depressing tappet plungers when checking
valve clearance.
1. Place valve tappet in tester, with plunger facing
upward. Pour hydraulic tester fluid into cup to a
level that will cover tappet assembly. The fluid
can be purchased from tester manufacturer.
Using kerosene or any other fluid will not provide
an accurate test.
2. Place a 7.94mm (5/16-inch) steel ball provided
with a tester in plunger cap.
3. Work tappet plunger up and down until tappet fills
with fluid and all traces of air bubbles have
disappeared.
4. Adjust length of ram so that pointer is 1.59mm
(1/16 inch) below starting mark when ram
contacts tappet plunger, to facilitate timing as
pointer passes Start Timing mark.
9. If a valve tappet is not within specifications

replace defective valve tappets with new ones. It
is not necessary to disassemble and clean new
valve tappets to test them since they are shipped
with testing fluid.
Camshaft Follower (if equipped)
Clean all parts thoroughly.
Make sure all oil passages are open.
Inspect the roller finger follower for indications of

scuffing or abnormal wear.
If the pad is grooved, replace the roller finger

follower.
Do not attempt to true this surface by

grinding.
SERVICE PROCEDURES
01-34
01-34
Intake Manifold Service

Cleaning
Inspection
Remove all gasket material from the machined

surfaces of the intake manifold. Clean the manifold in
a suitable solvent and dry it with compressed air.
Check for a hole or crack in top of piston caused

by pre-ignition or foreign object damage.
Inspect for excess wear in ring lands indicated by

visible steps worn in ring lands.
Check for scoring or gouges on piston skirt or

crown.
Check for looseness between piston and piston

pin.
Inspection
NOTE: Remove all filings and foreign matter that
may have entered the manifold as a result of
service.
Inspect the manifold for cracks, damaged gasket

surfaces, or other problems that would make it
unfit for further service.
Replace all studs that are stripped or otherwise

damaged.
Fitting Pistons
Oil Pan Service
Special Tool
Cleaning
Engine Cylinder Hone Set
Scrape any dirt or metal particles from the inside of

the oil pan. Scrape all old gasket material from the
gasket surface. Wash the pan in a solvent and dry it
thoroughly.
Make sure all foreign particles are
removed.
Inspection
Check the oil pan for cracks, holes or damaged

drain plug threads.
Check the gasket surface for damage caused by

overtightened bolts.
Replace with a new oil pan if repairs cannot be

made.
Piston Service
Cleaning
Clean piston using suitable solvent.
Using a putty knife or scraper, clean carbon off of

the top of the piston.
Do not use a power wire brush to clean the piston

skirt, crown, or piston ring grooves as it will
remove metal.
If using a ring groove scraper, be careful not to

remove metal from the piston ring lands.
T73L-6011-A
NOTE: There may be a piston that can be used

when the original standard-size bore shows little
wear and can be cleaned up. This piston must be
select-fitted to the cylinder bore. It will likely be
necessary to hone the cylinder bore in order to
produce the specified piston-to-bore clearance.
To determine if a Service Parts piston can be
installed, and if so, to fit the Service Parts piston,
proceed as follows:
1. Measure the cylinder bore as outlined in this
section under Cylinder Bore Measuring. If the
cylinder bore is not damaged, and wear, taper
and out-of-round are within specifications listed in
Section 02, the cylinder bore may be cleaned up
and a new Service Parts piston select-fitted to the
refurbished bore.
2. Hone the cylinder, if necessary, to restore a
proper crosshatch pattern so new rings can seat.
Remove as little of the cylinder wall as possible.
SERVICE PROCEDURES
01-35
3. After any necessary honing of the cylinder bore,

check that the piston-to-bore clearance is to
specification.
If the clearance is too great,
measure the cylinder bore diameter to determine
if it falls within the Service Limits found in the
Specifications in Section 02. If the bore diameter
falls within the Service Limits, it will be possible to
select-fit a new Service piston. If the bore
diameter exceeds the Service Limits, it will be
necessary to replace the cylinder block assembly.
Oversize pistons are not available for this engine.
01-35
3. Insert the ring in the cylinder bore.

4. Using the piston, without rings, turned upside
down, press the ring down to the center of the
bore.
Fitting Piston Rings

Do not reinstall used piston rings. A special break-in
finish, and sometimes an anti-scuff coating, is given to
new piston rings by the factory. The purpose of this
special finish is to help the new piston rings and
cylinder bore mate properly. The special finish, like
the crosshatching on the cylinder bore, wears off
during break-in. The special finish will be already
worn off used rings so they probably will not seat
properly. For this reason, attempting to reuse piston
rings could lead to excess oil consumption and
possible cylinder scoring.
1. Insert each piston ring backwards in the piston
ring groove into which it will be installed.
5. Make sure that the ring is square in the bore.

6. Using a feeler gauge, check the piston ring end
gap and compare to specification found in Section
02.
2. Measure the clearance between the ring and

groove (side clearance) with a feeler gauge and
check against the side clearance specifications in
Section 02.
SERVICE PROCEDURES
01-36
7. If the ring is too small, the ring will have to be

filled until the end gap is within specifications.
The use of a ring filing block helps ensure that the
ring ends are filed square.
01-36
8. Using a piston ring expander, install the piston

rings starting with the oil control rings. Make sure
rings are installed right side up.
Refer to
instructions with the ring set.
9. Rotate the rings so the end gaps are NOT lined
up but are spaced properly as shown.
CAUTION: Install the piston rings after

the piston has been installed on the
connecting rod. Since the piston may be
supported by the crown during this operation, the
rings could be damaged.
CAUTION: Use a piston ring expander to

install the piston rings. Attempting to
wind them on by hand may put a deep
scratch in the piston or break the ring.
SERVICE PROCEDURES
01-37
01-37
10. Using a feeler gauge, recheck piston ring side

clearance.
11. Continue with engine assembly as outlined in
Section 02.
Piston and Piston Pin Fit

NOTE: New pistons come with fitted piston pins
and should not require refitting unless the
connecting rod bore is oversize.
Some Power Product engines use piston pins which
press into the connecting rods. The piston pivots on
the pin. There is no connecting rod bushing but
rather an interference fit between the piston and the
connecting rod.
Refer to Section 02 for specifications and assembly
instructions.
1. Clean and inspect the connecting rod as outlined
in this section.
2. Clean and inspect the piston and piston pin as
outlined in this section.
3. Using a suitable micrometer, measure the piston
pin where the piston pivots and in the center
where it is pressed into the connecting rod.
4. Using a suitable set of plug gauges or bore

gauge, measure the upper bore of the connecting
rod. An interference fit is required. If the bore is
oversize it will be necessary to install an oversize
piston pin. It is not necessary to reborn or ream
the connecting rod.
5. If the pin-to-rod fit is OK, measure the piston pin
bores in the piston.
6. Subtract the piston pin size from the piston pin
bore sizes. Pin-to-piston clearance is listed in the
specifications section. If clearance is excessive it
will be necessary to fit an oversize piston pin.
7. To fit an oversize piston pin because either the
pin-to-connecting rod or pin-to-piston clearance
was excessive:
Obtain an appropriate oversize piston pin.
Hone or ream the piston pin bores in the

piston to obtain the correct clearance.
It is not necessary to hone or ream the

connecting rod piston pin bore oversize.
8. Once pin, connecting rod, and piston are correctly

sized, assemble as outlined in Section 02.
SERVICE PROCEDURES
01-38
01-38
DESIRED TOOLS (cont.)
SPECIAL TOOLS
Tool Number
Description
TOOL-6513-DD
Valve/Clutch Spring
Tester
TOOL-6565-AB
Cup Shaped Adapter
TOOL-4201-C
Dial Indicator with

Bracketry
REQUIRED TOOLS
Tool
Number/Description
Illustration
T50T-100-A Impact Slide

Hammer
T59L-100-B Impact Slide
Hammer
ROTUNDA EQUIPMENT
T73L-6011-A Engine
Cylinder Hone Set
T73L-6600-A Engine Oil

Pressure Gauge
DESIRED TOOLS
Tool Number
Description
D81L-6002-D
Piston Ring Groove

Cleaner
D81P-6002-E
Valve Seat Runout

Gauge
D81L-6002-B
Plastigage
D87C-77000-A
Transmission Test
Adapter
TOOL-6500-E
Hydraulic Tappet
Leakdown Tester
TOOL-6505-E
Valve Stem Clearance

Tool
SPECIAL TOOLS
Model
Description
112-R0030
Oil Leak Detector Kit
059-R0009
Compression Tester
014-00705
Pressurization Kit
059-00008
Vacuum/Pressure Tester
107-R0901
Taperset Installation Kit
054-00038
Boring Machine
112-r0015
Fluorescent Oil Additive
014-00975
Carbon Blaster and

Automotive Borescope
02-1
Engine Service - 2.5L
SECTION TITLE
02-1
PAGE

ENGINE SERVICE - 2.5L ...................................................................................................................................... 02-01
IGNITION SYSTEM ............................................................................................................................................... 03-01
FUEL PUMP ......................................................................................................................................................... 04-01
CARBURETOR...................................................................................................................................................... 05-01
STARTER MOTOR................................................................................................................................................ 06-01
GOVERNOR.......................................................................................................................................................... 07-01
COOLING SYSTEM .............................................................................................................................................. 08-01
GENERATOR ........................................................................................................................................................ 09-01
SECTION 02 - Engine Service - 2.5L

SUBJECT ..........................................PAGE
SUBJECT........................................... PAGE
DESCRIPTION ......................................................... 2
Cylinder Head ...................................................27
Engine Identification ............................................2
Water Pump ......................................................32
Engine Code Information ....................................3
Water Thermostat/Outlet Connection ...............33
Crankshaft...........................................................3
Intake Manifold (carb. only) ...............................33
Camshaft.............................................................3
Intake Manifold (EFI only)..................................35
Valve Train ..........................................................4
Carburetor ........................................................38
Positive Crankcase Ventilation System ...............4
Exhaust Manifold ..............................................39
Oil Pan ................................................................4
Oil Pump ...........................................................40
Oil Pump .............................................................4
Crankshaft Rear Oil Seal ..................................42
Engine Cooling System .......................................4
Oil Filter and Adapter ........................................42
Lubrication System..............................................5
Oil Pressure Sender ...........................................43
Drive Belt System................................................6
Engine Front Cover ..........................................44
Ignition System....................................................6
Oil Pan ..............................................................46
Fuel System ........................................................6
Oil Pump Screen, Cover, and Tube ..................47
Engine Governing System ..................................7
Crankshaft ........................................................47
Wiring Diagrams..................................................8
Crankshaft Main Bearings ................................51
Engine Components..........................................10
Pistons and Connecting Rods ..........................53
REMOVAL AND INSTALLATION ........................... 14
Connecting Rod Bearings .................................55
Valve Cover and Gasket ..................................14
Camshaft Position Sensor ..................................56
Camshaft Follower/Hydraulic Lash Adjuster ....14
Engine Coolant Temperature Sensor .................56
Valve Spring/Retainer/Stem Seal ....................15
Intake Air Temperature Sensor ..........................57
Crankshaft Pulley and Damper .......................17
Heated Oxygen Sensor ......................................57
Camshaft Timing Belt Outer Cover .................17
Flywheel Ring Gear ............................................58
Camshaft Timing Belt Inner Cover ..................18
DISASSEMBLY AND ASSEMBLY .......................... 59
Camshaft Timing Belt ......................................19
Cylinder Head.....................................................59
Camshaft and Oil Pump Sprocket ...................21
Piston and Piston Pins........................................64
Crankshaft Sprocket ........................................22
Cylinder Block.....................................................64
Timing Belt Tensioner .....................................22
Hydraulic Lash Adjuster......................................65
Camshaft .........................................................23
Bare Cylinder Block ............................................65
Camshaft and Oil Pump Oil Seal ....................25
ADJUSTMENTS ...................................................... 66
SPECIFICATIONS................................................... 67
Cylinder Block Front Cover Seal .....................26
02-2
02-2
Hydraulic lash adjusters are used in the valve train.

These units are placed at the fulcrum point of the cam
followers. Their action is similar to the hydraulic
tappets used in a push rod engine. The cylinder head
has drilled oil passages to provide engine oil pressure
to the lash adjusters.
NOTE: A set of metric wrenches is required to
service the 2.5L engine.
WARNING: TO AVOID T HE POSSIBILITY

OF PERSONAL INJURY OR DAMAGE,
DO NOT OPERATE THE ENGINE UNTIL THE FAN
BLADE HAS BEEN FIRST EXAMINED FOR
POSSIBLE CRACKS OR SEPARATION.
Engine Identification
For quick engine identification, refer to the
identification nameplate.
DESCRIPTION
Engine
The crankshaft is supported by five main bearings
and the camshaft by four. Main, connecting rod, and
camshaft shaft bearings are replaceable.
The nameplate is mounted on the applicable

equipment panels.
A build code and information label is also

attached to the engine.
The symbol code on the build code and

information label identifies each engine for
determining parts usage; for instance, engine
cubic inch displacement (CID) and model year.
The camshaft is driven by the crankshaft with a

cogged timing belt. The timing belt also operates the
oil pump. Tension on the timing belt is maintained by
a timing belt tensioner which bears on the outside of
the belt.
The water pump and the fan are driven from the
crankshaft by a six-ribbed poly-V belt which also
drives the generator.
DESCRIPTION
02-3
02-3
Crankshaft
The crankshaft:
Is made from precision cast nodular iron.
Has five main bearings so each connecting rod is

between two main bearings.
Thrust is taken on the center main bearing to

control end play.
Has a crankshaft damper consisting of a cast iron

hub, pulley and internal ring with rubber
compressed between them to help control
torsional vibration.
The crankshaft damper also has an integral pulse

wheel which provides timing information to the
crankshaft position sensor mounted in the engine
front cover.
Engine Code Information

The engine code information label, located on the
timing belt cover, provides the engine build date,
engine plant code and engine code as well as other
data.
Camshaft
The camshaft operates the engine valves and:
Is located in the cylinder head.
Is supported by four bearings which are pressed

into the cylinder head.
Has end play controlled by a combination thrust

and retainer plate which bolts to the rear
camshaft bearing support.
Is driven by a cogged timing belt which runs off

the crankshaft and also drives the engine oil
pump.
DESCRIPTION
02-4
02-4
Valve Train
The valve train consists of:
Roller finger follower arms.
Hydraulic lash adjusters.
Camshaft motion is transmitted through the rollers in

the finger follower arms to the engine valves.
The lash adjusters provide the finger follower fulcrum
point and automatically adjust valve lash for silent
operation.
Positive Crankcase Ventilation System

This engine is equipped with a positive, closed-type
crankcase ventilation system, which recycles
crankcase vapors to the intake manifold.
Oil Pan
The oil pump is a rotor type with an inner rotor which
turns inside of an off-center outer ring.
The oil pump is located in the front of the cylinder
block and is driven by the timing belt through a
sprocket identical to the camshaft sprocket.
Oil Pump
The oil pump contains a pressure relief valve. To
deliver sufficient pressure and volume at low rpm, the
pump is designed to provide high pressure and
volume at high rpm. To prevent damage or excess oil
consumption, the pressure relieve valve exhausts
excess pressure and volume at high rpm.
The oil pump is not serviced except to replace he
front seal and the two O-rings that seal it to the
cylinder block.
Engine Cooling System

The 2.5L Engine is liquid cooled using an engine
mounted water pump and external radiator. This is a
full flow system regulated by a water thermostat
located behind the water outlet connection. The
thermostat controls and maintains engine
temperature.
Typical coolant flow produced by the centrifugal water
pump is through the engine block and then into the
cylinder head. From the cylinder head it flows
through the thermostat and water outlet connection
into the upper radiator hose and down through the
radiator for cooling. A passage from the water outlet
connection through a heater/by-pass hose allows
coolant to flow to the intake manifold which provides
heat for fuel atomization. It then flows through
another heater/by-pass hose assembly to the inlet
side of the water pump.
DESCRIPTION
02-5
Lubrication System
The engine lubrication system consists of:
Oil pan
Oil pump screen cover and tube
Oil pump
Oil filter
Passageways in the cylinder block , crankshaft ,

camshaft and cylinder head.
The oil pan is pressure-cast aluminum and serves as

both an oil reservoir and engine bottom cover. The oil
pan has reinforcing ribs which strengthen the pan,
reduce engine noise transmission, and aid in oil
cooling.
DESCRIPTION
02-5
02-6
Drive Belt System

Engine accessories, such as the generator and water
pump , are driven by a single poly-V belt. A direct
drive fan is attached to the water pump pulley which is
driven by the poly-V belt when the engine is running.
Ignition System
The ignition used on the 2.5L engine is an Electronic
Distributorless Ignition System (EDIS). A crankshaft
position (CKP) sensor and vacuum port on the intake
manifold (provide the necessary information to an
ignition module. The module determines when to fire
the ignition coil mounted on the generator bracket,
based on the two sensors. Standard distributorless
ignition coil, wires and spark plugs are used to ignite
the fuel in the cylinders.
Fuel System
The fuel system includes a REMOTE-MOUNTED
electric fuel pump. The pump regulates and
maintains fuel flow, through an in-line fuel filter to the
carburetor mounted on the intake manifold.
Depending on engine application, either a Holley or
Zenith model carburetor can be used to provide the
necessary fuel for combustion.
DESCRIPTION
02-6
02-7
02-7
Engine Governing System
Velocity Governor
Mechanical Governor (Carb)
The velocity governor is an engine speed limiting

type, and operates by metering the air/fuel mixture
flow from the carburetor. The governor is installed
between the carburetor and the intake manifold. It
contains a disc valve mounted on a shaft which is
similar in appearance to a carburetor butterfly valve.
However, unlike a butterfly valve, the governor shaft
is mounted off center in the governor bore.
Mechanical, belt driven, flyweight type governors are

used on the 2.5L engine. Constant speed and
variable speed governors can be used depending on
application. The governor is attached to the
carburetor by a linkage system. The governor,
through the linkage, limits carburetor throttle plate
opening. This provides regulation and control of
engine rpm during operating engine loads.
The governor is attached to a bracket bolted to the
lower left front of the engine block and is slotted for
belt adjustment. A single V-type belt and pulley are
used to operate the governor.
Electronic Governor (Carb)
The electronic governor consists of three main
components:
Controller
Actuator
Carburetor with special throttle shaft and

mounting pad for the actuator
As engine speed increases, the velocity of the air/fuel

mixture passing across the disc valve increases.
Since the governor shaft is mounted off center, the
force of the flowing air/fuel mixture attempts to close
the disc valve, therefore restricting the flow and
slowing the engine. The force of the flowing air/fuel
mixture attempting to close the valve is opposed by a
spring. The force of the spring therefore establishes
maximum engine speed.
The controller is connected to the actuator by a wire

harness. The controller receives two input signals:
Engine speed is sensed from the EDIS

(Electronic Distributorless Ignition System)
Using a remote-mounted speed select switch, up

to four engine operating speeds can be selected.
There is one output from the controller:
The controller sends a modulated signal to the

actuator at the carburetor. The actuator in turn
controls the throttle shaft, which determines
throttle plate position. Signal strength is varied,
by the controller, depending on the input values.
The electronic governor has an internal FAIL-SAFE

circuit that instantly reacts to:
Interruption of power to the controller which

removes power to the actuator. A return spring in
the actuator moves the throttle shaft to minimum
fuel position.
Loss of speed signal input which causes the

controller to remove power to the actuator. A
return spring in the actuator moves the throttle
shaft to minimum fuel position.
DESCRIPTION
02-8A
Wiring Diagrams - Carbureted
DESCRIPTION
02-8A
02-8B
Wiring Diagrams - Carbureted
DESCRIPTION
02-8B
02-9A
Wiring Diagrams - EFI
DESCRIPTION
02-9A
02-9B
02-9B
Wiring Diagrams EFI
* CAUTION: EARLY
PRODUCTION CIRCUITS 674
AND 351D HAVE THE SAME
COLOR WIRE. CROSSING
THESE CIRCUITS WILL
CAUSE DAMAGE.
CIRCUIT #
915
914
787
* 674
658
570E
570C
359M
* 351D
307
306
253
209
198
151
107
39
37B
37
32A
32
16A
11
CIRCUIT DESCRIPTION
DATA LINK CONNECTOR RS485 (NEGATIVE)
DATA LINK CONNECTOR RS485 (POSITIVE)
TO FUEL PUMP
FUEL SELECT (OPEN CIRCUIT = PRIMARY FUEL; 12V = SECONDARY
MALFUNCTION INDICATOR LAMP (OPEN COLLECTOR OUTPUT 500 mA
POWER GROUND BATTERY (NEGATIVE)
POWER GROUND BATTERY (NEGATIVE)
DRIVE BY WIRE SIGNAL RETURN (SIGNAL RETURN FOR DRIVE BY
DRIVE BY WIRE VREF (5V REF VOLT FOR DRIVE BY WIRE POT)
GOVERNOR SPEED SELECT #2 (GVS2) SEE BELOW DESCRIPTION FOR
GOVERNOR SPEED SELECT #1 (GVS1)
0
0
OIL PRESSURE FOR INDICATOR LIGHT (OPEN = LOW PRESSURE;
SELF TEST INPUT (SHORT TO GROUND TO ACCESS TROUBLE CODES)
AUXILLIARY INPUT
DRIVE BY WIRE SIGNAL INPUT (0-5V SIGNAL)
DATA LINK CONNECTOR RS485 (GROUND)
WATER TEMPERATURE INDICATOR SENDER TO GAUGE
KEEP ALIVE POWER BATTERY
VPWR POWER RELAY SWITCHED SIDE 12V (BATT+)
TO STARTER SOLENOID S TERMINAL
FROM IGNITION SWITCH START MODE TERMINAL
SWITCHED IGNITION 12V
TO TACHOMETER
DESCRIPTION
COLOR
PK-LB
T-O
PK-BK
Y-BK
PK-LG
BK-W
BK-W
GY-R
BR-W
BK-Y
T-LB
DG-W
W-P
DG-O
LB-BK
P
R-W
Y
Y
DB
R-LB
R-LG
T-Y
GAUGE
18
18
16
18
18
12
12
18
18
18
18
18
18
18
18
18
18
18
12
16
16
16
18
42 PIN
3
11
5
7
6
42
34
33
31
25
24
26
18
37
14
22
16
8
9
15
13
1
2
02-10
02-10
Item
Description
Item
Description
Bolt, M10-1.5 x 55 (7 places)
35
Camshaft Sprocket
Exhaust Manifold
36
Crankshaft Front Seal
Engine Lifting Eye (rear)
37
Camshaft
Nut, M10-1.5
38
Water Outlet Connection
Stud, M10-1.5 x M10-1.5 x 84
39
Bolt, M8-1.25 x 18
Exhaust Manifold Gasket
40
Water Thermostat
Valve Cover Gasket
41
Thermostat Gasket
Valve Cover
42
Intake Valve
Crankcase Ventilation Hose
43
Exhaust Valve
10
Oil Filter Cap
44
Cylinder Head
11
Screw, M6-1 x 15
45
Engine Oil Pressure Sender
12
Bolt, M8-1.25 x 25 (7 places)
46
Camshaft Retaining Plate
13
Engine Lifting Eye (front)
47
Screw, M6-1 x 16
14
Nut, M8-1.25
48
Spark Plug
15
Bolt, M8-1.25 x 33
49
Spark Plug Wire and Bracket Assembly
16
Stud, M8-1.25 x 1.25 x 63.7
50
Bolt, M12-1.75 x 100.7 (10 places)
17
Intake Manifold
51
Valve Stem Seal
18
Intake Manifold Gasket
52
Valve Spring
19
Head Gasket
53
Valve Spring Retainer
20
Cylinder Block
54
Valve Spring Retainer Key
21
Inner Timing Belt Cover
55
Roller Finger Follower
22
Screw, M6-1 x 22.5
56
Hydraulic Lash Adjuster
23
Nut, M6-1
57
Camshaft Oil Flow Control Rod
24
Stud, M8-1.25 x 51
58
Expansion Plug
25
Plug, Rubber 1-1/4 x 7/16
26
Bolt, M6-1 x 17
27
Outer Timing Belt Cover
28
Bolt, M8-1.25 x 20
29
Timing Belt Spring Bolt
30
Timing Belt Tension Spring
31
Belt Tensioner Assembly
32
Timing Belt
33
Bolt, M12-1.75 x 45
34
Camshaft Sprocket Washer
DESCRIPTION
02-11
DESCRIPTION
02-11
02-12
DESCRIPTION
02-12
02-13
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
Description
Drive Belt Tensioner
Water Pump Inlet Tube
Screw, M6-1 x 22.5
O-ring
Bolt, M10-1.5 x 60
Ignition Coil
Generator Mounting Bracket
O-ring
Crankcase Vent Oil Separator
Screw, M6-1 x 15
PCV Valve and Hose Assembly
Closed Crankcase Vent Hose
Pipe Plug, 3/8-18 x 3/8
Water Temperature Indicator Sender
Oil Filter Mounting Insert
Oil filter
Crankshaft Rear Oil Seal
Crankshaft
Crankshaft Main Bearing (lower)
Stud, M10-1.5 x M12-1.75 x 108.5
Oil Pump Cover Screen and Tube
Nut, M10-1.5
Bolt, M8-1.25 x 20
Oil Pump Inlet Tube Gasket
Oil Pan Gasket
Bolt, M6-1 x 57.5
Oil Pan Drain Plug Gasket
Oil Pan Drain Plug
Screw, M6-1 x 27.5
Oil Pan
Bolt, M14-1.5 x 55
Crankshaft Pulley Retaining Washer
Crankshaft Pulley
Crankshaft Sprocket
Crankshaft Front Seal
Bolt, M6-1 x 37.5
Engine Front Cover
Engine Front Cover Gasket
Bolt, M12-1.75 x 80
Front Main Bearing Cap
Front Intermediate Main Bearing Cap
42
Center Main Bearing Cap
43
Rear Intermediate Main Bearing Cap
02-13
Item
Description
44
Rear Main Bearing Cap
45
Crankshaft Main Bearing Upper (blue)
46
Crankshaft Main Bearing Upper (3 places)
47
Crankshaft Thrust Main Bearing
48
Pipe Plug, 3/8-18
49
Bolt, M6-1 x 14
50
Cylinder Block Ventilation Baffle
51
Bolt, M6-1 x 20
52
Crankshaft Position Sensor
53
Stud, M6-1 x 1 x 61.9
54
Oil Pump Sprocket
55
Oil Pump Sprocket Washer
56
Bolt, M10-1.5-40
57
Oil Pump Front Seal
58
Bolt, M6-1 x 47.5
59
Oil Pump Assembly
60
O-ring, Oil Pump Outlet/Vent
61
O-ring, Oil Pump Inlet/Outlet
62
Oil Pump to Cylinder Block Gasket
63
Screw, M8-1.25 x 25
64
Water Pump Pulley
65
Bolt, M8-1.25 x 53
66
Water Pump
67
Water Pump Housing Gasket
68
Dowel
69
Piston and Connecting Rod
70
Upper Compression Ring
71
Second Compression Ring
72/73
Oil Control Ring
74
Piston and Rod Assembly
75
Connecting Rod
76
Connecting Rod Bearings
77
Connecting Rod Cap
78
Nut, M9-1
79
Woodruff Key
80
Piston Pin
81
Oil Control Ring Segment
DESCRIPTION
02-14
02-14
REMOVAL AND INSTALLATION
4. Snap ignition wiring harness and ignition cables

back into place in brackets attached to valve
cover.
Valve Cover and Gasket Removal
5. If removed, install oil filler cap.
1. Remove ignition harness.
6. Start engine and check for leaks.
2. Snap ignition cables out of ignition coil and place

to the side.
Camshaft Follower and Hydraulic Lash

Adjuster Removal
3. Remove bolts and valve cover.

4. Remove valve cover gasket from valve cover. If
necessary, remove oil filler cap.
Special Tools Required

Valve Spring Compressor
T95T-6565-A
1. Remove the valve cover as outlined in this

section.
2. Rotate the camshaft so the rocker arm to be
removed is on the heel of its cam.
3. Using Valve Spring Compressor T95T-6565-A,
compress and hold down the valve and valve
spring. Slide out the roller finger follower over the
lash adjuster.
4. Lift out the hydraulic lash adjuster.
Valve Cover and Gasket Installation

1. Clean valve cover. Clean valve cover gasket
surface on cylinder head.
2. Put valve cover gasket in place on cylinder head.
3. Install valve cover. Alternately tighten bolts to 913 Nm (84-120 lb-in).
02-15
Camshaft Follower and Hydraulic Lash

Adjuster Installation
1. Rotate camshaft so roller finger follower can be
slid under heel of cam.
2. Lubricate contact points of roller finger follower
with Ford Multi-Purpose Grease D0ZA-19584-AA,
or equivalent, meeting Ford specification ESRM1C159-AA.
02-15
Use an appropriate air line tool installed in the spark

plug hole. A minimum of 965 kPa (140 psi) line
pressure is required. If air pressure does not hold the
valve shut, the valve is damaged or burned and the
cylinder head must be removed and serviced. Refer
to the engine service section.
1. Remove the valve cover as outlined in this
section.
3. If removed, place the lash adjuster in position in

the bore.
2. Rotate the camshaft so the roller finger follower

for the valve to be serviced is on the heel of the
cam.
4. Compress the valve spring using Valve Spring

Compressor T95T-6565-A. Position the roller
finger follower over the hydraulic lash adjuster
and the valve stem. Release valve spring.

compress and hold down the valve spring. Slide
out the roller finger follower over the lash
adjuster.
4.
CAUTION: Make sure the hydraulic

lash adjuster has been collapsed and
released before rotating camshaft.
5. Using Valve Spring Compressor T88T-6565-BH,
compress and release hydraulic lash adjuster.
6. Install valve cover as outlined in this section.
Valve Spring, Retainer and Valve Stem

Seal Removal
T95T-6565-A
Valve Guide Replacer
T95T-6510-A
Valve Stem Seal Replacer
T95T-6510-B
If the valve or valve seat has not been damaged, the

valve spring, valve stem seal, valve spring retainer or
valve spring retainer keys may be replaced by holding
the affected valve against its seat using compressed
air.
5. Replace spark plug for cylinder being serviced

with an air line adapter. Mark location so spark
plug is returned to the same cylinder.
CAUTION: The crankshaft may
rotate when air pressure is applied.
Remove all objects from fan area
(lights, extension
cords, etc.).
6. Turn on air supply and pressurize cylinder. Air
pressure may rotate the crankshaft until the
piston reaches the bottom of the stroke.
compress the valve spring and remove the valve
spring retainer keys and valve spring retainer.
Remove and discard the stem seal.
8. If air pressure has forced the piston to the bottom
of the cylinder, any removal of air pressure will
allow the valve(s) to drop into the cylinder. Wrap
a rubber band, tape or string around the end of
the valve stem in such a way to prevent the valve
from falling in and to allow enough travel to check
the valve for binds.
9. Inspect the valve stem for damage. Rotate the
valve and check the stem tip for eccentric
movement. Move the valve up and down through
normal travel in the valve guide and check the
stem for any binding. If the valve has been
damaged, it will be necessary to remove the
cylinder head as outlined in this section.
02-16
02-16
Valve Spring, Retainer and Valve Stem

Seal Installation
CAUTION: Install valve seal protector
(plastic installation cap), included with
valve seal kit, over end of valve before
installing valve stem seal or valve stem seal will
be cut by valve retainer key grooves in valve. If
valve stem seal is cut it will leak causing oil
burning and valve fouling.
1. Put valve seal protector (plastic installation cap)
over end of valve as illustrated.
4. Apply a small amount of Ford Multi-Purpose

Grease D0A2-19584-AA, or equivalent, meeting
Ford specification ESR-M1C159-A to valve spring
retainer key to hold in place during installation.
2. Start valve stem seal carefully over cap. Push

valve stem seal down until jacket touches top of
valve guide.
3. Remove seal protector (plastic cap). Use Valve
Stem Seal Replacer T95T-6510-B to install valve
stem seal on valve guide.
5. With cylinder pressurized, place valve spring and

valve spring retainer into position.
6. Compress valve spring with Valve Spring
Compressor T95T-6565-A and install valve spring
retainer keys. Release spring to seat valve spring
retainer keys in proper cylinder.
7. Release air pressure and remove air adapter.
Install spark plug in proper cylinder.
8. Grease contact surfaces of roller finger follower
with Ford Multi-Purpose Grease D0AZ-19584-AA,
or equivalent, meeting Ford specification ESRM1C159-A.
compress and hold down the valve and spring.
Slide the roller finger follower into place over
valve and lash adjuster. Release spring.
compress and release lash adjuster.
02-17
02-17
Crankshaft Pulley and Damper Removal
4. Remove timing belt outer cover retaining screw.
1. Loosen crankshaft damper bolt.
5. Release seven cover interlocking tabs and

remove outer timing belt cover.
2. Using flex handle, rotate drive belt tensioner and

remove drive belt.
3. Remove crankshaft damper from crankshaft.
Crankshaft Pulley and Damper

Installation
1. Align keyway with key, install crankshaft damper
on crankshaft, and snug crankshaft damper bolt.
2. Position drive belt and rotate drive belt tensioner
away from drive belt.
3. Position drive belt under drive belt tensioner and
release drive belt tensioner, tensioning drive belt.
4. Tighten crankshaft damper retaining bolt to 127165 Nm (93-121 lb-ft).
Camshaft Timing Belt Outer Cover

Removal
Camshaft Timing Belt Outer Cover

Installation
1. Position outer timing belt cover and secure by
snapping the seven interlocking tabs into place.
2. Install timing belt cover retaining screw and
tighten to 8-12 Nm (70-106 lb-in).
3. Install water pump pulley and fan; snug bolts, but
do not tighten.
4. Install drive belt.
5. Using flex handle, rotate drive belt tensioner,
position drive belt, and rest tensioner pulley on
belt.
6. Tighten four clutch and pulley-to-water pump
bolts to 18-22 Nm (13-16 lb-ft).
1. Loosen four fan and water pump pulley -to-water

pump bolts.
2. Rotate drive belt tensioner and remove drive belt.
3. Remove four bolts, fan, and water pump pulley.
02-18
02-18
Camshaft Timing Belt Inner Cover

Installation
1. Position inner timing belt cover on front of engine
and stud.
2. Install nut and bolt and tighten to 8-12 Nm (72108 lb-in).
3. Tighten stud to 20-30 Nm (15-22 lb-ft).
4. Install oil pump sprocket as outlined in this
section.
5. Install timing belt tensioner as outlined in this
section. Tighten M8 bolt to 22-27 Nm (16-20 lbft) and M10 bolts (3) to 40-55 Nm (29-40 lb-ft).
6. Install timing belt as outlined in this section.
Camshaft Timing Belt Inner Cover

Removal
1. Remove timing belt as outlined in this section.
2. Remove timing belt tensioner as outlined in this
section.
3. Remove oil pump sprocket as outlined in this
section.
4. Remove screw and nut securing inner timing belt
cover to cylinder block.
5. Loosen stud two or three turns.
6. Remove inner timing belt cover.
02-19
Camshaft Timing Belt Removal

Camshaft Belt Tension
Adjusting Tool
T74P-6254-A
1. Remove spark plugs.

2. Align crankshaft so number one piston is at TDC
(top dead center) as indicated by timing marks.
Refer to illustration.
3. Remove outer timing belt cover as outlined in this
section.
CAUTION: If you attempt to remove

timing belt or adjust tension without
loosening both timing belt tensioner
adjusting bolt and spring pivot bolt, you will
break Camshaft Belt Tension Adjusting Tool
T74P-6254-A when you attempt to relieve
tension on belt.
4. Loosen timing belt spring pivot bolt. Do not
remove.
5. Hold tensioner with Camshaft Belt Tension
Adjusting Tool T74P-6254-A.
6. While holding tensioner, loosen adjusting bolt and
gradually release spring tension.
7. Using adjusting tool, rotate tensioner against
spring pressure, as far clockwise as possible.
While holding, tighten adjusting bolt to hold
tensioner away from belt.
8. Remove timing belt.
02-19
02-20
02-20
02-21
NOTE: Camshaft and oil pump

gears are identical and are
interchangable. Align the triangle
mark on the camshaft gear and the diamond mark on
the oil pump gear as shown in the above illustration.
02-21
12. Install outer timing belt covers as outlined in this

section.
Camshaft Timing Belt Installation

NOTE: Care must be taken during timing belt
installation to prevent damage to the inner timing
cover.
1. If not done:
a. Loosen tensioner adjusting bolt.
b. Using Camshaft Belt Tension Adjusting Tool
T74P-6254-A, pry tensioner clockwise
against spring tension as far as possible.
c.
Tighten adjusting bolt to hold tensioner in

released position.
2. Align crankshaft so number one piston is at TDC

(top dead center) with crankshaft key pointing
straight up and circle on crankshaft sprocket
aligned with notch in engine front cover.
3. Align triangle on camshaft sprocket with triangle
on inner timing belt cover.
4. Install timing belt over crankshaft sprocket. Then,
proceeding counterclockwise, install timing belt
over oil pump sprocket and camshaft sprocket.
5. Loosen tensioner adjusting bolt allowing tensioner
pulley to press against timing belt.
NOTE: When performing the following step, do
not rotate crankshaft counterclockwise as timing
belt may jump a cog, putting camshaft out of time.
6. Rotate crankshaft two revolutions clockwise.
7. Bring crankshaft slowly, without stopping, to
number one cylinder firing position (keyway
directly up).
8. Recheck timing mark alignment. Repeat the
above Steps if timing marks are not properly
aligned.
9. Rotate tensioner assembly against belt with
torque wrench up to 40-45 Nm (29-33 lb-ft) and
tighten adjusting bolt.
10. Tighten adjusting bolt to 35-45 Nm (26-33 lb-ft).
11. Tighten spring pivot bolt to 40-55 Nm (29-40 lbft).
Camshaft and Oil Pump Sprocket

Removal
NOTE: Removal and installation steps are the same
for both camshaft and oil pump (6600) sprockets.
Cam Sprocket Holding Tool
T74P-6256-B

section.
3. Install Cam Sprocket Holding/Removing Tool
T74P-6256-B on sprocket. Use tool to hold
sprocket and remove bolt and washer.
4. Install threaded puller insert in Cam Sprocket
Holding/Removing Tool T74P-6256-B and
remove sprocket.
5. Remove tool from sprocket.
02-22
Camshaft and Oil Pump Sprocket

Installation
1. Position key and sprocket on shaft.
T74P-6256-B, without threaded puller insert, on
sprocket.
3. Install sprocket bolt and washer and tighten to 7195 Nm (52-70 lb-ft).
02-22
Timing Belt Tensioner Removal

Belt Tension Adjusting Tool
T74P-6254-A
Camshaft Belt Tensioner Tool
T74P-6256-B
4. Remove tool.

section.
6. Install outer timing belt cover as outlined in this

section.
Crankshaft Sprocket Removal

section.
2. Remove crankshaft damper and crankshaft pulley
retaining washer.
3. Remove crankshaft damper.
NOTE: Belt tensioner assembly is under spring

tension.
3. Hold tensioner by prying against spring pressure
with Belt Tensioner Adjusting Tool T74P-6254-A.
Remove adjustment bolt (which goes through slot
in base of tensioner).
4. Release pressure.
5. Remove spring pivot bolt, spring, and tensioner
assembly.

5. Remove crankshaft sprocket.
Crankshaft Sprocket Installation

1. Install crankshaft sprocket.
section.
4. Install crankshaft pulley, washer, and bolt.
Tighten bolt to 125-165 Nm (92-121 lb-ft).
02-23
Timing Belt Tensioner Installation

1. Install belt tensioner and timing belt tensioner
spring on cylinder head placing one leg of spring
under stud on cylinder head and other leg against
pin on tensioner and install spring pivot bolt
loosely.
2. Using Camshaft Belt Tensioner Tool T74P-6256B, rotate tensioner clockwise against spring
tension as far as possible and install adjustment
bolt and tighten to restrain tensioner.
5. Remove camshaft sprocket using Cam Sprocket

Holding/Removing Tool T74P-6256-B.
6. Remove camshaft seal using Front Cover Seal
Remover T74P-6700-B.
7. Remove camshaft retainer plate (two screws).
CAUTION: Be careful to avoid

damaging journal and lobes.
8. Remove camshaft.
NOTE: Spring pivot bolt is to be tightened after

timing belt is installed. Adjusting bolt is tightened
as part of timing belt installation.
4. After installing timing belt, tighten spring pivot bolt
to 40-55 Nm (29-40 lb-ft).
section.
Camshaft Removal
T95T-6565-A
T74P-6256-B
Front Seals Replacer
T74P-6150-A
Front Cover Seal Remover
T74P-6700-B
02-23

section.
2. Remove valve cover as outlined in this section.
3. Rotate the camshaft so the rocker arm is on the
heel of its cam.
compress valve springs and remove all roller
finger followers.
02-24
02-24
02-25
02-25
Camshaft Installation
1. Coat the camshaft lobes with Ford Multi-Purpose
Grease D0AZ-19584-AA, or equivalent, meeting
Ford specification ESR-M1C159-A and lubricate
the journals with heavy oil before installation.
Carefully slide the camshaft through the camshaft
bearings.
2. Install camshaft retaining plate. Tighten screws
to 8-12 Nm (6-9 lb-ft).
3. Install camshaft front seal using Front Seals
Replacer T74P-6150-A.
4. Install camshaft sprocket to camshaft.
5. Install retaining bolt using Cam Sprocket
Holding/Removing Tool T74P-6256-B to hold
sprocket. Tighten to 71-95 Nm (52-70 lb-ft).
section.
compress valve spring and install followers.
compress and release valve tappet.
Camshaft and Oil Pump Oil Seal Removal

NOTE: The camshaft and oil pump shaft seals are
each replaced in the same manner with the same
tools after the respective sprocket has been removed.
NOTE: Always use a new attaching bolt when
replacing the camshaft sprocket or use Teflon, or
equivalent, sealing tape on the threads of the old bolt.
T74P-6256-B
T74P-6700-B
T74P-6150-A

section.
T74P-6256-B on sprocket and use tool to hold
sprocket and remove bolt and washer.
Holding/Removing Tool T74P-6256-B and pull
sprocket.
NOTE: When positioning Front Cover Seal Remover
T74P-6700-B, make sure the jaws are gripping the
thin edge of the seal very tightly before operating the
jack screw portion of the tool.
5. Install Front Cover Seal Remover T74P-6700-B,
making sure jaws are tightly gripping the thin
edge of the seal. Clean journal of debris.
6. Remove seal.
02-26
02-26

section.
Cylinder Block Front Cover Seal Removal

T74P-6700-B
Cam Bearing Adapter Tube
T72C-6250

section.
3. Remove crankshaft pulley hub bolt.
Camshaft and Oil Pump Oil Seal

Installation
4. Slide crankshaft pulley (63120 off crankshaft

(63030.
1. Position camshaft or oil pump shaft seal on Front

Seals Replacer T74P-6850-A and press into
place.
5. Slide crankshaft sprocket off of crankshaft.

6. Remove key from crankshaft.
NOTE: When positioning Front Cover Seal
Remover T74P-6700-B, make sure jaws are
gripping the thin edge of the seal tightly before
operating the jack screw portion of the tool.
7. Install Front Cover Seal Remover T74P-6700-B,
making sure jaws are gripping the thin edge of the
seal.
8. Remove seal.
9. Clean journal of debris.
Cylinder Block Front Cover Seal

Installation
1. Using Cam Bearing Adapter Tube T72C-6250
and crankshaft pulley hub bolt, press engine front
cover seal into engine front cover.
2. Remove tool.
2. Remove tool.
3. Install key.
3. Position sprocket on shaft.

T74P-6256-B,without threaded puller insert, on
sprocket.
5. Install sprocket bolt and washer and tighten to 7195 Nm (52-70 lb-ft).
4. Install crankshaft sprocket, crankshaft pulley,

washer, and bolt. Tighten bolt to 125-165 Nm
(92-121 lb-ft).
section.
6. Remove tool.
02-27
14. Remove fan and water pump pulley.
Cylinder Head Removal

Camshaft Belt Tensioner Tool
02-27
T74P-6254-A
15. Remove timing belt outer cover as outlined in this

section.
1. Disconnect battery ground cable.
17. Remove timing belt tensioner adjuster bolt, spring

pivot bolt, timing belt tensioner spring, and
tensioner.
2. Drain cooling system.
18. Remove front engine lifting eye.
3. Remove intake manifold as outlined in this

section.
19. Remove retaining bolts and intake manifold.

20. Remove rear engine lifting eye.
4. Remove ignition harness.

5. Remove spark plug wire set from spark plugs and
valve cover attachments.
6. Disconnect vacuum hose from ignition module.
7. Remove valve cover and retaining bolts and
remove cover.
8. Using flex handle, rotate drive belt tensioner
counterclockwise and remove drive belt.
9. Disconnect generator electrical connections.
10. Remove lower radiator hose and heater water
hose from water pump inlet tube and thermostat
housing.
11. Remove bolts securing water pump inlet tube to
generator mounting bracket and remove water
pump inlet tube.
12. Remove three bolts from generator. Remove

generator. Remove 3 bolts from generator
mounting bracket. Remove bracket with ignition
coil and ignition wire and brackets attached.
13. Disconnect upper radiator hose at both ends and
remove.
02-28
02-28
21. Remove the eight exhaust manifold retaining

bolts and studs (6 bolts, 2 studs).
22. Remove cylinder head retaining bolts (10).
23. Remove the cylinder head.
24. Clean cylinder head gasket surface at the block.
25. Clean intake manifold gasket surfaces.
26. Clean exhaust manifold gasket surface.
27. Clean exhaust manifold gasket surface at the
cylinder head.
28. Clean cylinder head gasket surface at the cylinder
head.
29. Clean intake manifold gasket surface at the
cylinder head.
30. Blow oil out of the cylinder block bolt holes.
31. Clean valve cover gasket surface on the cylinder
head.
32. Check cylinder head for flatness as outlined in the
engine service section. Cylinder head and
cylinder block head gasket surface should be flat
to 0.08mm (0.003 inch) over any 152mm (6
inches) and flat within 0.15mm (0.006 inch)
overall.
Cylinder Head Installation

1. Position head gasket on the block.
2. Position cylinder head to cylinder block.
3. Install 10 cylinder head bolts in numerical
sequence. Tighten to 70 Nm (52 lb-ft) in
illustrated sequence. Retighten to 70 Nm (52 lbft) in sequence. Then turn all head bolts an
additional 90-100 degrees in sequence.
02-29
4. Install valve cover and valve cover gasket .

Tighten retaining bolts to 9-13 Nm (80-115 lb-in).
5. Install intake manifold and gasket. Tighten
retaining bolts in sequence (refer to illustration) to
6-38 Nm (19-28 lb-ft).
6. Install front lifting eye and tighten nut and bolt to
20-30 Nm (15-22 lb-ft).
7. Install exhaust manifold, gasket, and eight
exhaust manifold retaining bolts and/or stud bolts.
Tighten the bolts in sequence in two steps: 20-30
Nm (15-22 lb-ft), then 48-68 Nm (35-50 lb-ft).
02-29
02-30
02-30
02-31
8. Install timing belt tensioner and timing belt

tensioner spring on cylinder head placing one leg
of timing belt tensioner spring under stud on
cylinder head and other leg against pin on timing
belt tensioner and install spring pivot bolt.
section.
11. Install generator mounting bracket with
assembled ignition coil and ignition wire and
brackets. Refer to the following installation
drawing for correct torque sequence. Tighten in
order illustrated.
02-31
12. Replace O-ring lubricated with silicone grease on

water pump inlet tube.
13. Install water pump inlet tube into water pump.
Tighten inlet tube-to-generator bracket bolts to 912 Nm (84-108 lb-in).
14. Install lower radiator hose.
15. Install generator. Tighten generator-to-bracket
bolts to 40-55 Nm (29-40 lb-ft).
16. Connect upper radiator hose and heater water
hose and tighten hose clamps.
17. Install water pump pulley and fan. Tighten bolts
snug.
18. Position drive belt.
19. Using flex handle, rotate drive belt tensioner,
drive belt.
20. Tighten four fan and pulley-to-water pump bolts to
17-23 Nm (13-17 lb-ft).
NOTE: Spark plug gap is 1.07-1.17mm (0.0420.046 inch).
21. Install spark plugs in proper locations.
22. Position and connect ignition harness. Install
ignition wires.
23. Fill cooling system.
24. Connect battery ground cable.
02-32
02-32
Water Pump Installation

1. Apply Pipe Sealant with Teflon D8AZ-19554A,
or equivalent, meeting Ford specification ESGM4G194-A to water pump bolts prior to
installation.
2. Position gasket and water pump on cylinder block
(6010) and install screws. Alternately tighten to
20-30 Nm (15-22 lb-ft).
3. Replace water inlet tube O-ring (lubricated with
silicone grease).
4. Install water pump inlet tube in water pump.
Tighten water inlet tube-to-generator bracket
bolts to 9-12 Nm (84-108 lb-in).
5. Install lower radiator hose to water pump.
6. Install heater water hose to the water pump inlet
tube.
7. Install water pump pulley and fan and tighten
bolts finger-tight.
8. Using half-inch drive handle, rotate drive belt
tensioner and install drive belt.
Water Pump Removal
9. Tighten fan and water pump pulley bolts to 20-25

Nm (15-19 lb-ft).
2. Using 1/2-inch drive handle, rotate drive belt

tensioner and remove drive belt.
3. Remove fan.
4. Remove water pump pulley.
5. Remove heater water hose to water pump inlet
tube.
6. Remove lower radiator hose from the water pump
inlet tube.
7. Remove water inlet tub-to-generator bracket bolts
and water pump inlet tube.
8. Remove water pump retaining bolts and remove
water pump.
9. Clean water pump gasket surface of cylinder
block.
02-33
02-33
4. Position the water outlet connection retaining

bolts through the water outlet connection holes
and hang gasket on retaining bolts.
5. Install water outlet connection, thermostat, and
gasket to cylinder head and hand-tighten
retaining bolts.
6. Tighten retaining bolts to 20-30 Nm (15-22 lb-ft).
7. Position hose clamp on upper radiator hose and
install clamp and upper radiator hose to water
outlet connection. Tighten and secure hose
clamp.
8. Position hose clamp on heater hose and install
heater hose and clamp on water outlet
connection. Tighten and secure hose clamp.
Water Thermostat and Outlet Connection

Removal
1. Drain the cooling system through the radiator until
the coolant level is below the water thermostat
and water outlet connection.
2. Loosen the hose clamp securing the heater hose
to the water outlet and remove the heater hose.
3. Loosen the clamp securing the upper radiator
hose to the water outlet connection and remove
the hose.
4. Remove water outlet connection retaining bolts
(2) and remove water outlet connection,
thermostat and gasket.
Water Thermostat and Outlet Connection

Installation
1. Clean the water outlet connection and cylinder
head water outlet connection gasket surfaces.
2. Apply Pipe Sealant with Teflon D8AZ-19554-A,
or equivalent, meeting Ford specification ESGM4G194-A to water outlet connection bolts prior
to installation.

Intake Manifold Removal (carb. only)

NOTE: If removing the intake manifold for access to
other components only, the carburetor may remain
attached.
1. Disconnect the battery ground cable.
2. Remove the air cleaner assembly.
3. Drain the coolant from the radiator to a level
lower than the intake manifold.
4. Loosen the heater hose clamp and remove the
heater hose from the coolant fitting on the intake
manifold.
5. Disconnect the electrical connections to:
the choke thermostat (if used).
Electronic governor actuator (if used).
6. Disconnect the manual choke cable from the

choke lever on the carburetor.
7. Remove the support bracket securing the choke
cable and set aside.
NOTE: To prevent incorrect thermostat installation,

the water outlet connection contains a locking recess
into which the thermostat is turned and locked.
8. Disconnect the governor throttle control rod (if

used) from the throttle lever on the carburetor.
3. Install the thermostat with its bridge section in the

water outlet connection. Twist and lock
thermostat into place.
9. Remove the vacuum line from the vacuum tee on

the intake manifold leading to the ignition control
module.
10. Disconnect the PCV valve from the oil separator
beneath the intake manifold.
02-34
11.
12. Disconnect the fuel inlet line from the carburetor
(9510) or fuel filter on the carburetor, depending
on the application.
Caution: Avoid spilling fuel on hot surfaces.
Use an absorbent rag placed under the fuel
line or fuel filter being removed to collect any
spilled fuel.
13. Remove the engine lifting eye.
14. Remove four bottom bolts from intake manifold.
15. Remove the four upper bolts/studs from the
intake manifold.
16. Remove the intake manifold and gasket.
6. Install the PCV valve into the oil separator. Install

the vacuum line from the ignition control module.
7. Connect the governor throttle control rod (if used)
to the carburetor throttle lever.
8. Install the choke cable bracket and the choke
cable to the choke lever on the carburetor.
9. Connect the electrical connections at the choke
thermostat (if used) and electronic governor
actuator (if used).
10. Install the hose clamp on the heater hose and
connect the heater hose to the fitting on the
intake manifold.
11. Install the air cleaner assembly.
12. Fill the cooling system.
Intake Manifold Installation
13. Install the negative battery cable.
1. Clean and inspect the mounting surfaces of the

intake manifold and the cylinder head. Both
surfaces must be clean and flat.
02-34
14. Start the engine and check for leaks.
2. Clean and lightly oil the manifold bolt/stud

threads.
3. Install a new intake manifold gasket.
4. Position the intake manifold to the
cylinder head. Install four manifold
upper retaining bolts/studs finger tight.
5. Install four remaining manifold bolts/studs.
Tighten all bolts/studs to 26-38 Nm 919-28 lb-ft)
following the tightening sequence. Install the
engine lifting eye.
02-35
02-35
Intake Manifold (EFI only)

1. Disconnect the battery ground cable.
12. Remove bolts attaching upper intake manifold.

13. Remove upper intake manifold and gasket.
3. Drain the coolant from the radiator to a level lower

than the intake manifold.
4. Loosen the hose clamp and remove the coolant
hose from the coolant fitting on the intake
manifold.
5. Mark and disconnect necessary electrical
connections.
6. Mark and remove vacuum lines from the vacuum
tee on the intake manifold.
7. Disconnect the PCV tube.
8. Remove the throttle actuator (if necessary).
9. Relieve fuel system pressure.
10.
11. Disconnect the fuel lines to the fuel rail.
Caution: Avoid spilling fuel on hot
surfaces. Use an absorbent rag
placed under the fuel line being
removed to collect any spilled fuel.
11. Remove the engine lifting eye.
02-36
14. Remove engine ground cable at lower intake

manifold.
15. Remove bolts attaching lower intake manifold.
16. Remove lower intake manifold and gasket.
02-36
02-37
Intake Manifold Installation

intake manifold and the cylinder head. Both
surfaces must be clean and flat.
02-37
10. Tighten all bolts to specifications in the tightening

sequence shown:
First pass = 7-10 Nm (5-7 lb-ft).
Final pass = 26-38 Nm (19-28 lb-ft).
2. Clean and lightly oil the manifold bolt/stud

threads.
3. Install a new lower intake manifold gasket.
4. Position the lower intake manifold to the cylinder
head.
5. Install retaining bolts/studs finger tight.
6. Tighten all bolts/studs to specifications in the
tightening sequence shown:
First pass = 7-10 Nm (5-7 lb-ft).
11. Install the engine lifting eye.

12. Connect the PCV tube.
13.
14. Connect the fuel lines to the fuel rail.
placed under the fuel line being
removed to collect any spilled fuel.
15. Install the throttle actuator (if removed).
Final pass = 26-38 Nm (19-28 lb-ft).
7. Install engine ground cable and nut at lower

intake manifold. Tighten to:
9-12 Nm (7-9 lb-ft).
8. Install a new upper intake manifold gasket.

9. Position the upper intake manifold to the cylinder
head. Install retaining bolts finger tight.
16. Connect the electrical connections and vacuum

lines as necessary.
17. Install the hose clamp on the coolant hose and
connect to the fitting on the intake manifold.
18. Install the air cleaner assembly.
19. Fill the cooling system.
20. Install the negative battery cable.
21. Start the engine and check for leaks.
02-38
02-38
Carburetor Removal
1. Disconnect the negative battery cable.
3. Disconnect the electrical connections to:
electronic governor actuator (if used).
NOTE: If the carburetor is not being serviced and is

going to be placed back on the intake manifold, do not
turn the carburetor upside down. This may cause any
float bowl sediment to restrict or clog carburetor
passages or prevent the inlet needle and seat
assembly from closing. The carburetors operation
may be affected.
Carburetor Installation
intake manifold and the base of the carburetor.
Both surfaces must be clean and free of any
gasket material.
2. Install the carburetor base gasket and carburetor
on the intake manifold.
3. Install the retaining nuts on the studs securing the
base of the carburetor.
4. Reconnect the fuel inlet line to the carburetor or
fuel filter on the carburetor, depending on the
application.
5. Reconnect the governor throttle control rod (if
used) to the throttle lever on the carburetor.
6. Perform governor adjustment after carburetor
installation is complete. Refer to Governor
Section.
4. Disconnect the manual choke cable from the
choke lever on the carburetor.
5. Disconnect the governor throttle control rod (if
used) from the throttle lever on the carburetor.
7. Reconnect the manual choke cable to the choke

lever on the carburetor. Adjust cable so that full
opening and closing of the choke plate is
possible.
6.
8. Reconnect the electrical connections to:
7. Disconnect the fuel inlet line from the carburetor

or fuel filter on the carburetor, depending on the
application.
placed under the fuel line or fuel filter
being removed, to collect any spilled
electronic governor actuator (if used).
9. Install air cleaner assembly.

Start the engine, let it warm to operating temperature,
and perform idle mixture and speed adjustments.
fuel.
8. Remove the retaining nuts from the studs
securing the base of the carburetor.
9. Remove the carburetor and carburetor base
gasket from the intake manifold.
02-39
02-39
Exhaust Manifold Removal
Exhaust Manifold Installation
1. Remove exhaust pipe and bracket.
1. If necessary, clean gasket surfaces on exhaust

manifold and cylinder head.
2. Remove two nuts and rear engine lifting eye from

exhaust manifold studs.
3. Remove two studs and six bolts
4. Remove exhaust manifold and gasket from
cylinder head.
2. Install exhaust manifold and exhaust manifold

gasket.
3. Install fasteners.
NOTE: Exhaust manifold fasteners must be
tightened in two stages.
4. Tighten fasteners to 20-30 Nm (15-22 lb-ft)
during the first stage.
5. Retighten fasteners to 60-80 Nm Nm (44-59 lbft) during the second stage.
6. Position rear engine lifting eye on studs and
install retaining nuts and tighten to 20-30 Nm
(15-22 lb-ft).
7. Install exhaust pipe and bracket.
02-40
02-40
Oil Pump Removal

1. Rotate crankshaft so number one piston is at
TDC (Top Dead Center) of its compression
stroke. Refer to the camshaft timing procedure in
this section.
CAUTION: Do not pry on sealing

surfaces.
6. Pry between cylinder block and ear on oil pump
as show to loosen oil pump.

section.
7. Remove oil pump and oil pump-to-cylinder block

gasket.

4. Remove oil pump timing belt sprocket as outlined
in this section.
5. Remove four oil pump screws.
02-41
Oil Pump Installation

NOTE: Inspect and clean oil pump hole in the
cylinder block before installing the oil pump.
1. If original oil pump is to be reused, install new oil
pump O-rings seals on oil pump.
2. Prime back of oil pump and O-rings with 236 ml
(eight ounces) of fresh motor oil.
3. Add oil to cylinder block hole.
4. Install oil pump and oil pump-to-cylinder block

gasket being careful to retain the priming oil in the
back of the pump.
5. Install four oil pump screws and tighten to 10-14
Nm (89-124 lb-in).
6. Install oil pump sprocket as outlined in this
section.
7. Check to make sure crankcase is filled to proper
level with motor oil.
8. Prime oil pump with a drill motor, by rotating oil
pump sprocket approximately 10 revolutions or
until resistance is felt.
9. Align timing marks and install timing belt as
section.
11. Install oil filler cap and tighten until it ratchets.
02-41
02-42
02-42
3. Position tool and crankshaft rear oil seal to rear of

engine. Alternate bolt tightening to seat the
crankshaft rear oil seal properly.
Oil Filter and Adapter Removal

1. Position oil drain pan under oil filter.
2. Using suitable oil filter wrench, loosen oil filter.
3. Unscrew oil filter by hand and remove. Properly
recycle or dispose of oil in filter.
Crankshaft Rear Oil Seal Removal

Jet Plug Remover
T77L-9533-B
Rear Main Seal Replacer
T82L-6701-A
NOTE: Clean exterior surface of crankshaft rear oil

seal and cylinder block before removing crankshaft
rear oil seal.
1. Using a sharp awl, punch one hole into the seal
metal surface between the seal lip and the
cylinder block.
2. Screw in the end of Jet Plug Remover T77L9533-B.
Oil Filter and Adapter Installation
3. Remove crankshaft rear oil seal.
1. Apply clean motor oil, of the same type as is

being used in the engine, to the oil filter gasket.
CAUTION: Use caution to avoid
scratching or damaging block or
crankshaft oil seal surface.
NOTE: Do not tighten filter with oil filter wrench.

2. Install oil filter and tighten by hand.
Crankshaft Rear Oil Seal Installation

1. Apply clean Motorcraft Super Premium Motor Oil
XO-5W30-QSP, or equivalent, meeting Ford
specification ESE-M2G153-E to seal lips and
inner seal edge.
2. Place crankshaft rear oil seal on Rear Main Seal
Replacer T82L-6701-A.
02-43
Oil Pressure Sender

NOTE: The pressure switch-type sender used with
the indicator lamp system is not interchangeable with
the variable resistance-type unit which is used with
the gauge system. Refer to the Master Parts Catalog
for proper parts usage. Installation of the wrong part
will result in an inoperative oil pressure indicating
system and a damaged sender unit or gauge.
1. Make sure the ignition switch is turned off.
2. Disconnect the wire at the sender terminal.
3. Remove the oil pressure sender from the cylinder
head.
4. Apply Pipe Sealant with Teflon D8AZ-19554-A,
or equivalent, meeting Ford specification WSKM2G350-A2 to new sender threads.
5. For installation, follow removal procedures in
reverse order. Tighten switch to 11-24 Nm (8-18
lb-ft).
02-43
02-44
02-44
8. Remove two screws and water pump inlet tube.
Engine Front Cover Removal

9. Remove one screw and crankshaft position

sensor.
T74P-6256-B
10. Remove one bolt and one nut from inner timing
belt cover.
T74P-6700-B
Front Cover Alignment Tool
T74P-6019-B
T74P-6150-A
NOTE: Remove the crankshaft front seal while

the front cover is still mounted on the engine.
12. Using Front Cover Seal Remover T74P-6700-B,
remove crankshaft front seal.
NOTE: This procedure will require the following

replacement parts: oil pan gasket , crankshaft front
seal, engine front cover gasket and a water pump
inlet tube O-ring.
13. Remove four bolts, engine front cover and gasket.
1. Remove outer timing belt cover and timing belt as

2. Remove engine oil pan as outlined in this section.
3. Remove crankshaft damper bolt.
5. Remove crankshaft sprocket.
6. Remove oil pump sprocket bolt. Using Cam
Sprocket Holding/Removing Tool T74P-6256-B;
remove oil pump sprocket.
7. Remove stud, screw, nut and timing belt
tensioner.
02-45
02-45
9. Lubricate and install new O-ring on water pump

inlet tube.
11. Install water inlet tube-to-generator bracket bolts
and tighten to 9-12 Nm (84-108 lb-in).
12. Install crankshaft sprocket, crankshaft damper,
washer, and bolt. Tighten bolt to 125-165 Nm
(92-121 lb-ft).
13. Install oil pump sprocket and tighten bolt to 40-55
Nm (29-40 lb-ft).
Engine Front Cover Installation

1. Install a new engine front cover gasket in engine
front cover.
2. Install front cover assembly onto cylinder block .
14. Align sprockets and install timing belt as outlined

in this section.
section.
3. Tighten three bolts and one stud to 13-15 Nm

(10-12 lb-ft).
4. Position a new crankshaft front seal on Front
Seals Replacer T74P-6150-A and press into
place using vibration damper bolt. Remove bolt
and tool.
5. Install a new oil pan gasket and the oil pan as
6. Install inner timing belt cover.
7. Tighten inner timing belt cover bolts to 8-12 Nm
(72-108 lb-in).
8. Install crankshaft position sensor and tighten bolt
to 8-12 Nm (72-108 lb-in).
02-46
Oil Pan Removal

1. Remove the oil pan retaining bolts
2. Remove the oil pan.
3. Remove the oil pan gasket.
4. Thoroughly clean the engine and oil pan gasket
surfaces.
Oil Pan Installation

1. Apply Silicone Gasket and Sealant F1AZ-19562A, or equivalent, meeting Ford specification WSEM4G320-A2, in six places at joints between
engine front cover and the cylinder block and rear
main bearing cap and engine block as shown.
2. Install a new oil pan gasket to the oil pan
3. Position the oil pan to the engine.
4. Install and tighten oil pan retaining bolts to 14-16
Nm (132-144 lb-in).
02-46
02-47
Oil Pump Screen, Cover, and Tube

Removal
Crankshaft Removal
1. Remove oil pan as outlined in this section.

2. Remove nut, two screws, oil pump screen cover
and tube.
3. Remove oil pump inlet tube gasket.
02-47
T74P-6256-B
T74P-6700-B
Cam Bearing Adapter Tube
T72C-6250
Clutch Aligner
T71P-7137-H
1. Remove engine and install on suitable engine

stand.
2. Drain oil from engine.
3. Remove engine oil level dipstick.
4. Remove crankshaft bolt and washer.
6. Remove outer timing belt cover screw, depress
tabs, and remove outer timing belt cover.
7. Remove screw retaining crankshaft position
sensor . Remove crankshaft position sensor from
engine front cover.
8. Loosen timing belt pivot bolt one-half turn.
9. Hold timing belt tensioner with T74P-6254-A
Camshaft Belt Tensioner Tool and remove
adjusting bolt. Relax tensioner spring.
10. Remove timing belt.
11. Install T74P-6256-B Cam Sprocket
Holding/Removing Tool on oil pump sprocket.
12. Remove oil pump sprocket bolt and washer.
Oil Pump Screen, Cover, and Tube

Installation
1. Thoroughly clean oil pump screen cover and
tube.
2. Clean all mounting surfaces.
3. Install oil pump screen cover and tube and oil
pump inlet tube gasket.
4. Install two screws and one nut.
5. Tighten screws to 20-30 Nm (15-22 lb-ft).
6. Tighten nut to 40-55 Nm (29-40 lb-ft).
7. Install oil pan as outlined in this section.
02-48
13. Install puller part of T74P-6256-B Cam Sprocket

Holding/Removing Tool. Remove oil pump
sprocket.
14. Slide crankshaft sprocket off crankshaft.
16. Remove oil pan screws and oil pan.
02-48
25. Remove bolts and main bearing caps.

26. Lift out crankshaft. Crankshaft rear oil seal
(6701) will come out with crankshaft. Remove
seal from crankshaft.
27. Inspect bearings and replace as necessary.
Inspect crankshaft as outlined in Section 01 and
recondition or replace as necessary.
17. Remove oil pan gasket.
Crankshaft Installation
18.
19. Rotate engine on stand so crankshaft is up.
20. Remove two bolts and nut and remove oil pump
screen cover and tube.
21. Using T74P-6700-B Front Cover Seal Remover,
remove front cover oil seal as outlined in this
section.
22. Remove bolts and front engine cover.
23. Make sure connecting rod caps are marked so
each cap can be kept with each rod.
24. Remove connecting rod nuts and four caps.
NOTE: Each main bearing cap, except rear cap,
is marked with arrows pointing to the front of the
engine. The number of arrows corresponds to
the number of the main bearing cap. For
example, one arrow for the front cap, two arrows
for the number two cap.
CAUTION: Lubricate parts with Motorcraft Super

Premium Motor Oil XO-5W30-QSP, or
equivalent, meeting Ford specification
ESE-M2C153-E during assembly to
prevent a dry start and engine damage.
1. If removed, install upper crankshaft bearings. If
reusing bearings, reinstall each bearing in the
same place from which it was removed.
2. Install crankshaft.
3. If removed, install bearings in main bearing caps.
If reusing bearings, install bearing in same place
from which it was removed.
4. Apply Plastigage to crankshaft bearing journals.
5. Install main bearing caps and bolts. Alternately
tighten bolts to 68-81 Nm (50-60 lb-ft). Retighten
to 108-122 Nm (79-90 lb-ft).
02-49
18. Remove caps. Check Plastigage for bearing

clearance using chart on package. If OK, go on
to next step. If not, correct clearance.
19. Apply 7mm (0.28-inch) dot of Silicone Gasket
and Sealant F1AZ-19562-A, or equivalent,
meeting Ford specification WSE-M4G320-A2 on
each side of cylinder block as shown in
illustration. No sealer allowed on inside diameter
of seal lip.
20. Lubricate bearings and reinstall main bearing
caps and bolts.
21. Alternately tighten main bearing bolts to 68-81
Nm (50-60 lb-ft). Retighten 102-115 Nm (75-85
lb-ft).
02-49
e. Finish pushing piston and rod assembly in

place.
f.
Apply Plastigage to bearing journal.
g. Install connecting rod cap and alternately

tighten connecting rod nuts to an initial torque
of 34-41 Nm (25-30 lb-ft). Then continue
tightening to a final torque of 41-49- Nm (3036 lb-ft).
h. Remove cap and check bearing clearance
with chart on Plastigage package.
i.
If within specification, lubricate connecting rod

bearings and reinstall cap.
j.
Alternately tighten connecting rod nuts to an

initial torque of 34-41 Nm (25-30 lb-ft). Then
continue tightening to a final torque of 41-49
Nm (30-36 lb-ft).
k.
Repeat for remaining piston and connecting

rod assemblies.
22. Check crankshaft end play as outlined in Section

01.
24. Using Cam Bearing Adapter Tube T72C-6250

and crankshaft damper bolt, press crankshaft
front seal into place in engine front cover.
25. Install oil pump screen cover and tube. Tighten
bolts to 20-30 Nm (15-22 lb-ft). Tighten pickup
tube-to-main bearing cap nuts to 40-55 Nm (2940 lb-ft).
26. Apply a small amount of Silicone Gasket and
Sealant F1AZ-19562-A, or equivalent meeting
Ford specification WSE-M4G320-A2 at joints
between front engine cover and cylinder block
and rear main cap and cylinder block as shown.
27. Press new oil pan gasket into groove in oil pan
and install oil pan. Tighten screws to 13-16 Nm
(10-12 lb-ft).
23. Attach piston and rod assemblies to crankshaft.
For each assembly:
a. Put a piece of hose or other protector over
connecting rod bolts to protect the crankshaft
journal.
b. Place the crankshaft journal for the piston
being installed, at the bottom of its stroke by
rotating the crankshaft.
c.
Push piston and rod assembly into place

guiding the rod bolts around crankshaft
journal.
d. Insert connecting rod bearings in connecting

rod end cap.
02-50
28. Install inner timing belt cover.

29. Install inner timing belt cover screw and nut and
tighten to 8-11 Nm (72-97 lb-in). Install stud nut
to inner timing belt cover and cylinder head and
tighten to 20-30 Nm (15-22 lb-ft).
02-50
37. Install and adjust timing belt as outlined in this

section.
38. Install crankshaft position sensor and tighten bolt
to 8-12 Nm (72-108 lb-in).
39. Install outer timing belt cover. Snap tabs into
slot. Install screw and tighten to 8-12 Nm (72-108
lb-in).
40. Install crankshaft pulley, and washer. Tighten
bolt to 125-165 Nm (72-108 lb-in).
41. Connect retaining clip for crankshaft position
sensor lead.
42. Remove engine from engine stand.
43. Install crankshaft rear oil seal using T82L-6701-A
Crankshaft Seal Installer.
44. Install engine.
30. Slide crankshaft sprocket onto crankshaft.

Recess goes toward cylinder block.
31. Apply Threadlock 262 E2FZ-19554-B, or
equivalent, meeting Ford specification WSKM2G351-A6 to camshaft bolt threads. Install bolt
and washer finger-tight.
T79P-6256-B on sprocket. Tighten camshaft bolt
to 70-95 Nm (52-70 lb-ft). Remove tool.
33. Install oil pump sprocket.
34. Install oil pump sprocket bolt and washer fingertight.
35. Prime oil pump.
T74P-6256-B on sprocket. Tighten bolt to 40-55
Nm (29-40 lb-ft). Remove tool.
02-51
Crankshaft Main Bearings Removal

NOTE: The main bearing inserts are a precision
selective fit. To check bearing clearances or to
select-fit a new bearing, refer to the engine service
section.
2. Remove oil pump screen cover and tube as
NOTE: Replace one bearing at a time, leaving
the other bearings securely fastened.
3. Remove main bearing cap to which new bearings
are to be installed.
4. Remove bearing from cap.
5. Press on end of upper bearing without tang to
start it out.
6. Rotate bearing out from between crankshaft and
cylinder block.
02-51
02-52
Crankshaft Main Bearings Installation

1. Place lubricated, upper bearing on crankshaft and
rotate into place.
2. Place lower bearing into cap.
3. Apply Plastigage across lower bearing.
4. Support crankshaft on either side of bearing being
installed.
NOTE: Failure to support crankshaft will cause
incorrect reading of Plastigage while checking
bearing clearance when installing bearing cap.
5. Install bearing cap.
6. Lightly oil main bearing bolt or stud. Alternately
tighten to an initial torque of 68-81 Nm (50-60 lbft). Then tighten bolt or stud to a final torque of
108-122 Nm (79-90 lb-ft).
7. Remove main bearing cap.
02-52
8. Check Plastigage for bearing clearance using

chart on package. Clearance should be 0.0100.056mm (0.0004-0.0022 inch) for front main
bearing or 0.020-0.066mm (0.0008-0.0026 inch)
for bearings 2-5.
9. If clearance is OK, lubricate bearings with Super
Premium Motor Oil X0-5W30-QSP, or equivalent,
meeting Ford specification ESE-M2C153-E and
reinstall cap.
10. Apply a 7mm (0.27-inch) dot of Silicone Gasket
and Sealant F1AZ-19562-A, or equivalent,
meeting Ford specification WSE-M4G320-A2 on
each side of cylinder block as shown in illustration
before installing the No. 5 cap.
11. Alternately tighten bolts or stud to an initial torque
of 68-81 Nm (50-60 lb-ft). Then tighten the bolts
or stud to a final torque of 102-115 Nm (75-85 lbft).
12. Check crankshaft end play as outlined in the
Section 01.
13. Install oil pump screen cover and tube as outlined
in this section.
02-53
Pistons and Connecting Rods Removal

1.
3. Remove oil pump screen cover and tube as
4. Remove cylinder head as outlined in this section.
02-53
CAUTION: Never cut into the ring travel area in

excess of 0.8mm (1/32 inch) when
removing ridges.
4. Remove any ridges and/or deposits from
the upper end of the cylinder bores as follows.
Turn the crankshaft until the piston to be removed is
at the bottom of its travel and place a cloth on the
piston head to collect the cuttings. Remove any ridge
and/or deposits from the upper end of the cylinder
bores. Remove the cylinder ridge with a ridge cutter.
Follow the instructions furnished by the tool
manufacturer.
5. Make sure all connecting rod caps are marked so
that they can be installed in their original
positions.
6. Turn the crankshaft until the connecting rod being
removed is down.
7. Remove the connecting rod nuts and caps.
CAUTION: Avoid damage to the

crankshaft journal or the cylinder
wall when removing the piston and
rod.
8. Push the connecting rod and piston assembly out
the top of the cylinder with the handle end of a
hammer.
9. Remove the bearing inserts from the connecting
rod and cap.
10. Select the proper bore gauge and micrometer.
Measure the cylinder bore for out-of-round and
taper as outlined in the engine service section.
Deglaze cylinder bore as outlined in the engine
service section.
11. Remove rings and clean ring grooves. Clean
carbon from piston, pin and ring.
12. Check ring gaps using the procedure given in the
engine service section.
NOTE: Never install compression rings on
pistons by hand. Always use a ring expander
tool.
13. Install rings using a ring expander tool. Check
ring side clearance.
14. Clean crankshaft journals.
15. If necessary, disassemble piston and rod
assemblies as outlined in this section.
16. Clean gasket surfaces and fasteners.
02-54
Pistons and Connecting Rods

Installation
1. If disassembled, assemble piston and connecting
rod assembly as outlined in this section.
2. Refer to Pistons, Piston Pins, and Piston Rings in
the engine service section for Cleaning,
Inspection, Pistons - Fitting, and Piston Rings Fitting.
02-54
piston head toward the front of the engine.

9. Apply motor oil to piston and cylinder bore and
start piston and rod assembly into cylinder,
guiding bolts around crankshaft journal.
10. Compress piston rings using suitable piston ring
compressor.
11. Tap piston assembly into place using bottom of
hammer handle.
3. If necessary, install piston and pin on connecting

rod as outlined in this section.
4. Using a piston ring expander, install the piston
rings, starting with the oil control rings. Make
sure rings are installed right side up. Refer to
instructions with piston ring set.
5. Rotate the rings so the end gaps are NOT lined
up but are spaced properly as shown.
12. Insert bearings in connecting rod and cap.

13. Apply Plastigage to bearing journal. Refer to
the engine service section.
14. Install connecting rod cap. Hand-start each
connecting rod nut until flush with end of rod bolt.
Alternately tighten connecting rod nuts to 34-41
Nm (25-30 lb-ft). Then continue tightening to
achieve a final torque of 41-49 Nm (30-36 lb-ft).
15. Remove cap and check bearing clearance with
chart on Plastigage package.
16. Lubricate connecting rod bearings with Super
Premium Motor Oil XO-5W30-05P, or equivalent,
meeting Ford specification ESE-M2C153-E.
6. Check the ring side clearance as outlined in the
engine service section. Side clearance for both
compression rings should be 0.041-0.084mm
(0.016-0.0033 inch) and snug fit for the oil control
ring.
17. Reinstall connecting rod cap.

18. Alternately tighten connecting rod nuts to 34-41
Nm (25-30 lb-ft). Then continue tightening to
achieve a final torque of 41-49 Nm (30-36 lb-ft).
7. Put a piece of hose or other protector over

connecting rod bolt to protect crankshaft journal.
8. Rotate crankshaft so journal for piston to be
installed is at the bottom of its stroke.
CAUTION: Install the piston, pin and

ring with the indentation notch in the
02-55
02-55
12. Out-of-round should be less than 0.01524mm

(0.0006 inch). Taper should be less than 0.06mm
per centimeter of length (0.006 inch per inch of
length).
13. Inspect connecting rod bearing bore, measure for
out-of-round and taper. Maximum out-of-round is
0.0120mm (0.0004 inch). Maximum taper is
0.0102mm (0.004 inch).
14. Thoroughly clean bearing bore of connecting rod
and cap.
Connecting Rod Bearings Installation

19. Check side clearance. Side clearance should be
0.09-0.29mm (0.0035-0.0114 inch).
1. Make sure bearing bore of connecting rod and

cap and bearing journal are clean.
2. Insert upper bearing insert into connecting rod.
20. Repeat for other piston and rod assemblies as

needed.
3. Insert lower bearing insert into connecting rod

cap.
21. Install cylinder head as outlined in this section.
4. Apply Plastigage to bearing journal. Refer to

the engine service section.

in this section.
Connecting Rod Bearings Removal

1. Remove spark plug of cylinder where bearing is
to be replaced.
3. Rotate engine so it is upside down and remove oil
pump screen cover and tube as outlined in this
section.
NOTE: Do not scratch journal with connecting rod

bolts.
5. Carefully pull piston and connecting rod assembly
into place on crankshaft.
6. Install connecting rod cap. Hand-start each
connecting rod nut until flush with end of rod bolt.
Alternately tighten connecting rod nuts to 34-41
Nm (25-30 lb-ft). Then continue tightening to a
final torque of 41-49 Nm (30-36 lb-ft).
7. Remove cap and check bearing clearance.
4. Rotate crankshaft until connecting rod and

bearing being services is placed at the bottom of
its stroke.
8. Lubricate connecting rod bearings with Motorcraft

Super Premium Motor Oil XO-5W30-QSP, or
equivalent, 5W30 motor oil meeting Ford
specification ESG-M2C153-E.
5. Remove two connecting rod nuts.
9. Install connecting rod cap.
6. Remove connecting rod cap.
10. Hand start connecting rod nuts until nuts are flush
with ends of connecting rod bolts.
7. Push piston and connecting rod assembly up into

bore.
8. Remove bearing insert from connecting rod.
9. Remove bearing insert from connecting rod cap.
10. Inspect connecting rod bearings as outlined in the
11. Inspect journal and measure for taper and out-ofround as outlined in the engine service section.
11. Alternately tighten connecting rod nuts to 34-41

Nm (25-30 lb-ft). Then alternately tighten again
to a final torque of 41-49 Nm (30-36 lb-ft).
in this section.
14. Install spark plugs.
02-56
02-56
Engine Coolant Temperature Sensor

Removal
2. Partially drain the cooling system.
3. Disconnect the electrical connector.
4. Remove the sensor.
Camshaft Position Sensor Removal

2. Disconnect electrical connector.
3. Remove screws.

Installation
1. Install the sensor. Tighten to:
Camshaft Position Sensor Installation
16-24 Nm (12-17 lb-ft).
1. Install the sensor.
2. Connect the electrical connector.
2. Install screws. Tighten to:
3. Connect the negative battery cable.
4. Fill the cooling system with the proper coolant.
5-7 Nm (45-61 lb-in).
3. Connect electrical connector.

02-57
02-57
Heated Oxygen Sensor Removal

3. Remove the sensor using an oxygen sensor
wrench.
If necessary, lubricate sensor using

penetrating lubricant such as E8AZ19A501-B or equivalent.
Intake Air Temperature Sensor Removal

Intake Air Temperature Sensor

Installation
1. Install the sensor. Tighten to:
w
Heated Oxygen Sensor Installation

1. Apply a light coat of Anti-seize compound such as
F6AZ-9L494-AA or equivalent meeting Ford
specification ESE-M12A4-A to the threads of the
sensor.
13-16 Nm (7-12 lb-ft).

2. Install the sensor using an oxygen sensor

wrench. Tighten to:
36-46 Nm (27-33 lb-ft).

02-58
02-58
Flywheel Ring Gear Removal
Flywheel Ring Gear Installation
1. Center punch ring gear and drill two holes

approximately 5/16 (7 to 8mm) diameter offset as
illustrated. Drill must only pass through ring gear
and not flywheel.
1. Place a new ring gear on a plate approximately

1/8 (2 - 3mm) thick and heat up to 260 - 280
Centigrade from below in area of ring gear itself
using a welding torch to give uniform heating.
2. Remove ring gear by means of a light blow with a

hammer noting position of chamfer on ring gear
teeth.
2. Note position of gear tooth chamfer. Slip ring

gear over flywheel with tongs so that ring gear
comes to rest on abutment rim. Allow to cool in
this position.
3. Starter ring gear is induction-hardened and loses
this hardness as soon as it is heated to over 290.
To monitor temperature, mark ring gear with a
thermocromatic colored pencil (Faber Castell
2815) before starting heating operation. On
reaching temperature required, color marked on
gear changes to color of pencil cover.
Example: If colored pencil is green and cover black,

indicated temperature of 260 - 280 C is reached
when green colored mark on ring gear changes to
black.
02-59
02-59
DISASSEMBLY AND ASSEMBLY

NOTE: When disassembling cylinder head, mark the
cam followers, lash adjusters, and valves to that they
can be installed in their original positions.
Cylinder Head Disassembly

1.
Remove cylinder head as outlined in this section.
2.
Remove the deposits from the combustion

chambers with scraper and wire brush.
Valve Spring compressor
T95T-6565-A
T74P-6256-B
T74P-6700-B
3.
Mount cylinder head on bench fixture.
Cam Bearing Replacer
T71P-6250-A
4.
Rotate the camshaft so the cam follower to be

removed is on the heel of its cam.
Camshaft Bearing Set
T65L-6250-A
T74P-6150-A
Valve Stem Seal Replacer
T95L-6510-A
Valve Guide Replacer
T95T-6510-B
02-60
5.
Using Valve Spring Compressor T95T-6565-A,

compress and hold down the valve spring. Slide
out the cam follower over the lash adjuster.
6.
Repeat steps 4 and 5 until all the cam followers

are removed.
7.
Store lash adjusters in order.
8.

compress valve spring and remove valve spring
retainer key, valve spring retainer, and valve
spring.
9.
02-60
14. Remove tool from sprocket.

NOTE: When positioning Front Cover Seal Remover
T74P-6700-B, make sure the jaws are gripping
the thin edge of the seal tightly before operating
the jack screw portion of the tool.
15. Install Front Cover Seal Remover T74P-6700-B.
Pull camshaft front seal.
16. Remove two screws and camshaft retaining plate.
17. Remove camshaft.
Remove valve and store in order.
10. Remove valve stem seal.

11. Repeat above steps until all the valves are
removed.
NOTE: It is not necessary to remove sprocket from
camshaft unless camshaft or sprocket is to be
serviced.
T74P-6256-B on sprocket. Using tool to hold
sprocket remove bold and washer.
Holding/Removing Tool T74P-6256-B and
remove sprocket.
02-61
02-61
standard and 0.08mm (0.003-inch) undersize

journal diameters.
NOTE: Make sure to align oil hold in camshaft
bearing with the oil hole in the cylinder head
before pressing camshaft bearing into place.
2.
Position new camshaft bearing at the bearing

bore and press into place using Camshaft
Bearing Set T65L-6250-A and Cam Bearing
Replacer T71P-6250-A.
3.
Make sure the cup plug is in the rear of the

camshaft.
4.
Lubricate the camshaft lobes and journals with

Motorcraft Super Premium Motor Oil XO-5W30ASP, or equivalent, meeting Ford specification
ESE-M2C153-E.
5.
Carefully slide the camshaft into place through

the camshaft bearings. Be careful not to scratch
camshaft bearings.
6.
Install the camshaft rear retainer. Tighten the two

screws to 8-12 Nm (72-108 lb-in).
7.
Position camshaft front seal on Front Seals

Replacer T74P-6150-A and press into place.
8.
Remove tool.
9.
Check camshaft end play as outlined in the

18. To remove camshaft bearing:

a. Use tool sets Cam Bearing Replacer T71P6250-A and Camshaft Bearing Set T65L6250-A.
b. Select proper size expanding collet and
backup nut, and assemble on expanding
mandrel.
c.
With expanding collet collapsed, install coiled

assembly in the camshaft bearing, and
tighten backup nut on the expanding mandrel
until the collet fits the camshaft bearing.
d. Assemble puller screw, cup, and nut on

expanding mandrel.
e. Tighten the puller nut against the thrust
bearing to remove the camshaft bearing. Be
sure to hold the end of the puller screw to
prevent it from turning.
f.
Repeat steps to remove the other three

bearings.
Cylinder Head Assembly

1.
Clean and inspect cylinder head, cam followers,

valve springs, and valves as outlined in the
Section 01.
10. Position camshaft sprocket on camshaft.
CAUTION: Failure to use the correct expanding

collet can cause severe bearing damage.
NOTE: The camshaft bearings are available
prefinished to size and require no reaming for

T74P-6256-B, without threaded puller insert, on
sprocket.
12. Install sprocket bolt and washer. Tighten to 70-95
Nm (52-70 lb-ft).
13. Remove tool.
02-62
14. Install valve lash adjusters.

15. Install one valve and check valve runout,
looseness in guide, and seating as outlined in the
02-62
18. Remove seal protector (plastic cap). Use Valve

Stem Seal Replacer T95T-6510-B to seat valve
stem seal on valve guide.
CAUTION: Install valve seal protector (plastic

installation cap) included with valve seal kit over
end of valve before installing valve stem seal or
valve stem seal will be cut by valve-keeper
grooves in valve. If valve stem seal is cut, it will
leak, causing oil burning and valve fouling.
16. Put valve seal protector (plastic installation cap)
over end of valve as illustrated.
19. Apply a small amount of Ford Multi-Purpose

Grease D0AZ-19584-AA, or equivalent, to valve
spring retainer keys to hold them in place during
installation.
17. Start valve stem seal carefully over cap. Push
valve stem seal down until jacket touches top of
guide.
20. Put valve spring and valve spring retainer into

place.
NOTE: Spring must not be compressed beyond a
height of 27.5mm (1.08 inch) during assembly.
21. Compress valve spring with Valve Spring
Compressor T95T-6565-A and install valve spring
retainer keys. Release spring to seat valve spring
retainer keys.
02-63
22. Check installed height of valve spring assembly:
Measure from cylinder head-machined spring

pad to top of valve spring. Dimension should
be 38.278-40.157mm (1.507-1.581 inch).
23. Repeat steps 15 through 22 until all valves are

installed.
24. Oil contact surfaces of cam followers with clean
engine oil.
25. With heel of cam facing down, use Valve Spring
Compressor T95T-6565-A to compress and hold
down the valve spring. Slide the cam follower
into place.
CAUTION: Make sure the affected lash adjuster

has been collapsed and released before rotating
camshaft.
compress and release lash adjuster.
27. Repeat the above steps until all cam followers are
installed.
28. Install cylinder head as outlined in this section.
02-63
02-64
Piston and Piston Pins Disassembly
2.
Install the piston rings using a suitable piston ring

expander. Check the end gap of all piston rings.
They must be within specifications of 0.2030.406mm (0.008-0.016 inch) for top ring, 0.330.50mm (0.013-0.019 inch) for second ring, and
0.254-0.762mm (0.010-0.030 inch) for oil control
ring.
3.
Check the ring side clearance. Refer to Section

01. Side clearance for both compression rings
should be 0.041-0.084mm (0.0016-.0033 inch)
and a snug fit for the oil control ring.
4.
Make sure the connecting rod bearings and the

bearing bore in the connecting rod and cap are
clean. Foreign material under the inserts will
distort the bearing and cause a failure. Install the
connecting rod bearings in the connecting rod
and cap with the tangs fitting in the slots provided.
5.
Make certain lock slots in cap are on the same

side of bore as the lock slot in rod. Avoid nicking
crank pin journals during rod installation.
6.
Install piston and connecting rod assembly as


Piston Pin Removing and
Installing Set
T68P-6135-A
1.
Remove the connecting rod bearing from the

connecting rod and cap.
2.
Install the cap on the connecting rod from which it

was removed.
3.
Remove the piston rings using a suitable piston

ring expander.
4.
Store the piston, pin and connecting rod to ensure

assembly with the same rod and installation in the
same cylinders from which they were removed.
5.
Using an arbor press and Piston Pin Removing

and Installing Set T68P-6135-A, press the piston
pin from the piston and connecting rod .
02-64
Cylinder Block Disassembly

1.
Mount the engine on a work stand
2.
Remove all parts not furnished with the new

cylinder block following engine disassembly and
assembly in this section.
3.
Remove the old cylinder block from the work

stand.
Cylinder Block Assembly
Piston and Piston Pins Assembly

1.
Apply a light coat of Motorcraft Super Premium

Motor Oil XO-5W30-QSP, or equivalent, to all
parts. Assemble the piston to the connecting rod
with the oil squirt hole on the side of the
connecting rod and the notch in the piston
positioned as shown. Use arbor press and Piston
Pin Removing and Installing Set T68P-6135-A.
1.
Clean the gasket and seal surfaces of all

serviceable parts and assemblies.
2.
Position the new cylinder block on a work stand
3.
Transfer all serviceable parts removed from the

old cylinder block, following engine disassembly
and assembly as outlined in this section.
4.
Check all assembly clearances and correct as

necessary.
02-65
02-65
Hydraulic Lash Adjuster Disassembly
Bare Cylinder Block Disassembly
NOTE: Do not mix parts between different lash

adjusters. Parts are select-fit and not
interchangeable.
1.
Before replacing a cylinder block , determine if it

is repairable. If so, make the necessary repairs
following the procedures given in the engine
service section.
2.
Completely disassemble the old engine, following

the engine disassembly procedure in this section.
3.
Remove core plugs as outlined in the engine

service section.
4.
Remove oil gallery pipe plugs.
1.
Remove snap ring.
2.
Remove fulcrum, plunger, and spring.
3.
Clean to remove all traces of motor oil and

varnish. Make sure check ball is free.
4.
To assemble, lubricate parts with clean Super

Premium Motor Oil XO-5W30-QSP or equivalent,
meeting Ford specification ESE-M2C153-E and
reverse disassembly steps. If it is necessary to
store lash adjusters for some time before
installation, protect them from dust and dirt. If not
kept clean, they may stick during operation.
5.
Perform leak-down test as outlined in the engine

service section.
NOTE: A rifle-cleaning brush is helpful for cleaning

engine oil galleries.
5.
Clean cylinder block and inspect as outlined in the

Bare Cylinder Block Assembly

1.
If using new or reconditioned cylinder block,

uncrate and clean preservative materials
according to the suppliers instructions.
2.
Position the new cylinder block in a work stand

and install all serviceable parts removed from the
old cylinder block, following engine assembly
procedure in this section.
3.
Check all assembly clearances and correct as

necessary.
02-66
ADJUSTMENTS
Valve Clearance, Hydraulic Valve Lash
Adjuster
Valve Spring compressor
T95T-6565-A
1.
Position the camshaft so that the base circle of

the lobe is facing the roller finger follower of the
valve to be checked.
2.

slowly apply pressure to the roller finger follower
until the lash adjuster is completely collapsed.
Hold the follower in this position and insert the
proper size feeler gauge between the base circle
of the cam and the follower.
3.
Remove the roller finger follower and inspect for

damage if the clearance is excessive.
4.
If the cam follower appears to be intact and not

excessively worn, measure the valve spring
assembled height to make sure the valve is not
sticking.
5.
If the valve spring assembled height is correct,

check the dimensions of the camshaft. Refer to
Camshaft Lobe Lift in the engine service section.
6.
If the camshaft dimensions meet specifications,

remove, clean and test the lash adjuster. Refer to
Hydraulic Tappets in the engine service section.
7.
Install the lash adjuster and check the clearance.

Replace damaged or worn parts as necessary.
ADJUSTMENTS
02-66
02-67
Camshaft Timing Check

An access plug is provided in the cam drive belt cover
so that camshaft timing can be checked without
removal of the cover or any other parts.
1.
Remove the rubber access cap in front of the

camshaft sprocket from the outer timing cover.
2.
Rotate crankshaft so that number one cylinder is

at the compression stroke of Top Dead Center
(TDC). TDC will be indicated when the timing
marks are aligned:
The triangular timing mark on the camshaft

sprocket will align with the timing mark on the
inner timing cover.
3.
If the triangle timing mark cannot be seen through

the access hole of the outer timing cover, rotate
crankshaft one revolution. TDC will be indicated
when the timing marks are aligned.
4.
If the triangle timing mark cannot be properly

aligned, timing must be adjusted. Refer to
Adjusting Timing Belt in this section.
NOTE: Camshaft and timing belt sprockets turn one

revolution for every two revolutions of the crankshaft.
NOTE: If the timing belt has greater than 3,000 hours
or five years of use, replace it. Refer to the service
procedures in this section.
02-67
The timing mark on the crankshaft damper

assembly will align with "TC" on outer timing
cover.
ADJUSTMENTS
02-18
13. Align triangle on camshaft sprocket with triangle

on inner timing belt cover.
Adjusting Timing Belt

Crankshaft Belt Tension Adjuster
1.
T74P-6254-A
Remove the outer timing belt cover as outlined in

this section.
NOTE: Timing belt should be replaced at 3,000 hours

or five-year intervals. If the timing belt has more
than 3,000 hours or five years of use, replace it.
Refer to the procedure in this section.
2.
02-18
Inspect belt for cracked or damaged teeth,

fraying, cracking, or oil. If the belt is worn or
damaged, replace it. If there is oil on the belt,
determine the source of the oil leak and repair or
replace as necessary.
CAUTION: Attempting to adjust timing belt

tension without loosening spring pivot bolt
will break Crankshaft Belt Tension Adjusting
Tool T74P-6254-A when relieving tension on
the belt.
3.
If belt timing or tension is incorrect, loosen timing

belt spring pivot bolt.
4.
Hold tensioner with Camshaft Belt Tension

Adjusting Tool T74P-6254-A.
5.
While holding tensioner, loosen adjusting bold

and gradually release spring tension.
6.
Using adjusting tool, pry tensioner away from belt.

While holding tensioner, tighten adjusting bolt.
There should be no tension on belt.
7.
Remove bolt, washer, and crankshaft damper.
8.
Remove the drive belt and inspect it for wear or

damage. If the belt is damaged, replace it.
9.
Remove the spark plugs. Mark locations on a

piece of tape for reinstallation.
14. Install timing belt over crankshaft sprocket (6306).

Then, proceeding counterclockwise, over oil
pump sprocket and camshaft sprocket, verify
timing marks are aligned.
15. Loosen tensioner adjusting bolt allowing tensioner
pulley to press against timing belt.
NOTE: When performing the following step, do not
rotate crankshaft counterclockwise as timing belt
may jump a cog, putting camshaft out of time.
16. Rotate crankshaft two revolutions clockwise.
17. Bring crankshaft slowly, without stopping, to
number one cylinder firing position (keyway
directly up).
18. Recheck timing mark alignment. Repeat the
above steps if timing marks are no longer
properly aligned.
19. Rotate tensioner assembly against bolt with
torque wrench up to 40-45 Nm (29-33 lb-ft) and
tighten adjusting bolt.
20. Tighten adjusting bolt to 35-45 Nm (26-33 lb-ft).
21. Tighten spring pivot bolt to 40-55 Nm (29-40 lbft).
section.
23. Install spark plugs in proper locations.
10. If not done:
Loosen tensioner adjusting bolt.
Using Camshaft Belt Tension Adjusting Tool

T74P-6254-A, pry tensioner clockwise
against spring tension as far as possible.
Tighten adjusting bolt to hold tensioner in

released position.
11. Align crankshaft (6303) so number one piston

(6108) is at TDC (top dead center) as indicated
by timing mark.
12. Align pointer circle on crankshaft sprocket with
line on engine front cover.
ADJUSTMENTS
02-67
SPECIFICATIONS
02-67
CYLINDER BLOCK
GENERAL
Displacement ....................................................... 2.5L (153 CID)
Bore . ............................................................... 96.01 mm (3.78")
Stroke............................................................... 86.36 mm (3.40")
Firing order....................................................................... 1-3-4-2
Idle speed....................................................................... 750 rpm
Rated engine speed ..................................................... 3600 rpm
Oil pressure (hot @ 2000 rpm) .....275.79-413.69 kPa (40-60 psi)
Cylinder bore...................95.9993-96.0145 mm (3.7795-3.7801")

Bore out-or-round (max.) ............................ 0.0381 mm (0.0015")
.........wear limit ............................................ 0.1270 mm (0.005")
Bore taper - wear limit .................................. 0.2540 mm (0.010")
Bore surface finish RMS..................................................... 18-38
Main bearing bore
......... diameter................60.8863-60.9067 mm (2.3971-2.3979")
Gasket surface flatness: ..............................................................
.........in any 152.4 mm (6") ......................... 0.0762 mm (0.003")
.........overall ................................................. 0.1524 mm (0.006")
Head gasket surface finish RMS ...................................... 60-150
Crankshaft to rear face of block runout
.........max. TIR ............................................. 0.1270 mm (0.005")
CYLINDER HEAD
Combustion chamber volume . 1409.70-1485.90 mm (55.5-58.5")
Compression pressure:
...........The lowest cylinder must be at least 75% of the highest cylinder
Valve guide bore diameter...7.0155-7.0434 mm (0.2762-0.2773")

Valve seat width (intake) ........ 1.7200-2.2352 mm (0.068-0.088")
Valve seat width (exhaust) ..... 1.7780-2.2860 mm (0.070-0.090")
Valve seat angle..................................................................... 45
Valve seat runout (max.) ............................ 0.0508 mm (0.0020")
Valve arrangement (front to rear)............................E-I-E-I-E-I-E-I
Valve tappet bore ............20.5359-20.6375 mm (0.8085-0.8125")
Gasket surface flatness:
.........in any 152.4 mm (6") ......................... 0.0762 mm (0.003")
.........overall ................................................. 0.1524 mm (0.006")
Head gasket surface finish RMS ...................................... 78-157
CAMSHAFT
Lobe lift ........................................................5.4940 mm (0.2163)
.........max. allowable loss.......................... ...0.1270 mm (0.005")
Theoretical valve lift @ zero lash................ 10.2108 mm (0.402")
End play ................................. 0.0254-0.1778 mm (0.001-0.007")
.........wear limit ............................................ 0.2286 mm (0.009")
Journal to bearing clearance .. 0.0254-0.0762 mm (0.001-0.003")
.........wear limit ............................................ 0.1524 mm (0.006")
Journal diameter..............44.9910-45.0088 mm (1.7713-1.7720")
.........max. runout......................................... 0.1270 mm (0.005")
.........max. out-of-round................................ 0.1270 mm (0.005")
Bearing location:
(distance that the rear edge of the bearing is installed
towards the front from the rear face of the
bearing tower)......................... 0.0-0.2540 mm (0.0-0.010")
CRANKSHAFT AND FLYWHEEL

Main bearing journal
.........diameter.................56.0095-56.0299 mm (2.2051-2.2059")
.........maximum out-of-round ...................... 0.0152 mm (0.0006")
.........maximum runout ............................... 0.0508 mm (0.0020")
wear limit ..................................... 0.1270 mm (0.005")
.........thrust face runout ................................ 0.0254 mm (0.001")
.........maximum taper ................................. 0.0127 mm (0.0005")
Thrust bearing journal length ......................30.5054-30.4546 mm
......... .................................................................... (1.201-1.199")
Main and rod bearing journal finish RMS (max) ....................... 10
Main bearing thrust face finish RMS ............35 front/25 rear max.
Connecting rod bearing journal:
.........diameter.................51.9786-51.9989 mm (2.0464-2.0472")
.........max. out-of-round.............................. 0.0152 mm (0.0006")
.........max. taper............................0.0152 mm (0.0006") per inch
Crankshaft free end play ........ 0.1016-0.2032 mm (0.004-0.008")
.........wear limit ............................................ 0.3048 mm (0.012")
Flywheel clutch face runout .......................... 0.1270 mm (0.005")
Flywheel ring gear lateral runout
.........standard trans..................................... 0.6350 mm (0.025")
.........automatic trans. .................................. 1.5240 mm (0.060")
CRANKSHAFT BEARINGS
Connecting rod bearings to crankshaft clearance:
.........desired.......................0.0203-0.0381 mm (0.0008-0.0015")
.........allowable....................0.0203-0.0660 mm (0.0008-0.0026")
Wall thickness
.........standard.....................1.5723-1.5850 mm (0.0619-0.0624")
.........0.0508 mm (0.002") thickness....... add 0.0254 mm (.001")
to standard thickness
Main bearing to crankshaft clearance
.........desired.......................0.0203-0.0381 mm (0.0008-0.0015")
.........allowable....................0.0203-0.0660 mm (0.0008-0.0026")
Wall thickness (standard) ....2.4155-2.4282 mm (0.0951-0.0956")
SPECIFICATIONS
02-68
CONNECTING ROD
Piston pin bore or bushing inside diameter
......... ..............................23.1242-23.1445 mm (0.9104-0.9112")
Connecting rod bearing bore
.........diameter.................55.1688-55.1891 mm (2.1720-2.1728")
.........out -of-round (max.) .......................... 0.0102 mm (0.0004")
.........taper (max.) ...................................... 0.0102 mm (0.0004")
Connecting rod alignment - maximum total diff. pin bushing and
crankshaft bearing bore must be parallel and in the same vertical
plane within the specified total difference at ends of 203.2 mm
(8") long bar measured 101.6 mm (4") on each side of rod.
.........twist .................................................... 0.0762 mm (0.003")
.........bend.................................................. 0.0381 mm (0.0015")
Connecting rod assembled to crankshaft
.........side clearance............0.0889-0.2921 mm (0.0035-0.0115")
.........wear limit .......................................... 0.3810 mm (0.0150")
CAPACITIES (approximate)
Crankcase capacity ........................................ 4.26 L (4.5 quarts)
.............................................................(includes oil filter)
02-68
PISTON
Diameter..............................95.961-95.974 mm (3.7779-3.7784")
(measured 90 to pin centerline and at 0.887" from bottom of skirt)
Piston to cylinder bore clearance....................0.0254-0.0508 mm

......... ................................................................ (0.0010-0.0020")
Piston pin bore diameter....23.184-23.1800 mm (0.9127-0.9125")
Ring groove width
.........top compression ring..... 1.536-1.525 mm (0.0604-0.0600")
.........bottom compression ring1.536-1.525 mm (0.0604-0.0600")
.........oil ring ........................3.0302-3.0556 mm (0.1193-0.1203")
PISTON PIN
Length .................................69.2912-70.1040 mm (2.728-2.760")
Diameter - standard.........23.1673-23.1699 mm (0.9121-0.9122")
To piston clearance ...........0.0051-0.0117 mm (0.0002-0.00046")
To connecting rod clearance ................................. interference fit
PISTON RINGS
FUEL PUMP - CARBURETED
Static pressure ...............................24.13-34.47 kPa (3.5-5.0 psi)
Volume flow................................. 1.9 Liters (2 quarts) per minute
FUEL PUMP - EFI
Static pressure ...............................................399.90 kPa (64 psi
NOTE: When pump return line is plugged, pressure can go to 100 psi.
Volume flow............................. 2.18 liters (2.3 quarts) per minute
IGNITION SYSTEM
Spark plug (EFI & carburetor)................................... AWSF-52-C
.........gap...................................................... 1.1176 mm (0.044")
Compression ring width

.........top .............................1.4605-1.4910 mm (0.0575-0.0587")
.........bottom........................1.4605-1.4910 mm (0.0575-0.0587")
Side clearance
.........compression rings......0.0406-0.0838 mm (0.0016-0.0033")
.........oil ring .....................................................................snug fit
.........wear limit ....................................0.1524 mm (0.006") max.
Ring gap
.........compression (top) ............... 0.0-0.4064 mm (0.000-0.016")
.........compression (bottom) ... 0.3302-0.4826 mm (0.013-0.019")
.........oil ring ........................... 0.2540-0.7620 mm (0.010-0.030")
MECHANICAL GOVERNOR BELT TENSION

New.. ............................................................... 70 lbs (311.38 N)
Used. ............................................................... 50 lbs (222.41 N)
(a used belt is one that has been in operation for 10 minutes or more.)
OIL PUMP
Relief valve spring tension............37.37-47.15 N @ 33.5280 mm
......... ........................................................(8.4-10.6 lbs @ 1.32")
Drive shaft to housing bearing clearance........0.0356-0.0838 mm
......... ................................................................ (0.0014-0.0033")
Relief valve clearance .........0.0381-0.0762 mm (0.0015-0.0030")
Rotor assembly end clearance
.........pump assembled........0.0254-0.1016 mm (0.0010-0.0040")
Outer race to housing radial clearance. ..........0.1397-0.3175 mm
......... ................................................................ (0.0055-0.0125")
SPECIFICATIONS
02-69
VALVE TRAIN
Rocker arm lift ratio ........................................................... 1.86:1
Valve lifter
.........diameter.................21.3919-21.4046 mm (0.8422-0.8427")
.........clearance to bore .......0.0178-0.0686 mm (0.0007-0.0027")
.........hydraulic leakdown rate .................................. 2-8 seconds
Collapsed lifter gap (at cam/roller)
.........allowable....................... 0.8890-1.3970 mm (0.035-0.055")
.........desired.......................... 1.0160-1.2700 mm (0.040-0.050")
Valve spring pressure - intake
......... ...... 253.55-280.24 N @ 39.6240 mm (57-63 lbs. @ 1.56")
Valve spring pressure - exhaust
......... ...524.89-587.17 N @ 29.4640 mm (118-132 lbs. @ 1.16")
Valve spring:
.........wear limit .......................................... 10% loss of pressure
.........free length...............................approx. 51.3080 mm (2.02")
.........assembled height (pad to retainer) .........39.1160-40.1320 mm
......... ....................................................................... (1.54-1.58")
.........out of square (max.)................................ 1.27 mm (0.050")
Valve stem to guide clearance
.........intake ........................0.0254-0.0686 mm (0.0010-0.0027")
.........exhaust ......................0.0381-0.0813 mm (0.0015-0.0032")
.........wear limit .......................................... 0.1397 mm (0.0055")
Valve head diameter
.........intake ............................ 43.9420-44.1960 mm (1.73-1.74")
.........exhaust ......................... 37.8460-38.3540 mm (1.49-1.51")
Valve face angle..................................................................... 45
Valve face runout (max.) .............................. 0.0508 mm (0.002")
Valve stem diameter - standard
.........intake .........................6.9748-6.9952 mm (0.2746-0.2754")
.........exhaust ......................6.9494-6.9698 mm (0.2736-0.2744")
Valve stem diameter - 0.015 oversize
.........intake .........................7.3558-7.3761 mm (0.2896-0.2904")
.........exhaust ......................7.3304-7.3507 mm (0.2886-0.2894")
Valve stem diameter - 0.030 oversize
.........intake .........................7.7368-7.7571 mm (0.3046-0.3054")
.........exhaust ......................7.7114-7.7317 mm (0.3036-0.3044")
STARTER
Motor diameter ........................................................... 78 mm (3")
Current draw under normal load ............................140-200 amps
Normal engine cranking speed ................................ 200-250 rpm
Minimum stall torque @ 5 volts ..................... 14.7 Nm (11 lb.ft.)
Maximum load ..............................................................800 amps
No load..................................................................... 7010 amps
Brush mfg. length ............................................... 16.8 mm (0.66")
Spring tension ......................................................... 18 N (64 oz.)
Maximum commutator runout ........................... 0.12 mm (0.005")
Maximum starting circuit voltage drop ..............................0.5 volt
(battery pos. terminal to starter terminal at normal engine temperature)
SPECIFICATIONS
02-69
02-70
02-70
NOTE: Oil threads with a lightweight engine oil unless the threads require oil or water resistant sealer.
TORQUE SPECIFICATIONS - General Applications

U.S. THREAD SIZES ........................................................Nm.................................................................... LB. FT.
1/4 - 20 ..............................................................................8 - 12 .................................................................. 6 - 9
5/16 - 18 ............................................................................16 - 24 ............................................................ 12 - 18
5/16 - 24 ............................................................................19 - 27 ............................................................ 14 - 20
3/8 - 16 ..............................................................................30 - 43 ............................................................ 22 - 32
3/8 - 24 ..............................................................................37 - 51 ............................................................ 27 - 38
7/16 - 14 ............................................................................54 - 75 ............................................................ 40 - 55
7/16 - 20 ............................................................................54 - 81 ............................................................ 40 - 60
1/2 - 13 ..............................................................................75 - 108 .......................................................... 55 - 80
METRIC THREAD SIZES..................................................Nm.................................................................... LB. FT.
M-6 ....................................................................................8 - 12 .....................................................................6 - 9
M-8 ....................................................................................19 - 28 ...............................................................14 - 21
M-10 ..................................................................................38 - 54 ...............................................................28 - 40
M-12 ..................................................................................68 - 96 ...............................................................50 - 71
M-14 ..................................................................................108 - 155 .........................................................80 - 114
PIPE THREAD SIZES .......................................................Nm.................................................................... LB. FT.
1/8......................................................................................7 - 11 .....................................................................5 - 8
1/4......................................................................................16 - 24 ...............................................................12 - 18
3/8......................................................................................30 - 45 ...............................................................22 - 33
1/2......................................................................................34 - 47 ...............................................................25 - 35
SPECIFICATIONS
02-71
02-71
TORQUE SPECIFICATIONS - Special Applications

ITEM
Nm
LB. FT.
Air Charge Temperature Sensor ........................................................... 13-16 ....................................................................................... 7-12

Belt tensioner (timing) pivot bolt ............................................................ 40-55 ..................................................................................... 30-41
Belt tensioner (timing) adjusting bolt ..................................................... 35-45 ..................................................................................... 26-33
Camshaft gear bolt................................................................................ 70-95 ..................................................................................... 52-70
Camshaft thrust plate bolt ..................................................................... 8-12 ........................................................................................... 6-9
Connecting rod nut ........................................................................... 41-49 ..................................................................................... 30-36
Crankcase vent baffle to block .............................................................. 8-12 ........................................................................................... 6-9
Crankshaft damper bolt......................................................................... 125-165 ............................................................................... 92-122
Crank position sensor to front cover...................................................... 8-12 ........................................................................................... 6-9
Cylinder head bolt
............................................................................ step 1 = 70 ................................................................................. 52
............................................................................................................. step 2 = turn 90
ECT sensor to water outlet connector ................................................... 16-24 ..................................................................................... 12-18
Exhaust man. to cyl head bolts/stud/nut
........................................... 60-80 ..................................................................................... 44-59
Flywheel to crankshaft bolt.................................................................... 73-87 ..................................................................................... 54-64
Front lifting eye bolt/nut......................................................................... 20-30 ..................................................................................... 15-22
Generator bracket to head & block ................................................... 40-55 ..................................................................................... 30-41
Ignition coil to bracket .......................................................................... 5-7............................................................................................. 4-5
Intake manifold, upper-vacuum fitting.................................................... 16-24 ..................................................................................... 12-18
Intake manifold, elbows & pipe plugs ................................................ step 1 = 7-10 ............................................................................. 5-7
............................................................................................................. step 2 = additional 1/2 turn
Intake manifold, upper to lower,
....................................................... step 1 = 7-10 ............................................................................. 5-7
and also manifold to cyl. head bolt or nut
......................................... step 2 = 26-38 ....................................................................... 19-28
Main bearing cap bolt ....................................................................... step 1 = 68-81 ....................................................................... 50-60
............................................................................................................. step 2 = 102-115 ................................................................... 75-85
Oil pressure sending unit to block ........................................................ 11-24 ....................................................................................... 8-18
Oil pump pickup tube to block ............................................................... 20-30 ..................................................................................... 15-22
Oil pump to block .................................................................................. 10-14 ....................................................................................... 7-10
Oil pan drain plug to pan ....................................................................... 20-34 ..................................................................................... 15-25
Oil pan to block ..................................................................................... 14-16 ..................................................................................... 10-12
Oil filter insert to block........................................................................... 28-35 ..................................................................................... 21-26
Oil separator bolt................................................................................... 8-12 ........................................................................................... 6-9
Rear lifting eye nut ................................................................................ 20-30 ..................................................................................... 15-22
Rocker arm cover to cylinder head........................................................ 9-13 ......................................................................................... 7-10
Starter solenoid bolt .............................................................................. 5-9............................................................................................. 4-7
Starter M & B terminal nuts ................................................................... 9-13 ......................................................................................... 7-10
Starter through bolt ............................................................................... 5-9............................................................................................. 4-7
Starter mounting bolt............................................................................. 21-27 ..................................................................................... 15-20
Starter brush plate screw ...................................................................... 3 ................................................................................................... 2
Spark plug to cylinder head................................................................... 9-20 ......................................................................................... 7-15
Temperature sending unit to block ........................................................ 11-24 ....................................................................................... 8-18
Water jacket drain plug to block ............................................................ 16-24 ..................................................................................... 12-18
Water outlet connection bolt.................................................................. 20-30 ..................................................................................... 15-22
Water pump to block bolt ...................................................................... 20-30 ..................................................................................... 15-22
Cylinder front cover bolt ........................................................................ 13-16 ..................................................................................... 10-12
Inner timing belt cover stud/bolt/nut ...................................................... 20-30 ..................................................................................... 15-22
Outer timing belt cover bolt ................................................................... 8-12 ........................................................................................... 6-9
42 pin connector to lower intake............................................................ 20-30 ..................................................................................... 15-22
Apply Teflon tape or liquid sealer to threads.

Refer to service manual for proper sequence.
SPECIFICATIONS
02-72
REQUIRED TOOLS
Tool
Number/Description
T59L-100-B Impact Slide
Hammer
T58L-101-B Puller
Attachment
T73L-6011-A Engine
Cylinder Hone Set
T74P-6015-A Engine
Plug Replacer
T68P-6135-A Piston Pin

Remover/Replacer
T74P-6312-A Crankshaft
Damper Remover
Illustration
T95T-6565-A Valve
Spring Compressor
T95T-6510-A Valve
Stem Seal Installer
T74P-6700-B Front
Cover Seal Remover
T82L-6701-A Rear Main

Seal Replacer
T95T-6510-B Valve
Stem Seal Replacer
T74P-6150-A Front
Seals Replacer
T71P-6250-A Cam
Bearing Replacer
T74P-6254-A Camshaft
Belt Tensioner Tool
02-72
DESIRED TOOLS
Tool Number
Description
D81L-6500-A
Blind Hole Puller
D79L-6731-B
Oil Filter Wrench
D78P-4201-G
Dial Indicator
Tool-4201-C
Dial Indicator with

Bracketry
T74P-6256-B Cam
Sprocket
Holding/Removing Tool
ROTUNDA EQUIPMENT
T74P-6306-A Crankshaft
Sprocket Remover
SPECIFICATIONS
Model
Description
021-00045
Belt Tension Gauge
03-1
Ignition System
SECTION TITLE
03-1
PAGE

ENGINE SERVICE - 2.5L ...................................................................................................................................... 02-01
IGNITION SYSTEM ............................................................................................................................................... 03-01
FUEL PUMP ......................................................................................................................................................... 04-01
CARBURETOR...................................................................................................................................................... 05-01
STARTER MOTOR................................................................................................................................................ 06-01
GOVERNOR.......................................................................................................................................................... 07-01
COOLING SYSTEM .............................................................................................................................................. 08-01
GENERATOR ........................................................................................................................................................ 09-01
SECTION 03 - IGNITION SYSTEM

NOTE: This system is used on both carbureted and EFI engines.
SUBJECT
PAGE
DESCRIPTION...........................................................................................................................................................................................................................2
Operation ..........................................................................................................................................................................................................................3
Inputs Affecting Ignition..............................................................................................................................................................................................3
UESC Module Outputs.................................................................................................................................................................................................4
Wiring Diagram ..............................................................................................................................................................................................................4
DIAGNOSIS ...............................................................................................................................................................................................................................5
Diagnosis Equipment....................................................................................................................................................................................................5
Service Checks................................................................................................................................................................................................................5
DIS Harness Checks......................................................................................................................................................................................................6
Secondary Resistance Checks..................................................................................................................................................................................7
Spark Plug Inspection...................................................................................................................................................................................................8
REMOVAL AND INSTALLATION.......................................................................................................................................................................................9
Ignition Coil .....................................................................................................................................................................................................................9
Crankshaft Position Sensor ....................................................................................................................................................................................10
Engine Coolant Temperature Sensor .................................................................................................................................................................11
Ignition Wires ...............................................................................................................................................................................................................12
Spark Plug ....................................................................................................................................................................................................................12
ADJUSTMENT.......................................................................................................................................................................................................................13
Ignition Timing .............................................................................................................................................................................................................13
SPECIFICATIONS .................................................................................................................................................................................................................14
General Ignition ...........................................................................................................................................................................................................14
Torques ...........................................................................................................................................................................................................................14
Special Tools.................................................................................................................................................................................................................14
REFER TO SEPARATE PUBLICATION ON ELECTRONIC FUEL INJECTION (EFI) SYSTEMS

FOR INFORMATION ON THAT SYSTEM.
03-2
Ignition System
03-2
The Purpose of an engines ignition system is to ignite

the fuel/air mixture at the correct time and sequence
based upon the input it receives.
DESCRIPTION
WARNING: HIGH TENSION VOLTAGE
PRODUCED BY A DISTRIBUTORLESS
IGNITION SYSTEM IS HIGHER THAN FOR
A CONVENTIONAL IGNITION SYSTEM. WHEN
CARRYING OUT SERVICE OPERATIONS ON AN
ENGINE EQUIPPED WITH DISTRIBUTORLESS
IGNITION, IT IS IMPORTANT TO BE AWARE OF
THE ABOVE POINT AS WELL AS ALL THE USUAL
SAFETY MEASURES TO PREVENT THE
POSSIBILITY OF ELECTRIC SHOCKS.
The Distributorless Ignition System (DIS) is a state of

the art system. The brain of this system is the
Universal Electronic Spark control (UESC) module.
This module receives four inputs:
Crankshaft position
Crankshaft speed
Engine temperature
Engine vacuum (load)
From these inputs, the UESC computes spark

strategy (spark advance) to obtain optimum engine
performance for correct input conditions.
DESCRIPTION
03-3
Ignition System
03-3
Operation
With this system, the electronic control module
monitors the engine load, speed and operating
temperature and decides what degree of spark
advance is correct for all of the operating conditions.
Because timing is set for life inherently in the design
of the engine, and there are no moving parts in the
ignition system itself, no maintenance is required
except for periodic spark-plug checks. The system
provides for fixed spark advance at start-up, for cold
weather starting, and for "average value" default
settings in case of component failure. Particular
attention has been given to spark optimization for
excellent fuel economy in the warm-up mode.
The spark plugs are paired so that one plug fires
during the compression stroke and its companion plug
fires during the exhaust stroke. The next time that
coil is fired, the plug that was on exhaust will be on
compression, and the one that was on compression
will be on exhaust. The spark in the exhaust cylinder
is wasted but little of the coil energy is lost.
Inputs Affecting Ignition

The spark strategy is based on sensors and manifold
vacuum input to the UESC module, which include the
following inputs:
Engine Speed and Crankshaft Position
The crankshaft position and speed information comes
to the UESC from the Crankshaft Position Sensor
(CKP Sensor), mounted in the engine front cover.
The CKP Sensor is triggered by teeth in the pulse
wheel. The pulse wheel is an integral part of the
crankshaft front pulley and damper assembly. The 36
teeth minus 1, spaced 10 degrees apart, indicate to
the UESC the crankshaft speed. The missing tooth
indicates crankshaft position.
Engine Load
The engine load information is processed into the
UESCs electronics by a pressure transducer located
within the UESC. A vacuum line connects the
transducer to the engine intake manifold. The engine
vacuum is proportional to its load.
Engine Temperature
The Engine Coolant Temperature Sensor (ECTS)
sends engine temperature information to the UESC.
The ECTS is located above the thermostat at the front
of the engine.
Fuel Octane Level Adjustment
In the event that the engine is operated on dry fuels
such as natural gas, compressed natural gas (CNG),
or liquefied petroleum gas (LPG), timing can be
modified. See the Adjustments section for details.
DESCRIPTION
03-4
Ignition System
03-4
UESC Module Outputs (Carb.)

Ignition Coil Driver
Transient Mode
The UESC switches two ignition coils on and off at the

correct times to give the desired spark advance.
Ignition timing is adjusted constantly by the UESC
module. Many factors, including all the sensor inputs,
affect the final ignition setting.
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 UESC
module.
Run Mode
Overspeed Mode
The UESC interprets engine speed above 200 RPM

as Run Mode.
If the engine speed exceeds 4000 RPM the dwell will

be reduced until the speed drops below 4000 RPM.
The Base Spark advance (BSA) is calculated by the

UESC module processing the engine speed and load
(Manifold Absolute Pressure) inputs.
Wiring Diagram
DESCRIPTION
03-5
Ignition System
DIAGNOSIS
03-5
12 volt timing light (Rotunda 059-00006)
This timing light uses an inductive pickup for

convenience and safety on 12 volt systems. This
timing light includes a tachometer which reads from
zero to 3000 RPM.
Service Checks.
Diagnosis Equipment
Each 400 hours of engine operation remove the

spark plugs and clean and adjust the electrode.
Clean and visually check spark plug high tension

leads, check for secure fit, and replace if
necessary.
Clean spark plugs as necessary using a wire

brush or professional spark plug cleaner (follow
manufacturers instructions). Inspect the firing tip.
Refer to Spark Plug Inspection Chart. Replace
spark plugs if they are worn or damaged.
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.
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.
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.
Spark tester, neon bulb type

(Champion CT-436)
There is no need to disconnect a plug wire; just place

this spark tester on a spark plug wire to determine if
spark is being provided to the plug. This is especially
useful for those hard-to reach plug wires.
Spark tester, gap type (D81P-666-A)
Connect this gap type spark tester between any spark

plug wire and engine ground to instantly determine if
spark is being provided to the plug. A spark plug with
a broken side electrode is not sufficient to check for
spark and may lead to incorrect results.
Volt-ohmmeter (Rotunda 014-00575)
A volt-ohmmeter is essential for gathering system

operating data during diagnosis, testing, and engine
servicing procedures. This digital volt-ohmmeter
(DVOM) can also be used for general purpose
electrical troubleshooting on conventional starting and
charging systems.
DIAGNOSIS
03-6
Ignition System
03-6
DIS Harness Checks

Check the following circuits with the volt-ohmmeter. Compare readings with the following chart. All sensors
connected to harness. Checks are made with the UESC disconnected.
Test No.
Harness Connector
Pin No.
DVOM Set
Selection
Reading
Ohms/VDC
Description of
Circuit
A-B
Ohm
315-385
Crankshaft Position
Sensor (CKP)
B-D
Ohm (1)
95,8515%
Engine Coolant Temp.

(ECT) Sensor
E-F
Ohm
Continuity
(0 resistance)
Engine Spark Advance

Circuit Base Advance
(Level 0)
F-H
Ohm
Continuity

Circuit
E-H
Ohm
Infinity (open)
Level 1 Advance
E-H
Ohm
Continuity

Circuit
F-H
Ohm
Infinity (open)
Level 2 Advance
E-H
Ohm
Continuity

Circuit
F-H
Ohm
Continuity
Level 3 Advance
G-H
20 VDC (2)
12 VDC
UESC Power Supply

Circuit
J-K
Ohm
0.5-1.3
Coil Primary Circuit
(1) ECTS brass only portion in 32F ice water. for the complete range of ECTS values, see the chart on the following page.
(2) Test must be conducted with KEY ON, ENGINE OFF (KOEO).
If readings are not to specifications, complete the following:
Remove the wire harness connector to the UESC.
Remove each sensor or component from the harness.
Using a high impedance digital volt-ohmmeter (DVOM) check each wire for continuity or resistance for wire
numbers and colors for the harness being used.
If the wire harness has open circuits or resistance higher than specifications, repair or replace the harness.
If the wire harness checks are to specifications, reconnect each sensor and component and complete another
DIS Harness Check.
If the same sensor or component circuit does not test to specifications, replace that sensor or coil.
If the engine will not start and/or run, install a new module and make a normal start.
DIAGNOSIS
03-7
Ignition System
03-7
Secondary Resistance Checks

Test No.
Test Connections
DVOM Set
Selection
Reading
Ohms/VDC
Description of
Circuit
Coil Secondary
Towers 1-4
Ohm
14,000
Coil Secondary
Circuit
Coil Secondary
Towers 2-3
Ohm
14,000
Coil Secondary
Circuit
Ends of Each Spark

Plug Wire
Ohm
9,000 to 16,000
Max. -30,000
Spark Plug Wire

Resistance
Engine Coolant Temperature sensor Characteristics

C
Ohms ( 5%)
-30
-22
496,051
-20
209,816
-10
14
160,313
32
95,851
10
50
58,987
20
68
37,340
30
86
24,253
40
104
16,113
50
122
10,926
60
140
7,548
70
158
5,335
80
176
3,837
90
194
2,804
100
212
2,080
110
230
1,564
120
248
1,191
130
266
918
140
284
715
150
302
563
DIAGNOSIS
03-8
Ignition System
Spark Plug Inspection
DIAGNOSIS
03-8
03-9
Ignition System
03-9

Ignition Coil Removal
2. Disconnect ignition coil multiplug.
Ignition Coil Installation

1. Position coil assembly, secure with four screws.
3. Squeeze the locking tabs on the coil retainer and
pull upward on the boot with a slight side-to-side
twist.
CAUTION: Do not pull on the spark plug

wire set.
2. Tighten screws to 4.5-7 Nm (36-63 lb-in).

3. Connect HT leads at coil, ensuring that locking
tabs snap into position.
NOTE: HT connections at coil are marked 1 to 4. It
is important that each HT lead is connected in correct
sequence.
4. Connect ignition coil multiplug.
6. Start engine and check coil operation.
4. Remove four screws

5. Remove the ignition coil assembly.
03-10
Ignition System
Crankshaft Position Sensor Removal
03-10
9. Disconnect multiplug from sensor.

3. Using flex handle, rotate drive belt tensioner and
remove drive belt.
4. Disconnect generator connectors.
5. Remove three bolts and generator.
6. Remove lower radiator hose and heater water
hose from water pump inlet tube.
10. Remove one screw.
7. Remove two bolts and water pump inlet tube.

8. Remove o-ring from water pump inlet tube.
11. Carefully pry crankshaft position sensor from

engine front cover.
03-11
Ignition System
03-11
SCALDING.
Crankshaft Position Sensor Installation

NOTE: Engine front cover design precisely locates
crankshaft position sensor so no adjustment is
required.
1. Fit engine speed sensor.
2. Install screw and tighten to 8-12 Nm (72-108 lbin).
3. Connect crankshaft position sensor.
4. Install new o-ring on water pump inlet tube.
6. Install water pump inlet tube to generator bracket
bolts and tighten to 9-12 Nm (84-108 lb-in).
7. Install lower radiator hose and heater water hose
on water pump inlet tube.
8. Install generator to generator mounting bracket
and hand start generator to bracket bolts.
Alternately tighten bolts to 41-54 Nm (30-40 lbft).
9. Connect generator electrical connectors.
10. Position drive belt. Rotate drive belt tensioner,
position drive belt and rest tensioner pulley on
belt.

Removal
3. Place a clean drain tray below engine under

radiator drain plug and remove drain plug. To
assist draining remove radiator cap. Drain
sufficient coolant to lower the level below the
temperature sensor.
4. Remove temperature sensor multiplug. To
remove multiplug, pull on multiplug, do not pull on
wiring.
5. Unscrew the sensor.

Installation
1. Install the sensor. Do not overtighten. Connect
multiplug, ensuring that locking tabs snap into
position.
2. Replace radiator drain plug and refill system with
correct solution. Remove rubber blanking cap on
water outlet. When coolant is evident, refit
blanking cap. Fill container to "maximum" mark
allowing time for air in system to bubble through.
Install radiator cap.
3. Connect battery and start engine. Allow engine to
warm to normal operating temperature. Check
and, if necessary, add coolant.
1.
2. Disconnect battery and release cooling system
pressure.
WARNING: WHEN RELEASING SYSTEM
PRESSURE, COVER CAP WITH A THICK
CLOTH TO PREVENT COOLANT
03-12
Ignition System
03-12
Ignition Wires Removal

Spark Plug Wire Remover
T74P-6666-A
1. Remove spark plug wires from spark plugs with

Spark Plug Wire Remover T74P-6666-A, pulling
outward on the boot with a slight side-to-side
twist.

wire set.
3. Remove the ignition wire separator from the spark

plug wire set and reinstall it in the same relative
position on the new set.
4. Route the spark plug wire set toward the spark
plugs.
5. Connect each spark plug wire set on the proper
spark plug.
Spark Plug Removal

NOTE: Refer to the Spark Plug Inspection Chart to
determine spark plug condition.
1. Remove ignition wires as outlined.
2. Squeeze the locking tabs on the coil retainer and

pull upward on the boot with a slight side-to-side
twist to disconnect the spark plug wire set from
the ignition coil.

wire set.
2. Loosen spark plugs and remove any dirt or

foreign material from spark plug areas of cylinder
head with compressed air.
3. Remove spark plugs and mark location using a
piece of masking tape.
4. To install, reverse removal procedure. Check and
adjust spark plugs. Tighten spark plugs to 9-20
Nm (7-15 lb-ft).
Ignition Wires Installation

1. Apply an even coating of Silicone Dielectric
Compound WA-10, D7AZ-19A331-A, or
equivalent, meeting Ford specification ESEM1C171-A to the entire interior surface of the
spark plug boot.
2. Squeeze locking tabs on coil retainer and push
down on boot with a slight side-to-side twist to
connect spark plug wire set on the ignition coil.
Each of the terminals is identified on the ignition
coil. The firing order of the coil is 1-3-4-2. Check
that each of the spark plug wires is fully seated
and both locking tabs are engaged.
03-13
Ignition System
03-13
ADJUSTMENT
Ignition Timing
In the event that the engine is operated on dry fuels, the timing can be modified by grounding, leaving open, or
applying 12 volts to circuits 674 and 72 of the module connector. The fuel type determines which circuit is altered
as shown in the chart below.
NORMAL OPERATION
Circuit 674
Circuit 72
(BR-W)
(Y-BK)
Gasoline
open
open
LPG
ground
Natural gas
ground
Timing effect
IF DETONATION OCCURS
Circuit 674
Circuit 72
(BR-W)
(Y-BK)
base = 15
open
ground
base = 12
open
base = 30
ground
ground
base = 27
+12 volts
base = 35
ground
open
base = 30
ADJUSTMENT
Timing effect
03-14
Ignition System
SPECIFICATIONS
General Ignition
Firing
Order
Ignition
Timing
Plug Type
Plug Gap
1-3-4-2
10 1
AWSF-52C
1.07-1.17mm
(.042-.046 in.)
Torques
Description
Nm
lb-ft
Spark Plugs
9-20
7-15
Coil Mounting Screws
5-7
Crankshaft Hub Bolt
125-165
Crankshaft Position
Sensor
8-12
lb-in
44-62
93-121
71-106
Special Tools
Spark Plug Wire Remover
T74P-6666-A
SPECIFICATIONS
03-14
04-1
Fuel Pump
SECTION TITLE
04-1
PAGE

ENGINE SERVICE - 2.5L ...................................................................................................................................... 02-01
IGNITION SYSTEM ............................................................................................................................................... 03-01
FUEL PUMP ......................................................................................................................................................... 04-01
CARBURETOR...................................................................................................................................................... 05-01
STARTER MOTOR................................................................................................................................................ 06-01
GOVERNOR.......................................................................................................................................................... 07-01
COOLING SYSTEM .............................................................................................................................................. 08-01
GENERATOR ........................................................................................................................................................ 09-01
SECTION 04 - FUEL PUMP

SUBJECT
PAGE
DESCRIPTION - EFI....................................................................................................................................................................................................................2
DESCRIPTION - CARB. .............................................................................................................................................................................................................3
DIAGNOSIS ..................................................................................................................................................................................................................................4
Electrical ...............................................................................................................................................................................................................................4
Fuel Supply and Pressure...............................................................................................................................................................................................4
SPECIFICATIONS .......................................................................................................................................................................................................................5

04-2
Fuel Pump
04-2
DESCRIPTION - EFI
Depending on engine application, either a Zenith Model 33 carburetor or an electronic fuel injection system is used
to deliver fuel to the cylinders.
The illustration above shows the electronic fuel injection fuel delivery system. This system operates at a much
higher pressure than a carbureted system.
Refer to the separate publication on electronic fuel injection for information on this system.
DESCRIPTION
04-3
Fuel Pump
04-3
DESCRIPTION - CARB.
The carbureted fuel system includes a remote mounted electric fuel pump.
CAUTION: The electric fuel pump MUST NOT be mounted directly on the engine assembly, as engine
vibration will shorten the life of the pump.
The fuel pump regulates and maintains fuel flow which will be used to provide necessary fuel for combustion.
This Section deals with the carbureted system only. Refer to the separate publication on electronic fuel injection for
information on this system.
DESCRIPTION
04-4
Fuel Pump
4.
If pressure fails to come up, check for an

obstruction in the supply line from the tank to the
pump, and between the pump and carburetor.
5.
Ensure that the fuel cap vent is operating

properly. The vent should allow air to enter the
tank as fuel is removed. Correct any obstruction
or restriction found.
DIAGNOSIS
NOTE: For the following tests, TEMPORARILY place
a jumper wire across the terminals of the oil pressure
switch.
04-4
Electrical
NOTE: IF NO OBSTRUCTION IS FOUND, AND THE

ELECTRICAL SUPPLY, GROUND, AND FUEL
SUPPLY TO THE PUMP AS DESCRIBED ABOVE
ARE VERIFIED ALL RIGHT, REPLACE THE PUMP
ASSEMBLY.
1.
Connect the positive lead of a voltmeter to the

pump power wire, and the negative lead to the
pump housing.
2.
Turn on the ignition switch.
3.
The voltmeter should read 12 volts. If not, check

the power supply to the pump, and the ground
wire between pump housing and engine cylinder
block.
1.
Start the engine and allow it to come up to

operating temperature.
2.
Set the throttle control to high idle. Place as full a

load onto the engine as possible.
ONCE YOU HAVE ESTABLISHED THE

INTEGRITY OF THE POWER SUPPLY AND
GROUND to the pump, if it still will not operate
replace the pump assembly.
3.
Fuel pressure should be maintained at a

minimum of 3.5 psi.
4.
If fuel pressure cannot be maintained, verify that

all of the above checks have been carried out.
4.
Fuel Supply and Pressure

If a problem with fuel supply or delivery is suspected,
first ensure that there is fuel in the tank. Then,
proceed as follows:
1.
Tee a pressure gauge into the fuel line at the

carburetor inlet.
2.
Turn on the ignition switch, but do not start the

engine.
3.
The pump should "click" rapidly for a short time,

and pressure should build to, and level off at, 3.5
to 5 psi.
CONDITION
Insufficient fuel delivery
IF ALL OF THE ABOVE CHECKS HAVE BEEN

CARRIED OUT, AND FUEL PRESSURE CANNOT
BE MAINTAINED, REPLACE THE FUEL PUMP
ASSEMBLY.
WARNING: ONCE ALL OF THE ABOVE TESTS
ARE COMPLETED, REMOVE THE JUMPER WIRE

FROM THE OIL PRESSURE SWITCH.
For additional diagnostic information, see the Service
Check Chart below.
POSSIBLE SOURCE
Clogged pump filter, screen, or fuel filter.

A break or restriction in fuel lines
An incorrect float level, malfunctioning inlet
ACTION
Clean or replace filter.

Repair fuel line or remove restriction.
Repair or replace as needed.
needle valve, or clogged inlet screen in the

carburetor.
Pump not operating
Damaged, loose ground, or improper wiring.
Inspect all mounting or wiring.
Carburetor flooding
Worn needle and seat assembly in carburetor.

Wrong pump application; that is, standard
Replace worn needle and seat assembly in
pressure pump for low pressure application.

Air leak on inlet side of pump due to holes in
carburetor.
Change to a low pressure pump.
Replace fuel line, and tighten fittings (apply a
fuel line or loose fittings.

Fuel pump leaks
Fuel line fitting connections at pump are loose

or dirty.
DIAGNOSIS
sealer, if necessary).
Tighten and clean all connections at pump.
04-5
Fuel Pump
SPECIFICATIONS
ITEM
SPECIFICATION
Shutoff pressure
3.5 - 5 psi
Maximum current draw
1.5 amp.
Minimum flow @ 3 psi,

12 volt input
3 GPH
SPECIFICATIONS
04-5
05-1
Carburetor
SECTION TITLE
05-1
PAGE

ENGINE SERVICE - 2.5L ...................................................................................................................................... 02-01
IGNITION SYSTEM ............................................................................................................................................... 03-01
FUEL PUMP ......................................................................................................................................................... 04-01
CARBURETOR...................................................................................................................................................... 05-01
STARTER MOTOR................................................................................................................................................ 06-01
GOVERNOR.......................................................................................................................................................... 07-01
COOLING SYSTEM .............................................................................................................................................. 08-01
GENERATOR ........................................................................................................................................................ 09-01
SECTION 05 - CARBURETOR
SUBJECT
PAGE
DESCRIPTION...........................................................................................................................................................................................................................2
Fuel Supply System.......................................................................................................................................................................................................2
Idle System.......................................................................................................................................................................................................................2
High Speed System.......................................................................................................................................................................................................3
Accelerating Pump System........................................................................................................................................................................................3
DIAGNOSIS ...............................................................................................................................................................................................................................4
Percolation........................................................................................................................................................................................................................4
Flooding.............................................................................................................................................................................................................................4
Hard Starting ...................................................................................................................................................................................................................4
Stalling ...............................................................................................................................................................................................................................4
Rough Idle.........................................................................................................................................................................................................................5
Surging Above Idle........................................................................................................................................................................................................5
Poor Acceleration...........................................................................................................................................................................................................5
Leaking Carburetor........................................................................................................................................................................................................5
Inconsistent Idle Speed ...............................................................................................................................................................................................5
Reduced Power Output ...............................................................................................................................................................................................5
DISASSEMBLY AND ASSEMBLY .....................................................................................................................................................................................6
Cleaning and Inspection..............................................................................................................................................................................................6
Air Intake Assembly ......................................................................................................................................................................................................7
Fuel Bowl Assembly......................................................................................................................................................................................................8
REFER TO SEPARATE PUBLICATION ON ELECTRONIC FUEL INJECTION (EFI) SYSTEMS FOR

INFORMATION ON THAT SYSTEM.
05-2
Carburetor
DESCRIPTION
On each carburetor an identification tag is found on
the carburetor body. Do not remove this tag for any
reason. The numbers stamped on this tag identify the
carburetor for the particular engine usage. These
numbers are used when finding specifications for
carburetor adjustments or in ordering replacement
parts.
05-2
As the fuel leaves the idle jet it is mixed with air from
the idle air bleed, which is located just above the jet in
the air intake, therefore a fuel and air mixture is
provided just before the passage to the idle discharge
holes. This air bleed calibration is to provide better
control of the fuel delivery and to prevent the fuel in
the bowl from being siphoned into the intake manifold
through the idle system when the engine is shut off.
The Zenith model #33 carburetor is a single

downdraft unit of two-piece construction, consisting of
a cast aluminum air intake and throttle body with a
fuel bowl. The single venturi is removable for easy
adaptability to meet different size engine
requirements.
The mounting flange holes are elongated to allow it to
fit either the SAE 1" or 1 1/4" flange. A vacuumoperated 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 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.
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
out (counterclockwise) allows a richer mixture.
As the throttle plate opens, extra fuel is discharged
from the secondary idle discharge holes as the
throttle plate passes them. This hole is precisely
located from the closed throttle plate with the size and
location depending on fuel requirements. As the
throttle plate is opened wider, the idle system
gradually ceases to function. The delivery of fuel
through the high speed system increases as the
throttle plate is advanced. Although the delivery of
fuel through the idle system diminishes as the throttle
plate approaches the wide open position, it continues
to deliver a small volume of fuel contributing to the
fuel delivered by the high speed system. It cannot be
said that the idle system ceases to deliver fuel entirely
at wide open throttle, but it must be made clear that
the amount of fuel delivered from the idle system at
wide open throttle is minute and relatively
unimportant.
DESCRIPTION
05-3
Carburetor
05-3
High Speed System
Accelerating Pump 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 accelerating pump controls the amount of fuel

that is discharged into the air stream on sudden
throttle openings. When the throttle is opened
suddenly, air rushes through the carburetor into the
intake manifold and to the engine. this air is lighter
than the liquid fuel and gets into motion more quickly.
That means that the air reaches the cylinders of the
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.
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 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.
When the throttle plate is opened to a point just above

the idle position, enough air passes through the
carburetor to lower the pressure at the discharge
tube. The float chamber is open to atmospheric
pressure; consequently, the greater pressure in the
float chamber will cause the fuel to flow from the fuel
bowl through the main jet into the main well and well
tube.
Air admitted through bleed holes in the well tube, an
amount measured by the well vent, is mixed with the
fuel. This mixture of fuel from the main well tube
passes through the discharge tube in the venturi and
is added to the air stream in the venturi. This mixture
then passes into the intake manifold.
The accelerating system consists of the pump

diaphragm assembly, accelerating jet, intake check
valve, and three parts making up the refill check. The
pump is vacuum operated. In this system the pump
diaphragm is pulled against the pump spring by the
engine manifold vacuum. When the throttle is
opened, the pull on the diaphragm drops allowing the
spring to push the diaphragm against the fuel causing
it to discharge through the accelerator jet. This
amount may be varied by adjusting the travel of the
pump spring. Such adjustment is made possible by
changing the length of the diaphragm protector and
the end of the pump spring.
DESCRIPTION
05-4
Carburetor
05-4
Percolation
DIAGNOSIS
Water and dirt that accumulate in the fuel tank can
cause a restricted fuel line or filter and malfunction of
the fuel pump or carburetor. Condensation, which is
the greatest source of water entering the fuel tank, is
formed by moisture in the air when it strikes the cold
interior walls of the fuel tank.
If the accumulation of dirt and water in the filter is
excessive, the fuel tank should be removed and
flushed, and the line from the fuel pump to the tank
should be blown out. Air leakage in the fuel inlet line
can cause low fuel pump pressure and volume.
A restricted fuel tank vent can cause low fuel pump
pressure and volume and can result in collapsed inlet
hoses or a collapsed fuel tank. High or low pressure
and the two most likely fuel pump troubles that will
affect engine performance. Low pressure will cause a
lean mixture and fuel starvation at high speeds and
excessive pressure will cause high fuel consumption
and carburetor flooding.
Dirt accumulation in the fuel and air passages,
improper idle adjustments, and improper fuel level are
the major sources of carburetor troubles.
Many problems attributed to the carburetor are
caused by other systems. Proper and careful
diagnosis is a must.
If the problem seems to occur in one engine cylinder,
the ignition system may be at fault. If the problem
seems to occur in all engine cylinders, then the
problem most likely is carburetion. When the
carburetor is thought to be at fault, check the fuel
system first. Dirt or water in the gas tank, leaks in the
fuel lines, or a defective fuel pump often show the
same symptoms as carburetion problems.
Observation, pressure and volume tests on the fuel
system show whether the fuel system is the cause of
the problem.
When the carburetor is shown to be at fault, a simple
cleaning may often solve the problem. Spraying a
carburetor cleaning solvent into the carburetors air
intake assembly with the engine running may solve
the problem.
Percolation symptoms are a strong smell of fuel

vapors and hard starting of a hot engine that has
been sitting for 20 minutes. Fuel drips from the end
of the throttle shaft or from the main discharge nozzle
causing a rich mixture in the air intake. Opening the
choke completely and cranking the engine clears the
vapors and eliminates percolation.
Flooding
Flooding occurs from a float level set too high, a
sticking choke plate, float, or float valve, or a fuel inlet
needle held off its seat either by improper seating or
dirt particles. A punctured or leaking float admitting
fuel becomes gas-logged causing a heavy float, high
fuel level and flooding.
Flooding has decreased due to the use of fuel filters
and Vitron fuel inlet needles. If flooding does occur,
disassemble the carburetor, observe the operation
and condition of components, and repair or replace as
necessary.
Hard Starting
Hard starting when attributed to the carburetor is
caused by a flooded engine due to improper starting
procedures. An improper idle fuel mixture, sometimes
due to improper fuel mixture, or idle fuel mixture
adjusting needles not turned equally in relation to the
other adjusting needle causes hard staring. A too
high or too low float level, due to misadjustment or
wear also causes hard starting. Repair, adjust or
replace components as necessary.
Stalling
Improper idle air/fuel mixture or an idle speed set too
low causes an engine to stall. Adjust these systems
as necessary. The stalling problem may be due to a
loose throttle shaft in the bore of the throttle body.
Repair as necessary. Clogged idle air bleeds, idle air
passages, or an idle discharge port cause stalling.
Cleaning eliminates this problem. Carburetor icing is
also a cause of stalling.
DIAGNOSIS
05-5
Carburetor
05-5
Rough Idle
Leaking Carburetor
An improper idle air/fuel mixture can cause rough idle.

This may be due to improper adjustment or damaged,
worn or grooved idle mixture adjusting screws.
Rough idle is caused by too high or too low a fuel
level due to floats misadjusted or damaged. A leak
between the carburetor and intake manifold, due to a
carburetor not tightened down, a damaged gasket or
a crack in either the carburetor or intake manifold
causes rough idle. Adjust, repair, or replace as
necessary. Clogged idle air bleeds, restricted idle air
passages or idle discharge ports also cause rough
idle. Clean or repair as necessary.
The causes of a carburetor leaking fuel are loose fuel

connections or a cracked carburetor body. Repair or
replace as needed.
Surging Above Idle
Inconsistent Idle Speed

Inconsistent idle speed is mostly a throttle related
problem. An incorrect throttle linkage adjustment, a
binding throttle linkage, a sticking throttle shaft, or a
loose throttle shaft in the throttle body or bore can
cause inconsistent idle speed. A sticking fuel inlet
needle can also cause this problem. Repair, replace
or adjust as necessary.
Reduced Power Output
Surging above idle is caused by a fuel level too low,

due to an improperly adjusted float, clogged main jets,
restricted main jet passages, or main jet having a size
not suited for the application. Adjust, clean, or
replace as necessary.
Poor Acceleration
Reduced power output is caused by a choke not fully

opened, an improperly adjusted throttle linkage, a
throttle not opening fully, a main jet not suited for this
application, or clogged main jets, main fuel passage,
or air bleeds. Clean, adjust, repair, or replace as
necessary.
Poor acceleration is caused by a mixture being too

rich or too lean. If a rich mixture is the cause of poor
acceleration, the fault may be an improperly adjusted
accelerator pump, a fuel level too high due to
damaged or misadjusted floats, fuel inlet needle not
seating due to damage or restriction, restricted air
bleeds, or a worn or damaged main jet. Adjust, repair
or replace as necessary.
If a lean mixture is the cause of poor acceleration, the
fault may be an improperly adjusted accelerator
pump, a damaged accelerator pump piston cap, an
accelerating pump check valve that is missing,
damaged, or not seating, a fuel float level set too low,
a clogged main metering jet, or a restricted main fuel
passage. Air leaks are also responsible for a lean
mixture causing poor acceleration. Leaks may occur
at the carburetor base to the intake manifold, or the
intake manifold to the cylinder head. Cracks in the
assemblies or worn gaskets cause these air leaks.
Clean, adjust, repair or replace as necessary.
DIAGNOSIS
05-6
Carburetor
05-6

Disassembly consists of separating the carburetor into two basic groups:
air intake
fuel bowl/throttle body

Thoroughly clean all metal parts in solvent or deepclene. Blow out all parts and channels with air pressure. Inspect
for damage, excessive wear, burrs or warpage. DO NOT CLEAN NON-METALLIC PARTS in solvent or Deepclene.
NOTE: The following assembly instructions and the exploded illustration are generalized and include all parts
possibly found in the carburetor at this time. Therefore, all of the parts shown and mentioned may not be included in
the particular assembly being worked on.
05-7
Carburetor
Air Intake Assembly

1.
Drive channel plug into vacuum channel flush

with surface.
2.
Drive cup plug into end of choke shaft hole

opposite choke lever.
3.
Insert choke shaft with milled flat toward top.
4.
Install choke plate in air intake and start screws.
NOTE: Edges are beveled to fit against wall when

closed. On plates including poppet valve, the spring
should face the top. Hold choke plate closed with
finger and tighten screws.
05-7
1.
Turn air intake upside down and insert vacuum

power piston into cylinder, making sure it will
move freely. Hold in place and stake casting with
punch at three points to retain piston assembly.
2.
Press well filler tube into casting with rolled down

orifice into casting until the bottom end is 1.25
inches from the cast surface. Do not bend or
distort.
3.
Press idle tube into casting with rolled down

orifice into casting until the bottom end is 1.25
inches from the cast surface. Do not bend or
distort.
05-8
Carburetor
Fuel Bowl Assembly

1. Install the following parts as needed (not normally
removed for service):
a)
Cup plug in shaft hole flush.
b) Fuel channel plug flush.

c)
Welch plug over idle port.
d) Idle channel plug flush.

e)
Welch plug over spark vacuum port.
f)
Spark vacuum tube to approximately 9/16

from casting.
g) Throttle body plug flush.

h) Pump Check Valve flush using tool C151-53.
i)
Well tube making sure that end openings

align with notch in casting at top and fuel
channel at bottom.
05-8
2. Slide seal over throttle shaft with lip toward lever

and install shaft in body.
3. Back out throttle stop screw and place body on
bench with mounting flange up.
4. With milled flat up, install throttle plate with short
side toward idle port and start screws. 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 in until it touches the casting, then screw in
an additional 3/4 turn.
6. Install idle needle washer and spring and screw in
to gently touch the seat. Back screw out
approximately one turn.
05-9
Carburetor
7. Install power jet valve using C161-9 wrench. No

gasket required.
8. Install main jet and seat firmly with screwdriver.
No gasket required.
9. Install main jet plug and washer 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 into
holes in float.
11. Lower float axle and float into slot provided in
body with the float needle sticking into the
threaded opening.
12. Install the fuel valve seat and washer making sure
that the fuel valve enters the seat properly (the
valve will enter the seat more easily if the float is
held in the up position) and tighten securely.
05-9
NOTE: If you have an older model unit with

removable accelerator jet; after intake gasket is in
place, an additional washer will be assembled
over the accelerator jet tube and set inside the
large hole in the intake gasket and on top of the
smaller washer. Lower air intake carefully onto
bowl and fasten securely and evenly using
attaching screws.
16. Place accelerator pump diaphragm in place on
body with bagged section into cavity. Insert
diaphragm protector into end of spring and install
spring with protector against diaphragm.
17. Place cover over spring and compress. Insert
screws and tighten evenly and securely.
NOTE: Pump spacer will install into cover before
assembly if required.
13. Insert float axle clip in slot to bear against axle

ends. Holding axle in place, raise float by
applying light finger pressure to the float bracket.
Float pontoons should be approximately level
when the valve is seated. If not, bend tab
carefully to adjust.
14. Install o-ring on venturi skirt and place venturi into

recess provided in body making sure that the
nozzle lines up with the notch in the fuel well.
15. Place intake gasket in position on body.
06-1
Starter Motor
SECTION TITLE
06-1
PAGE

ENGINE SERVICE - 2.5L ...................................................................................................................................... 02-01
IGNITION SYSTEM ............................................................................................................................................... 03-01
FUEL PUMP ......................................................................................................................................................... 04-01
CARBURETOR...................................................................................................................................................... 05-01
STARTER MOTOR................................................................................................................................................ 06-01
GOVERNOR.......................................................................................................................................................... 07-01
COOLING SYSTEM .............................................................................................................................................. 08-01
GENERATOR ........................................................................................................................................................ 09-01
SECTION 06 - STARTER MOTOR

SUBJECT
PAGE
DESCRIPTION...........................................................................................................................................................................................................................2
Starter Operation............................................................................................................................................................................................................2
DIAGNOSIS ...............................................................................................................................................................................................................................3
Preliminary Inspection..................................................................................................................................................................................................3
Symptom Chart ..............................................................................................................................................................................................................4
TEST A - Starter Voltage Test....................................................................................................................................................................................5
TEST B - Starter Relay Test.........................................................................................................................................................................................5
Starter Load Test............................................................................................................................................................................................................6
Starter No-Load Test.....................................................................................................................................................................................................7
Armature Open Circuit Test.......................................................................................................................................................................................7
Grounded Armature Test ............................................................................................................................................................................................7
Starter Solenoid Test ....................................................................................................................................................................................................7
Jump Starting..................................................................................................................................................................................................................8
REMOVAL AND INSTALLATION.......................................................................................................................................................................................9
Starter Motor ..................................................................................................................................................................................................................9
DISASSEMBLY AND ASSEMBLY ..................................................................................................................................................................................10
Disassembly ..................................................................................................................................................................................................................10
Cleaning and Inspection...........................................................................................................................................................................................10
Assembly........................................................................................................................................................................................................................12
Starter Drive Replacement ......................................................................................................................................................................................12
Armature Replacement.............................................................................................................................................................................................12
SPECIFICATIONS .................................................................................................................................................................................................................14
Torque Specifications................................................................................................................................................................................................14
General Specifications...............................................................................................................................................................................................14
Special Tools.................................................................................................................................................................................................................14
06-2
Starter Motor
Description
06-2
Starter Operation
The function of the starting system is to crank the

engine at a speed fast enough to permit the engine to
start. Heavy cables, connectors and switches are
used in the starting system because of the large
current required by the starter while it is cranking the
engine.
The amount of resistance in the starting circuit must
be kept to an absolute minimum to provide maximum
current for starter operation. A discharged or
damaged battery, loose or corroded connections, or
partially broken cables will result in slower than
normal cranking speeds, and may even prevent the
starter from cranking the engine.
The starting system includes the permanent magnet
gear-reduction starter motor with a solenoid-actuated
drive, the battery, a remote-control starter switch (part
of the ignition switch), the starter relay, the heavy
circuit wiring, and may include starter lock-out
devices.
An overrunning clutch in the drive assembly protects
the starter from excessive speeds during the brief
period as the engine starts.
1. The ignition switch is turned to the START

position.
2. A remote starter relay is energized, which
provides voltage to the starter solenoid. The
starter solenoid is energized, creating a magnetic
field in the solenoid coil.
3. The iron plunger core is drawn into the solenoid
coil.
4. A lever connected to the drive assembly engages
the drive pinion gear to the flywheel ring gear.
5. When the iron plunger core is all the way into the
coil, its contact disc closes the circuit between the
battery and the motor terminals.
6. The current flows to the motor, and the drive
pinion gear drives the flywheel and the engine
crankshaft.
7. As current flows to the motor, the solenoid pull-in
coil is bypassed.
8. The hold-in coil keeps the drive pinion gear
engaged with the flywheel.
9. The gear remains engaged until the ignition
switch is released from the START position.
DESCRIPTION
06-3
Starter Motor
06-3
DIAGNOSIS
A great many problems with the starting system are
caused by the malfunctioning of other components in
the electrical system. Therefore, it is best to start with
a battery check first when dealing with a starting
problem.
CAUTION: Be sure to disconnect battery

negative cable before servicing starter.
CAUTION: When disconnecting the

plastic hardshell connector at the
solenoid "S" terminal, grasp the plastic
connector and pull lead off. DO NOT pull
separately on lead wire.
WARNING: WHEN SERVICING STARTER

OR PERFORMING OTHER WORK IN THE
VICINITY OF THE STARTER, BE AWARE
THAT THE HEAVY GAUGE BATTERY INPUT
LEAD AT THE STARTER SOLENOID IS
ELECTRICALLY HOT AT ALL TIMES.
WARNING: WHEN WORKING IN AREA

OF THE STARTER, BE CAREFUL TO
AVOID TOUCHING HOT EXHAUST
COMPONENTS.
Make all digital volt/ohmmeter connections at the
component terminal rather than the cable or wiring
terminal. Making a connection at the wiring terminal
could result in false readings because the meter will
not pick up a high resistance between the wiring
connector and the component.
Preliminary Inspection
Inspect the following items before performing any
starter system diagnosis:
Inspect the condition of the battery using a battery

tester. A slow or no crank condition is often
caused by an undercharged battery.
Inspect for frayed or damaged battery and starter

cables and wires.
Make sure all the terminal connections at the

battery, starter relay, solenoid and starter are
clean and tight.
DIAGNOSIS
06-4
Starter Motor
06-4
Symptom Chart
If system does not operate properly, note condition, inspect starting system for loose connections, and continue
diagnosis using the following symptom chart:
CONDITION
Starter solenoid does not pull in and
starter does not crank (audible click
may or may not be heard).
Unusual starter noise during starter

overrun.
Starter cranks but engine does not

start.
Starter cranks slowly.
Starter remains engaged and runs

with engine.
POSSIBLE SOURCE
ACTION
Open fuse.
Check fuse continuity.
Low battery.
Test battery.
Defective remote relay.
Perform starter relay test.
Open circuit or high resistance

in external feed circuit to starter
solenoid.
Perform starter voltage test.
Defective starter.
Replace starter.
Starter not mounted flush

(cocked).
Realign starter on transmission

bell housing.
Noise from other components.
Investigate other accessory

noise contributors.
Ring gear tooth damage or

excessive ring gear runout.
Replace flywheel ring gear.
Defective starter.
Replace starter.
Problem in fuel system.
Refer to fuel system sections.
Problem in ignition system.
Refer to Ignition system section.
Refer to section 01, Diagnosis.
Charge or replace battery.
Engine related problem.
Low battery.
High resistance or loose

connections in starter solenoid
battery feed or ground circuit.
Ring gear runout excessive.
Replace ring gear.
Defective starter.
Replace starter.
Shorted ignition switch.
Replace ignition switch.
Battery cable touching solenoid

"S" terminal.
Replace or relocate cable.
Defective starter.
Replace starter.
DIAGNOSIS
Check that all connections are

secure.
06-5
Starter Motor
06-5
TEST A - Starter Voltage Test

TEST STEP
A1
ACTION TO TAKE
CHECK FOR VOLTAGE TO STARTER
Yes
Go to A2.
Key OFF. Transmission in Neutral.

Check for voltage between starter B+ terminal and starter
drive housing.
Is voltage 12-12.45 volts?
No
Check wire connections between battery and starter

solenoid and the ground circuit for open or short.
Yes
Check connections from output of starter relay to "S"

terminal for open or short.
No
Defective starter. Replace starter.
A2
RESULT
CHECK STARTER MOTOR
Key OFF. Transmission in Neutral.

Connect one end of a jumper wire to the starter B+ terminal
and momentarily touch the other end to solenoid "S"
terminal.
Does starter crank?
TEST B - Starter Relay Test

TEST STEP
B1
CHECK VOLTAGE AT STARTER RELAY START

TERMINAL
Key in START. Transmission in NEUTRAL.

Check for voltage between relay start terminal and case
ground.
B3
CHECK STARTER RELAY

Is case ground OK?
B2
RESULT
CHECK STARTER RELAY OUTPUT TERMINAL

VOLTAGE

Check for voltage at output terminal of remote relay.
ACTION TO TAKE
Yes
Go to B2.
No
Repair ground. Go to B2.
Yes
Go to B3.
No
Open circuit or high resistance exists in external circuit

wiring or components. Check the following:
All circuit connections including plastic hard shell

connector at solenoid "S" terminal to make sure it
is not broken or distorted.
Ignition switch.
Neutral switch or manual lever position sensor.
Yes
Refer to starter system diagnosis in this section.
No
DIAGNOSIS
Defective starter relay. Replace relay.
06-6
Starter Motor
Starter Load Test

Conduct this test if the starter cranks slowly and it is
desired to compare current to specifications.
1. Connect Rotunda Starting and Charging Tester
078-00005, or equivalent. Make sure that current
is not flowing through ammeter and heavy-duty
carbon pile rheostat portion of circuit (rheostat at
maximum counterclockwise position).
2. Place transmission or transaxle in NEUTRAL.
Crank engine with ignition off, and determine
exact reading on voltmeter. This test is
accomplished by disconnecting push-on
connector "S" at starter relay and by connecting a
remote control starter switch from positive battery
terminal to "S" terminal starter relay.
3. Stop cranking engine and reduce resistance of
carbon pile until voltmeter indicates same reading
as that obtained while starter cranked the engine.
The ammeter will indicate starter current draw
under load. Check this with value listed in
specifications.
DIAGNOSIS
06-6
06-7
Starter Motor
06-7
Armature Open Circuit Test

An open circuit armature may sometimes be detected
by examining the commutator for evidence of burning.
A burn spot on the commutator is caused by an arc
formed every time the commutator segment,
connected to the open circuit winding, passes under a
brush.
Starter No-Load Test
Grounded Armature Test
The starter no-load test will uncover such conditions

as open or shorted windings, or rubbing armature.
The starter can be tested, at no-load, on the test
bench only.
1. Make test connections with Rotunda Starting and
Charging Tester 078-00005, or equivalent, cables
connected to starter, large enough to carry high
current (the same as in the vehicle). The starter
will run at no-load. Be sure that no current is
flowing through ammeter (rheostat at maximum
counterclockwise position). determine exact
reading on voltmeter.
This test will determine if the winding insulation has

been damaged, permitting a conductor to touch the
frame or armature core. To determine if the armature
windings are grounded, check with a VOM as shown.
Infinite resistance indicates a normal condition.
Starter Solenoid Test

Make sure that the solenoid is isolated electrically
from the motor. Using a VOM, check for continuity
between "S" terminal and "M" terminal, and between
"S" terminal and ground (frame). If there is no
continuity, the wire is broken and the solenoid should
be replaced.
CAUTION: Make sure that the starter

is securely mounted in bench vise
while energizing, as starter will move
or jump
2. Disconnect starter from battery. Then, reduce
resistance of rheostat until voltmeter indicates
same reading as that obtained while starter was
running. The ammeter will indicate starter noload current draw. Refer to Specifications for a
comparative value.
3. If current exceeds specification, check for rubbing
armature, bent shaft, binding bearings, or shorts
in armature, or brush assembly.
DIAGNOSIS
06-8
Starter Motor
06-8
Jump Starting
For cases of a starter that cranks the engine very
slowly, connect a 12 volt booster battery to the
system.
To avoid damage to the equipment and battery or the
possibility of personal harm, follow these instructions
and precautions:
WARNING: HYDROGEN AND OXYGEN

GASES ARE PRODUCED DURING
NORMAL BATTERY OPERATION. THIS
GAS MIXTURE CAN EXPLODE IF FLAMES,
SPARKS OR LIGHTED TOBACCO ARE BROUGHT
NEAR THE BATTERY. WHEN CHARGING OR
USING A BATTERY IN AN ENCLOSED SPACE,
ALWAYS PROVIDE VENTILATION AND SHIELD
YOUR EYES.
KEEP OUT OF REACH OF CHILDREN.
BATTERIES CONTAIN SULFURIC ACID. AVOID
CONTACT WITH SKIN, EYES OR CLOTHING.
ALSO, SHIELD YOUR EYES WHEN WORKING
NEAR THE BATTERY TO PROTECT AGAINST
POSSIBLE SPLASHING OF THE ACID SOLUTION.
IN CASE OF ACID CONTACT WITH SKIN, EYES
OR CLOTHING, FLUSH IMMEDIATELY WITH
WATER FOR A MINIMUM OF 15 MINUTES. IF
ACID IS SWALLOWED, DRINK LARGE
QUANTITIES OF MILK OR WATER, FOLLOWED
BY MILK OF MAGNESIA, A BEATEN EGG, OR
VEGETABLE OIL. CALL A PHYSICIAN
IMMEDIATELY.
DO NOT DISCONNECT THE BATTERY OF THE
EQUIPMENT TO BE STARTED. DISCONNECTING
THE BATTERY COULD DAMAGE THE
EQUIPMENTS ELECTRONIC SYSTEM.
TO AVOID POSSIBILITY OF INJURY, USE
PARTICULAR CARE WHEN CONNECTING A
BOOSTER BATTERY TO A DISCHARGED
BATTERY.
2. Connect one end of second jumper cable to

negative ( - ) terminal of booster battery and other
end to an engine bolthead or good metallic
contact spot on engine of equipment to be
started, NOT TO NEGATIVE ( - ) BATTERY
TERMINAL.
WARNING: MAKING THE FINAL

CABLE CONNECTION COULD
CAUSE AN ELECTRICAL SPARK
NEAR THE BATTERY AND COULD CAUSE AN
EXPLOSION. REFER TO WARNING AT THE
BEGINNING OF THE JUMP STARTING
PROCEDURE.
CAUTION: When servicing starter or

performing other underhood work in the
vicinity of the starter, be aware that the
heavy gauge battery input lead at the starter
solenoid is "electrically hot" at all times.
Be sure to disconnect battery negative cable
before servicing starter.
3. Make sure jumper cables are not in way of
moving engine parts.
4. Start engine of equipment with good battery. Run
engine at a moderate speed.
1. Connect one end of first jumper cable to positive

(+) terminal of discharged battery and other end
to positive (+) terminal of booster battery.
5. Start engine of equipment with discharged

battery. Follow starting instructions in the
Operators Manual.
6. Completely discharged batteries may require an
electrical load to initialize charging.
7. Remove cables in exact REVERSE sequence.
Begin by removing cable from engine of
equipment that had discharged battery.
If the starter does not turn the engine over, even with
the booster battery attached, refer to Diagnosis.
DIAGNOSIS
06-9
Starter Motor
06-9
Starter Motor Removal

WARNING: WHEN SERVICING STARTER
OR PERFORMING ANY MAINTENANCE
IN THE AREA OF THE STARTER, NOTE
THAT THE HEAVY GAUGE INPUT LEAD
CONNECTED TO THE STARTER SOLENOID IS
HOT AT ALL TIMES. MAKE SURE THE
PROTECTIVE CAP IS INSTALLED OVER THE
TERMINAL AND IS REPLACED AFTER SERVICE.
1. Disconnect the negative battery ground cable.

2. Disconnect starter cable and push-on connector
from starter solenoid.
CAUTION: When disconnecting

hardshell connector at "S" terminal,
grasp the plastic shell and pull off.
Do not pull on wire. Be careful to pull straight
off to prevent damage to the connector and
"S" terminal. If any part of the connection is
damaged, replace the damaged components.
3. Remove upper bolt with a 3/8 inch drive ratchet,
swivel socket and a 22 inch long extension.
Access is in front of, and along side, the right
hand front engine mount.
4. Remove lower bolt.
Starter Motor Installation

1. Position starter motor to engine and install upper
and lower bolt finger tight.
2. Tighten the upper bolt to 21-27 Nm (15-20 lb-ft).
Access to upper bolt is with a 3/8 inch drive
ratchet, swivel socket and a 22 inch long
extension. Access is in front of, and along side,
the right hand front engine mount.
3. Tighten the lower bolt to 21-27 Nm (15-20 lb-ft).
4. Connect starter solenoid connector. Be careful to
push straight on and make sure connector locks
in position with a notable click or detent.
5. Install starter cable nut to starter terminal.
Tighten to 9-13 Nm (80-120 lb-in).
6. Replace red solenoid safety cap.
7. Connect negative battery ground cable.
It is recommended that wiring service kit F2PZ11K162-A be used, which includes a 70 inch long #12
gauge wire, a terminal nut, a terminal cover, four tie
wraps and insulation instructions.
CAUTION: A jumper wire must not be
installed between the large round
electrical terminal and the solenoid blade
terminal at the starter, to avoid use of the #12
wire. If done, voltage is generated to the solenoid
by the spinning starter after release of the start
key or button, causing the starter to remain
engaged, resulting in failure.
06-10
Starter Motor
Disassembly
06-10
1. Remove positive brush connector from solenoid

motor "M" terminal.
2. Remove solenoid retaining screws and solenoid.
3. Remove through bolts and separate drive end
housing from motor frame. Remove housing seal
assembly from drive. Remove drive and gear
assembly from drive end housing.
4. Remove drive lever from drive assembly.
Remove stop ring and retainer from driveshaft,
then remove drive assembly from shaft. Push Cring off driveshaft, and separate gear assembly
from driveshaft.
5. Remove brush plate screws and brush end plate
from motor frame. Remove brush assembly and
push armature out of frame.
CAUTION: Do not wash the drive

because the solvent will wash out the
lubricant causing drive to slip. Use a
brush or compressed air to clean the drive,
armature, brush, and gear assemblies, drive end
housing, pole pieces and planet gears. Wash all
other parts in solvent and dry.
1. Inspect armature windings for broken or burned
insulation and unwelded or open connections.
2. Check armature for open circuits, shorts and
grounds. Check for pole rub or rub on magnetic
shunts.
06-11
Starter Motor
06-11
3. Check commutator for runout. Inspect armature

shaft and two bearings for scoring and excessive
wear with Dial Indicator TOOL-4201-C or
equivalent. If commutator is rough, or more than
0.12mm (.005 inch) out of round, it must be
replaced.
4. Examine gears, spline on driveshaft, and drive

pinion for chipped, broken or worn conditions.
Replace if required.
06-12
Starter Motor
06-12
Assembly
1. Install armature assembly in starter frame. Apply
a thin coating of ESF-M1C218-A grease, or
equivalent low temperature grease, on both ends
of armature shaft and spline. Install brush
assembly ensuring brushes fit over commutator.
Apply grease to bearing bore in brush end plate.
Push back grommet onto frame and attach brush
end with brush plate screws. Tighten to 2.3-3.4
Nm (20-30 lb-in).
4. Apply a thin coating of ESF-M1C218-A grease, or

equivalent low temperature grease, on driveshaft
spline. Install new drive gear assembly on
driveshaft. Install new stop ring and retainer.
Attach drive lever.
2. Apply grease to driveshaft spline and place

stationary gear assembly over driveshaft. Install
armature thrust washer and push C-ring onto
driveshaft. Place drive assembly onto shaft and
install stop ring and retainer. Attach drive lever to
drive assembly.
6. Install lever support and housing seal in drive end

housing.
3. Grease and install planet gears.
8. Install solenoid. Refer to Assembly.
4. Apply grease into drive end housing bearing bore

(approximately one-quarter full). Install drive gear
assembly into housing, making sure to line up bolt
holes in gear assembly and housing. Place gear
retainer over gear assembly. Install housing seal
assembly into drive end housing.
Armature Replacement
5. Position starter frame to housing and install

through bolts. Tighten to 5.0-9.5 Nm (45-84 lbin).
6. Correctly position solenoid to housing ensuring
that solenoid plunger is attached through drive
lever (bottom solenoid terminal "M" should have a
metal strip attached to it). Tighten solenoid bolts
to 5.1-9.6 Nm (45-85 lb-in).
5. Partially fill drive end housing bearing bore with

grease (approximately one-quarter full). Install
drive gear assembly in housing, making sure to
line up bolt holes in gear assembly and housing.
7. Position starter frame to housing and install

through-bolts. Tighten to 5.0-9.5 Nm (45-84 lbin).

motor "M" terminal.
2. Remove through-bolts and separate motor from
gear assembly and drive end housing.
3. Remove brush end plate screws, brush end plate
and brush assembly from starter frame. Remove
armature from frame.
4. Install new armature in frame. Apply a thin
coating of ESF-M1C218-A grease, or equivalent
low temperature grease, on both ends of
armature shaft and pinion.
7. Attach positive brush connector to solenoid

(bottom terminal). Tighten nut to 9-13 Nm (80120 lb-in).
8. Check that starter no-load current draw is within
specification. Refer to Bench Tests.
Starter Drive Replacement

motor "M" terminal. Remove solenoid retaining
screws and remove solenoid.
2. Remove through-bolts and separate motor
assembly drive end housing. Remove housing
seal from drive end housing. Remove drive gear
assembly from housing and detach drive lever.
3. Remove stop ring and retainer from driveshaft
and then remove drive assembly.
06-13
Starter Motor
5. Install brush assembly. Using tool, make sure

that brushes fit over commutator. Push black
grommet onto frame. Apply grease to bearing
bore in brush end plate and attach to starter
frame.
6. Position starter frame to gear assembly and drive

end housing and install through-bolts. Tighten to
5.0-9.5 Nm (45-84 lb-in).
7. Attach positive brush connector to solenoid
(bottom terminal). Tighten nut to 9-13 Nm (80120 lb-in).
8. Check that starter no-load current draw is within
specification. Refer to "Starter No-Load Test".
06-13
06-14
Starter Motor
SPECIFICATIONS
Torque Specifications
Description
Nm
Lb-In
Solenoid Bolt
5.1-9.6
45-85
"M" Terminal Nut
9.0-13.5
80-120
"B" Terminal Nut
9.0-13.5
80-120
Through-bolt
5.0-9.5
45-84
Mounting Bolt
20.3-27
15-20 (lb-ft)
Brush Plate Screw
2.3-3.4
20-30
General Specifications
Motor Diameter
78mm (3")
Current draw under

normal load
140-200 amps
Normal cranking speed
200-250 rpm
Minimum stall torque @

5 volts
14.7 Nm (11.0 lb-ft)
Maximum load
800 amps
No load
70 10
Brush length
16.8 mm (0.66")
Brush spring tension
18 N (64 oz.)
Maximum commutator
runout
0.12 mm (0.005")
Maximum voltage drop

(battery positive to
starter)
0.5 volts @ normal

operating temperature
Special Tools
Tool Number
Description
TOOL-4201-C
Dial Indicator
078-00005
Starting/Charging Tester
SPECIFICATIONS
06-14
07-1
Governor
SECTION TITLE
07-1
PAGE

ENGINE SERVICE - 2.5L ...................................................................................................................................... 02-01
IGNITION SYSTEM ............................................................................................................................................... 03-01
FUEL PUMP ......................................................................................................................................................... 04-01
CARBURETOR...................................................................................................................................................... 05-01
STARTER MOTOR................................................................................................................................................ 06-01
GOVERNOR.......................................................................................................................................................... 07-01
COOLING SYSTEM .............................................................................................................................................. 08-01
GENERATOR ........................................................................................................................................................ 09-01
SECTION 07 - GOVERNOR
SUBJECT
PAGE
MECHANICAL GOVERNOR ................................................................................................................................................................................................2

Description .......................................................................................................................................................................................................................2
Diagnosis...........................................................................................................................................................................................................................3
Adjustment.......................................................................................................................................................................................................................5
Removal and Installation.............................................................................................................................................................................................8
ELECTRONIC GOVERNOR (CARB.) ..................................................................................................................................................................................9
Description .......................................................................................................................................................................................................................9
Diagnosis........................................................................................................................................................................................................................10
Adjustments..................................................................................................................................................................................................................12

07-2
Mechanical Governor
DESCRIPTION
The mechanical flyweight type governors can be used
on these engines. They are belt driven from the front
of the engine.
A direct mechanical linkage from the governor throttle
control lever to the carburetor throttle lever limits
carburetor action to the governor setting.
No Load on Engine
As the shaft rotates, centrifugal force developed by
the flyweights causes them to swing outward.
The force of the flyweight increases in proportion to

engine speed and is always used to close the engine
throttle. A spring is used to oppose this force and
balance it at a predetermined speed. The speed at
which the flyweight force and the spring force are in
balance is the governed speed.
Engine Load Applied

When a load is applied to the engine, it tends to slow
down, and the flyweight force decreases.
The spring force being now greater than the flyweight

force causes the governor throttle lever to move in a
direction to open the carburetor throttle to a point at
which the flyweight and spring forces are again in
balance.
DESCRIPTION
07-2
07-3
Mechanical Governor
07-3
Part-Load Surge
DIAGNOSIS
1.
Shorten the throttle rod two or three turns at the

rod-end ball joint.
2.
Look for worn flyweights in the governor.
Full-Load Surge
1.
Shorten throttle rod two or three turns at the

rod-end ball joint.
2.
Check for extra rich or extra lean air/fuel mixture

at the carburetor.
3.
Unresponsive To Changing Loads

1.
Incorrectly adjusted throttle linkage.
Look for air leaks caused by a loose intake

manifold.
2.
Engine parts (wires) rubbing on throttle linkage.
3.
Surge screw turned too far into governor body.
4.
Look for loose or worn linkage between the

governor and the carburetor.
4.
Worn or broken governor flyweights.
5.
Damaged flyweight carrier.
5.
Look for engine parts or wires rubbing against

the governor linkage.
Engine Dies Down Under Load
No-Load Surge
1.
Incorrectly adjusted throttle linkage.
The no-load surge adjustment is set at the factory and

rarely requires adjustment. If necessary, this
adjustment can be used to prevent hunting and
surging at no-load speeds, provided the rpm spread
adjustment is set properly.
2.
Lengthen throttle rod two, three, or more turns at

the rod-end ball joint.
3.
Check engine timing, and distributor advance.
4.
Look for excessive friction in the throttle link, at

governor and at carburetor.
5.
The load may be more than the engine can

handle at wide-open throttle.
Make the adjustment with the tachometer installed.

Increase the engine speed with the hand throttle or
variable speed lever to 75 rpm lower than the
maximum no-load desired control rpm.
NOTE: At this point, if the engine continues to surge,
light pressure applied to the governor throttle lever will
dampen surge.
Adjust the surge screw located on back of the

governor housing.
1.
Loosen the no-load surge adjusting screw

locknut.
2.
Turn this screw clockwise into the governor until

the engine speed stabilizes.
Overspeeds When Load Is Removed

1.
The governor drive belt may be slipping. Tighten

belt 40 to 45 pounds tension.
2.
Back off surge screw one or two turns.
3.
Shorten the throttle rod two or three turns at the

rod-end ball joints.
CAUTION: Do not turn the surge screw into the

housing any further, or attempt to adjust this
screw when the engine is under a load; the
engine speed may run away when the load is
removed.
1.
Tighten the lock-nut securely.
2.
Readjust the governor high-speed stop screw to

maintain the correct high-speed under load.
DIAGNOSIS
07-4
Mechanical Governor
Governor Does Not Re-Set At Load Or

No-Load Point
1.
Carburetor throttle shaft may be sticking due to

carbon or fuel deposits.
2.
Worn ball joints on the throttle linkage.
3.
Worn governor flyweights.
Noisy Governor Operation

1.
Governor main bearing worn.
2.
Governor flyweights worn or broken.
3.
Governor thrust sleeve and bearing worn.
4.
Governor main shaft bent.
Excessive Governor Vibration

1.
Governor pulley or main shaft bent or damaged.
2.
Governor flyweights worn or broken.
DIAGNOSIS
07-4
07-5
Mechanical Governor
07-5
ADJUSTMENT
Three preliminary checks must be made on the
mechanical governor before attempting any
adjustments:
1.
governor oil level
2.
drive belt tension
3.
throttle control rod length
Oil Level Check

Clean the body of the governor in the area of the fill
plug. Remove the oil level plug. If oil drips out, the
level is full. If oil doesnt drip out, remove the oil fill
plug and add 10W-30 or 10W-40 engine oil into the fill
hole until it starts dripping out of the oil level hole.
Reinstall plugs.
Throttle Control Rod Length
Belt Tension Adjustment

Belt tension should be checked on a cold belt only.
1.
Install the belt tension tool on the drive belt and

check the tension.
1.
Manually move the governor throttle lever to the

maximum open throttle with spring tension on the
governor.
2.
Check the gap between the carburetor throttle

shaft lever and its maximum open position stop.
It should be 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
5.
the rod with the ball joints.
BELT TENSION
New belt......................................70 lb.ft. (95 Nm)
Used belt.....................................50 lb.ft. (68 Nm)
2.
3.
Install the throttle control rod on the carburetor

throttle lever.
4.
Recheck the gap.
(used belt = in operation 10 minutes or more)
5.
If adjustments required, loosen the governor

adjusting bolts and move the governor until the
correct tension is obtained.
6.
3.
Remove the gauge.
4.
Tighten the governor adjusting bolts.
5.
Install the tension gauge and recheck the belt

tension.
Tighten the locknuts.
CAUTION: Be sure the throttle control rod is

properly installed with the long end at the
governor to prevent binding on the ignition wires.
ADJUSTMENT
07-6
Mechanical Governor
ADJUSTMENT
07-6
07-7
Mechanical Governor
07-7
Sensitivity or Droop Adjustment

Proper governor operation requires a difference
between full-load and no-load governed speed. Too
small an rpm spread between the two speeds will
cause governor hunting and surging. Too large a
spread will cause low response. For this governor,
normal rpm spread, or droop is approximately 250
rpm with the full-load speed range of 2000 - 2800
High Speed Adjustment

First attach a tachometer to the engine, then run the
engine until it reaches normal operating temperature.
1.
Loosen the locknut on the high-speed stop screw.
2.
Disengage engine load.
3.
Slowly pull the throttle to desired maximum

engine speed.
4.
Adjust the high speed stop screw on the governor

to attain the desired maximum engine speed. Do
not exceed the recommended maximum rpm.
5.
rpm.
1.
With the engine running under no-load at

maximum governed speed, loosen the locknuts.
Increase Droop = adjust the screw to move the

spring away from the lever hub.
Decrease Droop = adjust the screw to move the

spring closer to the lever hub.
2.
Tighten the locknuts.
3.
Recheck governor operation under full-load and

no-load conditions to determine if operation is
stabilized and sensitivity is satisfactory.
4.

Tighten the locknut.
ADJUSTMENT
07-8
Mechanical Governor
No-Load Surge Adjustment

The no-load surge adjustment is set at the factory and
rarely requires adjustment. If necessary, this
adjustment can be used to prevent hunting and
surging at no-load speeds, provided the rpm spread
adjustment is set properly.
1.
Make the adjustment with the tachometer

installed. Increase the engine speed with the
hand throttle or variable speed lever to 75 rpm
lower than the maximum no-load desired control
rpm.
NOTE: At this point, if the engine continues to

surge, light pressure applied to the governor
throttle lever will dampen surge.
2.
3.
Then loosen the no-load surge adjusting screw

locknut and turn the screw inward until the rpm
increases to the desired control rpm.
2.
CAUTION: Do not turn the screw in all the way. It
will interfere with proper governor operation and
prevent the governor from returning the engine to
idle speed.
3.

ADJUSTMENT
07-8
07-9
Mechanical Governor

Mechanical Governor Removal
1.
Disconnect hand throttle connection at governor

variable speed lever.
2.
Disconnect governor to carburetor throttle control

rod at governor.
3.
Loosen governor mounting nuts and bolts and

move governor toward engine to loosen drive
belt.
4.
Remove drive belt from governor pulley.
5.
Remove governor to bracket attaching bolts and

remove governor.
Mechanical Governor Installation

1.
Position the governor to the mounting bracket and

install the attaching bolts snugly.
2.
Position drive belt to governor pulley and move

the governor away from the engine to tighten the
belt. Tighten the attaching bolts.
3.
Adjust the belt tension.
4.
Connect the governor to carburetor throttle

control rod. Adjust the rod as described
previously.
5.
Connect hand throttle cable to governor variable

speed lever. Adjust cable as necessary to permit
operation from idle to maximum speed.
07-9
07-10
Electronic Governor (carb.)
07-10
DESCRIPTION
The Barber Colman electronic governor consists of
three main components:
controller
actuator
carburetor
The controller is a Barber Colman model 10851 digital

unit. This controller allows up to four engine speeds
to be used on one application. The operator changes
the engine speeds via a run speed select switch,
mounted on the control panel of the machine.
These governors are isochronous in operation; there
is no governor droop. The governor maintains the
same engine speed from no-load to full-load
operation. Each controller can be programmed with
up to four separate engine speeds. The carburetor
and actuator are integrated into one unit.
The carburetor is a Zenith model 33, offered with

either a manual or automatic choke. It is spring
loaded to keep the carburetor at its minimum fuel
position when no power is applied. This feature
causes the carburetor to go fully closed in the event of
governor power failure.
The rotary actuator is mounted directly to the end of

the throttle shaft. This feature eliminates any need for
throttle linkage. The actuator is electrically connected
to the controller through a two-wire Packard
connector. If the governor is used with any other fuel
system, such as LPG, then a linear actuator is
available.
DESCRIPTION
07-11
07-11
DIAGNOSIS
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
Governor appears
dead.
POSSIBLE SOURCE
ACTION
Remove the connector from the controller and with a voltmeter check for
battery power across pins A&B of the wiring harness connector.
If battery power is not present, check wiring to the controller.
Controller is not receiving the

speed signal.
If the controller is connected to an engine with a distributor, pins C&D should

both be connected to the negative side of the coil, or the tachometer output.
NOTE: This controller

receives its speed signal from
the ignition.
If the controller is connected to an engine with a DIS ignition, pin C should be

connected to one of the two tachometer outputs, and pin D should be
connected to the other tachometer output. The DIS ignition utilizes two coils.
NOTE: Do not short the tach leads; doing so could damage the spark
controller.
Using an ohmmeter, check continuity from pins C&D to the termination points.
If continuity is not present, repair the wiring.
Remove the wires connected to the actuator. With a DC voltmeter, check

between the actuator wires to battery (-). The voltmeter should read 12 volts
2 volts.
If the voltage is low, disconnect the connector from the controller and check
continuity between the wiring harness pins E&F, to their respective actuator
terminals. If there is no continuity, check for openings in the wires.
Using a voltmeter, check for battery voltage from controller terminals E&F to
battery (-). If battery power is not found, replace the controller and check the
actuator and actuator wiring for grounds and shorts.
Battery power is not supplied

to controller.
Actuator fails to operate.
NOTE: Check wiring before replacing controller. Bad wiring might destroy the new
controller.
Engine doesnt
change speeds.
Engine is hunting.
Incorrect engine speed.
Engine is misfiring due to idle

mixture mis-adjustment. This
causes engine hunt at noload condition.
Engine is misfiring.
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 are out of tolerance,
replace actuator.
With the engine running, connect battery power to pin H. This will select Run
2. If Run 2 is set at a higher speed than Run 1 and the speed does not
change, replace the controller. Contact OEM for speed settings.
With the engine running, connect battery power to pin G. This will select Run
3. If Run 3 is set higher than the previous speed and the speed does not
With the engine running, connect battery power to pins G&H. This will select
Run 4. If Run 4 is set higher than the previous speed and the speed does not
Disconnect the connector from the controller. The governor is now disabled
and a warm engine should be running at a mechanical idle of approximately
600 rpm.
If the engine is not running at the mechanical idle and is governed by an

integrated carburetor, loosen the three actuator fasteners and rotate the
actuator to achieve an idle of 600 rpm. If the engine is governed by a linear
actuator, adjust the idle speed screw to achieve 600 rpm.
Slowly rotate the idle mixture screw clockwise (CW) until the engine speed
begins to decrease. Slowly turn the idle mixture screw counterclockwise
(CCW) until the engine speed begins to decrease. Now, turn the idle mixture
screw clockwise (CW) until maximum idle speed is achieved. The idle
mixture is now adjusted.
disconnect the connector from the controller and consult the engine repair
manual.
DIAGNOSIS
07-12
DIAGNOSIS
07-12
07-13
07-13
ADJUSTMENTS
Calibration
Initial speed settings, as well as other parameters, can be set using a special interface connector, and an IBM
compatible PC 286 minimum with 640K RAM, of which 512K of conventional RAM must be available. Also required
is a 1.44 Meg High Density floppy drive and a VGA graphic display. Programming of the controller is covered in a
separate publication.
ADJUSTMENT
08-1
Cooling System
SECTION TITLE
08-1
PAGE

ENGINE SERVICE - 2.5L ...................................................................................................................................... 02-01
IGNITION SYSTEM ............................................................................................................................................... 03-01
FUEL PUMP ......................................................................................................................................................... 04-01
CARBURETOR...................................................................................................................................................... 05-01
STARTER MOTOR................................................................................................................................................ 06-01
GOVERNOR.......................................................................................................................................................... 07-01
COOLING SYSTEM .............................................................................................................................................. 08-01
GENERATOR ........................................................................................................................................................ 09-01
SECTION 08 - COOLING SYSTEM

SUBJECT
PAGE
Description.................................................................................................................................................................... 2
Cleaning Cooling System......................................................................................................................................... 2
Diagnosis ...................................................................................................................................................................... 3
Visual Inspection...................................................................................................................................................... 3
Cooling System Pressure Test ................................................................................................................................ 4
Radiator Cap Pressure Test .................................................................................................................................... 5
Thermostat Operation Check................................................................................................................................... 5
Removal and Installation............................................................................................................................................... 6
Cooling Fan.............................................................................................................................................................. 6
Drive Belt ................................................................................................................................................................. 6
Radiator Hose.......................................................................................................................................................... 7
Drain & Refill Cooling System.................................................................................................................................. 7
Thermostat Replacement......................................................................................................................................... 8
REFER TO SEPARATE PUBLICATION ON ELECTRONIC FUEL INJECTION (EFI)

SYSTEMS FOR INFORMATION ON THAT SYSTEM.
08-2
Cooling System
Description
The cooling system is of the full flow type with a
centrifugal pump. The thermostat, located in the
cylinder head, controls the flow through the system,
maintaining the proper temperature.
The coolant flows from the bottom of the radiator to
the water pump which delivers it to the cylinder block.
It then flows through the cored passages to cool each
cylinder wall. Upon reaching the rear of the cylinder
block, the coolant is directed upward in to the cylinder
head where it cools the combustion chambers, valves
and valve seats.
The coolant from the cylinder head flows past the
thermostat, if it is open, through the coolant outlet
housing and into the top of the radiator.
08-2
flushing water flow will loosen sediment more quickly

than a steady flow in the normal direction of coolant
flow. In severe cases where cleaning solvents will not
properly clean the cooling system for efficient
operation, it will be necessary to use the pressure
flushing method. Various types of flushing equipment
are available.
MIXTURE % (by volume)

PROTECTION
Above -X F
Anti-freeze
Solution
Water
20%
80%
35%
65%
45%
55%
55%
45%
(-4 C)
Above -X F
(-16 C)
Another passage in the head routes the warm coolant

through the intake manifold to help atomize the fuel
mixture, and then exits the intake manifold through a
hose to the inlet of the water pump.
Above -X F
Cleaning Cooling System
Above -X F
(-26 C)
To remove rust, sludge and other foreign material

from the cooling system, use Rotunda Cooling
System Cleanser. Removal of such material restores
cooling efficiency and avoids overheating. Always
remove the thermostat prior to pressure flushing. A
pulsating or reversed direction of
DIAGNOSIS
(-40 C)
08-3
Cooling System
08-3
Visual Inspection
Diagnosis
Check for leakage at:
The most frequent cooling system complaints are

leakage and overheating. Either of these problems
will soon render the engine inoperable.
all hoses and hose connections.
Most engines use an ethylene glycol base antifreeze

solution to which the manufacturers have added a dye
color. The dye color makes the antifreeze solution an
excellent leak detector.
radiator seams, radiator core, and radiator drain

petcock.
all block core plugs and drain plugs.
edges of all cooling system gaskets.
transmission oil cooler.
water pump shaft and bushing.
If this type of solution is not being used in the cooling

system, a vegetable dye may be added to aid in
locating external leakage.
Examine oil dipstick for evidence of coolant

contaminated engine oil (white milky appearance).
check radiator for evidences of oil in coolant (leakage
at transmission oil cooler).
Refer to the following Diagnosis Chart for cooling system problems, their possible cause and recommended
correction. Refer to the pertinent part for testing and repair.
CONDITION
Loss of coolant
Engine Overheats
Engine fails to
reach normal
operating
temperature
POSSIBLE SOURCE
Pressure cap and gasket
Leakage
External leakage
Internal leakage
Low coolant level

Loose fan belt
Pressure cap
Radiator obstruction
Closed thermostat
Fan drive clutch
Ignition
Temp gauge or cold light
Engine
Coolant mixture
Open thermostat
Temperature gauge or cold
light
DIAGNOSIS
ACTION
Inspect, wash gasket and test. Replace only if
cap will not hold pressure to specification.
Pressure test system.
Inspect hose, hose connection, radiator, edges
of cooling system gaskets, core plugs and
drain plugs, transmission oil cooler lines, water
pump, heater system components. Repair or
replace as required.
Disassembly engine as necessary - check
for:cracked intake manifold, blown head
gaskets, warped head or block gasket
surfaces, cracked cylinder head or engine
block.
Fill as required. Check for coolant loss.
Adjust.
Test. Replace if necessary.
Remove bugs, leaves, etc.
Test, Replace if necessary.
Test, replace if necessary.
Check timing and advance. Adjust as
required.
Check electrical circuits and repair as required.
Check water pump, block for blockage.
1/2 water and 1/2 permanent anti-freeze
mixture.
Test, replace if necessary.
Check electrical circuits and repair as required.
08-4
Cooling System
Cooling System Pressure Test
2.
Remove the radiator overflow hose from the

retainer clips. Make sure the hose is firmly
installed on the radiator overflow nipple and is in
good condition. Insert the free end of the
overflow hose into a container of water.
3.
Attach the pressure pump and gauge to the

adapter fitting and pressurize the cooling system
to the cap LOWER LIMIT.
4.
No bubbles should appear in the water container

when the system is pressurized to the caps
LOWER LIMIT. If the system is satisfactory at the
lower limit, gradually increase the system
pressure until a slight stream of bubbles appears
in the water container. This is the upper limit of
the pressure cap.
5.
Replace any radiator cap that exceeds the

specified UPPER LIMIT pressure without
discharging bubbles.
6.
If the radiator cap does not hold pressure, remove

and wash the cap in clean water to dislodge all
foreign particles from the gaskets. Check the
sealing surface in the radiator filler neck. Inspect
the cam lock flanges on both sides of the filler
neck for maximum cap engagement.
7.
Pressurize the cooling system (using a radiator

cap that operates within the original cap upper
and lower pressure limits) and observe the gauge
reading for approximately two minutes. Pressure
should not drop during this time.
1.
2.
Shut the engine off.
1.
CAUTION: To prevent loss of coolant and to
avoid the danger of being burned, let the engine
cool before removing the radiator cap.
1.
2.
3.
When removing the radiator cap, place a cloth

over the cap and rotate the cap SLOWLY
counter-clockwise to the safety stop and allow the
pressure to escape completely. Then, turn the
cap again SLOWLY counter-clockwise past the
safety stop to remove.
Adjust the radiator coolant (fill or drain) to one
inch below the filler neck opening before testing.
Wet the rubber sealing surface of the cap before
installing the cap tightly on the radiator.
Disconnect the electrical connector from the
engine temperature sending unit and remove the
temperature sending unit from the manifold.
NOTE: With the radiator cap installed and the cooling

system pressure relieved, only a small amount of
coolant will be lost when the sending unit is removed.
1.
Install the adapter fitting from the Rotunda

Pressure Tester 21-0012 (or equivalent) male
thread on one end, and a hose connector on the
other end to accommodate the tester hose, tightly
08-4
RESULTS:
If the pressure drops, check for leaks at engine-to
radiator hoses, bypass hose, water valve
hose (if applicable), thermostat housing
gasket and radiator. Also refer to engine
system checks if a leak cannot be located in
the cooling system. Any leaks which are
found must be corrected and the system
rechecked.
If the system holds pressure, proceed to the next
step.
into the cylinder block in place of the sending unit.
12. Release the system pressure by loosening the

radiator cap and remove the adapter. reinstall the
temperature sending unit, check coolant level and
replenish (if necessary) with the correct coolant
solution: 1/2 water and 1/2 permanent anti-freeze
mixture.
DIAGNOSIS
08-5
Cooling System
Radiator Cap Pressure Test
Thermostat Visual Inspection
1.
Remove the radiator cap from the radiator filler

neck.
2.
Immerse the radiator cap in water and install on

the shallow filler neck of the Rotunda 21-0012
Radiator Cap Pressure Test Adapter (or
equivalent).
NOTE: The adapter is designed to accept both

deep and shallow neck radiator caps.
1.
Immerse the filler neck seal in water and install in

the filler neck adapter.
1.
Install the filler neck adapter with filler neck seal

on the deep filler neck end to the radiator cap
pressure test adapter.
2.
Connect the female quick disconnect fitting of the

pressure test pump to the male quick disconnect
fitting of the filler neck adapter.
3.
SLOWLY depress the plunger of the pressure test

pump until the pressure gauge reading stops
increasing and note the highest pressure reading
obtained.
NOTE: If the plunger of the pump is depressed

too fast, an erroneous pressure reading will
result.
2.
1.
Hold thermostat up to the light.
2.
Leakage of light all around the valve (room

temperature) indicates a bad thermostat.
3.
A slight leakage of light at one or two locations on

the perimeter of the valve is normal.
Thermostat Operation Check
NOTE: the filler neck seal is reversible so that it

may be used on either a deep or shallow
radiator filler neck. It will also fit either end of
the radiator cap pressure test adapter.
1.
08-5
1.
Visually check the valve to be sure it is air tight.
2.
Place the thermostat and a thermometer in water.
3.
Gradually increase the water temperature
Replace thermostat if it does not open at least

0.23" after one minute at 212 F.
Release the pressure by turning the pressure

relief screw counter-clockwise. Then tighten the
pressure relief screw and pressure test again (at
least twice) to be sure the pressure test reading is
repeatable within the acceptable gauge reading
limits of the radiator cap and is not erratic.
If the pressure test gauge readings are not within
the acceptable gauge reading limits, replace the
radiator cap. If the pressure test gauge readings
are within the acceptable gauge reading limits,
perform the Cooling System Pressure Test.
DIAGNOSIS
INITIAL OPENING
TEMPERATURE
180F (82C)
FULL-OPEN
TEMPERATURE
199F - 204F
FULL-OPEN LIFT
0.33 (0.013 mm)
(93 - 96C)
08-6
Cooling System
08-6

Cooling Fan Removal
1.
Remove the screws and washer assemblies

attaching the fan and pulley to the water pump
hub.
2.
Remove the fan and pulley.
Drive Belt Removal

1.
Using a 3/8" breaker bar, pry against the tension

of the tensioner
2.
Remove the belt.
Cooling Fan Installation

1.
2.
3.
4.
Position the fan and pulley on the water pump

hub.
Drive Belt Installation
Loosen fan belt, if necessary.

1.
Using a 3/8" breaker bar, pry against the tension

of the tensioner.
2.
Install the belt.
Install the lock washer and screws and torque the

capscrews to specifications.
Adjust the fan belt tension to specifications.
08-7
Cooling System
08-7
WARNING: AVOID INJURY WHEN CHECKING A

HOT ENGINE. COVER THE RADIATOR CAP IN A
THICK CLOTH AND TURN IT SLOWLY
COUNTERCLOCKWISE TO THE FIRST STOP.
AFTER THE PRESSURE HAS BEEN
COMPLETELY RELEASED, PRESS DOWNWARD
AND FINISH REMOVING THE CAP. DO NOT ADD
COOLANT TO AN ENGINE THAT HAS BECOME
OVERHEATED UNTIL THE ENGINE COOLS.
ADDING COOLANT TO AN EXTREMELY HOT
ENGINE CAN RESULT IN A CRACKED BLOCK OR
CYLINDER HEAD. FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN DAMAGE TO
THE COOLING SYSTEM OR ENGINE AND/OR
PERSONAL INJURY.
Radiator Hose Removal

Radiator hoses should be replaced as directed in the
maintenance schedule or whenever they become
cracked, rotted or have a tendency to collapse.
Drain & Refill Cooling System

1.
Remove radiator cap.
1.
Drain the radiator.
2.
2.
Loosen the clamps at each end of the hose to be

removed.
Open drain cock at radiator and drain old coolant

from engine.
3.
Slide the hose off the radiator connection and the

engine water outlet connection (upper hose) or
the water pump connection (lower hose).
If rust, sludge or other foreign material are

present in the old coolant, see "Cleaning Cooling
System" at the beginning of this section.
4.
Fill radiator with a permanent type coolant that

meets ford specification ESE-M97B44-A, such as
Ford Cooling System Fluid.
3.
Radiator Hose Installation

1.
Position the clamps at least 1/8" from each end of

the hose.
5.
Operate engine until thermostat opens and the

radiator upper hose becomes hot.
2.
Coat the connection areas with an approved

water-resistant sealer and slide the hose on the
connection.
6.
Stop the engine and add coolant to approximately

one inch below the filler neck.
7.
Install radiator cap.
3.
Make sure the clamps are beyond the bead and

placed in the center of the clamping surface of the
connections.
8.
Operate engine and check all hoses and

connections for leaks.
4.
Tighten the clamps.
5.
Fill the radiator with the recommended permanent

antifreeze and water mixture.
Operate the engine for several minutes,

then check the hoses and connections
for leaks.
CAUTION: Do not use alcohol or methanol

antifreeze, or mix them with the specified coolant.
08-8
Cooling System
08-8
Thermostat Installation
1.
Check the thermostat before installing it, following

the procedures in this section.
2.
Clean the coolant outlet housing and cylinder

head or manifold gasket surfaces.
3.
Coat a new gasket with water resistant sealer.
4.
Position the gasket on the cylinder head opening.
5.
The gasket must be positioned on the cylinder

head before the thermostat is installed.
Thermostat Removal
1.
Drain the radiator so that the coolant level is

below the thermostat.
2.
Disconnect the heater return hose at the

thermostat housing located on the left front lower
side of engine.
3.
Remove the coolant outlet housing retainer bolts.
4.
Pull the elbow away from the cylinder head or

manifold sufficiently to provide access to the
thermostat.
5.
Remove the thermostat and gasket.
Caution: To prevent incorrect installation of the

thermostat, the water outlet casting contains a
locking recess into which the thermostat is
turned and locked.
1.
Install the thermostat with the bridge section in

the outlet casting.
2.
Turn the thermostat clockwise to lock it in position

on the flats cast into the outlet elbow.
3.
Position the coolant outlet elbow against the

cylinder head.
4.
Install and torque the retaining bolts to

specifications.
5.
Connect heater return hose to thermostat

housing.
6.
Fill the cooling system with the recommended

permanent antifreeze and water mixture.
7.
Check for leaks and proper coolant level after the

engine has reached normal operating
temperatures.
09-1
Generator
SECTION TITLE
09-1
PAGE

ENGINE SERVICE - 2.5L ...................................................................................................................................... 02-01
IGNITION SYSTEM ............................................................................................................................................... 03-01
FUEL PUMP ......................................................................................................................................................... 04-01
CARBURETOR...................................................................................................................................................... 05-01
STARTER MOTOR................................................................................................................................................ 06-01
GOVERNOR.......................................................................................................................................................... 07-01
COOLING SYSTEM .............................................................................................................................................. 08-01
GENERATOR ........................................................................................................................................................ 09-01
SECTION 09 - GENERATOR
SUBJECT
PAGE
DESCRIPTION...........................................................................................................................................................................................................................2
Operation ..........................................................................................................................................................................................................................2
DIAGNOSIS ...............................................................................................................................................................................................................................3
Visual Inspection ............................................................................................................................................................................................................3
Generator Output Test .................................................................................................................................................................................................4
Generator Voltage Test................................................................................................................................................................................................4
Symptom Chart ..............................................................................................................................................................................................................5
Pinpoint Tests..................................................................................................................................................................................................................6
TEST A - Dead Battery - No Generator Output ...................................................................................................................................................6
TEST B - Indicator Lamp On, Engine Running ....................................................................................................................................................7
TEST C - Indicator Lamp Flickers/Intermittent ...................................................................................................................................................8
TEST D - Charging Voltage High..............................................................................................................................................................................9
TEST E - Indicator Lamp Off, Key On, Engine Not Running...........................................................................................................................9
TEST F - Generator Noisy.........................................................................................................................................................................................10
TEST G - Radio Interference....................................................................................................................................................................................11
TEST H - Indicator Lamp On, Key Off..................................................................................................................................................................11
REMOVAL AND INSTALLATION....................................................................................................................................................................................12
Generator ......................................................................................................................................................................................................................12
Regulator .......................................................................................................................................................................................................................13
09-2
Generator
09-2
Operation
With the key in the RUN position, voltage is applied
through the charge indicator lamp "I" circuit to the
voltage regulator. This turns the voltage regulator on
allowing current to flow from the battery sense "A"
circuit to the generator field coil. When the engine is
started, the generator begins to generate alternating
(AC) current which is converted to direct (DC) current
by the rectifier internal to the generator. This current
is then supplied to the electrical system through the
Battery Positive Voltage (B+) terminal located on the
rear of the generator.
Once the generator begins generating current, a
voltage signal is taken from the stator and fed back to
the voltage regulator "S" circuit, turning off the charge
indicator lamp.
with the system functioning normally, the generator
output current is determined by the voltage at the "A"
circuit. This voltage is compared to a set voltage
internal to the voltage regulator, and the voltage
regulator controls the generator field current to
maintain proper generator output. The set voltage will
vary with temperature and is typically higher in the
winter than in the summer, allowing for better battery
recharge.
DESCRIPTION
The generator output circuit 38 (BK/O) is supplied
through the battery positive voltage (B+) output
connection to the battery and electrical system. The
B+ circuit is hot at all times. This circuit is protected
by a fuse link.
The "I" circuit or ignition switch, circuit 904 (LG/R) is
used to turn on the voltage regulator. This circuit is
closed with the ignition switch in the RUN position.
This circuit is also used to turn the charge indicator
lamp on if there is a fault in the charging system
operation or associated wiring circuits.
The "A" circuit, or battery sense circuit, circuit 36
(Y/W) is used to sense the battery voltage. This
voltage is used by the voltage regulator to determine
the output. This circuit is also used to supply power
to the field coil. The "A" circuit is hot at all times. This
circuit is protected by a fuse in the power distribution
box or a fuse link.
The "S" circuit, or stator circuit, circuit 4 (W/BK) is
used to feed back a voltage signal from the generator
to the voltage regulator. This voltage, typically 1/2
battery voltage when the generator is operating, is
used by the voltage regulator to turn off the charge
indicator lamp.
DESCRIPTION
09-3
Generator
DIAGNOSIS
Before performing generator tests on the unit, note
conditions such as:
slow cranking
dead battery
charge indicator lamp stays on with engine
running
This information will aid in isolating the problem.
Visual Inspection
Preliminary checks to the charging system should be
made regardless of the fault condition:
1.
Check battery posts and cable terminals for clean

and tight connections. Clean the posts and the
cables to ensure good electrical contact.
2.
Check for secure connections at the generator

output, regulator and engine ground. Also check
the connection at the load distribution point
(starter relay).
3.
Check the fuses/fuse links and wiring to the

generator to ensure that they are not burned or
damaged. This condition, resulting in an open
circuit or high resistance, can cause erratic or
intermittent charging system concerns.
4.
Check the battery voltage. If less than 12.3 volts

with the engine and all accessories off, charge
battery before proceeding.
5.
Check belt condition and tension.
In order to check the generator, the use of Rotunda

Starting and Charging System Tester 078-00005
(VAT-40) or equivalent, is recommended.
DIAGNOSIS
09-3
09-4
Generator
Generator Output Test

1.
09-4
Generator Voltage Test
Connect Rotunda Starting and Charging System

Tester 078-00005 (VAT-40) or equivalent as
shown.
NOTE: Refer to the test equipment users manual for

complete directions on examining the charging
system.
1.
Switch the tester to ammeter function.
2.
Connect the positive and negative leads of the

tester to the battery.
3.
Connect current probe to generator B+ output

lead circuit 38 (BK/O) to measure generator
output.
4.
With the engine running at 2000 rpm, adjust the

VAT-40 or equivalent load bank to determine the
maximum output of the generator. Generator
output should be greater than the values shown in
the graph.
1.
Switch the tester to the voltmeter function.
2.
Connect the positive lead to the generator "A"

terminal connector and the negative lead to
ground.
3.
Turn off all electrical accessories.
4.
With the engine running at 2000 rpm, check the

generator voltage.
5.
Voltage should be between 13.0-15.5 volts.
If voltage is NOT within specifications, refer to

symptom chart.
If amperage is NOT within specifications, refer to

symptom chart.
DIAGNOSIS
09-5
Generator
09-5
Symptom Chart
CONDITION
POSSIBLE SOURCE
Dead battery.
Key-off battery drain.
Battery will not stay charged.
Open/voltage drop in B+ circuit.
Slow crank.
Open voltage drop in A circuit.
Low battery voltage.
Open/high resistance in I circuit.
No generator output.
Voltage regulator.
Generator.
Open "A" circuit.
Shorted "I" circuit.
Open/high resistance in "S" circuit.
Voltage regulator.
Generator.
Loose connection to generator, voltage

regulator or battery.
Loose fuse or poor connection in "A"

circuit.
Loose brush holder screw.
Voltage regulator.
Generator.
Voltage drop in "A" circuit.
Voltage drop in "I" circuit.
Poor ground.
Voltage regulator.
Generator.
Open/high resistance in "I" circuit.
Burned out bulb.
Poor ground.
"S" circuit shorted to B+.
Voltage regulator.
Generator.
Accessory drive belt.
Accessory brackets.
Bent generator pulley.
Generator.
Other components.
Lamp circuit shorted to B+.
Improper lamp circuit wiring.
Indicator lamp on with engine running.
Indicator lamp flickers or intermittent.
Battery over charging (battery voltage

greater than 15.5 volts).
Indicator lamp off, key on, engine not

running.
Generator noisy.
Indicator lamp on, key off.
DIAGNOSIS
ACTION
Go to Pinpoint Test A.
Go to Pinpoint Test B.
Go to Pinpoint Test C.
Go to Pinpoint Test D.
Go to Pinpoint Test E.
Go to Pinpoint Test F.
Go to Pinpoint Test H.
09-6
Generator
09-6
Pinpoint Tests
All voltage measurements are referenced to the negative (-) battery post unless otherwise specified. Do not make
jumper connections except as directed. Improper connections may damage the voltage regulator or fuses/fuse links.
All "key ON" measurements are made with the engine not running unless directed to "start engine".
TEST A - Dead Battery - No Generator Output

TEST STEP
A1
RESULT
CHECK FOR KEY-OFF DRAIN
ACTION TO TAKE
Yes
Go to A2.
No
Check to ensure that the key switch is functioning

properly, and that all lights and accessories are "off"
with the key switch in the "off" position.
Yes
Go to A3.
No
Check fuse link in circuit 38, 290 and 37 and replace if

required. If OK, repair open in circuits 38, 290 and 37.
Yes
Go to A4.
No
Check fuse or fuse link in circuit 36 and replace if

required. If OK repair open in circuit 36.
Yes
Go to A5.
No
Go to A11.
Yes
Go to A6.
No
Repair open or high resistance in circuit 904.
Yes
Go to A7.
No
Repair excess voltage drop in circuit 36. Check fuses or

fuse link and connectors in circuit 36 and service as
required.
Yes
Go to A8.
No
Go to A11.
CHECK FOR SHORTED RECTIFIER
Yes
Replace generator.
Remove one pin "S" connector from generator.

Measure voltage between the "S" terminal on the back of
No
Go to A9.
the generator and ground.

Measure voltage between the positive (+) battery terminal
and the "S" terminal on the back of the generator.

Is either voltage reading greater than 1 volt?
Turn key to OFF position.

Turn off all accessories.
Connect an ammeter or test lamp between the negative (-)
battery cable and the negative battery post.

Is current drain less than 100 mA (or test lamp off)?
A2
CHECK FOR OPEN B+ CIRCUIT
Measure voltage at B+ terminal on the back of the
generator,
Is voltage equal to battery voltage?
A3
Measure voltage at test point "A" on the voltage regulator.

A4
CHECK FOR OPEN FIELD CIRCUIT
Measure voltage at test point "F" on the voltage regulator.

A5
CHECK FOR OPEN A CIRCUIT
CHECK FOR OPEN "I" CIRCUIT
Turn key to ON position.

Measure voltage at wiring harness "I" terminal.
NOTE: Voltage regulator must be connected to wiring harness

for this test.
Is voltage greater than 1 volt?

A6
CHECK VOLTAGE DROP IN "A" CIRCUIT
Measure voltage drop between test point "A" on the voltage
regulator and the positive (+) battery post.

Is voltage drop less than 0.25 volts?
A7
CHECK FIELD TURN-ON

Is voltage less than 2 volts?
A8
DIAGNOSIS
09-7
Generator
A9
CHECK VOLTAGE DROP IN B+ CIRCUIT
Install "S" connector.

Start engine.
Turn on headlights or any accessory.
With engine running at 2000 rpm, measure voltage drop
between the B+ terminal on the back of the generator and

the positive (+) battery post.
Is voltage drop less than 0.5 volt?
A10
CHECK FOR OPEN STATOR PHASE
Connect test point "F" on the voltage regulator to the
negative (-) battery post using a jumper wire.

Repeat generator output test.
Is generator output greater than the minimum output
09-7
Yes
Go to A10.
No
Repair excess voltage drop in circuits 38, 290, and 37.

Check fuse link in circuits 38, 290, and 37 and the
connections between the battery and under hood fuse
box.
Yes
Replace voltage regulator.
No
Replace generator.
Yes
Replace generator.
No
Check for worn brushes (less than 8mm long) or open

brush leads and replace if required. If OK, replace
voltage regulator.
specified?
A11
CHECK FOR OPEN/SHORTED FIELD
Remove generator.
Remove voltage regulator.
Measure resistance between the generator slip rings.
Is resistance greater than 10 ohms or less than 1 ohm?
TEST B - Indicator Lamp On, Engine Running

TEST STEP
B1
CHECK FOR OPEN "A" CIRCUIT
Measure voltage at test point "A" on the voltage regulator.

B2
RESULT
CHECK FOR SHORTED "I" CIRCUIT
Remove three pin voltage regulator connector.

Is indicator lamp on?
B3
CHECK "S" CIRCUIT FUNCTION
Install voltage regulator connector.

Remove one pin "S" connector.
Connect wiring harness "S" terminal, circuit 4 to the positive
battery post using a jumper wire.

B4
CHECK FOR OPEN "s" CIRCUIT
Remove three pin voltage regulator connector.

Measure wiring resistance between the one in "S: connector
and the "S" (center) pin of the voltage regulator connector.

Is resistance greater than 1 ohm?
B5
CHECK STATOR OUTPUT VOLTAGE
Start engine.
Measure voltage at the "S" terminal on the back of the
generator.
Is voltage at least 1/2 of battery voltage?
ACTION TO TAKE
Yes
Go to B2.
No
Check fuse or fuse link in circuit 36 and replace if

required. If OK, repair open in circuit 36.
Yes
Repair short to ground in circuit 904.
No
Go to B3.
Yes
Remove jumper wire. Go to B4.
No
Remove jumper wire. Go to B5.
Yes
Repair open or excess resistance in circuit 4.
No
Check for loose or bent pin in voltage regulator or

connector. If OK, replace voltage regulator.
Yes
Go to B6.
No
Go to Pinpoint Test A to find the cause of low generator

output
DIAGNOSIS
09-8
Generator
B6
09-8
CHECK GENERATOR OUTPUT VOLTAGE
Yes
Go to Pinpoint Test D to find the cause of high output

voltage.
Measure voltage at the B+ terminal on the back of the
No
generator with the engine running at 2000 rpm and all

accessories turned off.
Is voltage greater than 15.5 volts?
TEST C - Indicator Lamp Flickers/Intermittent

TEST STEP
C1
RESULT
ACTION TO TAKE
CHECK FOR LOOSE CONNECTIONS
Yes
Go to C2.
Check these connections for corrosion, loose or bent pins,
No
Clean or repair connections as required.
or loose eyelets:
Three-pin voltage regulator connector.
One-pin "S" connector.
Generator B+ eyelet.
Battery cables.
Are all connections clean and tight?
CHECK FOR FIELD CIRCUIT DRAIN
Yes
Go to C3.
Turn key to off position.

No
Go to C5.
Yes
Repair loose fuse connection.
No
Go to C4.
CHECK "A" CIRCUIT CONNECTIONS
Yes
Replace voltage regulator. If problem still exists,

replace generator.
With engine running, connect test point "A" on the voltage
No
Repair poor connection in circuit 36.
regulator to the positive (+) battery post using a jumper wire.

Does indicator lamp flicker?
CHECK BRUSH HOLDER SCREWS
Yes
Go to C6.
Remove generator from unit.

Check the brush holder screws, located on the voltage
No
Tighten screws to specification. 2.8-4.0 Nm (25-35 lb-
regulator (test points "F" and "A").

Are the brush holder screws tight?
C2
C3
CHECK FOR LOOSE "A" CIRCUIT FUSE
Start engine.
Check the generator fuse loose connection by wiggling the
fuse with the engine running.

Does indicator lamp flicker?
C4
C5
C6
in).
CHECK FOR GROUNDED SLIP RING

Measure resistance from each generator slip ring to the
generator housing.
Is resistance from either slip ring to housing less than 200
Yes
If grease or dirt has accumulated near the slip rings,

clean the slip rings and recheck resistance. If still less
than 200 ohms, replace generator.
No
ohms?
DIAGNOSIS
09-9
Generator
09-9
TEST D - Charging Voltage High

TEST STEP
D1
RESULT
ACTION TO TAKE
CHECK VOLTAGE DROP IN "A" CIRCUIT
Yes
Go to D2.

Measure voltage between test point A on the voltage
No
regulator and the positive (+) battery post.

Is voltage drop less than 0.25 volt?
Repair excess voltage drop in circuit 36. Check fuse or

fuse link and connectors in circuit 36 and service as
required.
Yes
Go to D3.
No
Repair high resistance in circuit 904.
CHECK FOR POOR GROUNDS
Yes
Go to D4.
Check for poor ground connections between voltage
No
Clean or repair grounds as required.
regulator and generator, generator and engine, or engine

and battery.
Are all ground connections clean and tight?
CHECK FOR FIELD CIRCUIT DRAIN
Yes
Generator is OK. Replace voltage regulator.

No
Go to D5.
Yes
If grease or dirt has accumulated near the slip rings,

Clean the slip rings and recheck resistance. If still less
than 200 ohms, replace generator.
No
D2
CHECK VOLTAGE DROP IN "I" CIRCUIT
Measure voltage at wiring harness "I" terminal, circuit 904.
NOTE: Voltage regulator must be connected to wiring harness

for this test.

D3
D4
D5
CHECK FOR GROUNDED SLIP RING
Remove generator from vehicle.

Measure resistance from each generator slip ring to the
generator housing.
Is resistance from either slip ring to housing less than 200
ohms?
TEST E - Indicator Lamp Off, Key On, Engine Not Running

TEST STEP
E1
RESULT
CHECK FOR OPEN "I" CIRCUIT
Remove three-pin voltage regulator connector.

Measure voltage at wiring harness "I" terminal.
Is voltage greater than 0 volts?
E2
CHECK FOR BURNED OUT BULB
Connect wiring harness "I" terminal to ground with a jumper
wire.
ACTION TO TAKE
Yes
Go to E2.
No
Repair open in circuit 904.
Yes
Remove jumper wire. Go to E3.
No
Replace bulb or repair high resistance in bulb socket or

circuit 904.
DIAGNOSIS
09-10
E3
Generator
09-10
CHECK FOR POOR GROUNDS
Yes
Go to E4.
Check for poor ground connections between voltage
No
Clean or repair grounds as required.
regulator and generator, generator and engine, or engine

and battery.
Are all ground connections clean and tight?
Yes
Service circuit 4. Circuit should be hot only when

engine is running. Check for swapped wires in voltage
regulator connector.
No
Go to E5.
Yes
If lamp is on with one-pin "S" connector removed,

replace generator.
No
E4
CHECK "S" CIRCUIT WIRING
Remove one-pin "S" connector from generator.

Measure voltage at wiring harness "S" terminal.
E5
CHECK FOR SHORTED RECTIFIER
Measure voltage at the "S" terminal on the back of the
generator.
TEST F - Generator Noisy

TEST STEP
F1
RESULT
CHECK FOR ACCESSORY-DRIVE NOISE
Check the drive belt to make sure that it is installed properly
and is not damaged.

Check the accessory mounting brackets for loose bolts or
out of alignment condition.

Check for a bent pulley.
Is accessory drive OK?
F2
SUBSTITUTE KNOWN GOOD GENERATOR
Remove generator and replace with a known good
generator.
Is noise present with known good part?
ACTION TO TAKE
Yes
Go to F2.
No
Service accessory drive as required.
Yes
Generator is OK. Install original part. Check other

accessories to find the cause of the noise.
No
Replace generator.
DIAGNOSIS
09-11
Generator
09-11
TEST G - Radio Interference

TEST STEP
RESULT
ACTION TO TAKE
VERIFY RADIO INTERFERENCE
Yes
Generator is OK. Interference is occurring elsewhere in

the electrical system.
Start engine.
Tune radio to a station where interference is present.
Is interference present with connector removed?
No
Go to G2.
Yes
Generator is OK. Interference is occurring elsewhere in

the electrical system.
No
Replace generator.
G1
G2
SUBSTITUTE KNOWN GOOD GENERATOR
Remove generator and replace with a known good
generator.
Is interference present with known good part?
TEST H - Indicator Lamp On, Key Off

TEST STEP
H1
CHECK LAMP CIRCUIT WIRING

Measure voltage at wiring harness "I" terminal, circuit 904.
RESULT
ACTION TO TAKE
Yes
Service circuit 904. Circuit should be hot in run position

only.
No
Service instrumentation system. Indicator lamp circuit is

finding a path to ground at a point other than the
generator.
DIAGNOSIS
09-12
Generator
WARNING: BATTERIES NORMALLY PRODUCE

EXPLOSIVE GASES WHICH CAN CAUSE
PERSONAL INJURY. THEREFORE, DO NOT
ALLOW FLAMES, SPARKS OR LIGHTED
SUBSTANCES TO COME NEAR THE BATTERY.
WHEN CHARGING OR WORKING NEAR A
BATTERY, ALWAYS SHIELD YOUR FACE AND
PROTECT YOUR EYES. ALWAYS PROVIDE
VENTILATION.
09-12
1.
Remove the bolts holding the generator to the

generator bracket.
2.
Remove the generator from the generator

bracket.
WHEN LIFTING A PLASTIC-CASED BATTERY,

EXCESSIVE PRESSURE ON THE END WALLS
COULD CAUSE ACID TO SPEW THROUGH THE
VENT CAPS, RESULTING IN PERSONAL INJURY.
LIFT WITH A BATTERY CARRIER OR WITH YOUR
HANDS ON OPPOSITE CORNERS.
WARNING: KEEP BATTERIES OUT OF REACH
OF CHILDREN. BATTERIES CONTAIN SULFURIC
ACID. AVOID CONTACT WITH SKIN, EYES OR
CLOTHING. ALSO, SHIELD YOUR EYES WHEN
WORKING NEAR THE BATTERY TO PROTECT
AGAINST POSSIBLE SPLASHING OF THE ACID
SOLUTION. IN CASE OF ACID CONTACT WITH
THE SKIN, EYES OR CLOTHING, FLUSH
IMMEDIATELY WITH WATER FOR A MINIMUM OF
FIFTEEN MINUTES. IF ACID IS SWALLOWED,
DRINK LARGE QUANTITIES OF MILK OR WATER,
FOLLOWED BY MILK OF MAGNESIA, A BEATEN
EGG, OR VEGETABLE OIL. CALL A PHYSICIAN
IMMEDIATELY.

NOTE: Only the regulator, brush holder and
generator pulley are serviceable. If the generator
needs further service, it must be replaced as an
assembly.
Generator Installation
1.
Position the generator on the generator bracket.
2.
Install generator.
3.
Tighten generator-to-bracket bolts to 40-55 Nm

(29-40 lb-ft).
4.
Position drive belt.
5.
Using flex handle, rotate drive belt tensioner,

drive belt.
6.
Connect generator voltage regulator wiring to the

voltage regulator. Tighten generator battery
positive voltage (B+) wire attaching nut to 9-12 N
m (6.5-9 lb-ft).
7.
Install wiring connector bracket.
8.
Install engine air cleaner intake tube.
9.
Install snow/ice shield.
Generator Removal
1.
Disconnect battery ground cable.
2.
Remove snow/ice shield.
3.
Remove engine air cleaner intake tube.
4.
Disconnect the generator voltage regulator wiring

to the voltage regulator.
5.
Remove wiring connector bracket.
6.
Loosen the drive belt tensioner and remove the

drive belt.
09-13
Generator
09-13
Regulator Installation
1.
Replace generator brush holder to voltage

regulator and install attaching screws.
2.
Replace cap on the head of the "A" terminal

screw.
3.
Depress the generator brushes into the generator

brush holder.
4.
Hold the generator brushes in position by

inserting a standard size paper clip (or equivalent)
through both the location hole in the voltage
regulator and through the holes in the generator
brush holders.
5.
Install the voltage regulator and generator brush

holder to the generator with attaching screws.
6.
Remove paper clip (or equivalent) from the

regulator.
Regulator Removal
1.
Remove the four screws (T20 Torx type head)

attaching the voltage regulator to the generator
housing. Remove the voltage regulator with
generator brush holder attached, from the
generator.
2.
Hold the voltage regulator generator regulator in

one hand and pry off the cap covering the "A"
screw head with a screwdriver.
3.
Remove two screws (T20 Torx type head)

attaching the regulator to the generator brush
holder. Separate the regulator from generator
brush holder.

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What safety precautions should be taken when working on engines?

What safety precautions should be taken when working on engines?

What are NOTES, CAUTIONS and WARNINGS and what is their purpose?

What are NOTES, CAUTIONS and WARNINGS and what is their purpose?

LRG-425

INDUSTRIAL ENGINE SERVICE MANUAL

IMPORTANT SAFETY NOTICE

NOTES, CAUTIONS, AND WARNINGS

Always wear safety glasses for eye protection.

The descriptions and specifications contained in this manual were in

Reroduction in any manner, in whole or in part, is prohibited without

ENGINE SERVICE - GENERAL ................................................................................................01

Engine Service - General

ENGINE SERVICE - General ................................................................................................................................ 01-01

SECTION 01 - Engine Service - General

Engine Service - General

Take added care to prevent scratching or gouging

aluminum sealing surfaces.

To maintain the required performance level, the fuel

WARNING: TO AVOID THE POSSIBILITY OF

Engine Identification Nameplate

CAUTION: Use of abrasive grinding discs to

Engine Service - General

Engine oil leaks.

Damaged and/or severely worn parts.

Loose mounting bolts, studs and nuts.

Worn piston ring(s).

Replace piston ring(s).

Service or replace cylinder block.

Damaged cylinder head gasket.

Replace cylinder head gasket.

Malfunctioning or damaged fuel system.

Refer to section on fuel system.

Malfunctioning or damaged ignition system.

Refer to section on ignition system.

Damaged hydraulic valve tappet.

Replace hydraulic valve tappet.

Damaged hydraulic valve tappet guide.

Replace hydraulic valve tappet

Improper valve to valve seat contact.

Replace valve and/or valve seat.

Damaged cylinder head gasket.

Replace cylinder head gasket.

Malfunctioning or damaged fuel system.

Refer to section on Fuel system.

Malfunctioning or damaged ignition system.

Refer to section on ignition system.

Damaged hydraulic valve tappet.

Replace hydraulic valve tappet.

Damaged hydraulic valve tappet bore.

Replace cylinder block.

Burnt or sticking valve.

Service or replace valve.

Weak or broken valve spring.

Replace valve spring.

Carbon accumulation in combustion chamber.

Eliminate carbon buildup.

Malfunctioning or damaged fuel system.

Refer to section on fuel system.

Malfunctioning or damaged ignition system.