LSG 875

Ford LSG 875 User Manual

173 pages

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1

Power

Products

A

LSG

875

SERVICE MANUAL

PPO-194 208-86

Table of Contents

Safety Notice4
Table of Contents5
7.5 Liter Engines5
Basic Engine5
Section Title5
- Industrial and Irrigation Identification6
- Marine Identification6
- Description and Operation7
- Manifolds7
Cylinder Heads7
Cylinder Block7
PART1 Basic Engine7
Valve Train8
Oil (Engine) - Health Warning9
Lubrication System9
Positive Crankcase Ventilation System10
Compression Gauge Check11
Camshaft Lobe Lift11
Compression Test11
Compression Test Conclusion12
Hydraulic Valve Lifter13
Crankcase Ventilation Regulator Valve Test14
Positive Closed-Type Ventilation System14
Crankshaft End Play14
Flywheel Face Runout14
Camshaft End Play15
Timing Chain Deflection15
- Exhaust Manifolds Cleaning and Inspection16
- Valve Rocker Arm Cleaning and Inspection16
Cleaning and Inspection16
Intake Manifold16
Push Rods16
- Cylinder Heads Cleaning and Inspection17
- Hydraulic Valve Lifters Cleaning and Inspection19
- Crankshaft Vibration Damper and Spacer Cleaning and Inspection19
- Timing Chain and Sprockets Cleaning and Inspection19
- Camshaft Cleaning and Inspection19
- Crankshaft Cleaning20
- Flywheel Inspection20
- Connecting Rods Cleaning and Inspection21
- Pistons, Pins and Rings Cleaning and Inspection21
Basic Engine21
- Main and Connecting Rod Bearings Cleaning and Inspection22
- Cylinder Block Cleaning and Inspection23
- Oil Pan Cleaning and Inspection23
- Oil Pump Cleaning and Inspection24
- Positive Closed-Type Crankcase Ventilation System Cleaning/Inspection24
- Cylinder Head Overhaul25
- Reaming Valve Guides25
- Refacing Valve Seats25
- Camshaft Repair26
  - Refacing Valves26
  - Select Fitting Valves26
- Valves26
- Crankshaft27
- Pistons, Pins and Rings28
- Cylinder Block/Refinishing Cylinder Walls29
- Push Rods29
- Repairing Sand Holes or Porous Engine Castings29
- Valve Rocker Arm29
- Valve Clearance Adjustment30
Overhaul25
Adjustments30
- Crankcase Ventilation System Removal and Installation31
- Valve Rocker Arm Cover and Rocker Arm Removal and Installation32
- Valve Spring, Retainer and Stem Seal Removal and Installation33
- Intake Manifold Removal and Installation34
- Valve Tappet Removal and Installation37
- Cylinder Heads Removal and Installation37
- Exhaust Manifold Removal and Installation38
- Water Pump Removal and Installation39
- Cylinder Front Cover and Timing Chain Removal39
- Cylinder Front Cover and Timing Chain Installation40
- Front Oil Seal Removal and Installation42
- Camshaft Removal42
- Camshaft Installation43
- Core Plugs Removal43
- Core Plugs Installation44
REMOVAL and INSTALLATION (Cont' D)44
- Crankshaft Rear Oil Seal Removal and Installation45
- Oil Pan Removal and Installation45
- Oil Pump Removal and Installation45
- Main Bearings Removal and Installation47
- Connecting Rod Bearing Removal and Installation48
- Pistons and Connecting Rods Removal and Installation49
- Crankshaft Removal and Installation51
- Camshaft Bearings Removal and Installation53
- Cylinder Head Disassembly and Assembly54
- Oil Filter Removal and Installation54
- Piston and Connecting Rod Disassembly and Assembly55
- Cylinder Assembly Disassembly and Assembly56
- Cylinder Block Disassembly and Assembly56
- Oil Pump Disassembly and Assembly56
- Ignition System57
- Solid State Ignition Description57
- Description58
  - Ignition System Diagrams58
  - Ignition System Diagnosis and Testing60
  - Initial Ignition Timing Adjustments60
- Diagnosis and Testing61
  - Start Circuit Test61
  - Run Circuit Test62
  - Module Voltage Test63
  - Ballast Resistor Test64
  - Supply Voltage Circuits Test65
  - Distributor Stator Assembly and Wiring Harness Test66
  - Ignition Coil Supply Voltage Test66
  - Ignition Coil Secondary Resistance Test67
  - Distributor Stator Assembly Test68
  - Module to Coil Wire Test68
  - Ignition Coil Primary Resistance Test69
  - Primary Circuit Continuity Test69
  - Distributor Ground Circuit Continuity Test70
  - Ground Circuit Continuity Test70
  - Distributor Removal and Installation71
  - Diaphragm Assembly Removal and Installation72
  - Distributor Cap, Adapter and Rotor Removal and Installation72
  - Stator Assembly Removal and Installation72
  - Distributor Assembly Cleaning and Inspection73
  - Distributor Cap and Rotor Cleaning and Inspection73
  - Ignition Wires Removal and Installation73
  - Spark Plugs Removal and Installation73
- CLEANING and INSPECTION (Cont' D)74
  - Ignition Coil Cleaning and Inspection74
  - Ignition Wires Cleaning and Inspection74
  - Spark Plugs Cleaning and Inspection74
- Adjustments and Repairs76
  - Breaker Plate and Sub-Plate Removal and Installation76
  - Breaker Points And/Or Condenser Removal and Installation76
- Prestolite Distributors (Marine and Irrigation Engines) Description and Operation76
  - Cam and Centrifugal Advance Weights Removal and Installation77
  - Distributor - Removal and Installation77
  - Bench Disassembly78
  - Conventional Ignition System Distributor78
  - Ignition System - Major Repair Operations78
- Bench Assembly79
- Major Repair Operations79
  - New Shaft and Gear79
  - Original Shaft and Gear79
- Mechanical Operation80
- Dwell Angle80
- Distributor Spark Advance Test80
- Centrifugal Advance80
- Fuel System81
- Fuel System Diagnosis and Testing82
- Fuel Pump Assembly Removal and Installation84
- Pressure and Capacity (Volume) Testing84
- Model 2300 2-V Carburetor Description85
- Carburetor Systems86
- Fuel Inlet System86
- Idle Fuel System86
- Main Metering System87
- Power Fuel System87
- Accelerating Pump System88
- Idle Mixture Adjustment89
- Erratic Engine Idle90
- Low Idle Speed Adjustment90
- Accelerator Pump Lever Adjustment/Accelerating Pump Stroke Adjustment90
- Fuel Level Float Adjustment - Dry90
- Fuel Level Adjustment - Wet91
- To Lower Fuel Level91
- To Raise Fuel Level91
- Accelerating Pump Diaphragm Removal and Installation92
- Carburetor Removal and Installation92
- Power Valve and Gasket Removal and Installation92
- Fuel Bowl and Gasket Metering Block and Gasket Removal/Installation92
- Fuel Inlet Needle and Seat Removal and Installation93
- Carburetor Disassembly and Assembly93
- Fuel Bowl and Metering Block93
- Main Body94
- Throttle Operating Shaft Housing94
- Carburetor Cleaning and Inspection95
- Carburetor Assembly96
- Throttle Body96
- Carburetor Exploded View99
- Model 4160 Carburetor Systems100
- Fuel Inlet System (4160)100
- Idle System (4160)102
- Main Metering System (Primary) (4160)103
- Power Enrichment System (Primary) (4160)103
- Accelerator Pump System104
- Integral Automatic Choke105
- Choke Systems105
- Electric Chokes106
- Hand Operated Chokes106
- Vacuum Systems Secondary Operation106
- Secondary Fuel Metering Systems106
- 4160 Carburetor Service Procedures108
- 4160 Carburetor Disassembly108
- 4160 Carburetor View109
- 4160 Carburetor Cleaning112
- 4160 Carburetor Assembly112
- Primary Fuel Bowl112
- Secondary Fuel Bowl112
- Main Body (4160)113
- Fuel Bowls and Metering Body113
- 4160 Carburetor Adjustments114
- Checking Accelerator Pump Lever Clearance/Choke Qualifying114
- Adjusting Secondary Throttle Stop114
- Secondary Diaphragm114
- Choke Unloader Adjustment115
- Curb Idle Adjustment115
- Erratic Engine Idle/Low Idle Speed Adjustment115
- Fast Idle Adjustment115
- Model 4160 Carburetor Exploded View116
- Idle Adjustment Procedure with Analyzer116
- Charging System118
- Alternator118
- Charging System Diagrams119
- Regulator120
- Charging System Application120
- Charging System Diagnosis121
- Normal Charge Indicator Light121
- Normal Charge Ammeter121
- Isolating the Problem121
- Capacity Test122
- Battery Testing122
- State of Charge - Maintenance-Free Batteries123
- Charging System Tests - Motorola123
- Ignition on - Engine Not Running123
- Field Draw Test - Ignition off123
- Ignition on - Engine Running at Fast Idle124
- Ignition on - Engine Running at Idle124
- Motorcraft124
- Base Voltage Test/No Load Test124
- General Charging System Test125
- Load Test126
- Over Voltage Tests126
- Under Voltage Tests126
- Regulator S and I Circuit Tests S-Circuit with Ammeter127
- S and I Circuit - with Indicator Light127
- Bench Tests128
- Rectifier Short or Grounded and Stator Grounded Test128
- Field Open or Short Circuit Test128
- Stator Coil Open Test129
- Stator Coil Grounded Test129
- Diode Test129
- Rotor Open or Short Circuit Test130
- Alternator Removal and Installation130
- Alternator Disassembly131
- Alternator Cleaning and Inspection133
- Alternator Assembly134
- Drive Belt Adjustment135
- Belt Tension135
- Starting System136
- Starting System Testing137
- To Jump Start (Negative Grounded Battery)137
- On Vehicle Testing - if Starter Cranks Slowly137
- If Starter Does Not Crank but Starter Relay Operates (Clicks)138
- If Starter Does Not Crank and Relay Chatters or Does Not Click138
- If Starter Spins (Humming Noise) but Does Not Crank Engine138
- Starter Load Test138
- Armature and Field Grounded Circuit Test139
- Armature Open Circuit Test139
- Starting System Bench Tests139
- Starter Cleaning and Inspection140
- Starter Removal and Installation140
- Starter Disassembly140
- Starting System Diagram141
- Starter Assembly143
- Starter Drive Replacement143
- Brush Replacement144
- Armature Replacement144
- Starter, Permanent Magnet145
- Jump Starting146
- Starter, Permanent Magnet Diagnosis and Testing147
- Check Starter Motor - Test a148
- Check Relay - Test B148
- Check Voltage at Remote Relay Start Terminal149
- Check Output Terminal Voltage149
- Bench Tests - Starter No-Load Test150
- Starter Motor Removal and Installation151
- Grounded Armature Test151
- Starter Solenoid Test151
- Starter Motor Disassembly and Assembly153
- Starter Motor Cleaning and Inspection153
- Starter Drive/Armature Replacement155
- Starter Specifications155
- Starting System - Special Service Tools156
- Governors157
- Mechanical Governor - Belt Driven, Description157
- Mechanical Governor Troubleshooting157
- Preliminary Checks of Mechanical Governors157
- Oil Level (Governor)158
- Belt Tension (Governor)158
- Throttle Control Rod (Governor)158
- RPM Adjustment/Spread Adjustment/No-Load Surge Adjustment158
- Draining and Filling the Cooling System159
- Coolant (Industrial)159
- Cooling159
- Cooling System Testing160
- Pressure Test160
- Thermostat Test160
- Cooling System Adjustments161
- Drive Belt/Belt Tension Adjustment161
- Thermostat Replacement161
- Cooling System Cleaning and Inspection162
- Specifications163
- Metrics168
- Nomenclature for Bolts169
- Bolt Strength Identification169
- Hex Nut Strength Identification170
- Other Types of Parts170
- Decimal and Metric Equivalents171
- English Metric Conversion172
- Torque Conversion173

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Ford LSG 875 Specifications

General

Brand	Ford
Model	LSG 875
Category	Engine
Language	English

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