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LSG 875
Service manual
Ford LSG 875 Service Manual
Lsg 875
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Safety Notice
Table of Contents
7.5 Liter Engines
Basic Engine
Section Title
Industrial and Irrigation Identification
Marine Identification
Description and Operation
Manifolds
Cylinder Heads
Cylinder Block
PART1 Basic Engine
Valve Train
Oil (Engine) - Health Warning
Lubrication System
Positive Crankcase Ventilation System
Compression Gauge Check
Camshaft Lobe Lift
Compression Test
Compression Test Conclusion
Hydraulic Valve Lifter
Crankcase Ventilation Regulator Valve Test
Positive Closed-Type Ventilation System
Crankshaft End Play
Flywheel Face Runout
Camshaft End Play
Timing Chain Deflection
Exhaust Manifolds Cleaning and Inspection
Valve Rocker Arm Cleaning and Inspection
Cleaning and Inspection
Intake Manifold
Push Rods
Cylinder Heads Cleaning and Inspection
Hydraulic Valve Lifters Cleaning and Inspection
Crankshaft Vibration Damper and Spacer Cleaning and Inspection
Timing Chain and Sprockets Cleaning and Inspection
Camshaft Cleaning and Inspection
Crankshaft Cleaning
Flywheel Inspection
Connecting Rods Cleaning and Inspection
Pistons, Pins and Rings Cleaning and Inspection
Basic Engine
Main and Connecting Rod Bearings Cleaning and Inspection
Cylinder Block Cleaning and Inspection
Oil Pan Cleaning and Inspection
Oil Pump Cleaning and Inspection
Positive Closed-Type Crankcase Ventilation System Cleaning/Inspection
Cylinder Head Overhaul
Reaming Valve Guides
Refacing Valve Seats
Camshaft Repair
Refacing Valves
Select Fitting Valves
Valves
Crankshaft
Fitting Main or Connecting Rod Bearings with Plastigage
Refinishing Journals
Fitting Piston Rings
Fitting Pistons
Pistons, Pins and Rings
Cylinder Block/Refinishing Cylinder Walls
Push Rods
Repairing Sand Holes or Porous Engine Castings
Valve Rocker Arm
Valve Clearance Adjustment
Overhaul
Adjustments
Crankcase Ventilation System Removal and Installation
Valve Rocker Arm Cover and Rocker Arm Removal and Installation
Valve Spring, Retainer and Stem Seal Removal and Installation
Intake Manifold Removal and Installation
Valve Tappet Removal and Installation
Cylinder Heads Removal and Installation
Exhaust Manifold Removal and Installation
Water Pump Removal and Installation
Cylinder Front Cover and Timing Chain Removal
Cylinder Front Cover and Timing Chain Installation
Front Oil Seal Removal and Installation
Camshaft Removal
Camshaft Installation
Core Plugs Removal
Core Plugs Installation
REMOVAL and INSTALLATION (Cont' D)
Crankshaft Rear Oil Seal Removal and Installation
Oil Pan Removal and Installation
Oil Pump Removal and Installation
Main Bearings Removal and Installation
Connecting Rod Bearing Removal and Installation
Pistons and Connecting Rods Removal and Installation
Crankshaft Removal and Installation
Camshaft Bearings Removal and Installation
Cylinder Head Disassembly and Assembly
Oil Filter Removal and Installation
Piston and Connecting Rod Disassembly and Assembly
Cylinder Assembly Disassembly and Assembly
Cylinder Block Disassembly and Assembly
Oil Pump Disassembly and Assembly
Ignition System
Solid State Ignition Description
Description
Ignition System Diagrams
Ignition System Diagnosis and Testing
Initial Ignition Timing Adjustments
Diagnosis and Testing
Start Circuit Test
Run Circuit Test
Module Voltage Test
Ballast Resistor Test
Supply Voltage Circuits Test
Distributor Stator Assembly and Wiring Harness Test
Ignition Coil Supply Voltage Test
Ignition Coil Secondary Resistance Test
Distributor Stator Assembly Test
Module to Coil Wire Test
Ignition Coil Primary Resistance Test
Primary Circuit Continuity Test
Distributor Ground Circuit Continuity Test
Ground Circuit Continuity Test
Distributor Removal and Installation
Diaphragm Assembly Removal and Installation
Distributor Cap, Adapter and Rotor Removal and Installation
Stator Assembly Removal and Installation
Distributor Assembly Cleaning and Inspection
Distributor Cap and Rotor Cleaning and Inspection
Ignition Wires Removal and Installation
Spark Plugs Removal and Installation
CLEANING and INSPECTION (Cont' D)
Ignition Coil Cleaning and Inspection
Ignition Wires Cleaning and Inspection
Spark Plugs Cleaning and Inspection
Adjustments and Repairs
Breaker Plate and Sub-Plate Removal and Installation
Breaker Points And/Or Condenser Removal and Installation
Prestolite Distributors (Marine and Irrigation Engines) Description and Operation
Cam and Centrifugal Advance Weights Removal and Installation
Distributor - Removal and Installation
Bench Disassembly
Conventional Ignition System Distributor
Ignition System - Major Repair Operations
Bench Assembly
Major Repair Operations
New Shaft and Gear
Original Shaft and Gear
Mechanical Operation
Dwell Angle
Distributor Spark Advance Test
Centrifugal Advance
Fuel System
Fuel System Diagnosis and Testing
Fuel Pump Assembly Removal and Installation
Pressure and Capacity (Volume) Testing
Model 2300 2-V Carburetor Description
Carburetor Systems
Fuel Inlet System
Idle Fuel System
Main Metering System
Power Fuel System
Accelerating Pump System
Idle Mixture Adjustment
Erratic Engine Idle
Low Idle Speed Adjustment
Accelerator Pump Lever Adjustment/Accelerating Pump Stroke Adjustment
Fuel Level Float Adjustment - Dry
Fuel Level Adjustment - Wet
To Lower Fuel Level
To Raise Fuel Level
Accelerating Pump Diaphragm Removal and Installation
Carburetor Removal and Installation
Power Valve and Gasket Removal and Installation
Fuel Bowl and Gasket Metering Block and Gasket Removal/Installation
Fuel Inlet Needle and Seat Removal and Installation
Carburetor Disassembly and Assembly
Fuel Bowl and Metering Block
Main Body
Throttle Operating Shaft Housing
Carburetor Cleaning and Inspection
Carburetor Assembly
Throttle Body
Carburetor Exploded View
Model 4160 Carburetor Systems
Fuel Inlet System (4160)
Idle System (4160)
Main Metering System (Primary) (4160)
Power Enrichment System (Primary) (4160)
Accelerator Pump System
Integral Automatic Choke
Choke Systems
Electric Chokes
Hand Operated Chokes
Vacuum Systems Secondary Operation
Secondary Fuel Metering Systems
4160 Carburetor Service Procedures
4160 Carburetor Disassembly
4160 Carburetor View
4160 Carburetor Cleaning
4160 Carburetor Assembly
Primary Fuel Bowl
Secondary Fuel Bowl
Main Body (4160)
Fuel Bowls and Metering Body
4160 Carburetor Adjustments
Checking Accelerator Pump Lever Clearance/Choke Qualifying
Adjusting Secondary Throttle Stop
Secondary Diaphragm
Choke Unloader Adjustment
Curb Idle Adjustment
Erratic Engine Idle/Low Idle Speed Adjustment
Fast Idle Adjustment
Model 4160 Carburetor Exploded View
Idle Adjustment Procedure with Analyzer
Charging System
Alternator
Charging System Diagrams
Regulator
Charging System Application
Charging System Diagnosis
Normal Charge Indicator Light
Normal Charge Ammeter
Isolating the Problem
Capacity Test
Battery Testing
State of Charge - Maintenance-Free Batteries
Charging System Tests - Motorola
Ignition on - Engine Not Running
Field Draw Test - Ignition off
Ignition on - Engine Running at Fast Idle
Ignition on - Engine Running at Idle
Motorcraft
Base Voltage Test/No Load Test
General Charging System Test
Load Test
Over Voltage Tests
Under Voltage Tests
Regulator S and I Circuit Tests S-Circuit with Ammeter
S and I Circuit - with Indicator Light
Bench Tests
Rectifier Short or Grounded and Stator Grounded Test
Field Open or Short Circuit Test
Stator Coil Open Test
Stator Coil Grounded Test
Diode Test
Rotor Open or Short Circuit Test
Alternator Removal and Installation
Alternator Disassembly
Alternator Cleaning and Inspection
Alternator Assembly
Drive Belt Adjustment
Belt Tension
Starting System
Starting System Testing
To Jump Start (Negative Grounded Battery)
On Vehicle Testing - if Starter Cranks Slowly
If Starter Does Not Crank but Starter Relay Operates (Clicks)
If Starter Does Not Crank and Relay Chatters or Does Not Click
If Starter Spins (Humming Noise) but Does Not Crank Engine
Starter Load Test
Armature and Field Grounded Circuit Test
Armature Open Circuit Test
Starting System Bench Tests
Starter Cleaning and Inspection
Starter Removal and Installation
Starter Disassembly
Starting System Diagram
Starter Assembly
Starter Drive Replacement
Brush Replacement
Armature Replacement
Starter, Permanent Magnet
Jump Starting
Starter, Permanent Magnet Diagnosis and Testing
Check Starter Motor - Test a
Check Relay - Test B
Check Voltage at Remote Relay Start Terminal
Check Output Terminal Voltage
Bench Tests - Starter No-Load Test
Starter Motor Removal and Installation
Grounded Armature Test
Starter Solenoid Test
Starter Motor Disassembly and Assembly
Starter Motor Cleaning and Inspection
Starter Drive/Armature Replacement
Starter Specifications
Starting System - Special Service Tools
Governors
Mechanical Governor - Belt Driven, Description
Mechanical Governor Troubleshooting
Preliminary Checks of Mechanical Governors
Oil Level (Governor)
Belt Tension (Governor)
Throttle Control Rod (Governor)
RPM Adjustment/Spread Adjustment/No-Load Surge Adjustment
Draining and Filling the Cooling System
Coolant (Industrial)
Cooling
Cooling System Testing
Pressure Test
Thermostat Test
Cooling System Adjustments
Drive Belt/Belt Tension Adjustment
Thermostat Replacement
Cooling System Cleaning and Inspection
Specifications
Metrics
Nomenclature for Bolts
Bolt Strength Identification
Hex Nut Strength Identification
Other Types of Parts
Decimal and Metric Equivalents
English Metric Conversion
Torque Conversion
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LSG 875
SERVICE MANUAL
PPO-194 208-86
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