LRG-423

Ford LRG-423 User Manual

192 pages

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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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