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EDI TSG-416 Service Manual

1.6 liter industrial engine
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INDUSTRIAL ENGINE SERVICE MANUAL 
 
 
 
Powertrain Assemblies  
& Components Provided 
By Ford Component Sales 
 
 
 
 
 
 
 
 
 
 
TSG‐416  
1.6 LITER  
 
 
 
EDI 1020120 
Revision 0 
December 2012 
 

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Summary of Contents for EDI TSG-416

  • Page 1 TSG‐416   1.6 LITER       INDUSTRIAL ENGINE SERVICE MANUAL          Powertrain Assemblies               & Components Provided          By Ford Component Sales  EDI 1020120  Revision 0  December 2012   ...
  • Page 2                 EDI 1020120  Revision 0  December 2012   ...
  • Page 3 Engine Distributors Inc (EDI) CHARGING         Section 06         EDI policy is one of continuous improvement and while every effort is made to ensure that this publication is up to date and correct in all respects, the right to change prices, STARTER specifications and equipment at any time without         Section 07      ...
  • Page 4 HEALTH & SAFETY WARNING: THE FOLLOWING HEALTH AND SAFETY RECOMMENDATIONS SHOULD BE CAREFULLY OBSERVED WARNING: CARRYING OUT CERTAIN OPERATIONS AND HANDLING SOME SUBSTANCES CAN BE DANGEROUS OR HARMFUL TO THE OPERATOR IF THE CORRECT SAFETY PRECAUTIONS ARE NOT OBSERVED. SUCH PRECAUTIONS ARE RECOMMENDED AT THE APPROPRIATE POINTS IN THIS BOOK.
  • Page 5 TSG‐416 GENERAL INFORMATION  INDEX      Subject General Information  Page  Introduction………………………………………………………………………………………………………………  01 – 3  Safety Notice…………………………………………………………………………….………………………………  01 – 3  Notes, Cautions, and Warnings…………………………………………………………………………………  01 – 3  Battery Handling and Charging……………………………………………….…………………………………  01 – 4  Forward…………………………………….………………………………………………………………………………  01 – 5  Engine Identification………..………….……………………………………………………………………………  01 – 5  Parts and Service………………………………………….……………………………………………………………  01 – 5  Description and Operation……………………………………………………..…………………………………  01 – 5    Diagnosis and Testing    Special Tools…………….…………………………………………………………………………………………………  01 – 6  Inspection and Verification…………………………………………………………………………………………  01 – 7  Symptom Chart…………………………………………………………………………………………………………..  01 – 7  PCV System Malfunction…………………………………………………………………………………………….  01 – 10  Engine Oil Leaks………………………………………………………………………………………………………….  01 – 10  Compression Tests……………………………………………………………………………………………………..  01 – 12  Cylinder Leakage Detection………………………………………………………………………………………..  01 – 13  Intake Manifold Vacuum Test……………………………………………………………………………………. ...
  • Page 6 TSG‐416 GENERAL INFORMATION  INDEX (CONT.)    Subject  General Service Procedures  Page  Piston Selection………………………………………………………………………………………………………….  01 – 26  Piston Ring End Gap…………………………………………………………………………………………………..  01 – 26  Piston Ring‐to‐Groove Clearance……………………………………………………………………………….  01 – 27  Crankshaft Connecting Rod Journal Diameter……………………………………………………………  01 – 27  Crankshaft Connection Rod Journal Taper………………………………………………………………...  01 – 27  Connecting Rod Cleaning……………………………………………………………………………………………  01 – 27  Connecting Rod Larger End Bore……………………………………………………………………………….  01 – 28  Piston Pin Diameter…………………………………………………………………………………………………..  01 – 28  Connecting Rod Bushing Diameter…………………………………………………………………………...  01 – 28  Connecting Rod Bend………………………………………………………………………………………………..  01 – 28  Connecting Rod Twist………………………………………………………………………………………………..  01 – 28  Connecting Rod Piston Pin Side Clearance………………………………………………………………..  01 – 29  Connecting Rod Journal Clearance…………………………………………………………………………….  01 – 29  Bearing Inspection…………………………………………………………………………………………………….  01 – 30  Roller Follower Inspection………………………………………………………………………………………...  01 – 30  Hydraulic Lash Adjuster Inspection……………………………………………………………………………  01 – 30  Valve Stem Diameter…………………………………………………………………………………………………  01 – 31  Valve Stem‐to‐Valve Guide Clearance……………………………………………………………………… ...

  • Page 7: General Information

     TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT METAL PARTS SUCH AS THE Engine Distributors Inc. (EDI) does not recommend RADIATOR, EXHAUST MANIFOLD, TAIL PIPE, using abrasive grinding discs to remove engine gasket CATALYTIC CONVERTER AND MUFFLER.
  • Page 8 TSG‐416 GENERAL INFORMATION  Battery Handling and Charging The handling and correct use of lead acid batteries is not It is important that all labeling on the battery is carefully as hazardous provided that sensible precautions are read, understood and complied with. The format of the observed and that operatives have been trained in their following symbols and labels is common to most brands use and are adequately supervised.
  • Page 9 Review the list in the back of this must be maintained according to the maintenance book, for an EDI distributor in your area. You can obtain schedule. Refer to the Maintenance and Operator’s a standard parts listing describing the parts. It remains a Handbook or contact your nearest EDI distributor listed distributor function to identify the part number.
  • Page 10 TSG‐416 GENERAL INFORMATION  DIAGNOSIS AND TESTING Special Tools Special Service Tools called by the procedures can be obtained by calling: 1-800-ROTUNDA (1-800-768-8632) 01‐6 ...
  • Page 11 TSG‐416 GENERAL INFORMATION  Inspection and Verification 1. Verify the customer concern by operating the engine to duplicate the condition. 3. If the inspection reveals obvious concerns that can be readily identified, repair as required. 2. Visually inspect for obvious signs of mechanical and electrical damage: 4.
  • Page 12 TSG‐416 GENERAL INFORMATION  01‐8 ...
  • Page 13 TSG‐416 GENERAL INFORMATION  01‐9 ...
  • Page 14 TSG‐416 GENERAL INFORMATION  PCV System Malfunction 3. Run the engine for 15 minutes. Stop the engine A malfunctioning Positive Crankcase Ventilation and inspect all seal and gasket areas for leaks System (closed type) may be indicated by loping or using the 12 Volt Master UV diagnostic rough engine idle.
  • Page 15 TSG‐416 GENERAL INFORMATION  Testing Procedure  Open the air supply valve until the pressure gauge maintains 20 kPa (3 psi).  Inspect sealed or gasketed areas for leaks by applying a solution of liquid detergent and water over areas for formation of bubbles which indicates leakage.
  • Page 16 TSG‐416 GENERAL INFORMATION  Compression Pressure Limit Chart Compression Tests Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly charged. Operate until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs.
  • Page 17 TSG‐416 GENERAL INFORMATION  Cylinder Leakage Detection Intake Manifold Vacuum Test Bring the engine to normal operating temperature. When a cylinder produces a low reading, use of the Connect a Vacuum/Pressure Tester, such as Rotunda Engine Cylinder Leak Detection/Air Pressurization Kit, Vacuum/Pressure Tester 059-00008 or equivalent, to the such as the Rotunda Pressurization Kit 014-00705, or intake manifold.
  • Page 18 TSG‐416 GENERAL INFORMATION  Interpreting Vacuum Gauge Readings 5. STICKING VALVES: When the needle (dotted) A careful study of the vacuum gauge reading while the remains steady at a normal vacuum but engine is idling will help pinpoint trouble areas. Always occasionally flicks (sharp, fast movement) down conduct other appropriate tests before arriving at a final and back about 13 kPa (4 in-Hg), one or more diagnostic decision.
  • Page 19 TSG‐416 GENERAL INFORMATION  Oil Consumption Test Excessive Engine Oil Consumption The following diagnostic procedure is used to determine The amount of oil an engine uses will vary with the way the source of excessive internal oil consumption. the equipment is driven in addition to normal engine to engine variation.
  • Page 20 TSG‐416 GENERAL INFORMATION  10. Record the vehicle mileage or hours. 19. Worn or damaged internal engine components can cause excessive oil consumption. Small 11. Instruct the customer to run engine as usual and deposits of oil on the tips of spark plugs can be perform the following: a clue to internal oil consumption.
  • Page 21 TSG‐416 GENERAL INFORMATION  Valve Train Analysis – Static Valve Train Analysis – Dynamic With engine off and valve cover removed, check for Start the engine and, while idling, check for proper damaged or severely worn parts and correct assembly. operation of all parts. Check the following: Make sure correct parts are used with the static engine analysis as follows.
  • Page 22 TSG‐416 GENERAL INFORMATION  Camshaft Lobe Lift Check the lift of each lobe in consecutive order and make a note of the readings. 1. Remove the valve covers. 2. Remove the rocker arm seat bolts, rocker arm seat and rocker arms (if equipped). 5.
  • Page 23 TSG‐416 GENERAL INFORMATION  NOTE: Lash adjusters cannot be checked with engine oil Hydraulic Valve Lash Adjuster in them. Use only testing fluid. New hydraulic lash Hydraulic lash adjuster noise can be caused by any of adjusters are already filled with testing fluid. the following: ...
  • Page 24 TSG‐416 GENERAL INFORMATION  GENERAL SERVICE PROCEDURES WARNING: TO AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE TO THE EQUIPMENT, DO NOT OPERATE THE ENGINE UNTIL THE FAN BLADE HAS BEEN EXAMINED FOR POSSIBLE CRACKS AND SEPARATION. NOTE: Illustrations are typical and may not reflect your particular engine.
  • Page 25 TSG‐416 GENERAL INFORMATION  Camshaft Lobe Lift Camshaft Runout 1. Use the Dial Indicator with Bracketry to measure NOTE: Camshaft journals must be within specifications camshaft intake lobe lift. before checking runout.  Use the Dial Indicator with Bracketry to measure the camshaft runout. ...
  • Page 26 TSG‐416 GENERAL INFORMATION  Crankshaft Main Bearing Journal Diameter Crankshaft Main Bearing Journal Taper   Measure each of the crankshaft main bearing Measure each of the crankshaft main bearing journal diameters in at least two directions. journal diameters in at least two directions at ...
  • Page 27 TSG‐416 GENERAL INFORMATION  Crankshaft Main Bearing Journal 4. Verify the crankshaft journal clearance. Clearance  If it is out of specification, replace as necessary NOTE: Crankshaft main bearing journals must be within specifications before checking journal clearance. 1. Remove the crankshaft main bearing caps and Bearing Inspection bearings.
  • Page 28 TSG‐416 GENERAL INFORMATION  Crankshaft End Play Use the Dial Indicator with Bracketry to measure the crankshaft runout.  Rotate the crankshaft and subtract the lowest dial indicator reading from the highest dial indicator reading to figure the crankshaft runout. If it is out of specification, replace as necessary. 1.
  • Page 29 TSG‐416 GENERAL INFORMATION  Cylinder Bore Out-of-Round  Make sure the oil ring holes are clean. Measure the cylinder bore in two directions. The difference is the out-of-round. Verify the out-of-round I within the wear limit and bore the cylinder to the next oversize limit.
  • Page 30 TSG‐416 GENERAL INFORMATION  CAUTION: Use care when fitting piston rings to Piston Selection avoid possible damage to the piston ring or the cylinder bore. NOTE: The cylinder bore must be within the specifications for taper and out-of-round before fitting a CAUTION: Piston rings should not be transferred piston.
  • Page 31 TSG‐416 GENERAL INFORMATION  Piston Ring-to-Groove Clearance Crankshaft Connecting Rod Journal Taper  Measure the crankshaft rod journal diameters in two directions perpendicular to one another at each end of the connecting rod journal. The difference in the measurements from one end to the other is the taper.
  • Page 32 TSG‐416 GENERAL INFORMATION  Connecting Rod Larger End Bore Connecting Rod Bushing Diameter  Measure the inner diameter of the connecting CAUTION: The connecting rod bolts are torque to rod bushing. Verify the diameter is within yield and must be discarded and replaced after this specification.
  • Page 33 TSG‐416 GENERAL INFORMATION  Connecting Rod Piston Pin Side Clearance 4. Install and torque to specifications, then remove  Measure the clearance between the connecting the connecting rod bearing cap. rod and the piston. Verify the measurement is within specification. 5. Measure the Plastigage® to get the connecting rod bearing journal clearance.
  • Page 34 TSG‐416 GENERAL INFORMATION  Bearing Inspection Roller Follower Inspection Inspect bearings for the following defects. Possible  Inspect the roller for flat spots or scoring. If any causes are shown: damage is found, inspect the camshaft lobes  Cratering – fatigue failure (A) and hydraulic lash adjusters for damage.
  • Page 35 TSG‐416 GENERAL INFORMATION  Valve Stem Diameter 2. Move the Valve Stem Clearance Tool toward the  Measure the diameter of each intake and Dial Indicator and zero the Dial Indicator. Move exhaust valve stem at the points shown. Verify the Valve Stem Clearance Tool away from the the diameter is within specification.
  • Page 36 TSG‐416 GENERAL INFORMATION  Valve Guide Inner Diameter Valve Spring Installed Length  1. Measure the inner diameter of the valve guides Measure the installed length of each valve in two directions where indicated. spring. 2. If the valve guide is not within specifications, ream the valve guide and install a valve with an oversize stem or remove the valve guide and install a new valve guide.
  • Page 37 TSG‐416 GENERAL INFORMATION  Valve Spring Compression Pressure Valve Seat Width  Measure the valve seat width. If necessary, grind the valve seat to specification.  Use the Valve/Clutch Spring Tester to check the valve springs for proper strength at the specified valve spring length. Valve Seat Runout ...
  • Page 38 TSG‐416 GENERAL INFORMATION  Flywheel Inspection Oil Pump Rotor Inspection  Inspect the oil pump rotor tips for damage or wear. 1. Inspect the flywheel for:  Cracks (A).  Oil Pump Side Clearance Worn ring gear teeth (B).  Chipped or cracked ring gear teeth (C). 2.
  • Page 39 TSG‐416 GENERAL INFORMATION  Cylinder Bore Honing NOTE: Before any cylinder bore is honed, all main bearing caps must be installed so the crankshaft bearing bores will not become distorted. NOTE: To correct taper or out-of-round, bore the cylinder block. NOTE: Honing should be done when fitting new piston rings or to remove minor surface.
  • Page 40 TSG‐416 GENERAL INFORMATION  Cylinder Block Repair - Cast Iron Porosity Defects CAUTION: Do not attempt to repair cracks, areas where temperature will exceed 260°C (500°F) or areas exposed to engine coolant or oil. These areas will not repair and could cause future failure. 2.
  • Page 41 TSG‐416 GENERAL INFORMATION  Cylinder Block Core Plug – Cup-Type CAUTION: Do not contact the flange when installing a cup type cylinder block core plug as this could damage the sealing edge and result in leakage. NOTE: When installed, the flanged edge must be below the chamfered edge of the bore to effectively seal the bore.
  • Page 42 TSG‐416 GENERAL INFORMATION  Spark Plug Thread Repair 2. Start the tap into the spark plug hole, being careful to keep it properly aligned. As the tap begins to cut new threads, apply aluminum cutting oil 3. Continue cutting the threads and applying oil CAUTION: The cylinder head must be removed from until the stop ring bottoms against the spark plug the engine before installing a tapersert.
  • Page 43 TSG‐416 GENERAL INFORMATION  Exhaust Manifold Straightness 6. Tighten the tapersert into the spark plug hole.  Place the Straightedge across the exhaust manifold flanges and check for warping with a feeler gauge. NOTE: The exhaust manifold shown is a typical exhaust manifold. 7.
  • Page 44 TSG‐416 GENERAL INFORMATION  SPECIFICATIONS NOTE: Ford engines are designed to perform with engine oils that are licensed by the American Petroleum Institute (API), and oils carrying the most current API Classification SJ or greater must be used. 01‐40 ...
  • Page 45 TSG‐416 ENGINE  INDEX    Subject   General Information  Page  Special Tools………………………………………………………………………………………………………………  02 – 3  Positive Crankcase Ventilation System……….…………………………….………………………………  02 – 5  Component Location…………………………………………………………………………………………………  02 – 6    Engine Repair    Valve Cover – Removal …………………………………………..………………………………………………… 02 – 10   Valve Cover – Installation…………….…………………………………………………………………………… 02 – 10   Camshaft – Removal ……………………………………………………..…………………………………………. 02 – 11   Camshaft – Installation……………………………………………………………………………………………… 02 – 12  Valve Stem Seal – Removal…….………………………………………………………………………………… 02 –13  Valve Stem Seal – Installation...………………..……………………………………………………………… 02 – 14  Intake Manifold – Removal……………………………………………………………………………………… 02 – 15  Intake Manifold – Installation………………………………………………………………………………….  02 – 15  Exhaust Manifold – Removal…………………………………………………………………………………… 02 – 16  Exhaust Manifold – Installation…………………….…..……………………………………………………. 02 – 16  Cylinder Head – Removal………………………………………………………………………………………… 02 – 17  Cylinder Head – Installation…………………….………..……………………………………………………. 02 ‐ 19  Oil Pump ‐ Removal…………………………….…………………………………………………………………..
  • Page 46 TSG‐416 ENGINE  INDEX (CONT.)    Subject                        Page Disassembly……………………………………………………………………………………………………………………………  02 ‐ 37    Subassemblies    Cylinder Block ………..…………………………………………………………………………………………………. 02 – 44  Piston – Disassembly…………………………………………………………………………………………………. 02 – 45  Piston – Assembly ……………………………………….……………………………………………………………. 02 – 45  Cylinder Head Disassembly……………………………………………………………………………………….. 02 – 46  Cylinder Head Assembly……………………………….…………………………………………………………… 02 – 47    Assembly……………………………………………………………………………………………………………………………  02 – 48      SPECIFICATIONS…………………………………………………………………………………………………………….………...  02 – 58       ...
  • Page 47 TSG‐416 ENGINE  GENERAL INFORMATION Special Tools 02‐3 ...

  • Page 48: Special Tools

    TSG‐416 ENGINE  Special Tools 02‐4 ...
  • Page 49 TSG‐416 ENGINE  Description Cylinder Head The 1.6L 4 cylinder Zetec Rocam engine has been The Zetec Rocam engine cylinder head is entirely made developed with the highest technology. Its main of aluminum which improves the thermal characteristics characteristics are:  and reduces weight. The assembly is attached using a electronic controlled multipoint sequential multi-layer steel gasket and 12 bolts.

  • Page 50: Component Location

    TSG‐416 ENGINE  Component Location 02‐6 ...
  • Page 51 TSG‐416 ENGINE  Component Location 02‐7 ...
  • Page 52 TSG‐416 ENGINE  Component Location 02‐8 ...
  • Page 53 TSG‐416 ENGINE  Component Location 02‐9 ...
  • Page 54 TSG‐416 ENGINE  ENGINE REPAIR Valve Cover - Installation Valve Cover - Removal 1. Contact surfaces must be clean and free of oil. 2. Install a new gasket and valve cover. 1. Remove any necessary wiring and vacuum hoses. Mark connections and routing as necessary to assure they are returned as they were removed.
  • Page 55 TSG‐416 ENGINE  Camshaft- Removal 5. Remove camshaft, lower bearings, roller NOTE: Store components to ensure assembly in the followers and lash adjusters. same order as they were removed. 1. Remove valve cover -- Refer to “Valve Cover - Removal” on page 10. 2.
  • Page 56 TSG‐416 ENGINE  Camshaft - Installation 6. Using tool 15-030A, install bolt and tighten to 52- NOTE: All components must be clean and assembled in 59 lb.ft. (70-80 Nm). the same positions as removed. Lubricate contact surfaces with clean engine oil. 1. Install lash adjusters. 2.
  • Page 57 TSG‐416 ENGINE  Valve Stem Seal - Removal 5. Turn on air supply and pressurize cylinder. Air NOTE: If the valve or valve seat has not been damaged, pressure may rotate the crankshaft until the the valve spring, seal, retainer or keys may be replaced piston reaches the bottom of the stroke.
  • Page 58 TSG‐416 ENGINE  Valve Stem Seal - Installation 4. Release air pressure and remove air adapter. NOTE: All components must be clean and assembled in Install spark plug in proper cylinder. the same positions as removed. Lubricate contact 5. Grease contact surfaces of roller follower with surfaces with clean engine oil.
  • Page 59 TSG‐416 ENGINE  Intake Manifold - Removal Intake Manifold - Installation 1. Remove any necessary wiring and vacuum hoses. Mark connections and routing as NOTE: All contact surfaces must be clean and free from necessary to assure they are returned as they any old gasket material.
  • Page 60 TSG‐416 ENGINE  Exhaust Manifold - Removal Exhaust Manifold - Installation 1. Remove any necessary wiring and vacuum NOTE: All contact surfaces must be clean and free from hoses. Mark connections and routing as any old gasket material. necessary to assure they are returned as they 1.
  • Page 61 TSG‐416 ENGINE  Cylinder Head - Removal 11. Rotate camshaft sprocket using tool 15-030A 1. Drain engine oil - refer to Operator Handbook. until the 2 copper links on timing chain are at 12 2. Drain engine coolant - refer to Section 05. o’clock.
  • Page 62 TSG‐416 ENGINE  CAUTION: Be careful to avoid the bolts falling into the timing chain compartment. 15. Remove 2 M8 bolts, cylinder head and gasket. 16. Carefully remove cylinder head and gasket while maintaining tension on timing chain. 02‐18 ...
  • Page 63 TSG‐416 ENGINE  Cylinder Head - Installation 3. Install new bolts using the sequence shown in the following 3 steps: NOTE: The contact surface of the cylinder head and  Step 1 - tighten M11 bolts to 29.5 lb.ft. (40 block must be clean and free of oil. Use new cylinder head bolts and lubricate the threads.
  • Page 64 TSG‐416 ENGINE  5. Using tool 15-030A, install camshaft sprocket 10. Install the coolant flow control module - refer to bolt. Tighten to 92 lb.ft. (125 Nm). Section 05. 11. Install spark plugs and wires - refer to Section 6. Install hydraulic tensioner and tighten to 30 lb.ft. (40 Nm).
  • Page 65 TSG‐416 ENGINE  Oil Pump - Removal CAUTION: The oil pump, pulley and sealer are provided as an assembly kept together by a clip (no. BF9A-6606-AA). Do not remove clip until oil pump is installed. If pulley is pushed out of the oil pump prior to oil pump installation.
  • Page 66 TSG‐416 ENGINE  Oil Pump - Installation 4. Remove clip. 5. Install oil pump housing bolts finger tight. NOTE: Contact surfaces of the oil pump and block must be clean and free of oil. CAUTION: The oil pump housing must be positioned during tightening of the oil pump housing bolts, so CAUTION: The oil pump, pulley and sealer are that the sealing flange of the oil pump housing is...
  • Page 67 TSG‐416 ENGINE  Crankshaft Rear Oil Seal – Removal Crankshaft Rear Oil Seal - Installation 1. Install new rear seal and retainer using tool 21- 1. Remove flywheel 046. 2. Remove oil pan 3. Remove bolts and rear oil seal retainer. 2. Install oil pan 3.
  • Page 68 TSG‐416 ENGINE  Camshaft Follower / Hydraulic Lash Camshaft Follower / Hydraulic Lash Adjuster – Removal Adjuster – Installation 1. Remove valve cover -- Refer to “Valve Cover - NOTE: All components must be kept clean and Removal” on page 10. lubricated with clean engine oil. 2.
  • Page 69 TSG‐416 ENGINE  Oil Pan - Removal 3. Align oil pan with rear portion of engine block 1. Remove bolts. 2. Remove oil pan. 3. Remove all gasket material from pan. CAUTION: Be careful not to contact surfaces. 4. Tighten oil pan bolts in 3 steps in the sequence shown: ...
  • Page 70 TSG‐416 ENGINE  Pick-up Tube / Deflector - Removal Pick-up Tube / Deflector - Installation 1. Remove oil pan -- Refer to “Oil Pump - 1. Install oil deflector. Removal” on page 21. 2. Install pick-up tube. 2. Remove 4 nuts and1 bolt. 3.
  • Page 71 TSG‐416 ENGINE  Crankshaft Main Bearings - Removal NOTE: To check bearing clearances or to select new bearings, refer to Section 01. 1. Remove oil pan -- Refer to “Oil Pan - Removal” on page 25. 2. Remove pick-up tube & deflector -- Refer to “Pick-up Tube / Deflector - Removal”...
  • Page 72 TSG‐416 ENGINE  Connecting Rod Bearings – Removal Connecting Rod Bearings - Installation 1. Remove oil pan -- Refer to “Oil Pan - Removal” NOTE: Make sure bearing bore of connecting rod and on page 25. cap and bearing journal are clean. Lubricate wear 2.
  • Page 73 TSG‐416 ENGINE  Piston – Removal 6. Remove 2 bolts, connecting rod cap and lower bearing. 1. Remove oil pan -- Refer to “Oil Pan - Removal” on page 25. 2. Remove pick-up tube and deflector -- Refer to “Pickup Tube / Deflector - Removal” on page 26. 3.
  • Page 74 TSG‐416 ENGINE  Piston - Installation 4. Install connecting rod caps with bearings NOTE: Crankshaft journal should be at its lowest point. (lubricate wear surface) and tighten bolts in 2 All components should be clean and dried with steps: compressed air or a lint free cloth. ...
  • Page 75 TSG‐416 ENGINE  Flywheel - Removal 1. Remove bolts. 2. Remove flywheel. 3. Check flywheel runout at clutch disc surface:  maximum runout 0.005 in. (0.13 mm) 4. Check flywheel runout at gear surface:  maximum runout 0.024 in. (0.6 mm) Flywheel - Installation 1.
  • Page 76 TSG‐416 ENGINE  Timing Chain and Sprockets – Removal 4. Remove the hydraulic tensioner. 1. Remove oil pump assembly -- Refer to “Oil Pump -Removal” on page 21. 2. Remove valve cover -- Refer to “Valve Cover - Removal” on page 10. 3.
  • Page 77 TSG‐416 ENGINE  6. Remove timing chain and crankshaft sprocket. 2. Install crankshaft sprocket with key at 12 o’clock 7. Remove tensioner arm and chain guide if position. necessary. 3. Assemble drive chain through chain housing cavity from top of engine and onto crankshaft sprocket.
  • Page 78 TSG‐416 ENGINE  6. Tighten guide and tensioner arm bolts to 18-21 8. Tighten hydraulic tensioner to 27-32 lb.ft. (36-44 lb.ft. (24-28 Nm). Nm). 9. Install valve cover -- Refer to “Valve Cover - 7. Using locking tool, tighten camshaft sprocket Installation” on page 10. bolt to 52-59 lb.ft.
  • Page 79 TSG‐416 ENGINE  Oil Level Indicator – Removal Oil Level Indicator – Installation 1. Remove bolt. 1. Apply sealer WSK-M2G 349-A4 (Loctite 648) to lower end of oil level indicator tube. 2. Remove oil level indicator & tube. 2. Install tube immediately into bore. 3.
  • Page 80 TSG‐416 ENGINE  Oil Filter and Adapter - Removal Oil Filter and Adapter – Installation NOTE: Place oil drain pan under oil filter to catch oil 1. Install a new gasket. drainage. 1. Remove oil filter. 2. Lubricate oil seal on a new filter and install to adapter.
  • Page 81 TSG‐416 ENGINE  DISASSEMBLY 3. Loosen the tensioner pulley and remove the 1. Install engine on an engine stand. drive belt. 2. Drain the engine oil. NOTE: Record drive belt routing and direction of travel for use during assembly. 4. Disconnect wiring at generator. 5.
  • Page 82 TSG‐416 ENGINE  7. Remove oil level indicator tube. 10. Remove the coolant flow control module. 8. Remove the return connector 11. Remove the intake manifold assembly. NOTE: Record routing of wiring harnesses and vacuum tubes so they may be returned to their original positions during assembly.
  • Page 83 TSG‐416 ENGINE  12. Remove the oil filter and support assembly. 16. Remove the valve cover assembly. 13. Remove oil pressure switch. 14. Remove crankshaft position (CKP) sensor. 17. Loosen the crankshaft pulley bolt. 15. Remove the flywheel and flywheel plate. 02‐39 ...
  • Page 84 TSG‐416 ENGINE  18. Remove 3 bolts and the water pump pulley. 22. Remove 4 nuts, 1 bolt, oil pick-up tube and oil deflector. 19. Remove 3 bolts, water pump and gasket. 23. Insert retaining clip # BF9A-6606-AA between crankshaft pulley and oil pump to prevent pulley axial movement.
  • Page 85 TSG‐416 ENGINE  26. Check to see if coppered links on the timing 28. Using tool 15-030A to lock camshaft sprocket, chain are still visible. If not, identify them as remove bolt and camshaft sprocket. follows:  Turn engine until timing mark on camshaft sprocket is at 12 o’clock.
  • Page 86 TSG‐416 ENGINE  CAUTION: Keep cylinder head in the vertical 33. Remove crankshaft rear seal retainer. position during removal to avoid warping and damage to the sealing surfaces. 31. Remove the M11 cylinder head bolts in 3 phases in the sequence shown. NOTE: Mark piston and cap so they may be returned to their original positions.
  • Page 87 TSG‐416 ENGINE  NOTE: Keep caps and bearings in order so they may be returned to their original positions. 36. Carefully remove the crankshaft and install it vertically on the flywheel to avoid warp running- 35. Remove bolts, caps and crankshaft lower main out.
  • Page 88 TSG‐416 ENGINE  SUBASSEMBLIES 3. Check the engine block for warpage, cracks or Clean crankcase and all subassemblies of all foreign any other damage. material. Scrape or wire brush RTV sealant from mating surfaces. Surfaces must be kept oil free for good adhesion of fresh RTV seal (during reassembly).
  • Page 89 TSG‐416 ENGINE  Piston - Disassembly Piston - Assembly NOTE: Store components to ensure assembly with the NOTE: Apply a light coat of clean engine oil contact same rod and installation in the same cylinders from surfaces. which they were removed. Refer to Section 01 for piston 1.
  • Page 90 TSG‐416 ENGINE  Cylinder Head - Disassembly 6. Remove all valve components using a suitable valve spring compressor. NOTE: Store components to ensure assembly in the same order as they were removed. 1. Remove bolts and camshaft bearing caps evenly in the sequence shown. 2.
  • Page 91 TSG‐416 ENGINE  Cylinder Head - Assembly 5. Check that spring installed height is 35.2 ± 1mm. NOTE: All components must be clean and assembled in the same positions as removed. Lubricate contact surfaces with clean engine oil. 1. Check that valves move freely in valve guides. 2.
  • Page 92 TSG‐416 ENGINE  ASSEMBLY NOTE: The main bearing caps are numbered and must NOTE: All components must be clean and dried with be assembled to corresponding numbers. The arrow on compressed air or a lint free cloth. For information on the main bearing caps must point to the front of the bearings &...
  • Page 93 TSG‐416 ENGINE  6. Set piston ring gaps as follows: 10. Install a new rear seal and retainer using tool  21-046. lower oil ring gap aligned with piston pin  center ring gap at 90° from the oil ring gap.  top ring gap at 180°...
  • Page 94 TSG‐416 ENGINE  15. Install new bolts using the sequence shown in 17. Install crankshaft sprocket with key at 12 o’clock the following 3 steps: position.  Step 1 - tighten M11 bolts to 29.5 lb.ft. 18. Assemble drive chain through chain housing (40 Nm) ...
  • Page 95 TSG‐416 ENGINE  21. Tighten guide and tensioner arm bolts to 18-21 23. Tighten hydraulic tensioner to 27-32 lb.ft. (36-44 lb.ft. (24-28 Nm). Nm). 22. Using locking tool, tighten camshaft sprocket CAUTION: The oil pump, pulley and sealer are bolt to 59 lb.ft. (70-80 Nm). provided as an assembly kept together by a clip (no.
  • Page 96 TSG‐416 ENGINE  24. Assemble gasket onto oil pump housing guiding 29. Tighten 2 outer oil pump housing bolts to 15 it with 2 outer bolts. lb.ft. (20 Nm). CAUTION: Do not apply oil to shaft or seal. Sealing 30. Tighten remaining oil pump housing bolts to 15 lip along with all contact surfaces must be free of oil.
  • Page 97 TSG‐416 ENGINE  31. Install water pump. 35. Install oil deflector. 32. Install bolts and tighten to 7 lb.ft. (10 Nm). 36. Install oil pick-up tube. 33. Install water pump pulley. 34. Install bolts and tighten to 9 lb.ft. (12 Nm). 37. Tighten nuts to 14 lb.ft. (19 Nm). Tighten bolt to 7 lb.ft.
  • Page 98 TSG‐416 ENGINE  39. Install the oil pan and bolts finger tight. 42. Install the oil pan drain plug. Tighten to 18 lb.ft. (25 Nm). 40. Align oil pan with rear portion of engine block. 43. Install flywheel using special locking tool 21-168. 41.
  • Page 99 TSG‐416 ENGINE  46. Check flywheel runout at gear surface: 50. Install oil filter support with new filter. Tighten  maximum runout 0.024 in. (0.6 mm) bolts to 15 lb.ft. (20 Nm). 47. Install valve cover and gasket. Tighten bolts to 7 lb.ft.
  • Page 100 TSG‐416 ENGINE  53. Install intake manifold and gasket. Tighten bolts 55. Apply sealer WSK-M2G 349-A4 (Loctite 648) to and nuts to 6 lb.ft. (8 Nm). lower end of oil level indicator tube. Install immediately and tighten bolt to 15 lb.ft. (20 Nm). 54.
  • Page 101 TSG‐416 ENGINE  57. Install generator support 59. Pry tensioner pulley as shown and install drive belt. 60. Install engine wiring and vacuum hoses 58. Install generator and electrical connectors. 61. Fill engine with clean engine oil of the correct type and quantity. NOTE: Ford Power Products industrial engines are designed to perform with engine oils that are licensed by the American Petroleum Institute (API) and oils carrying...
  • Page 102 TSG‐416 ENGINE  SPECIFICATIONS GENERAL SPECIFICATIONS 4 cylinder, 4 stroke spark ignition 90° ELECTRICAL SYSTEM Overhead Valve (OHV) chain driven, Engine Type: Polarity: Negative to earth (ground) overhead camshaft operating the valves via roller cam followers. IGNITION Liter/CID: 1.6 / 97.5 Spark Plug: Ford Part #: XS6F-12405-A1A (NGK Bore: mm (in) 82.070 mm (3.23in)
  • Page 103 TSG‐416 IGNITION SYSTEM    INDEX      Subject                      Page General Information………………………………………………………………………………………………………….  03 ‐ 2  Description………………………………………………………………………………………………………………..  03 – 3   Operation………………………………………………………………………………………………………………….  03 – 3  Wiring Diagram…………………………………………………………………………………………………….……  03 – 4     Diagnosis and Testing    Spark Plug Inspection..…………………………………………………………………………….…………………  03 – 5    Removal and Installation    Ignition Coil – Replacement……….…….……………………………………………………………………….  03 – 6  Spark Plug – Removal……………………..……………….………………………………………………………..  03 – 6  Spark Plug – Installation…………………………………………………………………..………………………..  03 – 6  Specifications……………………..………………………………………………………………………………………………..  03 – 7 ...
  • Page 104 TSG‐416 IGNITION SYSTEM    GENERAL INFORMATION  Description  The TSG-416 engine is equipped with an coil WARNING: HIGH TENSION VOLTAGE PRODUCED pack electronic ignition system. The brain of this BY A DISTRIBUTORLESS IGNITION SYSTEM IS system is the Electronic Engine Control (GCP) HIGHER THAN FOR A CONVENTIONAL IGNITION Module which receives inputs from the following: SYSTEM.
  • Page 105 TSG‐416 IGNITION SYSTEM    Fuel Octane Level Adjustment Operation In the event that the engine is operated on dry With this system, the GCP monitors the engine fuels such as natural gas, compressed natural speed and operating temperature and decides gas (CNG), or liquefied petroleum gas (LGP), what degree of spark advance is correct for all of timing can be modified by GCP “Fuel Type”.
  • Page 106 TSG‐416 IGNITION SYSTEM    Wiring Diagram 03 ‐ 4 ...
  • Page 107 TSG‐416 IGNITION SYSTEM    DIAGNOSIS AND TESTING Spark Plug Inspection Inspect the spark plug tip as in the chart below: 03 ‐ 5 ...
  • Page 108 TSG‐416 IGNITION SYSTEM    REMOVAL AND INSTALLATION Spark Plug – Removal Ignition Coil - Replacement 1. Remove and/or disconnect components 1. Remove ignition coil -- Refer to “Ignition to allow access and removal of the Coil - Replacement” on page 6 of this ignition coil pack.
  • Page 109 TSG‐416 IGNITION SYSTEM    SPECIFICATIONS  GENERAL SPECIFICATIONS Firing Order 1 – 3 – 4 - 2 Spark Plug Type: 5G5E-12405-AA Gap: 1.06 – 1.16 mm (0.042 – 0.046 in.) TORQUE SPECIFICATIONS Description Lb-ft Lb-in Spark Plugs Coil bolts 03 ‐ 7 ...
  • Page 110 TSG‐416 FUEL SYSTEM    INDEX    Subject                      Page      Cautions & Warnings………………………………………………………………………………………………………….  04 – 2   General Information – Gasoline………………………..……………………………………………………………….  04 – 3  Description………………………………………………………………………………………………………………..  04 – 3   Operation………………………………………………………………………………………………………………….  04 – 4  Fuel System Requirements……………………………………………………………………………………….  04 – 4  Wiring Diagram…………………………………………………………………………………………………….……  04 – 5    General Information – Dry Fuel…………………………..……………………………………………………………….  04 – 7  Description………………………………………………………………………………………………………………..  04 – 7  Operation………………………………………………………………………………………………………………….  04 – 7  Fuel System Requirements……………………………………………………………………………………….  04 – 8  Wiring Diagram…………………………………………………………………………………………………….……  04 – 9 ...
  • Page 111 TSG‐416 FUEL SYSTEM    CAUTIONS & WARNINGS WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
  • Page 112 TSG‐416 FUEL SYSTEM    GENERAL INFORMATION - GASOLINE Camshaft Position (CMP) Sensor Description The Camshaft Position (CMP) Sensor is The fuel system delivers fuel by an electronic mounted in the camshaft cover. This signal is fuel pump. A fuel pressure regulator controls fuel sent to the GCP which uses it to indicate the pressure and also contains a fuel filter.

  • Page 113: Fuel System Requirements

    Gasohol/Ethanol: A mixture of gasoline and They can only be programmed by authorized ethanol (grain alcohol) containing up to 10% personnel only. Contact your local EDI ethanol by volume with properly formulated Distributor listed in the back of this manual for cosolvents and other necessary additives.
  • Page 114 TSG‐416 FUEL SYSTEM    Wiring Diagrams Revision Level The following wiring schematics are taken from the wiring diagram listed below. Fuel Injectors Actuat or / Data Link 04 ‐ 5 ...
  • Page 115 TSG‐416 FUEL SYSTEM    Connector (DLC)   04 ‐ 6 ...
  • Page 116 TSG‐416 FUEL SYSTEM    GENERAL INFORMATION –  DRY FUEL  Description  This engine with the proper fuel equipment can also operate on dry fuel such as LPG Grade HD5 and natural gas (1050 BTU/ft ). Natural Gas fuel specification must meet or exceed 38.7 MJ/m (UK) 39.0 MJ/m (USA).
  • Page 117 TSG‐416 FUEL SYSTEM    The DEPR serves to control the vapor pressure to the mixer. After the propane is vaporized (vapor regulator), the DEPR monitors and controls the vapor pressure to the mixer in reference to the inlet air pressure to the carburetor (mixer).
  • Page 118 TSG‐416 FUEL SYSTEM    Wiring Diagrams    Revision Level  The following wiring schematics are taken  from the wiring diagram labeled below.    Engine Controls – Dry Fuel DEPR      04 ‐ 9 ...
  • Page 119 TSG‐416 FUEL SYSTEM    DIAGNOSIS AND TESTING ‐ LPG  Symptom Chart   Symptom Go to Engine cranking but will not start Page 12 Engine starts but has rough idle Page 14 Engine idles with rough acceleration at load Page 14 Engine is unable to reach full power Page 14 Overall power loss Page 12...

  • Page 120: Preliminary Test

    TSG‐416 FUEL SYSTEM    Preliminary Test This pinpoint test checklist is your guide to the most probably causes of an engine performance complaint when the malfunction is due to the fuel system. Test Step Result Action to Take Inspect Installation. Go to Step 2.. ...
  • Page 121 TSG‐416 FUEL SYSTEM    Diagnostic Charts Perform the preliminary test before proceeding. Engine Cranking but Will Not Start Test Step Result Action to Take Check fuel tank Fill or replace the fuel tank. (Do not exceed 80% of liquid Is fuel tank empty? capacity) Go to Step 2.
  • Page 122 TSG‐416 FUEL SYSTEM    Diagnostic Aids Fuel Lock Solenoid: The fuel lock is an electronic solenoid that is opened to allow fuel flow when the key is turned ON. High temperatures may cause the solenoid to become intermittent, not opening to supply sufficient fuel pressure.
  • Page 123 TSG‐416 FUEL SYSTEM    The pinpoint tests below should be performed after the preliminary tests and “Engine Cranks but Will Not Start” chart Steps 1-3. Any electrical diagnostics should have been performed to eliminate any sensor, GCP or solenoid valve problems before proceeding. Engine Idles With Rough Acceleration At Load, Not Able to Reach Full Power or Misses Test Step Result...
  • Page 124 TSG‐416 FUEL SYSTEM    Diagnostic Aids Mixer Assembly (Carburetor): It is possible that a Fuel Lock Solenoid: The fuel lock is an backfire may have caused the fuel valve to partially electronic solenoid that is opened to allow fuel come off of its retainer and restrict fuel, check the flow when the key is turned ON.
  • Page 125 TSG‐416 FUEL SYSTEM    The pinpoint tests below should be performed after the preliminary tests and “Engine Backfires” chart Steps 1-3. Any electrical diagnostics should have been performed to eliminate any sensor, GCP or solenoid valve problems before proceeding Engine Backfires Test Step Result Action to Take The presence of ice on the...
  • Page 126 TSG‐416 FUEL SYSTEM    The pinpoint tests below should be performed after the preliminary tests and “Emission failure – Rick Mixture” chart Steps 1-3. Any electrical diagnostics should have been performed to eliminate any sensor, GCP or solenoid valve problems before proceeding. Emission Failure - Rich Mixture Test Step Result...
  • Page 127 TSG‐416 FUEL SYSTEM    The pinpoint tests below should be performed after the preliminary tests and “Emission failure – Lean Mixture” chart Steps 1-3. Any electrical diagnostics should have been performed to eliminate any sensor, GCP or solenoid valve problems before proceeding. Emission Failure - Lean Mixture Test Step Result...
  • Page 128 TSG‐416 FUEL SYSTEM    The pinpoint tests below should be performed after the preliminary tests and “Engine Overheats” chart Steps 1-3. Any electrical diagnostics should have been performed to eliminate any sensor, GCP or solenoid valve problems before proceeding. Engine Overheats Test Step Result Action to Take The presence of ice on the...
  • Page 129 TSG‐416 FUEL SYSTEM    The pinpoint tests below should be performed after the preliminary tests and “Engine stops running and dies” chart Steps 1-3. Any electrical diagnostics should have been performed to eliminate any sensor, GCP or solenoid valve problems before proceeding. Engine Stops Running (Dies) Test Step Result...
  • Page 130 TSG‐416 FUEL SYSTEM    two most likely fuel pump troubles that will affect DIAGNOSIS AND TESTING – engine performance. Low pressure will cause a GASOLINE lean mixture and fuel starvation at high speeds, and excessive pressure will cause high fuel NOTE: For diagnosis of Electronic Engine consumption and possible flooding.
  • Page 131 TSG‐416 FUEL SYSTEM    Fuel Block Check The fuel block monitors the fuel pressure and fuel temperature, which is what the GCP display is reading.  Check wiring from the fuel block to the main engine harness  If damaged replace the fuel block jumper harness ...
  • Page 132 TSG‐416 FUEL SYSTEM    Quick Connect Coupling - Type I - Quick Connect Coupling - Type II - Disconnect Disconnect WARNING: REFER TO WARNINGS AT THE WARNING: REFER TO WARNINGS AT THE BEGINNING OF THIS SECTION. BEGINNING OF THIS SECTION. CAUTION: Do not use any tools. Use of tools CAUTION: Do not use any tools.
  • Page 133 TSG‐416 FUEL SYSTEM    Quick Connect Coupling - Type II – Connect 1. Inspect for damage and clean fittings. CAUTION: Make sure the fuel tube clicks into place when installing the tube. To make sure that the fuel tube is fully seated, pull on the tube.

  • Page 134: Removal And Installation

    TSG‐416 FUEL SYSTEM    CAUTION: After disconnecting fuel lines, REMOVAL AND INSTALLATION plug the ends to prevent fuel leakage. Fuel Rail & Injectors - Replacement 3. Disconnect fuel lines -- Refer to “General Service Procedures” on page 31of this section. WARNING: DO NOT SMOKE OR CARRY LIGHTED 4.
  • Page 135 TSG‐416 FUEL SYSTEM    Mixer - Removal Actuator - Removal 1. Remove top four bolts that hold the 1. Remove and/or disconnect components mixer to the mixer adapter to allow access and removal of the actuator. Label if necessary to allow for correct reinstallation.
  • Page 136 TSG‐416 FUEL SYSTEM    Mixer - Installation 4. Mount the DEPR to the mixer (if uninstalled). Ensure the rubber gasket 1. Reverse the removal procedure. Ensure on the DEPR is not damaged. to install the two gaskets on the actuator  Tighten to 35 lb-in (4Nm) before installing the mixer adapter.
  • Page 137 TSG‐416 COOLING SYSTEM  INDEX      Subject General Information  Page  Description………………………………………………………………………………………………………………..  05 – 3    Diagnosis and Testing    Visual Inspection…………………………………………………………………………………………………………  05 – 4  Coolant Inspection……………………………………………………………………………………………………..  05 – 4   Coolant Range Check………………………………………………………………………………………………….  05 – 4  Drive Belt Inspection………………………………………………………………………………………………….  05 – 5  Symptom Chart…………………………….…………………………………………………………………………….  05 – 6  Cooling System Pressure Test……………………….……………………………………………………………  05 – 7  Radiator Cap Pressure Test…………….………………………………………………………………………….  05 – 7  Thermostat Operational Check…………….……………………………………………………………..…….  05 – 7    General Service Procedures    Draining the Cooling System………………………………………………………………………………………  05 – 8  Flushing the Cooling System………………………………………………………………………………………  05 – 8  Filling the Cooling System………………………………………………………………………………………….  05 – 8      Removal and Installation   ...
  • Page 138 TSG‐416 COOLING SYSTEM  CAUTION: Under no circumstances should the CAUTIONS & WARNINGS engine be started without liquid in the cooling system. This may cause permanent damage to the engine. WARNING: THE RADIATOR OR DEGAS TANK IS EQUIPPED WITH A PRESSURE CAP. IT IS CAUTION: The use of straight water as a coolant will DANGEROUS TO REMOVE THIS WHEN THE cause permanent damage to the engine.
  • Page 139 TSG‐416 COOLING SYSTEM  GENERAL INFORMATION The coolant pump circulates the coolant through the engine block and cylinder heads to the thermostat. If th thermostat is closed, the coolant returns to the coolant pump through a bypass hose. Once the coolant reaches Description a specified temperature, the thermostat will open, allowing the coolant to flow to the radiator for heat The cooling system consists of the following:...
  • Page 140 TSG‐416 COOLING SYSTEM  DIAGNOSIS AND TESTING Coolant Inspection WARNING: REFER TO CAUTIONS AND WARNINGS WARNING: REFER TO CAUTIONS AND WARNINGS AT THE BEGINNING OF THIS SECTION. AT THE BEGINNING OF THIS SECTION. Check level and condition of coolant:  Begin diagnosis by verifying the customer’s concern by A dark brown color could indicate a stop leak operating the engine to duplicate the condition.
  • Page 141 TSG‐416 COOLING SYSTEM   Drive Belt Inspection Longer deposits building up to 50% of the rib height is also not a concern, except it can result in excessive noise. WARNING: REFER TO CAUTIONS AND WARNINGS AT THE BEGINNING OF THIS SECTION. With engine running, observe the belt movement. It should respond when engine is accelerated rapidly.
  • Page 142 TSG‐416 COOLING SYSTEM  Symptom Chart Refer to the following Diagnosis chart for cooling system problems, their possible cause and recommend correction. CONDITION POSSIBLE SOURCE ACTION   Loss of coolant Pressure cap and Inspect, wash gasket test. Replace only if cap will not hold gasket ...
  • Page 143 TSG‐416 COOLING SYSTEM  Cooling System Pressure Test NOTE: If the plunger of the pressure tester is depressed too fast, an incorrect pressure reading will result. 3. Slowly pump the pressure tester until the gauge stops increasing and note the highest pressure reading. 4.
  • Page 144 TSG‐416 COOLING SYSTEM  GENERAL SERVICE PROCEDURES Flushing the Cooling System To remove rust, sludge and other foreign material from the cooling system, use Rotunda Cooling System Draining the Cooling System Cleanser. Removal of such material restores cooling efficiency and avoids overheating. WARNING: REFER TO CAUTIONS AND WARNINGS Always remove the thermostat prior to pressure flushing.
  • Page 145 TSG‐416 COOLING SYSTEM  REMOVAL AND INSTALLATION Fan Belt – Installation 1. Place belt around the outer crank pulley (4 NOTE: If a major component of the cooling system is groove) and fan pulley renewed such as the radiator, water pump etc., the 2.
  • Page 146 TSG‐416 COOLING SYSTEM  Radiator Hose - Removal Radiator Hose - Installation 1. Position the clamps at least 1/8 inch from each end of the hose. 2. Coat the connection areas with an approved water resistant sealer and slide the hose on the WARNING: REFER TO CAUTIONS AND WARNINGS connection.
  • Page 147 TSG‐416 COOLING SYSTEM  Thermostat & Housing – Replacement WARNING: REFER TO CAUTIONS AND WARNINGS 3. Remove or disconnect components as AT THE BEGINNING OF THIS SECTION. necessary to gain access to the thermostat housing. NOTE: The thermostat and housing are serviced as an 4.
  • Page 148 TSG‐416 COOLING SYSTEM  Coolant Pump - Replacement WARNING: REFER TO CAUTIONS AND WARNINGS AT THE BEGINNING OF THIS SECTION. 1. Drain the cooling system -- Refer to “Draining the Cooling System” of this section. 2. Remove or disconnect components as necessary to gain access to the coolant pump. 3.
  • Page 149 TSG‐416 COOLING SYSTEM  Thermostat - Replacement WARNING: REFER TO CAUTIONS AND WARNINGS AT THE BEGINNING OF THIS SECTION. 1. Drain the cooling system -- Refer to “Draining the Cooling System” of this section. 2. Remove or disconnect components as necessary to gain access to the outlet pipe. 3.
  • Page 150 TSG‐416 COOLING SYSTEM  Coolant Bypass – Replacement 1. Drain the cooling system -- Refer to “Draining the Cooling System” of this section. 2. Remove or disconnect components as necessary to gain access to the bypass hose 3. Disconnect the coolant bypass hose from the tubes.
  • Page 151 TSG‐416 COOLING SYSTEM  GENERAL SPECIFICATIONS Coolant/Water Mixture 50/50 Pressure Relief Cap 89 – 124 kPa (13 – 18 psi) Opening Pressure kPa (psi) Radiator Pressure Test 138 kPa (20 psi) Thermostat start to open 82°C (180°F) temperature Thermostat full open 97°C (205°F) temperature Coolant Specification Motorcraft Premium Gold...
  • Page 152 TSG‐416 CHARGING SYSTEM  INDEX      Subject General Information  Page  Description………………………………………………………………………………………………………………..  06 – 3  Operation………………………………………………………………………………………………………………….  06 ‐ 3  Wiring Diagram…………………………………………………………………………………………………….……  06 ‐ 3    Diagnosis and Testing    Preliminary Checks.………………………………………………………………………………….…………………  06 – 5  Warning indicator check……………………………………………………………………………………………..  06 – 5   Symptom Chart…………………………………………………………………………………………………………..  06 – 6  Battery Drain Test……………………………………………………………………………………………………….  06 – 7  Battery Load Test………………………………………………………………………………………………………..  06 – 7  Generator Output Test……………………………………………………………………………………………….  06 – 8  Generator Voltage Test………………………………………………………………………………………………  06 – 8    General Service Procedures    Battery Cleaning and Inspection………………………………………………………………………………..  06 – 9  Battery Tools………………………………………………………………………………………………………………  06 – 9  Battery Charging………………………………………………………………………………………………………..  06 – 10     ...
  • Page 153 TSG‐416 CHARGING SYSTEM  Cautions & Warnings The handling and correct use of lead acid batteries is not as hazardous provided that sensible precautions are observed and that operatives have been trained in their use and are adequately supervised. It is important that all labeling on the battery is carefully read, understood and complied with. The format of the following symbols and labels is common to most brands of lead acid battery.
  • Page 154 TSG‐416 CHARGING SYSTEM   To act as a voltage stabilizer by smoothing out or reducing temporary high voltages within the GENERAL INFORMATION electrical system. Operation With the ignition on, voltage is applied to the voltage regulator. This turns the regulator on, allowing current to flow from the battery to the generator field coil.
  • Page 155 TSG‐416 CHARGING SYSTEM  Wiring Diagram Revision Level The following wiring schematics are taken from the wiring diagram labeled below: Charging System 06 ‐4 ...
  • Page 156 TSG‐416 CHARGING SYSTEM  DIAGNOSIS AND TESTING Warning Indicator Check Check the operation of the charging system warning indicator as follows: WARNING: REFER TO CAUTIONS & WARNINGS AT  Ignition OFF = Indicator should be OFF. THE BEGINNING OF THIS SECTION.  Ignition ON, Engine OFF = Indicator should be NOTE: When the battery is disconnected and ...
  • Page 157 TSG‐416 CHARGING SYSTEM  Symptom Chart CONDITION POSSIBLE SOURCE ACTION  Dead battery. Repair as necessary Key-off battery drain.  Open/voltage drop in B+ circuit. Battery will not stay charged.  Open voltage drop in A circuit. Slow crank.  Open/high resistance in I circuit. Low battery voltage.
  • Page 158 TSG‐416 CHARGING SYSTEM  Battery Drain Test 5. Remove the jumper wire and note the amperage draw:  There should not be any more than 50 WARNING: REFER TO CAUTIONS & WARNINGS AT mA (0.050 amp) draw. THE BEGINNING OF THIS SECTION.  If excessive, remove fuses one at a time until the circuit with the excessive draw A defective component or wiring defect may be causing...
  • Page 159 TSG‐416 CHARGING SYSTEM  Generator Output Test Generator Voltage Test WARNING: REFER TO CAUTIONS & WARNINGS AT WARNING: REFER TO CAUTIONS & WARNINGS AT THE BEGINNING OF THIS SECTION. THE BEGINNING OF THIS SECTION. 1. Switch the tester to the voltmeter function. CAUTION: To prevent damage to the generator, do 2.
  • Page 160 TSG‐416 CHARGING SYSTEM  GENERAL SERVICE PROCEDURES WARNING: REFER TO CAUTIONS & WARNINGS AT WARNING: GRIPPING THE END WALLS ON THE THE BEGINNING OF THIS SECTION. PLASTIC-CASED BATTERY COULD CAUSE ELECTROLYTE TO SPEW FROM SOME OF THE Battery Cleaning and Inspection CELLS, RESULTING IN PERSONAL INJURY AND POSSIBLY CAUSE DAMAGE TO SOME OF THE Keeping the battery top clean and dry reduces the need INTERNAL COMPONENTS.
  • Page 161 TSG‐416 CHARGING SYSTEM  Battery Charging A rapid recharge procedure has been developed for recharging batteries that only need a quick recharge. This can be due to battery in-service no-start battery WARNING: REFER TO CAUTIONS & WARNINGS AT failures (engine will not crank due to low battery state of THE BEGINNING OF THIS SECTION.
  • Page 162 TSG‐416 CHARGING SYSTEM  REMOVAL AND INSTALLATION Voltage Regulator – Replacement Generator – Replacement 1. Remove the generator -- Refer to “Generator - Replacement” in this section. 2. Remove 4 screws and voltage regulator (includes brush and holder). 3. Reverse procedure to install: ...
  • Page 163 TSG‐416 CHARGING SYSTEM  Generator Pulley - Replacement 1. Remove generator assembly -- Refer to “Generator - Replacement” of this section. 2. Remove nut. 3. Remove pulley. 4. Reverse procedure to install:  Tighten nut to 109 Nm (80 lb-ft). 06 ‐12 ...
  • Page 164 TSG‐416 CHARGING SYSTEM  Battery - Removal Battery - Installation 1. Clean cable terminals and battery hold down clamp with a wire brush. Replace all cables or parts that are worn or frayed. 2. Clean battery tray with a wire brush and scraper. 3.
  • Page 165 TSG‐416 CHARGING SYSTEM  SPECIFICATIONS GENERAL SPECIFICATIONS Generator Output 90 Amp at 600 RPM; 2.72:1 drive ratio Battery Motorcraft 12 volt 750 Battery charging voltage 13 – 15.5 volts TORQUE SPECIFICATIONS Description Lb-ft Lb-in Generator Mounting bolts Regulator attachment screws Battery cable nuts Generator pulley nut Generator...
  • Page 166 TSG‐416 Engine Controls    INDEX      Subject                      Page General Information  08 – 2  GCP and Sensors….…………….……………………………………………………………………………………..  08 – 2   Fuel System Components………………………………………………………………………………………….  08 – 8  Coil‐on‐plug ignition……….…………………………………………………………………………………….……  08 – 10  Open Loop and Closed Loop Operation……………………………………………………………………..  08 – 11  Adaptive Learn…………………………………………………………………………………………………………..  08 – 11  GCP Service Precautions…………………………………………………………………………………………….  08 – 11  Use of Circuit Testing Tools………………………………………………………………………………………..  08 – 11  Electrostatic Discharge Damage…………………………………………………………………………………  08 – 11  Diagrams and schematics…………………………………………………………………………………………..  08 – 12  Engine component locator view…………………………………………………………………………………  08 – 24     ...
  • Page 167 TSG‐416 Engine Controls    GENERAL INFORMATION GCP and Sensors Engine Control Module (GCP) The Engine Control Module (GCP) has the following  Configurable outputs available based on features:  ECT, RPM or MAP signals and customer Programmable four speed electronic requirements. governing, throttle-by-wire or variable speed ...
  • Page 168 TSG‐416 Engine Controls      It can be programmed to provide up to four low oil pressure  specific speeds with use of a matching unauthorized tampering toggle switch  over cranking starter motor.  It can be programmed to provide an infinite variety of speeds (with customer-specified The GCP controls the following: minimum and maximum) based on a variable...
  • Page 169 TSG‐416 Engine Controls    GCP Outputs (systems controlled) calculated sequential fuel injection mode based  on the last fuel injection pulse, and the engine Fuel control (Injectors/DEPR)  will continue to run. As long as the fault (DTC Electronic Throttle Control  342, CAM loss) is present, the engine can be Electric Fuel Pump (gasoline) ...
  • Page 170 TSG‐416 Engine Controls    Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) Sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance of 100,000 ohms at - 40°C (-40°F).
  • Page 171 TSG‐416 Engine Controls    Heated Oxygen Sensor (HO2S) Specifications  The Heated Oxygen Sensor (HO2S) is mounted Accuracy of measurement: ±1.5%  in the exhaust stream where it can monitor the Operating Temp. Range: 350°C to oxygen content of the exhaust gas. The oxygen 850°C (sensor tip) ...
  • Page 172 TSG‐416 Engine Controls    Temperature Manifold Absolute Pressure (TMAP) Throttle Position (TP) Sensor / Electronic Sensor Actuator The Temperature Manifold Absolute Pressure The Throttle Position (TP) Sensor is a dual track (TMAP) Sensor responds to changes in intake rotary potentiometer that uses a variable manifold pressure (vacuum).
  • Page 173 TSG‐416 Engine Controls    The GCP monitors signals from several sensors in order to determine the fuel needs of the Fuel System Components - Gasoline engine. Fuel is delivered under one of several conditions called “modes”. All modes are The fuel metering system is made up of the controlled by the GCP.
  • Page 174 TSG‐416 Engine Controls    Fuel Pump Electrical Circuit Vapor Regulator When the key is first turned “ON”, the GCP The vapor regulator is used with LPG and CNG energizes the fuel pump relay for two seconds to fuels. It converts LPG from a liquid state to a build up the fuel pressure quickly.
  • Page 175 TSG‐416 Engine Controls    Distributor less Coil Pack The ignition system controls fuel combustion by providing a spark to ignite the compressed air/fuel mixture at the correct time. To provide optimum engine performance, fuel economy, and control of exhaust emissions, the GCP controls the spark advance of the ignition system.

  • Page 176: Open Loop And Closed Loop Operation

    TSG‐416 Engine Controls     When testing for opens and shorts, do not Open Loop and Closed Loop ground or apply voltage to any of the GCP’s Operation circuits unless instructed to do so.  When measuring voltages, use only a digital NOTE: No DTC will be set unless engine has voltmeter with an input impedance of at least operated in closed loop status for more than 6...
  • Page 177 TSG‐416 Engine Controls    Diagrams and Schematics Symbols   08 ‐ 12 ...
  • Page 178 TSG‐416 Engine Controls    GCP - Power Distribution Box Part of -5210070- Engine Wiring Harness   08 ‐ 13 ...
  • Page 179 TSG‐416 Engine Controls    Wire Colors Revision Level The following wiring schematics are taken from the wiring diagram labeled below:   08 ‐ 14 ...
  • Page 180 TSG‐416 Engine Controls    Power Distribution   08 ‐ 15 ...
  • Page 181 TSG‐416 Engine Controls    Ignition System   08 ‐ 16 ...
  • Page 182 TSG‐416 Engine Controls    Starting System   08 ‐ 17 ...
  • Page 183 TSG‐416 Engine Controls    Charging System   08 ‐ 18 ...
  • Page 184 TSG‐416 Engine Controls    Engine Controls - Sensors (1 of 2)   08 ‐ 19 ...
  • Page 185 TSG‐416 Engine Controls    Engine Controls - Sensors (2 of 2)   08 ‐ 20 ...
  • Page 186 TSG‐416 Engine Controls    Fuel Injectors   08 ‐ 21 ...
  • Page 187 TSG‐416 Engine Controls    Engine Controls - Actuator / Data Link Connector (DLC)   08 ‐ 22 ...
  • Page 188 TSG‐416 Engine Controls    Engine Controls - Dry Fuel DEPR   08 ‐ 23 ...

  • Page 189: Diagnostic Approach

    TSG‐416 Engine Controls    By repairing DTC 112 first, the problem causing the DTC DIAGNOSIS AND TESTING 122 may also be corrected. On-Board Diagnostics - GCP Diagnostic Approach The diagnostic tests and circuit charts are designed to assist Use the following step by step approach when diagnosing an the technician to locate a faulty circuit or component through engine performance problem: a process of logical decisions.
  • Page 190 TSG‐416 Engine Controls     Power Derate 2 DTC 2116: FPP2 higher than IVS limit.  DTC 2140: FPP2 lower than IVS limit.  The actuator is limited to a maximum opening of DTC 2126: FPP1 higher than FPP2. 20%. If “Power Derate 2” is active, it will remain ...

  • Page 191: Diagnosis Using A Personal Computer

    TSG‐416 Engine Controls     The MIL is off for 1.2 seconds between digits of three digit DTCs.  The MIL is off for 2.4 seconds between DTCs.  Each DTC repeats 3 times before the next stored DTC begins flashing  Up to 6 DTCs can be stored.
  • Page 192 TSG‐416 Engine Controls    Interface Hook-Up For a connection to a laptop, use the below ECOM cable (5080050). ECOM Cable  Software CD    08 ‐ 27 ...
  • Page 193 TSG‐416 Engine Controls    GCP Software Installation You will now see a welcome screen. Insert CD into CD-ROM drive. Double click “My Computer” Icon. Double Click CD-ROM drive letter This will display the contents of the CD as shown. Click next. A screen will pop up telling you the name of the destination folder.
  • Page 194 TSG‐416 Engine Controls    You will see an Installation Success” screen Follow those install instructions. Once when the software is finished installing. successfully installed reboot your system. The software is now installed on your system in a folder called “GCP Display”. Refer now to “Using Technicians GCP Software”...
  • Page 195 TSG‐416 Engine Controls    Diagnostic Trouble Codes Below is an example of a DTC Dialogue Box. The System Fault screen is used to view and clear DTC’s, which have been set. Snap Shot Data Checking Diagnostic Trouble Codes The Snap Shot Data is a listing of specific The System Fault screen contains a listing of all engine system variables.
  • Page 196 TSG‐416 Engine Controls    Flight Data Recorder Data Stream - Reading Sensor & Actuator The Flight Data Recorder is also a listing of Values specific engine system variables. These variables are recorded by the GCP for an interval of 10 seconds. The 10 second interval includes 8 seconds before the DTC sets and 2 seconds after the DTC sets.
  • Page 197 TSG‐416 Engine Controls    Plotting and Data Logging Below is a sample of a plot. Logging Logging variables means the variables are Recording the values and voltages can be a stored to the PC. During logging, there is no plot very useful tool while diagnosing engine shown on the screen.
  • Page 198 TSG‐416 Engine Controls    Ignition System Test Injector Test The Spark Kill diagnostic mode allows the The Injector Kill mode is used to disable technician to disable the ignition on individual individual fuel injectors. If the Injector Kill mode cylinders. If the Spark Kill diagnostic mode is is selected with the engine running below 1000 selected with the engine running below 1000 RPM, the minimum throttle command will lock...
  • Page 199 TSG‐416 Engine Controls    Throttle Test RAW VOLTS Screen The RAW VOLTS screen shows actual voltage readings from various circuits. To select this test mode the engine must be off, Use the keys at the upper left corner or but the key must be in the ON position. the “page”...
  • Page 200 TSG‐416 Engine Controls    Visual Inspection Intermittent Problems Perform a careful visual and physical engine inspection before performing any diagnostic NOTE: An intermittent problem may or may not procedure. Perform all necessary repairs before turn on the MIL or store a DTC. Do not use the proceeding with additional diagnosis, this can DTC charts for intermittent problems.

  • Page 201: Symptom Charts

    NOTE: If you have a symptom of the pedal not working, and no DTC is set, go to the voltage NOTE: EDI engines are used in many different screen and check pedal voltage. If pedal voltage applications and equipment. When performing is.75-1.25 volts, and idle validation switch says...

  • Page 202: Lack Of Power

    TSG‐416 Engine Controls    Engine Performance - While Under Load SYMPTOM POSSIBLE CAUSE  Engine Stalls/Quits Faulty OEM Drivers Safety Shut-off Seat Switch  Low Battery Voltage  Low Fuel Pressure  OEM Safety Shutdowns  Bad MAP Sensor  Air Restriction ...

  • Page 203: Black Smoke

    TSG‐416 Engine Controls    Engine Concerns SYMPTOM POSSIBLE CAUSE Oil System Concerns  Positive Crankcase Ventilation (PCV) System - High Oil Consumption  Oil Viscosity  External Leaks  Improper Oil Dipstick  Valve Seals  Cylinder Wall Taper Excessive  Worn Piston Rings Cooling System Concerns ...
  • Page 204 TSG‐416 Engine Controls      Engine Control Module (GCP) –   Diagnostic Trouble Codes   CAUTION: When checking codes with the   diagnostic software, the DTC terminal can   NOT be grounded.     CAUTION: Removing battery power before   accessing diagnostic program will erase all  ...
  • Page 205 TSG‐416 Engine Controls    4. Remove plug. REMOVAL AND INSTALLATION   Camshaft Position (CMP) Sensor - Crankshaft Position (CKP) Sensor - Replacement Installation 1. Position CKP sensor and loosely install the bolt. 2. Adjust the CKP sensor with the 1. Disconnect battery ground cable -- refer alignment tool and tighten 2 bolts.
  • Page 206 TSG‐416 Engine Controls    Engine Coolant Temperature (ECT) Heated Oxygen Sensor (HO2S) - Sensor- Replacement Replacement NOTE: Removal steps in this procedure may contain installation details. 1. Disconnect battery ground cable -- refer to section 6 NOTE: The sensor is located at the rear of the cylinder head.
  • Page 207 TSG‐416 Engine Controls    Knock Sensor (KS) – Replacement Temperature Manifold Absolute Pressure (TMAP) Sensor - Replacement 1. Disconnect battery ground cable -- refer to section 6. 1. Disconnect battery ground cable -- refer 2. Remove or disconnect any component to section 6. to allow access and removal of the 2.
  • Page 208 TSG‐416 Engine Controls    2. Disconnect the connector from the Actuator/Throttle Position (TP) throttle Sensor - Replacement 3. Remove the bolts from the throttle to the   intake manifold NOTE: The gasket is to be reused unless damaged. Installation 1. To install, reverse the removal procedure.
  • Page 209 TSG‐416 METRICS    INDEX      Subject                      Page Introduction………………………………………………….…………………………………………………………………  09 ‐ 2  Nomenclature for Bolts……………….…………….………………………………………………………………………….  09 – 2    Bolt Strength Identification ……………..………………………………………………………………………………….  09 – 3   …………………………………………………………………………………….……  09 – 3  Hex Nut Strength Identification Other Types of Parts 09 – 4  ……..……………………………………………………………………………. English/Metric conversion   09 – 5  ……………………………………..……………………………………. Decimal and Metric Equivalents……………………………………………………………………………………….  09 – 6  Torque Conversion………………………………………………………………………………………………………….. ...
  • Page 210 TSG‐416 METRICS    INTRODUCTION  Most threaded fasteners are covered by specifications that define required mechanical properties, such as tensile strength, yield strength, proof load and hardness. These specifications are carefully considered in initial selection of fasteners for a given application. To ensure continued satisfactory vehicle performance, replacement fasteners used should be of the correct strength, as well as the correct nominal diameter, thread pitch, length, and finish.
  • Page 211 TSG‐416 METRICS    BOLT STRENGTH IDENTIFICATION English System English (inch) bolts: Identification marks correspond to bolt strength, increasing number of slashes represent increasing strength. Metric System Metric (mm) bolts: Identification class numbers correspond to bolt strength, increasing numbers represent increasing strength. Common metric fastener bolt strength properties are 9.8 and 10.9 with the class identification embossed on the bolt head.

  • Page 212: Other Types Of Parts

    TSG‐416 METRICS    OTHER TYPES OF PARTS Metric identification schemes vary by type of part, most often a variation of that used of bolts and nuts. Note that many types of English and Metric fasteners carry no special identification if they are otherwise unique.
  • Page 213 TSG‐416 METRICS    ENGLISH/METRIC CONVERSION 09 ‐ 5 ...
  • Page 214 TSG‐416 METRICS    DECIMAL AND METRIC TORQUE CONVERSION EQUIVALENTS 09 ‐ 6 ...
  • Page 215 TSG‐416 METRICS    J1930 TERMINOLOGY LIST Certain Ford Component names have been changed in this Service Manual to conform to Society of Automotive Engineers (SAE) directive J1930. SAE J1930 standardizes automotive component names for all vehicle manufacturers. 09 ‐ 7 ...
  • Page 216 TSG‐416 METRICS    09 ‐ 8 ...
  • Page 217 TSG‐416 METRICS    09 ‐ 9 ...
  • Page 218 TSG‐416 METRICS    09 ‐ 10 ...
  • Page 219 TSG‐416 METRICS    09 ‐ 11 ...
  • Page 220 TSG‐416 METRICS    09 ‐ 12 ...
  • Page 221 TSG‐416 METRICS    09 ‐ 13 ...
  • Page 222 TSG‐416 METRICS    09 ‐ 14 ...
  • Page 223 EDI Ford Industrial Engine Distributor List AUSTRALIA 10 Wilmette Place                       Mona Vale                                     All Marine Spares 61‐2‐99972788 N.S.W.                                            Australia 2103 EUROPE 45, Rue Charles Nodier, 93310 Le‐ 33‐148‐450‐394 33 FRANCE Fornaut S.A. Pre‐St.‐Gervais France 148‐457‐504 Sauer & Sohn Sauer  Gross Zimmerner Strasse 51 D‐ 49‐6071‐206‐330  GERMANY Motive Systems 64807 Dieburg Germany  49‐6071‐206‐219 School Lane Chandlers Ford  Industrial                            Estate,     44‐2380‐579‐800  GREAT BRITAIN Hendy Power Eastleigh, Hampshire  SO53 4DG  44‐2380‐271‐471 England Power Torque  Herald Way, Binly, Conventry  44‐2476‐635‐757   Engineering Warwichshire CV3 2RQ England 44‐2476‐635‐878 Compagnia    Via Magellano 1, I‐20090    39‐02‐450‐581   39‐ ITALY Technica Motori  ...
  • Page 224 NORTH AMERICA ‐ UNITED STATES 5400 C.W. Post Road              ALABAMA Engines, Inc. 1‐800‐562‐8049 Jonesboro, AR 72401                        6100 S. 6th Way                       ALASKA Perkins Pacific 877‐877‐3311 Ridgefield, WA 98642 Southwest Power  5143 W. Roosevelt           Phoenix,  ARIZONA 602‐269‐3581 Products AX 85043 5400 C.W. Post Road              ARKANSAS Engines, Inc. 1‐800‐562‐8049 Jonesboro, AR 72401                        1‐559‐264‐1776    Powertech Engines  2933 E. Hamilton Ave.               CALIFORNIA 1‐800‐891‐1776    Inc (Main Office) Fresno, CA 93721  1‐559‐264‐2933 1410 South Acacia Ave.              1‐714‐635‐1774    Powertech Engines  Suite B                                              1‐800‐678‐3673    Inc. Fullerton, CA 92831 1‐714‐635‐1771 Anderson Industrial  5532 Center Street                            COLORADA 402‐558‐8700 Engines Co.
  • Page 225 NORTH AMERICA ‐ UNITED STATES 5400 C.W. Post Road              LOUISIANA Engines , Inc. 1‐800‐562‐8049 Jonesboro, AR 72401                        Engine Distributors  41 Pope Road                               MAINE 1‐800‐220‐2700 Inc.  Holliston, MA 01746 Engine Distributors  400 University Court                    MARYLAND 1‐800‐220‐2700 Inc.  Blackwood, NJ 08012 Engine Distributors  41 Pope Road                               MASSACHUSETTS 1‐800‐220‐2701 Inc.  Holliston, MA 01746 1217 East Grand River                      MICHIGAN McDonald Equip. 1‐800‐445‐5273 Portland, MI 48875 Diesel Power  13619 Industrial Rd.                         MINNESOTA 800‐999‐5689 Equipment Omaha, NE 68137 5400 C.W. Post Road              MISSISSIPPI Engines, Inc. 1‐800‐562‐8049 Jonesboro, AR 72401                        Diesel Power ...
  • Page 226 NORTH AMERICA ‐ UNITED STATES Engine Distributors  400 University Court                    EASTERN PENNSYLVANIA 1‐800‐220‐2700 Inc.  Blackwood, NJ 08012 37200 Vine St.                          WESTERN PENNSYLVANIA McDonald Equip. 1‐800‐589‐9025 Willoughby, Ohio 44094 Engine Distributors  41 Pope Road                               RHODE ISLAND 1‐800‐220‐2700 Inc.  Holliston, MA 01746 Engine Distributors  259 Ellis Rd. South                          SOUTH CAROLINA 1‐800‐220‐2700 Inc.  Jacksonville, FL 32254 Diesel Power  13619 Industrial Rd.                         SOUTH DAKOTA 800‐999‐5689 Equipment Omaha, NE 68137 5400 C.W. Post Road              TENNESSEE Engines, Inc. 1‐800‐562‐8049 Jonesboro, AR 72401                        1906 S. Great S.W. Parkway         TEXAS M.G. Bryan 972‐623‐4300 Grand Prairie, TX 75051 6100 S. 6th Way                      ...
  • Page 227 NORTH AMERICA  ‐ CANADA 14355 120th Ave.                              ALBERTA,                       Industrial Engines  Edmonton, Alberta Canada,            780‐484‐6213 SASKATCHEWAN Ltd.  T5L 2R8 ALBERTA,                       8750‐58th Avenue, Edmonton,AB  Simson Maxwell 1‐800‐374‐6766 SASKATCHEWAN Canada T6E 6G6 ALBERTA,                       5711‐80 Avenue SE,Calgary,AB  Simson Maxwell 1‐800‐374‐6766 SASKATCHEWAN Canada T2C 4S6 1605 Kebet Way Port C, BC      BRITISH COLUMBIA Simson Maxwell 1‐800‐374‐6766 Canada V3C 5W9 #12‐4131 Mostar Road, Nanaimo  Simson Maxwell 1‐800‐374‐6766 BC, Canada V9T 5P8 1846 Quinn Street, Prince  Simson Maxwell 1‐800‐374‐6766 George, BC Canada V2L 3H4 8550 Delmeade                                  MONTREAL MARINDUSTRIAL Montreal, QUEBEC Canada,             514‐342‐2748 H4T 1L7 NEW BRUNSWICK, NOVA ...
  • Page 228 EDI Worldwide Service Engine Distributors Inc. 400 University Court Blackwood, NJ 08012 Service/Warranty 1‐800‐220‐2700 1‐856‐228‐7298 1‐856‐228‐5657 (fax parts & service) 1‐856‐228‐5531 (fax sales)

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