ESG-642 42 LITER INDUSTRIAL ENGINE SERVICE MANUAL FPP-194-309 April, 2001 Ford Power Products 28333 Telegraph Rd, Suite 300 Southfield, MI 48034 248 945 4500 (Fax) 248 945 4501 Ford Power Products, LTD 20/586 Arisdale Avenue South Ockendon Essex, RM 15 5TJ England 44 1708 672 415 (Fax) 44 1708 672 815 Ford Power Products, GmbH Stolberger Str 313 D-50933 Köln, Germany 49 221 94700 551 (Fax) 49 221 94700 560 HEALTH & SAFETY ! WARNING: THE FOLLOWING HEALTH AND SAFETY RECOMMENDATIONS SHOULD BE CAREFULLY OBSERVED. CARRYING OUT CERTAIN OPERATIONS AND HANDLING SOME SUBSTANCES CAN BE DAN- GEROUS OR HARMFUL TO THE OPERATOR IF THE CORRECT SAFETY PRECAUTIONS ARE NOT OBSERVED. SOME SUCH PRECAUTIONS ARE RECOMMENDED AT THE APPROPRIATE POINTS IN THIS BOOK. WHILE IT IS IMPORTANT THAT THESE RECOMMENDED SAFETY PRECAUTIONS ARE OB- SERVED, CARE NEAR MACHINERY IS ALWAYS NECESSARY, AND NO LIST CAN BE EXHAUS- TIVE. ALWAYS BE CAUTIOUS TO AVIOD POTENTIAL SAFETY RISKS. The following recommendations are for general guidance: 1. Always wear correctly fitting protective clothing which should be laundered regularly. Loose or baggy clothing can be extremely dangerous when working on running engines or machinery. Clothing which becomes impregnated with oil or other substances can constitute a health hazard due to prolonged contact with the skin even through underclothing. 2. So far as practicable, work on or close to engines or machinery only when they are stopped. If this is not practicable, remember to keep tools, test equipment and all parts of the body well away from the moving parts of the engine or equipment—fans, drive belts and pulleys are particularly dangerous. The electric cooling fan used on some installations is actuated automatically when the coolant reaches a specified temperature. For this reason, care should be taken to ensure that the ignition/isolating switch is OFF when working in the vicinity of the fan as an increase in coolant temperature may cause the fan suddenly to operate. 3. Avoid contact with exhaust pipes, exhaust manifolds and silencers when an engine is, or has recently been running; these can be very hot and can cause severe burns. 4. Many liquids used in engines or vehicles are harmful if taken internally or splashed into the eyes. In the event of accidentally swallowing gasoline (petrol), oil, diesel fuel, antifreeze, battery acid etc, DO NOT ENCOURAGE VOMITING AND OBTAIN QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY. Wear protective goggles when handling liquids which are harmful to the eyes; these include ammonia and battery acid. If any of these substances are splashed in the eyes, wash out thoroughly with clean water and OBTAIN QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY. ! WARNING: ! The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all industrial engines as well as the personal safety of the individual doing the work. This Service Manual provides general directions for accomplishing service and repair work with tested, effective techniques. Following them will help assure reliability. Section 01 ESG-642 Section 02 ENGINE - 4 2L Section 03 IGNITION Section 04 FUEL Section Index Section 05 COOLING Section 06 CHARGING Reproduction in any manner, in whole or in part, is prohibited without the express permission in writing from: Section 07 STARTER Ford Power Products, Marketing Department Ford Power Products policy is one of continuous ELECTRONICS & DIAGNOSTIC improvement and while every effort is made to ensure Section 08 that this publication is up to date and correct in all TROUBLE CODES respects, the right to change prices, specifications and equipment at any time without notice is reserved Accordingly this publication is not to be regarded as a final description of any individual engine Section 09 METRICS Section 10 DEALERS ESG-642 INDEX SUBJECT PAGE SUBJECT PAGE 01 Description ................................................................... 01-3 Diagnosis And Testing (Continued) Introduction .................................................................. 01-3 Valves and Cylinder Head .........................................01-22 Engine Identification Nameplate ................................. 01-3 Valve Train Analysis – Dynamic .................................01-22 Rocker Arm ................................................................01-22 Safety Notices .............................................................. 01-5 Push Rods .................................................................01-22 Notes, Cautions and Warnings ................................... 01-5 Positive Rotator and Valve Spring Retainer Keys .....01-22 General Warnings ........................................................ 01-5 Valves and Cylinder Head .........................................01-22 Camshaft Lobe Lift .....................................................01-22 Battery Handling And Charging .................................. 01-6 OHV Engines .............................................................01-22 Typical Engine With Push Rods .................................01-22 Foreward ....................................................................... 01-7 Hydraulic Valve Tappet ..............................................01-23 Engine Identification .................................................... 01-7 Leakdown Testing ......................................................01-23 European Service Identification Plate ........................ 01-8 General Service Procedures ....................................01-25 Sprockets ...................................................................01-25 U.S.A. Engine Identification Decal .............................. 01-9 Gears .........................................................................01-26 Camshaft Journal Diameter .......................................01-26 Description And Operation ........................................01-10 Camshaft Journal Clearance – OHV Engines ..........01-27 Engine System ...........................................................01-10 Camshaft Lobe Surface .............................................01-27 Camshaft Lobe Lift .....................................................01-28 Diagnosis And Testing ...............................................01-11 Camshaft Runout .......................................................01-28 Engine System ...........................................................01-11 Crankshaft Main Bearing Journal Diameter ..............01-29 Special Tools..............................................................01-11 Crankshaft Main Bearing Journal Taper....................01-29 Inspection and Verification .........................................01-11 Crankshaft Main Bearing Journal Clearance ............01-30 Symptom Chart ..........................................................01-11 Bearing Inspection .....................................................01-31 Component Tests .......................................................01-14 Crankcase End Play ..................................................01-31 Engine Oil Leaks .......................................................01-14 Cylinder Bore Taper ...................................................01-33 Fluorescnt Oil Aditive Method ....................................01-14 Cylinder Bore Out-of-Round ......................................01-33 Pressure Method .......................................................01-15 Piston Inspection .......................................................01-33 Testing Procedure ......................................................01-15 Piston Diameter .........................................................01-34 Leakage Points ..........................................................01-15 Piston to Cylinder Bore Clearance ............................01-34 Under Engine ............................................................01-15 Piston Selection .........................................................01-35 With Transmission and Flywheel Removed ..............01-15 Piston Ring End Gap .................................................01-35 Compression Tests ....................................................01-15 Piston Ring-to-Groove Clearance .............................01-36 Test Results ................................................................01-16 Crankshaft Connecting Rod Journal Diameter .........01-37 Compression Pressure Limit Chart ...........................01-16 Crankshaft Connecting Rod Journal Taper ...............01-37 Interpreting Compression Readings .........................01-16 Connecting Rod Cleaning .........................................01-38 Cylinder Leakage Detection ......................................01-17 Connecting Rod Larger End Bore .............................01-38 Oil Leak and Valve Stem Seal Test ............................01-17 Piston Pin Diameter ...................................................01-39 Intake Manifold Vacuum Test .....................................01-17 Connecting Rod Bushing Diameter ..........................01-39 Interpreting Vacuum Gauge Readings ......................01-17 Connecting Rod Bend ...............................................01-40 Excessive Engine Oil Consumption ..........................01-19 Connecting Rod Twist ................................................01-40 Oil