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Engine
302
Service manual
PCM 302 Service Manual
Ford and chevrolet based marine engines
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Index
Model Identification
Electrical Theory/Refresher
Electricity and Magnetism, Terms
Electrical Source
Electromagnets
Generating Electric Current
Voltage Regulator
Battery
Ignition Coil Operation and Construction
Engine Accessories, Test and Tune
Starter Motor Principle
Alternator, Regulator and Wiring Harness
General Wiring Diagram
Alternator Group Exploded View
Regulator Check
Carburetor and Fuel Pump
Electrical System
Overhaul of Carburetor
Circuit Breaker
Battery Specifications
Ignition Coil and Resistor
Distributor and Spark Cables
Engine Timing and Ignition
Firing Order - Cylinder Numbering/Engine Rotation
Prestolite Distributors (Marine Engines) Description and Operation
Adjustments and Repairs - Breaker Points And/Or Condenser
Centrifugal Advance Mechanism View
Weights, Spring and Cam Installed View
Breaker Plate and Sub-Plate Removal and Installation
Cam and Centrifugal Advance Weights Removal and Installation
Distributor Removal and Installation
Conventional Ignition System Distributor
Bench Assembly - Original Shaft and Gear
Bench Assembly - New Shaft and Gear
Distributor Assembly (Conventional) Exploded View
Oil Coolers
Starter and Relay
Cooling System, Raw Water Cooled Models
Troubleshooting the Cooling System
Overheating
Internal Leaks
Water in Crankcase
External Leaks (Not Evident)
Sherwood Raw Water Supply Pump - Exploded View
Cooling System - Fresh Water Cooled Models
Water Pump, Circulating
Water Pump, Raw Water Supply
Flywheel Housing, Drive Damper, Flywheel
Senders, Oil Pressure and Temperature
Holley Carburetor Repair and Diagnostic Procedures
Holley Two-Barrel Carburetor - Model 2300 Description
Main Body (Carburetor Model 2300)
Throttle Body
Carburetor Systems
Metering Block
Fuel Bowl Assembly
Fuel Inlet System
Idle Fuel System
Main Metering System
Carburetor Adjustments (Model 2300)
Power Fuel System
Accelerating Pump System
Float or Fuel Level Adjustments
Dry Adjustment - Externally Adjusted Float
Wet Adjustment - Externally Adjusted Float
Dry Adjustment - Internally Adjusted Float
Checking Fuel Level - Internally Adjusted Float
Accelerating Pump Override Spring Adjustment
Accelerating Pump Stroke Adjustment
Electric Automatic Choke Plate Clearance (Pulldown) Adjustment
Dechoke Clearance Adjustment
Carburetor Disassembly
Automatic Choke Thermostatic Spring Housing Adjustment
Idle Speed Adjustment
Idle Fuel Mixture Adjustment
Carburetor Assembly
Fuel Bowl and Metering Block
Model 2300C Carburetor Exploded View
Model 2300C Carburetor Nomenclature
Hollwy Four-Barrel Carburetors - Models 4150 and 4160 Description
Fuel Inlet System (4150/4160)
Idle Fuel System (4150/4160)
Main Metering System (4150/4160)
Secondary Metering Block 4160
Primary Metering Block 4150, 4160
Secondary Metering Block 4150
Power Fuel System (4150, 4160)
Secondary Operation - Vacuum Systems (4150, 4160)
Accelerator Pump (4150, 4160)
Float or Fuel Level Adjustments (4150, 4160)
Dry Adjustments/Wet Adjustments (4150, 4160)
Checking Fuel Level - Internally Adjusted Float (4150, 4160)
Accelerating Pump Override Spring Adjustment (4150, 4160)
Accelerating Pump (4150, 4160)
Secondary Throttle Stop Adjustment (4150, 4160)
Choke Plate Clearance (Pulldown) Adjustment (4150, 4160)
Dechoke Clearance Adjustment (4150, 4160)
Carburetor Models 4150 and 4160 Service Procedures
Automatic Choke Thermostatic Spring Housing Adjustment (4150, 4160)
Idle Speed Adjustment (4150, 4160)
Idle Fuel Mixture Adjustment (4150, 4160)
Carburetor Models 4150 and 4160 Disassembly
Carburetor Models 4150 and 4160 Assembly
Assembling Primary Metering Body (4150, 4160)
Assembly Fuel Bowls (Primary) (4150, 4160)
Secondary Fuel Bowl (External Needle and Seat) (4150, 4160)
Fuel Bowls with Internal Fuel Inlet Needle and Seat
Assembling Main Body (4150, 4160)
Model 4160 Assembly
Primary Bowl and Metering Body Assembly (4160)
Model 4150 Secondary Bowl and Metering Body Assembly
Assembling Secondary Diaphragm
Externally Adjusted Needle and Seat Exploded View
Carburetors Models 4150 and 4160 Nomenclature
Carburetors Models 4150 and 4160 Troubleshooting
Carburetor Assembly - 4150 with Governor, Diagram
Carburetor Specifications
Holley Carburetor Problem Diagnosis
Rochester Carburetor Repair and Diagnostic Procedures
Model 4MV Carburetor - General Description
Model 4MV Carburetor View
Model 4MV Carburetor Identification
Model 4MV Carburetor Systems Diagrams
Float Level Adjustment (4MV)
Pump Adjustment (4MV)
Choke Rod (Fast Idle Cam) Adjustment - Angle Gauge Method (4MV)
Air Valve Rod Adjustment (4MV)
Vacuum Break Adjustment - Angle Gauge Method (4MV)
Automatic Choke Coil Rod Adjustment (4MV)
Unloader Adjustment - Angle Gauge Method (4MV)
Secondary Closing Adjustment (4MV)
Secondary Opening Adjustment (4MV)
Air Valve Spring Adjustment (4MV)
Idle Speed Adjustment - Without Solenoid (4MV)
Andle Degree to Decimal Conversion - Model 4MV Carburetor
Model 4MV Carburetor On-Engine Service
4MV Carburetor Adjustments
Checking Carburetor Choke (4MV)
Idle Mixture Adjustment (4MV)
Carburetor Replacement (4MV)
Model 4MV Carburetor Disassembly
Air Horn Disassembly (4MV)
Float Bowl (4MV)
Float Bowl Disassembly (4MV)
Throttle Body Disassembly (4MV)
4MV Carburetor Cleaning and Inspection
4MV Carburetor Assembly
Float Level (4MV)
Air Horn to Bowl Assembly (4MV)
4MV Carburetor Torque Specifications
Rochester Carburetor Diagnosis
Engine Cranks Normally - will Not Start
Engine Starts - will Not Keep Running
Engine Starts Hard (Cranks Normally)
Engine Idles Abnormally (too Fast or too Slow)
Engine Diesels (after Run) Upon Shut off
Engine Hesitates on Acceleration
Engine Has Less than Normal Power at Normal Accelerations
Less than Normal Power on Heavy Acceleration or at High Speed
Engine Surges
Excessive Fuel Consumption
Engine Feels Like It Is Running out of Gas - Surging Occurs
Engine Starts but will Not Continue to Run
Fuel Starvation
Ford Engine Starting System Repair and Diagnostic Procedures
Ford Engine Starting System Description and Operation
Positive Engagement Starter
Solenoid Actuated Starter
Solenoid Operation
Connector Link
Booster Battery Testing
On Vehicle Testing Solenoid Starter
Starter Cranking Circuit Test
Starter Solenoid Test
Bench Tests - Starter No-Load Test
Armature Open Circuit Test
Armature and Field Grounded Circuit Test
Starting System On-Vehicle Testing
Starter Drive and Starter Test
Alternate Starter Drive Test
Positive Engagement - Starter Cranking Circuit Test
Starter Load Test
Starter No-Load Test - Bench Test
Armature Open Circuit Test - on Test Bench
Armature and Field Grounded Circuit Test - on Test Bench
Starter Removal and Installation
Overhaul Positive Engagement
Starter Disassembly
Solenoid Actuated Starter Disassembly
Starter Cleaning and Inspection
Assembly Positive Engagement Starter
Assembly Solenoid Starter
Starter Drive Replacement
Brush Replacement - Positive Engagement Starter
Brush Replacement - Solenoid Starter
Armature Replacement
Starter Terminal Removal
Starter Terminal Installation
Starting System Specifications
Delco Starter Systems Repair and Diagnostic Procedures
Delco Starter System General Description
Starter Motor Construction
Armature
Drive Mechanism
Solenoid
Starting Motor Cross Section View
Typical Cranking System
Delco Starter System Diagnosis
No Cranking Action
Cranking Speed Abnormally Low
Voltage Test of Starting System and Solenoid Switch
Amperage Test of Solenoid Switch Windings
Delco Starter System on Vehicle Service
Delco Starter System Lubrication
Starting Motor Replacement/Bench Test
Checking Pinion Clearance
Starting Motor Disassembly - Except Diesel
Starting Motor Cleaning and Inspection
Starting Motor Parts Layout
Armature Test for Shorts
Armature Test for Ground
Field Coil Test for Open Circuit/Field Coil Test for Ground
Field Coil Replacement
Delco Starting Motor Assembly
Loose Electrical Connections
Turning the Commutator
Brush Holder Replacement/Overrunning Clutch
Pinion Clearance Check
Starting Solenoid Removal
Replacement of Contacts (Starting Solenoid)
Starting Solenoid Installation
Starter (Diesel Engine) Disassembly
Starter (Diesel Engine) Cleaning, Inspection and Tests
Solenoid Switch
Starter (Diesel Engine) Assembly
Pinion Clearance
Delco-Remy - Enclosed Shift Lever Type Cranking Motors
Cranking Motor Lubrication
Troubleshooting the Cranking Circuit
Cranking Motor Tests
Magnetic Switch or Solenoid and Control Switches
No-Load Test
Cranking Motor Disassembly
Cranking Motor Component Inspection and Repair
Typical Cranking Motor Circuits View
Basic Solenoid Circuit
Connections for Checking Solenoid
Cranking Motor Reassembly
Cranking Motors and Miscellaneous DC Motors - No-Load Test
Starting Motor Specifications
Ford Engines Repair and Diagnostic Procedures
Ford Engine Index
460 Engines Description and Operation
Manifolds
Cylinder Heads/Cylinder Block
Valve Train
Lubrication System
Positive Crankcase Ventilation System
Carburetors
Distributors
302 And 351 Engines Description and Operation
Engine Overhaul
Manifold Vacuum Diagnosis and Testing
Camshaft Identification
Valve Spring Color Code
Rear Main Seal Color Code - All Engines
Engine Water Pump Identification
Camshaft Lobe Lift Diagnosis and Testing
Compression Test
Compression Gauge Check
Hydraulic Valve Lifter
Positive Closed-Type Ventilation System
Air Intake Test
Crankcase Ventilation Regular Valve Test
Crankshaft End Play
Flywheel Face Runout
Camshaft End Play
Timing Chain Deflection
Intake Manifold Cleaning and Inspection
Exhaust Manifolds Cleaning and Inspection
Valver Rocker Arm Assembly Cleaning and Inspection
Bush Rods Cleaning and Inspection
Cylinder Heads Cleaning and Inspection
Hydraulic Valve Lifters Cleaning and Inspection
Crankshaft Vibration Damper and Sleeve Cleaning and Inspection
Timing Chain and Sprockets Cleaning and Inspection
Camshaft Cleaning and Inspection
Crankshaft Cleaning and Inspection
Flywheel Inspection
Connecting Rods Cleaning and Inspection
Pistons, Pins and Rings Inspection
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
Cylinder Head Overhaul
Reaming Valve Guides
Refacing Valve Seats
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Model Identification
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Table of
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Table of Contents
Troubleshooting
Cooling system, raw water cooled models
23
Carburetors models 4150 and 4160 troubleshooting
61
Delco-Remy - Enclosed Shift Lever Type Cranking Motors
122
71C and 72C transmissions troubleshooting
265
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This manual is also suitable for:
460
351
454
305
350
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