Ford Tsg 416 Engine Shop Manual

TSG-416 GENERAL INFORMATION - PRELIMINARY

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INDEX

Subject
General Information
Page
01
Introduction ............................................................................................................................................... 01 - 3
Safety Notice ............................................................................................................................................. 01 - 4
Notes, Cautions, and Warnings................................................................................................................. 01 - 4
Battery Handling and Charging ................................................................................................................. 01 - 5
Forward ..................................................................................................................................................... 01 - 6
Engine Identification .................................................................................................................................. 01 - 6
Parts and Service ...................................................................................................................................... 01 - 8
Diagnosis and Testing
Special Tools............................................................................................................................................. 01 - 9
Inspection and Verification ...................................................................................................................... 01 - 10
Symptom Chart ....................................................................................................................................... 01 - 11
PCV System Malfunction......................................................................................................................... 01 - 13
Engine Oil Leaks ..................................................................................................................................... 01 - 14
Compression Tests ................................................................................................................................. 01 - 16
Cylinder Leakage Detection .................................................................................................................... 01 - 17
Intake Manifold Vacuum Test.................................................................................................................. 01 - 17
Excessive Engine Oil Consumption ........................................................................................................ 01 - 19
Oil Pressure Test..................................................................................................................................... 01 - 20
Valve Train Analysis – Static................................................................................................................... 01 - 21
Valve Train Analysis – Dynamic.............................................................................................................. 01 - 21
Camshaft Lobe Lift .................................................................................................................................. 01 - 22
Hydraulic Valve Lash Adjuster ................................................................................................................ 01 - 23
General Service Procedures
Camshaft Journal Diameter..................................................................................................................... 01 - 24
Camshaft Journal Clearance................................................................................................................... 01 - 24
Camshaft Lobe Surface........................................................................................................................... 01 - 24
Camshaft Lobe Lift .................................................................................................................................. 01 - 25
Camshaft Runout .................................................................................................................................... 01 - 25
Camshaft End Play.................................................................................................................................. 01 - 25
Crankshaft Main Bearing Journal Diameter ............................................................................................ 01 - 26
Crankshaft Main Bearing Journal Taper.................................................................................................. 01 - 26
Crankshaft Main Bearing Journal Clearance........................................................................................... 01 - 27
Bearing Inspection .................................................................................................................................. 01 - 27
Crankshaft End Play................................................................................................................................ 01 - 28
Crankshaft Runout .................................................................................................................................. 01 - 28
Cylinder Bore Taper ................................................................................................................................ 01 - 28
Cylinder Bore Out-of-Round.................................................................................................................... 01 - 29
Piston Inspection ..................................................................................................................................... 01 - 29
Piston Diameter....................................................................................................................................... 01 - 29
Piston to Cylinder Bore Clearance .......................................................................................................... 01 - 29
Piston Selection ...................................................................................................................................... 01 - 30
Piston Ring End Gap............................................................................................................................... 01 - 30
Piston Ring-to-Groove Clearance ........................................................................................................... 01 - 31
Crankshaft Connecting Rod Journal Diameter........................................................................................ 01 - 31
Crankshaft Connecting Rod Journal Taper ............................................................................................. 01 - 31
Connecting Rod Cleaning ....................................................................................................................... 01 - 31
Connecting Rod Larger End Bore ........................................................................................................... 01 - 32
Piston Pin Diameter................................................................................................................................. 01 - 32
Connecting Rod Bushing Diameter ......................................................................................................... 01 - 32
Connecting Rod Bend ............................................................................................................................. 01 - 32
Connecting Rod Twist ............................................................................................................................. 01 - 32

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 TSG-416 GENERAL INFORMATION - PRELIMINARY

INDEX (CONT.)

Subject Page
General Service Procedures
Connecting Rod Piston Pin Side Clearance............................................................................................ 01 - 33
Connecting Rod Journal Clearance ........................................................................................................ 01 - 33
Bearing Inspection .................................................................................................................................. 01 - 34
Roller Follower Inspection ....................................................................................................................... 01 - 34
Hydraulic Lash Adjuster Inspection ......................................................................................................... 01 - 34
Valve Stem Diameter .............................................................................................................................. 01 - 35
Valve Stem-to-Valve Guide Clearance.................................................................................................... 01 - 35
Valve Inspection ...................................................................................................................................... 01 - 35
Valve Guide Inner Diameter .................................................................................................................... 01 - 36
Valve Guide Reaming ............................................................................................................................. 01 - 36
Valve Spring Installed Length.................................................................................................................. 01 - 36
Valve Spring Free Length........................................................................................................................ 01 - 36
Valve Spring Out-of-Square .................................................................................................................... 01 - 36
Valve Spring Compression Pressure ...................................................................................................... 01 - 37
Valve and Seat Refacing Measurements ................................................................................................ 01 - 37
Valve Seat Width..................................................................................................................................... 01 - 37
Valve Seat Runout .................................................................................................................................. 01 - 37
Flywheel Inspection................................................................................................................................. 01 - 38
Oil Pump Gear Radial Clearance ............................................................................................................ 01 - 38
Oil Pump Rotor Inspection ...................................................................................................................... 01 - 38
Oil Pump Side Clearance ........................................................................................................................ 01 - 38
Cylinder Bore Honing .............................................................................................................................. 01 - 38
Cylinder Bore Cleaning ........................................................................................................................... 01 - 38
Cylinder Block Repair - Cast Iron Porosity Defects................................................................................. 01 - 39
Cylinder Block Core Plug Replacement .................................................................................................. 01 - 39
Cylinder Head - Distortion ....................................................................................................................... 01 - 39
Spark Plug Thread Repair....................................................................................................................... 01 - 41
Exhaust Manifold Straightness................................................................................................................ 01 - 42
SPECIFICATIONS .......................................................................................................................................... 01 - 42

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 TSG-416 GENERAL INFORMATION - PRELIMINARY

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 dur-
ing 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 en-
gine damage.

Ford Power Products 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.

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 TSG-416 GENERAL INFORMATION - PRELIMINARY

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.

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 TSG-416 GENERAL INFORMATION - PRELIMINARY

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.
It is important that all labelling 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.

Typical Battery Labelling

Read relevant
instructions
Explosive gases

Keep away from

children
Eye protection must
be WORN.

Do not dispose of as
household waste.
No smoking or naked
flames.

Recycle (via
recognized disposal
system).

Corrosive acid

Electrical current may

Flush eyes cause injury to
immediately when personnel
contacted with acid

Caution/important
notice.

NOTE: Observe all manufacturers’ instructions when using charging equipment.

CAUTION: Batteries should not be charged in the vehicle or equipment. May damage electrical components.

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 TSG-416 GENERAL INFORMATION - PRELIMINARY

Forward Product distributors for a distributor in your area. You

can obtain a standard parts listing describing the parts.
This book contains operating and maintenance
It remains a distributor function to identify the part
instructions for the engine(s) listed on the title page. number.
The life of your engine unit and the delivery of the high
The key to identifying the engine is the identification
performance built into it will depend on the care it decal mounted on the engine rocker cover. That decal
receives throughout its life. It is the operator’s provides not only the engine serial number, but also the
responsibility to ensure that the engine is correctly
exact model or type, configuration code and customer
operated and that the maintenance operations outlined name. The combination of that data permits you to
in this book are carried out regularly after the specified isolate the precise engine, build level and customer so
hours of operation have been reached. We consider it
you can determine the correct replacement parts.
to be in your interests to enlist the aid of an authorized
Ford Power Products Distributor not only when repairs
U.S.A. Engine Identification Decal
are required but also for regular maintenance.
Distributors are listed at the back of this manual. An identification Decal is affixed to the valve cover of
Regular maintenance will result in minimal operating the engine. The decal contains the engine serial
costs. number which identifies this unit from all others. Use all
numbers when seeking information or ordering
Engines manufactured by Ford Motor Company are replacement parts for this engine.
available through Ford Power Products 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 Ford 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
For a handy reference, this information is recorded on
optional equipment not specifically covered in the
your Ford Power Products Operations Engine
following text. Nevertheless, the maintenance
Registration copy (Form #194-103-D).
procedures outlined in this book still apply to your
engine.
The emission decal is affixed to the valve cover on all
Engine Identification certified engines over 25 horsepower distributed in the
State of California with an engine build date after
Because Ford Power Products Operations markets January 1st, 2001. The decal identifies that the engine
such a wide range of industrial gasoline and diesel is compliant with California's Air Resources Board's
engines - manufactured both in the U.S. and overseas - (ARB) Large Spark Ignited (LSI) Engine Regulations.
it is important that you have as complete identification of Use all numbers when seeking information or ordering
the engine as possible in order to provide the correct replacement parts for this engine.
replacement parts. Review the list of Ford Power
Unique Engine
Serial Number

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 TSG-416 GENERAL INFORMATION - PRELIMINARY

Fuel Type

Non-Certified Engine Decal

The identification decal shown below is an example (Non-certified engine build shown) OF THE DECAL THAT
MUST BE AFFIXED to the valve cover of the engine for a Non-certified engine build or export of an engine outside
of the United States.
Unique Engine Serial Number

Engine Build Identification Label

The TSG-416 Engine Build Identification Label is located on the front side of the valve cover near the oil level
indicator. This label contains assembly information as shown below.

Sequential # for
the engine Engine Type
Assembly date: dd mm y
this day

Part #
Working Shift

NOTE: This engine was assembled on June 27, 2004

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 TSG-416 GENERAL INFORMATION - PRELIMINARY

European Service Identification Plate

This plate is fixed to the engine in a prominent position. Panels 1 to 6
on the plate shown to the right, refer to various engine details as listed
below: 1

1. Serial No: This identifies the engine as supplied by Ford Power 2 3 4

Products.
5
Date: The two letters following the serial No. indicate the year and
month in which the specified build components were assembled - 6
refer to the chart below:

YEAR JAN FEB MAR APRIL MAY JUNE JULY AUG SEP OCT NOV DEC
1997 U B R A G C K D E L Y S T
1998 V J U M P B R A G C K D E
1999 W L Y S T J U M P B R A G
2000 X C K D E L Y S T J U M P
2001 Y B R A G C K D E L Y S T
2002 Z J U M P B R A G C K D E
2003 A L Y S T J U M P B R A G
2004 B C K D E L Y S T J U M P
2005 C B R A G C K D E L Y S T
2006 D J U M P B R A G C K D E

NOTE: The letters I, O and Q are not used in the year column. The letter representing the month repeats every five
years.
2. This identifies the country of origin of the engine.
3. Engine capacity in liters.
4. Engine model identification.
5. The Build Number indicates the complete specification. The digit to the extreme right hand side is the build
scheme chart issue number.
6. This space is provided for Equipment Manufacturers’ use when extra equipment is fitted outside of the Ford
Motor Company. Reference should be made to the Equipment Manufacturer for any information or parts
required.

Parts and Service

Replacement parts can be obtained through your local Ford Power Products Distributors listed in the back portion
of this manual. They also may be found in the yellow pages under “Engines” or contact Ford Power Products.
Ford Power Products 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.

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 TSG-416 GENERAL INFORMATION - PRELIMINARY

DIAGNOSIS AND TESTING

Special Tools

Commercially Available Compression Tester

Leakdown Tester 014-00707 or Equivalent

Cup Shaped Adapter Dial Indicator with Bracketry

TOOL-6565-AB or Equivalent TOOL-4201-C or Equivalent

Engine Cylinder Leak Engine Oil Pressure Gauge

Detection/Air Pressurization Kit T73L-6600-A
014-00705 or Equivalent

12 Volt Master UV Diagnostic Vacuum/Pressure Tester 164-

Inspection Kit 164-R0756 or R0253 or Equivalent
Equivalent

Special Service Tools called for by the procedures can

be obtained by calling:
1-800-ROTUNDA (1-800-768-8632).

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Ford Tsg 416 Engine Shop Manual
TSG-416 GENERAL INFORMATION - PRELIMINARY
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Inspection and Verification

3. If the inspection reveals obvious concerns that can
1. Verify the customer concern by operating the engine be readily identified, repair as required.
to duplicate the condition. 4. If the concerns remain after the inspection,
2. Visually inspect for obvious signs of mechanical and determine the symptoms and go to the symptom
electrical damage: chart.
• Engine coolant leaks.
• Engine oil leaks.
• Fuel leaks.
• Damaged or severely worn pads.
• Loose mounting bolts, studs, and nuts.

01-10
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