Table Of Contents - EDI TSG-416 Service Manual

Table of Contents

Health And Safety Recommendations4
Index5
Table Of Contents5
General Information6
Notes, Cautions, And Warnings7
Introduction7
Safety Notice7
Battery Handling And Chargin8
Engine Identification9
Description And Operation9
Forward9
Parts And Service9
Diagnosis And Testing10
Special Service Tools10
Inspection And Verification11
Symptom Chart11
Pcv System Malfunction14
Engine Oil Leaks14
Fluorescent Oil Additive Method14
Pressure Method14
Testing Procedure15
Leakage Points15
Compression Tests16
Compression Gauge Check16
Compression Pressure Limit Chart16
Interpreting Compression Readings16
Cylinder Leakage Detection17
Intake Manifold Vacuum Test17
Oil Leak And Valve Stem Seal Test17
Interpreting Vacuum Gauge Readings18
Excessive Engine Oil Consumption19
Oil Consumption Test19
Oil Pressure Test20
Valve Train Analysis - Static21
Valve Train Analysis - Dynamic21
Camshaft Lobe Lift22
Hydraulic Valve Lash Adjuster23
Leak Down Testing23
General Service Procedures24
Camshaft Journal Diameter24
Camshaft Journal Clearance24
Camshaft Lobe Surface24
Camshaft Runout25
Camshaft End Play25
Crankshaft Main Bearing Journal Diameter26
Crankshaft Main Bearing Journal Taper26
Crankshaft Main Bearing Journal Clearance27
Bearing Inspection27
Crankshaft End Play28
Crankshaft Runout28
Cylinder Bore Taper28
Cylinder Bore Out-Of-Round29
Piston Inspection29
Piston Diameter29
Piston To Cylinder Bore Clearance29
Piston Selection30
Piston Ring End Gap30
Piston Ring-To-Groove Clearance31
Crankshaft Connecting Rod Journal Diameter31
Crankshaft Connection Rod Journal Taper31
Connecting Rod Cleaning31
Connecting Rod Larger End Bore32
Piston Pin Diameter32
Connecting Rod Bushing Diameter32
Connecting Rod Bend/Connecting Rod Twist32
Connecting Rod Piston Pin Side Clearance33
Connecting Rod Journal Clearance33
Roller Follower Inspection34
Hydraulic Lash Adjuster Inspection34
Valve Stem Diameter35
Valve Stem-To-Valve Guide Clearance35
Valve Inspection35
Valve Guide Inner Diameter36
Valve Guide Reaming36
Valve Spring Installed Length36
Valve Spring Free Length/Valve Spring Out-Of-Square36
Valve Spring Compression Pressure37
Valve And Seat Refacing Measurements37
Valve Seat Width37
Valve Seat Runout37
Flywheel Inspection38
Oil Pump Gear Radial Clearance38
Oil Pump Rotor Inspection38
Oil Pump Side Clearance38
Cylinder Bore Honing39
Cylinder Bore Cleaning39
Cylinder Bore Repair - Cast Iron Porosity Defects40
Cylinder Bore Core Plug Replacement40
Cylinder Head – Distortion40
Spark Plug Thread Repair42
Exhaust Manifold Straightness43
General Specifications44
Special Tools47
Engine Description49
Engine Identification Number49
Component Location Diagrams50
Engine Repair54
Valve Cover - Removal54
Valve Cover - Installation54
Camshaft- Removal55
Camshaft - Installation56
Valve Stem Seal - Removal57
Valve Stem Seal - Installation58
Intake Manifold - Removal59
Intake Manifold - Installation59
Exhaust Manifold - Removal60
Exhaust Manifold - Installation60
Cylinder Head - Removal61
Cylinder Head - Installation63
Oil Pump - Removal65
Oil Pump - Installation66
Crankshaft Rear Oil Seal – Removal67
Crankshaft Rear Oil Seal - Installation67
Camshaft Follower/Hydraulic Lash Adjuster – Removal68
Camshaft Follower/Hydraulic Lash Adjuster – Installation68
Oil Pan - Removal69
Oil Pan - Installation69
Pick-Up Tube/Deflector - Removal70
Pick-Up Tube/Deflector - Installation70
Crankshaft Main Bearings - Removal71
Crankshaft Main Bearings - Installation71
Connecting Rod Bearings – Removal72
Connecting Rod Bearings - Installation72
Piston – Removal73
Piston - Installation74
Flywheel - Removal75
Flywheel - Installation75
Timing Chain And Sprockets – Removal76
Timing Chain And Sprockets - Installation77
Oil Level Indicator – Removal79
Oil Level Indicator – Installation79
Oil Filter And Adapter - Removal80
Oil Filter And Adapter – Installation80
Disassembly81
Subassemblies88
Cylinder Block88
Piston - Disassembly89
Piston - Assembly89
Cylinder Head - Disassembly90
Cylinder Head - Assembly91
Assembly92
Specifications102
Ignition System103
Ignition System Description104
Ignition System Operation105
Fuel Octane Level Adjustment105
Ignition Coil Driver105
Run Mode/Transient Mode105
Ignition System Wiring Diagram106
Ignition System Diagnosis And Testing107
Spark Plug Inspection107
Ignition System - Removal And Installation108
Ignition Coil - Replacement108
Spark Plug – Removal108
Ignition System Specifications109
Fuel System110
Fuel System - Cautions And Warnings111
Fuel System Description112
Fuel System Operation113
Fuel System Requirements113
Fuel System Wiring Diagrams114
Fuel Injectors Wiring Diagram114
Connector (Dlc) Wiring Diagram115
Dry Fuel Description116
Dry Guel Operation116
Mixer Assembly View116
Engine Controls – Dry Fuel Depr118
Diagnosis And Testing - Lpg119
Fuel System Preliminary Test120
Fuel System Diagnosis Chart121
Engine Cranking But Will Not Start121
Engine Idles With Rough Acceleration At Load123
Engine Backfires125
Emission Failure - Rich Mixture126
Emission Failure - Lean Mixture127
Engine Overheats128
Engine Stops Running (Dies)129
Fuel System Diagnosis And Testing - Gasoline130
Fuel Pressure Check130
Fuel Pump Check130
Fuel Block Check131
Quick Connect Coupling - Type I/Ii - Disconnect/Disconnect132
Fuel System - Removal And Installation134
Fuel Rail & Injectors - Replacement134
Actuator - Removal135
Actuator - Installation135
Mixer - Removal135
Fuel System Specifications136
Mixer - Installation136
Cooling System137
Cooling System - Cautions And Warnings138
Cooling System General Information139
Cooling System Diagnosis And Testing140
Coolant Inspection140
Coolant Range Check140
Drive Belt Inspection141
Cooling System Symptom Chart142
Cooling System Pressure Test143
Radiator Cap Pressure Test143
Thermostat Operational Check143
Cooling System Service Procedures144
Draining The Cooling System144
Flushing The Cooling System144
Filling The Cooling System144
Cooling System - Removal And Installation145
Fan Belt – Removal/Installation145
Drive Belt - Removal/Installation145
Belt Tensioner – Replacement/Idler Pulley - Replacement145
Radiator Hose - Removal146
Radiator Hose - Installation146
Thermostat & Housing – Replacement147
Coolant Pump - Replacement148
Thermostat - Replacement149
Coolant Bypass – Replacement150
Cooling System Specifications151
Charging System152
Cautions & Warnings153
Charging System - General Information154
Charging System Wiring Diagram155
Charging System Diagnosis And Testing156
Warning Indicator Check156
Charging System Symptom Chart157
Battery Drain Test158
Battery Load Test158
Generator Output Test159
Generator Voltage Test159
Charging System Service Procedures160
Battery Cleaning And Inspection160
Battery Tools160
Battery Charging161
Charging System - Removal And Installation162
Generator – Replacement162
Voltage Regulator – Replacement162
Generator Pulley - Replacement163
Battery - Removal164
Battery - Installation164
Charging System Specifications165
Engine Controls166
Gcp And Sensors167
Engine Control Module (Gcp) Description167
Gcp Inputs (Operating Conditions Read)168
Gcp Outputs (Systems Controlled)169
Crankshaft Position (Ckp) Sensor169
Camshaft Position (Cmp) Sensor169
Engine Coolant Temperature (Ect) Sensor170
Tsg‐416 Engine Controls Heated Oxygen Sensor (Ho2S)171
Temperature Manifold Absolute Pressure (Tmap) Sensor172
Throttle Position (Tp) Sensor/Electronic Actuator172
Fuel System Components - Gasoline173
Fuel Injector173
Fuel Rail173
Fuel Filter173
Fuel Pump Electrical Circuit174
Mixer (Gaseous Fuels)174
Vapor Regulator174
Fuel Lock Off Valve174
Distributor Less Coil Pack175
Open Loop And Closed Loop Operation176
Gcp Service Precautions176
Use Of Circuit Testing Tools176
Electrostatic Discharge Damage176
Engine Controls - Diagrams And Schematics177
Engine Controls - Symbols177
Gcp - Power Distribution Box178
Part Of -5210070- Engine Wiring Harness178
Engine Controls - Wire Colors179
Revision Level179
Power Distribution Diagram180
Ignition System Diagram181
Starting System Diagram182
Charging System Diagram183
Engine Controls - Sensors (1 Of 2)184
Engine Controls - Sensors (2 Of 2)185
Fuel Injectors Diagram186
Engine Controls - Actuator/Data Link Connector (Dlc) Diagram187
Engine Controls - Dry Fuel Depr Diagram188
Engine Controls Diagnosis And Testing189
Gcp Diagnostic Overview189
On-Board Diagnostics - Gcp189
Power Derate 1189
Diagnostic Approach189
Intermittent Mil190
Malfunction Indicator Lamp (Mil) Dtc Retrieval Procedure190
Fault Low Rev Limit190
Force To Idle190
Diagnosis Using A Personal Computer191
Mil Bulb Test191
Dtc Extraction191
Interface Hook-Up192
Gcp Software Installation193
Using Gcp Software - Menu Functions194
Engine Controls Diagnostic Trouble Codes195
Snap Shot Data195
Flight Data Recorder196
Data Stream - Reading Sensor & Actuator Values196
Plotting And Data Logging197
Ignition System Test198
Disabling Ignition Ouputs198
Injector Test198
Disabling Injectors198
Throttle Test199
Raw Volts Screen199
Engine Controls Visual Inspection200
Intermittent Problems200
Engine Controls Symptom Charts201
Engine Performance - No Load201
Engine Performance - While Under Load202
Lack Of Power202
Engine Concerns203
Black Smoke203
Blue Smoke203
Engine Noise203
Engine Control Module (Gcp) – Diagnostic Trouble Codes204
Engine Controls - Removal And Installation205
Camshaft Position (Cmp) Sensor Replacement205
Crankshaft Position (Ckp) Sensor Removal205
Crankshaft Position (Ckp) Sensor Installation205
Engine Coolant Temperature (Ect) Sensor Replacement206
Heated Oxygen Sensor (Ho2S) - Replacement206
Knock Sensor (Ks) – Replacement207
Temperature Manifold Absolute Pressure (Tmap) Sensor Replacement207
Actuator/Throttle Position (Tp) Sensor - Replacement208
Metrics209
Nomenclature For Bolts210
Bolt Strength Identification211
Nex Nut Strength Identification211
Other Types Of Parts212
English/Metric Conversion213
Decimal And Metric Equivalents214
Torque Conversion214
J1930 Terminology List215