EDI TSG-416 Manuals

Manuals and User Guides for EDI TSG-416. We have 1 EDI TSG-416 manual available for free PDF download: Service Manual

EDI TSG-416 Service Manual

EDI TSG-416 Service Manual (229 pages)

1.6 Liter Industrial Engine

Brand: EDI | Category: Engine | Size: 11.73 MB

Table of Contents

Health and Safety Recommendations
4
Table of Contents
5
Index
5
General Information
6
GeneralInformationPage

7
- Notes, Cautions, and Warnings
  7
- Introduction
  7
- Safety Notice
  7
  - General Information
    7
  - Battery Handling and Chargin
    8
- Engine Identification
  9
- Description and Operation
  9
- Forward
  9
- Parts and Service
  9
Diagnosis and Testing

10
- Special Service Tools
  10
- Inspection and Verification
  11
- Symptom Chart
  11
- Engine Oil Leaks
  14
- Fluorescent Oil Additive Method
  14
- PCV System Malfunction
  14
  - Pressure Method
    14
  - Leakage Points
    15
  - Testing Procedure
    15
  - Compression Gauge Check
    16
  - Compression Pressure Limit Chart
    16
- Compression Tests
  16
- Interpreting Compression Readings
  16
- Cylinder Leakage Detection
  17
- Intake Manifold Vacuum Test
  17
  - Oil Leak and Valve Stem Seal Test
    17
  - Interpreting Vacuum Gauge Readings
    18
- Excessive Engine Oil Consumption
  19
- Oil Consumption Test
  19
- Oil Pressure Test
  20
- Valve Train Analysis - Dynamic
  21
- Valve Train Analysis - Static
  21
- Camshaft Lobe Lift
  22
- Hydraulic Valve Lash Adjuster
  23
- Leak down Testing
  23
General Service Procedures

24
- Camshaft Journal Diameter
  24
- Camshaft Journal Clearance
  24
  - Camshaft Lobe Surface
    24
  - Camshaft Runout
    25
  - Camshaft End Play
    25
- Camshaft Lobe Lift
  25
- Crankshaft End Play
  28
- Crankshaft Runout
  28
- Cylinder Bore Taper
  28
  - Cylinder Bore Out-Of-Round
    29
  - Piston Inspection
    29
  - Piston Diameter
    29
  - Piston to Cylinder Bore Clearance
    29
GeneralServiceProcedures

30
Subject

30
- Piston Selection
  30
- Connecting Rod Cleaning
  31
  - Connecting Rod Larger End Bore
    32
  - Piston Pin Diameter
    32
  - Connecting Rod Bushing Diameter
    32
  - Connecting Rod Bend/Connecting Rod Twist
    32
  - Connecting Rod Piston Pin Side Clearance
    33
  - Connecting Rod Journal Clearance
    33
  - Roller Follower Inspection
    34
  - Hydraulic Lash Adjuster Inspection
    34
  - Bearing Inspection
    34
  - Valve Stem Diameter
    35
    
    Valve Inspection
    35
    
    Valve Stem-To-Valve Guide Clearance
    35
    
    Valve Guide Inner Diameter
    36
  - Valve Guide Reaming
    36
  - Valve Spring Installed Length
    36
    
    Valve Spring Free Length/Valve Spring Out-Of-Square
    36
    
    Valve and Seat Refacing Measurements
    37
    
    Valve Seat Runout
    37
    
    Valve Seat Width
    37
    
    Valve Spring Compression Pressure
    37
    
    Flywheel Inspection
    38
    
    Oil Pump Gear Radial Clearance
    38
    
    Oil Pump Rotor Inspection
    38
    
    Oil Pump Side Clearance
    38
    
    Cylinder Bore Cleaning
    39
    
    Cylinder Bore Honing
    39
    
    Cylinder Bore Core Plug Replacement
    40
    
    Cylinder Bore Repair - Cast Iron Porosity Defects
    40
    
    Cylinder Head – Distortion
    40
    
    Spark Plug Thread Repair
    42
    
    Exhaust Manifold Straightness
    43
    
    General Specifications
    44
    
    Special Tools
    47
    
    Engine Description
    49
    
    Engine Identification Number
    49
    
    Component Location Diagrams
    50
    
    Engine Repair
    54
    
    Valve Cover - Installation
    54
    
    Valve Cover - Removal
    54
    
    Camshaft- Removal
    55
    
    Camshaft - Installation
    56
    
    Valve Stem Seal - Removal
    57
    
    Valve Stem Seal - Installation
    58
    
    Intake Manifold - Installation
    59
    
    Intake Manifold - Removal
    59
    
    Exhaust Manifold - Installation
    60
    
    Exhaust Manifold - Removal
    60
    
    Cylinder Head - Removal
    61
    
    Cylinder Head - Installation
    63
    
    Oil Pump - Removal
    65
    
    Oil Pump - Installation
    66
    
    Crankshaft Rear Oil Seal - Installation
    67
    
    Crankshaft Rear Oil Seal – Removal
    67
    
    Camshaft Follower/Hydraulic Lash Adjuster – Installation
    68
    
    Camshaft Follower/Hydraulic Lash Adjuster – Removal
    68
    
    Oil Pan - Installation
    69
    
    Oil Pan - Removal
    69
    
    Pick-Up Tube/Deflector - Installation
    70
    
    Pick-Up Tube/Deflector - Removal
    70
    
    Crankshaft Main Bearings - Installation
    71
    
    Crankshaft Main Bearings - Removal
    71
    
    Connecting Rod Bearings - Installation
    72
    
    Connecting Rod Bearings – Removal
    72
    
    Piston – Removal
    73
    
    Piston - Installation
    74
    
    Flywheel - Installation
    75
    
    Flywheel - Removal
    75
    
    Timing Chain and Sprockets – Removal
    76
    
    Timing Chain and Sprockets - Installation
    77
    
    Oil Level Indicator – Installation
    79
    
    Oil Level Indicator – Removal
    79
    
    Oil Filter and Adapter - Removal
    80
    
    Oil Filter and Adapter – Installation
    80
    
    Disassembly
    81
    
    Cylinder Block
    88
    
    Subassemblies
    88
    
    Piston - Assembly
    89
    
    Piston - Disassembly
    89
    
    Cylinder Head - Disassembly
    90
    
    Cylinder Head - Assembly
    91
    
    Assembly
    92
    
    Specifications
    102
    
    Ignition System
    103
    
    Ignition System Description
    104
    
    Fuel Octane Level Adjustment
    105
    
    Ignition Coil Driver
    105
    
    Ignition System Operation
    105
    
    Run Mode/Transient Mode
    105
    
    Ignition System Wiring Diagram
    106
    
    Ignition System Diagnosis and Testing
    107
    
    Spark Plug Inspection
    107
    
    Ignition Coil - Replacement
    108
    
    Ignition System - Removal and Installation
    108
    
    Spark Plug – Removal
    108
    
    Ignition System Specifications
    109
    
    Fuel System
    110
    
    Fuel System - Cautions and Warnings
    111
    
    Fuel System Description
    112
    
    Fuel System Operation
    113
    
    Fuel System Requirements
    113
    
    Fuel Injectors Wiring Diagram
    114
    
    Fuel System Wiring Diagrams
    114
    
    Connector (DLC) Wiring Diagram
    115
    
    Dry Fuel Description
    116
    
    Dry Guel Operation
    116
    
    Mixer Assembly View
    116
    
    Engine Controls – Dry Fuel DEPR
    118
    
    Diagnosis and Testing - LPG
    119
    
    Fuel System Preliminary Test
    120
    
    Engine Cranking but will Not Start
    121
    
    Fuel System Diagnosis Chart
    121
    
    Engine Idles with Rough Acceleration at Load
    123
    
    Engine Backfires
    125
    
    Emission Failure - Rich Mixture
    126
    
    Emission Failure - Lean Mixture
    127
    
    Engine Overheats
    128
    
    Engine Stops Running (Dies)
    129
    
    Fuel Pressure Check
    130
    
    Fuel Pump Check
    130
    
    Fuel System Diagnosis and Testing - Gasoline
    130
    
    Fuel Block Check
    131
    
    Quick Connect Coupling - Type I/II - Disconnect/Disconnect
    132
    
    Fuel Rail & Injectors - Replacement
    134
    
    Fuel System - Removal and Installation
    134
    
    Actuator - Installation
    135
    
    Actuator - Removal
    135
    
    Mixer - Removal
    135
    
    Fuel System Specifications
    136
    
    Mixer - Installation
    136
    
    Cooling System
    137
    
    Cooling System - Cautions and Warnings
    138
    
    Cooling System General Information
    139
    
    Coolant Inspection
    140
    
    Coolant Range Check
    140
    
    Cooling System Diagnosis and Testing
    140
    
    Drive Belt Inspection
    141
    
    Cooling System Symptom Chart
    142
    
    Cooling System Pressure Test
    143
    
    Radiator Cap Pressure Test
    143
    
    Thermostat Operational Check
    143
    
    Cooling System Service Procedures
    144
    
    Draining the Cooling System
    144
    
    Filling the Cooling System
    144
    
    Flushing the Cooling System
    144
    
    Belt Tensioner – Replacement/Idler Pulley - Replacement
    145
    
    Cooling System - Removal and Installation
    145
    
    Drive Belt - Removal/Installation
    145
    
    Fan Belt – Removal/Installation
    145
    
    Radiator Hose - Installation
    146
    
    Radiator Hose - Removal
    146
    
    Thermostat & Housing – Replacement
    147
    
    Coolant Pump - Replacement
    148
    
    Thermostat - Replacement
    149
    
    Coolant Bypass – Replacement
    150
    
    Cooling System Specifications
    151
    
    Charging System
    152
    
    Cautions & Warnings
    153
    
    Charging System - General Information
    154
    
    Charging System Wiring Diagram
    155
    
    Charging System Diagnosis and Testing
    156
    
    Warning Indicator Check
    156
    
    Charging System Symptom Chart
    157
    
    Battery Drain Test
    158
    
    Battery Load Test
    158
    
    Generator Output Test
    159
    
    Generator Voltage Test
    159
    
    Battery Cleaning and Inspection
    160
    
    Battery Tools
    160
    
    Charging System Service Procedures
    160
    
    Battery Charging
    161
    
    Charging System - Removal and Installation
    162
    
    Generator – Replacement
    162
    
    Voltage Regulator – Replacement
    162
    
    Generator Pulley - Replacement
    163
    
    Battery - Installation
    164
    
    Battery - Removal
    164
    
    Charging System Specifications
    165
    
    Engine Controls
    166
    
    Engine Control Module (GCP) Description
    167
    
    GCP and Sensors
    167
    
    GCP Inputs (Operating Conditions Read)
    168
    
    Camshaft Position (CMP) Sensor
    169
    
    Crankshaft Position (CKP) Sensor
    169
    
    GCP Outputs (Systems Controlled)
    169
    
    Engine Coolant Temperature (ECT) Sensor
    170
    
    TSG‐416 Engine Controls Heated Oxygen Sensor (HO2S)
    171
    
    Temperature Manifold Absolute Pressure (TMAP) Sensor
    172
    
    Throttle Position (TP) Sensor/Electronic Actuator
    172
    
    Fuel Filter
    173
    
    Fuel Injector
    173
    
    Fuel Rail
    173
    
    Fuel System Components - Gasoline
    173
    
    Fuel Lock off Valve
    174
    
    Fuel Pump Electrical Circuit
    174
    
    Mixer (Gaseous Fuels)
    174
    
    Vapor Regulator
    174
    
    Distributor Less Coil Pack
    175
    
    Electrostatic Discharge Damage
    176
    
    GCP Service Precautions
    176
    
    Open Loop and Closed Loop Operation
    176
    
    Use of Circuit Testing Tools
    176
    
    Engine Controls - Diagrams and Schematics
    177
    
    Engine Controls - Symbols
    177
    
    GCP - Power Distribution Box
    178
    
    Part of -5210070- Engine Wiring Harness
    178
    
    Engine Controls - Wire Colors
    179
    
    Revision Level
    179
    
    Power Distribution Diagram
    180
    
    Ignition System Diagram
    181
    
    Starting System Diagram
    182
    
    Charging System Diagram
    183
    
    Engine Controls - Sensors (1 of 2)
    184
    
    Engine Controls - Sensors (2 of 2)
    185
    
    Fuel Injectors Diagram
    186
    
    Engine Controls - Actuator/Data Link Connector (DLC) Diagram
    187
    
    Engine Controls - Dry Fuel DEPR Diagram
    188
    
    Diagnostic Approach
    189
    
    Engine Controls Diagnosis and Testing
    189
    
    GCP Diagnostic Overview
    189
    
    On-Board Diagnostics - GCP
    189
    
    Power Derate 1
    189
    
    Fault Low Rev Limit
    190
    
    Force to Idle
    190
    
    Intermittent MIL
    190
    
    Malfunction Indicator Lamp (MIL) DTC Retrieval Procedure
    190
    
    Diagnosis Using a Personal Computer
    191
    
    DTC Extraction
    191
    
    MIL Bulb Test
    191
    
    Interface Hook-Up
    192
    
    GCP Software Installation
    193
    
    Using GCP Software - Menu Functions
    194
    
    Engine Controls Diagnostic Trouble Codes
    195
    
    Snap Shot Data
    195
    
    Data Stream - Reading Sensor & Actuator Values
    196
    
    Flight Data Recorder
    196
    
    Plotting and Data Logging
    197
    
    Disabling Ignition Ouputs
    198
    
    Disabling Injectors
    198
    
    Ignition System Test
    198
    
    Injector Test
    198
    
    RAW VOLTS Screen
    199
    
    Throttle Test
    199
    
    Engine Controls Visual Inspection
    200
    
    Intermittent Problems
    200
    
    Engine Controls Symptom Charts
    201
    
    Engine Performance - no Load
    201
    
    Engine Performance - While under Load
    202
    
    Lack of Power
    202
    
    Black Smoke
    203
    
    Blue Smoke
    203
    
    Engine Concerns
    203
    
    Engine Noise
    203
    
    Engine Control Module (GCP) – Diagnostic Trouble Codes
    204
    
    Camshaft Position (CMP) Sensor Replacement
    205
    
    Crankshaft Position (CKP) Sensor Installation
    205
    
    Crankshaft Position (CKP) Sensor Removal
    205
    
    Engine Controls - Removal and Installation
    205
    
    Engine Coolant Temperature (ECT) Sensor Replacement
    206
    
    Heated Oxygen Sensor (HO2S) - Replacement
    206
    
    Knock Sensor (KS) – Replacement
    207
    
    Temperature Manifold Absolute Pressure (TMAP) Sensor Replacement
    207
    
    Actuator/Throttle Position (TP) Sensor - Replacement
    208
    
    Metrics
    209
    
    Nomenclature for Bolts
    210
    
    Bolt Strength Identification
    211
    
    Nex Nut Strength Identification
    211
    
    Other Types of Parts
    212
    
    English/Metric Conversion
    213
    
    Decimal and Metric Equivalents
    214
    
    Torque Conversion
    214
    
    J1930 Terminology List
    215

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