EDI TSG-416 User manual

EDI1020120
Revision0
December2012
TSG‐416
1.6LITER
INDUSTRIALENGINESERVICEMANUAL
PowertrainAssemblies
&ComponentsProvided
ByFordComponentSales

EDI1020120
Revision0
December2012

Section
Index
Reproduction in any manner, in whole or in
part, is prohibited without the express
permission in writing from:
Engine Distributors Inc (EDI)
EDI 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 change prices,
specifications and equipment at any time without
notice is reserved. Accordingly this publication is
not to be regarded as a final description of any
individual engine.
Section01GENERALINFO
Section02ENGINE
Section03IGNITION
Section04FUEL
Section05COOLING
Section06CHARGING
Section07STARTER
Section08ENG.CONTROLS
Section09METRICS
Section10DISTRIBUTORS

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. SUCH PRECAUTIONS ARE RECOMMENDED
AT THE APPROPRIATE POINTS IN THIS BOOK. WARNING: WHILE IT IS IMPORTANT THAT THESE
RECOMMENDED SAFETY PRECAUTIONS ARE OBSERVED, CARE NEAR MACHINERY IS ALWAYS
NECESSARY, AND NO LIST CAN BE EXHAUSTIVE. ALWAYS BE CAUTIOUS TO AVIOD POTENTIAL
SAFETY RISKS.
The following recommendations are for general guidance:
1. Always wear correctly fitting protective clothing which should be laundered regularly. Loose or baggy clothing can be
extremely dangerous when working on running engines or machinery. Clothing which becomes impregnated with oil or
other substances can constitute a health hazard due to prolonged contact with the skin even through underclothing.
2. So far as practicable, work on or close to engines or machinery only when they are stopped. If this is not practicable,
remember to keep tools, test equipment and all parts of the body well away from the moving parts of the engine or
equipment—fans, drive belts and pulleys are particularly dangerous. The electric cooling fan used on some installations is
actuated automatically when the coolant reaches a specified temperature. For this reason, care should be taken to ensure
that the ignition/isolating switch is OFF when working in the vicinity of the fan as an increase in coolant temperature may
cause the fan suddenly to operate.
3. Avoid contact with exhaust pipes, exhaust manifolds and silencers when an engine is, or has recently been running;
these can be very hot and can cause severe burns.
4. Many liquids used in engines or vehicles are harmful if taken internally or splashed into the eyes. In the event of
accidentally swallowing gasoline (petrol), oil, diesel fuel, antifreeze, battery acid etc, do NOT encourage vomiting and
OBTAIN QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY.
Wear protective goggles when handling liquids which are harmful to the eyes; these include ammonia and battery acid. If
any of these substances are splashed in the eyes, wash out thoroughly with clean water and OBTAIN QUALIFIED
MEDICAL ASSISTANCE IMMEDIATELY.
IMPORTANT SAFETY NOTICE
Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all industrial
engines as well as the personal safety of the individual doing the work. This Service Manual provides general directions
for accomplishing service and repair work with tested, effective techniques. Following them will help assure reliability.

TSG‐416GENERALINFORMATION
01‐1
INDEX
Subject
GeneralInformationPage
Introduction………………………………………………………………………………………………………………01–3
SafetyNotice…………………………………………………………………………….………………………………01–3
Notes,Cautions,andWarnings…………………………………………………………………………………01–3
BatteryHandlingandCharging……………………………………………….…………………………………01–4
Forward…………………………………….………………………………………………………………………………01–5
EngineIdentification………..………….……………………………………………………………………………01–5
PartsandService………………………………………….……………………………………………………………01–5
DescriptionandOperation……………………………………………………..…………………………………01–5
DiagnosisandTesting
SpecialTools…………….…………………………………………………………………………………………………01–6
InspectionandVerification…………………………………………………………………………………………01–7
SymptomChart…………………………………………………………………………………………………………..01–7
PCVSystemMalfunction…………………………………………………………………………………………….01–10
EngineOilLeaks………………………………………………………………………………………………………….01–10
CompressionTests……………………………………………………………………………………………………..01–12
CylinderLeakageDetection………………………………………………………………………………………..01–13
IntakeManifoldVacuumTest…………………………………………………………………………………….01–13
ExcessiveEngineOilConsumption……………………………………………………………………………..01–15
OilPressureTest…………………………………………………………………………………………………………01–16
ValveTrainAnalysis–Static………………………………………………………………………………………..01–17
ValveTrainAnalysis–Dynamic…………………………………………………………………………………..01–17
CamshaftLoveLift……………………………………………………………………………………………………….01–18
HydraulicValveLashAdjuster…………………………………………………………………………………….01–19
GeneralServiceProcedures
CamshaftJournalDiameter………………………………………………………………………………………..01–20
CamshaftJournalClearance……………………………………………………………………………………….01–20
CamshaftLobeSurface…..………………………………………………………………………………………….01–20
CamshaftLobeLift………………………………………………………………………………………………………01–21
CamshaftRunout……………………………………………………………………………………………………….01–21
CamshaftEndPlay……………………………………………………………………………………………………..01–21
CrankshaftMainBearingJournalDiameter……………………………………………………………….01–22
CrankshaftMainBearingJournalTaper…………………………………………………………………….01–22
CrankshaftMainBearingJournalClearance………………………………………………………………01–23
BearingInspection…………………………………………………………………………………………………….01–23
CrankshaftEndPlay…………………………………………………………………………………………………...01–24
CrankshaftRunout……………………………………………………………………………………………………..01–24
CylinderBoreTaper……………………………………………………………………………………………………01–24
CylinderBoreOut‐of‐Round……………………………………………………………………………………...01–25
PistonInspection……………………………………………………………………………………………………….01–25
PistonDiameter…………………………………………………………………………………………………………01–25
PistontoCylinderBoreClearance……………………………………………………………………………..01–25

TSG‐416GENERALINFORMATION
01‐2
INDEX(CONT.)
Subject
GeneralServiceProceduresPage
PistonSelection………………………………………………………………………………………………………….01–26
PistonRingEndGap…………………………………………………………………………………………………..01–26
PistonRing‐to‐GrooveClearance……………………………………………………………………………….01–27
CrankshaftConnectingRodJournalDiameter……………………………………………………………01–27
CrankshaftConnectionRodJournalTaper………………………………………………………………...01–27
ConnectingRodCleaning……………………………………………………………………………………………01–27
ConnectingRodLargerEndBore……………………………………………………………………………….01–28
PistonPinDiameter…………………………………………………………………………………………………..01–28
ConnectingRodBushingDiameter…………………………………………………………………………...01–28
ConnectingRodBend………………………………………………………………………………………………..01–28
ConnectingRodTwist………………………………………………………………………………………………..01–28
ConnectingRodPistonPinSideClearance………………………………………………………………..01–29
ConnectingRodJournalClearance…………………………………………………………………………….01–29
BearingInspection…………………………………………………………………………………………………….01–30
RollerFollowerInspection………………………………………………………………………………………...01–30
HydraulicLashAdjusterInspection……………………………………………………………………………01–30
ValveStemDiameter…………………………………………………………………………………………………01–31
ValveStem‐to‐ValveGuideClearance………………………………………………………………………01–31
ValveInspection……………………………………………………………………………………………………….01–31
ValveGuideInnerDiameter……………………………………………………………………………………..01–32
ValveGuideReaming………………………………………………………………………………………………..01–32
ValveSpringInstalledLength…………………………………………………………………………………….01–32
ValveSpringFreeLength…………………………………………………………………………………………..01–32
ValveSpringOut‐of‐Square……………………………………………………………………………………….01–32
ValveSpringCompressionPressure………………………………………………………………………….01–33
ValveandSeatRefacingMeasurements…………………………………………………………………..01–33
ValveSeatWidth………………………………………………………………………………………………………01–33
ValveSeatRunout……………………………………………………………………………………………………01–33
FlywheelInspection………………………………………………………………………………………………..01–34
OilPumpGearRadialClearance………………………………………………………………………………01–34
OilPumpRotorInspection………………………………………………………………………………………01–34
OilPumpSideClearance………………………………………………………………………………………….01–34
CylinderBoreHoning……………………………………………………………………………………………….01–35
CylinderBoreCleaning…………………………………………………………………………………………….01–35
CylinderBoreCorePlugReplacement…………………………………………………………………….01–36
CylinderBoreRepair–CastIronPorosityDefects………………………………………………....01–36
CylinderBlock–Distortion………………………………………………………………………………………01–36
SparkPlugThreadRepair………………………………………………………………………………………..01–38
ExhaustManifoldStraightness………………………………………………………………………………..01–39
SPECIFICATIONS…………………………………………………………………………………………………………….………...01–40

TSG‐416GENERALINFORMATION
01‐3
GENERAL INFORMATION
Introduction
This section covers various engine tests, adjustments,
service procedures and cleaning/inspection procedures.
Engine assembly and service specifications appear at
the end of the Section 02.
For engine disassembly, assembly, installation,
adjustment procedures and specifications, refer to
Section 02.
This engine incorporates a closed-type crankcase
ventilation system.
To maintain the required performance level, the fuel
system, ignition system and engine must be kept in good
operating condition and meet recommended adjustment
specifications.
Before replacing damaged or worn engine components
such as the crankshaft, cylinder head, valve guide,
valves, camshaft or cylinder block, make sure part(s) is
not serviceable.
WARNING: TO AVOID THE POSSIBILITY OF
PERSONAL INJURY OR DAMAGE, DO NOT
OPERATE THE ENGINE UNTIL THE FAN BLADE HAS
FIRST BEEN EXAMINED FOR POSSIBLE CRACKS
OR SEPARATION.
CAUTION: Use of abrasive grinding discs to remove
gasket material from the engine sealing surfaces
during repair procedures can contribute to engine
damage and wear. Airborne debris and abrasive grit
from the grinding disc may enter the engine through
exposed cavities causing premature wear
and eventual engine damage.
Engine Distributors Inc. (EDI) 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.
Take added care to prevent scratching or gouging
aluminum sealing surfaces.
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. Accordingly,
anyone who departs from the instructions provided in
this Manual must first establish that neither personal
safety nor equipment integrity are compromised by the
choice of methods, tools or parts.
Notes, Cautions, and Warnings
As you read through the procedures, you will come
across NOTES, CAUTIONS, and WARNINGS. Each one
is there for a specific purpose. NOTES gives you added
information that will help you to complete a particular
procedure. CAUTIONS are given to prevent you from
making an error that could damage the equipment.
WARNINGS remind you to be especially careful in those
areas where carelessness can cause personal injury.
The following list contains some general WARNINGS
that you should follow when you work on the equipment.
GENERAL WARNINGS:
TO HELP AVOID INJURY:
ALWAYS WEAR SAFETY GLASSES FOR EYE
PROTECTION.
USE SAFETY STANDS WHENEVER A
PROCEDURE REQUIRES YOU TO BE UNDER THE
EQUIPMENT.
BE SURE THAT THE IGNITION SWITCH IS
ALWAYS IN THE OFF POSITION, UNLESS
OTHERWISE REQUIRED BY THE PROCEDURE.
SET THE PARKING BRAKE (IF EQUIPPED) WHEN
WORKING ON THE EQUIPMENT. IF YOU HAVE AN
AUTOMATIC TRANSMISSION, SET IT IN PARK
(ENGINE OFF) OR NEUTRAL (ENGINE ON)
UNLESS INSTRUCTED OTHERWISE FOR A
SPECIFIC OPERATION. PLACE WOOD BLOCKS
(4”X 4” OR LARGER) TO THE FRONT AND REAR
SURFACES OF THE TIRES TO PROVIDE
FURTHER RESTRAINT FROM INADVERTENT
EQUIPMENT MOVEMENT.
OPERATE THE ENGINE ONLY IN A WELL
VENTILATED AREA TO AVOID THE DANGER OF
CARBON MONOXIDE.
KEEP YOURSELF AND YOUR CLOTHING AWAY
FROM MOVING PARTS WHEN THE ENGINE IS
RUNNING, ESPECIALLY THE FAN BELTS.
TO PREVENT SERIOUS BURNS, AVOID CONTACT
WITH HOT METAL PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD, TAIL PIPE,
CATALYTIC CONVERTER AND MUFFLER.
DO NOT SMOKE WHILE WORKING ON THE
EQUIPMENT.
ALWAYS REMOVE RINGS, WATCHES, LOOSE
HANGING JEWELRY, AND LOOSE CLOTHING
BEFORE BEGINNING TO WORK ON THE
EQUIPMENT. TIE LONG HAIR SECURELY BEHIND
THE HEAD.
KEEP HANDS AND OTHER OBJECTS CLEAR OF
THE RADIATOR FAN BLADES. ELECTRIC
COOLING FANS CAN START TO OPERATE AT
ANY TIME BY AN INCREASE IN UNDERHOOD
TEMPERATURES, EVEN THOUGH THE IGNITION
IS IN THE OFF POSITION. THEREFORE, CARE
SHOULD BE TAKEN TO ENSURE THAT THE
ELECTRIC COOLING FAN IS COMPLETELY
DISCONNECTED WHEN WORKING UNDER THE
HOOD.

TSG‐416GENERALINFORMATION
01‐4
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.
NOTE: Observe all manufacturers’ instructions when
using charging equipment.
CAUTION: Batteries should not be charged in the
vehicle or equipment. May damage electrical
components.
It is important that all labeling 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.

TSG‐416GENERALINFORMATION
01‐5
Forward
This book contains service information for the engine(s)
listed on the title page.
The life of your engine unit and the delivery of the high
performance built into it will depend on the care it
receives throughout its life. It is the operator’s
responsibility to ensure that the engine is correctly
operated. We consider it to be in your interests to enlist
the aid of an authorized EDI Distributor, not only when
repairs are required but also for regular maintenance.
Distributors are listed at the back of this manual.
Engines manufactured by Ford Motor Company are
available through EDI Distributors. 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
EDI affiliated Company in your area whose address
appears at the end of this book.
Where the terms “Right” or “Left” occur in this
publication, they refer to the respective sides of the
engine when viewed from the rear or flywheel end.
Pistons and valves are numbered from the front or timing
cover end of the engine commencing at No. 1.
You may find that your engine assembly includes
optional equipment not specifically covered in the
following text. Nevertheless, the service procedures
outlined in this book still apply to your engine.
Engine Identification
Because Ford Power Products markets such a wide
range of industrial gasoline and diesel 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. Review the list in the back of this
book, for an EDI distributor in your area. You can obtain
a standard parts listing describing the parts. It remains a
distributor function to identify the part number.
An identification Decal is affixed to the valve cover of the
engine. The decal contains the engine serial number
which identifies this unit from all others. Use all numbers
when seeking information or ordering replacement parts
for this engine.
Parts and Service
Replacement parts can be obtained through your local
EDI Distributor listed in the back portion of this manual.
They also may be found in the yellow pages under
“Engines” or contact EDI directly at 1 800 220 2700.
EDI Distributors 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.
Description and Operation
Section 01 of this manual covers general procedures
and diagnosis of the engine system, including base
engine repair procedures that would be common to most
engines. Refer to Section 02 for more specific service
information on the TSG-416 engine.
The TSG-416 engine incorporates a closed positive
crankcase ventilation system and an exhaust emission
control system.
The engine’s, fuel, ignition, emissions system and
exhaust system all affect exhaust emission levels and
must be maintained according to the maintenance
schedule. Refer to the Maintenance and Operator’s
Handbook or contact your nearest EDI distributor listed
in the back of this manual.

TSG‐416GENERALINFORMATION
01‐6
DIAGNOSIS AND TESTING
Special Tools
Special Service Tools called by the procedures can be
obtained by calling:
1-800-ROTUNDA (1-800-768-8632)

TSG‐416GENERALINFORMATION
01‐7
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.
Damaged or severely worn pads.
Loose mounting bolts, studs, and nuts.
Symptom Chart
3. If the inspection reveals obvious concerns that
can be readily identified, repair as required.
4. If the concerns remain after the inspection,
determine the symptoms and go to the symptom
chart.

TSG‐416GENERALINFORMATION
01‐8

TSG‐416GENERALINFORMATION
01‐9

TSG‐416GENERALINFORMATION
01‐10
PCV System Malfunction
A malfunctioning Positive Crankcase Ventilation
System (closed type) may be indicated by loping or
rough engine idle. Do not attempt to compensate for this
idle condition by disconnecting the PCV system and
making an air bypass or idle speed adjustment.
CAUTION: The removal of the PCV system from the
engine will adversely affect fuel economy and
engine crankcase ventilation with resultant
shortening of engine life.
Engine Oil Leaks
NOTE: When diagnosing engine oil leaks, the source
and location of the leak must be positively identified prior
to service.
Prior to performing this procedure, clean the cylinder
block, cylinder heads, valve covers, oil pan and flywheel
with a suitable solvent to remove all traces of oil.
Fluorescent Oil Additive Method
Use a 12 Volt Master UV Diagnostic Inspection Kit, such
as the Rotunda Oil Leak Detector Y112-R0021 or
equivalent, to perform the following procedure for oil leak
diagnosis.
1. Clean the engine with a suitable solvent to
remove all traces of oil.
2. Drain engine oil crankcase and refill with
recommended oil, premixed with Diesel Engine
Oil Dye 164-R3705 meeting Ford specification
ESEM9C103- B1 or equivalent. Use a minimum
14.8 ml (0.5 ounce) to a maximum 29.6 ml (1
ounce) of fluorescent additive to all engines. If
the oil is not premixed, fluorescent additive must
first be added to crankcase.
3. Run the engine for 15 minutes. Stop the engine
and inspect all seal and gasket areas for leaks
using the 12 Volt Master UV diagnostic
Inspection Kit. A clear bright yellow or orange
area will identify the leak. For extremely small
leaks, several hours may be required for the
leak to appear.
4. If necessary, pressurize the main oil gallery
system to locate leaks due to improperly sealed,
loose or cocked plugs.
5. Repair all leaks as required.
Pressure Method
The crankcase can be pressurized to locate oil leaks.
The following materials are required to fabricate the tool
to be used:
air supply and air hose
air pressure gauge that registers pressure in 4
kPa (1 psi) increments
airline shutoff valve
appropriate fittings to attach the above parts to
oil fill, PCV grommet hole and crankcase
ventilation tube
appropriate plugs to seal any openings leading
to the crankcase
a solution of liquid detergent and water to be
applied with a suitable applicator such as a
squirt bottle or brush
Fabricate the air supply hose to include the airline
shutoff valve and the appropriate adapter to permit the
air to enter the engine through the crankcase ventilation
tube. Fabricate the air pressure gauge to a suitable
adapter for installation on the engine at the oil filler
opening.
CAUTION: Use extreme caution when pressurizing
crankcase. Applying air pressure above specified
pressure risks damage to seals, gaskets and core
plugs. Under no circumstances should pressure be
allowed to exceed 27 kPa (4 psi)

TSG‐416GENERALINFORMATION
01‐11
Testing Procedure
Open the air supply valve until the pressure
gauge maintains 20 kPa (3 psi).
Inspect sealed or gasketed areas for leaks by
applying a solution of liquid detergent and water
over areas for formation of bubbles which
indicates leakage.
Leakage Points - Above Engine
Examine the following areas for oil leakage.
valve cover gaskets
intake manifold gaskets
cylinder head gaskets
oil filter
oil pump (if external)
oil level indicator tube connection
oil pressure sensor
Leakage Points - Under Engine
oil pan gaskets
oil pan sealer
oil pan rear seal
engine front cover gasket
crankshaft front seal
crankshaft rear oil seal
Leakage Points - with Flywheel Removed
NOTE: Air leakage in the area around a crankshaft rear
oil seal does not necessarily indicate a crankshaft rear
oil seal leak. However, if no other cause can be found for
oil leakage, assume that the crankshaft rear oil seal
is the cause of the oil leak.
NOTE: Light foaming equally around valve cover bolts
and crankshaft seals is not detrimental; no repairs are
required.
rear main bearing cap and seals
flywheel mounting bolt holes (with flywheel
installed)
camshaft rear bearing covers or pipe plugs at
the end of oil passages (except for overhead
cam)
Oil leaks at crimped seams in sheet metal parts and
cracks in cast or stamped parts can be detected when
pressurizing the crankcase.

TSG‐416GENERALINFORMATION
01‐12
Compression Tests
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. Turn
the ignition switch to the OFF position, then
remove all the spark plugs.
2. Set the throttle plates in the wide-open position.
3. Install a Compression Tester such as Rotunda
Compression Tester 059-R0009, or equivalent,
in the No. 1 cylinder.
4. Install an auxiliary starter switch in the starting
circuit. With the ignition switch in the OFF
position, and using the auxiliary starter switch,
crank the engine a minimum of five compression
strokes and record the highest reading. Note the
approximate number of compression strokes
required to obtain the highest reading.
5. Repeat the test on each cylinder, cranking the
engine approximately the same number of
compression strokes.
Test Results
The indicated compression pressures are considered
within specification if the lowest reading cylinder is within
75 percent of the highest reading. Refer to the
Compression Pressure Limit Chart.
If one or more cylinders reads low, squirt approximately
one tablespoon of clean engine oil meeting Ford
specification ESE-M2C153-E on top of the pistons in the
low-reading cylinders. Repeat the compression pressure
check on these cylinders.
Example Readings
If, after checking the compression pressures in all
cylinders, it was found that the highest reading obtained
was 1351 kPa (196 psi), and the lowest pressure
reading was 1069 kPa (155 psi), the engine is within
specification and the compression is considered
satisfactory.
Compression Pressure Limit Chart
Interpreting Compression Readings
1. If compression improves considerably, with the
addition of oil, piston rings are faulty.
2. If compression does not improve with oil, valves
are sticking or seating improperly.
3. If two adjacent cylinders indicate low
compression pressures and squirting oil on each
piston does not increase compression, the head
gasket may be leaking between cylinders.
Engine oil or coolant in cylinders could result
from this condition.
Use the Compression Pressure Limit Chart when
checking cylinder compression so that the lowest
reading is within 75 percent of the highest reading.

TSG‐416GENERALINFORMATION
01‐13
Cylinder Leakage Detection
When a cylinder produces a low reading, use of the
Engine Cylinder Leak Detection/Air Pressurization Kit,
such as the Rotunda Pressurization Kit 014-00705, or
equivalent, will be helpful in pinpointing the exact cause.
The leakage detector is inserted in the spark plug hole,
the piston is brought up to dead center on the
compression stroke, and compressed air is admitted.
Once the combustion chamber is pressurized, a special
gauge included in the kit will read the percentage of
leakage. Leakage exceeding 20 percent is excessive.
While the air pressure is retained in the cylinder, listen
for the hiss of escaping air. A leak at the intake valve will
be heard in the throttle body. A leak at the exhaust valve
can be heard at the tail pipe. Leakage past the piston
rings will be audible at the positive crankcase ventilation
(PCV) connection. If air is passing through a blown
head gasket to an adjacent cylinder, the noise will be
evident at the spark plug hole of the cylinder into which
the air is leaking. Cracks in the cylinder blocks or gasket
leakage into the cooling system may be detected by a
stream of bubbles in the radiator.
Oil Leak and Valve Stem Seal Test
The cylinder leakage detector tests for engine oil leaks
and checks the valve stem seals for leakage.
1. Plug all crankcase openings except the one
used for connecting the leakage detector.
2. Connect the Engine Cylinder Leak Detection/Air
Pressurization Kit to a crankcase opening (an oil
level indicator tube is convenient). Adjust the air
pressure to approximately 34 kPa (5 psi).
3. Using a solution of liquid soap and water, brush
the solution along the gasket sealing surfaces
and bearing seals. Look for bubbles or foam.
4. Remove the spark plugs and rotate the
crankshaft slowly with a wrench. Check for large
amounts of air escaping into the cylinders as
each intake valve and exhaust valve opens.
5. The spark plugs on the leaking cylinders will
probably show deposits of burned oil.
Intake Manifold Vacuum Test
Bring the engine to normal operating temperature.
Connect a Vacuum/Pressure Tester, such as Rotunda
Vacuum/Pressure Tester 059-00008 or equivalent, to the
intake manifold. Run the engine at the specified idle
speed.
The vacuum gauge should read between 51-74 kPa
(15-22 in-Hg) depending upon the engine condition and
the altitude at which the test is performed. Subtract 5.5
kPa (1 in-Hg) from the specified reading for every 500
meters (1,000 feet) of elevation above sea level.
The reading should be quite steady. If necessary, adjust
the gauge damper control (where used) if the needle is
fluttering rapidly. Adjust the damper until the needle
moves easily without excessive flutter.

TSG‐416GENERALINFORMATION
01‐14
Interpreting Vacuum Gauge Readings
A careful study of the vacuum gauge reading while the
engine is idling will help pinpoint trouble areas. Always
conduct other appropriate tests before arriving at a final
diagnostic decision. Vacuum gauge readings, although
helpful, must be interpreted carefully.
Most vacuum gauges have a normal band indicated on
the gauge face.
The following are potential gauge readings. Some are
normal; others should be investigated further.
1. NORMAL READING: Needle between 51-74
kPa (15-22 in-Hg) and holding steady.
2. NORMAL READING DURING RAPID
ACCELERATION AND DEACCELERATION:
When the engine is rapidly accelerated (dotted
needle), the needle will drop to a low reading
(not to zero). When the throttle is suddenly
released, the needle will snap back up to a
higher than normal figure.
3. NORMAL FOR HIGH-LIFT CAMSHAFT WITH
LARGE OVERLAP: The needle will register as
low as 51 kPa (15 in-Hg) but will be relatively
steady. Some oscillation is normal.
4. WORN RINGS OR DILUTED OIL: When the
engine is accelerated (dotted needle), the
needle drops to 0 kPa (0 in-Hg). Upon
deceleration, the needle runs slightly above 74
kPa (22 in-Hg).
5. STICKING VALVES: When the needle (dotted)
remains steady at a normal vacuum but
occasionally flicks (sharp, fast movement) down
and back about 13 kPa (4 in-Hg), one or more
valves may be sticking.
6. BURNED OR WARPED VALVES: A regular,
evenly spaced, downscale flicking of the needle
indicates one or more burned or warped valves.
Insufficient hydraulic lash adjuster or hydraulic
lash adjuster (HLA) clearance will also cause
this reaction.
7. POOR VALVE SEATING: A small but regular
downscale flicking can mean one or more valves
are not seating.
8. WORN VALVE GUIDES: When the needle
oscillates (swings back and forth) over about a
13 kPa (4 in- Hg) range at idle speed, the valve
guides could be worn. As engine speed
increases, the needle will become steady if
guides are responsible.
9. WEAK VALVE SPRINGS: When the needle
oscillation becomes more violent as engine rpm
is increased, weak valve springs are indicated.
The reading at idle could be relatively steady.
10. LATE VALVE TIMING: A steady but low reading
could be caused by late valve timing.
11. IGNITION TIMING RETARDING: Retarded
ignition timing will produce a steady but
somewhat low reading.
12. INSUFFICIENT SPARK PLUG GAP: When
spark plugs are gapped too close, a regular,
small pulsation of the needle can occur.
13. INTAKE LEAK: A low, steady reading can be
caused by an intake manifold or throttle body
gasket leak.
14. BLOWN HEAD GASKET: A regular drop of
approx. 33-50 kPa (10-15 in-Hg) can be caused
by a blown head gasket or warped cylinder
head-to-cylinder block surface.
15. RESTRICTED EXHAUST SYSTEM: When the
engine is first started and is idled, the reading
may be normal, but as the engine rpm is
increased, the back pressure caused by a
clogged muffler, kinked tail pipe or other
concerns will cause the needle to slowly drop to
0 kPa (0 in-Hg). The needle then may slowly
rise. Excessive exhaust clogging will cause the
needle to drop to a low point even if the engine
is only idling.
When vacuum leaks are indicated, search out and
correct the cause. Excess air leaking into the system will
upset the fuel mixture and cause concerns such as
rough idle, missing on acceleration or burned valves. If
the leak exists in an accessory unit such as the power
brake booster, the unit will not function correctly. Always
fix vacuum leaks.

TSG‐416GENERALINFORMATION
01‐15
Excessive Engine Oil Consumption
The amount of oil an engine uses will vary with the way
the equipment is driven in addition to normal engine to
engine variation. This is especially true during the first
340 hours or 16,100 km (10,000 miles) when a new
engine is being broken in or until certain internal engine
components become conditioned. Engines used in
heavy-duty operation may use more oil. The following
are examples of heavy-duty operation:
severe loading applications
sustained high speed operation
Engines need oil to lubricate the following internal
components:
cylinder block, cylinder walls
pistons, piston pins and rings
intake and exhaust valve stems
intake and exhaust valve guides
all internal engine components
When the pistons move downward, a thin film of oil is left
on the cylinder walls. As the engine is operated, some oil
is also drawn into the combustion chambers past the
intake and exhaust valve stem seals and burned.
The following is a partial list of conditions that can affect
oil consumption rates:
engine size
operator driving habits
ambient temperature
quality and viscosity of the oil
Operating under varying conditions can frequently be
misleading. An engine that has been run for short hours
or in below-freezing ambient temperatures may have
consumed a “normal” amount of oil.
However, when checking engine oil level, it may
measure up to the full mark on the oil level dipstick due
to dilution (condensation and fuel) in the engine
crankcase. The engine might then be run at high speeds
where the condensation and fuel boil off. The next time
the engine oil is checked, it may appear that a liter
(quart) of oil was used in about 3 to 3-1/2 hours.
This perceived 3 to 3-1/2 hours per liter (quart) oil
consumption rate causes customer concern even though
the actual overall oil consumption rate is about
50 hours per liter (quart).
Make sure the selected engine oil meets Ford
specification WSS-M2C153-F and the recommended
API performance category “SJ” or higher and SAE
viscosity grade as shown in the equipment Owner’s or
Operators Engine handbook. It is also important that the
engine oil is changed at the intervals specified. Refer to
the Engine Operator’s handbook.
Oil Consumption Test
The following diagnostic procedure is used to determine
the source of excessive internal oil consumption.
NOTE: Oil use is normally greater during the first 300
hours of service. As hours increase, oil use generally
decreases. Engines in normal service should get at least
31.7 hours per quart (900 miles per quart) after
300 hours of service. High speeds, heavy loads, high
ambient temperature and other factors may result in
greater oil use.
1. Determine customer’s engine load habits, such
as sustained high speed operation, extended
idle, heavy work loads and other considerations.
2. Verify that the engine has no external oil leak as
described under Engine Oil Leaks in the
Diagnosis and Testing portion of this section.
3. Verify that the engine has the correct oil level
dipstick.
4. Verify that the engine is not being run in an
overfilled condition. Check the oil level at least
five minutes after a hot shutdown with the
engine/vehicle parked on a level surface. In no
case should the level be above the top of the
cross-hatched area and the letter F in FULL. If
significantly overfilled, perform= steps 5 through
9. If not proceed to step 10.
5. Drain the engine oil, remove and replace the oil
filter and refill with one quart less than the
recommended amount.
6. Run the engine for three minutes (10 minutes if
cold), and allow the oil to drain back for at least
five minutes with the engine/vehicle on a level
surface.
7. Remove oil level dipstick and wipe clean.
CAUTION: Do not wipe with anything contaminated
with silicone compounds.
8. Reinstall the oil level dipstick, being sure to seat
it firmly in the oil level indicator tube. Remove
the oil level dipstick and draw a mark on the
back (unmarked) surface at the indicated oil
level. This level should be about the same as
the ADD mark on the face of the oil level
dipstick.
9. Add one quart of oil. Restart the engine and
allow to idle for at least two minutes. Shut off the
engine and allow the oil to drain back for at least
five minutes. Mark the oil level dipstick, using
the procedure above. This level may range from
slightly below the top of the cross-hatched area
to slightly below the letter F in FULL.

TSG‐416GENERALINFORMATION
01‐16
10. Record the vehicle mileage or hours.
11. Instruct the customer to run engine as usual and
perform the following:
Check the oil level regularly at intervals
of 3 to 3-1/2 hours.
Return to the service point when the oil
level drops below the lower (ADD) mark
on the oil level dipstick.
Add only full quarts of the same oil in an
emergency. Note the mileage at which
the oil is added.
12. Check the oil level under the same conditions
and at the same location as in Steps 7-9
Measure the distance from the oil level
to the UPPER mark on the oil level
dipstick and record.
Measure the distance between the two
scribe marks and record.
Divide the first measurement by the
second.
Divide the hours run during the oil test
by the result. This quantity is the
approximate oil consumption rate in
hours per quart.
13. If the oil consumption rate is unacceptable,
proceed to next step.
14. Check the positive crankcase ventilation (PCV)
system. Make sure the system is not plugged.
15. Check for plugged oil drain-back holes in the
cylinder heads and cylinder blocks.
16. If the condition still exists after performing the
above steps, proceed to next step.
17. Perform a cylinder compression test – Refer to
“Compression Tests” on page 12 or perform a
cylinder leak detection test with Engine Cylinder
Leak Detection/Air Pressurization Kit – Refer to
“Cylinder Leakage Detection” on page 13. This
can help determine the source of oil
consumption such as valves, piston rings or
other areas.
NOTE: After determining if worn parts should be
replaced, make sure correct replacement parts are used.
18. Check valve guides for excessive guide
clearances. REPLACE all valve stem seals after
verifying valve guide clearance.
19. Worn or damaged internal engine components
can cause excessive oil consumption. Small
deposits of oil on the tips of spark plugs can be
a clue to internal oil consumption. If internal oil
consumption still persists, proceed as follows:
Remove the engine from the vehicle and
place it on an engine work stand.
Remove the intake manifolds, cylinder
heads, oil pan and oil pump.
Check piston ring clearance, ring gap
and ring orientation. Repair as required.
Check for excessive bearing clearance.
Repair as required.
20. Perform the oil consumption test to confirm the
oil consumption concern has been resolved.
Oil Pressure Test
1. Disconnect and remove the oil pressure sensor
from the engine.
2. Connect the Engine Oil Pressure Gauge and
Transmission Test Adapter to the oil pressure
sender oil gallery port.
3. Run the engine until normal operating
temperature is reached.
4. Run the engine at 3000 rpm and record the
gauge reading.
5. The oil pressure should be within specifications.
6. If the pressure is not within specification, check
the following possible sources:
insufficient oil
oil leakage
worn or damaged oil pump
oil pump screen cover and tube
excessive main bearing clearance
excessive connecting rod bearing clearance
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