Ford LRG-423 Manuals

Manuals and User Guides for Ford LRG-423. We have 1 Ford LRG-423 manual available for free PDF download: Service Manual

Ford LRG-423 Service Manual

Ford LRG-423 Service Manual (193 pages)

2.3 LITRE INDUSTRIAL ENGINE

Brand: Ford | Category: Engine | Size: 29.92 MB

Table of Contents

Important Safety Notice
2
Notes, Cautions and Warnings
2
Introduction
3
Engine Service
4
Table of Contents
5
Description and Operation
6
Engine Identification Nameplate
6
Diagnosis and Testing
7
Engine Diagnosis
7
Service Procedures
9
- Engine Oil Leaks
  9
- Fluorescent Oil Additive Method
  9
- Pressure Method
  9
- Compression Gauge Check
  10
- Compression Test
  10
- Leakage Points
  10
- Test Results
  10
- Compression Readings
  11
- Cylinder Leakage Detector
  11
- Example Readings
  11
- Oil Leak and Valve Guide Seal Test
  11
- Vacuum Gauge Readings
  12
- Oil Consumption Test
  13
- Restricted Exhaust System
  13
- Intake Valve Cleaning
  14
- Oil Pressure Test
  14
- Valve Train Analysis
  14
- Valves and Cylinder Head
  14
- Intake Valve Deposit Rating System
  15
- Camshaft End Play
  16
- Hydraulic Valve Tappet/Lash Adjuster
  16
- Camshaft Timing and Cylinder Identification Timing Check
  17
- Timing Belt
  17
- Connecting Rod Side Clearance
  18
- Crankshaft End Play
  18
- Cylinder Block Distortion
  18
- Cylinder Head Deck Flatness
  18
- Cylinder Bore
  19
- Cylinder Bore Taper
  19
- Cylinder Walls, Refinishing
  19
- Cylinder Bore Diameter
  20
- Cylinder Out-Of-Round
  20
- Cup Type
  21
- Engine Block Plugs
  21
- Expansion Type
  21
- Special Service Tools
  21
- Crankshaft Main and Connecting Rod Bearings
  22
- Bore Gauge Method
  23
- Crankshaft Runout
  24
- Crankshaft Sprocket
  24
- Journals Refinishing
  24
- Piston Rings - Fitting
  25
- Pistons, Piston Pins and Piston Rings
  25
- Piston and Piston Pin Fit
  26
- Camshaft
  27
- Camshaft Bearings
  27
- Connecting Rods
  27
- Piston Pin Clearance
  27
- Cam Lobe Lift
  28
- Camshaft Bearing Journals
  28
- Camshaft Journals Oil Clearance
  28
- Camshaft Runout
  28
- Camshaft Sprocket
  29
- Hydraulic Valve Tappets
  29
- Leakdown Testing
  29
- Cylinder Heads
  30
  - Spark Plug Thread Service
    30
  - Cleaning
    30
  - Inspection
    30
  - Cylinder Head Flatness
    31
  - Valve Seat Runout
    31
  - Valve Stem-To-Valve Guide Clearance
    31
  - Valves, Select Fitting
    32
  - Valve Guides, Reaming
    32
  - Valve Seats, Refacing
    32
  - Valves, Inspection
    33
  - Valves, Refacing
    33
  - Valve Spring Tension
    34
  - Valve Spring Squareness
    34
- Oil Pan
  30
- Camshaft Follower (2.3L)
  34
- Intake Manifold
  34
  - Cleaning
    34
  - Inspection
    34
- Exhaust Manifold
  35
  - Cleaning
    35
  - Inspection
    35
General Engine Specifications
36
Specifications
36
- Special Service Tools Desired
  37
- Rotunda Equipment
  37
Special Service Tools/Equipment
37
- 2.3L Engine
  38
- Engine Service, 2.3L
  39
- Subject Page
  39
- Description and Operation
  40
- Engine Identification
  40
- Camshaft
  41
- Crankshaft
  41
- Engine Code Information
  41
- Valve Train
  41
- Engine Lubrication System
  42
- Oilpan
  42
- Oilpump
  42
- Positive Crankcase Ventilation System
  42
- Drive Belt System
  45
- Electronic Governor
  45
- Engine Cooling System
  45
- Fail-Safe
  45
- Fuel System
  45
- Ignition System
  45
- Mechanical Governor
  45
- Velocity Governor
  45
- 2.3L Engine Service
  46
- Camshaft Follower and Hydraulic Lash Adjuster
  50
- Installation
  50
- Removal
  50
- Valve Cover and Gasket
  50
- Installation
  51
- Removal
  51
- Valve Spring, Retainer and Valve Stem Seal
  51
- Crankshaft Pulley and Damper
  52
- Installation
  52
- Removal
  52
- Camshaft Timing Belt Outer Cover
  53
- Installation
  53
- Camshaft Timing Belt Inner Cover
  54
- Installation
  54
- Removal
  54
- Camshaft Timing Belt
  55
- Removal
  55
- Installation
  57
- Timing Mark Alignment
  57
- Camshaft and Oil Pump Sprocket
  58
- Removal
  58
- Crankshaft Sprocket
  59
- Installation
  59
- Removal
  59
- Timing Belttensioner
  59
Camshaft
60
- Removal
  60
- Camshaft and Oil Pump Oil Seal
  62
- Installation
  62
- Removal
  62
- Cylinder Block Front Cover Seal
  63
- Installation
  63
- Removal
  63
- Water Pump
  64
- Installation
  69
- Removal
  69
- Water Thermostat and Outlet Connection
  69
- Installation
  70
- Intake Manifold
  70
- Removal
  70
- Water Outlet Connection and Thermostat
  70
- Installation
  71
- Carburetor
  72
- Installation
  72
- Removal
  72
- Exhaust Manifold
  74
- Installation
  74
- Removal
  74
Oil Pump
75
Removal
75
- Installation
  75
- Crankshaft Rear Oil Seal
  76
- Removal
  76
- Installation
  76
- Oil Filter and Adapter
  77
- Oil Pressure Sender
  77
Engine Front Cover
77
- Installation
  77
- Removal
  77
- Removal and Installation
  77
- Sensors
  77
- Removal
  78
- Engine Front Cover Installation
  79
- L ENGINE SERVICE (Cont' D.)
  79
- Installation
  81
- Oil Pan
  81
- Removal
  81
- Installation
  82
- Oil Pump Screen, Cover, and Tube
  82
- Removal
  82
- Crankshaft
  83
- Removal
  83
- Installation
  84
- Rear Main Bearing Cap Sealing
  84
- Crankshaft Main Bearings
  86
- Removal
  86
- Installation
  87
- Rear Main Bearing Cap Area Sealing
  87
- Pistons and Connecting Rods
  88
- Removal
  88
- Installation
  89
- Connecting Rod Bearings
  90
Removal
90
- Installation
  90
- Subassemblies
  92
- Cylinder Head
  92
- Disassembly and Assembly
  92
- Disassembly
  93
- DISASSEMBLY and ASSEMBLY (Cont' D.)
  97
- Piston and Piston Pins
  97
- Disassembly
  97
Assembly
97
- Cylinder Block Assembly
  97
- Adjustments
  98
- Assembly
  98
- Cylinder Block, Bare
  98
- Disassembly
  98
- Disassembly and Assembly
  98
- Hydraulic Lash Adjuster
  98
- Valve Clearance, Hydraulic Valve Lash Adjuster
  98
- Camshaft Timing
  99
- Checking Timing
  99
- Inspecting Camshaft and Oil Pump Sprocket Timing
  100
- Adjusting Timing Belt
  101
- Specifications
  105
Engine Operating Speeds - LRG
108
Special Service Tools/Equipment
109
- Auxiliary Systems
  110
- Inputs Affecting Ignition
  113
- Engine Temperature
  113
- Engine Speed and Crankshaft Position
  113
- Ignition Coil Driver
  113
- Service Adjustments and Checks
  114
- Transcient Mode
  114
- Overspeed Mode
  114
- Diagnosis Equipment
  115
- Ignition Coil
  119
- Engine Speed Sensor
  119
- Engine Coolant Temperature Sensor
  120
- Crankshaft Position Sensor
  121
- Ignition Coil Pack
  123
- Ignition Wires
  124
- Spark Plugs
  124
- Spark Plug Inspection Chart
  125
- Ignition Specifications
  126
- Ignition Adjustments
  126
- Ignition Timing
  126
- Carburetor Identification
  127
- Fuel System Description and Operation
  127
- Electric Fuel Pump
  127
- Fuel System Diagnosis and Testing
  128
- Fuel Supply and Pressure
  128
- Service Check Chart
  128
- Fuel Pump Service and Maintenance
  129
- Fuel Pump Specifications
  130
- Carburetor Diagnosis
  131
- Hard Starting
  131
- Stalling
  131
- Rough Idle
  131
- Reduced Power Output
  132
- Leaking Carburetor
  132
- Inconsistent Idle Speed
  132
- Fuel Supply System
  133
- Idle System
  133
- High Speed System
  135
- Accelerating Pump System
  137
- Assembly of Air Intake
  141
- Assembly of Fuel Bowl
  141
- Carburetor Description
  143
- Carburetor Systems
  143
- Idle Fuel System
  143
- Fuel Inlet System
  143
- Accelerator Pump System
  144
- Main Metering System
  144
- Power Fuel System
  144
- Float Adjustment
  145
- Accelerator Pump Piston Stroke Adjustment
  145
- Idle Speed Adjustment
  145
- Fast Idle Adjustment
  146
- Idle Mixture Adjustment
  146
- Carburetor Body Disassembly
  148
- Adjustments During Assembly
  149
- Starter, Permanent Magnet Description and Operation
  152
- Sequence of Operation
  152
- Negative Grounded Battery
  153
- Jump Starting
  153
- Road Service
  153
- Evaluation
  155
- Check Starter Motor
  155
- Check Relay
  155
- Starter Load Test
  155
- Bench Tests
  156
- Starter No-Load Test
  156
- Starter Solenoid Test
  157
- Armature Open Circuit Test
  157
- Grounded Armature Test
  157
- Starter Motor
  158
- Wiring
  158
- Starter, Permanent Magnet Disassembly and Assembly
  160
- Pinion and Ring Gear Wear Patterns
  161
- Starter Drive Replacement
  162
- Armature Replacement
  162
- Torque Specifications
  163
- Governors, Mechanical Description and Operation
  165
- Governors, Adjustments
  166
- Preliminary Checks
  166
- Throttle Control Rod
  166
- Oil Level
  166
- High Speed
  167
- Sensitivity or Droop
  167
- Low Speed Idle
  168
- No-Load Surge
  168
- Decrease Droop
  168
- Increase Droop
  168
- Basic Wiring Diagram
  173
- Cooling System
  174
- Visual Inspection
  175
- Cooling System Pressure Test
  175
- Radiator Cap Pressure Test
  176
- Thermostat Teest
  177
- Cooling Fan
  178
- Fan Drive Belt
  178
- Radiator Hose
  178
- Thermostat
  178
- Cleaning Cooling System
  179
- Generator
  180
- Battery Positive Voltage Output
  180
- A Circuit
  180
- S Circuit
  180
- Generator Diagnosis and Testing
  181
- Generator Output Test
  181
- Generator Voltage Test
  181
- Pinpoints Tests
  183
- Dead Battery/No Generator Output
  183
- Check for Key off Drain
  183
- Indicator Lamp On, Engine Running
  184
- Check for Open Stator Phase
  184
- Check for Shorted Rectifier
  184
- Check Stator Output Voltage
  185
- Check Generator Output Voltage
  185
- Check for Loose Connections
  185
- Check for Field Circuit Drain
  185
- Check Voltage Drop in a Circuit
  186
- Check Voltage Drop in I Circuit
  186
- Generator Removal and Installation
  190
- Regulator Removal
  190
- Generator Removal
  190
- Generator Disassembly and Assembly
  192
- Generator Parts Cross-Reference
  192
- Generator Mounting Specifications
  192

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