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Engine distributors WSG-1068 Service Manual

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INDUSTRIAL ENGINE SERVICE MANUAL 
 
 
 
 
WSG‐1068   
 
    
  6.8 LITER 
 
 
 
 
EDI #1050180 
March, 2009 
 
 
 
 

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  • Page 1                   WSG‐1068                    6.8 LITER      INDUSTRIAL ENGINE SERVICE MANUAL    EDI #1050180  March, 2009   ...
  • Page 2 Pages 251‐ 298 Engine Distributors Inc. Engine Distributors Inc policy is one of continuous improvement and while every effort is made to ensure that this publication is up to date and correct in all respects, the right to Pages 299 ‐ 312...
  • Page 3 HEALTH & SAFETY WARNING: THE FOLLOWING HEALTH AND SAFETY RECOMMENDATIONS SHOULD BE CAREFULLY OBSERVED WARNING: CARRYING OUT CERTAIN OPERATIONS AND HANDLING SOME SUBSTANCES CAN BE DANGEROUS OR HARMFUL TO THE OPERATOR IF THE CORRECT SAFETY PRECAUTIONS ARE NOT OBSERVED. SOME SUCH PRECAUTIONS ARE RECOMMENDED AT THE APPROPRIATE POINTS IN THIS BOOK.

  • Page 4: Table Of Contents

    WSG-1068 GENERAL INFORMATION INDEX Subject Page General Information Introduction ............................Safety Notice............................Notes, Cautions, and Warnings......................Battery Handling and Charging ......................Forward ..............................Engine Identification..........................Parts and Service ..........................Diagnosis and Testing Special Tools............................Inspection and Verification ........................Symptom Chart ............................
  • Page 5 WSG-1068 GENERAL INFORMATION INDEX (CONT.) Subject Page General Service Procedures Bearing Inspection ............................Roller Follower Inspection........................... Hydraulic Lash Adjuster Inspection ......................Valve Stem Diameter ..........................Valve Stem-to-Valve Guide Clearance......................Valve Inspection............................Valve Guide Inner Diameter........................Valve Guide Reaming ..........................Valve Spring Installed Length........................

  • Page 6: General Information

    Engine Distributors Inc does not recommend using abrasive grinding discs to remove engine gasket material. Use manual gasket scrapers for removing gasket material from the engine sealing surfaces.

  • Page 7: Safety Notice

    WSG-1068 GENERAL INFORMATION Safety Notice There are numerous variations in procedures, techniques, tools and parts for servicing equipment, as well as in the skill of the individual doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each.

  • Page 8: Battery Handling And Charging

    WSG-1068 GENERAL INFORMATION Battery Handling and Charging The handling and correct use of lead acid batteries is not as hazardous provided that sensible precautions are observed and that operatives have been trained in their use and are adequately supervised. It is important that all labelling on the battery is carefully read, understood and complied with. The format of the following symbols and labels is common to most brands of lead acid battery.

  • Page 9: Forward

    Regular maintenance will result in minimal operating costs. Engines manufactured by Ford Motor Company are available through Engine Distributors Incorporated. When in need of parts or service, contact your local Authorized Distributor. In overseas territories, in the event of difficulties, communicate directly with the supervising Ford affiliated Company in your area whose address appears at the end of this book.

  • Page 10: Engine Identification

    WSG-1068 GENERAL INFORMATION Engine Identification Because of such a wide range of industrial engines – manufactured both in the U.S. and overseas – it is important that you have as complete identification of the engine as possible in order to provide the correct replacement parts. New engines being shipped include a standard parts listing describing the parts which does not tell the owner the part number.

  • Page 11: Parts And Service

    “Engines” or contact Engine Distributors. Engine Distributors Inc are equipped to perform major and minor repairs. They are anxious to see that all of your maintenance and service needs are quickly and courteously completed.

  • Page 12: Diagnosis And Testing

    WSG-1068 GENERAL INFORMATION DIAGNOSIS AND TESTING Special Tools 6   ...

  • Page 13: Inspection And Verification

    WSG-1068 GENERAL INFORMATION Inspection and Verification 1. Verify the customer concern by operating the engine to duplicate the condition. 2. Visually inspect for obvious signs of mechanical and electrical damage:  Engine coolant leaks.  Engine oil leaks.  Fuel leaks.

  • Page 14: Symptom Chart

    WSG-1068 GENERAL INFORMATION Symptom Chart Condition Possible Source Action 8   ...
  • Page 15 WSG-1068 GENERAL INFORMATION 9   ...

  • Page 16: Engine Oil Leaks

    WSG-1068 GENERAL INFORMATION NOTE: When diagnosing engine oil leaks, the source Engine Oil Leaks and location of the leak must be positively identified prior to service. Testing Procedure Prior to performing this procedure, clean the cylinder  block, cylinder heads, valve covers, oil pan and flywheel Open the air supply valve until the pressure gauge with a suitable solvent to remove all traces of oil.

  • Page 17: Compression Tests

    WSG-1068 GENERAL INFORMATION Compression Tests Compression Pressure Limit Chart Compression Gauge Check 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly charged. Operate until the engine is at normal operating temperature.

  • Page 18: Cylinder Leakage Detection

    WSG-1068 GENERAL INFORMATION Cylinder Leakage Detection Intake Manifold Vacuum Test When a cylinder produces a low reading, use of the Engine Cylinder Leak Detection/Air Pressurization Kit Bring the engine to normal operating temperature. will be helpful in pinpointing the exact cause.
  • Page 19 WSG-1068 GENERAL INFORMATION Interpreting Vacuum Gauge Readings needle drops to 0 kPa (0 in-Hg). Upon A careful study of the vacuum gauge reading while the deceleration, the needle runs slightly above 74 engine is idling will help pinpoint trouble areas. Always kPa (22 in-Hg).

  • Page 20: Excessive Engine Oil Consumption

    WSG-1068 GENERAL INFORMATION the Engine Operator’s handbook. Excessive Engine Oil Consumption The amount of oil an engine uses will vary with the way Oil Consumption Test the equipment is driven in addition to normal engine-to The following diagnostic procedure is used to determine engine variation.

  • Page 21: Oil Pressure Test

    WSG-1068 GENERAL INFORMATION 11. Instruct the customer to run engine as usual and 20. Perform the oil consumption test to confirm the perform the following: oil consumption concern has been resolved.  Check the oil level regularly at intervals of 3 to 3-1/2 hours.

  • Page 22: Valve Train Analysis - Static

    WSG-1068 GENERAL INFORMATION Valve Train Analysis – Static Valve Train Analysis – Dynamic Start the engine and, while idling, check for proper With engine off and valve cover removed, check for operation of all parts. Check the following: damaged or severely worn parts and correct assembly.

  • Page 23: Camshaft Lobe Lift

    WSG-1068 GENERAL INFORMATION Camshaft Lobe Lift Check the lift of each lobe in consecutive order and 7. Compare the total lift recorded on the dial make a note of the readings. indicator with specifications. 1. Remove the valve covers. 8. To check the accuracy of the original dial 2.

  • Page 24: Hydraulic Lash Adjuster

    WSG-1068 GENERAL INFORMATION 1. Clean the lash adjuster to remove all traces of Hydraulic Lash Adjuster engine oil. Hydraulic lash adjuster noise can be caused by any of the following: NOTE: lash adjusters/lash adjuster cannot be checked  excessive collapsed lash adjuster gap with engine oil in them.

  • Page 25: General Service Procedures

    WSG-1068 GENERAL INFORMATION GENERAL SERVICE PROCEDURES WARNING: TO AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE TO THE EQUIPMENT, DO NOT OPERATE THE ENGINE WITH THE HOOD OPEN UNTIL THE FAN BLADE HAS BEEN EXAMINED FOR POSSIBLE CRACKS AND SEPARATION.

  • Page 26: Camshaft Lobe Lift

    WSG-1068 GENERAL INFORMATION Camshaft Lobe Lift Camshaft Runout Special Tool(s) 1. Use the Dial Indicator with Bracketry to measure camshaft intake lobe lift. NOTE: Camshaft journals must be within specifications before checking runout.  Use the Dial Indicator with Bracketry to measure the camshaft runout.

  • Page 27: Crankshaft Main Bearing Journal Diameter

    WSG-1068 GENERAL INFORMATION Crankshaft Main Bearing Journal Diameter Crankshaft Main Bearing Journal Taper   Measure each of the crankshaft main bearing Measure each of the crankshaft main bearing journal diameters in at least two directions. journal diameters in at least two directions at each end of the main bearing journal.

  • Page 28: Crankshaft Main Bearing Journal Clearance

    WSG-1068 GENERAL INFORMATION Crankshaft Main Bearing Journal 4. Verify the crankshaft journal clearance. Clearance  If it is out of specification, replace as necessary Special Tool(s) NOTE: Crankshaft main bearing journals must be within specifications before checking journal clearance. 1. Remove the crankshaft main bearing caps and Bearing Inspection bearings.

  • Page 29: Crankshaft End Play

    WSG-1068 GENERAL INFORMATION Crankshaft End Play Crankshaft Runout Special Tool(s) Special Tool(s) 1. Measure the crankshaft end play. Use the Dial NOTE: Crankshaft main bearing journals must be within Indicator with Bracketry to measure crankshaft specifications before checking runout. end play.

  • Page 30: Cylinder Bore Out-Of-Round

    WSG-1068 GENERAL INFORMATION Cylinder Bore Out-of-Round Measure the cylinder bore in two directions. The difference is the out-of-round. Verify the out-of-round is within the wear limit and bore the cylinder to the next oversize limit. 2. Use the Piston Ring Groove Cleaner to clean the piston ring grooves.

  • Page 31: Piston Selection

    WSG-1068 GENERAL INFORMATION Piston Selection NOTE: The cylinder bore must be within the specifications for taper and out-of-round before fitting a piston. 1. Select a piston size based on the cylinder bore. CAUTION: Use care when fitting piston rings to avoid possible damage to the piston ring or the cylinder bore.

  • Page 32: Piston Ring-To-Groove Clearance

    WSG-1068 GENERAL INFORMATION Piston Ring-to-Groove Clearance Crankshaft Connecting Rod Journal Taper  Measure the crankshaft rod journal diameters in Special Tool(s) two directions perpendicular to one another at each end of the connecting rod journal. The difference in the measurements from one end to the other is the taper.

  • Page 33: Connecting Rod Larger End Bore

    WSG-1068 GENERAL INFORMATION Connecting Rod Larger End Bore Connecting Rod Bushing Diameter  Measure the inner diameter of the connecting CAUTION: The connecting rod bolts are torque to rod bushing. Verify the diameter is within yield and must be discarded and replaced after this specification.

  • Page 34: Connecting Rod Piston Pin Side Clearance

    WSG-1068 GENERAL INFORMATION Connecting Rod Piston Pin Side Clearance NOTE: Do not turn the crankshaft during this step.  Measure the clearance between the connecting rod and the piston. Verify the measurement is 3. Install and torque to specifications, then remove within specification.

  • Page 35: Roller Follower Inspection

    WSG-1068 GENERAL INFORMATION Bearing Inspection Roller Follower Inspection  Inspect the roller for flat spots or scoring. If any Inspect bearings for the following defects. Possible damage is found, inspect the camshaft lobes causes are shown: and hydraulic lash adjusters for damage.

  • Page 36: Valve Stem Diameter

    WSG-1068 GENERAL INFORMATION Valve Stem Diameter 2. Move the Valve Stem Clearance Tool toward the  Measure the diameter of each intake and Dial Indicator and zero the Dial Indicator. Move exhaust valve stem at the points shown. Verify the Valve Stem Clearance Tool away from the the diameter is within specification.

  • Page 37: Valve Guide Inner Diameter

    WSG-1068 GENERAL INFORMATION Valve Guide Inner Diameter Valve Spring Installed Length  Measure the installed length of each valve 1. Measure the inner diameter of the valve guides in two directions where indicated. spring. 2. If the valve guide is not within specifications,...

  • Page 38: Valve Spring Compression Pressure

    WSG-1068 GENERAL INFORMATION Valve Spring Compression Pressure Valve Seat Width  Measure the valve seat width. If necessary, grind the valve seat to specification. Special Tool(s)  Use the Valve/Clutch Spring Tester to check the valve springs for proper strength at the specified valve spring length.

  • Page 39: Flywheel Inspection

    WSG-1068 GENERAL INFORMATION Oil Pump Rotor Inspection  Inspect the oil pump rotor tips for damage or Flywheel Inspection wear. Special Tool(s) 1. Inspect the flywheel for:  Cracks (A).  Worn ring gear teeth (B). Oil Pump Side Clearance ...

  • Page 40: Cylinder Bore Honing

    WSG-1068 GENERAL INFORMATION Cylinder Bore Honing Cylinder Bore Cleaning Special Tool(s) CAUTION: If these procedures are not followed, rusting of the cylinder bores may occur. 1) Clean the cylinder bores with soap or detergent and water. 2) Thoroughly rinse with clean water and wipe dry with a clean, lint-free cloth.

  • Page 41: Cylinder Block Repair - Cast Iron Porosity Defects

    WSG-1068 GENERAL INFORMATION Cylinder Block Repair - Cast Iron Porosity 2. Inspect the cylinder block plug bore for any Defects damage that would interfered with the proper sealing of the plug. If the cylinder block plug CAUTION: Do not attempt to repair cracks, areas bore is damaged, bore for the next oversize where temperature will exceed 260°C (500°F) or...
  • Page 42 WSG-1068 GENERAL INFORMATION Cylinder Block Core Plug – Cup-Type CAUTION: Do not contact the flange when installing a cup type cylinder block core plug as this could damage the sealing edge and result in leakage. NOTE: When installed, the flanged edge must be below the chamfered edge of the bore to effectively seal the bore.

  • Page 43: Spark Plug Thread Repair

    WSG-1068 GENERAL INFORMATION Spark Plug Thread Repair 2. Start the tap into the spark plug hole, being careful to keep it properly aligned. As the tap Special Tool(s) begins to cut new threads, apply aluminum cutting oil. 3. Continue cutting the threads and applying oil until the stop ring bottoms against the spark plug seat.

  • Page 44: Exhaust Manifold Straightness

    WSG-1068 GENERAL INFORMATION 6. Tighten the tapersert into the spark plug hole. Exhaust Manifold Straightness Special Tool(s)  Place the Straightedge across the exhaust manifold flanges and check for warping with a feeler gauge. NOTE: The exhaust manifold shown is a typical exhaust 7.
  • Page 45 WSG-1068 ENGINE INDEX Subject Page General Information Description............................Engine Identification..........................Engine Code Information........................Module View............................Engine Intake Components........................ Low End Components........................Upper End Components........................Major Front End Components ......................Diagnosis and Testing............................ Engine Repair Intake Manifold - Variable Resonance Induction System (VRIS) - Removal........
  • Page 46 WSG-1068 ENGINE INDEX (CONT.) Subject Page Specifications Torque Specifications.......................... General Specifications ........................30   ...
  • Page 47 WSG-1068 ENGINE GENERAL INFORMATION Description The 6.8 liter engine consists of four basic modules that can be repaired individually. Remove only those components required to repair the module. The induction module consists of an upper and lower intake manifold (9424).
  • Page 48 WSG-1068 ENGINE Module View 32   ...
  • Page 49 WSG-1068 ENGINE Engine Intake Components 33   ...
  • Page 50 WSG-1068 ENGINE 34   ...
  • Page 51 WSG-1068 ENGINE Low End Components 35   ...
  • Page 52 WSG-1068 ENGINE 36   ...
  • Page 53 WSG-1068 ENGINE Upper End Components 37   ...
  • Page 54 WSG-1068 ENGINE 38   ...
  • Page 55 WSG-1068 ENGINE Major Front End Components 39   ...
  • Page 56 WSG-1068 ENGINE DIAGNOSIS AND TESTING Refer to Section 01 for basic mechanical concerns. 40   ...
  • Page 57 WSG-1068 ENGINE ENGINE REPAIR WARNING: DO NOT SMOKE OR CARRY Intake Manifold – Variable Resonance   LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY.
  • Page 58 WSG-1068 ENGINE 9. Disconnect the hose clamps and remove the heater water hose (18472). 10. Remove the water thermostat (8575). 11. Remove the two studs retaining the heater water return tube. 12. Remove the bolts, the upper intake manifold and the intake manifold gasket (9439).
  • Page 59 WSG-1068 ENGINE 14. Separate the upper and lower intake manifolds (9424).  Remove the ten bolts.  Discard the intake manifold gasket. 15. Clean all mating surfaces. Intake Manifold – Variable Resonance Induction System (VRIS) - Installation 1. Position the lower intake manifold gasket (9461) and the upper intake manifold on the intake manifold and loosely install the ten bolts.
  • Page 60 WSG-1068 ENGINE 2. NOTE: Tighten the bolts in two stages. Tighten the bolts in the sequence shown.  Stage 1: Tighten to 2 Nm (18 lb/in).  Stage 2: Tighten to 8-12 Nm (71-106 lb/in). 3. Position the water return tube as shown.
  • Page 61 WSG-1068 ENGINE 5. Install the upper intake manifold.  Position the upper intake manifold gaskets and the intake manifold, and loosely install the bolts. 6. Install the thermostat, gasket and the thermostat housing and loosly install the bolts. 7. NOTE: Be sure to tighten the bolts in two stages.
  • Page 62 WSG-1068 ENGINE 8. Install the heater water hose and position the clamp. 9. Connect the water temperature indicator sending unit electrical connector. 10. Install the generator. 11. Install the drive belt 12. Install the ignition coils. 46   ...
  • Page 63 WSG-1068 ENGINE 13. Connect the engine vacuum hoses.  Vacuum source. 14. Connect the engine water outlet hose and position the hose clamp. 15. Install the air cleaner outlet tube (9B659). 16. Fill the cooling system; refer to Section 05.
  • Page 64 WSG-1068 ENGINE Valve Cover – Left - Installation CAUTION: Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant. Failure to follow this procedure can cause future oil leakage.
  • Page 65 WSG-1068 ENGINE 4. Tighten the nuts and bolts in the sequence shown. 49   ...
  • Page 66 WSG-1068 ENGINE Valve Cover – Right - Removal WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY.
  • Page 67 WSG-1068 ENGINE  Use metal surface cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B292-A. 2. Apply silicone in two places where the engine front cover (6019) meets the cylinder head (6049). 3. Position the valve cover on the cylinder head and loosely install the bolts.
  • Page 68 WSG-1068 ENGINE 4. Tighten the bolts in the sequence shown. 5. Reinstall the PCV valve. 52   ...
  • Page 69 WSG-1068 ENGINE Crankshaft Pulley - Removal Special Tool(s) Special Service Tools called for by the procedures can be obtained by calling: 1-800-ROTUNDA (1-800-768-8632). 1. Remove the engine cooling fan and fan shroud (8146). 2. Remove the drive belt (8620). 3. Remove the crankshaft pulley bolt (6A340).
  • Page 70 WSG-1068 ENGINE Crankshaft Pulley - Installation CAUTION: Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant. Failure to follow this procedure can cause future oil leakage.
  • Page 71 WSG-1068 ENGINE Crankshaft Front Oil Seal - Removal Special Tool(s) Special Service Tools called for by the procedures can be obtained by calling: 1-800-ROTUNDA (1-800-768-8632). 1. Remove the crankshaft pulley (6312); refer to this section. 2. Using the (a) Front Cover Seal Remover, remove the (B) crankshaft front seal (6700).
  • Page 72 WSG-1068 ENGINE Crankshaft Front Oil Seal - Installation 1. Lubricate the (A) engine front cover (6019) and the (B) crankshaft front seal inner lip.  Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. 2. Use the (A) Crankshaft Seal Replacer to install the (B) crankshaft front seal into the (C) engine front cover.
  • Page 73 WSG-1068 ENGINE Front Engine Cover - Removal WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY.
  • Page 74 WSG-1068 ENGINE 10. Remove the engine front cover fasteners. 11. Remove the engine front cover (6019) from the front cover to cylinder block dowels (6C002). 1. Install a new engine front cover gasket (6020) on the engine front cover, then position the engine front cover on the front cover to cylinder block dowels.
  • Page 75 WSG-1068 ENGINE 59   ...
  • Page 76 WSG-1068 ENGINE 2. Tighten the fasteners in two stages following the sequence shown.  Stage 1: Tighten fasteners 1 through 5 to 20-30 Nm (15-22 lb/ft).  Stage 2: Tighten fasteners 6 through 15 to 40-55 Nm (30-41 lb/ft). 3. NOTE: Be sure to tighten the bolts through the front of the oil pan in two stages.
  • Page 77 WSG-1068 ENGINE 4. Connect the CKP sensor electrical connector. 5. Install the water pump pulley. 6. Connect the CMP electrical connector. 7. Install a new crankshaft front seal and the crankshaft pulley (6312); refer to Crankshaft Pulley in this section.
  • Page 78 WSG-1068 ENGINE Timing Drive Components - Removal Special Tool(s) Special Service Tools called for by the procedures can be obtained by calling: 1-800-ROTUNDA (1-800-768-8632). 1. Remove the engine front cover (6019); refer to Engine Front Cover in this section. 2. Remove the crankshaft sensor ring from the crankshaft (6303).
  • Page 79 WSG-1068 ENGINE 4. Remove the balance shaft. CAUTION: Unless otherwise instructed, at no time when the timing chains (6268) are removed and the cylinder heads (6049) are installed may the crankshaft or camshaft (6250) be rotated. Severe piston (6108) and valve damage could occur.
  • Page 80 WSG-1068 ENGINE 6. Install the Camshaft Holding Tools on the camshafts. 7. Remove the bolts and the timing chain tensioners (6L266). Remove the timing chain tensioner arms (6L253) from the dowel pins. 64   ...
  • Page 81 WSG-1068 ENGINE 8. Remove the LH and RH timing chain and the crankshaft sprockets (6306). 1. Remove the RH timing chain from the camshaft sprocket (6256). 2. Remove the RH timing chain and outer crankshaft sprocket from the crankshaft. 3. Repeat for the LH timing chain and crankshaft sprocket.
  • Page 82 WSG-1068 ENGINE 9. Remove the timing chain guides (6K297).  Remove the bolts.  Remove the timing chain guides. Timing Drive Components - Installation CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
  • Page 83 WSG-1068 ENGINE 2. Using a small screwdriver or pick, push back and hold the ratchet mechanism. 3. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing. 4. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation.
  • Page 84 WSG-1068 ENGINE 5. If copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks. 6. Install the timing chain guides. 68   ...
  • Page 85 WSG-1068 ENGINE 10. NOTE: Be sure the upper half of the 7. Remove the Crankshaft Holding Tool timing chain is below the tensioner 8. Install the inner crankshaft sprocket with the long hub facing outward. 9. Install the inner timing chain on the crankshaft sprocket with the timing marks aligned.
  • Page 86 WSG-1068 ENGINE CAUTION: The camshaft sprocket can jump time if the Camshaft Holding Tool is not secured. NOTE: Be sure the chain link and crankshaft sprocket timing marks are aligned. NOTE: The lower half of the timing chain must be positioned above the dowel.
  • Page 87 WSG-1068 ENGINE Camshaft Assembly Timing Mark Alignment 71   ...
  • Page 88 WSG-1068 ENGINE Timing Chains, Camshaft Gears and Crankshaft Gears Alignment 72   ...
  • Page 89 WSG-1068 ENGINE 14. Position the LH and RH timing chain tensioner arms on the dowel pins. Position the timing chain tensioners and install the bolts. 15. Remove the retaining pins from the RH and LH timing chain tensioners. 73   ...
  • Page 90 WSG-1068 ENGINE 16. Remove the Camshaft Holding Tools from the camshafts. 17. Install the crankshaft sensor ring on the crankshaft. 18. Lubricate the balance shaft journals with engine oil.  Use Super Premium SAE 5W30 Motor Oil XO- 5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
  • Page 91 WSG-1068 ENGINE 21. Lubricate the bearing caps with engine oil.  Use Super Premium SAE 5W30 Motor Oil XO- 5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. 22. Install the bearing caps, the bolts and tighten the bolts in the sequence shown.
  • Page 92 WSG-1068 ENGINE Camshaft - Removal Special Tool(s) Special Service Tools called for by the procedures can be obtained by calling: 1-800-ROTUNDA (1-800-768-8632). WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL- RELATED COMPONENTS.
  • Page 93 WSG-1068 ENGINE 6. Use the Valve Spring Compressor to compress the valve springs (6513) and remove the camshaft roller followers. CAUTION: The caps must be marked for installation in their original location or damage to the engine may occur. 7. Remove the bolts, the camshaft bearing caps (6B280) and the camshaft (6250) from the cylinder block (6010).
  • Page 94 WSG-1068 ENGINE 2. Install the bearing caps in their original locations and the bolts. 3. Tighten the bolts in the sequence shown. 78   ...
  • Page 95 WSG-1068 ENGINE 4. Use the Valve Spring Compressor to compress the valve springs and install the camshaft roller followers. 5. Lubricate the balance shaft journals with engine oil.  Use Super Premium SAE 5W30 Motor Oil D9AZ- 19579-A or equivalent meeting Ford specification WSS-M2C153-G.
  • Page 96 WSG-1068 ENGINE 9. Lubricate the balance shaft journals with engine oil.  Use Super Premium SAE 5W30 Motor Oil D9AZ- 19579-A or equivalent meeting Ford specification WSS-M2C153-G. 10. Position the bearing caps in their original locations and the bolts. Tighten the bolts in the sequence shown.
  • Page 97 WSG-1068 ENGINE Exhaust Manifold – RH - Removal 1. Remove the nuts from exhaust pipe and remove exhaust pipe. 2. Remove the ten nuts and the exhaust manifold (9430) and exhaust manifold gasket (9448). Discard the exhaust manifold gasket. 3. Clean and inspect the exhaust manifold; refer to Section 01.
  • Page 98 WSG-1068 ENGINE Exhaust Manifold - RH - Installation 1. Follow the removal procedure in reverse order. 82   ...
  • Page 99 WSG-1068 ENGINE Exhaust Manifold – LH - Removal 1. Remove the nuts from the exhaust pipe and remove pipe. 2. Remove the exhaust manifold nuts and the exhaust manifold (9430). Discard the exhaust manifold gaskets (9448). 3. Clean and inspect the exhaust manifold; refer to Section 01.
  • Page 100 WSG-1068 ENGINE Exhaust Manifold – LH - Installation 1. Follow the removal procedure in reverse order. Cylinder Head - Removal Special Tool(s) Special Service Tools called for by the procedures can be obtained by calling: 1-800-ROTUNDA (1-800-768-8632). 84   ...
  • Page 101 WSG-1068 ENGINE WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND CAN BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY.
  • Page 102 WSG-1068 ENGINE 7. NOTE: Sealant must be removed and area cleaned with solvent. CAUTION: Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant. Failure to follow this procedure can cause future oil leakage.
  • Page 103 WSG-1068 ENGINE 3. NOTE: Head bolts are torque to yield and must be replaced whenever cylinder head is removed. Install the cylinder head on the head gasket and loosely install new bolts.  The LH is shown; the RH is similar.
  • Page 104 WSG-1068 ENGINE 1. Remove the bolt and remove the oil level indicator tube (6754). 2. Inspect the oil level indicator tube for damage. 1. Follow the removal procedure in reverse order. 2. Replace and lubricate the O-rings with Super Premium SAE 5W30 Motor Oil D9AZ-19579-A or equivalent meeting Ford specification WSS-M2C153-G.
  • Page 105 WSG-1068 ENGINE 1. Disconnect the battery ground cable (14301). 2. Partially drain the radiator (8005) and disconnect the upper radiator hose (8260) at the radiator. 3. Drain the engine oil and remove the oil bypass filter (6714). 4. Remove the nuts retaining the front engine support insulator (6038) to the front engine support bracket (6028).
  • Page 106 WSG-1068 ENGINE 5. Remove the flywheel inspection plate. 6. Remove the bolts and partially lower the oil pan (6675). 90   ...
  • Page 107 WSG-1068 ENGINE 7. Remove the two bolts and the nut retaining the oil pump screen cover and tube (6622) and let them drop into the oil pan. 8. Remove the oil pan and oil pan gasket (6710) from the rear of the engine.
  • Page 108 WSG-1068 ENGINE 3. NOTE: Be sure to tighten the bolts in three stages. Replace oil pan and bolts. Tighten the bolts in the sequence shown.  Stage 1: Tighten to 2 Nm (18 lb/in).  Stage 2: Tighten to 20 Nm (15 lb/ft).
  • Page 109 WSG-1068 ENGINE 1. Disconnect the battery ground cable (14301). 2. Remove the engine front cover (6019) and crankshaft sprockets (6306); refer to Engine Front Cover in this section. 3. Remove the oil pan (6675); refer to Oil Pan in this section.
  • Page 110 WSG-1068 ENGINE 1. Disconnect the battery ground cable (14301). 2. Remove generator from bell housing. 3. Remove bell housing. 4. Remove the bolts and the flywheel (6375). 1. Follow the removal procedure in reverse order. 94   ...
  • Page 111 WSG-1068 ENGINE 1. Disconnect the battery ground cable (14301). 2. Remove the flywheel (6375); refer to Flywheel in this section. 3. Use the Rear Crankshaft Slinger Remover and the Slide Hammer to remove the crankshaft oil slinger (6310). 4. Use the Rear Crankshaft Seal Remover and the Impact Slide Hammer to remove the crankshaft rear oil seal (6701).
  • Page 112 WSG-1068 ENGINE Crankshaft Rear Oil Seal - Installation CAUTION: Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant. Failure to follow this procedure can cause future oil leakage.
  • Page 113 WSG-1068 ENGINE Crankshaft Rear Oil Seal (with retainer plate) - Removal 1. Disconnect the battery ground cable (14301). Remove the flywheel (6375); refer to Flywheel in this section. 2. Use the Rear Crankshaft Slinger Remover and the Impact Slide Hammer to remove the crankshaft oil slinger (6310).
  • Page 114 WSG-1068 ENGINE 3. Use the Rear Crankshaft Seal Remover and the Impact Slide Hammer to remove the crankshaft rear oil seal (6701). 4. Remove the oil pan; refer to Oil Pan in this section. 5. Remove the crankcase bolts and the crankshaft rear oil seal retainer plate.
  • Page 115 WSG-1068 ENGINE 3. NOTE: If the rear main oil seal is still in place and being reinstalled, be sure the lip is not folded over or wrinkled during the retainer plate installation. The seal lip must start squarely on the crankshaft journal.
  • Page 116 WSG-1068 ENGINE 1. Disconnect the battery ground cable (14301). 2. Remove the intake manifold (9424); refer to Intake Manifold – Variable Resonance Induction System (VRIS) in this section. 3. Remove the radiator upper and lower radiator supports (16138). 4. Remove the radiator (8005), fan shroud (8146) and engine cooling fan.
  • Page 117 WSG-1068 ENGINE 6. At the oil cooler water inlet, disconnect and set aside the lower radiator hose (8286). 7. Disconnect the engine harness. 8. Remove exhaust pipe nuts. 9. Drain engine oil and remove the oil bypass filter (6714). 10. Remove the starter motor (11002); refer to Section 101 ...
  • Page 118 WSG-1068 ENGINE 11. Remove the engine support insulator nuts. 12. Install the Modular Lifting Bar. 13. Remove the engine from the equipment. 102   ...
  • Page 119 WSG-1068 ENGINE 14. Remove the bolts, and remove the flywheel. 15. Use the Rear Crankshaft Slinger Remover and the Impact Slide Hammer to remove the crankshaft oil slinger (6310). 16. Use the Rear Crankshaft Seal Remover and the Impact Slide Hammer to remove the crankshaft rear oil seal (6701).
  • Page 120 WSG-1068 ENGINE Engine - Disassembly 1. With the engine on the engine stand, remove the engine wiring harness. 104   ...
  • Page 121 WSG-1068 ENGINE 2. Remove the bolts, the oil pan (6675), and the oil pan gasket (6710). 3. Remove the two bolts and nut retaining the oil pump screen cover and tube (6622) and remove the oil pump screen cover and tube.
  • Page 122 WSG-1068 ENGINE 4. NOTE: The bolts are a part of the valve cover (6582) and are not to be removed. LH is shown; RH is similar.  Fully loosen the sixteen bolts, and remove the valve cover gasket (6584). 106 ...
  • Page 123 WSG-1068 ENGINE 5. Remove the drive belt. 6. Remove the water pump pulley (8509). 1. Remove the four bolts. 2. Remove the water pump pulley. 7. Remove the four bolts from the water pump. 8. Remove the (A) water pump (8501) from the (B) cylinder block (6010).
  • Page 124 WSG-1068 ENGINE 9. Remove the crankshaft pulley bolt (6A340). Use the Crankshaft Damper Remover to remove the crankshaft pulley (6312). 10. Use the (A) Front Cover Seal Remover to remove the (B) crankshaft front seal (6700). 11. Remove the engine front cover fasteners.
  • Page 125 WSG-1068 ENGINE 13. Remove the crankshaft sensor ring from the crankshaft (6303). 14. Remove the balancing shaft bearing caps. 15. Remove balancing shaft. 109   ...
  • Page 126 WSG-1068 ENGINE CAUTION: Unless otherwise instructed, at no time when the timing chains (6268) are removed and the cylinder heads (6049) are installed is the crankshaft or camshaft (6250) to be rotated. Severe piston (6108) and valve damage will occur.
  • Page 127 WSG-1068 ENGINE 18. Remove the bolts and the timing chain tensioners (6L266). Remove the timing chain tensioner arms (6L253) from the dowel pins. 111   ...
  • Page 128 WSG-1068 ENGINE CAUTION: Unless otherwise instructed, at no time when the timing chain are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.  Remove the Crankshaft Holding Tool.
  • Page 129 WSG-1068 ENGINE 20. Remove the timing chain guides (6K297).  Remove the bolts.  Remove the timing chain guides. 113   ...
  • Page 130 WSG-1068 ENGINE 21. Remove the ten nuts and the RH exhaust manifold (9430) and exhaust manifold gasket (9448). Discard the exhaust manifold gasket. 22. Remove the ten nuts, the LH exhaust manifold and the exhaust manifold gaskets. Discard the exhaust manifold gasket.
  • Page 131 WSG-1068 ENGINE 23. Remove the oil level dipstick, the bolt and the oil level indicator tube (6754). 24. Install the Lifting Handles on both ends of the cylinder head. CAUTION: These bolts must be replaced with new bolts. They are tighten-to-yield designed and cannot be reused.
  • Page 132 WSG-1068 ENGINE 26. Use silicone gasket and sealant F6AZ-19562- AA equivalent meeting Ford specification WSE-M4G323-A6. NOTE: Sealant must be removed and area cleaned with solvent if above instructions are not followed.  Use metal surface cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSEM5B292-A.
  • Page 133 WSG-1068 ENGINE 30. Remove the twelve bolts and the two lower crankshaft bearing supports. CAUTION: Make sure connecting rods (6200) and rod caps are numbered, to keep in proper orientation. Remove the bolts and the connecting rod caps.  Rotate the crankshaft so that the connecting rod is at bottom dead center.
  • Page 134 WSG-1068 ENGINE CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the connecting rod. Remove the piston and rod assembly.  Use the Connecting Rod Guide Tools to guide piston and rod assembly out of the cylinder.
  • Page 135 WSG-1068 ENGINE 34. Remove and discard the twelve cross-mounted bolts. 35. Remove the main bearing bolts and discard the bolts. 36. Remove the main bearing cap dowel pins. 119   ...
  • Page 136 WSG-1068 ENGINE 37. Remove the main bearing caps, the lower crankshaft main bearings (6333) and the thrust washer. 38. Remove the crankshaft and the crankshaft main bearings from the cylinder block. 120   ...
  • Page 137 WSG-1068 ENGINE 1. Remove the Camshaft Holding Tool from the camshaft(6250). 121   ...
  • Page 138 WSG-1068 ENGINE CAUTION: Do not remove the camshaft before removing the roller followers. CAUTION: Place the cylinder head on a cardboard or wood surface to prevent damage to the joint face. Install the Valve Spring Spacer between the valve spring coils to prevent valve stem seal damage.
  • Page 139 WSG-1068 ENGINE CAUTION: Keep the valves and the valve spring retainer keys (6518) in order so they can be installed in the same positions. NOTE: The 8-cylinder is shown. The 10-cylinder is similar. NOTE: Shown without camshaft for clarity. Remove the (A) valve spring retainer keys, the (B) valve spring retainers (6514), the (C) valve springs, and the valves.
  • Page 140 WSG-1068 ENGINE Cylinder Head - Assembly CAUTION: Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant. Failure to follow this procedure can cause future oil leakage.
  • Page 141 WSG-1068 ENGINE 4. Tighten the bolts in the sequence shown. 5. Install the valves in the valve guides located in the cylinder block (6010). 125   ...
  • Page 142 WSG-1068 ENGINE 6. Install the valve spring and the valve spring retainer onto the valve. 7. Install the valve spring spacer between the valve spring coils to prevent valve stem seal damage. 8. Use the Valve Spring Compressor to compress the valve spring, and install the valve spring retainer keys.
  • Page 143 WSG-1068 ENGINE 10. Install the roller followers. 11. Remove the Valve Spring Spacer. 127   ...
  • Page 144 WSG-1068 ENGINE 1. NOTE: Before assembling the cylinder block (6010), all seating surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear. Lubricate and install the crankshaft upper main bearings into the cylinder block.
  • Page 145 WSG-1068 ENGINE 2. Install the crankshaft (6303) into the cylinder block and onto the upper crankshaft main bearings (6333). 3. Push the crankshaft rearward and install the rear lower crankshaft thrust washer (6334) at the back of the No. 6 main boss.
  • Page 146 WSG-1068 ENGINE 6. Install the No. 1 through No. 5 crankshaft lower main bearings into the main bearing caps. Locate the main bearing caps on the cylinder block and tap into place using a plastic or dead-blow hammer. 7. Install new main cap bearing bolts.
  • Page 147 WSG-1068 ENGINE 9. Tighten fasteners 1 through 12 in two stages in the sequence shown.  Stage 1: Tighten to 37-43 Nm (22-32 lb/ft).  Stage 2: Tighten an additional 85 degrees to 95 degrees. 10. Tighten fasteners 13 through 24 in two stages in the sequence shown.
  • Page 148 WSG-1068 ENGINE 11. Use the Connecting Rod Guide Tool and Piston Ring Compressor to install the piston and connecting rod assembly. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod (6200). Once the connecting rod is seated on the crankshaft journal, remove the connecting rod guide tools.
  • Page 149 WSG-1068 ENGINE 16. Install the oil filter adapter (6881). 17. Install the front engine support insulators (6038). 18. Install the lower crankshaft bearing supports and tighten fasteners in the sequence shown. 133   ...
  • Page 150 WSG-1068 ENGINE 19. Install the oil level indicator tube (6754). 20. Position the oil pump (6600) and install the bolts loosely. Tighten the bolts in the sequence shown. 21. Rotate the crankshaft to position the keyway at 12 o’clock. NOTE: After crankshaft has been positioned, do not turn the crankshaft until instructed to do so.
  • Page 151 WSG-1068 ENGINE 22. Install the head gasket (6051) over the dowel pins. 23. Install the Camshaft Holding Tools. 24. Install the Lifting Handles. 25. Install the cylinder head (6049) on the head gasket and loosely install new bolts.  The LH is shown; the RH is similar.
  • Page 152 WSG-1068 ENGINE 27. Install the left and right exhaust manifold gaskets (9448) and exhaust manifolds (9430). Loosely install the nuts. Tighten the nuts in the sequence shown. 136   ...
  • Page 153 WSG-1068 ENGINE CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons (6108) will result. If removed, install the left and right camshaft sprockets (6256). CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
  • Page 154 WSG-1068 ENGINE 32. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation. 33. If the copper links are not visible, mark two links on one end and one link on the other end to use as timing marks.
  • Page 155 WSG-1068 ENGINE 35. Install the timing chain guides (6K297). 139   ...
  • Page 156 WSG-1068 ENGINE 36. Rotate the LH camshaft sprocket until the timing mark is approximately at 12 o’clock. Rotate the RH camshaft until the timing mark is approximately at 11 o’clock. Tighten the Camshaft Holding Tools to maintain camshaft pre-positioning. 37. CAUTION: Unless otherwise instructed, at...
  • Page 157 WSG-1068 ENGINE 39. Position the inner crankshaft sprocket (6306) with the long hub facing outward. 40. Install the LH timing chain/belt onto the crankshaft sprocket, aligning the one copper link on the timing chain with the slot on the crankshaft sprocket.
  • Page 158 WSG-1068 ENGINE 42. CAUTION: The camshaft sprocket can jump time if the Camshaft Holding Tool is not secured. NOTE: Be sure the copper chain link and the crankshaft sprocket timing mark are aligned. NOTE: The lower half of the timing chain must be positioned above the dowel.
  • Page 159 WSG-1068 ENGINE 44. As a post-check, verify timing mark alignment. 45. Position the LH and RH timing chain tensioner arm (6L253) on the dowel pins. Position the timing chain tensioners (6L266), and install the bolts. 46. Remove both the RH and LH retaining pins from the timing chain tensioner assembly.
  • Page 160 WSG-1068 ENGINE 47. Remove the Camshaft Holding Tools from the camshafts. 48. Lubricate the balance shaft journals with engine oil.  Use Super Premium SAE 5W30 Motor Oil XO- 5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. 49. Position the balance shaft on the journals.
  • Page 161 WSG-1068 ENGINE 51. Lubricate the balance shaft journals with engine oil.  Use Super Premium SAE 5W30 Motor Oil XO- 5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. 52. Install the bearing caps and the bolts. Tighten the bolts in the sequence shown.
  • Page 162 WSG-1068 ENGINE CAUTION: Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant. Failure to follow this procedure can cause future oil leakage.  Use silicone gasket and sealant F6AZ-19562-AA...
  • Page 163 WSG-1068 ENGINE 57. Tighten the fasteners in two stages; refer to the preceding illustration.  Stage 1: Tighten fasteners 1 through 5 to 20-30 Nm (15-22 lb/ft).  Stage 2: Tighten fasteners 6 through 15 to 40-55 Nm (30-41 lb/ft).
  • Page 164 WSG-1068 ENGINE 58. Position the oil pump screen cover and tube (6622) and install the bolts and nut. 59. CAUTION: Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant.
  • Page 165 WSG-1068 ENGINE CAUTION: Do not rotate the water pump housing once the water pump (8501) has been positioned in the cylinder block. Damage to the O-ring seal will occur. Install the water pump. 1. Lubricate the new O-ring seal using Premium...
  • Page 166 WSG-1068 ENGINE CAUTION: Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant. Failure to follow this procedure can cause future oil leakage.  Use silicone gasket and sealant F6AZ-19562-AA or equivalent meeting Ford specification WSEM4G323-A6.
  • Page 167 WSG-1068 ENGINE 68. Position the water pump pulley (8509) on the water pump and install the bolts. 151   ...
  • Page 168 WSG-1068 ENGINE CAUTION: Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant. Failure to follow this procedure can cause future oil leakage.  Use silicone gasket and sealant F6AZ- 19562-AA or equivalent meeting Ford specification WSEM4G323-A6.
  • Page 169 WSG-1068 ENGINE 1. Attach the Modular Lifting Bar. 2. Remove the engine from the engine stand. CAUTION: Mating parts must make contact to each other within 4 minutes and connecting bolts must be torqued within 15 minutes after applying sealant. Failure to follow this procedure can cause future oil leakage.
  • Page 170 WSG-1068 ENGINE 5. Install the retainer plate. Tighten the bolts to 8-12 Nm (71-107 lb/in). 6. Use the Rear Crankshaft Seal Replacer and Rear Crankshaft Seal Adapter to install the crankshaft rear oil seal (6701). 7. With the Rear Crankshaft Seal Adapter still installed, use the Rear Crankshaft Slinger Replacer to install the crankshaft oil slinger.
  • Page 171 WSG-1068 ENGINE 10. Connect the left and right exhaust pipes and install and tighten the nuts. NOTE: Apply a light coat of anti-sieze compound F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A to the threads of the exhaust manifold studs. 11. Connect the LH and RH heated exhaust gas oxygen sensor connector if equipped.
  • Page 172 WSG-1068 ENGINE SPECIFICATIONS 156   ...
  • Page 173 WSG-1068 ENGINE 157   ...
  • Page 174 WSG-1068 ENGINE 158   ...
  • Page 175 WSG-1068 IGNITION SYSTEM INDEX Subject Page General Information Color Abbreviations........................How to Find Electrical Concerns ....................Troubleshooting Tools........................ Switch Circuit Check and Voltage Check................... Continuity Check (locating open circuits) .................. Short Check ..........................Ground Check ........................... Troubleshooting Wiring Harness & Connector Hidden Concerns ..........
  • Page 176 WSG-1068 IGNITION SYSTEM GENERAL INFORMATION Step 5: Make the repair.  Repair or replace the inoperative component. Step 6: Verify the repair.  Operate the system as in Step 1 and check that your repair has removed all symptoms without creating and new symptoms.
  • Page 177 WSG-1068 IGNITION SYSTEM Switch Circuit Check & Voltage Check Figure 2 – Test Lamp A Test Light is a 12-volt bulb with two test leads (Figure 2). Uses: Voltage Check, Short Check. Self-Powered Test Lamp Figure 4 – Switch Circuit Check and...
  • Page 178 WSG-1068 IGNITION SYSTEM  Short Check If the Test Lamp goes on, the short is in the wiring.You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, in Figure 5 with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3.
  • Page 179 WSG-1068 IGNITION SYSTEM Troubleshooting Wiring Harness and Connector Hidden Concerns The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration.
  • Page 180 WSG-1068 IGNITION SYSTEM 164   ...
  • Page 181 Volts. increases. Description The cylinder heat temperature (CHT sensor): The WSG-1068 engine uses a Coil On Plug Ignition  Sends a signal to the Ignition Control Module System to ignite the fuel/air mixture at the correct time indicating the cylinder head temperature.
  • Page 182 WSG-1068 IGNITION SYSTEM Overview The Ignition System is designed to ignite the compressed air/fuel mixture in an internal combustion engine by a high voltage spark from an ignition coil. The ignition system also provides engine timing information to the GCP for proper engine operation and misfire detection.
  • Page 183 WSG-1068 IGNITION SYSTEM The Fuel Select Switch Crankshaft Position Sensor (CKP Sensor) In the event that the engine is operated on alternate The CKP sensor is a magnetic transducer mounted on fuels such as natural gas, compressed natural gas the engine block adjacent to a pulse wheel located on (CNG), or liquefied petroleum gas (LPG), timing can be the crankshaft.
  • Page 184 WSG-1068 IGNITION SYSTEM Coil On Plug The coil on plug (COP) ignition operates similar to standard coil pack ignition except each plug has one coil per plug. COP has three different modes of operation: engine crank, engine running and CMP Failure Mode Effects Management (FMEM).
  • Page 185 WSG-1068 IGNITION SYSTEM Electronic Engine Controls Refer to Section 08 of this manual. Cylinder Head Temperature Sensor (CHT Sensor) The cylinder head temperature (CHT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases.
  • Page 186 WSG-1068 IGNITION SYSTEM Starting Mode Module enters start mode at first application of power. exists which caused the engine to stall. Over No spark is applied for first turn of crankshaft. Timing is temperature reaction is experienced when temperature fixed at 10 degrees BTDC. Dwell is fixed at 10 degrees reaches 250°F.
  • Page 187 WSG-1068 IGNITION SYSTEM Ignition System - Components Location The 6.8L engine is equipped with a coil on plug ignition system. This system has a separate ignition coil mounted on each spark plug. Operation of the coils is controlled by global control platform (GCP), which computes ignition timing based on inputs from the electronic engine control system sensors.
  • Page 188 WSG-1068 IGNITION SYSTEM Firing Order 172   ...
  • Page 189 WSG-1068 IGNITION SYSTEM Ignition Coil-On Plug - Removal 1. Disconnect the wiring at the coil. 2. Remove the bolt and the coil. Ignition Coil-On Plug - Installation WARNING: ALWAYS WEAR SAFETY GLASSES TO PROTECT EYES FROM FLYING FOREIGN MATERIAL. 1. NOTE: Remove any foreign material from spark plug wells with compressed air.
  • Page 190 WSG-1068 IGNITION SYSTEM Harness Connector Pinout Description I / O = Input / Output 174   ...
  • Page 191 WSG-1068 IGNITION SYSTEM Fuel Select Operation Fuel Select is Used to select ignition table for fuel type. The user has several options for this which is all dependent on whether pin 7 of the 42 pin connector is Open, grounded or has 12 volts. The configurations are listed below.
  • Page 192 WSG-1068 IGNITION SYSTEM DIAGN0SIS AND TESTING Service Adjustments And Checks CAUTION: There should be no wires spliced to the main wire harness for source of power or RPM 1. Each 400 hours of engine operation remove the signal unless pre-approved by Ford Power Products.
  • Page 193 WSG-1068 IGNITION SYSTEM Preliminary Checks Shorts to Power Key ON to power up circuit. Measure voltage between Before using this section verify the customer complaint the suspect circuit at the harness connector and a and refer to the appropriate symptom chart. Perform the reliable ground.
  • Page 194 WSG-1068 IGNITION SYSTEM Engine Controls 178   ...
  • Page 195 WSG-1068 IGNITION SYSTEM Engine Sensors (part of SK2U1L-12A200-BA) 179   ...
  • Page 196 WSG-1068 IGNITION SYSTEM 42 Pin Engine Harness Connectors F8JL-14324-AC & F8JL-14324-BA SH 4/5/06 42 pin engine to frame harness (6.8L) GCP Engine to Frame Harness Pinout (Harness Part # F8JL-14324-AC or BA) Pin # Wire Color Description Red/Light Green +12 V switched...
  • Page 197 WSG-1068 IGNITION SYSTEM 90 Pin GCP Connector 181   ...
  • Page 198 WSG-1068 IGNITION SYSTEM Pinpoint Test A - Ignition Check The ignition system check will verify the required inputs and outputs recommended by Engine Distributors Inc. Always locate and inspect all power, ground and terminal connections prior to the start of this test, as failures and corrosion associated with these areas can adversely affect the engine to start properly.
  • Page 199 WSG-1068 IGNITION SYSTEM 183   ...
  • Page 200 WSG-1068 FUEL SYSTEM INDEX Subject General Information Page System Operation - LPG ........................System Operation - Natural Gas ......................Diagnosis and Testing Pinpoint Test A - Fuel Pressure Check ....................NOTE: For further information on Servicing the fuel system, refer to Manufacturer’s Service Information.
  • Page 201 WSG-1068 FUEL SYSTEM GENERAL INFORMATION System Operation - LPG High pressure liquefied Petroleum Gas passes through a solenoid operated fuel shut-off valve into an engine coolant heated vaporizer/regulator unit where it is converted into a low pressure gas. This gas is then fed...
  • Page 202 WSG-1068 FUEL SYSTEM System Operation – Natural Gas Natural gas passes through a vacuum operated fuel shutoff valve into a regulator unit where it is converted into a low pressure gas. This gas is then fed into the mixer where a vacuum operated gas metering valve ensures that the correct air-to-fuel ratio is maintained.
  • Page 203 WSG-1068 FUEL SYSTEM DIAGNOSIS AND TESTING Pinpoint Test A - Fuel Pressure Check Inspection and Verification 1. Visually inspect for obvious signs of mechanical and electrical damage. 2. Visually inspect for and note auxiliary system connections not shown on the Recommended Customer Connections Wiring Schematic.
  • Page 204 WSG-1068 FUEL SYSTEM 188   ...
  • Page 205 WSG-1068 COOLING SYSTEM INDEX Page Subject General Information Engine Cooling........................... Coolant Flow ............................Coolant............................... Recycled Coolant ..........................Unsatisfactory Coolant Materials......................General Service Procedures Cooling System Draining........................Cooling System Filling........................Drive Belt Routing ..........................Cooling System Flushing........................Removal and Installation Radiator Hose - Removal........................
  • Page 206 WSG-1068 COOLING SYSTEM INDEX (CONT.) Subject Page Specifications General Specifications ........................Torque Specifications......................... 190   ...
  • Page 207 WSG-1068 COOLING SYSTEM GENERAL INFORMATION Engine Cooling Walter C. Avrea, the owner of patents 3,601,181 and RE27,965, has granted Ford Motor Company rights with respect to cooling systems covered by these patents. The cooling system components are:  Cylinder head temperature sensor (CHT sensor).
  • Page 208 WSG-1068 COOLING SYSTEM Coolant Flow is as follows:  The water pump (8501) circulates the coolant.  From the water pump to the engine block and the cylinder heads (6049) to the thermostat. CAUTION: Alkaline brine solutions will cause – Thermostat closed, the coolant returns to the serious engine cooling system damage.
  • Page 209 WSG-1068 COOLING SYSTEM GENERAL SERVICE PROCEDURES WARNING: NEVER REMOVE THE PRESSURE Cooling System Draining RELIEF CAP WHILE THE ENGINE IS OPERATING OR WHEN THE COOLING SYSTEM IS HOT. MAY CAUSE PERSONAL INJURY OR DAMAGE TO COOLING SYSTEM OR ENGINE. TO AVOID HAVING SCALDING...
  • Page 210 WSG-1068 COOLING SYSTEM CAUTION: The coolant must be recovered in a suitable, clean container for reuse. If the coolant is contaminated it must be recycled or disposed of properly. NOTE: About 80% of coolant capacity can be recovered with the engine in the vehicle. Dirty, rusty or contaminated coolant requires replacement.
  • Page 211 WSG-1068 COOLING SYSTEM 6. When the coolant is drained, make sure drain plugs are installed and tight. 7. Close the radiator draincock when finished. Cooling System Filling 1. Add the proper engine coolant mixture to the degas bottle or radiator.
  • Page 212 WSG-1068 COOLING SYSTEM 4. Add the proper engine coolant mixture to the degas bottle or radiator until the coolant level is between the “COOLANT FILL LEVEL’’ marks. NOTE: Systems without degas bottle fill radiator up to 1 inch below the filler neck.
  • Page 213 WSG-1068 COOLING SYSTEM Drive Belt Routing Cooling System Flushing Special Tool(s) Special Service Tools called for by the procedures can be obtained by calling: 1-800-ROTUNDA (1-800-768-8632). 197   ...
  • Page 214 WSG-1068 COOLING SYSTEM REMOVAL AND INSTALLATION Radiator Hose - Removal Radiator hoses should be replaced whenever they become cracked, rotted or have a tendency to collapse. Drain the radiator into appropriate container then loosen the clamps at each end of the hose to be removed. Slide...
  • Page 215 WSG-1068 COOLING SYSTEM With or Without Dry Fuel Evaporator Plumbing Installation of Water Heater Return Tube Removal of Heater Water Inlet Tube Assembly with by-pass Hose 1. Lightly lubricate the o-rings prior to installing the (18663) water outlet tube. 1. Drain the cooling system.
  • Page 216 WSG-1068 COOLING SYSTEM Cylinder Head Temperature (CHT) Sensor Fan Drive Belt - Removal and Installation - Replacement 1. Remove the upper and lower intake manifold together. For additional information, refer to Section 01. 2. Remove the cylinder head temperature (CHT) sensor.
  • Page 217 WSG-1068 COOLING SYSTEM Belt Tensioner - Removal 1. Remove the drive belt (8620). For additional information, refer to Fan Drive Belt page 05-12. 2. Remove the belt tensioner. 1. Remove the bolts. 2. Remove the belt tensioner. Belt Tensioner - Installation 1.
  • Page 218 WSG-1068 COOLING SYSTEM Belt Idler Pulley - Removal 1. Remove the fan drive belt (8620) off of the belt idler pulley (8678). For additional information, refer to Fan Drive Belt page 05-12. 2. Remove the bolt and the belt idler pulley.
  • Page 219 WSG-1068 COOLING SYSTEM Water Pump - Removal Material 1. Drain the cooling system. For additional information, refer to Cooling System Draining, 6. Remove the (A) water pump from the (B) Filling and Flushing page 05-05. cylinder block.  2. Remove the engine cooling fan.
  • Page 220 WSG-1068 COOLING SYSTEM 2. Position the pulley onto the water pump. 3. Install the fan spacer and fan. 4. Install the drive belt. 5. Refill the cooling system. For additional information, refer to Cooling System Draining, Filling and Flushing in this section.
  • Page 221 WSG-1068 COOLING SYSTEM DIAGNOSING AND TESTING NOTE: A small amount of antifreeze coming out the water pump weep hole may be normal. Refer to the following Diagnosis Chart for cooling system problems, their possible cause and Most vehicles use an ethylene glycol base antifreeze recommended correction.
  • Page 222 WSG-1068 COOLING SYSTEM Cooling System Visual Test Special Tool(s) 3. Inspect the coolant in both the radiator and the degas bottle for coolant color:  Clear, light green or blue indicates higher water content than required  Dark brown indicates unauthorized stop leak may have been used.
  • Page 223 WSG-1068 COOLING SYSTEM 4. If the engine coolant appearance is good, test Thermostat Test – Thermostat Removed the engine coolant range with the battery and antifreeze tester: WARNING: USE CAUTION WORKING WITH  Maximum ratio is 60/40. HOT BOILING WATER AND WEAR APPROPRIATE PROTECTIVE GEAR.
  • Page 224 WSG-1068 COOLING SYSTEM Radiator Leak Test, Removed From  The electrical resistance of the (CHT) sensor Vehicle changes with temperature. As engine coolant temperature increases, the (CHT) resistance decreases. CAUTION: Never leak test an aluminum  Output is a variable voltage signal which radiator in the same water that copper/brass typically ranges from 0.3 volt to 4.5 volts.
  • Page 225 WSG-1068 COOLING SYSTEM CHT Sensor Data Temperature Sensor Characteristics 209   ...
  • Page 226 WSG-1068 COOLING SYSTEM V-Ribbed Serpentine Drive Belt Cracks Across Ribs - Normal Chunks of Rib Missing - Replace Belt Drive Belt Symptom Chart 210   ...
  • Page 227 WSG-1068 COOLING SYSTEM Drive Tensioner/Belt Length Indicator Drive Belt Misalignment CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the drive pulleys. Non-standard replacement drive belts may track differently or improperly. If a replacement drive belt tracks improperly, replace it with an original equipment drive belt to avoid performance failure or loss of belt.
  • Page 228 WSG-1068 COOLING SYSTEM Visual Inspection Chart Inspection and Verification Special Tool(s) Special Service Tools called for by the procedures can be obtained by calling: 1-800-ROTUNDA (1-800-768-8632). Inspection and Verification 3. If the inspection reveals an obvious concern that 1. Verify the customer’s concern by operating the can be readily identified, repair as necessary.
  • Page 229 WSG-1068 COOLING SYSTEM PINPOINT TEST A: LOSS OF COOLANT 213   ...
  • Page 230 WSG-1068 COOLING SYSTEM PINPOINT TEST A: LOSS OF COOLANT (Continued) 214   ...
  • Page 231 WSG-1068 COOLING SYSTEM PINPOINT TEST B: THE ENGINE OVERHEATS PINPOINT TEST A: LOSS OF COOLANT (Continued) 215   ...
  • Page 232 WSG-1068 COOLING SYSTEM PINPOINT TEST B: THE ENGINE OVERHEATS (Continued) 216   ...
  • Page 233 WSG-1068 COOLING SYSTEM 217   ...
  • Page 234 PINPOINT TEST B: THE ENGINE OVERHEATS (Continued) WSG-1068 COOLING SYSTEM 218   ...
  • Page 235 PINPOINT TEST C: THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE WSG-1068 COOLING SYSTEM 219   ...
  • Page 236 SPECIFICATIONS General Specifications NOTE: Bolt information on installation page this section. Torque Specifications WSG-1068 CHARGING SYSTEM 220   ...
  • Page 237 INDEX Subject Page General Information Generator ..............................Circuit Description ..........................Diagnosis and Testing Recommended Accessory Wiring ......................Recommended Generator Wiring......................Voltage Regulator and Back of Governor....................Visual Inspection ............................. Generator Output Test ..........................Generator Voltage Test .......................... Battery - Drain Test ..........................Symptom Chart ............................
  • Page 238 WSG-1068 CHARGING SYSTEM GENERAL INFORMATION Battery Positive Voltage (B+) Output Generator With the key in the RUN position, voltage is applied The generator output circuit 38 (BK/O) is supplied through the charge indicator lamp “I” circuit to the through the battery positive voltage (B+) output voltage regulator.
  • Page 239 WSG-1068 CHARGING SYSTEM DIAGNOSIS AND TESTING Recommended Accessory Wiring 223   ...
  • Page 240 WSG-1068 CHARGING SYSTEM Recommended Generator Wiring Before performing generator tests on the unit, note conditions such as: slow cranking, dead battery, charge indicator lamp stays on with engine running, etc. This information will aid in isolating the part of the system causing the symptom.
  • Page 241 WSG-1068 CHARGING SYSTEM Visual Inspection Generator Voltage Test 1. Switch the tester to the voltmeter function. Preliminary checks to the charging system should be 2. Connect the positive lead to the generator A- made regardless of the fault condition. These checks...
  • Page 242 WSG-1068 CHARGING SYSTEM Check for current drains on the battery in excess of 50 milliamps (0.050 amp) with all the electrical accessories off and the engine off. Current drains can NOTE: If the meter settings need to be switched or the...
  • Page 243 WSG-1068 CHARGING SYSTEM Symptom Chart 227   ...
  • Page 244 WSG-1068 CHARGING SYSTEM Pinpoint Test A: Generator Output Voltage Inspection and Verification 1. Visually inspect for obvious signs of terminal corrosion and electrical harness damage. 2. Inspect fusible links and generator connector for bent or backed-out connector pins, or damage to wiring.
  • Page 245 WSG-1068 CHARGING SYSTEM 229   ...
  • Page 246 WSG-1068 CHARGING SYSTEM Pinpoint Test B: Voltage Output High Inspection and Verification 1. Visually inspect for obvious signs of terminal corrosion and electrical harness damage. 2. Inspect for poor ground connections or backed-out connector pins, or damage to wiring. 3. Visually inspect for and note auxiliary system connections not shown on the Recommended Customer Connections Wiring Schematic.
  • Page 247 WSG-1068 CHARGING SYSTEM Pinpoint Test C: Indicator Lamp ON, Engine Running Inspection and Verification 1. Visually inspect for obvious signs of terminal corrosion and electrical harness damage or a bulb failure. 2. Inspect fusible links and generator connector for bent or backed-out connector pins, or damage to wiring.
  • Page 248 WSG-1068 CHARGING SYSTEM REMOVAL AND INSTALLATION Regulator - Removal 1. NOTE: for ease or removal and installation of Generator - Removal regulator, remove the generator from engine as described above. 1. Disconnect battery ground cable (14301). Remove the four screws (T20 Torx type head) 2.
  • Page 249 WSG-1068 CHARGING SYSTEM 2. Hold the voltage regulator in one hand and pry Regulator - Installation off the cap covering the “A” screw head with a screwdriver. 1. Replace generator brush holder to voltage regulator and install attaching screws. 3. Remove two screws (T20 Torx type head) attaching the regulator to the generator brush 2.
  • Page 250 WSG-1068 CHARGING SYSTEM SPECIFICATIONS Torque Specifications Generator Parts Cross-Reference Special Tools 234   ...
  • Page 251 WSG-1068 STARTER SYSTEM INDEX Page Subject General Information Sequence of Operation ........................Jump Starting ............................Negative Grounded Battery........................Diagnosis and Testing Starter Load Test ..........................Bench Tests ............................Starter No-Load Test..........................System Inspection and Verification ...................... Symptom Chart ............................ Pinpoint Test A - Starter Lockout Relay Check..................
  • Page 252 WSG-1068 STARTER SYSTEM GENERAL INFORMATION 5. When the iron plunger core is all the way into The function of the starting system is to crank the engine the coil, its contact disc closes the circuit at a speed fast enough to permit the engine to start.
  • Page 253 WSG-1068 STARTER SYSTEM For cases of a starter that cranks the engine very slowly, AN EXPLOSION. REFER TO WARNING AT THE connect a 12-volt booster battery to the system. BEGINNING OF THE JUMP STARTING PROCEDURE. NOTE: Engine may not start if crank sensor reads less than 140 RPM.
  • Page 254 WSG-1068 STARTER SYSTEM DIAGNOSIS AND TESTING Starter Load Test ignition off, and determine exact reading on Conduct this test if the starter cranks slowly and it is voltmeter. This test is accomplished by desired to compare current to specifications. disconnecting push-on connector “S’’ at starter relay and by connecting a remote control starter 1.
  • Page 255 WSG-1068 STARTER SYSTEM Starter No-Load Test Wire Color Relay Circuit Terminal Description Voltage to Lt Bl / Pink Starter Relay Coil Red / Lt Gn Power Lt Gn / Pr To GCP Lt Bl / Pink Ignition Feed Auxiliary Run...
  • Page 256 WSG-1068 STARTER SYSTEM System Inspection and Verification NOTE: Be sure to disconnect battery negative cable before servicing starter. CAUTION: When disconnecting the plastic 1. Inspect starting system for loose connections. hardshell connector at the solenoid “S” terminal, grasp the plastic connector and pull lead off. DO 2.
  • Page 257 WSG-1068 STARTER SYSTEM Pinpoint Test A - Starter Lockout Relay Check Inspection and Verification 1. Visually inspect for obvious signs of mechanical and electrical damage. 2. Visually inspect for and note auxiliary system connections not shown on the recommended wiring schematic.
  • Page 258 WSG-1068 STARTER SYSTEM Pinpoint Test B - Starter Does Not Crank Inspection and Verification 1. Visually inspect for obvious signs of mechanical and electrical damage. 2. Visually inspect for and note auxiliary system connections not shown on the Recommended Customer Connections Wiring Schematic.
  • Page 259 WSG-1068 STARTER SYSTEM 243   ...
  • Page 260 WSG-1068 STARTER SYSTEM gage the remote starter switch. Read and record Component Tests the voltage. The voltage reading should be 0.5 volts or less. Starter Motor - Voltage Drop Test 5. If the voltage reading is 0.5 volts or less -- Refer to“Starter Motor - Motor Ground Circuit”...
  • Page 261 WSG-1068 STARTER SYSTEM Starter Motor - Motor Ground Circuit 4. Engage the remote starter switch and crank the engine. Read and record the voltage reading. A slow cranking condition can be caused by resistance The reading should be 0.5 volts or less.
  • Page 262 WSG-1068 STARTER SYSTEM Starter Drive and Flywheel Ring Gear Inspection 1. Check the wear patterns on the (A) starter drive (11350) and the (B) flywheel ring gear. If the wear pattern is normal, install the starter motor; refer to Starter Motor - Installation on page 07- 2.
  • Page 263 WSG-1068 STARTER SYSTEM REMOVAL AND INSTALLATION CAUTION: A jumper wire must not be installed between the large round electrical terminal and the solenoid blade terminal at the starter. If done, voltage is generated to the solenoid by the spinning starter after release of the start key or button, causing the starter to remain engaged, resulting in failure.
  • Page 264 WSG-1068 STARTER SYSTEM Starter Motor - Removal WARNING: WHEN CARRYING OUT MAINTENANCE ON THE STARTER SYSTEM BE AWARE THAT HEAVY GAUGE LEADS OR CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
  • Page 265 WSG-1068 STARTER SYSTEM 6. Remove the bolt and nut. 7. Remove the starter motor. Starter Motor - Installation WARNING: WHEN CARRYING OUT MAINTENANCE ON THE STARTER SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE.
  • Page 266 WSG-1068 STARTER SYSTEM 2. Connect the starter motor electrical connections. 1. Position the starter solenoid wire. 2. Position the battery cable. 3. Install the nuts. 3. Install the starter motor solenoid terminal cover. 4. Connect the battery ground cable. 250 ...
  • Page 267 WSG-1068 STARTER SYSTEM SPECIFICATIONS Torque Specifications Electrical Specifications General Specifications Special Tools Special Service Tools called for by the procedures can be obtained by calling: 1-800-ROTUNDA (1-800-768-8632). 251   ...
  • Page 268 WSG-1068 ENGINE CONTROLS Subject Page General Information........................GCP and Sensors ......................... Fuel System Components - Gasoline..................Coil-on-plug Ignition ......................Open Loop and Closed Loop Operation................Adaptive Learn ........................hhhh GCP Service Precautions....................... Use of Circuit Testing Tools ....................Electrostatic Discharge Damage.....................

  • Page 269: General Information

    WSG-1068 ENGINE CONTROLS GENERAL INFORMATION GCP and Sensors Engine Control Module (GCP) throttle-by-wire or variable speed control governing.  The Engine Control Module (GCP) has the following Programmable emergency warning/shut-down features: feature for high water temperature, low oil  Programmable four speed electronic governing, pressure, etc ...
  • Page 270 WSG-1068 ENGINE CONTROLS speeds (with customer-specified minimum and The GCP constantly observes the information from maximum) based on a variable signal input.  various sensors. The GCP controls the systems that It can be an electronic replacement for a throttle cable with maximum speed governing (throttle- affect engine performance.
  • Page 271 WSG-1068 ENGINE CONTROLS Crankshaft Position (CKP) Sensor The Crankshaft Position (CKP) Sensor provides a signal used by the Engine Control Module (GCP) to calculate the ignition sequence. The sensor initiates the reference pulses which the GCP uses to calculate RPM and crankshaft position.
  • Page 272 WSG-1068 ENGINE CONTROLS Engine Coolant Temperature (ECT) Sensor The Engine Coolant Temperature (ECT) Sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance of 100,000 ohms at -40°C (-40°F). High temperature causes a low resistance of 70 ohms at 130°C (266°F).
  • Page 273 WSG-1068 ENGINE CONTROLS Cylinder Head Temperature (CHT) Sensor isolated case ground which goes to Signal Return (SIGRTN) either in the processor (as a dedicated HO2S The Cylinder Head Temperature (CHT) Sensor is a ground) or as a jumper to SIGRTN in the wiring thermistor which changes its resistance based on the harness.
  • Page 274 WSG-1068 ENGINE CONTROLS Temperature Manifold Absolute Pressure (TMAP) reference voltage and ground to the sensor and Sensor monitors the sensor’s ratio metric output voltage to determine precise throttle position. The electronic The Temperature Manifold Absolute Pressure (TMAP) actuator has two TP outputs that the GCP monitors.

  • Page 275: Fuel System Components - Gasoline

    WSG-1068 ENGINE CONTROLS Fuel System Components - Gasoline Fuel Injector The fuel metering system is made up of the following parts: The Electronic Fuel Injection (EFI) fuel injector is a  The fuel injectors solenoid operated device controlled by the GCP. The ...

  • Page 276: Coil-On-Plug Ignition

    WSG-1068 ENGINE CONTROLS Fuel Filter  Increased available ignition coil saturation time The fuel filter is an inline filter assembly. Refer to  Section 4 for information on relieving fuel pressure, Elimination of high tension wires disconnecting fuel lines and fuel filter replacement.

  • Page 277: Open Loop And Closed Loop Operation

    WSG-1068 ENGINE CONTROLS  When measuring voltages, use only a digital voltmeter with an input impedance of at least 10 Open Loop and Closed Loop Operation megohms. NOTE: No DTC will be set unless engine has operated  Do not employ any non-standard practices such as in closed loop status for more than 6 seconds.

  • Page 278: Diagrams And Schematics

    WSG-1068 ENGINE CONTROLS Diagrams and Schematics Symbols 262   ...
  • Page 279 WSG-1068 ENGINE CONTROLS GCP - Power Distribution Box 263   ...
  • Page 280 WSG-1068 ENGINE CONTROLS Wire Colors Revision Level The following wiring schematics are taken from the wiring diagram labeled below: 264   ...
  • Page 281 WSG-1068 ENGINE CONTROLS Power Distribution 265   ...
  • Page 282 WSG-1068 ENGINE CONTROLS Ignition System 266   ...
  • Page 283 WSG-1068 ENGINE CONTROLS Starting System 267   ...
  • Page 284 WSG-1068 ENGINE CONTROLS Charging System 268   ...
  • Page 285 WSG-1068 ENGINE CONTROLS Engine Controls - Sensors (1 of 2) 269   ...
  • Page 286 WSG-1068 ENGINE CONTROLS Engine Controls - Sensors (2 of 2) 270   ...
  • Page 287 WSG-1068 ENGINE CONTROLS Fuel Injectors 271   ...
  • Page 288 WSG-1068 ENGINE CONTROLS Engine Controls - Actuator / Data Link Connector (DLC) WSG-1068 ENGINE CONTROLS 272   ...
  • Page 289 Engine Controls - Dry Fuel EPR 273   ...

  • Page 290: Engine Component Locator View

    WSG-1068 ENGINE CONTROLS Engine Component Locator View 274   ...

  • Page 291: Diagnosis And Testing

    WSG-1068 ENGINE CONTROLS If more than one DTC is detected, begin with the lowest DIAGNOSIS AND TESTING number DTC and diagnose each problem to correction unless directed to do otherwise by the fault tree. The Diagnostic Approach DTC’s are numbered in order of importance. Having...

  • Page 292: Intermittent Mil

    WSG-1068 ENGINE CONTROLS The actuator is limited to a maximum opening of 20%. If RPM. If the “Force to Idle” is active, it will remain active “Power Derate 2” is active, it will remain active until the until the active DTC goes away.

  • Page 293: Diagnosis Using A Personal Computer

    WSG-1068 ENGINE CONTROLS KOER operation a DTC is stored, the MIL will illuminate Diagnosis Using a Personal Computer and remain on steady if the code is active. Equipment Requirements MIL Bulb Test You will need a laptop computer (with a serial port) or...
  • Page 294 WSG-1068 ENGINE CONTROLS Interface Hook-up laptop computer. Connect interface cable to the to the For connection to a laptop, use kit PN 5080050. diagnostic connector on the engine harness. Connect USB port on the back of the Laptop Computer  Diagnostic  Connector ...
  • Page 295 WSG-1068 ENGINE CONTROLS GCP Software Installation Insert CD into CD-ROM drive. Double click “My Computer” Icon. A screen will pop up telling you the name of the Double Click CD-ROM drive letter destination folder. This will display the contents of the CD as shown.
  • Page 296 WSG-1068 ENGINE CONTROLS Using GCP Software - Menu Functions You will see an Installation Success” screen when the software is finished installing. You can begin using the technicians GCP software after installation, by clicking Start - Programs - GCP Display - GCP Display as shown.
  • Page 297 WSG-1068 ENGINE CONTROLS Diagnostic Trouble Codes Hear is an example of a DTC Dialogue Box. The System Fault screen is used to view and clear DTC’s, which have been set. Snap Shot Data The Snap Shot Data is a listing of specific engine system variables.
  • Page 298 WSG-1068 ENGINE CONTROLS Data Stream - Reading Sensor & Actuator Values Flight Data Recorder The Flight Data Recorder is also a listing of specific engine system variables. These variables are recorded by the GCP for an interval of 10 seconds. The 10 second interval includes 8 seconds before the DTC sets and 2 seconds after the DTC sets.
  • Page 299 WSG-1068 ENGINE CONTROLS Plotting and Data Logging Here is a sample of a plot. Recording the values and voltages can be a very useful Logging tool while diagnosing engine problems. The FORD Logging variables means the variables are stored to the diagnostic software includes real time plotting and real PC.
  • Page 300 WSG-1068 ENGINE CONTROLS Ignition System Test The Spark Kill diagnostic mode allows the technician to disable the ignition on individual cylinders. If the Spark Kill diagnostic mode is selected with the engine running below 1000 RPM, the minimum throttle command will lock into the position it was in when the test mode was entered.
  • Page 301 WSG-1068 ENGINE CONTROLS Throttle Test Injector Test To select this test mode the engine must be off, but the The Injector Kill mode is used to disable individual fuel key must be in the ON position. injectors. If the Injector Kill mode is selected with the...
  • Page 302 WSG-1068 ENGINE CONTROLS RAW VOLTS Screen The RAW VOLTS screen shows actual voltage readings from various circuits. Use the keys at the upper left corner or the “page” command to toggle the three main screens (GAUGES, FAULTS AND RAW VOLTS).

  • Page 303: Visual Inspection

    WSG-1068 ENGINE CONTROLS Visual Inspection Intermittent Problems Perform a careful visual and physical engine inspection NOTE: An intermittent problem may or may not turn on before performing any diagnostic procedure. Perform the MIL or store a DTC. Do not use the DTC charts for all necessary repairs before proceeding with additional intermittent problems.

  • Page 304: Symptom Charts

    WSG-1068 ENGINE CONTROLS Symptom Charts NOTE: If you have a symptom of the pedal not working, NOTE: EDI engines are used in many different and no DTC is set, go to the voltage screen and check applications and equipment. When performing any pedal voltage.
  • Page 305 WSG-1068 ENGINE CONTROLS Engine Performance - While Under Load 289   ...
  • Page 306 WSG-1068 ENGINE CONTROLS Engine Concerns 290   ...

  • Page 307: Engine Control Module (Gcp) - Diagnostic Trouble Codes

    WSG-1068 ENGINE CONTROLS Engine Control Module (GCP) - Diagnostic Trouble Codes CAUTION: When checking codes with the diagnostic software, the DTC terminal can NOT be grounded. CAUTION: Removing battery power before accessing diagnostic program will erase all codes recorded. This section contains circuit description information and troubleshooting charts on all the DTC’s obtained by...
  • Page 308 WSG-1068 ENGINE CONTROLS Diagnostic Trouble Code  265  Injector Coil Shorted  11  Intake cam / distributor position  267  Injector Loop Open or Low‐side short to Ground  16  Never crank synced at start  268  Injector Coil Shorted  24  Exhaust cam position  270  Injector Loop Open or Low‐side short to Ground  91  FP low voltage  271  Injector Coil Shorted  92  FP high voltage  273  Injector Loop Open or Low‐side short to Ground  107  MAP Low Voltage  274  Injector Coil Shorted  108  MAP High Pressure  276  Injector Loop Open or Low‐side short to Ground  111  IAT higher than expected 1  277  Injector Coil Shorted  112  IAT low voltage ...
  • Page 309 616  Start relay control ground short  1183  Megajector autozero / lockoff failed  617  Start relay coil short to power  1311  Misfire detected  627  Fpump relay coil open  1312  Misfire detected  628  Fpump relay control ground short  1313  Misfire detected  FPump motor loop open or high‐side shorted to  1314  Misfire detected  628  ground  1315  Misfire detected  629  Fpump relay coil short to power  1316  Misfire detected  629  FPump motor high‐side shorted to power  1317  Misfire detected  642  5VE1 low voltage  1318  Misfire detected  643  5VE1 high voltage  1511  AUX analog PU1 high  650  MIL open ...
  • Page 310 1621  Rx Inactive  2122  FPP1 high voltage  1622  Rx Noise  2123  FPP1 low voltage  1623  Invalid Packet Format  2125  FPP2 invalid voltage and FPP1 disagrees with IVS  1626  CAN Tx failure  2126  FPP1 higher than FPP2  1627  CAN Rx failure  2127  FPP2 low voltage  1628  CAN addresss conflict failure  2128  FPP2 high voltage  1629  J1939 TSC1 message receipt lost  2130  IVS stuck at‐idle, FPP1/2 match  1630  J1939 ETC message receipt lost  2131  IVS stuck off‐idle, FPP1/2 match  1631  PWM1‐Gauge1 open / ground short  2135  TPS1/2 simultaneous voltages out of range  1632  PWM1‐Gauge1 short to power  2139  FPP1 lower than IVS limit  1633 ...

  • Page 311: Removal And Installation

    WSG-1068 ENGINE CONTROLS REMOVAL AND INSTALLATION Camshaft Position (CMP) Sensor - Replacement 5. Install special tool 303-507 and turn the crankshaft pulley bolt to position the No. 1 cylinder at top dead center (TDC). 1. Disconnect battery ground cable -- refer to 6.

  • Page 312: Crankshaft Position (Ckp) Sensor - Installation

    WSG-1068 ENGINE CONTROLS Crankshaft Position (CKP) Sensor - Installation 1. Position CKP sensor and loosely install the 2 6. Install the plug: bolts.  Tighten to 10 Nm (89 lb-in) NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not available separately.

  • Page 313: Cylinder Head Temperature (Cht) Sensor - Replacement

    WSG-1068 ENGINE CONTROLS Cylinder Head Temperature (CHT) Sensor - Replacement Heated Oxygen Sensor (HO2S) - Replacement 1. Disconnect battery ground cable -- refer to section 6. 2. Remove or disconnect any component to allow access and removal of the CHT Sensor.

  • Page 314: Knock Sensor (Ks) - Replacement

    WSG-1068 ENGINE CONTROLS Knock Sensor (KS) - Replacement Temperature Manifold Absolute Pressure (TMAP) Sensor - Replacement 1. Disconnect battery ground cable -- refer to section 6. 1. Disconnect battery ground cable -- refer to 2. Remove or disconnect any component to allow section 6.

  • Page 315: Specifications

    WSG-1068 ENGINE CONTROLS SPECIFICATIONS 299   ...
  • Page 316 WSG-1068 METRICS INDEX Page Subject Introduction ..............................Nomenclature for Bolts ..........................Bolt Strength Identification..........................Hex Nut Strength Identification ........................Other Types of Parts............................English/Metric conversion ..........................Decimal and Metric Equivalents ........................Torque Conversion ............................J1930 Terminology List ..........................300   ...
  • Page 317 WSG-1068 METRICS INTRODUCTION Most threaded fasteners are covered by specifications that define required mechanical properties, such as tensile strength, yield strength, proof load and hardness. These specifications are carefully considered in initial selection of fasteners for a given application. To ensure continued satisfactory vehicle performance, replacement fasteners used should be of the correct strength, as well as the correct nominal diameter, thread pitch, length, and finish.
  • Page 318 WSG-1068 METRICS BOLT STRENGTH IDENTIFICATION English System English (inch) bolts: Identification marks correspond to bolt strength, increasing number of slashes represent increasing strength. Metric System Metric (mm) bolts: Identification class numbers correspond to bolt strength, increasing numbers represent increasing strength. Common metric fastener bolt strength property are 9.8 and 10.9 with the class identification embossed on the bolt head.
  • Page 319 WSG-1068 METRICS OTHER TYPES OF PARTS Metric identification schemes vary by type of part, most often a variation of that used of bolts and nuts. Note that many types of English and Metric fasteners carry no special identification if they are otherwise unique.
  • Page 320 WSG-1068 METRICS ENGLISH/METRIC CONVERSION 304   ...
  • Page 321 WSG-1068 METRICS DECIMAL AND METRIC EQUIVALENTS TORQUE CONVERSION 305   ...
  • Page 322 WSG-1068 METRICS J1930 TERMINOLOGY LIST Certain Ford Component names have been changed in this Service Manual to conform to Society of Automotive Engineers (SAE) directive J1930. SAE J1930 standardizes automotive component names for all vehicle manufacturers. 306   ...
  • Page 323 WSG-1068 METRICS 307   ...
  • Page 324 WSG-1068 METRICS 308   ...
  • Page 325 WSG-1068 METRICS 309   ...
  • Page 326 WSG-1068 METRICS 310   ...
  • Page 327 WSG-1068 METRICS 311   ...
  • Page 328 WSG-1068 METRICS 312   ...
  • Page 329 WSG-1068 METRICS 313   ...
  • Page 330 314   ...
  • Page 331 EDI Worldwide Service Engine Distributors Inc 400 University Court Blackwood NJ 08012 Service/Warranty 1-800-220-2700 1-856-228-7298 1-856-228-5657(fax parts & service) 1-856-228-5531(fax sales) 315   ...

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