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Briggs & Stratton Vanguard 430000 User Manual

3-cylinder ohv liquid-cooled gasoline engines
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Other Briggs & Stratton
Commercial Power Repair Manuals:
272147 - Vanguard
Single Cylinder OHV Air-Cooled Engines
™
272144 - Vanguard
Twin Cylinder OHV Air-Cooled Engines
™
275429 - Vanguard
™
Twin Cylinder OHV Liquid-Cooled Engines
MS-1055 - Vanguard
3-Cylinder OHV Liquid-Cooled Diesel Engines
™
Quality Starts With A
Master Service Technician
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bRiGGsandstRattoN.coM (consumers)
BRIGGS&STRATTON
coRPoRatioN
MS - 0750 - 5/10
Post office box 702
Milwaukee, wi 53201 usa
©2010 Briggs & Stratton Corporation
Vanguard
™
Liquid-Cooled Gasoline Engines
3-Cylinder OHV

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Summary of Contents for Briggs & Stratton Vanguard 430000

  • Page 1 Other Briggs & Stratton Commercial Power Repair Manuals: 272147 - Vanguard Single Cylinder OHV Air-Cooled Engines ™ 272144 - Vanguard Twin Cylinder OHV Air-Cooled Engines ™ 275429 - Vanguard ™ Twin Cylinder OHV Liquid-Cooled Engines MS-1055 - Vanguard 3-Cylinder OHV Liquid-Cooled Diesel Engines ™...

  • Page 2: Section 1 - Safety

    FORWARD This manual was written to assist engine technicians and service personnel with the repair and maintenance procedures for Briggs & Stratton® engines. It assumes that persons using this manual have been properly trained in and are familiar with the servicing procedures for these products, including the proper use of required tools and safety equipment and the application of appropriate safety practices.
  • Page 3 This engine repair manual includes the following engine models: • MODEL 430000 • MODEL 580000...

  • Page 4: Table Of Contents

    SECTION 1 - Safety SECTION 2 - Cylinder Heads and Valves SECTION 3 - Governor, Timing Gears, and Gear Case SECTION 4 - Flywheel and Rear Seal Retainer SECTION 5 - Cylinder Block Disassembly SECTION 6 - Cylinder Block Inspection and Repair SECTION 7 - Crankshaft, Camshaft, and Bearings SECTION 8 - Pistons, Rings, and Connecting Rods SECTION 9 - Cylinder Block Assembly...
  • Page 5 THISPROPER SERVICE AND REPAIR IS IMPORTANT TO THE SAFE, ECONOMICAL AND RELIABLE...
  • Page 6 SECTION 1 - SAFETY AND MAINTENANCE SAFETY INFORMATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4...

  • Page 7: Safety Information

    SAFETY INFORMATION This repair manual contains safety information that is designed to: • Make you aware of hazards associated WARNING with engines. Before attempting to service this equipment, • Inform you of the risk of injury associated read and understand this manual and the with those hazards.
  • Page 8 WARNING WARNING Certain components in this product and its Fuel and its vapors are extremely flam- mable and explosive. related accessories contain chemicals known Fire or explosion can cause severe to the State of California to cause cancer, birth burns or death. defects, or other reproductive harm.
  • Page 9 WARNING WARNING Unintentional sparking can result in fire Charging batteries produce hydrogen or electrical shock. gas. Do not store or charge a battery Unintentional start-up can result in near an open flame or device that uti- entanglement, traumatic amputation, or lizes a pilot light or can create a spark.
  • Page 10 SECTION 2 - CYLINDER HEAD AND VALVES REMOVE CYLINDER HEAD - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 DISASSEMBLE CYLINDER HEAD - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10 REMOVE VALVES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -11 INSPECT CYLINDER HEAD - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -12...

  • Page 12: Remove Cylinder Head

    Remove Cylinder Head 1. Drain cooling system and disconnect radiator hoses and bypass hose at water pump. 2. Remove the alternator adjusting bracket screw (A, Figure 1), V-belt (B), and fan (C), from the engine. Figure 3 6. Remove the ignition coil bracket (Figure 4) and the ignition coils.

  • Page 13: Disassemble Cylinder Head

    9. Rotate crankshaft pulley until timing mark on Disassemble Cylinder Head pulley is aligned with reference point (A, 1. Loosen cylinder head bolts in the order Figure 6) on timing cover (B). shown (Figure 8). Figure 6 • If intake and exhaust valves have Figure 8 clearance, the Number 1 piston is at TDC (compression stroke).

  • Page 14: Remove Valves

    Remove Valves 2. Refer to the following cylinder head components (Figure 9) when proceeding to the next part of the disassembly process: • (A) - Cylinder Head Assembly • (B) - Cylinder Head Gasket • (C) - Valve Stem Cap •...

  • Page 15: Inspect Cylinder Head

    Inspect and Repair • Replace if damaged or if reject gauge enters valve guide. Inspect Cylinder Head NOTE: Be sure all gasket material is removed from surfaces before checking. Use a gasket scraper if necessary. 1. Inspect cylinder head for cracks or damage. 2.
  • Page 16 Figure 18 Figure 16 • Use a 45° (B) cutter to narrow seat from 10. Valve faces may be resurfaced to 30°. Check bottom. valve seat dimensions before resurfacing. (A, Figure 17) should be 0.05 - 0.06” (1.2 - • Use a 15° (C) cutter to narrow seat from 1.6mm) and (B) should be at least 0.0312”.
  • Page 17 Figure 20 14. Inspect valve springs for squareness and free length (Figure 21). Figure 21 • Replace if out of square more than 0.040 in. (1.0 mm). • Replace if free length is less than 0.150 in. (29.2 mm).

  • Page 18: Disassemble Rocker Arm Shaft

    Disassemble Rocker Arm Shaft Remove snap rings (A, Figure 22) from ends of rocker arm shaft (B). Remove set screw (C) from center rocker arm support (D). Disassemble rocker arm assembly. Note position of rocker arms (E), thrust washers (F) and springs (G). Figure 22 1.

  • Page 19: Assemble Rocker Arm Shaft

    Assemble Rocker Arm Shaft 1. Oil all components before assembling. 2. Small grooves in rocker shaft (A) next to oil holes (B) must face down. 3. Assemble rocker arm (G) components, noting order of assembly shown in Figure 24. Figure 24 4.

  • Page 20: Assemble Cylinder Head

    Assemble Cylinder Head Cylinder Head Components (Figure 25) • (A) - Cylinder Head • (B) - Cylinder Head Gasket • (C) - Valve Stem Cap • (D) - Valve Spring Retainer Locks • (E) - Valve Spring Retainer • (F) - Valve Spring •...

  • Page 21: Install Cylinder Head

    Figure 29 2. Install cylinder head assembly. Figure 27 3. Lubricate threads of cylinder head bolts with engine oil. NOTE: Lightly coat valve stems with Valve Guide Lubricant #93963, before installing valves. 4. Torque head bolts in 10 ft. lbs. (13.0 Nm) increments in sequence shown (Figure 30).
  • Page 22 Figure 33 Figure 31 10. Insert governor spring into original hole in governor lever. 7. Install washers and torque nuts to values listed in Section 14 - Engine Specifications. NOTE: Normal spring position is in center hole in the governor lever (Figure 34). NOTE: Make sure rocker adjustments studs are seated in recessed end of push rods.

  • Page 23: Adjust Valves

    Figure 35 Figure 38 12. Install water pump with new gasket (Figure NOTE: Belt deflection limit is 3/8-1/2 in./22 lb. (10.0- 36). Torque screws and nuts to values listed 12.0 mm/10 kg). in Section 14 - Engine Specifications. Adjust Valves 1.
  • Page 24 Figure 40 3. With Number 1 piston at TDC of compression stroke, check and adjust valve clearances for cylinders (Figure 41). 4. Rotate crankshaft one complete turn 360° clockwise to check and adjust remaining valves. 5. Install valve cover (Figure 41).Torque cover nuts to values listed in Section 14 - Engine Specifications.

  • Page 26: Section 3 - Governor, Timing Gears, And Gear Case

    SECTION 3 - GOVERNOR, TIMING GEARS, AND GEAR CASE REMOVE TIMING GEAR COVER AND GEARS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -24 INSPECT GEARS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -25 REMOVE GEAR CASE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -26 DISASSEMBLE GOVERNOR SHAFT ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -27...

  • Page 27: Remove Timing Gear Cover And Gears

    TIMING GEARS, GEAR CASE, ELECTRONIC GOVERNOR Remove Timing Gear Cover and Gears NOTE: Make sure the Number 1 cylinder is at Top Dead Center (TDC), compression stroke. See Section 2. 1. Remove V-belt and fan (if equipped). 2. Drain oil from engine. NOTE: Before removing governor spring, note hole position of governor spring in governor lever.

  • Page 28: Inspect Gears

    6. Remove oil pan screws and nuts. 7. Remove oil pan and discard gasket. 8. Remove oil pick-up tube (A, Figure 2) and strainer. Discard gasket. Figure 4 12. Remove governor gear (A, Figure 5), governor cup (B), E-ring (C), governor gear (D), and thrust washer (E).

  • Page 29: Remove Gear Case

    7. If gears are worn, it is recommended that they be replaced as a set. Figure 6 3. If back lash exceeds 0.008 in. (0.2 mm) check idler gear bearing and shaft for wear (Figure 7). Figure 8 Reject dimensions for Idler Gear: •...

  • Page 30: Disassemble Governor Shaft Assembly

    Figure 12 Figure 10 Assemble Governor Shaft Assembly 1. Install thrust washer (A, Figure 13) on shaft followed by the governor gear (B), E-ring Disassemble Governor Shaft Assembly (C), and governor cup (D). 1. Remove cotter pin (A, Figure 11) and washer (B).

  • Page 31: Assemble Timing Gear Case And Gears

    Figure 16 Figure 14 NOTE: It may be necessary to rotate oil pump drive to engage oil pump rotors. Assemble Timing Gear Case and Gears 1. Clean and lubricate oil pump rotor (A, Figure NOTE: Position camshaft retainer so that the center 15) with engine oil and install on cylinder hole does not interfere with the camshaft.
  • Page 32 Figure 18 Engine models 430000 and 580000 built after date Figure 20 code 990111007 are equipped with right angle helical timing gears. Timing marks are identified by 10. Install timing gear cover with new gasket. letters (A, AA, B, BB, etc.), instead of numbers. Note position, length, and number of screws The timing procedure is the same.
  • Page 33 12. Remove flywheel holder (A) and install trigger assembly and wire (B). Figure 24 19. Insert governor spring into original hole in Figure 22 governor lever. 13. Install oil pick-up tube and strainer with new NOTICE: Governor spring must be installed in gasket.

  • Page 34: Adjust Governor

    Adjust Governor 1. Move governor control lever (A, Figure 26) up to end of travel and hold in this position (throttle wide open). 2. Rotate governor shaft (B) clockwise to end of travel. 3. Torque governor nut (C) to value listed in Section 14 - Engine Specifications.

  • Page 35: Electronic Governor

    Electronic Governor The ignition module and related wiring for the electronic governor is supplied by the equipment manufacturer. NOTE: Engines equipped with an electronic governor do not have mechanical governor components. A - Governor Actuator B - Governor Link C - Governor Link Spring D - Wiring Harness...

  • Page 36: Inspect Governor Actuator

    Inspect Governor Actuator Install Governor Actuator 1. Disconnect harness at connector (A, Figure 1. Assemble governor link spring and link to 29). actuator lever (Figure 31). 2. Touch test leads (B) to terminals of a known good 12 volt battery. NOTE: Open ends of spring must face cylinder head.

  • Page 38: Section 4 - Flywheel And Rear Seal Retainer

    SECTION 4 - FLYWHEEL AND REAR SEAL RETAINER REMOVE OIL PAN AND FLYWHEEL- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -36 REMOVE REAR SEAL RETAINER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -36 REPLACE OIL SEAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -36 INSTALL REAL SEAL RETAINER AND FLYWHEEL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -37...
  • Page 39 Removing Pan and Flywheel Remove Rear Seal Retainer 1. Drain oil from engine. 1. Remove rear seal retainer and discard gasket (Figure 3). 2. Remove oil pan screws and nuts (Figure 1). 3. Remove oil pan and discard gasket. Figure 3 Figure 1 Replacing Oil Seal 4.
  • Page 40 Figure 7 Figure 5 3. Torque flywheel screws to values listed in Section 14 - Engine Specifications. Installing Rear Seal Retainer and Flywheel 1. Install real seal retainer with new gasket 4. Remove flywheel holder. (Figure 6). Torque screws to values listed in Section 14 - Engine Specifications.

  • Page 42: Section 5 - Cylinder Block Disassembly

    SECTION 5 - CYLINDER BLOCK DISASSEMBLY CYLINDER BLOCK DISASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -40 CYLINDER BLOCK...
  • Page 43 Cylinder Block Disassembly An automotive type engine stand is recommended when complete engine disassembly is required. See drawings below for dimensions to make an engine stand mounting fixture. The engine stand shown below is manufactured by Snap-On®.
  • Page 44 1. Remove cylinder head. See Section 2. 2. Remove oil pan, timing cover, gears, and case. See Section 3. 3. Remove flywheel and rear seal retainer. See Section 4. 4. Remove starter motor (Figure 1). Figure 3 7. Remove camshaft (Figure 4). NOTE: Use care when removing camshaft to prevent damaging cam bearing, journals, and lobes.
  • Page 45 NOTE: Main bearing caps are numbered 1 through Figure 5 9. Remove connecting rod and piston Figure 7 assemblies (Figure 6). 11. Remove crankshaft (A, Figure 8). NOTE: Remove carbon or ridge from cylinder and • Remove crankshaft thrust washers (#3 number connecting rod/piston assemblies before main bearing).

  • Page 46: Section 6 - Cylinder Block Inspection And Repair

    SECTION 6 - CYLINDER BLOCK INSPECTION AND REPAIR CHECK CYLINDER BLOCK - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -44 CHECK CYLINDER BORE FOR WEAR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -44 REPLACE CAMSHAFT BEARINGS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -45 REPLACE CAMSHAFT PLUG - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -45...
  • Page 47 Inspect Cylinder Block 1. Remove all traces of sealant and gasket material from mounting surfaces. Inspect cylinder block for damage, cracks, and stripped threads. 2. Inspect cylinder block deck for distortion (Figure 1). • Distortion Limit - 0.003 in. (0.08 mm). Figure 3 NOTE: Always resize to exactly 0.010 in.
  • Page 48 Replace Camshaft Plug 1. Remove rear camshaft plug (Figure 8). NOTICE: Use a wood dowel or brass rod to prevent damage to the camshaft bearing. Figure 5 Replace Camshaft Bearing 1. Using Camshaft Bearing Puller #19421, remove camshaft bearing (Figure 6). Figure 8 2.
  • Page 49 Figure 10 4. Remove timing gear oil nozzle (A, Figure 11). Figure 11 5. When reinstalling oil nozzle, oil hole must be positioned at a 45° angle, pointing towards the idler gear (A, Figure 12). Figure 12...
  • Page 50 SECTION 7 - CRANKSHAFT, CAMSHAFT AND BEARINGS INSPECT CRANKSHAFT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -48 CHECK MAIN BEARING CLEARANCES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -49 CHECK CONNECTING ROD BEARING CLEARANCES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -50 CHECK CRANKSHAFT END PLAY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -50...

  • Page 51: Inspect Crankshaft

    Inspect Crankshaft 1. Inspect crankshaft journals for grooves or signs of scoring. If found, crankshaft must be re-ground or replaced. 2. Check the main bearing and crankpin journals for wear and taper (Figure 1). Figure 2 • Maximum Run-out - 0.0023 in. (0.06 mm) NOTE: If run-out exceeds specification shown, the crankshaft must be replaced.

  • Page 52: Check Main Bearing Clearances

    Check Main Bearing Clearances NOTE: If main bearings show signs of flaking or scoring, bearings must be replaced. NOTE: Main bearing saddles in cylinder block, main bearing caps, main bearings, and crankshaft journals must be clean and free of oil. 1.

  • Page 53: Check Connecting Rod Bearing Clearances

    Check Connecting Rod Bearing Clearances 4. Remove the connecting rod cap. Measure the plastigage at its widest point (A, Figure 9). If the clearance is not within specification, NOTE: If connecting rod bearings show signs of replace the bearings. flaking or scoring, bearings must be replaced. •...

  • Page 54: Inspect Camshaft

    Figure 12 Figure 10 3. Measure camshaft run-out (Figure 13). • Maximum Run-out - 0.0012 in. (0.03 mm) Inspect Camshaft 4. If a run-out exceeds specification, the 1. Measure camshaft lobe height (Figure 11). If camshaft must be replaced. lobes are not to specification, replace the camshaft.
  • Page 56 SECTION 8 - PISTON, RINGS AND CONNECTING ROD DISASSEMBLE PISTON AND CONNECTING ROD - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -54 INSPECT PISTONS AND RINGS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -54 CHECK PISTON PIN AND CONNECTING ROD - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -55 ASSEMBLE PISTON AND CONNECTING ROD - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -56...
  • Page 57 If the cylinder bore is to be resized there is no reason to check the piston as a new oversized piston will be used. If the cylinder is not going to be resized, and the piston shows no signs of scoring, the piston should be checked.
  • Page 58 3. Check crankpin bearing end of connecting rod (Figure 8). Figure 8 Figure 5 • Maximum out of round: 0.0008 in. (0.02 • Replace if greater than 0.710 in. (18.03 mm) or 0.0004 in. (0.01 mm) out of round. • If out of round exceeds specification shown, the connecting rod must be replaced.
  • Page 59 Assemble Piston and Connecting Rod Assemble Piston Rings to Piston 1. Assemble piston to connecting rod using 1. Install oil ring expander first. Piston Pin Fixture #19419. 2. Spiral bottom oil control ring into top ring groove, center ring groove, and then into position below expander (Figure 12).

  • Page 60: Section 9 - Cylinder Block Assembly

    SECTION 9 - CYLINDER BLOCK ASSEMBLY INSTALL CRANKSHAFT- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -58 INSTALL PISTONS AND CONNECTING RODS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -59 GENERAL ASSEMBLY- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -59 INSTALL TIMING GEAR CASE, CAMSHAFT, AND GEARS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -60...

  • Page 61: Install Crankshaft

    Install Crankshaft 1. Install main bearings in cylinder block. NOTE: Upper bearing has an oil groove (A, Figure 1) and oil holes (B). Figure 3 9. Install main bearing caps. Lubricate threads Figure 1 of screws with engine oil. 10. Install bearing caps in their respective 2.

  • Page 62: Install Pistons And Connecting Rods

    Install Pistons and Connecting Rods General Assembly 1. Install connecting rod bearings. Be sure tang 1. Install gasket, oil pick-up tube and strainer on bearing is seated in notch (A, Figure 5) in (Figure 7). Torque screws to values listed in connecting rod and cap.

  • Page 63: Install Timing Gear Case, Camshaft, And Gears

    Figure 9 Figure 11 Install Timing Gear Case, Camshaft, and Gears 5. Lubricate and install camshaft in cylinder block. Take care not to damage lobes or cam 1. Lubricate oil pump rotor (A, Figure 10) with bearing. engine oil and install in cylinder block. 6.
  • Page 64 Figure 15 Figure 13 11. Install camshaft gear (A, Figure 16), idler 9. Assemble idler gear shaft (A, Figure 14) with gear (B), and oil pump gear (C). Torque ID mark (B) up. screws to values listed in Section 14 - Engine Specifications.

  • Page 65: Install Oil Pan

    Figure 19 Figure 17 3. Torque screws to values listed in Section 14 - 14. Torque screws to values listed in Section 14 - Engine Specifications. Engine Specifications. 15. Install crankshaft pulley with timing mark at Install Alternator 12 o'clock position (Number 1 cylinder). 1.
  • Page 66 SECTION 10 - CARBURETOR AND RELATED COMPONENTS MANUAL CHOKE CARBURETOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -66 REMOVE CARBURETOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -66 DISASSEMBLE CARBURETOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -66 CLEAN CARBURETOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -68...
  • Page 67 INITIAL CARBURETOR ADJUSTMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -280 FINAL CARBURETOR ADJUSTMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -280 ELECTRIC FUEL PUMP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -81 CHECK FUEL PUMP OUTPUT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -82...
  • Page 68 MANUAL CHOKE CARBURETOR AUTOMATIC CHOKE CARBURETOR...

  • Page 69: Manual Choke Carburetor

    Manual Choke Carburetor 6. Remove choke link (A, Figure 3) from choke lever. Remove Carburetor 1. Disconnect fuel line (A, Figure 1). 2. Remove air cleaner tube from carburetor air horn. Disconnect fuel solenoid wire, if equipped. Figure 3 7. Remove nuts, air horn (A, Figure 4), carburetor (B), and insulator (C).
  • Page 70 4. Remove fixed high speed jet (A, Figure 8). 5. Remove emulsion tube (B). Figure 5 2. Drive out float hinge pin (A, Figure 6) from Figure 8 choke plate side of carburetor (B) with a small punch. Remove float (C) and fuel inlet NOTE: Consult the illustrated parts list for correct valve (D).

  • Page 71: Clean Carburetor

    Figure 12 Figure 10 Clean Carburetor 9. Remove screw and choke plate Remove gasket material from mounting surfaces. (A, Figure 11). Gummy or dirty carburetors should be cleaned in a 10. Remove choke shaft (B) and spring (C). carburetor cleaner. DO NOT soak rubber, neoprene, or plastic parts in cleaner.

  • Page 72: Assemble Carburetor

    Figure 13 Figure 15 2. Inspect throttle shaft and choke shaft for wear Install Choke Valve (Figure 14). 1. Assemble spring (A, Figure 16) to choke shaft (B) and insert in body. 2. Rotate shaft clockwise to pre-load spring. 3. Install choke plate with hole facing fuel inlet side of body (C).

  • Page 73: Install Float

    4. Install idle mixture screw (A, Figure 20) and spring (B). Figure 17 Figure 20 Install Float NOTE: DO NOT tighten idle mixture screw. 1. Assemble inlet valve (A, Figure 18) to float. 2. Install float hinge pin (B) from throttle side of Install Carburetor carburetor.

  • Page 74: Initial Carburetor Adjustment

    6. Assemble governor spring (A, Figure 22) to Final Carburetor Adjustment governor control lever (B). NOTICE: All carburetor adjustments must be made with the air cleaner installed. NOTE: Governor spring must be installed in correct hole in governor control lever by engine model. 1.
  • Page 75 6. Hold throttle lever against idle speed screw and readjust idle speed to 1500 RPM, or equipment manufacturer’s specification. NOTE: If carburetor is equipped with an idle mixture limiter cap, install at this time. 7. Position limiter cap (B) so that stop(s) on the limiter cap are at mid point between stop(s) on carburetor body and press into position.

  • Page 76: Automatic Choke Carburetor

    Automatic Choke Carburetor Disassemble Carburetor 1. Remove fuel shut off solenoid (A, Figure 28) and gasket (B). Remove float bowl (C) and Remove Carburetor bowl shim gasket (D). 1. Disconnect fuel line and remove air cleaner tube from carburetor air horn. Disconnect vacuum line (A, Figure 26) from vacuum choke break.
  • Page 77 7. Remove screw and choke pre-load lever (A, Figure 33). Figure 30 5. Remove fixed main jet (A, Figure 31) and gasket (B). Discard gasket. Figure 33 8. Remove two screws, choke plate (B) and choke shaft (C). 9. Remove two screws and vacuum choke break (A, Figure 34).

  • Page 78: Clean Carburetor

    Figure 37 Figure 35 Clean Carburetor Remove gasket material from mounting surfaces. 11. Remove idle mixture screw (A, Figure 36) Gummy or dirty carburetors should be cleaned in a and o-ring (B). Discard o-ring. carburetor cleaner. DO NOT soak rubber, neoprene, or plastic parts in cleaner.

  • Page 79: Check Throttle, Choke Shaft, And Body

    Inspect Throttle, Choke Shaft, and Body 1. Lay carburetor on flat surface and check throttle and choke shaft clearance (Figure 38). NOTE: Throttle shaft and choke shaft clearance must not exceed 0.010 in. (0.25 mm). Figure 40 2. Install idle mixture screw (A, Figure 41) with new o-ring (B).
  • Page 80 4. Assemble vacuum choke break (A, Figure 43) to bracket. Note correct position of pivot arm (B). Figure 45 10. Hold choke plate closed and rotate thermostat until match marks are aligned (Figure 46). Tighten screws. Figure 43 5. Install choke shaft through pivot arm bushing NOTE: Make sure choke plate remains closed while and into carburetor body (Figure 44).

  • Page 81: Check Vacuum Choke Break

    12. Install float. Assemble inlet valve to float (A, Figure 48). 13. Install float hinge pin (B), idle passage plug (C), fixed main jet with new gasket (D), and new bowl gasket (E). Figure 50 1. Connect vacuum pump to choke break and activate pump to specification shown.

  • Page 82: Check P.t.c. Heater

    • Bend lever to right to decrease dimension Install Carburetor (C). 1. Assemble insulator with gaskets, carburetor 4. Recheck and adjust as necessary. and air horn to intake manifold. NOTE: Attach thermostat ground wire (A, Figure 54) to air horn. Figure 52 Check P.T.C.

  • Page 83: Initial Carburetor Adjustment

    Initial Carburetor Adjustment 3. SLOWLY turn idle mixture screw clockwise until engine speed just starts to slow (lean 1. Turn idle mixture screw clockwise until it just mixture). seats. DO NOT FORCE. Turn screw counter- clockwise 1/2 turn (Figure 56). This setting 4.

  • Page 84: Electric Fuel Pump

    Electric Fuel Pump NEW STYLE PUMP OLD STYLE PUMP...

  • Page 85: Check Fuel Pump Output

    Check Fuel Pump Output NOTE: A graduated container is required when testing the fuel pump. 1. Disconnect fuel line at carburetor. 2. Turn ignition switch to ON position and note fuel flow into graduated container. Figure 60 Test Fuel Pump Wiring 1.

  • Page 86: Anti-Afterfire Solenoid

    Anti-Afterfire Solenoid Some carburetors are equipped with an anti- afterfire solenoid controlled by the equipment ignition switch. When the equipment switch is in the OFF position, the solenoid valve plunger closes, stopping fuel flow through the fixed main jet or high speed nozzle.

  • Page 87: Fuel Filter

    4. When battery is removed, plunger should Carburetor Main Jets return freely. The carburetor main jet orifice size is stamped in the body of the jet (Figure 67). 5. Replace solenoid if plunger sticks or doesn’t move. Figure 67 Figure 65 Fuel Filter Figure 66 •...

  • Page 88: Electronic Fuel Injection System

    ELECTRONIC FUEL INJECTION (EFI) EFI Components SYSTEM The system includes the following components: • Air Temperature Sensor • Crankshaft Position Sensor • Crankshaft Reluctor Wheel WARNING • Engine Control Unit (ECU) • Engine Coolant Temperature Sensor The EFI fuel system remains under •...
  • Page 89 Crankshaft Position Sensor Engine Control Unit (ECU) The crankshaft position sensor (Figure 2) provides The Engine Control Unit (ECU) (Figure 4) collects the ECU the signals needed to calculate RPM. This information from the intake manifold pressure sensor controls the timing for the system to inject sensor, engine RPMs and various other sensors to fuel as each intake valve opens, and controls when determine the amount of compensation needed to...
  • Page 90 Fuel Pump Fuel Rail An electric fuel pump (Figure 6) transfers fuel in the The fuel rail (Figure 8) is a formed tube assembly EFI system. Depending on the application, the that feeds fuel to the top of the injectors. A valve in pump may be inside the fuel tank, or in the fuel line the rail allows for testing the operating pressure or near the tank.
  • Page 91 Heated Oxygen Sensor Malfunction Indicator Light (MIL) The oxygen sensor (Figure 10) is the last in-line If the self-diagnostic feature detects a fault, the fault device to the ECU, providing information about the code is displayed on the malfunction indicator lamp effectiveness of the ECU’s output commands.

  • Page 92: Troubleshooting

    Troubleshooting Electrical System The EFI system is 12VDC with negative ground. A When troubleshooting an engine with EFI, basic fully-charged 12 volt battery with a minimum of 350 engine operating problems must be addressed cold cranking amps is required to maintain reliable before turning to the EFI system components.

  • Page 93: Fault Codes

    FAULT CODES FAULT COMPONENT MIL Flashes CODE Long Flash Short Flash Crankshaft Position Sensor Intake Manifold Pressure Sensor Water Temperature Sensor Intake Air Temperature Sensor Oxygen Sensor Battery Voltage VCC Circuit Fuel Injector #1 Fuel Injector #2 Fuel Injector #3 Ignition Coil #1 Ignition Coil #2 Ignition Coil #3...

  • Page 94: Flash Code On Mil Indicator

    Fault Code on MIL Indicator The MIL will display sequences of flashes that indicate a fault within the EFI system. The number of flashes represents the number of the code. For example, if there was an issue with battery voltage, the fault code 24 would be displayed on the MIL.This is represented by two long flashes followed by four short flashes, as shown below.

  • Page 95: Troubleshooting Charts

    TROUBLESHOOTING ENGINE PERFORMANCE ISSUES...
  • Page 114 SECTION 11 - ELECTRICAL SYSTEMS IGNITION SYSTEM COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -113 TEST EQUIPMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -114 TEST TRIGGER- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -114 IGNITION MODULE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -114...
  • Page 115 STARTER CURRENT DRAW TEST- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -126 TEST STARTER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -126 TEST STARTER (NO LOAD)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 126 TEST SOLENOID- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -127...

  • Page 116: Ignition System Components

    Ignition System Components The ignition system consists of three major components (Figure 1): 1. A permanent trigger and signal rotor integral with the crankshaft pulley. 2. A transistorized ignition module which advances and retards the ignition timing electronically. 3. A battery powered ignition coil for each cylinder.

  • Page 117: Test Equipment

    Test Equipment Ignition Module Two different ignition modules are used. The test 1. The Digital Multimeter #19390 is required to specifications are different depending upon the test the ignition components (Figure 2). identifications number on the ignition module (Figure 4). NOTE: All ignition tests are performed with engine NOT running.

  • Page 118: Test Ignition Module Id 19200-87801

    Test Ignition Module - Identification NO. 19200-87801 The following test will be made with the meter in the Ω position. The ignition module test is performed by measuring the resistance (Ω) between the terminals shown in Figure 5. Specifications are shown in the chart below. Attach red meter test lead to the terminal shown at the top of the column.

  • Page 119: Test Ignition Module Id 19200-87804

    Test Ignition Module - Identification NO. 19200-87804 The following test will be made with the meter in the Ω position. The ignition module test is performed by measuring the resistance (Ω) between the terminals shown in Figure 6. Specifications are shown in the chart below. Attach red meter test lead to the terminal shown at the top of the column.

  • Page 120: Test Ignition Coils

    Test Ignition Coils 14 Amp Charging System The 14 Amp charging system consists of two The following test will be performed with the meter components: in the position. 1. The belt driven permanent magnet alternator 1. Check coil primary resistance between + and produces AC voltage (Figure 9).

  • Page 121: Test Equipment

    Test Equipment • If alternator output is within specification, The Digital Multimeter #19390 and the DC Shunt, reconnect alternator wires and test #19468 (Figure 11), are required to test the regulator-rectifier. charging system. NOTE: The digital multimeter will withstand DC Test Regulator-Rectifier - DC Output input of 10-20 amps for up to 30 seconds.

  • Page 122: Charging Indicator Circuit

    Charging Indicator Circuit 2. Disconnect output harness at regulator- The green wire from the regulator-rectifier is used to rectifier. activate the charging indicator light. With the 3. Check continuity between charging indicator keyswitch in the ON position and the engine not wire (green) and ground (Figure 16).

  • Page 123: 40 Amp Charging System

    40 Amp Charging System 2. The regulator-rectifier test will be performed in the 300mV== position. The 40 Amp charging system consists of a belt 3. Attach RED meter test lead to the RED post driven, internally regulated alternator (Figure 17). terminal on shunt.
  • Page 124 2. Remove pulley and spacer. Replace pulley if damaged or worn. 3. Remove nut and insulator at “B” terminal (A, Figure 20). Remove three screws and brush cover (B). Figure 22 6. Remove stator lead screws from rectifier (A, Figure 23). 7.

  • Page 125: Inspect Bearings

    Figure 26 Figure 24 NOTE: DO NOT reuse ball bearings that have been removed from drive end housing. The bearing races 11. Remove rotor from drive end housing (Figure are usually damaged during removal. 25). Install Ball Bearing NOTE: Stator is NOT removable. 1.

  • Page 126: Inspect Brushes

    Figure 28 Figure 30 2. Check for continuity between slip ring and rotor shaft. • Meter should display “OL,” (no continuity). Check Regulator 1. Set the meter to the +)))) position. 3. Measure slip ring diameter (Figure 29). 2. Attach BLACK meter test lead to terminal (A, •...

  • Page 127: Assemble Alternator

    • If meter displays “OL” or makes a Assemble Alternator continuous tone, diode is defective. 1. Assemble rotor to drive end housing (Figure Replace rectifier. 34). 4. Repeat test at (B,C, and D) terminals. 2. Assemble spacer, pulley, and nut to rotor shaft.
  • Page 128 • Screw #1 - 0.45 in. (11.5 mm) (A, Figure 39). • Screw #2 - 0.35 in. (9.0 mm) (B). Figure 36 8. Install regulator with screws (A, Figure 37). Figure 39 11. Install rear cover and screws (A, Figure 40). Torque to values listed in Section 14 - Engine Specifications.

  • Page 129: Starter System

    Test Starter NOTE: To prevent engine from starting, remove spark plug wires from spark plugs. Leave spark plugs installed. 1. Set meter to the 300mV== position. 2. The DC Shunt must be installed on the negative (-) terminal of the battery (Figure 43).

  • Page 130: Test Solenoid

    Figure 44 Figure 45 2. Place meter in the 300mV== position. 1. Attach one end of battery cable to negative 3. Ensure the DC Shunt is installed on the battery terminal and other end of cable to a negative terminal of the battery. good ground such as the drive housing 4.

  • Page 131: Replace Solenoid

    Replace Solenoid Remove Pinion Gear Assembly 1. Remove nut and field coil wire from stud 1. Remove solenoid. terminal (Figure 47). 2. Remove starter thru bolts (A, Figure 49). 2. Remove solenoid mounting nuts and solenoid. 3. Lift solenoid to disengage drive lever from plunger.

  • Page 132: Install Pinion Gear Assembly

    Install Pinion Gear Assembly 1. Lubricate helix with a light coat of grease and assemble pinion gear and clutch. 2. Assemble new lower retainer to shaft (Figure 53). 3. Install new snap ring. Figure 51 8. Remove and discard lower and upper retainer and snap ring.

  • Page 133: Disassemble Starter Motor

    Figure 57 3. Remove thru bolts and lift off end cap. Figure 55 4. Remove brush retainer plate (A, Figure 58). 5. Remove brushes and springs from brush 7. Install drive housing (Figure 56). holder (B). 8. Install thru bolts and torque to value listed in 6.

  • Page 134: Inspect Armature Commutator

    Inspect Brushes Minimum brush dimension is 2.95 in. (7.5 mm) (Figure 61). If brushes are worn less than specification, replace the brushes or stator housing. Figure 59 Inspect Armature Commutator Figure 61 The armature commutator may be cleaned with fine sandpaper (#300-500 grit).
  • Page 135 NOTE: Terminals B and D must be no less than the following specifications (Figure 65): • L: 0.063 - 0.070 in. (1.6 -1.8 mm) • W: 0.255 - 0.295 in. (6.5 - 7.5 mm) Figure 63 • Meter should make continuous tone (continuity).

  • Page 136: Assemble Starter

    Figure 67 Figure 69 3. Install brush holder, inserting tabs on brush holder into slots in starter housing (Figure Assemble Starter 70). 1. Assemble drive lever to pinion and install armature and drive lever into drive housing (Figure 68). Figure 70 Figure 68 4.
  • Page 137 Figure 73 Figure 71 6. Install brush retainer plate. 7. Assemble rubber seal to starter housing (Figure 72). • Be sure notch in rubber seal is inserted over tab on housing. Figure 72 8. Install end cap (Figure 73) and torque thru bolts to values listed in Section 14 - Engine Specifications.

  • Page 138: Section 12 - Lubrication System

    SECTION 12 - LUBRICATION SYSTEM CHANGE OIL- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -137 CHANGE OIL FILTER- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -137 CHECK OIL PRESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -138 DISASSEMBLE GEAR CASE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -138...
  • Page 139 LUBRICATION SYSTEM...

  • Page 140: Change Oil

    Description Briggs & Stratton Daihatsu gasoline and diesel engines use a full pressure lubrication system with an oil filter. The gear driven oil pump draws oil from a screened oil pickup in the oil pan and pumps the oil through the oil filter. The filtered oil flows through oil galleries in the cylinder block and is distributed to the main bearings, connecting rod bearings, camshaft...

  • Page 141: Check Oil Pressure

    Check Oil Pressure 1. Oil level should be between the LOW and FULL mark on the dipstick (Figure 4). If oil Low Oil Pressure level is low, check for leaks and add to FULL mark. Engine RPM Too Low Wrong Viscosity or Diluted Oil Low Oil Level Broken Pressure Relief Spring Missing Pressure Relief Plunger...
  • Page 142 Figure 8 10. Remove trigger (Figure 9) and wire. Remove Figure 6 timing gear cover and discard timing gear gasket. 5. Remove oil pan screws and nuts. 6. Remove oil pan and discard gasket. 7. Remove oil pick-up tube (A, Figure 7) and strainer.

  • Page 143: Remove Gear Case

    Figure 10 Figure 12 Remove Gear Case 1. Remove three screws (A, Figure 11) and camshaft retainer. Assemble Timing Gear Case and Gears 2. Remove remaining five screws (B). 1. Clean and lubricate oil pump rotor (A, Figure 13) with engine oil and install in cylinder block.
  • Page 144 Figure 16 Engine models 430000 and 580000 built after date Figure 14 code 990111007 are equipped with right angle helical timing gears. Timing marks are identified by NOTE: It may be necessary to rotate oil pump drive letters (A, AA, B, BB, etc.), instead of numbers. The to engage oil pump rotors.
  • Page 145 Figure 18 Figure 20 10. Install timing gear cover with new gasket. Note position, length, and number of screws 13. Install oil pick-up tube and strainer with new (Figure 19). Torque screws to values listed in gasket. Section 14 - Engine Specifications. 14.

  • Page 146: Adjust Governor

    Figure 24 Figure 22 19. Insert governor spring into original hole in governor lever. NOTICE: Governor spring must be installed in correct hole in governor control lever by engine model (Figure 23). • Model 430400 - Top Hole • Model 580400 - Bottom Hole Figure 23 Adjust Governor 1.

  • Page 148: Section 13 - Cooling System

    SECTION 13 - COOLING SYSTEM GENERAL INFORMATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -146 PRESSURE TEST COOLING SYSTEM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -147 CHANGE COOLANT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -147 TEST RADIATOR CAP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -147...

  • Page 149: General Information

    THERMOSTAT CLOSED THERMOSTAT OPEN General Information Briggs & Stratton Daihatsu gasoline and diesel WARNING engines use a pressurized, forced circulation cooling system. The cooling system is pressurized. Do not The water pump circulates coolant through the remove the radiator cap while the engine is cylinder block, cylinder head, intake manifold, and hot.

  • Page 150: Pressure Test Cooling System

    Pressure Testing Cooling System NOTE: Follow state or federal laws regarding the proper procedure for disposing of antifreeze. 1. Remove radiator cap and make sure coolant is at correct level. Test Radiator Cap 1. Ensure that the rubber seal on the radiator NOTE: Coolant level must be no more than 25 mm cap is not damaged or distorted.

  • Page 151: Inspect Thermostat

    Install Thermostat 1. Insert thermostat in housing and install locating screw (A, Figure 5). Figure 3 Inspect Thermostat Figure 5 2. Install coolant outlet housing with new NOTE: A thermostat capable of reading 210 °F (100 gasket. °C) or more is required. 3.

  • Page 152: Remove Water Pump

    Figure 7 4. If water pump shows evidence of leaking or if the bearings are rough, replace the water Figure 9 pump. 4. Clean all traces of gasket material from mounting surfaces and inspect mounting NOTE: Most water pump and cooling system surfaces for damage.
  • Page 153 7. Install radiator hoses. Figure 11 8. Install fan (Figure 12) (if equipped) and water pump pulley. Torque screws to values listed in Section 14 - Engine Specifications. Figure 12 9. Install V belt (Figure 13). • Belt tension adjustment: 3/8 - 1/2 in./22lb. (10.0 - 12.0 mm/10 kg).
  • Page 154 SECTION 14 - ENGINE SPECIFICATIONS MODEL 430000 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -152 MODEL 580000 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -154...
  • Page 155 MODELS 430000 ENGINE SPECIFICATIONS Spark Plug Gap 0.030 in. (0.76 mm) Valve Clearance – Intake 0.007 in. (0.18 mm) Valve Clearance – Exhaust 0.007 in. (0.18 mm) FASTENER TORQUE SPECIFICATIONS TORQUE Alternator Adjustment Bracket 170 in. lbs. (19 Nm) Alternator (to bracket) 170 in.
  • Page 156 REJECT DIMENSIONS STANDARD SIZE REJECT SIZE Camshaft Journals Front 1.415 - 1.416 in. (35.96 - 35.98 mm) 1.413 in. (35.89 mm) Center 1.413 - 1.415 in. (35.91 - 35.96 mm) 1.411 in. (35.84 mm) Rear 1.413 - 1.415 in. (35.91 - 35.96 mm) 1.411 in.
  • Page 157 MODELS 580000 ENGINE SPECIFICATIONS Spark Plug Gap 0.030 in. (0.76 mm) Valve Clearance – Intake 0.007 in. (0.18 mm) Valve Clearance – Exhaust 0.007 in. (0.18 mm) FASTENER TORQUE SPECIFICATIONS TORQUE Alternator Adjustment Bracket 170 in. lbs. (19 Nm) Alternator (to bracket) 170 in.
  • Page 158 REJECT DIMENSIONS STANDARD SIZE REJECT SIZE Camshaft Journals Front 1.415 - 1.416 in. (35.96 - 35.98 mm) 1.413 in. (35.89 mm) Center 1.413 - 1.415 in. (35.91 - 35.96 mm) 1.411 in. (35.84 mm) Rear 1.413 - 1.415 in. (35.91 - 35.96 mm) 1.411 in.

This manual is also suitable for:

Vanguard 580000

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