Ford VSG-411 and 413 service manual

VSG-4111413 ENGINE The SERVICE MANUAL I uwer... Worldwide TM For Engines Produced 1993 and Later

IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles as well as the personal safety of the individual doing the work. This Shop Manual provides general direc- tions for accomplishing service and repair work with tested, effective techniques. Following them will help assure reliability. There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well as in the skill of the individual doing the work. This Manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in this Manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts. NOTES, CAUTIONS, AND WARNINGS As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is there for a specific purpose. NOTES give you added information that will help you to complete a particular procedure. CAUTIONS are given to prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury. The following list contains some general WARNINGS that you should follow when you work on a vehicle. Always wear safety glasses for eye protection. Use safety stands whenever a procedure requires you to be under the vehicle. Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure. Set the parking brake when working on the vehicle. If you have an automatic transmission, set it in PARK unless instructed otherwise for a specific operation. If you have a manual transmission, it should be in REVERSE (engine OFF) or NEUTRAL (engine ON) unless instructed otherwise for a specific operation. Place wood blocks (4” x 4” or larger) to the front and rear surfaces of the tires to provide further restraint from inad- vertent vehicle movement. 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. 60 not smoke while working on the vehicle To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle. Tie long hair securely behind the head. 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 though the ignition is in the OFF position. Therefore, care should be taken to ensure that the electric cooling fan is completely disconnected when workina under the hood. The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

Introduction In general, this manual covers the servicing of the engine and asso- ciated standard equipment. In many cases, engines are supplied with accessories and equipment that are unique to the application. If service information is ever required on such unique accessories or equipment it is suggested that Power Products Division/GRI be con- tacted. The proper information will either be forwarded or the Ser- vice Technician will be advised where it can be obtained. The information in this manual is grouped in sections according to the type of work being performed. The various sections are 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. POWER PRODUCTS DIVISION/GRI The Source for Power... 28333 TELEGRAPH ROAD - #300 Worldwide rev SOUTHFIELD, MICHIGAN 48034 The descriptions and specifications contained in this manual were in effect at the time the book was released for printing. Power Products Division/GM 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 ___ - -- I_ I . . . . . . .I

01-l Basic Engine 01-I SECTION TITLE PAGE SECTION TITLE PAGE BASICENGINE ....................................... 01-l STARTING SYSTEM .................................. 051 IGNITION SYSTEM - DISTRIBUTORLESS ............... 02-l GOVERNOR ......................................... 06-l FUEL SYSTEM ....................................... 03-I COOLING SYSTEM ................................... 07-I EMISSION CONTROL SYSTEM ........................ 03A-1 SPECIFICATIONS .................................... 08-l CHARGINGSYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-l SECTION 01 - Basic Engine SUBJECT PAGE IDENTIFICATION ..................................... 01-3 DESCRIPTION ....................................... 01-4 DIAGNOSIS AND TESTING ............................ 01-6 Camshaft Lobe Lift ................................ 01-6 Compression Test ................................. 01-6 Compression Gauge Check ...................... 01-6 Test Conclusion ................................. 01-6 Crankshaft End Play ............................... 01-7 Flywheel Face Runout ............................. 01-7 Camshaft End Play ................................ 01-7 OVERHAUL .......................................... 01-8 Cylinder Head ..................................... 01-8 Reaming Valve Guides ........................... 01-8 Refacing Valve Seats ............................ 01-8 Valves.. .......................................... 01-8 Refacing Valves ................................. 01-8 Select Fitting Valves ............................. 01-9 Camshaft Repair .................................. 01-9 Crankshaft ........................................ 01-9 Refinishing Journals ............................ 01-9 Fitting Main or Connecting Rod Bearings With Plastigage ............................... 01-9 Pistons, Pins and Rings ........................... 01-10 Fitting Pistons .................................. 01-l 0 Fitting Piston Rings ............................. 01-10 Fitting Piston Pins ............................... 01-11 Valve Rocker Arm and/or Shaft Assembly ........... 01-11 PushRods ........................................ 01-11 Cylinder Block .................................... 01-11 Refinishing Cylinder Walls ....................... 01-11 Repairing Sand Holes or Porous Engine Castings ...................................... 01-11 CLEANING AND INSPECTION ......................... 01-l 2 Intake Manifold .................................... 01-I 2 Exhaust Manifolds ................................. 01-l 2 Valve Rocker Arm and/or Shaft Assembly ........... 01-12 PushRods.. ...................................... 01-12 SUBJECT PAGE Cylinder Heads .................................... 01-12 Tappets ........................................... 01-14 Timing Chain and Sprockets ....................... 01-14 Camshaft ......................................... 01-14 Camshaft Bores ................................... 01-I 4 Crankshaft ........................................ 01-I 4 Flywheel .......................................... 01-l 5 Connecting Rods .................................. 01-l 5 Pistons, Pins and Rings ........................... 01-16 Main and Connecting Rod Bearings ................. 01-16 Cylinder Block .................................... 01-l 6 Oil Pan ........................................... 01-17 Oil Pump ......................................... 01-17 REMOVAL AND INSTALLATION ........................ 01-I 9 Valve Rocker Arm Cover, Rocker Arm and/or Shaft ... 01-19 Intake Manifold .................................... 01-I 9 Exhaust Manifold .................................. 01-l 9 Cylinder Head ..................................... 01-20 Valve Spring, Retainer and Stem Seal ............... 01-21 Cylinder Head Removed ......................... 01-21 Cylinder Head Installed .......................... 01-21 Water Pump ....................................... 01-22 Cylinder Front Cover and Timing Chain, or Crankshaft Sprockets ............................ 01-22 Adjusting Valve Clearances ........................ 01-23 Crankshaft Front Oil Seal .......................... 01-24 Camshaft and/or Valve Lifters ...................... 01-24 Camshaft Bearings ................................ 01-25 Oil Pump ......................................... 01-26 Oil Pan ........................................... 01-26 Flywheel Ring Gear ................................ 01-26 Crankshaft Rear Oil Seal ........................... 01-27 Pistons and Connecting Rods ...................... 01-27 Oil Filter .......................................... 01-28 DISASSEMBLY AND ASSEMBLY ....................... 01-29 Engine Assembly .................................. 01-29 Oil Pump ......................................... 01-32

01-2 Basic Engine 01-2 BLANK

01-3 Basic Enaine 01-3 IDENTIFICATION An Identification Decal is affixed to the left side of the rocker cover of each engine. The decal contains the engine serial number which identifies this unit from all others. Next is the engine displacement which determines the engine specifications, then the model number and S.O. or special options which determine the parts or components required on this unit. Use all numbers when seeking information or ordering replacement parts for this engine. Identification of the cylinder block and therefore of the basic engine type can be made by reference to the stampings on the left rear top edge of the cylinder block. A SERIAL NUMBER B ENGINE CODE C ENGINE BUILD DATE The engine code will begin with a “G” This will indicate that it is a 1.I liter engine. The engine build date follows the corporate system. Example: “4K26”. The first number indicates the year. The letter indicates the month in alphabetical sequence, A January, B February, etc. omitting I. The last two numbers are the day of the month.

01-4 DESCRIPTION Basic Engine 01-4 The engine is a water-cooled, 4 cylinder, 4 stroke, in-line The oil pump is bolted onto the outside of the cylinder block gasoline engine. The cylinder head in which the combustion chambers are located is of a cross-flow type, the fresh fuel/air mixture is drawn in on one side and burnt gases are passed into the exhaust system on the opposite side. The valves are suspended in the cylinder head and are operated by means of tappets, pushrods and rocker arms. The valves are disposed in an alternating pattern in the cylinder head starting with an exhaust valve by the thermostat housing. The three-bearing camshaft is located on the right side of the cylinder block and driven by roller chain from the crankshaft. The common driving gear shared by the distributor and oil pump is located behind the second cam on the camshaft, the eccentric cam driving the fuel pump is located between the sixth and seventh cams. below the distributor. The full-flow oil filter is angled downwards and mounted directly on the oil pump. The crankshaft is mounted in five bearings. The crankshaft end play is determined by thrust half rings at the center main bearing. The front crankshaft journal is sealed by means of an oil seal installed in the timing cover. The rear crankshaft journal is sealed by means of an oil seal pressed into an oil seal carrier. The timing cover has cast ignition timing degree marks or a TDC reference pointer. A notch on the crankshaft belt pulley is used in conjunction with either the degree or TDC reference points when installing the distributor and checking timing. They are visible on the front, left side of the engine.

01-5 Basic Engine 01-5 DESCRIPTION (Continued) The spark plugs have a tapered seat without a sealing ring. The result is a closed ventilation system in which the fumes Engine Ventilation: from the crankcase pass back via the inlet manifold into the The ventilation system consists of an oil filler cap with two cylinders for combustion. connecting hoses, one of which passes to the inlet Gas flow is regulated by a calibrated orifice in the oil filler manifold and the other to the air cleaner. cap. A VENTILATION AT IDLE SPEED AND HALF THROTTLE B VENTILATION AT FULL THROTTLE HOSE CONNECTION TO AIR C PRESS IN ORIFICE HOSE C INTAKE MANIFOLD VACUUM FITTING Lubrication Circuit: An eccentric twin-rotor oil pump draws oil via a strainer from the sump and forces it into the full-flow oil filter. Oil pressure is regulated by a relief valve inside the pump. The filtered oil passes through the center of the filter element, then along a short passage (right hand side of the engine) to the oil pressure switch and through a transverse bore to the main oil gallery (left hand side of the engine). The crankshaft main bearings are fed directly from the main oil gallery and the camshaft bearings are linked, in turn for their lubrication with the front, center and rear main bearings. Each of the rod journals are supplied with oil by the nearest main bearing through oblique passages. An oil hole in the connecting rod ensures splash lubrication of the piston pins and the trailing side of the cylinders. Timing chain and sprockets are also lubricated via a splash hole. The camshaft front bearing journal has a machined groove through which oil is intermittently forced to the rocker shaft (via passages in cylinder block and cylinder head). LUBRICATION CIRCUIT

01-6 Basic Enaine 01-6 DIAGNOSIS AND TESTING Camshaft Lobe Lift Compression Test Check the lift of each lobe in consecutive order and make a note of the readings. 1. Remove the air cleaner and the valve rocker arm cover. 2. Remove the valve rocker arm shaft assembly as detailed in the pertinent section. 3. Make sure the push rod is in the valve lifter socket. Install a dial indicator in such a manner as to have the ball socket adapter of the indicator on the end of the push rod and in the same plane as the push rod movement. Compression Gauge Check 1. Be sure the crankcase is at the proper level and the battery is properly charged. Operate the engine for a minimum of 30 minutes at 1200 rpm or until the engine is at normal operating temperature. Turn the ignition switch off; then remove all the spark plugs. 2. Set the carburetor throttle plates and choke plate in the wide open position. 3. Install a compression gauge in No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. Using the auxiliary starter switch, crank the engine (with the ignition switch off) at least five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder as was required to obtain the highest reading on the No. 1 cylinder. Test Conclusion 1-A 4. Connect an auxiliary starter switch in the starting circuit. Crank the engine with the ignition switch OFF. Bump the crankshaft over until the tappet or lifter is on the base circle of the camshaft lobe. At this point, the push rod will be in its lowest position. 5. Zero the dial indicator. Continue to rotate the crankshaft slowly until the push rod is in the fully raised position (highest indicator reading). 6. Compare the total lift recorded on the indicator with specifications. 7. To check the accuracy of the original indicator reading, continue to rotate the crankshaft until the indicator reads zero. If the lift on any lobe is below specified wear limits, the camshaft and the valve lifters operating on the worn lobe(s) must be replaced. 8. Remove the dial indicator and auxiliary starter switch. 9. Install the rocker arm shaft assembly as detailed under Removal and Installation. IO. Install the valve rocker arm cover and the air cleaner. The indicated compression pressures are considered normal if the lowest reading cylinder is within 75% of the highest. Refer to the following example. Seventy-five percent of 140, the highest cylinder reading, is 105. Therefore, cylinder No. 7 being less than 75% of cylinder No. 3 indicates an improperly seated valve or worn or broken piston rings. If one or more cylinders read low, squirt approximately 15 ml (one tablespoon) of engine oil on top of the pistons in the low reading cylinders. Repeat compression pressure check on these cylinders. 1. If compression improves considerably, the piston rings are at fault. 2. If compression does not improve, valves are sticking or seat ing poorly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on the pistons does not increase the compression, the cause may be a cylinder head gasket leak between the cylinders. Engine oil and/or coolant in the cylinders could result from this problem. It is recommended the following quick reference chart be used when checking cylinder compression pressures. The chart has been calculated so that the lowest reading number is 75% of the highest reading. Example After checking the compression pressures in all cylinders, it was found that the highest reading obtained was 196 psi. The lowest pressure reading was 155 psi. The engine is within specifications and the compression is considered satisfactory.

01-7 Basic Engine 01-7 DIAGNOSIS AND TESTING (Continued) Maximum Minimum Maximum Minimum kPa PSI kPa PSI kPa PSI kPa PSI 924 134 696 101 1200 174 903 131 938 136 703 102 1214 176 910 132 952 138 717 104 1227 178 917 133 965 140 724 105 1241 180 931 135 979 142 738 107 1255 182 938 136 993 144 745 108 1269 184 952 138 1007 146 758 110 1282 186 965 140 1020 148 765 111 1296 188 972 141 1034 150 779 113 1310 190 979 142 1048 152 786 114 1324 192 993 144 1662 154 793 115 1338 194 1000 145 1076 156 807 117 1351 196 1014 147 1089 158 814 118 1365 198 1020 148 1103 160 827 120 1379 200 1034 150 1117 162 834 121 1393 202 1041 151 1131 164 848 123 1407 204 1055 153 1145 166 855 124 1420 206 1062 154 1158 168 869 126 1434 208 1076 156 1172 170 -876 127 1448 210 1083 157 1186 172 889 129 1462 212 1089 158 Maximum Minimum kPa PSI kPa PSI 1476 214 1103 160 1489 216 1117 162 1503 218 1124 163 1517 220 1138 165 1531 222 1145 166 1544 224 1158 168 1558 226 1165 169 1572 228 1179 171’ 1586 230 1186 172 1600 232 1200 174 1613 234 1207 175 1627 236 1220 177 1641 238 1227 178 1655 240 1241 180 1669 242 1248 181 1682 244 1262 183 1696 246 1269 184 1710 248 1282 186 1724 250 1289 187 Crankshaft End Play 1. Force the crankshaft toward the rear of the engine. 2. Install a dial indicator so that the contact point rests against the crankshaft flange and the indicator axis is parallel to the crankshaft axis. 3. Zero the dial indicator. Push the crankshaft forward and note the reading on the dial. 4. If the end play exceeds the wear limit, replace the thrust washers. If the end play is less than the minimum limit, inspect the thrust bearing faces for scratches, burrs, nicks, or dirt. Camshaft End Play Push the camshaft toward the rear of the engine. Install a dial indicator so that the indicator point is on the camshaft sprocket attaching screw or gear hub. Zero the dial indicator. Position a large screwdriver between the camshaft sprocket and the cylinder head. Pull the camshaft forward and release it. Compare the dial indicator reading with specifications. If the end play is excessive, replace the thrust plate retaining the camshaft. Remove the dial indicator. Flywheel Face Runout Install a dial indicator so that the indicator point bears against the flywheel face. Turn the flywheel, making sure that it is full forward or rearward so that the crankshaft end play will not be indicated as flywheel runout. If the clutch face runout exceeds specifications, remove the flywheel and check for burrs between the flywheel and the face of the crankshaft mounting flange. If no burrs exist, check the runout of the crankshaft mounting flange. Replace the flywheel, or machine the crankshaft-flywheel mounting face sufficiently to true up the surface if the mounting flange runout exceeds specifications. Replace it or reinstall it on the flywheel.

Ford VSG-411 and 413 service manual

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