LRG-423

Ford LRG-423 User Manual

192 pages

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LRG-423

Power

2.3 LITRE

Products

INDUSTRIAL ENGINE

Worldwide TM

SERVICE MANUAL

Table of Contents

Important Safety Notice2
Notes, Cautions and Warnings2
Introduction3
Engine Service4
Table of Contents5
Description and Operation6
Engine Identification Nameplate6
Diagnosis and Testing7
Engine Diagnosis7
Service Procedures9
- Engine Oil Leaks9
- Fluorescent Oil Additive Method9
- Pressure Method9
- Compression Gauge Check10
- Compression Test10
- Leakage Points10
- Test Results10
- Compression Readings11
- Cylinder Leakage Detector11
- Example Readings11
- Oil Leak and Valve Guide Seal Test11
- Vacuum Gauge Readings12
- Oil Consumption Test13
- Restricted Exhaust System13
- Intake Valve Cleaning14
- Oil Pressure Test14
- Valve Train Analysis14
- Valves and Cylinder Head14
- Intake Valve Deposit Rating System15
- Camshaft End Play16
- Hydraulic Valve Tappet/Lash Adjuster16
- Camshaft Timing and Cylinder Identification Timing Check17
- Timing Belt17
- Connecting Rod Side Clearance18
- Crankshaft End Play18
- Cylinder Block Distortion18
- Cylinder Head Deck Flatness18
- Cylinder Bore19
- Cylinder Bore Taper19
- Cylinder Walls, Refinishing19
- Cylinder Bore Diameter20
- Cylinder Out-Of-Round20
- Cup Type21
- Engine Block Plugs21
- Expansion Type21
- Special Service Tools21
- Crankshaft Main and Connecting Rod Bearings22
- Bore Gauge Method23
- Crankshaft Runout24
- Crankshaft Sprocket24
- Journals Refinishing24
- Piston Rings - Fitting25
- Pistons, Piston Pins and Piston Rings25
- Piston and Piston Pin Fit26
- Camshaft27
- Camshaft Bearings27
- Connecting Rods27
- Piston Pin Clearance27
- Cam Lobe Lift28
- Camshaft Bearing Journals28
- Camshaft Journals Oil Clearance28
- Camshaft Runout28
- Camshaft Sprocket29
- Hydraulic Valve Tappets29
- Leakdown Testing29
- Cylinder Heads30
  - Spark Plug Thread Service30
  - Cleaning30
  - Inspection30
  - Cylinder Head Flatness31
  - Valve Seat Runout31
  - Valve Stem-To-Valve Guide Clearance31
  - Valves, Select Fitting32
  - Valve Guides, Reaming32
  - Valve Seats, Refacing32
  - Valves, Inspection33
  - Valves, Refacing33
  - Valve Spring Tension34
  - Valve Spring Squareness34
- Oil Pan30
- Camshaft Follower (2.3L)34
- Intake Manifold34
  - Cleaning34
  - Inspection34
- Exhaust Manifold35
  - Cleaning35
  - Inspection35
General Engine Specifications36
Specifications36
- Special Service Tools Desired37
- Rotunda Equipment37
Special Service Tools/Equipment37
- 2.3L Engine38
- Engine Service, 2.3L39
- Subject Page39
- Description and Operation40
- Engine Identification40
- Camshaft41
- Crankshaft41
- Engine Code Information41
- Valve Train41
- Engine Lubrication System42
- Oilpan42
- Oilpump42
- Positive Crankcase Ventilation System42
- Drive Belt System45
- Electronic Governor45
- Engine Cooling System45
- Fail-Safe45
- Fuel System45
- Ignition System45
- Mechanical Governor45
- Velocity Governor45
- 2.3L Engine Service46
- Camshaft Follower and Hydraulic Lash Adjuster50
- Installation50
- Removal50
- Valve Cover and Gasket50
- Installation51
- Removal51
- Valve Spring, Retainer and Valve Stem Seal51
- Crankshaft Pulley and Damper52
- Installation52
- Removal52
- Camshaft Timing Belt Outer Cover53
- Installation53
- Camshaft Timing Belt Inner Cover54
- Installation54
- Removal54
- Camshaft Timing Belt55
- Removal55
- Installation57
- Timing Mark Alignment57
- Camshaft and Oil Pump Sprocket58
- Removal58
- Crankshaft Sprocket59
- Installation59
- Removal59
- Timing Belttensioner59
Camshaft60
- Removal60
- Camshaft and Oil Pump Oil Seal62
- Installation62
- Removal62
- Cylinder Block Front Cover Seal63
- Installation63
- Removal63
- Water Pump64
  - Intake Torque Sequence66
  - Generator and Bracket Torque Sequence67
  - Water Pump Inlet Tube68
- Installation69
- Removal69
- Water Thermostat and Outlet Connection69
- Installation70
- Intake Manifold70
- Removal70
- Water Outlet Connection and Thermostat70
- Installation71
- Carburetor72
- Installation72
- Removal72
- Exhaust Manifold74
- Installation74
- Removal74
Oil Pump75
Removal75
- Installation75
- Crankshaft Rear Oil Seal76
- Removal76
- Installation76
- Oil Filter and Adapter77
- Oil Pressure Sender77
Engine Front Cover77
- Installation77
- Removal77
- Removal and Installation77
- Sensors77
- Removal78
- Engine Front Cover Installation79
- L ENGINE SERVICE (Cont' D.)79
- Installation81
- Oil Pan81
- Removal81
- Installation82
- Oil Pump Screen, Cover, and Tube82
- Removal82
- Crankshaft83
- Removal83
- Installation84
- Rear Main Bearing Cap Sealing84
- Crankshaft Main Bearings86
- Removal86
- Installation87
- Rear Main Bearing Cap Area Sealing87
- Pistons and Connecting Rods88
- Removal88
- Installation89
- Connecting Rod Bearings90
Removal90
- Installation90
- Subassemblies92
- Cylinder Head92
- Disassembly and Assembly92
- Disassembly93
- DISASSEMBLY and ASSEMBLY (Cont' D.)97
- Piston and Piston Pins97
- Disassembly97
Assembly97
- Cylinder Block Assembly97
- Adjustments98
- Assembly98
- Cylinder Block, Bare98
- Disassembly98
- Disassembly and Assembly98
- Hydraulic Lash Adjuster98
- Valve Clearance, Hydraulic Valve Lash Adjuster98
- Camshaft Timing99
- Checking Timing99
- Inspecting Camshaft and Oil Pump Sprocket Timing100
- Adjusting Timing Belt101
- Specifications105
Engine Operating Speeds - LRG108
Special Service Tools/Equipment109
- Auxiliary Systems110
- Inputs Affecting Ignition113
- Engine Temperature113
- Engine Speed and Crankshaft Position113
- Ignition Coil Driver113
- Service Adjustments and Checks114
- Transcient Mode114
- Overspeed Mode114
- Diagnosis Equipment115
- Ignition Coil119
- Engine Speed Sensor119
- Engine Coolant Temperature Sensor120
- Crankshaft Position Sensor121
- Ignition Coil Pack123
- Ignition Wires124
- Spark Plugs124
- Spark Plug Inspection Chart125
- Ignition Specifications126
- Ignition Adjustments126
- Ignition Timing126
- Carburetor Identification127
- Fuel System Description and Operation127
- Electric Fuel Pump127
- Fuel System Diagnosis and Testing128
- Fuel Supply and Pressure128
- Service Check Chart128
- Fuel Pump Service and Maintenance129
- Fuel Pump Specifications130
- Carburetor Diagnosis131
- Hard Starting131
- Stalling131
- Rough Idle131
- Reduced Power Output132
- Leaking Carburetor132
- Inconsistent Idle Speed132
- Fuel Supply System133
- Idle System133
- High Speed System135
- Accelerating Pump System137
- Assembly of Air Intake141
- Assembly of Fuel Bowl141
- Carburetor Description143
- Carburetor Systems143
- Idle Fuel System143
- Fuel Inlet System143
- Accelerator Pump System144
- Main Metering System144
- Power Fuel System144
- Float Adjustment145
- Accelerator Pump Piston Stroke Adjustment145
- Idle Speed Adjustment145
- Fast Idle Adjustment146
- Idle Mixture Adjustment146
- Carburetor Body Disassembly148
- Adjustments During Assembly149
- Starter, Permanent Magnet Description and Operation152
- Sequence of Operation152
- Negative Grounded Battery153
- Jump Starting153
- Road Service153
- Evaluation155
- Check Starter Motor155
- Check Relay155
- Starter Load Test155
- Bench Tests156
- Starter No-Load Test156
- Starter Solenoid Test157
- Armature Open Circuit Test157
- Grounded Armature Test157
- Starter Motor158
- Wiring158
- Starter, Permanent Magnet Disassembly and Assembly160
- Pinion and Ring Gear Wear Patterns161
- Starter Drive Replacement162
- Armature Replacement162
- Torque Specifications163
- Governors, Mechanical Description and Operation165
- Governors, Adjustments166
- Preliminary Checks166
- Throttle Control Rod166
- Oil Level166
- High Speed167
- Sensitivity or Droop167
- Low Speed Idle168
- No-Load Surge168
- Decrease Droop168
- Increase Droop168
- Basic Wiring Diagram173
- Cooling System174
- Visual Inspection175
- Cooling System Pressure Test175
- Radiator Cap Pressure Test176
- Thermostat Teest177
- Cooling Fan178
- Fan Drive Belt178
- Radiator Hose178
- Thermostat178
- Cleaning Cooling System179
- Generator180
- Battery Positive Voltage Output180
- A Circuit180
- S Circuit180
- Generator Diagnosis and Testing181
- Generator Output Test181
- Generator Voltage Test181
- Pinpoints Tests183
- Dead Battery/No Generator Output183
- Check for Key off Drain183
- Indicator Lamp On, Engine Running184
- Check for Open Stator Phase184
- Check for Shorted Rectifier184
- Check Stator Output Voltage185
- Check Generator Output Voltage185
- Check for Loose Connections185
- Check for Field Circuit Drain185
- Check Voltage Drop in a Circuit186
- Check Voltage Drop in I Circuit186
- Generator Removal and Installation190
- Regulator Removal190
- Generator Removal190
- Generator Disassembly and Assembly192
- Generator Parts Cross-Reference192
- Generator Mounting Specifications192

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Ford LRG-423 Specifications

General

Brand	Ford
Model	LRG-423
Category	Engine
Language	English

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