Vortec 1600 Service Manual
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Vortec 1600 Service Manual

1.6l industrial engine
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Original Issue
Dated August 2003
Publication Number 36100009
1.6L
INDUSTRIAL ENGINE
SERVICE MANUAL

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Summary of Contents for Vortec 1600

  • Page 1 Original Issue Dated August 2003 Publication Number 36100009 1.6L INDUSTRIAL ENGINE SERVICE MANUAL...
  • Page 2 Table Of Contents General Information Section 0 Engine Mechanical Section 1 Engine Cooling Section 2 Engine Electrical Section 3 No part of this publication may be reproduced without the written permission of Power Solutions, Inc. At the time of publication, all of the information included in this publication is accurate to the best of our knowledge.

  • Page 3: Table Of Contents

    Industrial 1.6L General Information 0-1 Section 0 General Information Fastener Notice ............0-2 Oil Filter ..............0-16 General Information - 1.6L ........0-3 Engine Air Cleaner ..........0-16 Conversion - English/Metric ........0-3 Safety Element ............0-16 Equivalents - Decimal and Metric ......0-3 Cooling System Maintenance ......

  • Page 4: Fastener Notice

    0-2 General Information Industrial 1.6L Fastener Notice NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number of that application. UNLESS OTHERWISE SPECIFIED, Do Not use supplemental coatings (paints, greases or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces.

  • Page 5: General Information - 1.6L

    Industrial 1.6L General Information 0-3 General Information - 1.6L Conversion - English/Metric Conversion - English/Metric (cont’d) English Multiply / Metric English Multiply / Metric Divide by Divide by Length Velocity 25.4 1.6093 km/h 0.3048 Temperature °C (°F-32) / 1.8 0.9144 °F (°C X 1.8) + 32 1.609...

  • Page 6: Equivalents - Decimal And Metric

    0-4 General Information Industrial 1.6L Arrows and Symbols Equivalents - Decimal and Metric (cont’d) This service manual uses various symbols in order to Fraction (in) Decimal (in) Metric (mm) describe different service operations. You may find some or all of these symbols used in the manual. 33/64 0.515625 13.09687...

  • Page 7: Engine Id Location

    Industrial 1.6L General Information 0-5 Engine ID Location FASTENERS To help identify the engine and its serial number, an Metric Fasteners identification label is affixed to the top of the camshaft The 1.6L engine is dimensioned in the metric system. housing cover.

  • Page 8: Fastener Strength Identification

    0-6 General Information Industrial 1.6L Fastener Strength Identification 171891 Legend (1) English Bolt, Grade 2 (Strength Class) (4) English Bolt, Grade 8 (Strength Class) (2) English Bolt, Grade 5 (Strength Class) (5) Metric Nut, Strength Class 9 (3) English Bolt, Grade 7 (Strength Class) (6) Metric Bolts, Strength Class Increases as Numbers Increase...

  • Page 9: Prevailing Torque Fasteners

    Industrial 1.6L General Information 0-7 Prevailing Torque Fasteners A prevailing torque nut is designed in order to develop an interface between the nut and bolt threads. Distor- tion of the top of the metal nut or using a nylon patch on the threads in the middle of the hex flat causes that interface.

  • Page 10: Prevailing Torque Specifications (Metric)

    0-8 General Information Industrial 1.6L Prevailing Torque Specifications (Metric–Size Fasteners) Specification Application English Metric Nuts and All Metal Bolts/Screws 6 mm 0.4 N•m 4 lb in 6.3 mm 0.4 N•m 4 lb in 8 mm 0.6 N•m 7 lb in 10 mm 1.4 N•m 12 lb in...

  • Page 11: Thread Inserts

    Industrial 1.6L General Information 0-9 THREAD INSERTS Repair Procedure Tools Required General purpose thread repair kits. These kits are available commercially. Caution: Wear safety glasses in order to avoid eye damage. Important: Refer to the thread repair kit manufacturer’s instructions regarding the size of the drill and tap to use.
  • Page 12 0-10 General Information Industrial 1.6L Abbreviations and Their Meanings (cont’d) Abbreviations and Their Meanings (cont’d) Abbreviation Meaning Abbreviation Meaning APCM Accessory Power Control Module Commutator End American Petroleum Institute CEAB Cold Engine Air Bleed Adjustable Part Throttle Cubic Feet per Minute Assembly, Accelerator and Servo Center of Gravity Control Module...
  • Page 13 Industrial 1.6L General Information 0-11 Abbreviations and Their Meanings (cont’d) Abbreviations and Their Meanings (cont’d) Abbreviation Abbreviation Meaning Meaning Digital Multimeter Exhaust DOHC Dual Overhead Camshafts ºF Degrees Fahrenheit Electrical Center, Engine Control Fan Control Engine Coolant Level Fuel Data Center Engine Control Module, Electronic Federal (All United States except Control Module...
  • Page 14 0-12 General Information Industrial 1.6L Abbreviations and Their Meanings (cont’d) Abbreviations and Their Meanings (cont’d) Abbreviation Abbreviation Meaning Meaning Heavy Duty Kilopascals Heavy Duty Cooling Knock Sensor Mercury Kilovolts Hi Alt High Altitude HO2S Heated Oxygen Sensor Liter Horsepower Four Cylinder Engine, In–line Hertz Pound lb ft...
  • Page 15 Industrial 1.6L General Information 0-13 Abbreviations and Their Meanings (cont’d) Abbreviations and Their Meanings (cont’d) Abbreviation Meaning Abbreviation Power Inverter Module Meaning Permanent Magnet (Generator) Part Number Normally Closed Pink Negative Pilot Operated Absolute (Valve) Neutral Positive, Position NiMH Nickel Metal Hydride Potentiometer (Variable Resistor) NLGI National Lubricating Grease Institute...
  • Page 16 0-14 General Information Industrial 1.6L Abbreviations and Their Meanings (cont’d) Abbreviations and Their Meanings (cont’d) Abbreviation Meaning Abbreviation Meaning Revolutions per Minute (Engine Top Dead Center Speed) TEMP Temperature Regular Production Option Term Terminal Right Rear Throttle Position Throttle Valve Second(s) Thermal Vacuum Valve Society of Automotive Engineers...

  • Page 17: Maintenance And Lubrication

    Industrial 1.6L General Information 0-15 MAINTENANCE AND LUBRICATION Initial Start Up Maintenance The initial start-up checks must be made before putting the engine into service. Please refer to Maintenance Schedule - 1.6L Engine on page 0-19 and perform the initial start-up operations in the sequence shown in column 1.

  • Page 18: Engine Oil Recommendation

    0-16 General Information Industrial 1.6L Engine Oil Recommendation Multi-viscosity oils are recommended. SAE 10W30 is recommended for your engine from 0 degrees F (-18 degrees C) or above. If ambient temperatures are consistently below 0 degrees F, SAE 5W30 oil can be used. Synthetic oils are not recommended for industrial or stationary engines.

  • Page 19: Radiator

    Industrial 1.6L General Information 0-17 Coolant Level - Continued Use only a permanent-type coolant when refilling or flushing the coolant system. Recommended ethylene glycol mix 52/48 is normal up to a maximum of 60% glycol, 40% water. Refer to the mixture chart on the container for additional antifreeze protection information. DO NOT use alcohol or methanol antifreeze, or mix them with the specified coolant.

  • Page 20: Ignition Systems

    0-18 General Information Industrial 1.6L Fuel Delivery System Maintenance - Continued CAUTION: Failure to change the fuel system filters as recommended can result in premature failure of the TBI fuel system components. NOTE: Some original equipment manufacturers install their own fuel systems. Please refer to the manufacturers manual if the gasoline fuel system is different than described here.

  • Page 21: Maintenance Schedule - 1.6L Engine

    Industrial 1.6L General Information 0-19 MAINTENANCE SCHEDULE - 1.6L ENGINE Initial Start-Up Operation Daily Weekly Every Every Every Every Every Sequence Req. Checks Check Engine Oil Level Check Coolant Level Check for Fluid Leaks Governor, Mechanical (Check oil level)(2) Change Engine Oil & Filter (1) Battery, Check Charge &...

  • Page 22: Filter Chart - 1.6L Engine

    0-20 General Information Industrial 1.6L FILTER CHART - 1.6L ENGINE Engine 1.6L Oil Filter 94632619 25010792 Fuel Filter (Carbureted) Fuel Filter (PSI TBI Coarse) Fuel Filter (PSI TBI Fine) Fuel Filter Gasoline Zenith Z.E.E.M.S C282-224 C282-5 Air Filter Primary (PSI Power Unit) Air Filter Safety (PSI Power Unit)
  • Page 23 Industrial 1.6L Engine Mechanical 1-1 Section 1 Engine Mechanical Fastener Notice ............1-2 Drive Disc, Remove and Install ........ 1-54 Flywheel, Remove and Install ........1-54 Engine Mechanical - 1.6L ........1-3 Seal Ring - Rear Crankshaft, Replace ...... 1-55 Specifications ............

  • Page 24: Fastener Notice

    1-2 Engine Mechanical Industrial 1.6L Fastener Notice NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number of that application. PSI will call out those fasteners that require a replacement after removal. PSI will also call out the fasteners that require thread lockers or thread sealant.

  • Page 25: Engine Mechanical - 1.6L

    Industrial 1.6L Engine Mechanical 1-3 Engine Mechanical - 1.6L Specifications Specification Engine Z16 SE 1.6L Industrial Engine 1.6L Industrial English Metric Number of cylinders/layout 4 In Line Number of valves Capacity 1598 cm 97.5 cu in Bore Diameter 79 mm 3.11 in Stroke 81.5 mm...

  • Page 26: Fastener Tightening Specifications

    1-4 Engine Mechanical Industrial 1.6L Fastener Tightening Specifications Specification Application English Metric Starter to cylinder block 13 lb ft 40 N@m Drive disc to crankshaft 18 lb ft 25 N@m Exhaust manifold to cylinder head + 30º + 15º 106 lb in Camshaft sensor fastening bolt to camshaft housing 13 lb ft 18 N@m...
  • Page 27 Industrial 1.6L Engine Mechanical 1-5 Fastener Tightening Specifications (Continued) Specification Application English Metric Fuel supply and return line to throttle valve guards 11 lb ft 15 N@m Coolant pump to cylinder block 71 lb in 8 N@m Coolant pipe to cylinder block 15 lb ft 20 N@m Crankshaft bearing cap to cylinder block...
  • Page 28 1-6 Engine Mechanical Industrial 1.6L Sealants, Adhesives, and Lubricants E n g i n e 1 .6 L Z 1 6 L E C r a n k s h a f t D im e n s io n s M a in B e a r in g J o u r n a ls 1 - 5 C o lo r C o d e S ta n d a r d s iz e...

  • Page 29: Engine Mechanical Specifications

    Industrial 1.6L Engine Mechanical 1-7 Engine Mechanical Specifications Engine Identification Code / Engine Number The engine identification code is embossed on the flattened area (arrow) of the cylinder block on the upper rear side. Engine Management E n g ine D isp lacem e n t 1 .6 L E n g ine D e sig n a tio n M u lte c-S Z 16 S E...

  • Page 30: Cylinder Head

    1-8 Engine Mechanical Industrial 1.6L Cylinder Head Cylinder Head Illustration 1 Cylinder head height 2 Installation height of valve guide 3 Installation height of valve 4 Valve seat width in cylinder head 5 Valve seat angle in cylinder head 6 Valve stem diameter 7 Valve seat angle at valve 8 Valve length 9 Valve head –...
  • Page 31 Industrial 1.6L Engine Mechanical 1-9 Cylinder Head (Continued) Specification Cylinder Head – 1.6L Engine English Metric Cylinder head height 95.9 – 96.1 mm 3.776 – 3.783 in Intake valve seat width in cylinder head 1.3 – 1.5 mm 0.051 – 0.059 in Exhaust valve seat width in cylinder head 1.6 –...
  • Page 32 1-10 Engine Mechanical Industrial 1.6L Crank Drive, Cylinder Block Crank Drive, Cylinder Block Illustration 1 Main Bearing Journals 2 Con–rod bearing journal 3 Main Bearing Journals (Guide Bearing) 4 Crankshaft color code 5 Bearing shell color code 6 Bearing shell identification...
  • Page 33 Industrial 1.6L Engine Mechanical 1-11 Crank Drive, Cylinder Block (Continued) E n g in e 1 .6 L Z 1 6 L E C ran k sh aft D im e n s io ns M a in B e a rin g J o u rn a ls 1 -5 C o lo r C o d e S tan d a rd size 5 4 .98 0 –...
  • Page 34 1-12 Engine Mechanical Industrial 1.6L Crank Drive, Cylinder Block (Continued) Engine 1.6 L Z 16 SE Crankshaft bearing Low er crankshaft bearing shell 1,2,4,5 Color code Thickness Thickness Code (Metric) (English) GM 400 Standard Size brown 1.989 – 1.995 mm 0.0783 –...
  • Page 35 Industrial 1.6L Engine Mechanical 1-13 Crank Drive, Cylinder Block (Continued) Engine 1.6 L Z 16 SE 3 w ide main bearing Color code W idth W idth Code journals (guide bearing) (Metric) (English) GM 400 Standard Size green-brown 25.850 – 25.900 mm 1.0177 –...

  • Page 36: Crank Drive, Cylinder Block

    1-14 Engine Mechanical Industrial 1.6L Crank Drive, Cylinder Block (Continued) Crank Drive, Cylinder Block (Continued) Illustration 1 Index – identification of cylinder bore 2 Cylinder bore 3 Double bevelled ring with spiral–type expander 4 Tapered compression ring or double trapezoidal ring 5 Rectangular compression ring 6 Piston diameter Illustration...
  • Page 37 Industrial 1.6L Engine Mechanical 1-15 Crank Drive, Cylinder Block (Continued) E n g in e 1 .6 L Z 1 6 S E C ylin d e rb o re W id th W id th (M e tric ) (E n g lish ) S ta n d a rd siz e In d ex...
  • Page 38 1-16 Engine Mechanical Industrial 1.6L Crank Drive, Cylinder Block (Continued) E n g in e 1 .6 L Z 1 6 S E P is to n R in g s S p e c ific atio n (M etric) S p ecification (E n g lish ) R ectangular com pression ring...

  • Page 39: Diagnostic Information And Procedures

    Industrial 1.6L Engine Mechanical 1-17 Diagnostic Information and Procedures Ribbed V–belt Tension, Check Drive belts must grip the entire contact area of the pully. When drive belts are too loose, the belts can slip, tear, burn, or grab and snap. More belts fail from being too loose than too tight.

  • Page 40: Engine Loss Of Compression Test

    1-18 Engine Mechanical Industrial 1.6L Installation Procedure 1. Insert fuel pump relay in base and close relay holder cover. Connect wiring harness plug to DIS ignition module. 3. Install spark plugs with KM–194–E into cylinder head – Tighten Tightening torque 25 Nm / 18 lb. ft. 4.

  • Page 41: Oil Pressure Check

    Industrial 1.6L Engine Mechanical 1-19 Inspect 1. Air outlet at: inlet or exhaust side, compensation tank and crankcase housing. Max. difference in pressure be- tween individual cylinders: 10%. The max. pressure loss of a cylinder should not exceed 25%. 2. Check pressure loss at 3rd, 4th and 2nd cylinders analo- gously.

  • Page 42: Timing Check

    1-20 Engine Mechanical Industrial 1.6L Valve Timing, Check Removal Procedure 1. Disconnect ground cable from battery. 2. Remove upper part of toothed belt cover – see operation Toothed Belt Cover – Upper Part, Remove and Install. Inspect 1. At fastening bolt of toothed belt drive gear, turn crank- shaft in engine rotational direction to ”1st cylinder TDC”...
  • Page 43 Industrial 1.6L Engine Mechanical 1-21 Adjust 1. Screw fastening bolt for toothed belt drive gear into crankshaft and turn crankshaft in engine rotational di- rection until pointer (4) on toothed belt drive gear is flush with mark on oil pump housing. 2.
  • Page 44 1-22 Engine Mechanical Industrial 1.6L Adjust 1. At hex of camshaft, turn camshaft sprocket (short way) to mark. Notch (2) on camshaft sprocket must align with mark (1) on rear toothed belt cover. Installation Procedure 1. Attach toothed belt – ensure that tension side (I) is taut. Note running direction of toothed belt.

  • Page 45: Toothed Belt Tension Check

    Industrial 1.6L Engine Mechanical 1-23 Toothed Belt Tension, Check Notice: Testing is performed with the engine cold – at room temperature. Removal Procedure 1. Disconnect ground cable from battery. 2. Remove upper part of toothed belt cover – see operation Toothed Belt Cover –...

  • Page 46: Toothed Belt Tension Adjust

    1-24 Engine Mechanical Industrial 1.6L Toothed Belt Tension, Adjust Notice: Testing is performed with the engine cold – at room temperature. Removal Procedure 1. Remove upper part of toothed belt cover – see operation Toothed Belt Cover – Upper Part, Remove and Install. 2.

  • Page 47: Repair Instructions

    Industrial 1.6L Engine Mechanical 1-25 Adjust 1. Turn crankshaft two revolutions (720°) in engine rota- tional direction, until timing marks align. Turn crankshaft slowly and uniformly and do not change position of cool- ant pump. 2. Reduce toothed belt tension by turning coolant pump in direction of arrow with KM–421–A until pointer (1) and notch (2) on toothed belt tension roller carrier plate align.

  • Page 48: Toothed Belt Cover, Upper Part, Remove And Install

    1-26 Engine Mechanical Industrial 1.6L Installation Procedure Tools Required: • • • • • 6” Steel Rule 1. Slide the belt over the fan blades and route it over the pulleys. 2. Move the generator outward until the fan belt measures approximately 1/2 inch (13 mm) deflection.

  • Page 49: Toothed Belt Cover, Lower Part, Remove And Install

    Industrial 1.6L Engine Mechanical 1-27 Toothed Belt Cover, Lower Part, Remove and Install Removal Procedure 1. Remove upper part of toothed belt cover – see operation Toothed Belt Cover – Upper Part, Remove and Install. 2. Remove ribbed V–belts – see operation Ribbed V–belts, Remove and Install.

  • Page 50: Toothed Belt, Remove And Install

    1-28 Engine Mechanical Industrial 1.6L Toothed Belt, Remove and Install Removal Procedure 1. Remove upper part of toothed belt cover – see operation Toothed Belt Cover – Upper Part, Remove and Install. 2. Remove ribbed V–belts – see operation Ribbed V–belts, Remove and Install.

  • Page 51: Toothed Belt Tension Roller, Remove And Install

    Industrial 1.6L Engine Mechanical 1-29 Toothed Belt Tension Roller, Remove and Install Removal Procedure 1. Remove upper part of toothed belt cover – see operation Toothed Belt Cover – Upper Part, Remove and Install. 2. Remove ribbed V–belts – see operation Ribbed V–belts, Remove and Install.

  • Page 52: Seal Ring In Front Camshaft Housing, Replace

    1-30 Engine Mechanical Industrial 1.6L Seal Ring in Front Camshaft Housing, Replace Removal Procedure 1. Remove upper part of toothed belt cover – see operation Toothed Belt Cover – Upper Part, Remove and Install. 2. Remove ribbed V–belts – see operation Ribbed V–belts, Remove and Install.
  • Page 53 Industrial 1.6L Engine Mechanical 1-31 Removal Procedure 1. Remove engine vent hose from camshaft housing cover. 2. Detach wiring trough from camshaft housing cover. 3. Remove camshaft housing cover from camshaft housing. 4. Remove camshaft sprocket (1) from camshaft – counterhold with open–ended spanner on hex of cam- shaft.

  • Page 54: Rear Toothed Belt Cover, Remove And Install

    1-32 Engine Mechanical Industrial 1.6L Rear Toothed Belt Cover, Remove and Install Removal Procedure 1. Remove upper part of toothed belt cover – see operation Toothed Belt Cover – Upper Part, Remove and Install. 2. Remove ribbed V–belts – see operation Ribbed V–belts, Remove and Install.
  • Page 55 Industrial 1.6L Engine Mechanical 1-33 Removal Procedure 1. Remove engine bleeding hose (1) from camshaft housing cover. 2. Remove camshaft housing cover (3) from camshaft hous- ing. 3. Remove camshaft sprocket – counterhold with open– ended spanner on hex of camshaft. 4.

  • Page 56: Cylinder Head

    1-34 Engine Mechanical Industrial 1.6L Cylinder Head Seal Ring in Rear Camshaft Housing, Replace Removal Procedure 1. Remove DIS ignition module – see operation DIS Igni- tion Module, Remove and Install. 2. Remove carrier plate (1) from camshaft housing. Clean 1.

  • Page 57: Exhaust Manifold, Remove And Install

    Industrial 1.6L Engine Mechanical 1-35 Exhaust Manifold, Remove and Install Removal Procedure 1. Disconnect spark plug connectors (2) from 1st, 2nd and 3rd cylinder. 2. Remove heat shields (3) of 2nd and 3rd cylinders with KM–834–A from cylinder head. 3. Remove heat shield (4) from exhaust manifold. 4.

  • Page 58: Intake Manifold, Remove And Install - Port Fuel Injected Models

    1-36 Engine Mechanical Industrial 1.6L Intake Manifold, Remove and Install - Port Fuel Injected Models 80361003 Important: Fuel leak – observe safety regulations and national legislation. Reduce fuel pressure with Pressure Tester KM–J–34730–91 via testing port – collect escaping fuel in suitable container. Removal Procedure 1.
  • Page 59 Industrial 1.6L Engine Mechanical 1-37 Intake Manifold, Remove and Install - Port Fuel Injected Models (Continued) 80361003 Installation Procedure Notice: Refer to Fastener Notice on page 1-2. 1. Install the intake manifold, a new gasket, and the intake manifold mounting bolts. Tighten Tighten the intake manifold bolts to 22 N•m (16 lb ft).

  • Page 60: Intake Manifold, Remove And Install - Throttle Body Fuel Injected Models

    1-38 Engine Mechanical Industrial 1.6L Intake Manifold, Remove and Install - Throttle Body Injected Models Important: Fuel leak – observe safety regulations and national legislation. Reduce fuel pressure with Pressure Tester KM–J–34730–91 via testing port – collect escaping fuel in suitable container. Removal Procedure 1.
  • Page 61 Industrial 1.6L Engine Mechanical 1-39 Removal Procedure 9. Remove ground cable (2) from engine control unit. 10. Disconnect wiring harness plug (4) from oxygen sensor, (5) throttle body, (7) camshaft sensor and injectors. 11. Detach wiring harness bracket (1) from intake manifold and lay wiring harness aside.

  • Page 62: Heat Shields, Remove And Install

    1-40 Engine Mechanical Industrial 1.6L Installation Procedure 1. Attach coolant hoses to throttle body. 2. Install ribbed V–belt – see operation Ribbed V–belt, Remove and Install. 3. Attach engine vent hoses to camshaft housing cover. 4. Close coolant drain bolt. 5.
  • Page 63 Industrial 1.6L Engine Mechanical 1-41 Important: Before dismantling the toothed belt – screw fastening bolt for toothed belt drive gear into crankshaft and move crankshaft in engine rotational direction by 60° (dimension I) to before TDC mark. Removal Procedure 1. Move toothed belt tension roller upward against spring force until bore holes align.
  • Page 64 1-42 Engine Mechanical Industrial 1.6L Removal Procedure 1. Attach Valve Lifter Depressor MKM–891 to camshaft housing. 2. Uniformly compress all cam followers. 3. Pull camshaft (1) out of camshaft housing. 4. Release valve lifter depressor and remove from camshaft housing. 5.

  • Page 65: Hydraulicd Valve Lifter, Replace (Cylinder Head Installed)

    Industrial 1.6L Engine Mechanical 1-43 Installation Procedure 1. Install toothed belt – see operation Toothed Belt, Re- move and Install. 2. Remove fastening bolt from toothed belt drive gear and install toothed belt cover, lower part – see operation Toothed Belt Cover, Lower Part, Remove and Install. 3.

  • Page 66: Camshaft, Remove And Install (Cylinder Head Removed)

    1-44 Engine Mechanical Industrial 1.6L Installation Procedure 1. Insert hydraulic valve lifter (1) in camshaft housing. 2. Coat sliding surfaces of the rocker arm with MoS2 lubri- cating paste (grey) and insert in camshaft housing – note thrust piece. Adjust 1.

  • Page 67: Camshaft Housing, Replace

    Industrial 1.6L Engine Mechanical 1-45 Installation Procedure 1. Coat sliding surfaces of the camshaft with MoS2 lubri- cating paste (grey), insert camshaft in camshaft housing. 2. Install pressure plate on camshaft housing. Tighten Tightening torque: 8 Nm / 6 lb. ft. 3.
  • Page 68 1-46 Engine Mechanical Industrial 1.6L Removal Procedure 1. Remove cylinder head – see operation Cylinder Head, Remove and Install. 2. Remove DIS ignition module – see operation DIS Igni- tion Module, Remove and Install. 3. Remove carrier plate – see operation Seal Ring in Rear Camshaft Housing, Replace.

  • Page 69: Camshaft Housing, Check For Plane Surface

    Industrial 1.6L Engine Mechanical 1-47 Camshaft Housing, Check for Plane Surface Clean 1. Clean sealing surfaces and remove gasket remnants. Inspect 1. Check sealing surfaces in length and width for deforma- tion and check for warping along the diagonals – use straight edge.
  • Page 70 1-48 Engine Mechanical Industrial 1.6L Removal Procedure 1. Remove lower part of toothed belt cover – see operation Toothed Belt Cover – Lower Part, Remove and Install. 2. Screw fastening bolt for toothed belt drive gear into crank- shaft and move crankshaft in engine rotational direction by 90°...
  • Page 71 Industrial 1.6L Engine Mechanical 1-49 Removal Procedure 1. Move toothed belt tension roller upwards against spring force until bore holes align. 2. Fix toothed belt tension roller in place with suitable drift (2). 3. Mark running direction of the toothed belt for identifica- tion and remove toothed belt.
  • Page 72 1-50 Engine Mechanical Industrial 1.6L Removal Procedure 1. Remove rear part of toothed belt cover (arrow) from oil pump and camshaft housing. 2. Detach cylinder head bolts in sequence shown. 3. Remove camshaft housing from cylinder head. 4. Remove cam followers, thrust pieces and hydraulic valve lifter –...
  • Page 73 Industrial 1.6L Engine Mechanical 1-51 Installation Procedure 1. Install cylinder head gasket – mark ”OBEN/TOP” on top and towards timing side of engine. 2. Place cylinder head on cylinder block. 3. Insert hydraulic valve lifters, thrust pieces and cam fol- lowers with MoS2 paste (grey) –...
  • Page 74 1-52 Engine Mechanical Industrial 1.6L Installation Procedure 1. Install lower part of toothed belt cover – see operation Toothed Belt Cover – Lower Part, Remove and Install. 2. Attach ignition cable wiring trough to camshaft housing Tighten Tightening torque 8 Nm / 6 lb. ft. 3.

  • Page 75: Cylinder Head, Check For Plane Surface

    Industrial 1.6L Engine Mechanical 1-53 Cylinder Head, Check for Plane Surface Clean 1. Clean sealing surface and remove sealant remnants. Inspect 1. Check length and width of cylinder head sealing surfaces for deformation and diagonals for warpage – use straight edge.

  • Page 76: Crank Drive, Cylinder Block

    1-54 Engine Mechanical Industrial 1.6L Crank Drive, Cylinder Block Drive Disc, Remove and Install Removal Procedure 1. Counterhold drive disc with KM–652 (1) and remove from crankshaft. Installation Procedure 1. Attach drive disc with new bolts to crankshaft. Counterhold drive disc with KM–652. Tighten Tightening torque 55 Nm / 41 lb.

  • Page 77: Seal Ring - Rear Crankshaft, Replace

    Industrial 1.6L Engine Mechanical 1-55 Seal Ring – Rear Crankshaft, Replace Removal Procedure 1. Remove flywheel or drive disc – see operation Flywheel, Remove and Install or Drive Disc, Remove and Install. 2. Edge out seal ring (1) with suitable tool. Important: Do not damage sealing surfaces.

  • Page 78: Engine Vent Flange Or Gasket, Remove And Install

    1-56 Engine Mechanical Industrial 1.6L Engine Vent Flange and/or Gasket – Remove and Install Removal Procedure 1. Remove engine vent hose (1) from camshaft housing and engine vent flange. 2. Detach engine vent flange (3) from cylinder block and remove downward with gasket. Clean 1.

  • Page 79: Piston With Con-Rod, Remove And Install

    Industrial 1.6L Engine Mechanical 1-57 Piston with Con–rod, Remove and Install Removal Procedure 1. Remove oil pan – see operation Oil pan, Remove and Install. 2. Remove cylinder head – see operation Cylinder Head, Remove and Install. 3. Remove oil intake tube (1) from oil pump and cylinder block.
  • Page 80 1-58 Engine Mechanical Industrial 1.6L Important: Re-install the rod cap to the rod when the piston is removed from the engine block. The mating surfaces must be protected from damage. Inspect 1. Check all parts, clean and if necessary, replace. Re- place piston –...
  • Page 81 Industrial 1.6L Engine Mechanical 1-59 Installation 1. Coat piston rings with engine oil and compress with piston ring pliers. 2. Push piston into cylinder bore with hammer shaft. Important: Note installation position of piston and con– rod. Arrow (1) on piston head points to engine timing side, bead (2) on con–rod points to rear side of engine.
  • Page 82 1-60 Engine Mechanical Industrial 1.6L Installation Procedure Note: Note sequence of con–rod bearing caps. 1. Install con–rod bearing cap – bead (1) of con–rod bearing caps points to flywheel side. 2. Attach con–rod bearing cap to con–rod with new bolts. Torque Tightening torque 25 Nm / 18.5 lb.

  • Page 83: Piston Rings, Remove And Install

    Industrial 1.6L Engine Mechanical 1-61 Piston Rings, Remove and Install Removal Procedure 1. Remove piston with con–rod – see operation Piston with Con–rod, Remove and Install. 2. Remove piston rings with piston ring pliers (1). Clean 1. Clean piston ring grooves – use ground–down side of old piston ring.
  • Page 84 1-62 Engine Mechanical Industrial 1.6L Inspect 1. Check piston ring vertical play with feeler gauge in piston ring groove. Permissible vertical play: Squared ring (1): 0.02 to 0.04 mm Tapered ring (2): 0.04 to 0.06 mm Oil scraper ring (3): 0.01 to 0.03 mm.

  • Page 85: Con-Rod Bearing, Replace

    Industrial 1.6L Engine Mechanical 1-63 Con–rod Bearing, Replace Removal Procedure 1. Remove oil pan – see operation Oil Pan, Remove and Install. 2. Remove oil intake tube (1) from oil pump and cylinder block. Important: Mark order of con–rod bearing caps. 3.

  • Page 86: Con-Rod Bearing Clearance, Check (Determine Bearing Clearance With 50 Plastigage)

    1-64 Engine Mechanical Industrial 1.6L Con–rod Bearing Clearance, Check (Determine Bearing Clearance with Plastigage) Removal Procedure 1. Mark installation position (1) of con–rod bearing cap – remove con–rod bearing cap from con–rod. Important: To prevent the strip from tearing when removing the con–rod bearing cap, remove grease from the con–rod journal and lightly oil con–rod bearing shell.

  • Page 87: Con-Rod Bearing Clearance, Check (Determine Bearing Clearance With Micrometer And Inside Micrometer)

    Industrial 1.6L Engine Mechanical 1-65 Measure 1. Remove con–rod bearing cap again. Compare width of flattened plastic thread (arrow) with measuring scale. Permissible con–rod bearing clearance: 0.019 to 0.071 Notice: When reading the value, do not confuse millimeters and inches on the measuring scale. Installation Procedure 1.

  • Page 88: Piston, Replace

    1-66 Engine Mechanical Industrial 1.6L Measure 1. The con–rod bearing journal diameter is measured with a micrometer at points I and II and then calculated. Formula for calculating the average con–rod bearing jour- nal diameter: I + II Example: 42.729 mm + 42.725 mm 85.454 mm / 2 = 42.727 mm The average con–rod bearing journal diameter is 42.727...
  • Page 89 Industrial 1.6L Engine Mechanical 1-67 Important: Installation position: Bead (arrow) on con–rod points to flattened area (arrow) of the piston pin eye. Notice: Firmly seated piston pin cannot be pressed further. Perform assembly quickly. Assemble 1. Con–rod (1), piston pin, piston (2). 2.

  • Page 90: Crankshaft, Remove And Install

    1-68 Engine Mechanical Industrial 1.6L Crankshaft, Remove and Install Removal Procedure 1. Remove engine – see operation Engine, Remove and Install. 2. Mount engine with Adapter KM–412–10–A on Assembly Stands KM–412. 3. Remove oil pan – see operation Oil Pan, Remove and Install.
  • Page 91 Industrial 1.6L Engine Mechanical 1-69 Removal Procedure 1. Identify sequence of crankshaft bearing caps. 2. Remove crankshaft bearing caps from cylinder block. 3. Remove crankshaft from cylinder block. Clean 1. Clean all parts. Inspect 1. Check crankshaft – see operation Crankshaft, Check. Installation Procedure 1.

  • Page 92: Crankshaft, Check

    1-70 Engine Mechanical Industrial 1.6L Crankshaft, Check Crankshaft End Clearance, Check Measure 1. Attach Dial Gauge MKM–571–B with dial gauge bracket to one face of cylinder block and position probe of dial gauge on crankshaft. 2. Slide crankshaft in longitudinal direction. Permissible crankshaft longitudinal play: 0.100 to 0.202 mm.

  • Page 93: Crankshaft Bearing Clearance, Check (Determine Crankshaft Bearing Clearnace Using External Micrometer And Inside Micrometer)

    Industrial 1.6L Engine Mechanical 1-71 Removal Procedure 1. Remove crankshaft bearing cap. Measure 1. Compare width of flattened plastic thread (arrow) with measuring scale. ”Plastigage” is available for various measuring ranges. Perm. crankshaft bearing play: 0.015 to 0.041 mm. Torque – Angle Method 1.

  • Page 94: Cylinder Block, Check For Plane Surface

    1-72 Engine Mechanical Industrial 1.6L Measure 1. The crankshaft journal diameter is measured with a micrometer at points I and II and then calculated. Formula for calculating the average crankshaft bearing journal diameter: I + II Example: 54.962 mm +54.964 mm 109.926 mm / 2 = 54.963 mm The average crankshaft journal diameter is 54.963 mm.

  • Page 95: Oil Circuit

    Industrial 1.6L Engine Mechanical 1-73 Oil Circuit Oil Filter, Replace Removal Procedure 1. Remove oil filter with KM–726–A (1) – place collecting basin underneath. Installation Procedure 2. Coat seal ring of new oil filter lightly with engine oil and attach to cylinder block. Tighten Tightening torque 15 Nm / 11lb.
  • Page 96 1-74 Engine Mechanical Industrial 1.6L Important: Before dismantling the toothed belt – screw fastening bolt for toothed belt drive gear into crankshaft and move crankshaft in engine rotational direction by 60° (dimension I) to before TDC mark. Removal Procedure 1. Remove toothed belt – see operation Toothed Belt, Re- move and Install.
  • Page 97 Industrial 1.6L Engine Mechanical 1-75 Installation Procedure 1. Slide Protective Sleeve KM–417 (1) onto crankshaft jour- nal. Lightly coat sealing lip of the new seal ring with sili- con grease (white) and slide over the protective sleeve onto crankshaft journal. Removal Procedure 1.

  • Page 98: Oil Pan, Remove And Install

    1-76 Engine Mechanical Industrial 1.6L Oil Pan, Remove and Install Removal Procedure 1. Open oil drain plug – place collecting basin underneath. 2. Remove oil pan from cylinder block and oil pump. Clean 1. Clean sealing surfaces and remove gasket remnants. Installation Procedure 1.

  • Page 99: Oil Pump, Remove And Install

    Industrial 1.6L Engine Mechanical 1-77 Oil Pump, Remove and Install Important: Prior to removing toothed belt – set crankshaft to approx. 60° (dimension I) before TDC mark. Removal Procedure 1. Remove oil pan – see operation Oil Pan, Remove and Install.
  • Page 100 1-78 Engine Mechanical Industrial 1.6L Installation Procedure 1. Attach oil pump with new seal (1) to cylinder block. Tighten Tightening torque 10 Nm / 7 lb. ft. 2. Slide Protective Sleeve KM–417 onto crankshaft journal. 3. Lightly coat sealing lip of the new seal ring with silicon grease (white) and slide over the protective sleeve onto crankshaft journal.

  • Page 101: Oil Pump, Check

    Industrial 1.6L Engine Mechanical 1-79 Oil Pump, Check Removal Procedure 1. Remove oil pan – see operation Oil Pan, Remove and Install. 2. Remove upper part of toothed belt cover – see operation Toothed Belt Cover – Upper Part, Remove and Install. 3.
  • Page 102 1-80 Engine Mechanical Industrial 1.6L Installation Procedure 1. Oil pump cover to oil pump. Tighten Tightening torque 6 Nm / 4 lb. ft. 2. Install safety valve with new seal ring in oil pump. Tighten Tightening torque 50 Nm / 37 lb. ft. 3.

  • Page 103: Safety Valve, Remove And Install

    Industrial 1.6L Engine Mechanical 1-81 Safety Valve, Remove and Install Removal Procedure 1. Remove closure plug (1) from oil pump. 2. Remove seal ring, spring, piston from oil pump. Installation Procedure 1. Insert piston (2) – ensure installation position is correct. 2.

  • Page 104: Oil Baffle Plate, Remove And Install

    1-82 Engine Mechanical Industrial 1.6L Oil Baffle Plate, Remove and Install Removal Procedure 1. Remove oil pan – see operation Oil Pan, Remove and Install. 2. Remove oil baffle plate (1). Installation Procedure 1. Attach oil baffle plate to oil pan. Tighten Tightening torque 8 Nm / 6 lb.

  • Page 105: Oil Dipstick Tube, Remove And Install

    Industrial 1.6L Engine Mechanical 1-83 Oil Dipstick Guide Tube, Remove and Install Removal Procedure 1. Withdraw oil dipstick guide tube (1) from cylinder block. Installation Procedure 1. Push new seal ring (2) onto oil dipstick guide tube and lightly coat with engine oil. 2.

  • Page 106: Coolant Thermostat, Remove And Install

    1-84 Engine Mechanical Industrial 1.6L Coolant Thermostat, Remove and Install Refer to operation Coolant Thermostat, Remove and Install in Section 2, Engine Cooling. Coolant Pump, Remove and Install Refer to operation Coolant Pump, Remove and Install in Section 2, Engine Cooling. Fuel Pressure, Check Important: Fuel escapes.

  • Page 107: Coolant Temperature Sensor, Remove And Install

    Industrial 1.6L Engine Mechanical 1-85 Coolant Temperature Sensor, Remove and Install Removal Procedure Installation Procedure 1. Open coolant drain bolt – collect escaping coolant. 1. Attach coolant temperature sensor to cylinder head with new seal ring (3). 2. Detach wiring harness plug (2). Tighten 3.

  • Page 108: Starter

    1-86 Engine Mechanical Industrial 1.6L Starter Starter, Remove and Install Removal Procedure 1. Disconnect negative battery cable. 2. Remove cable connections (1) and (2) from starter. 3. Remove ground cable (4). 4. Remove fastening nut (3) and fastening bolt (5) from starter.
  • Page 109 Industrial 1.6L Engine Mechanical 1-87 Installation Procedure 1. Position alternator in alternator support and hand–tighten lower alternator fastening bolt. 2. Attach cable connections to alternator. 3. Attach alternator and wiring harness bracket to alterna- tor shackle. Tighten Tightening torque 20 Nm/ 15 lb. ft. 4.

  • Page 110: Special Tools And Equipment

    1-88 Engine Mechanical Industrial 1.6L Special Tools and Equipment KM–135 Adapter KM–340–1–F Cutter Set To measure engine oil pressure in conjunction with To mill, rework valve seats KM–498–B KM–348 Spring Compressor KM–194–E Spark Plug Key To compress valve springs, cylinder head removed To remove and install spark plugs, A/F 16 mm KM–301 Gauge Bar To check piston projection...
  • Page 111 Industrial 1.6L Engine Mechanical 1-89 Special Tools and Equipment (Continued) KM–352 Installer KM–419 Distance Gauge To install valve stem sealing To check valve stem projection KM–412 Engine Overhaul Stand KM–421–A Adjusting Wrench To hold removed engine To adjust toothed belt tension KM–412–10 Adapter To hold engine in conjunction with KM–412 KM–417 Assembly Sleeves...
  • Page 112 1-90 Engine Mechanical Industrial 1.6L Special Tools and Equipment (Continued) KM–422 Installer KM–498–B Oil pressure gauge To press seal ring in camshaft housing To check engine oil pressure in conjunction with KM–135 KM–427 Remover / Installer To install guide pins into engine block KM–565–A Remover / Installer To remove and install rocker arms and valve play KM–470–B Angular Torque Wrench...
  • Page 113 Industrial 1.6L Engine Mechanical 1-91 SpecialTools and Equipment (Continued) MKM–571–B Dial Gauge KM–609 Electronic Kit I To measure piston projection Diagnosis of electric and electronic systems MKM–588–A Pressure Gauge MKM–610 Torque Wrench, 1/2” To check fuel pressure Range 30 – 130 Nm / 22 – 96 lb. ft. MKM–596–A Temperature Gauge To measure oil temperature, exhaust gas special test (Ger- man AU)
  • Page 114 1-92 Engine Mechanical Industrial 1.6L Special Tools and Equipment (Continued) MKM–611 Torque Wrench, 3/8” KM–658 Installer Range 10 – 60 Nm / 7 – 44 lb. ft. To install crankshaft rear seal ring KM–634 Remover / Installer KM–664 Reamer Set 7 mm To remove/install piston pin Valve guide ream (j 7 mm) KM–652 Flywheel Holder...
  • Page 115 Industrial 1.6L Engine Mechanical 1-93 SpecialTools and Equipment (Continued) MKM–669 Torque Wrench, 1/2” KM–834–A Remover / Installer Range 50 – 300 Nm / 37 – 221 lb. ft. To remove and install heat sleeves KM–726–A Oil Filter Wrench KM–840 Remover To remove/install the oil filter To remove valve stem seal KM–796–A Remover...
  • Page 116 1-94 Engine Mechanical Industrial 1.6L Special Tools and Equipment (Continued) MKM–889 Automatic Valve Spring Lever KM–911 Flywheel Holder To remove/install the valve stem seals (cylinder head installed) To lock flywheel/drive disc MKM–891 Valve Lifter Depressor KM–2355 Socket Wrench T55 To remove/install camshaft (cylinder head installed) To loosen/tighten cylinder head bolts KM–904 Base Frame To remove and install various vehicle components...
  • Page 117 Industrial 1.6L Engine Mechanical 1-95 Special Tools and Equipment (Continued) KM–6000 Centering Tool KM–6179 Remover / Installer To remove and install front axle in conjunction with To remove and install oxygen sensor KM–904 KM–J–34730–91 Pressure Tester KM–6001–A Engine Mount To check fuel pressure To align engine to body in conjunction with KM–6173 KM–6173 Engine Mount To support engine on front axle body in conjunction with KM–...
  • Page 118 Industrial 1.6L Engine Cooling 2-1 Section 2 Engine Cooling Fastener Notice ............2-2 Coolant Pipe and/or Hose Replacement ....2-11 Specifications ............2-3 Drive Belt Replacement .......... 2-12 Fastener Tightening Specifications ......2-3 Cooling Fan Replacement ........2-12 Engine Cooling System Specifications ...... 2-3 Fan Shroud Replacement ........

  • Page 119: Fastener Notice

    2-2 Engine Cooling Industrial 1.6L Fastener Notice NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number of that application. UNLESS OTHERWISE SPECIFIED, Do Not use supplemental coatings (paints, greases or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces.

  • Page 120: Specifications

    Industrial 1.6L Engine Cooling 2-3 Engine Cooling - 1.6L Specifications Fastener Tightening Specifications Application N•m lb ft lb in Coolant Temperature Sensor Drain Cock to Radiator Fan Blade to Pulley Bolts 15-18 10-13 Fan Guard Mounting Bolts 16-20 12-15 12-15 Fan Housing Mounting Bolts 16-20 12-15...

  • Page 121: Diagnostic Information And Procedures

    2-4 Engine Cooling Industrial 1.6L Diagnostic Information and Procedures Engine Overheating Step Action Value(s) — Check the coolant level. Go to Step 2 Go to Step 3 Is the coolant level low? — Add coolant to the system Go to Step 3 System OK Does the engine still overheat? —...

  • Page 122: Loss Of Coolant

    Industrial 1.6L Engine Cooling 2-5 Loss of Coolant Step Action Value(s) — — Do a visual system check to look for a coolant loss. Check the ground under the equipment. Go to Step 2 Is there coolant on the ground? —...

  • Page 123: Engine Fails To Reach Normal Operating Temp

    2-6 Engine Cooling Industrial 1.6L Thermostat Diagnosis (Cont’d) Use the following procedure in order to check for a cold engine, slow warm–up or the engine does not reach normal ° ° ° ° operating temperature of 86.6 C (188 F) to 96.6 C (206 1.

  • Page 124: Coolant Concentration Testing

    Industrial 1.6L Engine Cooling 2-7 Coolant Concentration Testing Hydrometer Due to changes in commercially available antifreeze, the use of a hydrometer may give an incorrect reading. The hydrometer should be used to test an ethylene glycol–based antifreeze only. Ethylene glycol–based antifreeze is recommended for year round use.

  • Page 125: Cooling System Leak Testing

    2-8 Engine Cooling Industrial 1.6L On–Equipment Pressure Testing • The tester temperature scale is reversed from the standard thermometer scale in that below Tools Required zero readings are on the upper half of the J 24460–01 Radiator Pressure Tester scale. Readings on the lower half of the scale, which are the above zero readings, indicate solutions without enough antifreeze concentration to provide adequate rust...

  • Page 126: Repair Instructions

    Industrial 1.6L Engine Cooling 2-9 2. Check the engine drain plug in order to ensure that the Repair Instructions drain plug is closed. Draining and Filling Cooling System 3. Place a large funnel in the radiator fill hole. 4. Fill the system with ethylene glycol based coolant to the Draining Procedure radiator.

  • Page 127: Radiator Hose Replacement

    2-10 Engine Cooling Industrial 1.6L Radiator Hose Replacement Removal Procedure 1. Drain the coolant from the radiator so that the level of the coolant is below the hose that is being removed. 2. Remove the radiator hose clamps. 3. Remove the upper radiator hose from the radiator and the coolant thermostat housing.

  • Page 128: Engine Cooling

    Industrial 1.6L Engine Cooling 2-11 Coolant Pipe and/or Hose Replacement Removal Procedure 1. Drain the coolant from the radiator so that the level of the coolant is below the hose that is being removed. 2. Remove the radiator hose clamps. 3.

  • Page 129: Drive Belt Replacement

    2-12 Engine Cooling Industrial 1.6L Drive Belt Replacement Removal Procedure 1. Remove the fan guard. Refer to Fan Guard Replacement. 2. Loosen the generator mounting bolts. 3. Move the generator inward to loosen the tension on the drive belt. 4. Slide the belt off of the pulleys and over the fan blades.

  • Page 130: Fan Shroud Replacement

    Industrial 1.6L Engine Cooling 2-13 8. Remove the fan blade mounting bolts and washers. 9. Remove the fan, pulley and spacer, if equipped. Installation Procedure 1. Position fan, pulley, and spacer, if equipped, onto the water pump shaft. Notice: Refer to Fastener Notice. 2.

  • Page 131: Fan Guard Replacement

    2-14 Engine Cooling Industrial 1.6L Installation Procedure 1. Tilt the radiator forward and position the fan shroud over the cooling fan blades. Notice: Refer to Fastener Notice. 2. Install the fan shroud mounting bolts and washers. Tighten Tighten the fan shroud mounting bolts to 16-20 N•m (12- 15 lb ft).

  • Page 132: Coolant Thermostat And/Or Housing Replacement

    Industrial 1.6L Engine Cooling 2-15 Coolant Thermostat and/or Housing Replacement Removal Procedure 1. Drain the cooling system. Refer to Draining and Filling Cooling System. 2. Remove the upper radiator hose from the thermostat housing. Refer to Radiator Hose Replacement. 3. Remove the radiator upper support. Refer to Radiator Replacement.

  • Page 133: Water Pump Replacement

    2-16 Engine Cooling Industrial 1.6L 9. Install the radiator upper support. Refer to Radiator Replacement. 10. Connect the upper radiator hose to the coolant thermostat housing (1). Refer to Radiator Hose Replacement. 11. Fill the cooling system. Refer to Draining and Filling Cooling System.
  • Page 134 Industrial 1.6L Engine Cooling 2-17 Installation Procedure 1. Coat the sealing surfaces of the water pump with silicon (white) grease. Important: When installing the water pump, align the mark on the cylinder block (1) with the mark on the water pump (2).

  • Page 135: Drain Cock Replacement

    2-18 Engine Cooling Industrial 1.6L Drain Cock Replacement Removal Procedure 1. Drain the cooling system. Refer to Draining and Filling Cooling System. 2. Remove the drain cock from the radiator. nstallation Procedure Notice: Refer to Fastener Notice. 1. Install the drain cock to the radiator. Tighten Tighten the drain cock to 18 N•m (13 lb ft).

  • Page 136: Description And Operation

    Industrial 1.6L Engine Cooling 2-19 Description and Operation • Internal system leaks. Cooling System Description - The cylinder head gasket Cooling System - The cracked block This equipment has a pressure-type engine cooling - The timing chain cover system. The system has thermostatic control of the - The intake manifold gasket coolant circulation.

  • Page 137: Pressure Cap Description

    2-20 Engine Cooling Industrial 1.6L Pressure Cap Description Radiator Cap Caution: As long as there is pressure in the cooling system, the temperature can be considerably higher than the boiling temperature of the solution in the radiator, without causing the solution to boil. Removal of the radiator cap while the engine is hot and the pressure is high will cause the solution to boil instantaneously and possibly with explosive...

  • Page 138: Water Pump Description

    Industrial 1.6L Engine Cooling 2-21 Special Tools and Equipment Water Pump Description The die–cast pump is a centrifugal vane impeller type. Illustration Tool Number/Description The impeller turns on a steel shaft that rotates in a permanently lubricated ball bearing. The pump inlet connects to the bottom of the radiator by a rubber hose.
  • Page 139 Industrial 1.6L Engine Electrical 3-1 Section 3 Engine Electrical Fastener Notice ............3-2 Spark Plug Wires Not Operating Properly ....3-28 Engine Electrical - 1.6L .......... 3-3 Spark Plug Wire Resistance Test ......3-28 Specifications ............3-3 Spark Plug Wire Routing .......... 3-28 Fastener Tightening Specifications ......

  • Page 140: Fastener Notice

    3-2 Engine Electrical Industrial 1.6L Fastener Notice NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number of that application. UNLESS OTHERWISE SPECIFIED, Do Not use supplemental coatings (paints, greases or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces.

  • Page 141: Engine Electrical - 1.6L

    Industrial 1.6L Engine Electrical 3-3 Engine Electrical - 1.6L Specifications Fastener Tightening Specifications Specification Application English Metric Battery Case Retainer Nut or Bolt 18 N•m 13 lb ft Battery Case Top Bar Nut 10 N•m 89 lb in Battery Side Terminal Bolts 12 N•m 106 lb in Battery Top Terminal Nuts...
  • Page 142 3-4 Engine Electrical Industrial 1.6L Schematic and Routing Diagrams - Continued 80363001...
  • Page 143 Industrial 1.6L Engine Electrical 3-5 Schematic and Routing Diagrams - Continued 80363010...
  • Page 144 3-6 Engine Electrical Industrial 1.6L Schematic and Routing Diagrams - Continued 80363011...

  • Page 145: Component Locator

    Industrial 1.6L Engine Electrical 3-7 Component Locator Engine Electrical Components Name Location Locator View Wiring Diagram Battery Determined by customer usage and application — Pages 3xx Page 3-4 Generator At the RH front of the engine Engine Electrical Component Locator Views Ignition Switch Determined by customer usage and application...

  • Page 146: Diagnostic Information And Procedures

    3-8 Engine Electrical Industrial 1.6L Diagnostic Information and Procedures Charging System Check Step Action Normal Result(s) Abnormal Result* / Action The drive belt is correctly Adjust or replace the drive belt Check the generator pulley drive tensioned. Refer to Drive Belt Replacement in belt tension.

  • Page 147: Battery Common Causes Of Failure

    Industrial 1.6L Engine Electrical 3-9 Battery Common Causes of Failure • The battery may be damaged. - Cracked case - Corroded battery cable terminals - Loose battery cable connections - Loose battery hold–down - There may be a mechanical problem. - Loose or slipping drive belt - Structural failure of aftermarket mounting brackets - Misaligned pulleys...

  • Page 148: Battery Check

    3-10 Engine Electrical Industrial 1.6L Battery Check Step Action Normal Result(s) Abnormal Result(s)* Replace battery. Inspect the following areas • The battery case, the battery for battery acid: tray, and the surrounding • The battery case area are dry. • •...

  • Page 149: Battery Terminal Check

    Industrial 1.6L Engine Electrical 3-11 Battery Terminal Check q¯¤­ _¢¯¨¬« t ©°¤F®G w¤® l¬ a °¯¨¬«X>p¤¥¤r>¯¬>` ¯¯¤r´>a °¯¨¬«®>¬«>­ ¦¤>QKUL OL r°r«>¯§¤>¨¦«¨¯¨¬«>k¤´>¯¬>¯§¤>mdd>­¬®¨¯¨¬«L Å PL _¯¯¤ª­¯>¯¬>r¬¯ ¯¤>¯§¤>«¤¦ ¯¨±¤>F G>¡ ¯¯¤r´>¢ ¡©¤ ¢¬««¤¢¯¬r>¢©¬¢k²¨®¤>²¨¯§>©¨¦§¯>¥¨«¦¤r>­r¤®®°r¤L e¬>¯¬>q¯¤­>P e¬>¯¬>q¯¤­>Q b¬¤®>¯§¤>«¤¦ ¯¨±¤>F G>¢¬««¤¢¯¬r>r¬¯ ¯¤] ON>lĪ s®¤> >¯¬rq°¤>²r¤«¢§>¨«>¬r£¤r>¯¬>±¤r¨¥´>¯§¤>¯¬rq°¤>¯¬>©¬¬®¤« FVR>©¡>¨«G ¯§¤>«¤¦ ¯¨±¤>F G>¡ ¯¯¤r´>¯¤rª¨« ©>¡¬©¯L e¬>¯¬>q¯¤­>R e¬>¯¬>q¯¤­>Q g®>¯§¤>¯¬rq°¤> ¡¬±¤>¯§¤>®­¤¢¨¥¨¤£>± ©°¤] Å Å b¨®¢¬««¤¢¯>¯§¤>«¤¦ ¯¨±¤>F G>¡ ¯¯¤r´>¢ ¡©¤L e¬>¯¬>q¯¤­>S g®>¯§¤>¢ ¡©¤>£¨®¢¬««¤¢¯¤£] Å Å...
  • Page 150 3-12 Engine Electrical Industrial 1.6L Battery Terminal Check (cont’d) q¯¤­ _¢¯¨¬« t ©°¤F®G w¤® l¬ OP>lĪ Å OL a¬««¤¢¯>¯§¤>­¬®¨¯¨±¤>FIG>¡ ¯¯¤r´>¢ ¡©¤>¯¬>¯§¤>¡ ¯¯¤r´ FONT>©¡>¨«G ­¬®¨¯¨±¤>FIG>¯¤rª¨« ©L PL r¨¦§¯¤«>¯§¤>¢ ¡©¤>¡¬©¯>¯¬>¯§¤>®­¤¢¨¥¨¤£>± ©°¤L e¬>¯¬>q¯¤­>OO g®>¯§¤>¢ ¡©¤>¡¬©¯>­r¬­¤r©´>¯¨¦§¯¤«¤£] OL a¬««¤¢¯>¯§¤>«¤¦ ¯¨±¤>F - G>¡ ¯¯¤r´>¢ ¡©¤>¯¬>¯§¤>¡ ¯¯¤r´ OP>lĪ Å FONT>©¡>¨«G «¤¦ ¯¨±¤>FKG>¯¤rª¨« ©L ` ¯¯¤r´>r¤rª¨« ©® PL r¨¦§¯¤«>¯§¤>¢ ¡©¤>¡¬©¯>¯¬>¯§¤>®­¤¢¨¥¨¤£>± ©°¤L g®>¯§¤>¢ ¡©¤>¡¬©¯>­r¬­¤r©´>¯¨¦§¯¤«¤£] Battery Not Operating Properly •...
  • Page 151 Industrial 1.6L Engine Electrical 3-13 Battery Not Operating Properly q¯¤­ _¢¯¨¬« t ©°¤F®G w¤® l¬ r¬¬©®>p¤q°¨r¤£ h>RPNNN>` ¯¯¤r´>r¤®¯¤r h>QWPNN>b¨¦¨¯ ©>k°©¯¨ª¤¯¤r>FbkkG nMl>OPQNQNRN>` ¯¯¤r´>r¤rª¨« ©>_£ ­¯¤r®>Fq¨£¤>n¬®¯>` ¯¯¤r¨¤®>m«©´G Å e¬>¯¬>` ¯¯¤r´ f ®>¯§¤>` ¯¯¤r´>a§¤¢k>¡¤¤«>­¤r¥¬rª¤£] e¬>¯¬>q¯¤­>P a§¤¢kL Å g®>¯§¤>¡ ¯¯¤r´>¨«>¯§¤>±¤§¨¢©¤J>²¨¯§>¯§¤>¡ ¯¯¤r´>¢ ¡©¤® e¬>¯¬>q¯¤­>R e¬>¯¬>q¯¤­>Q ¢¬««¤¢¯¤£] Å Å OL j¨¦§¯©´>²¨r¤>¡r°®§>¯§¤>©¤ £>¥ ¢¤®>¬¥>¡¬¯§>¡ ¯¯¤r´ ¯¤rª¨« ©®L PL g«®¯ ©©>¯§¤>¯¤rª¨« ©> £ ­¯¤r®>¯¬>¡¬¯§>¬¥>¯§¤>¡ ¯¯¤r´ ¯¤rª¨« ©®L>p¤¥¤r>¯¬>nMl>OPQNQNRNL e¬>¯¬>q¯¤­>T _r¤>¯§¤>¡ ¯¯¤r´>¯¤rª¨« ©> £ ­¯¤r®>¨«®¯ ©©¤£] Å c«®°r¤>¯§ ¯>¯§¤>¡ ¯¯¤r´>¯¤rª¨« ©®> r¤>¢©¤ «J>¯¨¦§¯J> «£>¨« e¬>¯¬>` ¯¯¤r´...
  • Page 152 3-14 Engine Electrical Industrial 1.6L Battery Not Operating Properly (cont’d) q¯¤­ _¢¯¨¬« t ©°¤F®G w¤® l¬ SLS>t s®¤> >h>QWPNN>£¨¦¨¯ ©>ª°©¯¨ª¤¯¤r>FbkkG>¨«>¬r£¤r>¯¬>¯¤®¯>¯§¤ ¡ ¯¯¤r´>±¬©¯ ¦¤>²¨¯§>¯§¤>h>RPNNN>¯¤®¯¤r>¢¬««¤¢¯¤£L e¬>¯¬>q¯¤­>PS e¬>¯¬>q¯¤­>PW g®>¯§¤>±¬©¯ ¦¤> ¯>¬r>¡¤©¬²>¯§¤>®­¤¢¨¥¨¤£>± ©°¤] Å s®¤>¯§¤>®¢r¬©©>k¤´®>¬«>¯§¤>h>RPNNN>¯¤®¯¤r>¯¬>®¤©¤¢¯>¤¨¯§¤r gl–tcfgajc>F¥¬r>¬«K¤q°¨­ª¤«¯>¯¤®¯¨«¦G>¬r>msr–md– tcfgajc>F¥¬r>¬¥¥K¤q°¨­ª¤«¯>¯¤®¯¨«¦GJ>£¤­¤«£¨«¦>¬«>¯§¤ ¥¬©©¬²¨«¦>¢¬«£¨¯¨¬«®X • s®¤>gl–tcfgajc>¯¤®¯¨«¦>¨¥>¯§¤>¡ ¯¯¤r´>¢ ¡©¤®> r¤ ¢¬««¤¢¯¤£>¯¬>¯§¤>¡ ¯¯¤r´L • s®¤>msr–md–tcfgajc>¯¤®¯¨«¦>¨¥>¯§¤>¡ ¯¯¤r´ ¢ ¡©¤®> r¤>£¨®¢¬««¤¢¯¤£> «£>¯§¤>¯¤rª¨« ©> £ ­¯¤r®  r¤>¨«®¯ ©©¤£L e¬>¯¬>q¯¤­>OO e¬>¯¬>q¯¤­>OP u ®>gl–tcfgajc>¯¤®¯¨«¦>®¤©¤¢¯¤£] Å r§¤>£¨®­© ´>¬«>¯§¤>¯¤®¯¤r>²¨©©>®§¬²>_ju_wq>rcqr>_r `_rrcpw>rcpkgl_jJ> «£>¯§¤«>¢§ «¦¤>¯¬>qcjcar p_rgleL e¬>¯¬>q¯¤­>OQ e¬>¯¬>q¯¤­>QU b¬¤®>¯§¤>£¨®­© ´>r¤ £>qcjcar>p_rgle]...

  • Page 153: Engine Electrical

    Industrial 1.6L Engine Electrical 3-15 Battery Not Operating Properly (cont’d) q¯¤­ _¢¯¨¬« t ©°¤F®G w¤® l¬ Å OL nr¤®®>¯§¤>ambc>¡°¯¯¬«>¬«>¯§¤>h>RPNNNL PL d¬r>² rr «¯´>­°r­¬®¤®J>²r¨¯¤>¯§¤>£¨®­© ´¤£>¢¬£¤>¬« ¯§¤>r¤­ ¨r>¬r£¤rL e¬>¯¬>q¯¤­>PR e¬>¯¬>q¯¤­>PQ g®>¯§¤>¦r¤¤«>£¬¯>F¨¥> ­­©¨¢ ¡©¤G>±¨®¨¡©¤>¨«>¯§¤>¡ ¯¯¤r´’® §´£r¬ª¤¯¤r] Å a§ r¦¤>¯§¤>¡ ¯¯¤r´L>p¤¥¤r>¯¬>` ¯¯¤r´>a§ r¦¨«¦L e¬>¯¬>q¯¤­>PR e¬>¯¬>q¯¤­>QW g®>¯§¤>¦r¤¤«>£¬¯>F¨¥> ­­©¨¢ ¡©¤G>±¨®¨¡©¤>¨«>¯§¤>§´£r¬ª¤¯¤r] Å Å r§¤>¡ ¯¯¤r´>¨®>miL>g«®¯ ©©>¯§¤>¡ ¯¯¤r´L>p¤¥¤r>¯¬>` ¯¯¤r´ p¤­© ¢¤ª¤«¯L q´®¯¤ª>mi g®>¯§¤> ¢¯¨¬«>¢¬ª­©¤¯¤] Å Å OL nr¤®®>¯§¤>ambc>¡°¯¯¬«>¬«>¯§¤>h>RPNNN>¯¤®¯¤rL PL d¬r>² rr «¯´>­°r­¬®¤®J>²r¨¯¤>¯§¤>£¨®­© ´¤£>¢¬£¤>¬«...
  • Page 154 Industrial 1.6L Engine Electrical 3-21 Generator Not Operating Properly (cont’d) q¯¤­ _¢¯¨¬« t ©°¤F®G w¤® l¬ OP>t OL b¨®¢¬««¤¢¯>¯§¤>«¤¦ ¯¨±¤>¡ ¯¯¤r´>¢ ¡©¤>¥r¬ª>¯§¤>¡ ¯¯¤r´L PL b¨®¢¬««¤¢¯>¯§¤>¡ ¯¯¤r´>F²§¨¯¤G>²¨r¤>¥r¬ª>¯§¤>¦¤«¤r ¯¬r ¡ ¯¯¤r´>¯¤rª¨« ©L QL a¬««¤¢¯>¯§¤>r¤£> ªª¤¯¤r>©¤ £>¯¬>¯§¤>¦¤«¤r ¯¬r>¡ ¯¯¤r´ ¯¤rª¨« ©> «£>¯§¤>¡© ¢k>©¤ £>¯¬>¯§¤>¦¤«¤r ¯¬r>¡ ¯¯¤r´ ²¨r¤>¯¤rª¨« ©L RL p¤K¢¬««¤¢¯>¯§¤>«¤¦ ¯¨±¤>¡ ¯¯¤r´>¢ ¡©¤>¯¬>¯§¤>¡ ¯¯¤r´L SL m¡®¤r±¨«¦>­¬© r¨¯´J>¢¬««¤¢¯>¯§¤>±¬©¯ª¤¯¤r>©¤ £®>¯¬>¯§¤ ­¬®¨¯¨±¤> «£>«¤¦ ¯¨±¤>¡ ¯¯¤r´>¯¤rª¨« ©®L e¬>¯¬>q¯¤­>W e¬>¯¬>q¯¤­>V g®>¯§¤>±¬©¯ ¦¤> ¡¬±¤>¯§¤>®­¤¢¨¥¨¤£>± ©°¤] Å Å OL p¤¢§¤¢k>¯§¤>¢¬««¤¢¯¨¬«®>¯§ ¯>²¤r¤>ª £¤>¨«>q¯¤­>UL e¬>¯¬>q¯¤­>W PL a¬rr¤¢¯>¯§¤>¢¬««¤¢¯¨¬«®>¨¥>¯§¤´>²¤r¤>r¤±¤r®¤£L UN>_ a °¯¨¬«X>k k¤>®°r¤>¯§ ¯>¯§¤>©¬ £>¨®>¢¬ª­©¤¯¤©´>¯°r«¤£...
  • Page 155 3-22 Engine Electrical Industrial 1.6L Generator Not Operating Properly (cont’d) q¯¤­ _¢¯¨¬« t ©°¤F®G w¤® l¬ Å e¬>¯¬>a§ r¦¨«¦ Å a °¯¨¬«X>k k¤>®°r¤>¯§ ¯>¯§¤>©¬ £>¨®>¢¬ª­©¤¯¤©´>¯°r«¤£ q´®¯¤ª>a§¤¢k ¬¥¥>¡¤¥¬r¤>¢¬««¤¢¯¨«¦>¬r>£¨®¢¬««¤¢¯¨«¦> >¢ r¡¬«>­¨©¤ ©¬ £>¯¤®¯¤r>¯¬>¯§¤>¡ ¯¯¤r´L>m¯§¤r²¨®¤J>®­ rk¨«¦>¢¬°©£ ¨¦«¨¯¤>¡ ¯¯¤r´>¦ ®®¤®>²§¨¢§> r¤>¤³¯r¤ª¤©´>¥© ªª ¡©¤  «£>ª ´>¤³­©¬£¤>±¨¬©¤«¯©´L OL b¨®¢¬««¤¢¯>¯§¤>£¨¦¨¯ ©>ª°©¯¨ª¤¯¤rL PL r°r«>mdd>¯§¤>©¬ £>¨«>¯§¤>¢ r¡¬«>­¨©¤>¯¤®¯¤rL QL r°r«>¯§¤>¨¦«¨¯¨¬«>®²¨¯¢§>¯¬>mdd>¯¬>®¯¬­>¯§¤>¤«¦¨«¤L RL b¨®¢¬««¤¢¯>¯§¤>¢ r¡¬«>­¨©¤>¯¤®¯¤r>¢ ¡©¤®>¥r¬ª>¯§¤ ¡ ¯¯¤r´L SL b¨®¢¬««¤¢¯>¯§¤>¡ ¯¯¤r´>«¤¦ ¯¨±¤>¯¤rª¨« ©L TL g«®­¤¢¯>¯§¤>¢¨r¢°¨¯>¡¤¯²¤¤«>¯§¤>¡ ¯¯¤r´>­¬®¨¯¨±¤>FIG ¯¤rª¨« ©> «£>¯§¤>¦¤«¤r ¯¬r>¬°¯­°¯>¯¤rª¨« ©>¥¬r> >§¨¦§– r¤®¨®¯ «¢¤>¢¬««¤¢¯¨¬«L>b¨® ®®¤ª¡©¤> «£>¢©¤ «> ©© ¢¬««¤¢¯¨¬«®>¨«>¯§¨®>¢¨r¢°¨¯L UL _®®¤ª¡©¤>¯§¤>¢¬««¤¢¯¨¬«®> «£>¯¨¦§¯¤«>¯¬...
  • Page 156 Industrial 1.6L Engine Electrical 3-23 Generator Assembly Bench Check This test requires both a fully charged battery and a generator test stand to operate the generator. The generator can be tested quicker and easier while it is still on the equipment. Refer to Generator Not Operat- ing Properly.
  • Page 157 3-24 Engine Electrical Industrial 1.6L Loud Whoop Sound after the Engine Fires nr¬¡©¤ª _¢¯¨¬« bcdglgrgmlX>_>©¬°£>²§¬¬­>®¬°«£> ¥¯¤r>¯§¤>¤«¦¨«¤>¥¨r¤®J>¡°¯>²§¨©¤>¯§¤>®¯ r¯¤r>¨®>®¯¨©©>§¤©£>¤«¦ ¦¤£L>r§¤>®¬°«£>¨®>®¨ª¨© r>¯¬>  ®¨r¤«>¨¥>¯§¤>¤«¦¨«¤>¨®>r¤±±¤£>²§¨©¤>¯§¤>®¯ r¯¤r>¨®>¤«¦ ¦¤£L r§¤>®¯ r¯¤r>ª¬¯¬r>¢©°¯¢§>¨®>²¬r«L OL p¤ª¬±¤>¯§¤>®¯ r¯¤r>ª¬¯¬rL>p¤¥¤r>¯¬>q¯ r¯¤r>k¬¯¬r>p¤­© ¢¤ª¤«¯L PL a§¤¢k>¯§¤>¢©°¯¢§L>p¤¥¤r>¯¬>q¯ r¯¤r>k¬¯¬r>g«®­¤¢¯¨¬«L Rumble, Growl, or a Knock nr¬¡©¤ª _¢¯¨¬« bcdglgrgmlX>_>r°ª¡©¤J>¦r¬²©J>¬r> >k«¬¢k>F¨«>®¤±¤r¤>¢ ®¤®G> ®>¯§¤>®¯ r¯¤r>¨®>¢¬ ®¯¨«¦>£¬²«>¯¬> >®¯¬­> ¥¯¤r>®¯ r¯¨«¦>¯§¤ ¤«¦¨«¤L r§¤>®¯ r¯¤r> rª ¯°r¤>¨®>¡¤«¯>¬r>°«¡ © «¢¤£L OL p¤ª¬±¤>¯§¤>®¯ r¯¤r>ª¬¯¬rL>p¤¥¤r>¯¬>q¯ r¯¤r>k¬¯¬r>p¤­© ¢¤ª¤«¯L PL a§¤¢k>¯§¤>¢©°¯¢§L>p¤¥¤r>¯¬>q¯ r¯¤r>k¬¯¬r>g«®­¤¢¯¨¬«L Starter No Load Test Tools Required •...
  • Page 158 Industrial 1.6L Engine Electrical 3-25 Starter Solenoid Does Not Click q¯¤­ _¢¯¨¬« t ©°¤F®G w¤® l¬ Å e¬>¯¬>` ¯¯¤r´ f ®>¯§¤>` ¯¯¤r´>a§¤¢k>¡¤¤«>­¤r¥¬rª¤£] e¬>¯¬>q¯¤­>P a§¤¢kL OL nr¬¡¤>¯§¤>®¯ r¯¤r>®¬©¤«¬¨£>²¨¯§> >£¨¦¨¯ ©>ª°©¯¨ª¤¯¤r ON>t ¥r¬ª>¯¤rª¨« ©>q>¯¬>¤«¦¨«¤>¦r¬°«£L PL r°r«>¯§¤>¨¦«¨¯¨¬«>®²¨¯¢§>¯¬>¯§¤>qr_pr>­¬®¨¯¨¬«L e¬>¯¬>q¯¤­>R e¬>¯¬>q¯¤­>Q b¬¤®>¯§¤>±¬©¯ ¦¤>ª¤ ®°r¤>ª¬r¤>¯§ «>¯§¤>®­¤¢¨¥¨¤£>± ©°¤] Å Å OL c«®°r¤>¯§ ¯>¯§¤>¡ ¯¯¤r´>¯¤rª¨« ©®> r¤>¢©¤ «> «£>¯¨¦§¯L PL p¤ª¬±¤>¯§¤>®¯ r¯¤rL QL a©¤ «>¯§¤>®¯ r¯¤r>ª¬¯¬r>ª¬°«¯¨«¦>¡¬©¯®J>¯§¤>®¯ r¯¤r ª¬¯¬r> «£>¯§¤>ª¬°«¯¨«¦>®°r¥ ¢¤L RL g«®¯ ©©>¯§¤>®¯ r¯¤rL SL _¯¯¤ª­¯>¯¬>®¯ r¯>¯§¤>¤«¦¨«¤L TL g¥>¯§¤>¤«¦¨«¤>£¬¤®>«¬¯>®¯ r¯J>r¤­© ¢¤>¯§¤>®¯ r¯¤r>ª¬¯¬rL p¤¥¤r>¯¬>q¯ r¯¤r>k¬¯¬r>p¤­© ¢¤ª¤«¯L...
  • Page 159 3-26 Engine Electrical Industrial 1.6L Starter Solenoid Clicks, Engine Does Not Crank or Cranks Slowly q¯¤­ _¢¯¨¬« t ©°¤F®G w¤® l¬ e¬>¯¬>q¯¤­>P e¬>¯¬>q¯ r¯¨«¦ u ®>¯§¤>q¯ r¯¨«¦>q´®¯¤ª>a§¤¢k>­¤r¥¬rª¤£] q´®¯¤ª>a§¤¢kL WLT>t OL b¨®¢¬««¤¢¯>¯§¤>bgq>¨¦«¨¯¨¬«>¤©¤¢¯r¨¢ ©>¢¬««¤¢¯¬rL PL a¬««¤¢¯> >£¨¦¨¯ ©>ª°©¯¨ª¤¯¤r>¥r¬ª>¯§¤>¡ ¯¯¤r´>­¬®¨¯¨±¤ FIG>¯¤rª¨« ©>¯¬>¯§¤>¡ ¯¯¤r´>«¤¦ ¯¨±¤>F G>¯¤rª¨« ©L QL r°r«>¯§¤>¨¦«¨¯¨¬«>®²¨¯¢§>¯¬>¯§¤>qr_pr>­¬®¨¯¨¬«L RL ar «k>¯§¤>¤«¦¨«¤>¥¬r>OS>®¤¢¬«£®L SL k¤ ®°r¤>¯§¤>±¬©¯ ¦¤> ¯>¯§¤>¤«£>¬¥>¢r «k¨«¦L TL p¤¢¬««¤¢¯>¯§¤>bgq>¨¦«¨¯¨¬«>¤©¤¢¯r¨¢ ©>¢¬««¤¢¯¬rL l¬¯¨¢¤X>l¤±¤r>¬­¤r ¯¤>¯§¤>®¯ r¯¤r>ª¬¯¬r>¥¬r>ª¬r¤>¯§ «>OS ®¤¢¬«£®> ¯> >¯¨ª¤L>_©©¬²>¨¯>¯¬>¢¬¬©> ¯>©¤ ®¯>¯²¬>ª¨«°¯¤®...
  • Page 160 Industrial 1.6L Engine Electrical 3-27 Starter Solenoid Clicks, Engine Does Not Crank or Cranks Slowly (cont’d) q¯¤­ _¢¯¨¬« t ©°¤F®G w¤® l¬ NLS>t OL b¨®¢¬««¤¢¯>¯§¤>bgq>¨¦«¨¯¨¬«>¤©¤¢¯r¨¢ ©>¢¬««¤¢¯¬rL PL a¬««¤¢¯> >£¨¦¨¯ ©>ª°©¯¨ª¤¯¤r>¥r¬ª>¯§¤>­¬®¨¯¨±¤>FIG ¡ ¯¯¤r´>¯¤rª¨« ©>¯¬>®¯ r¯¤r>®¬©¤«¬¨£>¯¤rª¨« ©>`L QL r°r«>¯§¤>¨¦«¨¯¨¬«>®²¨¯¢§>¯¬>¯§¤>qr_pr>­¬®¨¯¨¬«L RL m¡®¤r±¤>¯§¤>±¬©¯ ¦¤>²§¨©¤>¢r «k¨«¦L SL p¤¢¬««¤¢¯>¯§¤>bgq>¨¦«¨¯¨¬«>¤©¤¢¯r¨¢ ©>¢¬««¤¢¯¬rL l¬¯¨¢¤X>l¤±¤r>¬­¤r ¯¤>¯§¤>®¯ r¯¤r>ª¬¯¬r>¥¬r>ª¬r¤>¯§ «>OS ®¤¢¬«£®> ¯> >¯¨ª¤L>_©©¬²>¨¯>¯¬>¢¬¬©> ¯>©¤ ®¯>¯²¬>ª¨«°¯¤® ¡¤¥¬r¤>¢r «k¨«¦> ¦ ¨«L>c³¢¤®®¨±¤>¢r «k¨«¦>¢ «>¢ °®¤ ¬±¤r§¤ ¯¨«¦J>²§¨¢§>²¨©©>¢ °®¤>®¤r¨¬°®>£ ª ¦¤>¯¬>¯§¤>®¯ r¯¤r ª¬¯¬rL e¬>¯¬>q¯¤­>U e¬>¯¬>q¯¤­>V b¬¤®>¯§¤>±¬©¯ ¦¤>ª¤ ®°r¤>ª¬r¤>¯§ «>NLS>±¬©¯®] Å...

  • Page 161: Spark Plug Wires Not Operating Properly

    3-28 Engine Electrical Industrial 1.6L Spark Plug Wires Not Operating Properly 1. Check the routing of the wires, Improper routing can cause cross-firing. 2. Check each wire for any signs of cracks or splits in the wire. 3. Inspect each boot for signs of tears, piercing, arc through, or carbon tracking.

  • Page 162: Repair Instructions

    Industrial 1.6L Engine Electrical 3-29 REPAIR INSTRUCTIONS Battery Cable Replacement Notice: Always turn the ignition switch OFF when connecting or disconnecting batteries, battery chargers, or jumper cables. Failure to do so may damage the electronic control unit or other electrical components. Removal Procedure Important: Whenever battery cables are replaced, always use a replacement cable that is the same type, diameter, and length.

  • Page 163: Battery Charging

    3-30 Engine Electrical Industrial 1.6L Battery Charging Basic Rules When charging the battery, follow these basic rules: • Use a charger with an end of charge voltage of 16.0 volts. The charger should have a voltmeter that is accurate within 1 percent. •...
  • Page 164 3-16 Engine Electrical Industrial 1.6L Battery Not Operating Properly (cont’d) q¯¤­ _¢¯¨¬« t ©°¤F®G w¤® l¬ Å gª­¬r¯ «¯X>r¤ª­¤r ¯°r¤>¢¬ª­¤«® ¯¨¬«>¨®>¬«©´>«¤¢¤®® r´ ²§¤«>¯§¤>¯¤®¯¤r>£¤¯¤¢¯®>¯§ ¯>¯§¤>¡ ¯¯¤r´>¯¤ª­¤r ¯°r¤>ª ´  ¥¥¤¢¯>¯§¤>r¤®°©¯®>¬¥>¯§¤>¯¤®¯L OL s®¤>¯§¤>®¢r¬©©>k¤´®>¯¬>¨«£¨¢ ¯¤>²§¤¯§¤r>¯§¤>¨«¯¤r« © ¯¤ª­¤r ¯°r¤>¬¥>¯§¤>¡ ¯¯¤r´>¨®> ¡¬±¤>¬r>¡¤©¬²>N_a FQP_dGL>s®¤>¯§¤>¯¤ª­¤r ¯°r¤>¬¥>¯§¤>¡ ¯¯¤r´>¯¬>²§¨¢§ ¯§¤>¡ ¯¯¤r´>§ ®>¡¤¤«>¤³­¬®¤£>¥¬r>¯§¤>­ ®¯>®¤±¤r © §¬°r®>¨«>¬r£¤r>¯¬>¤®¯¨ª ¯¤>¯§¤>¯¤ª­¤r ¯°r¤L PL n°®§>¯§¤>clrcp>k¤´L r§¤>¯¤®¯¤r>²¨©©>¡r¨¤¥©´>£¨®­© ´>¯§¤>pcrcqrgle>ª¤®® ¦¤  «£>¯§¤>aa_>r ¯¨«¦>®¤©¤¢¯¤£>¥¬r>¯§¤>¯¤®¯L>r§¤>¯¤®¯>r¤®°©¯® ²¨©©>¯§¤«>®§¬²>¬«>¯§¤>£¨®­© ´L b¬>¯§¤>¯¤®¯>r¤®°©¯®>®§¬²>¬«>¯§¤>£¨®­© ´] e¬>¯¬>q¯¤­>OR e¬>¯¬>q¯¤­>QU Å Å OL r§¤>¯¤®¯¤r>£¤¯¤¢¯®>¯§ ¯> «>¤©¤¢¯r¨¢ ©>©¬ £>¨®>­r¤®¤«¯ F®°¢§> ®> >©¨¦§¯>¨®>¬«>¬r>¯§¤>¨¦«¨¯¨¬«>k¤´>¨®>«¬¯>¨«>¯§¤ mdd>­¬®¨¯¨¬«GL PL r°r«>mdd> ©©>¬¥>¯§¤>®´®¯¤ª>¤©¤¢¯r¨¢ ©>©¬ £®L e¬>¯¬>q¯¤­>QS _r¤> ©©>¬¥>¯§¤>®´®¯¤ª>¤©¤¢¯r¨¢ ©>©¬ £®>mdd] Å...
  • Page 165 Industrial 1.6L Engine Electrical 3-17 Notice: Always turn the ignition switch OFF when 11. If the fuse in the jumper wire does not blow, turn connecting or disconnecting batteries, battery charg- the J 38758 test switch ON, set the J 39200 to the ers, or jumper cables.
  • Page 166 3-18 Engine Electrical Industrial 1.6L Battery Hydrometer Displays Dark or Refer to Charging System Check or Battery Yellow Dot Electrical Drain/Parasitic Load. The maintenance–free battery has a built–in hydrom- • A clear or light yellow color means that eter which consists of a ball floating in the electrolyte. the battery fluid level is below the bottom of the The hydrometer is temperature–compensated.
  • Page 167 Industrial 1.6L Engine Electrical 3-19 Engine Cranks/Cranks Slowly, But Does Not Start q¯¤­ _¢¯¨¬« t ©°¤F®G w¤® l¬ OP>t s®¤> >£¨¦¨¯ ©>ª°©¯¨ª¤¯¤r>¯¬>ª¤ ®°r¤>¯§¤>±¬©¯ ¦¤>¬¥>¯§¤ ¡ ¯¯¤r´L g®>¯§¤>±¬©¯ ¦¤>¦r¤ ¯¤r>¯§ «>¬r>¤q° ©>¯¬>¯§¤>®­¤¢¨¥¨¤£>± ©°¤] e¬>¯¬>q¯¤­>S e¬>¯¬>q¯¤­>P Å OL c«®°r¤>¯§¤>¡ ¯¯¤r´>¯¤rª¨« ©®> «£>¯¤rª¨« ©>¡¬©¯®> r¤ ¥r¤¤>¥r¬ª>¢¬rr¬®¨¬«L PL a§ r¦¤>¯§¤>¡ ¯¯¤r´L>p¤¥¤r>¯¬>` ¯¯¤r´>a§ r¦¨«¦L QL b¨®¢¬««¤¢¯>¯§¤>bgq>¨¦«¨¯¨¬«>ª¬£°©¤>¢¬««¤¢¯¬rL RL _¯¯¤ª­¯>¯¬>¢r «k>¯§¤>¤«¦¨«¤L e¬>¯¬>q¯¤­>Q e¬>¯¬>q¯¤­>S b¬¤®>¯§¤>¤«¦¨«¤>¢r «k>«¬rª ©©´] Å OL a¬««¤¢¯>¯§¤>bgq>¨¦«¨¯¨¬«>ª¬£°©¤>¢¬««¤¢¯¬rL PL t¤r¨¥´>¯§ ¯>¯§¤>¢§ r¦¨«¦>®´®¯¤ª>¨®>¬­¤r ¯¨«¦>¢¬rr¤¢¯©´L p¤¥¤r>¯¬>a§ r¦¨«¦>q´®¯¤ª>a§¤¢kL q´®¯¤ª>mi e¬>¯¬>q¯¤­>R...
  • Page 168 3-20 Engine Electrical Industrial 1.6L Engine Cranks/Cranks Slowly, but Does Not Start (cont’d) q¯¤­ _¢¯¨¬« t ©°¤F®G w¤® l¬ Å Å p¤­ ¨r>¯§¤>§¨¦§–r¤®¨®¯ «¢¤>¢¬««¤¢¯¨¬«L q´®¯¤ª>mi g®>¯§¤>r¤­ ¨r>¢¬ª­©¤¯¤] Å Å p¤­© ¢¤>¯§¤>«¤¦ ¯¨±¤>F * G>¡ ¯¯¤r´>¢ ¡©¤L>p¤¥¤r>¯¬>` ¯¯¤r´ a ¡©¤>p¤­© ¢¤ª¤«¯L q´®¯¤ª>mi g®>¯§¤>r¤­ ¨r>¢¬ª­©¤¯¤] Å OL g«®­¤¢¯>¯§¤>®¯ r¯¤r>¯¬>£¤¯¤rª¨«¤>¨¥>¯§¤r¤>¨®> >§¨¦§– r¤®¨®¯ «¢¤>¢¬««¤¢¯¨¬«> ¯>¯§¤>®¯ r¯¤r>`>¯¤rª¨« ©L PL g¥>¯§¤>¡ ¯¯¤r´>­¬®¨¯¨±¤>FIG>¯¤rª¨« ©>² ®>«¬¯>­r¤±¨¬°®©´ ¨«®­¤¢¯¤£J>¤³ ª¨«¤>¯§¤>­¬®¨¯¨±¤>FIG>¯¤rª¨« ©> «£ ¯¤rª¨« ©>¡¬©¯>¥¬r>¢¬rr¬®¨¬«>²§¨¢§>²¬°©£>¨«£¨¢ ¯¤> >§¨¦§– r¤®¨®¯ «¢¤>¢¬««¤¢¯¨¬«L e¬>¯¬>q¯¤­>OR e¬>¯¬>q¯¤­>OS u ®>¯§¤r¤> >§¨¦§–r¤®¨®¯ «¢¤>¢¬««¤¢¯¨¬«>¥¬°«£]...

  • Page 169: Charging Time Required

    Industrial 1.6L Engine Electrical 3-31 Charging Time Required The time required to charge a battery will vary. The time depends on the following factors: • Size of the battery - A completely discharged heavy–duty battery requires more than twice the recharging time as a completely discharged light–duty battery.

  • Page 170: Battery Charge Low Or Completely Discharged

    3-32 Engine Electrical Industrial 1.6L Battery Charge Low or Completely Discharged Tools Required J 39200 Digital Multimeter (DMM), or Equivalent Caution: Refer to Battery Cautions on page 3-9. Notice: Always turn the ignition OFF when connecting or disconnecting battery cables, battery chargers, or jumper cables.

  • Page 171: Jump Starting In Case Of Emergency

    Industrial 1.6L Engine Electrical 3-33 Battery Replacement - Continued Installation Procedure 1. Install the battery into the carrier. Notice: Refer to Fastener Notice on page 3-2. 2. Install the battery hold–down retainers or the top bars. Tighten Tighten the retainer bolt to 18 N•m (13 lb ft). Tighten the top bar nut to 10 N•m (89 lb in). 3.

  • Page 172: Starter Motor Inspection

    3-34 Engine Electrical Industrial 1.6L Starter Motor Inspection Cleaning Procedure Notice: Do not use grease dissolving solvents for cleaning the overrunning clutch or armature. Solvents dissolve the grease packed in the clutch and damage the armature and the field coil insulation. Clean all starter motor parts with a soft cloth prior to testing.

  • Page 173: Starter Motor Replacement

    Industrial 1.6L Engine Electrical 3-35 Starter Motor Replacement Removal Procedure Notice: Never operate the starter motor more than 15 seconds at a time without pausing to allow it to cool for at least 2 minutes. Overheating, caused by excessive cranking, will damage the starter motor. Starter motors do not require lubrication except during overhaul.

  • Page 174: Generator Replacement

    3-36 Engine Electrical Industrial 1.6L Generator Replacement Removal Procedure The removal and installation instructions serve only as a guide. Additional operations may be required on some equipment to remove other equipment in order to gain access to the generator, the drive belt, and the brackets.

  • Page 175: Dis Ignition Module Replacement

    Industrial 1.6L Engine Electrical 3-37 DIS Ignition Module Replacement Removal Procedure 1. Noting their positions, remove the spark plug wires from the module. 2. Disconnect the engine wiring harness connector from the module. 3. Remove the three module mounting bolts. 4.
  • Page 176 3-38 Engine Electrical Industrial 1.6L 3. Remove the sensor mounting bolt. 4. Noting the pigtail routing, remove the sensor and pigtail from engine. 80363007 Installation Procedure 1. Position the crankshaft position sensor in its mounting bracket. 2. Install the sensor mounting bolt. Tighten Tighten the mounting bolt to 8 N•m (71 lb in).

  • Page 177: Description And Operation

    Industrial 1.6L Engine Electrical 3-39 Description and Operation Starting System Description Cranking Circuit The cranking circuit consists of the following compo- nents: • The battery • The starter motor • The ignition switch • All related electrical wiring For detailed schematics of the starting system refer to Schematic and Routing Diagrams.

  • Page 178: Batteries

    3-40 Engine Electrical Industrial 1.6L Batteries 3. A clear or light yellow dot means the electrolyte level is below the bottom of the hydrometer and is PSI does not supply batteries to equipment manufac- too low for diagnosis. When you find a battery in turers.

  • Page 179: Charging System Description

    Industrial 1.6L Engine Electrical 3-41 Charging System Description The charging system consists of the following compo- nents: • The battery • The generator • The voltmeter gauge • All related electrical wiring The generator supplies the electrical power for charg- ing the battery and for operating the accessories.

  • Page 180: Voltage Regulator

    3-42 Engine Electrical Industrial 1.6L Voltage Regulator The integral voltage regulator protects the unit’s operating accessories from receiving high voltage and the battery from being overcharged. No current regulation is needed because it determined by the design of the generator. The regulator is an extremely reliable device composed of two circuits.

  • Page 181: Ignition System Description

    Industrial 1.6L Engine Electrical 3-43 IGNITION SYSTEM DESCRIPTION The 1.6 Liter, 4-cylinder engine, is equipped with a distributorless ignition system (DIS). The electronic control unit (ECU) performs all of the ignition control functions based on signals from the crankshaft position sensor. The ignition system consists of a battery, the DIS ignition module containing two coil packs, a crankshaft position sensor, an ignition switch, the spark plugs, and...

  • Page 182: Spark Plugs

    3-44 Engine Electrical Industrial 1.6L Spark Plugs The 1.6 Liter engine uses resistor type spark plugs. The plugs used in this engine have a tapered seat, so a gasket is not required. A spark plug must operate within certain temperature limits to provide the performance and service life expected.

  • Page 183: Special Tools And Equipment

    Industrial 1.6L Engine Electrical 3-45 Special Tools and Equipment NOTE: The diagnostic tools shown here are available from Kent-Moore. However, equivalent tools supplied by other manufacturers are permissible for use. Illustration Tool Number/Description Illustration Tool Number/Description J 34142-B J 21008 -A Unpowered Test Light Self-Powered Test Light 5382...

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