Kawasaki Gas Engines

John Deere K Series Liquid-cooled Engines

COMPONENT TECHNICAL MANUAL John Deere Lawn & Grounds Care Division CTM39 (Oct93) Replaces CTM39 (28JAN91)

Litho in U.S.A

INTRODUCTION This component technical manual is written for an experienced technician. It covers recommended repair procedures, starting with the engine removed from the machine and on a workbench or engine stand. Some components may be serviced in the machine. Determine the repair procedure before removing the engine. Use this manual in conjunction with the machine technical manual. It is a part of a total product support program. Use the Fundamental Of Service (FOS) manual as reference for fundamentals of service and basic theory of operation.

Safety Specifications and Information Intake, Muffler & Breather Fuel System & Governor

The manual is organized so that all the information on a particular system is kept together. The order of grouping is as follows: • • • • •

Table of Contents Safety Specifications Theory of Operation Repair

Note: Depending on the particular section or system being covered, not all of the above groups may be used.

Each section will be identified with a symbol rather than a number. The pages within a section will be consecutively numbered.

Cylinder Head & Valves Cylinder Block, Pistons & Rods Camshaft, Crankshaft & Flywheel Power Train Lubrication System Cooling System

All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.

We appreciate your input on this manual. To help, there are postage paid post cards included at the back. If you find any errors or want to comment on the layout of the manual please fill out one of the cards and mail it back to us.

Electrical System Troubleshooting Component Analysis Miscellaneous

COPYRIGHT© 1993 JOHN DEERE HORICON WORKS Horicon, Wisconsin All rights reservedl

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SAFETY HANDLE FLUIDS SAFELY-AVOID FIRES

HANDLE CHEMICAL PRODUCTS SAFELY

• BE PREPARED FOR EMERGENCIES

TS1132 TS291

TS1133

Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives. A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.

TS227

• DISPOSE OF WASTE PROPERLY When you work around fuel, do not smoke or work near heaters or other fire hazards. Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. Make sure machine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn spontaneously. Be prepared if a fire starts.

Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries. Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain, or into any water source. Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer.

Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

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SAFETY USE SAFE SERVICE PROCEDURES

• WORK IN CLEAN AREA

• Before starting a job

• WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate for the job. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

1. Clean work area and machine: 2. Make sure you have all necessary tools to do your job. 3. Have the right parts on hand. 4. Read all instructions thoroughly; do not attempt shortcuts.

. • ILLUMINATE WORK AREA SAFELY Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil. TS206

• WORK IN VENTILATED AREA

TS228

• SERVICE MACHINES SAFELY Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

TS220

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension. If you do not have an exhaust pipe extension, open the doors and get outside air into the area.

• USE PROPER TOOLS Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards. Use power tools only to loosen threaded parts and fasteners. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches. Use only service parts meeting John Deere specifications.

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SAFETY • REMOVE PAINT BEFORE WELDING OR HEATING Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly. Remove paint before welding or heating: If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

LIVE WITH SAFETY TS231

• AVOID HARMFUL ASBESTOS DUST Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer. Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated.

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the material containing asbestos. Keep bystanders away from the area.

REPLACE SAFETY SIGNS

TS201

Replace missing or damaged safety signs. See the machine operator's manual for correct safety sign placement.

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CONTENTS

SPECIFICATIONS & INFORMATION

CONTENTS Page

SPECIFICATIONS & INFORMATION BASIC ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ENGINE APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ENGINE MODEL CONFIGURATION CHANGES . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ENGINE SERIAL NUMBER PLATE LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CARBURETOR SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

TEST & ADJUSTMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 5 REPAIR SPECIFICACATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 FD440V/501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 FD590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

METRIC TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 GASOLINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 FUEL STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 OIL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 SYNTHETIC LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 FD440V/501V/590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 INTERNAL ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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NOTES

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SPECIFICATIONS & INFORMATION

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SPECIFICATIONS & INFORMATION BASIC ENGINE SPECIFICATIONS FD440V AS00

FD501V AS00

FD590VAS00/02

FD590VAS03

FD620D AS04/11

FD620D ASO2

FD620D AS00/01

HORSEPOWER

11.1 kW (15 HP)

12.6kW (17 HP)

13.4 kW (18 HP)

14.9kW (20 HP)

13.4 kW (18 HP)

14.9kW (20 HP)

16.4 kW (22 HP)

CYLINDER

2

2

2

2

2

2

2

CYCLE

4

4

4

4

4

4

4

BORE

67 mm (2.64 in.)

67 mm (2.64 in.)

74 mm (2.90 in.)

74 mm (2.90 in.)

76 mm (2.99 in.)

76 mm (2.99 in.

76 mm (2.99 in.

STROKE

62 mm (2.44 in.)

62 mm (2.44 in.)

68 mm (2.66 in.)

68 mm (2.66 in.)

68 mm (2.66 in.)

68 mm (2.66 in.)

68 mm (2.66 in.)

437 cm3 (26.7 cu. in.)

437 cm3 (26.7 cu. in.)

585 cm3 (35.7 cu. in.)

585 cm3 (35.7 cu. in.)

617 cm3 (35.7 cu. in.)

617 cm3 (35.7 cu. in.)

617 cm3 (35.7 cu. in.)

ENGINE

DISPLACEMENT

ENGINE APPLICATIONS NOTE: Refer to the engine application chart to identify product-model/engine type-model relationship. Lawn Tractors Machine Engine Model No. LX178. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD440V - AS00 LX188. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD501V - AS00 Lawn And Garden Tractors 285 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 w/Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FD590V - AS00 FD590V - AS01 FD590V - AS00 FD620D - AS02 FD620D - AS01

Front Mowers F911 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD620D - AS00 F725 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD590V - AS03 Golf And Turf Equipment 1800 Utility Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2243 Professional Greensmower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2653 Professional Utility Mower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6X4 Gator Utility Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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FD620D - AS04 FD590V - AS02 FD620D - AS04 FD620D - AS11

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SPECIFICATIONS & INFORMATION ENGINE MODEL CONFIGURATION CHANGES

FD440V/FD501V/FD590V:

FD590V The following is a list of the major differences between the model configurations of the FD590V-AS00 through the FD590V-AS03. • The FD590V-AS00 is the first configuration used and its first application was in the 285 Lawn and Garden Tractor. • FD590V-AS01 was converted to a electronic fuel injection system. The carburetor was replaced by a throttle body and a water temperature sensor was added. • FD590V-AS02 engine is used in the 2243 Triplex Professional Greensmower. • FD590V-AS03 is used in the F725 Front Mower. The power was increased from 18 to 20 horsepower. To obtain the higher horsepower the following components were changed: • A larger redesigned intake manifold • The cylinder head induction passage and combustion chamber was redesigned. • A larger carburetor is used.

M53952

The engine serial number (A) is located on the side of the cooling air duct. FD620D:

NOTE: The FD440V, FD501V and FD590V are vertical shaft engines. The FD620D is a horizontal shaft engine. FD620D The differences in horsepower are due to the following: • rpm that the engine must run for the application. • the efficiencies of fuel injection on the FD620 - AS01.

ENGINE SERIAL NUMBER PLATE LOCATIONS NOTE: Refer to the engine model designation on the engine serial number plate to identify repair information covered in the Component Technical Manual

M53953

The engine serial number (A) is located on the crankcase cover.

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SPECIFICATIONS & INFORMATION

TEST & ADJUSTMENT SPECIFICATIONS

CARBURETOR SERIAL NUMBER LOCATIONS FD440V/FD501V/FD590V:

FD620D:

M53957

The carburetor serial number (A) is located on the top of carburetor.

M53958

The carburetor serial number (A) is located on the side of carburetor.

TEST & ADJUSTMENT SPECIFICATIONS Engine: Oil pressure sensor activates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 kPa (14.2 psi) Oil pressure (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 kPa (40 psi) Oil filter bypass valve opening pressure . . . . . . . . . . . 78.5—117.5 kPa (11.4—17.1 psi) Cylinder compression pressure (minimum) . . . . . . . . . . . . . . . . . . . . 1171 kPa (170 psi) Maximum compression pressure variation between cylinders . . . . . . . . 138 kPa (20 psi) Crankcase vacuum (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 mm (1 in.) water Intake and exhaust valve clearance (cold) . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.01 in.) Intake and exhaust valve adjustment interval . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 hrs. Valve clearance adjusting nut torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (79 lb-in) Fuel/Air System: Fuel Pump Minimum flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 ml (3.5 oz) in 15 seconds Minimum pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 kPa (1.5 psi) Carburetor SLOW idle mixture screw initial setting. . . . . . . . . . . . . . . . . . . . . . . . . 1 Turn Carburetor SLOW idle stop screw setting . . . . . . . . . . . . . . . 50 rpm less than throttle control arm SLOW idle stop screw setting Throttle Cable Throttle control arm SLOW idle stop screw setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1175+25 / -50 rpm Throttle control arm FAST idle stop screw setting . . . . . . . . . . . . . . . . . . 3650 ± 75 rpm Air Restriction Indicator Normal restriction vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . .102—178 mm (4—7 in.) Maximum restriction vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381 mm (15 in.) Fuel Tank Check valve opening pressure (maximum) . . . . . . . . . . . . . . . . . . . . . . 3 kPa (0.4 psi) Cooling System: Radiator cap Maximum test pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 kPa (17 psi) Minimum pressure after 15 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 kPa (13 psi) Opening pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83–96 kPa (12–14 psi) Minimum pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 kPa (11 psi) Thermostat Begin-to-open temperature . . . . . . . . . . . . . . . . . . . . . . . approximately 63°C (145°F) Full-open temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . approximately 80°C (176°F) Full-closed temperature . . . . . . . . . . . . . . . . . . . . . . . . . . approximately 63°C (145°F)

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SPECIFICATIONS & INFORMATION

REPAIR SPECIFICACATIONS

REPAIR SPECIFICACATIONS FD440V/501V Crankcase Oil Capacity With Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 L (3.59 pt) Without Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 L (3.20 pt) Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.) Drain Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N•m (204 lb-in.)

Fuel System Carburetor Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (71 lb-in.) Intake Manifold Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (71 lb-in.) Fuel Pump Push Rod Maximum Bend . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) CYLINDER HEAD AND VALVES Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) Rocker Arm Minimum Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.95 mm (0.470 in.) Maximum Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.07 mm (0.475 in.) Adjusting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (79 lb-in.) Push Rod Maximum Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.031 in.) Valves and Springs Minimum Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . 27.30 mm (1.074 in.) Minimum Valve Stem O.D. Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.93 mm (0.194 in.) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.92 mm (0.193 in.) Maximum Valve Guide I.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.06 mm (0.199 in.) Maximum Valve Stem Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.) Standard Valve Seating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.031 in.) Valve Seating Width Tolerance. . . . . . . . . . . . . . . . . . 0.50 - 1.10 mm (0.020 - 0.043 in.) Valve Seat and Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Minimum Valve Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.020 in.) Valve Narrowing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° Cylinder Head Maximum Cylinder Head Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (0.002 in.) Cap Screw Torque In Sequence (Lubricated) Initial Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 N•m (115 lb-in.) Final Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.) Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (150 lb-in.) FLYWHEEL Flywheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 N•m (66 lb-ft) CAMSHAFT AND TAPPETS Camshaft Minimum End Journals O.D.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum Lobe O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum Fuel Pump Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . Maximum Cover Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum Crankcase Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . .

2-6

13.91 mm (0.548 in.) 24.43 mm (0.962 in.) 19.50 mm (0.760 in.) 14.05 mm (0.553 in.) 14.07 mm (0.554 in.)

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REPAIR SPECIFICACATIONS

SPECIFICATIONS & INFORMATION

PISTON, CONNECTING ROD AND CRANKSHAFT Piston Maximum Ring Groove Clearance Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.) Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Measured Maximum Ring End Gap Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.040 in.) Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Measured Minimum Pin O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.98 mm (0.629 in.) Maximum Pin Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.04 mm (0.631 in.) Distance from bottom of piston skirt Height of piston O.D. measurement . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 mm (0.531 in.) Piston O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.950 - 66.965 mm (2.6358 - 2.6364 in.) Piston-to-Cylinder Bore Clearance. . . . . . . . . . 0.015 - 0.150 mm (0.00059 - 0.0059 in.) Connecting Rod Maximum Crankshaft Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . 31.06 mm (1.223 in.) Maximum Piston Pin Bearing I.D.. . . . . . . . . . . . . . . . . . . . . . . . . . 16.05 mm (0.632 in.) End-Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 N•m (106 lb-in.) Crankshaft Minimum Side Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.92 mm (1.178 in.) Minimum Connecting Rod Journal . . . . . . . . . . . . . . . . . . . . . . . . . 30.93 mm (1.218 in.) Maximum T.I.R. (Total Indicated Runout) . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) Plain Bearings Maximum Crankcase and Cover I.D. . . . . . . . . . . . . . . . . . . . . . . . 30.09 mm (1.185 in.) CYLINDER BLOCK Cylinder Bore Standard I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.98 - 67.00 mm (2.637 - 2.638 in.) Maximum I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.06 mm (2.640 in.) Rebore Cylinder Oversize Diameter 0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.46 - 67.48 mm (2.656 - 2.657 in.) LUBRICATION SYSTEM Oil Pump Minimum Rotor Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.92 mm (0.430 in.) Maximum Rotor Shaft Bearing I.D.. . . . . . . . . . . . . . . . . . . . . . . . . 11.07 mm (0.436 in.) Minimum Outer Rotor O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.43 mm (1.592 in.) Maximum Outer Rotor Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . 40.80 mm (1.606 in.) Minimum Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 mm (0.748 in.) GOVERNOR Governor Arm Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (72 lb-in.) IGNITION AND CHARGING SYSTEM See Ignition and Charging Specifications in this Group.

4/7/95

2-7

SPECIFICATIONS & INFORMATION

REPAIR SPECIFICACATIONS

ELECTRIC STARTER See this group for continuity checks. Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.240 in.) Maximum No Load Starter Draw . . . . . . . . . . . . . . . . . . . . . 50 amps at 6000 rpm (min) COOLING SYSTEM Engine Coolant Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 L (2.2 qt) Thermostat Begin Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82°C (180°F) Fully Open Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95°C (203°F) Water Pump Minimum Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.94 mm (0.391 in.) Maximum Pump and Crankcase Housing Bore I.D. . . . . . . . . . . . . 10.09 mm (0.397 in.) Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (70 lb-in.) Crankcase Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.) Over-flow Reservoir Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.)

2-8

4/7/95

REPAIR SPECIFICACATIONS

SPECIFICATIONS & INFORMATION

FD590V Crankcase Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 L (4.44 pt) Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.) Drain Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N•m (204 lb-in.)

FUEL SYSTEM Carburetor Nut Torque (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (71 lb-in.) (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (133 lb-in.) Intake Manifold Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 N•m (53 lb-in.) Fuel Pump Push Rod Maximum Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) CYLINDER HEAD AND VALVES Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.) Rocker Arm Minimum Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.95 mm (0.470 in.) Maximum Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.07 mm (0.475 in.) Adjusting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (79 lb-in.) Push Rod Maximum Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.031 in.) Valves and Springs Minimum Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.70 mm (1.170 in.) Minimum Valve Stem O.D. Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.94 mm (0.234 in.) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.92 mm (0.233 in.) Maximum Valve Guide I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.05 mm (0.238 in.) Maximum Valve Stem Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.) Standard Valve Seating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.031 in.) Valve Seating Width Tolerance. . . . . . . . . . . . . . . . . . 0.50 - 1.10 mm (0.020 - 0.043 in.) Valve Seat and Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Minimum Valve Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.60 mm (0.024 in.) Valve Narrowing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° Cylinder Head Maximum Cylinder Head Flatness . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (0.002 in.) Cap Screw Torque In Sequence (Lubricated) Initial Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 N•m (115 lb-in.) Final Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.) Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (177 lb-in.) FLYWHEEL Flywheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 - 118 N•m (72 - 87 lb-ft)

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SPECIFICATIONS & INFORMATION

REPAIR SPECIFICACATIONS

CAMSHAFT AND TAPPETS Camshaft Minimum End Journals O.D.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum Lobe O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum Fuel Pump Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . Maximum Cover and Crankcase Bearing I.D. . . . . . . . . . . . . . . . .

15.91 mm (0.626 in.) 25.23 mm (0.993 in.) 19.50 mm (0.760 in.) 16.07 mm (0.633 in.)

PISTON, CONNECTING ROD, AND CRANKSHAFT Piston Maximum Ring Groove Clearance Top and Second Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.) Oil Ring Not Measured Maximum Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 mm (0.040 in.) Minimum Pin O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.98 mm (0.668 in.) Maximum Pin Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.04 mm (0.671 in.) Distance from bottom of piston skirt Height of piston O.D. measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 mm (0.433 in.) Piston O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.935 - 73.950 mm (2.9108 - 2.9114 in.) Piston-to-Cylinder Bore Clearance. . . . . . . . . 0.030 - 0.170 mm (0.00118 - 0.00670 in.) Connecting Rod Maximum Crankshaft Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . 34.06 mm (1.341 in.) Maximum Piston Pin Bearing I.D.. . . . . . . . . . . . . . . . . . . . . . . . . . 17.05 mm (0.671 in.) End-Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.) Crankshaft Minimum Side Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.91 mm (1.335 in.) Minimum Connecting Rod Journal . . . . . . . . . . . . . . . . . . . . . . . . . 33.93 mm (1.336 in.) Maximum T.I.R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) Plain Bearings Maximum Crankcase and Cover I.D . . . . . . . . . . . . . . . . . . . . . . . 34.07 mm (1.341 in.) CYLINDER BLOCK Cylinder Bore Standard I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.98 - 74.00 mm (2.915 - 2.916 in.) Maximum I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.07 mm (2.918 in.) Rebore Cylinder Oversize Diameter 0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.46 - 74.48 mm (2.934 - 2.935 in.) LUBRICATION SYSTEM Oil Pump Minimum Rotor Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum Rotor Shaft Bearing I.D.. . . . . . . . . . . . . . . . . . . . . . . . . Minimum Outer Rotor O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum Outer Rotor Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . Minimum Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . .

2 - 10

10.92 mm (0.430 in.) 11.07 mm (0.436 in.) 40.43 mm (1.592 in.) 40.80 mm (1.606 in.) 19.50 mm (0.770 in.)

4/7/95

REPAIR SPECIFICACATIONS

SPECIFICATIONS & INFORMATION

GOVERNOR Governor Arm Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (72 lb-in.) IGNITION AND CHARGING SYSTEM See Ignition and Charging Specifications in this Group. ELECTRIC STARTER See this group for continuity checks. Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.240 in.) Maximum No Load Starter Draw . . . . . . . . . . . . . . . . . . . . . 30 amps at 6000 rpm (min) COOLING SYSTEM Engine Coolant Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.04 L (3.2 qt) Thermostat Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82°C (180°F) Fully Open Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95°C (203°F) Water Pump Minimum Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.94 mm (0.391 in.) Maximum Pump and Crankcase Housing Bore I.D. . . . . . . . . . . . . 10.09 mm (0.397 in.) Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (70 lb-in.) Crankcase Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.) Over-flow Reservoir Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.)

4/7/95

2 - 11

SPECIFICATIONS & INFORMATION

REPAIR SPECIFICACATIONS

FD620D Crankcase Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 L (3.2 pt) Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.) Drain Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N•m (204 lb-in.)

FUEL SYSTEM Carburetor Mounting Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (12 lb-ft) Intake Manifold Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 N•m (53 lb-in.) CYLINDER HEAD AND VALVES Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010 in.) Rocker Arm Minimum Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.95 mm (0.470 in.) Maximum Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.07 mm (0.475 in.) Adjusting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (79 lb-in.) Push Rod Maximum Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.031 in.) Valves and Springs Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.70 mm (1.170 in.) Minimum Valve Stem O.D. Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.94 mm (0.234 in.) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.92 mm (0.233 in.) Maximum Valve Guide I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.05 mm (0.238 in.) Maximum Valve Stem Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.) Standard Valve Seating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.031 in.) Valve Seating Width Tolerance. . . . . . . . . . . . . . . . . . 0.50 - 1.10 mm (0.020 - 0.043 in.) Valve Seat and Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Minimum Valve Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.60 mm (0.024 in.) Valve Narrowing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° Cylinder Head Cylinder Head Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (0.002 in.) Cap Screw Torque In Sequence (Lubricated) Initial Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 N•m (115 lb-in.) Final Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.) Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (177 lb-in.) FLYWHEEL Flywheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 N•m (80 lb-ft) Sheave Half Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.) CAMSHAFT AND TAPPETS Camshaft Minimum End Journals O.D.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum Lobe O.D. Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum Cover and Crankcase Bearing I.D. . . . . . . . . . . . . . . . .

2 - 12

15.91 mm (0.626 in.) 25.21 mm (0.993 in.) 25.46 mm (1.002 in.) 16.07 mm (0.633 in.)

4/7/95

REPAIR SPECIFICACATIONS

SPECIFICATIONS & INFORMATION

PISTON, CONNECTING, AND RODCRANKSHAFT Piston Maximum Ring Groove Clearance Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.14 mm (0.006 in.) Second Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.) Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Measured Maximum Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 mm (0.050 in.) Minimum Pin O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.98 mm (0.668 in.) Maximum Pin Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.04 mm (0.671 in.) Distance from bottom of piston skirt (Area to measure piston O.D.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 mm (0.433 in.) Piston O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.935 - 75.950 mm (2.989 - 2.990 in.) Piston-to-Cylinder Bore Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 - 0.170 mm (0.00118 - 0.00670 in.) Connecting Rod Maximum Crankshaft Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . 34.06 mm (1.341 in.) Maximum Piston Pin Bearing I.D.. . . . . . . . . . . . . . . . . . . . . . . . . . 17.05 mm (0.671 in.) End-Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.) Crankshaft Minimum Side Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.91 mm (1.335 in.) Minimum Connecting Rod Journal . . . . . . . . . . . . . . . . . . . . . . . . . 33.93 mm (1.336 in.) Maximum T.I.R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) Plain Bearings Maximum Crankcase Cover I.D.. . . . . . . . . . . . . . . . . . . . . . . . . . . 34.07 mm (1.341 in.) Maximum Crankcase I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.11 mm (1.343 in.) CYLINDER BLOCK Cylinder Bore Standard I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.98 - 76.00 mm (2.994 - 2.995 in.) Maximum I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.07 mm (2.997 in.) Rebore Cylinder Oversize Diameter 0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.46 - 76.48 mm (3.012 - 3.013 in.) LUBRICATION SYSTEM Oil Pump Minimum Rotor Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum Rotor Shaft Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . Minimum Outer Rotor O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum Outer Rotor Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . Minimum Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . . .

10.92 mm (0.430 in.) 11.07 mm (0.436 in.) 40.43 mm (1.592 in.) 40.80 mm (1.606 in.) 19.50 mm (0.770 in.)

GOVERNOR Governor Arm Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (72 lb-in.) IGNITION AND CHARGING SYSTEM See Ignition and Charging Specifications in this Group.

4/7/95

2 - 13

SPECIFICATIONS & INFORMATION

REPAIR SPECIFICACATIONS

ELECTRIC STARTER See this group for continuity checks. Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.240 in.) Maximum No Load Starter Draw . . . . . . . . . . . . . . . . . . . . . 30 amps at 6000 rpm (min) COOLING SYSTEM Sheeve/Half Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.)

Thermostat Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65°C (148°F) Fully Open Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80°C (176°F) Water Pump Minimum Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.94 mm (0.391 in.) Maximum Pump and Crankcase Housing Bore I.D. . . . . . . . . . . . . 10.09 mm (0.397 in.) Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (70 lb-in.) Crankcase Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)

2 - 14

4/7/95

SPECIFICATIONS & INFORMATION

METRIC TORQUE VALUES

METRIC TORQUE VALUES 4.8

9.8

10.9

4.8

8.8

9.8

10.9

12.9

4.8

8.8

9.8

10.9

12.9

10

5 5

10

10

12.9 12

10 10

10

5

Property Class and Nut Markings

12.9

8.8

12

Property Class and Head Markings

12

Ts1163

Class 4.8

Class 8.8 or 9.8

Lubricateda

Drya

SIZE

Nm

lb-ft

Nm

M6

48

3.5

M8

12

M10

Class 10.9

Lubricateda

Drya

lb-ft

Nm

lb-ft

Nm

6

4.5

9

6.5

8.5

15

11

22

23

17

29

21

M12

40

29

50

M14

63

47

M16

100

M18

Class 12.9

Lubricateda

Drya

Lubricateda

Drya

lb-ft

Nm

lb-ft

Nm

lb-ft

Nm

lb-ft

Nm

lb-ft

11

8.5

13

9.5

17

12

15

11.5

19

14.5

16

28

20

32

24

40

30

37

28

47

35

43

32

55

40

63

47

80

60

75

55

95

70

37

75

55

95

70

110

80

140

105

130

95

165

120

80

60

120

88

150

110

175

130

225

165

205

150

260

109

73

125

92

190

140

240

175

275

200

350

225

320

240

400

300

135

100

175

125

260

195

330

250

375

275

475

350

440

325

560

410

M20

190

140

240

180

375

275

475

350

530

400

675

500

625

460

800

580

M22

260

190

330

250

510

375

650

475

725

540

925

675

850

625

1075

800

M24

330

250

425

310

650

475

825

600

925

675

1150

850

1075

800

1350

1000

M27

490

360

625

450

950

700

1200

875

1350

1000

1700

1250

1600

1150

2000

1500

M30

675

490

850

625

1300

950

1650

1200

1850

1350

2300

1700

2150

1600

2700

2000

M33

900

675

1150

850

1750

1300

2200

1650

2500

1850

3150

2350

2900

2150

3700

2750

M36

1150

850

1450

1075

2250

1650

2850

2100

3200

2350

4050

3000

3750

2750

4750

3500

DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically.

approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value.

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.

a “Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. “Dry” means plain or zinc plated without any lubrication.

Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original. Make sure fasteners threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening.

b

Grade 2 applies for hex cap screws (not hex bolts) up to 152 mm (6-in.) long. Grade 1 applies for hex cap screws over 152 mm (6-in.) long, and for all other types of bolts and screws of any length.

Tighten plastic insert or crimped steel-type lock nuts to 4/7/95

2 - 15

SPECIFICATIONS & INFORMATION GASOLINE SPECIFICATIONS

GASOLINE SPECIFICATIONS

FUEL STORAGE

CAUTION:

Keep fuel in a clean container in a protected area. Water and sediment must bromated before fuel gets to the engine. Do not use deicers to remove water from fuel. Do not depend on fuel filters to remove water.

Handle fuel with care, it is highly flammable. DO NOT refuel machine:

If possible, install a water separator at the storage tank outlet.

c

• Indoors. Always fill fuel tank outdoors. • While you smoke. • When machine is near and open flame or sparks. • When engine is running. STOP engine. • When engine is hot. Allow it to cool.

IMPORTANT: Keep all dirt, scale, water or other foreign material out of fuel. If vehicle is either stored or used during the winter, add TY6295 John Deere Gasoline Storage Stabilizer or an equivalent to the fuel. Follow directions on can.

Help prevent fires: • Fill fuel tank only to bottom of filler neck. • Clean oil, grease and dirt from machine. • Clean up spilled fuel immediately. • Do not store machine with fuel in tank in a building where fumes may reach an open flame or spark. To prevent fire and explosion caused by static electric discharge while you fill tank: • Use approved, non-metal fuel container. • When using a funnel, MAKE SURE it is PLASTIC. • Avoid using a funnel which has a metal screen or filter. IMPORTANT: To avoid engine damage: DO NOT mix oil with gasoline Use only clean oil and fuel Use clean approved containers and funnels. Store oil and fuel in an area protected from dust, moisture and other contamination. Unleaded fuel is recommended because it burns cleaner and leaves less unburned deposits in engine combustion chamber. Regular leaded gasoline with an anti-knock index of 87 or higher may be used.Use of gasohol is acceptable as long as the ethyl alcohol blend does not exceed 11 percent. Unleaded gasohol is preferred over leaded gasohol. Fill fuel tank at end of each day's operation. Fill only to bottom of filler neck.

2 - 16

4/7/95

SPECIFICATIONS & INFORMATION

LUBRICANT SPECIFICATIONS

LUBRICANT SPECIFICATIONS

ENGINE COOLANT

ENGINE OIL Use oil viscosity based on the expected air temperature range during the period between oil changes. The following oil is preferred:

Use ethylene glycol base coolant. These coolants usually have labels stating “For Automobile and Light Duty Service.” These products are also often labeled for use in aluminum engines. Check container label before using. IMPORTANT: To prevent engine damage, DO NOT use pure antifreeze or more than 50% antifreeze in the cooling system. DO NOT mix or add any other type additives to the cooling system.

• John Deere PLUS-4®

Mix approximately 50 percent antifreeze with 50 percent distilled or deionized water. This mixture will provide freeze protection to -340 F (-37 0 C). Certain geographical areas may require lower temperature protection. See the label on your antifreeze container or consult your John Deere dealer to obtain the latest information and recommendations. The recommended antifreeze provides: • Adequate heat transfer. • Corrosion-resistant environment within the cooling system. • Compatibility with cooling system hose and seal material. • Protection during cold and hot weather operations.

SYNTHETIC LUBRICANTS TS1411

Other oils may be used if they meet one of the following: • API Service Classification SG • API Service Classification SF • CCMC Specification G4 Oils meeting Military Specification MIL-L-46167B may be used as arctic oils.

OIL FILTERS

Synthetic lubricants may be used in John Deere equipment if they meet the applicable performance requirements (industry classification and/or military specification) as shown in this group. The recommended temperature limits and service or oil change intervals should be maintained as shown in the operator’s manual. Avoid mixing different brands, grades, or types of oil. Oil manufacturers blend additive in their oils to meet certain specifications and performance requirements. Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance.

Filtration of oils is critical to proper lubrication. Always change filters regularly. Use filters meeting specification.

4/7/95

John

Deere

performance

2 - 17

SPECIFICATIONS & INFORMATION

COMPONENT LOCATION

COMPONENT LOCATION FD440V/501V/590V

Radiator Outlet Hose Air Cleaner Cover

Oil Pressure Switch

Oil Dipstick

Oil Filter Breather Hose Drain Plug Fuel Pump

Control Plate Ignition Coil Water Pump

Cylinder Head

Rocker Arm Cover

Spark Plug Lead

M45816

Right-Hand Side Shown

NOTE: Bare block components are similar between engines, some peripheral components may be different between applications.

2 - 18

4/7/95

SPECIFICATIONS & INFORMATION

COMPONENT LOCATION

COMPONENT LOCATION - FD440V/501V/590V - Continued Radiator Cap

Radiator Screen Overflow Hose

Radiator Inlet Hose Radiator

Fan Housing Thermostat Cover Coolant Temperature Switch

Overflow Reservoir

Cylinder Head

Rocker Arm Cover Spark Plug Lead Ignition Coil Crankcase Starter

Regulator/ Rectifier

Starter Solenoid

Ignition Module M45645

Left-Hand Side Shown

4/7/95

2 - 19

SPECIFICATIONS & INFORMATION

INTERNAL ENGINE COMPONENTS

INTERNAL ENGINE COMPONENTS Air Cleaner Paper Element

Air Cleaner Foam Element

Fan

Valve Seat Intake Valve

Flywheel

Valve Springs

Stator Crankshaft

Valve Cover Crankshaft Gear

Valve Guide Exhaust Valve Water Pump Gear

Oil Pump

Water Pump Impeller Oil Screen

Governor Gear

Governor

Camshaft Gear Camshaft Flyweights

M45646

Side View Cutaway

2 - 20

4/7/95

INTERNAL ENGINE COMPONENTS

SPECIFICATIONS & INFORMATION

INTERNAL ENGINE COMPONENTS - Continued Breather Hose

Carburetor

Rocker Arm Shaft

Throttle Control Plate

Rocker Arm

Breather Cover

Adjusting Screw and Lock Nut

Push Rod Tappet

Camshaft Piston Pin Pulsar Coil

Piston Rings Oil Filter Piston Connecting Rod

Starter Motor Oil Pressure Sensor Stator Starter Solenoid Connecting Rod Cap

Regulator/Rectifier M45647

Top View Cutaway

4/7/95

2 - 21

SPECIFICATIONS & INFORMATION

INTERNAL ENGINE COMPONENTS

ENGINE COMPONENTS - FD620D Coolant Pump Gear

Governor Drive Gear Carburetor

Camshaft Gear

Governor Arm

Muffler Pistons

Fan Belt Drive Crankcase Breather Chamber Rocker Arms

Connecting Rod

Push Rods Oil Filter

Valves

Cylinder Head

Outer Sheave Halve

Tappets

Camshaft

Flywheel Crankshaft Gear Oil Pump Gear

Crankshaft

Cylinder Block

M54274

Cutaway - FD620D

The FD620D engine components are similar to the horizontal shaft engines except for the orientation of the oil pickup screen. Differences of the external components consist of an optional fan drive and a down draft carburetor.

2 - 22

4/7/95

CONTENTS

INTAKE, EXHAUST & BREATHER

CONTENTS Page

INTAKE, EXHAUST & BREATHER AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4/7/95

3-1

INTAKE, EXHAUST & BREATHER

AIR CLEANER

AIR CLEANER FD440V/FD501V/FD590V IMPORTANT: Carefully remove air cleaner cover and elements. Inspect inside paper element and intake passage for signs of dust. If present, replace elements and test engine compression or inspect for damage. Do not clean paper element with solvent or compressed air. Any time air cleaner base is removed, check for free choke operation during reassembly. Air Cleaner Cover Foam Element Wash with detergent and water, Replace if stretched or torn. Oil lightly with engine oil. Squeeze out excess,

Paper Element

Do Not clean. Replace if oily, dirty or damaged in any way or direct light can be seen through paper.

M53973

FD620D Mounting Screws (3)

Use medium strength Thread Lock and Sealer

Breather Hose

Tighten evenly. Foam Element Wash with detergent and water, Replace if stretched or torn. Oil lightly with engine oil. Squeeze out excess.

Paper Element

Do Not clean. Replace if oily, dirty or damaged in any way or direct light can be seen through

3-2

To Air Filter Restriction Indicator

M57331

4/7/95

INTAKE, EXHAUST & BREATHER

INTAKE MANIFOLD

INTAKE MANIFOLD

NOTE: Cracks not visible to the eye may be detected by coating suspected area with a mixture of 25% kerosene and 75% light engine oil. Wipe area dry and immediately apply a coat of zinc oxide dissolved in wood alcohol. If cracks are present, the coating will become discolored at the crack location.

REMOVAL 1. Remove carburetor and governor control panel.

17 N•m (12 lb-ft) Air Horn (If equipped)

INSTALLATION 1. Before installing manifold, install cylinder heads and tighten head bolts in sequence to half the rated torque value. 2. Install intake manifold and tighten bolts in two steps to a final torque of 6 N•m (52 lb-in.). 3. Tighten cylinder head bolts to 21 N•m (15 lb-ft.).

Carburetor See Fuel System for repair 17 N•m (12 lb-ft)

Stud

MUFFLER Gasket Replace

Intake Elbow

NOTE: Muffler design may vary between applications.

Gasket Manifold Bolts 6 N•m (52 lb-in.) Intake Mainiflod Intake Gasket M57355

Side Draft Carburetor Configuation Shown

Nut 6-7.5 N•m (52-69 lb-in.)

IMPORTANT: To prevent warpage, loosen bolts 1/4 turn at a time, in sequence, until all bolts are loose.

5

7

Manifold Bolts Tighten in 3 N•m increments. Final Torque 6 N•m (52 lb-in.) 4

1

3

2

8

6 M46862

Torquing Sequence

2. Visually inspect manifold passages for corrosion, cracks, porous castings or deposits. Clean or replace as necessary.

4/7/95

Lock Washer

Mounting Bolt 14 -19 N•m (10 -13.5 lb-ft)

Gasket Replace Stud 6-7.5 N•m (52-69 lb-in.)

M46434

• Clean exhaust pipe flanges and install new gasket before installing muffler. • Use medium strength, Thread Lock and Sealer on studs and nuts. • Loosely tighten flange nuts. • If equipped with extra supporting brackets, also loosely tighten mounting bolts. • Tighten flange nuts first then mounting bolts.

3-3

INTAKE, EXHAUST & BREATHER BREATHER

BREATHER

REPAIR Inspect reed valve for breakage, hairline cracks or distortion, replace if necessary.

OPERATION The breather controls crankcase pressure, preventing oil from being forced out passed the piston rings, oil seals and gaskets. The reed valve limits air flow out of the crankcase caused by piston movement, then blocks return air flow creating a vacuum in the crankcase. Oil ladden air enters the breather chamber where it is directed through a mase, separating most of the oil from the air. The oil drains back to the crankcase and the air vents back the the intake air in the air cleaner.

• Inspect the backing plate for damage or a rough contact surface, replace if necessary. • Inspect the valve seating surface for damage, repair if necessary. Reed Valve Seating Surface

Backing Plate

Air Vent to Intake M51757

Drain Hole

• breather reed valve tip air gap of 0.2 mm (0.008 in.).

Gasket Reed Valve Back Plate Cover

M54277

3-4

4/7/95

CONTENTS

FUEL SYSTEM & GOVERNOR

CONTENTS Page

FUEL SYSTEM & GOVERNOR CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SIDE DRAFT CARBURETOR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 DOWN DRAFT CARURETOR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 CLEAN AND REBUILD CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 FLOAT LEVEL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

MECHANICAL FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 FUEL PRESSURE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 THROTTLE BODY REPAIR - FD590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 THROTTLE BODY REPAIR - FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4/7/95

4-1

NOTES

4-2

FUEL SYSTEM & GOVERNOR

4/7/95

FUEL SYSTEM & GOVERNOR

CARBURETOR

CARBURETOR SPECIFICATIONS Side Draft: Mounting Stud Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (12 lb-ft) Intake Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (12 lb-ft) Choke & Throttle Plate Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.88 N•m (7.8 lb-in.) Down Draft: Throttle Shaft Retaining Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 N•m (17 lb-in.) Drain Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 N•m (10 lb-in.) Choke &Throttle Valve Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.88 N•m (7.8 lb-in.) Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 N•m (87 lb-in.) Main Jet & Main Air Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 N•m (8.9 lb-in.) Mounting Stud Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (12 lb-ft) Carburetor Repair Kits • Gasket Kit • Jet Kit

Mixture too rich

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Adjust Idle mixture and check engine performance.

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Choke is not completely open. Adjust.

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Inlet needle and seat leaking

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4/7/95

Engine overheats

Engine is hard to start when cold ●

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Choke is not completely shut. Adjust. Clean Carburetor

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Clean under engine shrouding

Loss of power

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Engine speed unstable (surging)

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Mixture too lean Check and clean air cleaner

Spark plug burned white

Engine will not start, plug wet

Spark plug fouled black

Run worse when warm

Black smoky exhaust

Check or Solution

Engine is sluggish

Problem or Symptom

Runs better without air cleaner

TROUBLESHOOTING

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4-3

FUEL SYSTEM & GOVERNOR

CARBURETOR

THEORY OF OPERATION

Choke Operation:

Carburetors operate on the principles that air moving through a tube will speed up with a resulting drop in pressure when it passes through the venturi. The low pressure at the venturi allows normal air pressure in the float bowl to force fuel through the main jet and up into the carburetor throat where it is atomized by the high speed flow of air and carried into the engine.

The choke plate restricts most of the air flow though the carburetor to provide a very fuel rich mixture for starting. Because of the restriction and very low pressure area in carburetor throat, fuel is forced though all ports (main and pilot). Air is mixed with the main air jet and pilot air jets as previously described. The fuel/ air mixture is richer because there is less air flow through the venturi.

Float System: The float and inlet needle valve controls the inlet of fuel into the carburetor. It is continually opening and closings the inlet needle valve to maintains a constant fuel supply and level. Proper level is important because it will effect the ability of atmospheric pressure to force the transfer of fuel through the passages Pilot System:

Fuel Shut-off Solenoid: It’s purpose is to help control engine backfire. When the ignition key is turned on, the solenoid retracts a plunger that was plugging the main jet or access passage to the main jet, and allows fuel to enter main jet or cavity. When the engine is turned off, the fuel shut-off solenoid releases the plunger, closing off fuel flow. This allows the engine to starve for fuel, preventing excess fuel that might have ignited during engine shutdown.

The pilot system meters fuel/air mixture while engine is idling and running under light load. At idle, the throttle plate will be nearly closed. Only the pilot outlet port is uncovered. There is not enough air volume or velocity to draw fuel through the main circuit. Fuel flow is metered by the pilot jet. Some air is also metered by a pilot air jet and allowed to mix with the pilot fuel for better atomization.Some pilot air jets are lock into the correct position with a clip and cap screw.Tis is done to align internal passages. The pilot jet and pilot air jet are not adjustable. The pilot mixture air screw only adjusts the mixture out the pilot outlet and does not effect the transition ports.Each transition port is uncovered as the throttle opens, allowing more fuel flow. Main Jet System: The main circuit functions when the engine is at partial to full throttle (throttle plate full open), moderate to heavy loads. In this condition, air flows very quickly through the venturi, creating a very low pressure area at the end of the main nozzle. Air pressure in the bowl now can push fuel up through the main jet and out the nozzle. At the same time, air is also drawn through the main air jet, into a cavity surrounding the main nozzle called the emulsion tube. Here the fuel is mixed with air bubbles created by the small holes, Raw fuel and air begin atomizing. The main jet and main air jet are not adjustable. Only the main jet can be removed and replaced by a different size to compensate for higher or lower altitude operation. The engine and it’s application determine the size of the main jet used in each carburetor.

4-4

4/7/95

CARBURETOR

FUEL SYSTEM & GOVERNOR

Side Draft Carburetor with Fuel Shut-off Solenoid

Down Draft Carburetor with Fuel Shut-off Solenoid

4/7/95

4-5

FUEL SYSTEM & GOVERNOR

CARBURETOR

SIDE DRAFT CARBURETOR REPAIR

c

CAUTION

Gasoline is extremely flammable. Do not smoke. Always work in a ventilated area away from open flame or spark producing equipment, this includes equipment that utilizes pilot lights. Refer to the illustration and the following notes for disassembly and assembly. Spring

Throttle Shaft Replace carburetor if worn Seal Pilot Jet Note position before removing

Choke Shaft Replace Carburetor if worn Restriction Indicator Fitting Washer Use Thread Sealant Seal Intake Nuts Adapter 17 N•m 12 lb-ft) Bushing Pilot Air Jet

Idle Stop Screw Idle Mixture Screw No damage to tapered end.

Gasket Use Thread Lock & Sealer

Carburetor Body

Choke Plate Main Air Jet

Use Thread Lock & Sealer

Intake Elbow 17 N•m (12 lb-ft)

Needle Replace

Emulsion Tube Main Jet

Vent Hose

Float

Gasket

Gasket Pin Drain Screw

Bowl Screw Intake Manifold

M56705

4-6

4/7/95

FUEL SYSTEM & GOVERNOR

CARBURETOR

DOWN DRAFT CARURETOR REPAIR Refer to the illustration and the following notes for disassembly and assembly. Air Horn (If equipped)

O-Ring

Cap Screws 2.9 N•m (26 lb-in.)

Choke Plate

Collars

Choke Shaft Gasket Needle Valve Float High Altitude Main Jet

Float Pin J Pilot Jet Carburetor Body

Fuel Shut-off Solenoid (If Equipped) Washer Main Jet

Seal

Springs

Retainer

Drain Screw Idle Mixture Screw Low Idle Screw Throttle Plate

4/7/95

Throttle Shaft

2 N•m (17 lb-in.)

Spring M57347

4-7

FUEL SYSTEM & GOVERNOR

CARBURETOR

CLEAN AND REBUILD CARBURETOR

FLOAT LEVEL ADJUSTMENT

There are a n umber of plates or boll plugs on/in the carburetor that should not be removed.

NOTE: Plastic floats are non-adjustable.

• Turn the idle mixture screw in and note the number of turns required to lightly seat it before removing it. NOTE: If all rubber or plastic parts cannot be removed for cleaning, use a solvent, with a high flash point, that will not damage these parts when cleaning. • Remove rubber or plastic parts from the carburetor. Immerse all the carburetor metal parts in a carburetor cleaning solution. • Rinse the parts in water and dry with compressed air, do not use rags or paper to dry parts. Lint can plug the tiny passages in the carburetor. • Inspect the carburetor body for damage. Ensure the sealing surfaces and flanges are smooth and free of nicks and burrs. • Turn the idle mixture screw in until lightly seated and back it out the same number of turns counted during disassembly. • Install the choke valve with the metering hole towards the fuel inlet joint of the carburetor. • Ensure the float pin extends the same distance on both sides of the float hinge bracket when reassembling the carburetor. • Ensure the throttle and choke valves move freely and that the shaft bosses are not elongated or worn. If shaft bosses have any of these conditions, replace the carburetor. • Inspect the inlet needle for wear or damage. The tip should be smooth, without any grooves, scratches or tears. If worn or damaged, replace the float assembly and carburetor body as a set. • Inspect the idle mixture screw for wear or damage, replace it if necessary.

4-8

Tap

Float

Mating Surface Air Horn

Needle

GOOD

REPLACE

M57333

1. Hold air horn upside down at eye level with float assembly installed. 2. Gently support float with a finger and lower it slowly until the float arm tab just touches the float valve needle. 3. The float lower surface should be parallel with the body mating surface. 4. If necessary, bend float arm tab to adjust float level.

4/7/95

FUEL SYSTEM & GOVERNOR

MECHANICAL FUEL PUMP

MECHANICAL FUEL PUMP

REPAIR

THEORY OF OPERATION Function: Transfer fuel from the fuel tank to the carburetor. Theory of Operation: From Tank

Inlet Chamber Outlet Chamber

To Carburetor

Fuel Pump

Outlet Valve

M51693

Inlet Valve

Plunger

Disconnect fuel line and remove fuel pump and rod.

Diaphragm Spring

M49793

Gasket

The fuel pump is a mechanical drive type unit. A cam on the camshaft of the engine moves actuating plunger. This plunger moves pivot arm which is connected to diaphragm. A spring is also connected to the diaphragm. As the contact point of the plunger on the cam changes from the base to the tip during rotation, the plunger moves outward. This rotates the pivot arm and pulls the diaphragm downward increasing the volume of the pump chamber. This creates a low pressure area and fuel is drawn in from the fuel tank past inlet valve. When the contact point of the plunger changes from the tip to the base on the plunger moves inward and the pivot arm rotate the opposite direction. This allows the spring to push the diaphragm upward and reduce the volume in the pump chamber. Fuel is forced out of the pump chamber past outlet valve to the carburetor. The maximum pressure that the pump can develop controlled by the strength of the spring. This design prevents over pressurizing the fuel being delivered the carburetor.

4/7/95

Push Rod

Insulator

Cap Screw 14 -19 N•m (10 - 13 lb-ft)

M57334

Inspect pump and insulator for wear or damage. Replace as necessary. Check push rod for bend using V-blocks and a dial indicator. Install push rod, insulator and fuel pump. Pump Push Rod Specifications Maximum Bend. . . . . . . . . . . . . . 0.05 mm (0.002 in.)

4-9

FUEL SYSTEM & GOVERNOR

GOVERNOR

GOVERNOR THEORY OF OPERATION IMPORTANT: Do not remove flyweight assembly or shaft unless damaged. Removal damages the assembly.

Sleeve Flyweight Assembly Do Not remove unless damaged. Thrust Washer

Link and Spring

Inner Flange

Governor Arm Shaft

32.2 - 32.8 mm (1.267 - 1.291 in.)

Groove

Oil Seal Lips toward engine. Press in 1.0 mm (0.04 in.) below crankcase surfaces.

Governor Shaft

Governor Spring

Projections

Shaft Arm

Theory of Operation: The governor controls engine speed. Governed engine speed is a balance between governor spring tension, set by the throttle control, and actual engine speed, countered by centrifugal force of the governor flyweights. As tension is applied to governor spring, governor arm opens carburetor throttle shaft, increasing engine rpm. As engine speed increases, flyweight assembly, driven by the crankshaft, pushes on governor shaft, rotating governor arm, closing throttle shaft, reducing rpm.

REPAIR 1. Remove camshaft 2. Use two suitable pry-bars to pry flyweights assembly from shaft. Do Not damage crankcase sealing surfaces. 3. Unscrew governor arm clamp nut and remove

4 - 10

Throttle Shaft

Crankcase

Sleeve

Clamp Nut 7.8 N•m (69 lb-in.) M57332

governor arm. 4. Turn governor shaft 1/4 turn clockwise to remove shaft. 5. Replace shaft seal. Press in to dimensions, 6. Install governor shaft by properly positioning it between the two projections on crankcase. NOTE: Install sleeve into governor and install as an assembly. 7. Push assembly onto shaft until it snaps into place. Check assembly for freedom of movement 8. Install governor arm loose in governor shaft. 9. Hold top of governor arm counterclockwise to open throttle plate. 10. Turn governor shaft fully counterclockwise to end of its travel. Check dimension from arm to end of shaft. 11. Tighten arm clamp nut. 4/7/95

FUEL SYSTEM & GOVERNOR

FUEL INJECTION SYSTEM

FUEL INJECTION SYSTEM

all sensors. NOTE: For more information on fuel injection testing, see the appropriate vehicle technical manual.

THEORY OF OPERATION The fuel injected engines uses a digital fuel injection system to control fuel delivery to the injector. Throttle Body

FUEL INJECTOR

Fuel Pressure Regulator Fuel Injection Module

THEORY OF OPERATION Function: Injects fuel into the throttle body at the correct time and duration.

Throttle Sensor Injector

FD590V Shown The following sensors and circuits monitor engine operating conditions. • throttle sensor (FD590V) • air temperature sensor • coolant temperature sensor • starter voltage circuit • engine speed circuit • battery voltage circuit • altitude compensation (Optional on FD590V) These sensors send digital signals to a computer in the fuel injection module. The computer processes these signals and determines the correct amount of fuel to inject to match the present engine operating conditions. A fuel control circuit that consists of a fuel pump and fuel pump relay are also controlled by the injection module computer to provide the correct fuel delivery. Fuel system pressure is controlled by the fuel pressure regulator. The FD620D uses a injection system that is similar in operation to of that of the FD590V with the following differences. • There is an additional air pressure sensor to compensate for altitude. • The ignition module is combined with the fuel injection module so there is only one module. • All the sensors are used to help adjust engine timing, unlike the FD590V where only the engine speed effected timing. • Throttle sensor is no longer used. Engine speed is sensed by the pulser • Only one pulser is used. It controls ignition timing, injection timing and engine speed. The flywheel has four tabs that are used by the single pulser. • This injection system has self-diagnosis that checks

4/7/95

Electrical Terminal

Air Temperature Sensor M70805

Fuel Inlet Spring

Filter

Solenoid Core

Valve

Nozzle Fuel Outlet

M45335

Theory of Operation: The fuel injector is a solenoid operated type valve with single point injection. Fuel is injected into the throttle body when the solenoid is energized by the computer. The amount of fuel injected depends on the length of time the injector valve is open and on fuel pressure. High pressure fuel from the fuel pump flows through filter to the inlet passage. High pressure fuel also flows out the outlet passage to the pressure regulator. The pressure regulator maintains the correct fuel pressure needed for injection. When the solenoid is energized, the solenoid core pulls the valve open against spring tension. High pressure fuel is injected in the throttle body through the nozzle. After a precise amount of fuel is injected, the computer de-energizes the solenoid. Spring tension closes valve guickly to prevent additional leakage.

4 - 11

FUEL SYSTEM & GOVERNOR

FUEL INJECTOR

REPAIR

FUEL PRESSURE REGULATOR

NOTE: See electrical system for electrical tests.

THEORY OF OPERATION

IMPORTANT: Do not drive against tip. Plastic cover can crack and nozzle will be damaged. Do not drop injector.

Function:

O-rings Replace

Maintains a constant differential in pressure between fuel pressure at the injector and air pressure in the throttle body.Therefore, the amount of fuel injected is determined by the opening time of the injector. Spring To Throttle Body

Screen Clean

M48181

Diaphragm

Spring Chamber

Valve Support

Valve 1. Remove injector retainer. Grip end of injector, twist and pull.

Fuel Chamber Inlet From Injector

IMPORTANT: Always install new o-rings on injector when injector is removed. 2. Replace injector o-rings and clean fuel screen. 3. Lubricate o-rings with clean engine oil. 4. Install injector in the same orientation as removed. Return to Tank

M44227

Theory of Operation: The pressure regulator is an overflow type regulator. The spring chamber is connected to the throttle boby to insure that they are operating at the same air pressure. High pressure fuel from the injector flows to the pressure regulator inlet and fills the fuel chamber. A hose from the vacuum inlet is connected to the intake manifold. This allows the air pressure in the spring chamber and intake manifold to be equal. When intake manifold vacuum increases, the spring chamber vacuum also increases and overcomes spring tension allowing the diaphragm to move upward. With the valve connected to the diaphragm, the valve moves upward and allows more fuel to flow out the outlet and return to the fuel tank. This lowers the fuel pressure. As intake manifold vacuum decreases, the spring chamber vacuum decreases and the spring returns the diaphragm to the original position. The valve restricts fuel flow to return and fuel pressure increases.

4 - 12

4/7/95

FUEL SYSTEM & GOVERNOR

THROTTLE BODY

REPAIR

Replace regulator if defective. Install new o-ring on regulator inlet and install regulator.

IMPORTANT: Relieve fuel disconnecting fuel line.

pressure

before

Remove fuel lines, vacuum line and regulator.

NOTE:

Valve will not move without maximum fuel pressure on inlet.

THROTTLE BODY THEORY OF OPERATION NOTE: The throttle body and fuel pressure regulator for both the FD590 and FD620 work under the same principles.

Regulator

Function: Injects and atomizes the fuel into the intake air for the proper combustion.

M57358

FD590V Fuel Regulator

Throttle Body Regulator

Throttle Sensor

Fuel Inlet

Injector M57359

Fuel Pressure Regulator

FD620D Fuel Regulator

Return to Tank

Test Regulator:

M57361

FD590D Throttle Body

Apply vacuum to vaccum port of regulator. Regulator must hold vaccum.

Operation: An electric fuel pump, controled by the computer, supplies fuel to the inlet of the throttle body to the injector. The fuel pressure regulator holds the fuel under pressure in the injector. The computer recieves signals from the throttle sensor and other sensors then controls the time the injector is open. The injector injects the atomized into the throat of the throttle body. Excess fuel not used by the injector flows through the pressure regulator back to the fuel tank.

O-ring

The FD620 has an extra passage in the throttle body the allows for a means to relieve the fuel pressure in the fuel lines before any work is done on the system. M57360

4/7/95

4 - 13

FUEL SYSTEM & GOVERNOR

Throttle Body

Injector

THROTTLE BODY

Regulator

4. Mark position of throttle sensor before removal. This will aid in obtaining approximate idle speed when reassembled. 5. Remove throttle plate and throttle shaft only if there is evidence of wear.

Fuel Inlet

NOTE: Some individual components can be replaced without removing throttle body. Disassemble throttle body only if necessary. Such as: fuel leakage, or component malfunction. Remove regulator and temperature sensor. Fuel Return to Tank Fuel Pressure Relief Plug

M57362

FD620 Throttle Body

Throttle Body Throttle Sensor

THROTTLE BODY REPAIR - FD590V

Throttle Shaft

Remove Throttle Body Cap Screws

Throttle Plate

Injector

Pressure Regulator O-Ring

Retainer Air Temperature Sensor

Return

Stud & Nut (2) Injector

M48180

6. Use thread Lock and Sealer on throttle plate screws. 7. Assemble all parts. Install new O-rings and gaskets. 8. Install throttle body and connect governor linkage. Tighten nuts and air shrouding cap screws. 9. Connect throttle cable and all hoses.

Fuel Inlet M48179

THROTTLE BODY REPAIR - FD620D

1. Disconnect: • Fuel inlet hose • Fuel Return Hose • Injector • Breather Hose • Throttle Cable Close openings using caps and plugs. 2. Remove cap screws from air shrouding and throttle body retaining nuts. 3. Disconnect governor linkage as throttle body is being removed.

4 - 14

M57363

4/7/95

FUEL SYSTEM & GOVERNOR

THROTTLE BODY

c

CAUTION

Relieve fuel pressure before removing any fuel line or components. Loosen Fuel Pressure Relief Valve Plug. Do not remove throttle shaft unless it appears to be worn or damaged. If throttle shaft is worn, check throttle body bushing. If worn, replace throttle body. The throttle plate must be perfectly centered in bore when closed. It must also operate freely when plate screws are tightened.

O-ring Seal Replace if damaged.

Shaft Retainer 2 N•m (17 lb-in.)

Nut 17 N•m (12 lb-ft)

Throttle Shaft

Seal Install lips out Throttle Plate

Injector Cover

Plate Screw Use Thread Lock 0.8 N•m (8 lb-in.)

Cover Cap Screws

Tighten evenly. Spring Injector Twist and pull to remove. Clean screen. Lubricate o-rings with engine oil. Stud(2)

Low Idle Stop Screw

Throttle Body Fuel Regulator

O-rings

Fuel Pressure Relief Plug 15 N•m (133 lb-in.)

Gasket Replace

M57338

4/7/95

4 - 15

FUEL SYSTEM & GOVERNOR

4 - 16

THROTTLE BODY

4/7/95

CONTENTS

CYLINDER HEAD & VALVES

CONTENTS Page

CYLINDER HEAD & VALVES SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

HEAD AND VALVE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 VALVE, VALVE SEAT AND GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 VALVE SPRING FREE LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 PUSH ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4/7/95

5-1

NOTES

5-2

CYLINDER HEAD & VALVES

4/7/95

SPECIFICATIONS

CYLINDER HEAD & VALVES

SPECIFICATIONS Cylinder Head Compression (Min.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1171 kPa (170 psi) Cylinder Head Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (.002 in.) Cap Screw Torque In Sequence Initial Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 N•m (115 lb-in.) Final Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.) Spark Plug Torque FD440V//FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N•m (150 lb-in.) FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (177 lb-in.) Rocker Arm Minimum Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.95 mm (0.470 in.) Maximum Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.07 mm (0.475 in.) Adjusting Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 N•m (79 lb-in.) Push Rod Maximum Runnout (bend) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm (0.03 in.) Valves and Springs Valve Clearance FD440V/FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (.010 in.) Spring Free Length FD440V/FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.30 mm (1.074 in.) FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.70 mm (1.170 in.) Minimum Valve Stem O.D. Intake FD440V/FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.93 mm (0.194 in.) FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.94 mm (0.234 in.) Exhaust FD440V/FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.92 mm (0.193 in.) FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.92 mm (0.233 in.) Maximum Valve Guide I.D. FD440V/FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.06 mm (0.199 in.) FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.05 mm (0.238 in.) Maximum Valve Stem Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.) Standard Valve Seating Surface . . . . . . . . . . . . . . . . . . . . . 0.5 -1.10 mm (.020-.043 in.) Valve Seating Width Tolerance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 mm (0.08 in.) Valve Seat and Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45o Minimum Valve Margin FD440V/FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.020 in.) FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.60 mm (0.024 in.) Valve Narrowing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30o

4/7/95

5-3

CYLINDER HEAD & VALVES

CYLINDER HEAD

CYLINDER HEAD

CLEANING AND INSPECTION

REMOVAL

NOTE: Use tools that will not gouge or damage the cylinder head.

IMPORTANT: Loosen cylinder head bolts 1/4 turn at a time, in the sequence shown, to avoid warping the cylinder head Mark position of all valve train parts so they can be reinstalled in their original position.

2

1. Scrape heads to remove carbon deposits or use a de-carbonizing agent. Clean head with a suitable solvent and dry with compressed air. 2. Lay a straight edge along the sealing surface of head and measure warpage with a thickness gauge at several different points. If warpage exceeds service limit, repair or replace cylinder head. 3. Check cylinder head for cracks. 4. Apply clean engine oil to all contact surfaces and assemble cylinder head.

4 5

1

3 Special Bolt M46437

HEAD AND VALVE COMPONENTS Valve Cover Circlip

Gasket Replace

Rocker Arm Shaft Minimum Diameter: 11.95 mm (0.470 IN.)

Top Retainer Cover Cap Screws

Seals Replace

Keepers

Head Bolts 21 N•m (15 lb-ft)

Springs Check Free Length Bottom Retainer

Exhaust Valve

Cylinder Head Warp(max):0.06 mm (0.002 in.) Lock Nut 9 N•m (79 lb-in.) Adjuster Screw

Head Gasket Intake Valve Guide Pin Rocker Arm Minimum I.D.:12.074 mm (0.4754 in.) M57335

5-4

4/7/95

CYLINDER HEAD & VALVES

VALVE, VALVE SEAT AND GUIDE

VALVE, VALVE SEAT AND GUIDE

• Valve guides are not replaceable. If worn, replace head. • If grinding the valve and valve seat is necessary, follow tool manufacturer’s instructions carefully. • Lap valves after grinding with lapping compound and recheck valve seating surface for correct width and evenness of seating pattern.

INSPECTION A

. 45° B

45°

Correct Seat Position

C

Seat Too High

Seat Too Deep M18615

• D

M57341

A - Valve Margin (Min.) FD440V/FD501V . . . . . . . . . . . . . 0.50 mm (0.020 in.) FD590v/FD620D . . . . . . . . . . . . . . 0.6 mm (0.024 in.) B - Valve Seating Width . . . . . . . . . . . . . . . . . . . 0.5 - 1.1 mm (0.02 - 0.043 in.) C - Valve Stem Diameter (Min.) Intake:

FD440V/FD501V . . . . . . . . . . . . . 4.93 mm (0.194 in.) FD590V/FD620D . . . . . . . . . . . . . 5.94 mm (0.234 in.) Exhaust:

If seats are warped or distorted beyond reconditioning, replace cylinder head. • Check valve seating pattern for correct width and evenness all the way around. • Clean and measure valve stem at three points along length of stem.

VALVE SPRING FREE LENGTH • Inspect valve spring for pitting, rust and burrs. FREE LENGTH SPECIFICATIONS (MIN) FD440/501V . . . . . . . . . . . . . . . . 27.30 mm (1.074 in.) FD590V/FD620D . . . . . . . . . . . 29.70 mm (1.170 in.))

FD440V/FD501V . . . . . . . . . . . . . 4.92 mm (0.193 in.) FD590V/FD620D . . . . . . . . . . . . . 5.92 mm (0.233 in.) Intake: . . . . . . . . . . . . . . . . . . . 5.945 mm (0.2341 in.) Exhaust: . . . . . . . . . . . . . . . . . 5.925 mm (0.2332 in.) D - Guide I.D. (Max.) FD440V/FD501V . . . . . . . . . . . . . 5.06 mm (0.199 in.) FD590V/FD620D . . . . . . . . . . . . . 6.05 mm (0.238 in.) M50036

Valve Stem Run out (Max.) . . . . 0.05 mm (0.002 in.)

4/7/95

5-5

CYLINDER HEAD & VALVES

VALVE, VALVE SEAT AND GUIDE

PUSH ROD INSPECTION Push Rod Maximum run-out : 0.8 mm (0.03 in.)

M50044

INSTALLATION IMPORTANT: Handle head gaskets carefully to avoid removing the sealing agents from the surface during handling. Use a torque wrench when tightening cylinder head bolts in sequence shown. NOTE: For easier assembly turn flywheel until cam lobes are at their lowest position. Install the push-rods in their original positions. This will allow head to be installed without compressing valve springs. Torque should be applied in 3 N•m (27 lb-in.) increments. • Tighten cylinder head bolts to half the required torque. • Install manifold before applying a final torque of 21 N•m (186 lb-in.). • Adjust Valve Clearance.

2

4 5 1 3 Special Bolt M46437

5-6

4/7/95

CYLINDER BLOCK, PISTONS & RODS

CONTENTS

CONTENTS Page

CYLINDER BLOCK, PISTONS & RODS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 FD440V/FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 FD590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 REMOVE PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 INSPECT REPLACE CRANKSHAFT PLAIN BEARINGS . . . . . . . . . . . . . . . . . . . 8 REPLACE CRANKSHAFT JOURNAL BUSHING AND SEALS . . . . . . . . . . . . . . . 9 INSPECT BLOCK CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 DEGLAZE CYLINDER BORE 10 REBORE CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REMOVE AND INSTALL PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 CHECK PISTON RING END GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSPECT PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 INSPECT CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 ASSEMBLE CONNECTING ROD AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . 14

4/7/95

6-1

NOTES

6 -2

CYLINDER BLOCK, PISTONS & RODS

4/7/95

SPECIFICATIONS

CYLINDER BLOCK, PISTONS & RODS

SPECIFICATIONS FD440V/FD501V CYLINDER BLOCK Cylinder Bore Standard I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.98 - 67.00 mm (2.637 - 2.638 in.) Maximum I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.06 mm (2.640 in.)

Rebore Cylinder Oversize Diameter 0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.46 - 67.48 mm (2.656 - 2.657 in.) Plain Bearings Maximum Crankcase and Cover I.D. . . . . . . . . . . . . . . . . . . . . . . . 30.09 mm (1.185 in.) Piston Maximum Ring Groove Clearance Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.) Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Measured Maximum Ring End Gap Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.040 in.) Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Measured Minimum Pin O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.98 mm (0.629 in.) Maximum Pin Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.04 mm (0.631 in.) Distance from bottom of piston skirt Height of piston O.D. measurement . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 mm (0.531 in.) Piston O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.950 - 66.965 mm (2.6358 - 2.6364 in.) Piston-to-Cylinder Bore Clearance. . . . . . . . . . 0.015 - 0.150 mm (0.00059 - 0.0059 in.) Connecting Rod Maximum Crankshaft Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . 31.06 mm (1.223 in.) Maximum Piston Pin Bearing I.D.. . . . . . . . . . . . . . . . . . . . . . . . . . 16.05 mm (0.632 in.) End-Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 N•m (106 lb-in.)

4/7/95

6-3

CYLINDER BLOCK, PISTONS & RODS

SPECIFICATIONS

FD590V CYLINDER BLOCK Cylinder Bore Standard I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.98 - 74.00 mm (2.915 - 2.916 in.) Maximum I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.07 mm (2.918 in.) Rebore Cylinder Oversize Diameter 0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.46±74.48 mm (2.934±2.935 in.) Plain Bearings Maximum Crankcase and Cover I.D . . . . . . . . . . . . . . . . . . . . . . . 34.07 mm (1.341 in.) Piston Maximum Ring Groove Clearance Top and Second Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.) Oil Ring Not Measured Maximum Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 mm (0.040 in.) Minimum Pin O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.98 mm (0.668 in.) Maximum Pin Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.04 mm (0.671 in.) Distance from bottom of piston skirt Height of piston O.D. measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 mm (0.433 in.) Piston O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.935 - 73.950 mm (2.9108 - 2.9114 in.) Piston-to-Cylinder Bore Clearance . . . . . . . . 0.030 - 0.170 mm (0.00118 - 0.00670 in.) Connecting Rod Maximum Crankshaft Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . 34.06 mm (1.341 in.) Maximum Piston Pin Bearing I.D.. . . . . . . . . . . . . . . . . . . . . . . . . . 17.05 mm (0.671 in.) End-Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)

6-4

4/7/95

SPECIFICATIONS

CYLINDER BLOCK, PISTONS & RODS

FD620D CYLINDER BLOCK Cylinder Bore Standard I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.98 - 76.00 mm (2.994 - 2.995 in.) Maximum I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.07 mm (2.997 in.) Rebore Cylinder Oversize Diameter 0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.46 - 76.48 mm (3.012 - 3.013 in.) Piston Maximum Ring Groove Clearance Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.14 mm (0.006 in.) Second Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.) Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Measured Maximum Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 mm (0.050 in.) Minimum Pin O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.98 mm (0.668 in.) Maximum Pin Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.04 mm (0.671 in.) Distance from bottom of piston skirt (Area to measure piston O.D.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 mm (0.433 in.) Piston O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.935 - 75.950 mm (2.989 - 2.990 in.) Piston-to-Cylinder Bore Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 - 0.170 mm (0.00118 - 0.00670 in.) Connecting Rod Maximum Crankshaft Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . 34.06 mm (1.341 in.) Maximum Piston Pin Bearing I.D.. . . . . . . . . . . . . . . . . . . . . . . . . . 17.05 mm (0.671 in.) End-Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.) Plain Bearings

Maximum Crankcase Cover I.D.. . . . . . . . . . . . . . . . . . . . . 34.07 mm (1.341 in.) Maximum Crankcase I.D. . . . . . . . . . . . . . . . . . . . . . . . . . 34.11 mm (1.343 in.)

4/7/95

6-5

CYLINDER BLOCK, PISTONS & RODS

REPAIR

REPAIR CRANKCASE DISASSEMBLY 1. Drain crankcase. 2. Remove water pump. NOTE: Crankcase is pinned by oil filter and opposite side. Do not force cover.

5

6

7

4 3

1

2

1

3

2

4

5

6 M53974

FD440V/FD501V

8

M517207

FD590V/FD620D

3. Remove crankcase cover and gasket..

6-6

4/7/95

CYLINDER BLOCK, PISTONS & RODS

REPAIR

COMPONENTS

Fan Drive Coupling

15 N•m (130 lb-in)

Nut

Gasket FD440/501: 90 N•m (66 lb-ft) FD590/620: 110 N•m (80 lb-ft)

Washer Flywheel

Stator

Oil Pump Assembly Lifters

Breather Assembly Oil Pressure Sensor

Governor Flyweight Seal Bushing

Oil Filter

Oil Pick-up Screen Camshaft

Piston Rings Cylinder Block Crankshaft

Crankcase Seal

Piston Piston Pin

Gear Pin Crankcase Cap Screws 21 N•m (186 lb-in.) Crankshaft Gear

Rod Cap

FD440/501V: 12 N•m (106 lb-in.) FD590/620: 21N•m (186 lb-in. )

4/7/95

M57345

6-7

CYLINDER BLOCK, PISTONS & RODS REMOVE PISTONS

REPAIR

INSPECT & REPLACE CRANKSHAFT PLAIN BEARINGS

Match Marks

Raised Letters (MADE IN JAPAN)

Flywheel Side

Large Chamfers

M46447

NOTE: Note location of the arrow match mark on the piston head in relation to “Made in Japan” on the connecting rod. No. 1 piston is opposite no.2. Keep parts together as a set. 1. Turn the crankshaft to expose the connecting rod end caps. Mark the end caps for reassembly in the same position as removed. 2. Remove carbon and/or ridge from the top of the cylinder bore with a suitable ridge remover and remove the piston and connecting rod through the top of the cylinder bore.

6-8

M50072

Measure crankshaft bearings in crankcase and crankcase cover. Replace block, cover or shells, if equipped, if diameter is greater than specifications. (See this group.)

BEARING I.D. SPECIFICATIONS (MAX) Crankcase and Cover FD440/501V . . . . . . . . . . . . . . FD590V . . . . . . . . . . . . . . . . . FD620D Crankcase Cover . . . . . . . . . Crankcase . . . . . . . . . . . . . .

30.09 mm (1.185 in.) 34.07 mm (1.341 in.) 34.07 mm (1.341 in.) 34.11 mm (1.343 in.)

4/7/95

CYLINDER BLOCK, PISTONS & RODS

REPAIR

REPLACE CRANKSHAFT JOURNAL BUSHING AND SEALS

To Design a Bushing Tool

1. Place crankcase on bench with oil seal side up.

A

B

C M46456

M44227

Crankcase Seal

2. Remove oil seal. NOTE: Do not re-use oil seal. Replace with new.

Bushing Tool Dimensions (A) . . . . . . . . . . . . . . . . . . . . . . . . 40 mm (1.575 in.) (B) . . . . . . . . . . . . . . . . . . . . . . . . 26 mm (1.024 in.) (C) . . . . . . . . . . . . . . . . . . . . . . 33.8 mm (1.331 in.) 3. Remove bearing shell using a bushing, bearing and seal driver set and press. 4. Apply a light coat of oil on outside diameter of new bearing shell. 5. Install new bearing shell flush with crankcase flange surface.

Bushing Tool Flange Surface

Flange Surface

Spring Loaded Lip

New Bushing Dust Lip

Lip Seal High Temperature Grease M46445

Support Block

M46455

• The service bushing is to be reinstalled using a bushing tool as shown. • Coat the bushing and flange surface with a light film of oil, Press in the new bushing flush with the flange surface. • No finish reaming is required

4/7/95

6. Remove crankshaft oil seal and press in a new seal with spring loaded lip towards inside of the engine and outside edge of seal flush with flange surface. 7. Pack space between seal lip and dust lip with high temperature grease. 8. Install new seal with flange flush with case.

6-9

CYLINDER BLOCK, PISTONS & RODS

REPAIR

INSPECT BLOCK CYLINDERS

DEGLAZE CYLINDER BORE

1. Clean and check block for cracks. 2. Cracks not visible to the eye may be detected by coating the suspected area with mixture of 25 percent kerosene and 75 percent light engine oil. 3. Wipe area dry and immediately apply coating of zinc oxide dissolved in wood alcohol. If crack is present, coating becomes discolored at the defective area. Replace block if any cracks are found.

1. Deglaze cylinder bore using a rigid hone with a 220 to 300 grit stone. 2. Use hone as instructed by manufacturer to obtain 45° crosshatch pattern as shown. IMPORTANT: Do not use gasoline, kerosene, or commercial solvents to clean cylinder bores. Solvents will not remove all abrasives from cylinder walls. 3. Clean cylinder walls using clean white rags and water. Continue to clean cylinder until white rags show no discoloration.

REBORE CYLINDER BLOCK IMPORTANT: Check stone for wear or damage. Use correct stone for the job. M54745

4. Measure cylinder bore parallel with crankshaft and right angles to crankshaft at top and bottom of ring travel. 5. If cylinder bore exceeds wear limit, replace cylinder block or rebore cylinder.

NOTE: The cylinder block can be rebored to use 0.50 ( 0.020 ) oversize pistons and rings. Have a reliable repair shop rebore the block, or use a drill press and honing tool.

45° - 60°

NOTE: Before reboring, check availablity of oversize piston and rings. They must be installed. CYLINDER BORE SPECIFICATIONS Standard Wear Limit FD440V FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.98 - 67.00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . (2.637 - 2.638 in.) Wear Limit. . . . . . . . . . . . . . . 67.06 mm (2.640 in.) FD590V . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.98 - 74.00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . (2.915 - 2.916 in.) Wear Limit . . . . . . . . . . . . . . . 74.07 mm (2.918 in.) FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.98 - 76.00 mm . . . . . . . . . . . . . . . . . . . . . . . . . (2.9913 - 2.9921 in.) Wear Limit . . . . . . . . . . . . . . . 76.07 mm (2.997 in.)

6 - 10

M82412a

1. Rebore cylinder with a honing tool to initial and final bore specifications. 2. Align center of bore to press center. Set the press to operate from 200±250 rpm. 3. Lower and raise hone until ends extend 20±25 mm (0.75±1.0 in.) past ends of cylinder. 4. Turn adjusting nut on hone until stones contact cylinder wall at narrowest point.

4/7/95

REPAIR

CYLINDER BLOCK, PISTONS & RODS

5. Coat inside of cylinder with honing oil. Turn hone by hand. If you cannot turn it, hone is too tight. 6. Start drill press. Move hone up and down in cylinder approximately 20 times per minute to get 40 -60° cross-hatch pattern. 7. Check cylinder diameter regularly during honing. Stop press before measuring. Remove hone from cylinder.

First Compression Ring Second Compression Ring

Side Rails

CYLINDER INITIAL BORE SPECIFICATIONS Piston Oversize: 0.50 mm (0.020 in.) FD440V/FD501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.46 - 67.48 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (2.656 -2.657 in. ) FD590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.46 - 74.48 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . (2.934 - 2.935 in. ) FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.46 - 76.48 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . (3.012 - 3.013 in. ) 8. Hone the cylinder an additional 0.028 - 0.030 mm (0.0011 - 0.0012 in.) for final bore specifications. This allows for 0.020 mm (0.0008 in.) shrinkage when cylinder cools.

Spacer

M80429

3. Install top compression ring and second ring, if equipped, with R or NPR mark facing up. Rings should turn freely in grooves. 4. Oil ring: Install spacer, then side rails. Put side rail end gaps 180° apart.

CHECK PISTON RING END GAP Before installing rings on piston, check end gap in cylinder bore.

IMPORTANT: DO NOT use gasoline or commercial solvents to clean cylinder bores. Solvents will not remove metal particles produced during honing. 9. Clean the cylinder thoroughly using soap, warm water and clean rags. Continue to clean cylinder until white rags show no discoloration. 10. Apply oil to cylinder walls.

REMOVE AND INSTALL PISTON RINGS 1. Remove piston rings with a piston ring expander. 2. Inspect piston. Clean piston ring grooves. Check piston ring end gap.

M53962

Install each ring squarely in bore approximately 25.4 mm (1.0 in.) down from top of cylinder. Check end gap. Replace ring if end gap is more than specifications.

NOTE: FD590V and FD620D engines are equipped with a second compression ring. Install ring with mark facing up

END GAP SPECIFICATIONS (MAX) Compression Rings FD440V/501/590V . . . . . . . . . . . . 1.00 mm (0.040 in.) FD620D . . . . . . . . . . . . . . . . . . . . 1.20 mm (0.050 in.) Oil Rings . . . . . . . . . . . . . . . . . . . . . . . Not Measured

4/7/95

6 - 11

CYLINDER BLOCK, PISTONS & RODS INSPECT PISTON

REPAIR FD440V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NA FD590V . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.) FD620D . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)

IMPORTANT: Do not use a caustic cleaning solution or a wire brush to clean piston.

Oil Control Rings: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not Meassured

1. Remove all deposits from the piston. IMPORTANT: Note location of arrow match mark on piston head in relation to MADE IN JAPAN on connecting rod. No. 1 piston is opposite of No. 2 piston. Keep parts together as a set.

Arrow

“Made in Japan” M29916

2. Clean carbon from piston ring grooves with a ring groove cleaner. If cleaning tool is not available, break an old ring and use it carefully to clean groove. 3. Check that oil return passages in grooves are open. 4. Inspect piston for scoring or fractures. Replace piston if damaged. NOTE: Inspect clearance visually. Replace piston if clearance appears excessive.

C-ring Replace

Connecting Rod

M50063

Piston Pin

6. Remove piston pin and connecting rod. 7. Measure piston pin outer diameter and piston pin bore.

5. Check ring grooves for wear at several points around piston. Replace piston if clearance is greater than specification.

M50064

M80427

PISTON AND PISTON PIN SPECIFICATIONS Piston Pin O.D. (MIN)

M38102

FD440/501V . . . . . . . . . . . . . . . . 15.98 mm (0.629 in.) FD590V/FD620D . . . . . . . . . . . . 16.98 mm (0.668 in.) Piston Pin Bore I.D. (MAX)

RING SIDE CLEARANCE SPECIFICATION (MAX)

FD440/501V . . . . . . . . . . . . . . . . 16.04 mm (0.631 in.) FD590V/FD620D . . . . . . . . . . . . 17.04 mm (0.671 in.)

Top Ring: FD440V/FD501V/ FD590V . . . . . 0.10 mm (0.004 in.) FD620D . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) Second Ring:

6 - 12

4/7/95

CYLINDER BLOCK, PISTONS & RODS

REPAIR

A

Crankshaft Bearing

B M80248

Piston Pin Bearing 10. Measure piston O.D. (B) perpendicular to piston pin bore at approximate specified distance (A) from bottom of piston skirt. 12. Subtract piston O.D. measurement (B) from cylinder bore measurement to determine piston-tocylinder bore clearance. 13. Replace piston and/or rebore cylinder block if not within specifications. Distance (A) FD440/501V . . . . . . . . . . . . . . . . . 13.5 mm (0.531 in.) FD590V/FD620D . . . . . . . . . . . . . . 11 mm (0.433 in.) Piston O.D. (B) FD440V . . . . . . . . . . . . . . . . . . . . 66.950 - 66.965 mm . . . . . . . . . . . . . . . . . . . . . . . . . (2.6358 - 2.6364 in.) FD590V . . . . . . . . . . . . . . . . . . . . 73.935 - 73.950 mm . . . . . . . . . . . . . . . . . . . . . . . . . (2.9108 - 2.9114 in.) FD620D . . . . . . . . . . . . . . . . . . . . 75.935 - 75.950 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . (2.989 - 2.990 in.) Piston-to-Cylinder Bore Clearance FD440V . . . . . . . . . . . . . . . . . . . . . . 0.015 - 0.150 mm . . . . . . . . . . . . . . . . . . . . . . . . (0.00059 - 0.0059 in.) FD590V/FD620D . . . . . . . . . . . . . . . 0.030 - 0.170 mm . . . . . . . . . . . . . . . . . . . . . . . . (0.00118 - 0.0067 in.)

M50066

Measure connecting rod crankshaft bearing and piston pin bearing. Replace connecting rod if either measurement is greater than specifications. CONNECTING ROD SPECIFICATIONS (MAX)

BEARING

I.D.

Crankshaft Piston Bearing FD440/501V . . . . . . . . . . . . . . . . . . . . . . . . 31.06 mm (1.223 in.) FD590V/ FD620D . . . . . . . . . . . . . . . . . . . . . . . . 34.06 mm (1.341 IN.) Piston Pin Bearing FD440/501V . . . . . . . . . . . . . . . . . . . . . . . . . . 16.05 mm (0.632 in.) FD590v/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . 17.05 mm (0.671 in.)

INSPECT CONNECTING ROD Install connecting rod cap. Tighten to specification. CAP TORQUE SPECIFICATIONS FD440/501V . . . . . . . . . . . . . . . . . . 12 N•m (106 lb-in.) FD590V/FD620D . . . . . . . . . . . . . . 21 N•m (186 lb-in.) Clean and inspect rod. Replace if scored.

4/7/95

6 - 13

CYLINDER BLOCK, PISTONS & RODS

REPAIR

ASSEMBLE CONNECTING ROD AND PISTON NOTE: With pistons installed, No. 1 piston is designated by the large chamfer on connecting rod facing toward flywheel. No. 2 piston is designated by the large chamfer on connecting rod facing away from flywheel. The arrow match mark on both piston heads should point toward the flywheel. IMPORTANT: Do not reuse piston pin retaining rings.

Arrow

“Made in Japan”

C-ring Replace

Connecting Rod

Piston Pin

M50063

IMPORTANT: No. 1 piston, align arrow match mark (A) on piston head with MADE IN JAPAN (B) on connecting rod. No. 2 piston, align arrow match mark on piston head opposite MADE IN JAPAN on connecting rod.

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4/7/95

CONTENTS

CAMSHAFT, CRANKSHAFT & FLYWHEEL

CONTENTS Page

CAMSHAFT, CRANKSHAFT & FLYWHEEL SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INSPECT CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CAMSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INSPECT CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REMOVE AND INSTALL TAPPETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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7-1

NOTES

7-2

CAMSHAFT, CRANKSHAFT & FLYWHEEL

4/7/95

SPECIFICATION

CAMSHAFT, CRANKSHAFT & FLYWHEEL

SPECIFICATION Crankshaft - FD440/501V Minimum Side Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.92 mm (1.178 in.) Minimum Connecting Rod Journal . . . . . . . . . . . . . . . . . . . . . . . . . 30.93 mm (1.218 in.) Maximum T.I.R. (Total Indicated Runout) . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) Crankshaft - FD590V/FD620D Minimum Side Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.91 mm (1.335 in.) Minimum Connecting Rod Journal . . . . . . . . . . . . . . . . . . . . . . . . . 33.93 mm (1.336 in.) Maximum T.I.R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) Block and Crankcase Plain Bearings Maximum Crankcase Cover I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . 34.07 mm (1.341 in.) Maximum Crankcase I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.11 mm (1.343 in.) Camshaft Bearing Journals FD440/501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.91 mm (0.548 in.) FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.91 mm (0.626 in.) Lobes Journal FD440/501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.43 mm (0.962 in.) FD590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.23 mm (0.993 in.) FD620D Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.21 (0.993 in.) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.46 mm (1.002 in.) Fuel Pump Lobe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.50 mm (0.760 in.) Connecting Rod Cap Bolt Torque FD440/501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 N•m (106 lb-in.) FD590V/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.)

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7-3

CAMSHAFT, CRANKSHAFT & FLYWHEEL CAMSHAFT

CAMSHAFT SPECIFICATIONS (MIN)

REMOVAL

Bearing Journals

CAMSHAFT

FD440/501V . . . . . . . . . . . . . . . . 13.91 mm (0.548 in.) FD590V/FD620D . . . . . . . . . . . . 15.91 mm (0.626 in.)

IMPORTANT: Align timing marks to prevent damage to tappets when removing camshaft. Cam Lobes Journal FD440/501V . . . . . . . . . . . . . . . . 24.43 mm (0.962 in.) FD590V . . . . . . . . . . . . . . . . . . . 25.23 mm (0.993 in.) FD620D Intake . . . . . . . . . . . . . . . . . . . . . . . 25.21 (0.993 in.) Exhaust . . . . . . . . . . . . . . . . . 25.46 mm (1.002 in.) Fuel Pump Lobe . . . . . . . . . . . . 19.50 mm (0.760 in.)

Timimg Marks

INSPECT CAMSHAFT BEARINGS Measure camshaft bearings in cylinder block and crankcase cover. Replace block or cover if diameter is greater than specification. M44227

1. Rotate crankshaft until timing marks (A) align. 2. Remove and inspect camshaft.

INSTALLATION 3. Lubricate journals. 4. Align timing marks and install camshaft.

INSPECT CAMSHAFT Inspect camshaft for worn or broken teeth and loose rivets holding gear to camshaft. Replace camshaft if loose.

M51723

Cylinder Block Bearing Cam Lobes Flywheel Side Journal

Fuel Pump Lobe

PTO side Journal

M51722

Measure journals cam lobes. Replace camshaft if less than specifications.

M51724

Crankcase Cover Bearing

NOTE: On FD440V and FD590V engines, measure fuel pump lobe. Not used on FD620D.

7-4

4/7/95

CAMSHAFT, CRANKSHAFT & FLYWHEEL

CRANKSHAFT Camshaft Bearing Specifications (Max)

CRANKSHAFT

Cylinder Block Bearing

REMOVAL

FD440V . . . . . . . . . . . . . . . . . . . FD590V/FD620D . . . . . . . . . . . . Crankcase Cover Bearing FD440/501V . . . . . . . . . . . . . . FD590V/FD620D . . . . . . . . . .

14.07 mm (0.554 in.) 16.07 mm (0.633 in.) 14.05 mm (0.553 in.) 16.07 mm (0.633 in.)

1. Remove camshaft. IMPORTANT: Mark connecting rod caps so they can be reinstalled in the same location.

REMOVE AND INSTALL TAPPETS 1. Remove camshaft. NOTE: Mark tappets so they can be installed in their original guides during assembly Rod Caps

.

M53975

2. Remove connecting rod caps and push pistons to top of cylinder. Remove crankshaft. IMPORTANT: A bent crankshaft must be replaced; it cannot be straightened. Tappets

INSPECTION 1. Check crankshaft alignment (T.I.R). • Place crankshaft into an alignment jig. Using dial indicators, rotate crankshaft slowy.

M53975

2. Remove tappets.Replace if scored. 3. Install tappets in original positions.

M80432

Maximum Crankshaft Bend All. . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)

4/7/95

7-5

CAMSHAFT, CRANKSHAFT & FLYWHEEL 2. Clean and inspect crankshaft. Measure crankshaft main bearing journals and connecting rod journal.

CRANKSHAFT

INSTALLATION 1. Cover keyway on flywheel end of crankshaft with tape to prevent seal damage when installing crankshaft. 2. Put a light film of oil on crankshaft bearing surfaces. 3. Pack grease in oil seals and install crankshaft. 4. Install connecting rod caps and torque. Connecting Rod Cap Bolt Torque FD440/501V . . . . . . . . . . . . . . . . 12 N•m (106 lb-in.) FD590V/FD620D . . . . . . . . . . . . . 21 N•m (186 lb-in.)

M51729

NOTE: Under-size connecting rod is not available for FD440/501V engine. Replace crankshaft if measurements are less than specifications. On FD590Vand FD620D engines, connecting rod journal can be resized to accept undersized rod. Have grinding done by a reliable repair shop. Before sending crankshaft for grinding, inspect journal radii for cracks. Crankshaft Specifications (Min) Main Bearing Journal FD440/501V . . . . . . . . . . . . . . 29.92 mm (1.178 in.) FD590V/ FD620D. . . . . . . . . . 33.91 mm (1.335 in.) Connecting Rod Journal FD440/501V . . . . . . . . . . . . . . 30.93 mm (1.218 in.) FD590V/ FD620D. . . . . . . . . . 33.91 mm (1.336 in.))

A D B C

M57348

Resizing Specifications -FD590V/FD620D A B C D

. . . . . . . . . . 33.48 - 33.47 mm (1.3181 - 1.3176 in.) . . . . . . . . . . . . . . 2.30 - 2.70 mm (0.090 - 0.110 in.) . . . . . . . . . . . . . . . . . . . . . 44.50 mm Max 1.752 in.) . . . . . . . . . . 34.00 - 33.95 mm (1.3386 - 1.3366 in.)

7-6

4/7/95

LUBRICATION SYSTEM

CONTENTS

CONTENTS Page

LUBRICATION SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PUMP REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 4 5

DISASSEMBLE AND ASSEMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 INSPECT OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4/7/95

8-1

NOTES

8-2

LUBRICATION SYSTEM

4/7/95

SPECIFICATIONS

LUBRICATION SYSTEM

SPECIFICATIONS Oil Pump Minimum Rotor Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.92 mm (0.430 in.) Maximum Rotor Shaft Bearing I.D.. . . . . . . . . . . . . . . . . . . . . . . . . 11.07 mm (0.436 in.) Minimum Outer Rotor O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.43 mm (1.592 in.) Maximum Outer Rotor Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . 40.80 mm (1.606 in.) Minimum Relief Valve Spring Free Length FD440/501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.05 - 21.55 mm (0.829 - 0.848 in.) FD590VFD/620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.50 mm (0.770 in.) Inner and Outer Rotor Clearence Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 mm (0.012 in.) Pump Housing Depth Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.230 mm (1.6063 in.) Outer Rotor Thickness (Max.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.830 mm (0.3870)

4/7/95

8-3

LUBRICATION SYSTEM

LUBRICATION SYSTEM OPERATION

LUBRICATION SYSTEM OPERATION A positive displacement gerotor pump is used to pressurize the lubrication system. The lubrication system is protected by an oil pressure relief valve, low oil pressure switch, and a oil filter with bypass. The oil pump (F) draws oil (B) from the sump through screen (G). Pressure oil (A) from the pump flows to the oil pressure relief valve (E). If oil pressure exceeds 296 kPa (43 psi), the relief valve opens allowing oil to return to sump. Relief valve is not adjustable. Pressure oil from the relief valve flows to the oil filter .

The filter contains a bypass valve which opens if the element becomes plugged to insure engine lubrication. An oil pressure switch mounted above the oil filter turns on a warning light if oil pressure is below 28 kPa (4 psi). Filtered pressure oil flows through a passage in the oil sump to the crankshaft main bearing (PTO side). Drilled passages in the crankshaft distribute oil from the main bearing to the connecting rod journals, and crankshaft main bearing (flywheel side). A drilled passage in the connecting rods allow oil from the connecting rod journal to lubricate the piston and cylinder walls.

COMPONENTS Water Pump Gear

Rocker Arms and Valves

Piston

Tappets Camshaft Governor Gear Connecting Rod

Oil Pressure Sensor

Crankshaft

Oil Filter

Crankshaft Main Bearings Oil Pressure Relief Valve

Oil Pump Pick-up Screen M57349

8-4

4/7/95

LUBRICATION SYSTEM

OIL PUMP REPAIR

OIL PUMP REPAIR

INSPECT OIL PUMP

DISASSEMBLE AND ASSEMBLE Gear Oil Pump Assembly

Cover

Screen Cover Cover Cap Screws

7.8 N•m (69 lb-in.)

Pin (Two used)

Rotor Shaft Oil Pressure Relief Valve

Inner Rotor

Spring Ball Oil Pick-up Screen Outer Rotor M53966

Cover

FD440V Shown

IMPORTANT: Oil pressure relief valve spring and ball will be loose when pump cover is removed. 1. Remove oil pump assembly, relief valve spring and ball. 2. Remove, clean or install a new oil pick-up screen.

Plate Hole

Pins

Gear

Screen

M53967

NOTE: Rotors and rotor shaft are replace as a kit. If any of the parts show signs of wear or are scored, replace.

Inner Rotor Outer Rotor

Spring

Ball M57350

3. Install oil pressure relief valve ball, spring and oil pump assembly. IMPORTANT: Fill rotor housing with engine oil for initial lubrication. 4. Install cover so that hole in cove plate is centered over relief valve. Tighten cover screws evenly.

4/7/95

8-5

LUBRICATION SYSTEM

OIL PUMP REPAIR

Outer Rotor Bearing Shaft Bearing

M44227

Measure parts per the oil pump specifications. Replace crankcase if bearing surfaces are worn or scored greater than specifications. If parts show signs of premature wear, check condition of pick-up screen and sealing area around screen. OIL PUMP SPECIFICATIONS Rotor Shaft Minimum Shaft O.D. . . . . . . . . 10.92 mm (0.430 in.) Maximum Bearing I.D. . . . . . . . 11.07 mm (0.436 in.)

Outer Rotor Minimum Rotor O.D. . . . . . . . . 40.43 mm (1.592 in.) Maximum Bearing I.D. . . . . . . . 40.80 mm (1.606 in.) Thickness (Max.) . . . . . . . . . . . . . 9.830 mm (0.3870) Inner and Outer Rotor Clearence Maximum. . . . . . . . . . . . . . . . . . 0.3 mm (0.012 in.) Pump Housing Depth Maximum . . . . . . . . . . . . . 10.230 mm (1.6063 in.) Spring Free Length Specifications (MIN) FD440/501V . . . 21.05 - 21.55 mm (0.829 - 0.848 in.) FD590V/FD620D . . . . . . . . . . . 19.50 mm (0.770 in.)

8-6

4/7/95

COOLING SYSTEM

CONTENTS

CONTENTS Page

COOLING SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4 5 6

FD440/501V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 FD590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 TEST THERMOSTAT 8

COOLANT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REMOVAL & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 COOLANT PUMP REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 COOLING FAN AND BRACKET -FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 COOLING FAN DRIVE BELT ADJUSTMENT - FD620D . . . . . . . . . . . . . . . . . . . 10

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9-1

NOTES

9-2

COOLING SYSTEM

4/7/95

SPECIFICATIONS

COOLING SYSTEM

SPECIFICATIONS Engine Coolant Capacity FD440/FD501. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 L (2.2 qt) FD590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.04 L (3.2 qt) FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.95 L (1 qt) Thermostat FD440/501/590 Begin Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fully Open Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FD620D Begin Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fully Open Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82°C (180°F) 95°C (203°F) 65°C (148°F) 80°C (176°F)

Water Pump Minimum Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.94 mm (0.391 in.) Maximum Pump and Crankcase Housing Bore I.D. . . . . . . . . . . . . 10.09 mm (0.397 in.) Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N•m (70 lb-in.) Crankcase Cover Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . 21 N•m (186 lb-in.) Over-flow Reservoir Mounting Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N•m (31 lb-in.) Sheave/Half - FD620D Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N•m (130 lb-in.)

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9-3

COOLING SYSTEM COOLING SYSTEM OPERATION Function: Remove heat from engine. Theory of Operation: The engine is liquid-cooled and uses a pressurized, fintype radiator, water pump, and thermostat to regulate engine temperature. The cooling system is protected by a coolant temperature switch that warns the operator if the engine temperature becomes too high. The water pump is driven off the camshaft gear (H) When the engine temperature is cold, below 82°C (180°F), the thermostat (R) is closed. The closed | thermostat stops coolant flow into the radiator(A). Now the water pump (J) must draw coolant from the bypass hose (O) which is between the cylinder head and the water pump. An impeller (I) forces the low temperature coolant (U) through the cylinder block coolant passages (N) to the piston coolant passage (L). Coolant flows around the piston coolant passage, and then through the right cylinder head, intake manifold (M), and left cylinder head to the bypass hose. The engine heat is transferred to the coolant and the coolant temperature increases. Since the high temperature coolant (T) bypasses the radiator, the engine warms up to operating temperature quickly.

9-4

COOLING SYSTEM OPERATION When the engine temperature is 82°C (180°F), the thermostat begins to open and is fully open at 95°C (203°F). High temperature coolant from the left cylinder head flows through the thermostat to the radiator. The radiator is cooled by a radiator fan (E) that is mounted to the flywheel (G). The radiator fan pulls in air from the front of the engine and forces the air upward through the radiator fins. The coolant temperature decreases as the coolant flows from the radiator inlet to the outlet. With the thermostat open, the water pump draws low temperature coolant from the radiator through the radiator outlet hose (K) instead of the bypass hose. The low temperature coolant is circulated through the engine to provide constant cooling. A coolant temperature switch (Q) mounted in the left cylinder head turns on a warning light if coolant temperature is above 111°C (232°F). The radiator cap (B) maintains a constant pressure of 88 kPa (13 psi) inside the radiator which actually raises the boiling point of the coolant. The radiator cap contains a pressure valve and a vacuum valve. When the coolant is hot and pressure is above 88 kPa (13 psi), the pressure valve opens allowing some coolant to flow to the overflow reservoir. After the engine is stopped, the coolant cools and the pressure inside the radiator decreases to a partial vacuum. The vacuum opens the vacuum valve and some coolant from the overflow reservoir flows back to the radiator

4/7/95

COOLING SYSTEM

COMPONENTS

COMPONENTS Radiator Fan Radiator Cap

Inlet Hose

Outlet Hose

Thermostat

Coolant Temperature Switch

Piston Coolant Passage Intake Manifold

Cylinder Head Coolant Passage

Cylinder Block Coolant Passage

Cylindar Block Coolant Passage

Water Pump Gear High Temperature Coolant

4/7/95

Impeller

Bypass Hose Low Temperatire Coolant

M44227

9-5

COOLING SYSTEM

REPAIR

REPAIR FD440V/501V

c

CAUTION

Reduce compressed air to less than 210 kPa (2 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection.

Screen Clean.

Radiator Clean. Straighten bent fins. Over Flow Tube

Reservoir

4 N•m (31 lb-in.)

Cover

Damper Bushings Replace if hard or cracked. 6 N•m (53 lb-in,)

Retaining Clip

Top Half Air Duct

Studs* 6 N•m (53 lb-in,)

Return Hose

Bottom Half Air Duct

Outlet Hose

6 N•m (53 lb-in,) Fan Extension Thermostat Housing Coolant Pump See Pump Repair.

Thermostat See Test. Bypass Hose

M57353

*FD440V: Studs are coated with LOCTITE. To remove studs, install nut and strike stud sharply with a hammer to loosen.

9-6

4/7/95

COOLING SYSTEM

REPAIR

FD590V

c

CAUTION

Reduce compressed air to less than 210 kPa (2 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection.

Dampner Bushing Replace if hard or cracked.

Screen

Radiator Clean. Straighten bent fins

Over Flow Tube

Seal Must sit in groove. Replace if cracked or deformed.

Bracket

Reservoir 6 N•m (53 lb-in.) Retaining Clip

15 N•m (10 lb-ft)

Top Half Air Duct Fan 6 N•m (53 lb-in.)

Bottom Half Air Duct

6 N•m (53 lb-in.)

6 N•m (53 lb-in.) Return Hose O-Ring

Intake Elbow Fan Extension

Thermostat Housing Thermostat M57352

4/7/95

9-7

COOLING SYSTEM

COOLANT PUMP

THERMOSTAT

TEST THERMOSTAT

NOTE: FD440/501V: Remove both halves of cooling air duct.

Check thermostat using a thermostat tester. Heat thermostat in water to check opening temperature. Replace, if not according to specifications. THERMOSTAT SPECIFICATIONS

Thermostat Housing

FD440/501V Begin Opening . . . . . . . . . . . . . . . . . . . Fully Open. . . . . . . . . . . . . . . . . . . . . . . FD620D Begin Opening . . . . . . . . . . . . . . . . . Fully Open . . . . . . . . . . . . . . . . . . . .

82°C (180°F) 95°C (203°F) 65°C (148°F) 80°C (176°F)

COOLANT PUMP M51700

REMOVAL & INSTALLATION

FD590V Shown B

Thermostat Housing

C A

Drain Plug

D M51701 M53946

FD620D Shown

Disconnect hoses and remove pump assembly, noting position and lenght of cap screws. TORQUE SPECIFICATIONS Mounting Cap Screws . . . . . . . . . . 8 N•m (70 lb-in.) Cap Screw (B)* . . . . . . . . . . . . . 21 N•m (186 lb-in.) *Cap screw (B) attaches crankcase cover to crankcase.

9-8

4/7/95

COOLING SYSTEM

COOLANT PUMP

COOLANT PUMP REPAIR

NOTE: Mechanic seal is sealed into place and will be difficult to remove.

IMPORTANT: Leakage from water pump will drain into engine block and could cause engine damage. If there if any doubt of the condition of water pump, replace it as a complete assembly.

When installing impeller assembly to housing, coat mating surfaces with clean water. 6. Install new mechanical seal. Oil Seal

Pin

Impeller

Shaft

Impeller Mechanical Seal

Oil Seal Mating Ring O-Ring

Housing

Pin

Shaft M51707

Washer

PUMP SPECIFICATIONS (MIN) Spur Gear

M44227

1. Remove gear with a puller. 2. Remove impeller assembly from shaft. Disassemble impeller assembly. 3. Measure outside diameter of shaft. If less than specifications or shows any signs of corrosion, replace it. 4. Measure pump shaft bore in housing. Replace housing if greater than specifications. 5. Drive old mechanical seal from housing.

4/7/95

Machnical Seal Coat mating surfaces with clean coolant

Shaft O.D. (MIN) . . . . . . . . . . . . . 9.94 mm (0.391 in.) Housing Shaft Bore/ I.D. (MAX) . . . . . . . . . . . . . . . . . . 10.09 mm (0.397 in.)

9-9

COOLING SYSTEM

COOLANT PUMP

COOLING FAN AND BRACKET -FD620D Fan I Install with ridges on inside diameter of fan pointing away from engine. Pulley Mountng Flange Bearing

Spacer

Bracket Belt Tension 245 - 391 N (55 - 88 lb)

Snap Ring

Bearing

15 N•m (130 lb-in.)

Washers

Outer Fan Drive Sheave

Nut Shim(S) Add to loosen belt. Remove to tighten.

IMPORTANT: Bearings are a pressed fit. Remove only if being replaced. To avoid pinching fan belt between flywheel and outer sheave half, rotate flywheel while tightening outer sheave half mounting cap screws.

c

M57354

COOLING FAN DRIVE BELT ADJUSTMENT - FD620D Apply approximately (force) pressure between fan and drive sheave. If deflection is not within 12 - 19 mm (0.472 - 0.748 in.), remove drive sheave and add shims to loosen belt or remove shims to tighten belt.

CAUTION

DO NOT heat oil over 182°C (360°F). Oil fumes or oil can ignite above 193°C (380°F). Use a thermometer. DO NOT allow a flame or heating element to come in direct contact with the oil. Heat the oil in a well-ventilated area.

1. Heat mounting bracket with bearings (E) in hot oil to remove bearings. Tap bearings from mounting bracket. 2. Install bearings using a bushing, bearing and seal driver set and a press.

9 - 10

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ELECTRICAL SYSTEM

CONTENTS

CONTENTS Page

ELECTRICAL SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REPLACE STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

IGNITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REPLACE PULSER COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REPLACE IGNITION COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REPLACE IGNITION MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 STARTER SERVICE PARTS KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ANALYZE STARTER CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 BENCH TEST SOLENOID SHIFT STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 INSPECT STARTER - SOLENOID SHIFT TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . 6 TEST FEILD WINDINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 TEST STARTER ARMATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 TEST STARTER SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 FUEL INJECTOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 FUEL INJECTION TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 FUEL INJECTION AIR TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 8 FUEL INJECTION AIR PRESSURE SENSOR - FD620D . . . . . . . . . . . . . . . . . . . . 9 FUEL INJECTION THROTTLE SENSOR - FD590D . . . . . . . . . . . . . . . . . . . . . . . 9 ALTITUDE COMPENSATION SWITCH CIRCUIT - OPTIONAL FD590D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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10 - 1

NOTES

10 - 2

ELECTRICAL SYSTEM

4/7/95

SPECIFICATION

ELECTRICAL SYSTEM

SPECIFICATION CHARGING SYSTEM Capacity FD440/501/590V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Amps FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Amps Stator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 VAC @ 3000 RPM INJECTOR FD590D Resistance at 20°C (68°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 - 12.9 Ohms FD620D Resistance at 20°C (68°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.8 Ohms IGNITION SYSTEM Pulser Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 - 1.0 VAC ELECTRIC STARTER Minimum Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.240 in.) Maximum No Load Starter Draw FD440/501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 amps at 6000 rpm (min) FD590/FD620D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 amps at 6000 rpm (min)

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10 - 3

ELECTRICAL SYSTEM

STATOR OPERATION

STATOR OPERATION The charging system is a permanent magnet and stator design. As the flywheel rotates, a permanent magnet in the flywheel induces AC current in the stator windings. This current flows to the regulator-rectifier where it is converted to DC current needed to charge the battery.

REPLACE STATOR Clamp Stator

1. Remove: • cooling air duct or flywheel guard • FD590V: radiator support brackets • FD620D: fan bracket • Remove pulser coil(s) • wire ties from wiring harness. 2. Disconnect wiring harness from ignitor. 3. Install coils. 4. Install fan or radiator brackets. 5. Connect plug to ignitor. 6. Install new wire ties where needed.

Connector

REPLACE IGNITION COILS

M51685

FD590V Stator Shown

1. Remove: • flywheel • Wire clamp(s) • stator wiring lead pins from connector • Cut wire tie from wiring harness and remove stator 2. Install stator and connect wiring leads to plug.

REPLACE PULSER COILS NOTE: Pulser coils are mounted in a fixed position.

Wire Leads

Coil M52688

FD590V Ignition Coil

1. Disconnect plug wire from spark plug lead and primary wire leads from coil. 2. Remove ignition coil. 3. Install ignition coil and connect wiring leads.

Some application only use one pulser coil.

Pulser Coil

M51686

FD590 Pulser Coil

10 - 4

4/7/95

ELECTRICAL SYSTEM

REPLACE IGNITION MODULE

REPLACE IGNITION MODULE

BENCH TEST SOLENOID SHIFT STARTER NOTE:

Ground Lead

Ignition Module

Connectors

Perform bench test before disassembling starter motor to determine cause of problem.

IMPORTANT: Never operate motor longer than 20 seconds. Allow at least two minutes for cooling and battery recovery before operating again. Overheating, caused by excessive operation, will seriously damage starting motor. 1. Remove starter from engine.

M51960

Battery Terminal

NOTE:

B M

S

Module may not be mounted on engine on some applications.

Remote Switch Switch Terminal

Note position of ground wire. Module must be grounded 1. Disconnect connectors and remove ignition module. 2. When installing ignition, put wire lead under cap screw. 3. Install ignition module and connect plugs.

_ Starter Frame

+

12V Battery

STARTER SERVICE PARTS KITS The following kits are available through your parts catalog: • Brush Kit • Clutch Kit

2. Connect battery to starter using heavy duty cables and remote starter switch as shown. When switch is activated, starter should engage and run. SPECIFICATIONS

ANALYZE STARTER CONDITION 1. The starter overheats because of: • Long cranking. • Armature binding. 2. The starter operates poorly because of: • Armature binding. • Dirty or damaged starter drive. • Badly worn brushes or weak brush springs. • Excessive voltage drop in cranking system. • Battery or wiring defective. • Shorts, opens, or grounds in armature. NOTE: Starter repair is limited to brushes, end caps, and starter drive. Fields in starter are permanent magnets and are not serviceable. If housing or armature is damaged, replace starter 4/7/95

Terminal Voltage (Min) . . . . . . . . . . . . . . . . 11.5 volts Starter Motor RPM (Min) . . . . . . . . . . . . . . 6000 rpm Current Draw (Max) . . . . . . . . . . . . . . . . . . . 50 amps Results: •

IF SOLENOID CHATTERS; hold-in winding is open-circuited.

• IF NOTHING HAPPENS; either the solenoid pullin winding is open-circuited or mechanical parts are sticking. • IF SOLENOID ENGAGES, BUT MOTOR DOES NOT RUN; check solenoid switch continuity, brushes, armature and field windings. Solenoid cannot be repaired, replace it.

10 - 5

ELECTRICAL SYSTEM

INSPECT STARTER - SOLENOID SHIFT TYPE

INSPECT STARTER - SOLENOID SHIFT TYPE NOTE: Mark body and end cover to aid reassembly. Armature Solenoid Shift Lever Pinion Pinion Stopper Half End Cover

Retaining Clip Always replace with new

Retaining Bolt

Pinion Stopper Half

Brushes Washer

Front Cover Insulator Brush Spring Brush Holder Case with Field Windings

1. Mark body and covers to aid alignment for reassembly. 2. Separate pinion stopper halves to remove retaining clip to remove starter drive. 3. Test and inspect starter parts for wear or damage. 4. Replace brushes as a set if length of any one is less than 6 mm (0.240 in.). Brushes must be soldered to field windings 5. Apply very light coat of multipurpose grease to: • sliding surfaces of armature and solenoid shift lever pivots. • armature shaft spline. • points where shaft contacts cover. 6. Assemble starter. Hook solenoid plunger over shift fork.

M53943

TEST FEILD WINDINGS NOTE:

Field winding case is a tie point for many separate field coils. It may be difficult to detect one bad coil. If rpm was slow and armature tests are normal, replace field coil assembly.

Replace field coil if not according to specifications. Field Brushes Continuity between brushes and to case To Solenoid

Brush Assembly Tips: • With front cover facing down in vise, assemble front cover, armature and body. • Assemble brush holder over armature. • Install brushes against armature. • Squeeze springs into place. • install insulator and cover.

Test For Open Starter Case Armature Brushes Continuity between brushes and solenoid lead. Open to case.

M57356

10 - 6

4/7/95

ELECTRICAL SYSTEM

TEST STARTER ARMATURE

TEST STARTER ARMATURE

TEST STARTER SOLENOID

IMPORTANT: Do not clean armature with solvent. Solvent can damage insulation on windings. Use only mineral spirits and a brush.

NOTE: If bench test indicated solenoid problems, use an ohmmeter or test light to check solenoid.

Switch Arm

Solenoid Body

Solenoid Terminal M24861

1. Locate short circuits by rotating armature on a growler while holding a hacksaw blade or steel strip on armature. The hacksaw blade will vibrate in area of short circuit. 2. Shorts between bars are sometimes caused by dirt or copper between bars. Inspect for this condition. 3. If test indicates short circuited windings, clean the commutator of dust and fillings. Check armature again. If test still indicates short circuit, replace armature.

High Current Terminals M51705

1. Test solenoid terminals for continuity. There should be no continuity. 2. Depress switch arm. There should be continuity when arm is fully depressed. 3. Test for open circuits between terminal and tab There should be continuity. 4. Test for open circuits between tabs and body. There should be continuity. If solenoid fails any test, it is defective and must be replaced. When installing solenoid, hook switch arm over shift fork, so that when solenoid is activated it will pull shift fork in.

Test For Grounds

Test For Open M50112, M50113

4. Using an ohmmeter, test each individual armature windings for grounded or open circuits. Armature windings are connected in parallel, so each commutator bar needs to be checked. • If test either test fails, armature must be replaced

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10 - 7

ELECTRICAL SYSTEM

TEST STARTER ARMATURE

FUEL INJECTOR TEST NOTE:

FUEL INJECTION AIR TEMPERATURE SENSOR

Also see Fuel Injector in Fuel System and Governor section.

Function Monitors coolant temperature for computer to determine the amount of fuel delivery for starting a cold engine or warm engine operation.

Sensor

Terminals M48181

Measure resistance specification replace.

across

terminal.

If

out

of

Resistance Specification at 20° C(68° F). . . . . . . . . . . . . . . . . 11.1 - 12.9 ohms Connect jumper wire from battery ground to fuel injector terminal. Briefly and repeatedly connect a positive wire from battery to other injector terminal. Injector must click each time wire contact is made. No click, replace injector.

M44227

FD590D Air Temperature Sensor Air Temperature Sensor

FUEL INJECTION TEMPERATURE SENSOR Function: Monitors coolant temperature for computer to determine the amount of fuel delivery for starting a cold engine or warm engine operation. M57364

Coolant Temperature Sensor

FD620D Air Temperature Sensor

When changing sensor make sure sensor and groment are sealed and in place. Sensor is on clean air side of filter.

M48182

Replace temperature sensor and gasket as needed. Do not attempt to turn plastic connector. Use a thread sealer.

10 - 8

4/7/95

ELECTRICAL SYSTEM

TEST STARTER ARMATURE

FUEL INJECTION AIR PRESSURE SENSOR - FD620D

FUEL INJECTION THROTTLE SENSOR - FD590D

Function:

Function:

The computer uses the signal from this sensor to determine throttle plate position and engine load.

Mechanically senses throttle shaft position which calibrates the fuel injection computer to the throttle plate position

Air Pressure Sensor

Throttle Sensor

M57336 M57367

Make sure vacuum hose is not pinched, cracked or any pin holes. Connections must be tight to throttle body and sensor.

Adjustment:

1. Set throttle shaft at slow idle position. Turn slow idle screw out so throttle plate is completely closed. 2. With sensor connected to vehicle wiring harness, read voltage of white wire. Adjust sensor until voltage reads between 0.35 - 0.38 volts. 3. Hold throttle sensor in this position and tighten cap screws. 4. Open and close throttle plate several times and recheck voltage. Readjust if necessary. 5. Replace sensor if voltage can not be obtained. 6. Readjust slow idle stop screw.

ALTITUDE COMPENSATION SWITCH CIRCUIT - OPTIONAL FD590D Function: The altitude compensation switch circuit allows the fuel injection module computer to adjust the fuel-air mixture when the unit is operated above 1500 m (4918 ft.). The unit must be operated above 1500m (4918 ft.) for the altitude compensation switch to operate. When the unit is operated below 1500m (4918 ft.), the altitude compensation switch is closed and provides a path to ground to energize the circuit. When the unit is operated above 1500m (4918 ft.), the altitude compensation switch opens breaking the path to ground which denergizes the circuit. This leans the fuel-air mixture for high altitude operation.

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10 - 9

ELECTRICAL SYSTEM

10 - 10

TEST STARTER ARMATURE

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TROUBLESHOOTING

CONTENTS

CONTENTS Page

TROUBLESHOOTING TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 PERFORMANCE DAIGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 COMPRESSION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 CRANKCASE VACUUM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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11 - 1

NOTES

11 - 2

TROUBLESHOOTING

4/7/95

TROUBLESHOOTING

TROUBLESHOOTING

Engine RPM Low Or Engine Stalls

Engine overheats

Coolant leakage

Engine knocks

Engine backfires

Excessive oil consumption

Excessive fuel consumption

Engine misses at low rpm

Engine misses at high rpm

Engine runs erratically

Check or Solution

Loss of power

Problem or Symptom

Engine cranks but will not start

TROUBLESHOOTING

Weak or faulty spark plug Faulty high tension leads Faulty ignition Module Faulty ignition coil Faulty pulser coil Contaminated fuel or faulty fuel supply system Fuel shut-off solenoid not allowing fuel into main jet Defective fuel pump Air being drawn in through a hole in the fuel line(s) Fuel shut-off valve closed (Inline valve) Clogged fuel line or filter Fuel tank vent line clogged Vapor lock Improper use of choke Air filter restricted Defective breather valve Float level too high Poor compression. Worn piston/piston rings stuck or not seated. Worn cylinder bore Cylinder head loose

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11 - 3

TROUBLESHOOTING

Engine RPM Low Or Engine Stalls

Engine overheats

Coolant leakage

Engine knocks

Engine backfires

Excessive oil consumption

Excessive fuel consumption

Engine misses at low rpm

Engine misses at high rpm

Engine runs erratically

Loss of power

Check or Solution

Engine cranks but will not start

Problem or Symptom

TROUBLESHOOTING

Worn or burn valves or improper clearance Worn valve stem(s) or valve guide(s) Warped cylinder head Broken valve spring Defective head gasket Low oil level Too much oil in crankcase Carburetor out of adjustment Air/fuel passages clogged Carbon deposits in exhaust pipe/muffler Carbon deposits in combustion chamber Lack of coolant Governor linkage out of adjustment Faulty governor spring Governor gear assembly binding or broken Air being drawn through carburetor or intake manifold flanges Incorrect timing gear alignment Plugged oil ring groove Oil leakage along governor shaft Defective oil seal Drain-back hole in breather chamber plugged

11 - 4

4/7/95

Engine RPM Low Or Engine Stalls

Engine overheats

Coolant leakage

Engine knocks

Engine backfires

Excessive oil consumption

Engine misses at low rpm

Engine misses at high rpm

Engine runs erratically

Loss of power

Check or Solution

Engine cranks but will not start

Problem or Symptom

Excessive fuel consumption

TROUBLESHOOTING

TROUBLESHOOTING

Incorrect oil viscosity Carburetor flange loose or leaking at gasket Carburetor body and throttle shaft worn Intake valve burned or sticking Excessive engine load Fan belt slippage Defective radiator hose or clamp Broken or missing fan shroud Defective radiator Cracked or porous casting Loose stud bolts and cap screw Engine overheating Damaged water pump seals Improperly installed gasket Improper or defective radiator cap Battery weak or discharged

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11 - 5

TROUBLESHOOTING

DIAGNOSIS

DIAGNOSIS STARTING MOTOR Test Conditions: • Known good battery

Test/Check Point

Normal

If Not Normal

Engine will Not Crank 1. Starter solenoid (Solenoid does not click)

Solenoid clicks when key is in start position

See cranking and neutral start circuits of product technical manual. Check wire connections at battery and solenoid switch terminals of solenoid. Check solenoid, starter motor and engine to battery ground. Faulty solenoid - test and replace

2. Starter motor (Solenoid clicks but starter does not rotate)

Starter motor should crank engine

Disconnect all external drives. Rotate engine by hand to check for seized engine Check starter solenoid to starter motor connection Remove and test starter motor.

3. Starter Motor (Starter rotates but engine does not crank)

Engine cranking

Worn pinion or ring gear. Replace Incorrect starter alignment or starter drive cover broken. Faulty starter drive clutch. Replace.

Engine cranking at a minimum of 250 rpm.

Check solenoid to motor connection. Test or repair starter. Engine seizing. Repair engine.

5. Starter Drive (Starter motor continues to run)

Disengages when key is returned to run.

Faulty ignition switch. Replace Faulty solenoid. Replace

6. Starter Drive (Starting motor disengages)

Retracts when motor disengages

Faulty pinion and ring gear Starter shift fork binding

Engine cranking speed good but will not start

Starts and runs with no performance complaints

Continue testing

Engine Cranks Slow 4. Starter Motor

Starter Does not disengage

11 - 6

4/7/95

TROUBLESHOOTING

DIAGNOSIS

ENGINE Test Conditions: • Engine cranking speed above specification

Test/Check Point

Normal

If Not Normal

ENGINE WILL NOT START Conditions: • Engine cranking Hot blue spark No sparks between high tension wire and block

Spark: Go to step 5. Spark at spark tester but not plug: Faulty spark plug. Replace Check high tension cap and high tension lead condition.

Spark plug not wet

Plug dry: No fuel, see carburetor or fuel injection system test. No fuel in tank. Plug Wet: See Carburetion Checks

Battery voltage at positive terminal of coil. Spark at spark plug when negative terminal is grounded.

No voltage at Coil: Check engine harness connection. No battery voltage at connector, see product technical manual. Battery voltage at harness connector: Repair or replace engine harness Voltage at positive terminal of coil and no spark when negative coil is grounded: Test and replace coil. No spark with engine cranking: Check ignition module connections and continue testing.

3. Pulser Coil(s) connectors

0.1 - 1.0 volts AC output from each coil.

No voltage: replace pulser coils Voltage: check ignition module connections and ground.

4. Ignition module or fuel injection module

Voltage to module

See product technical manual. Replace module with known good one.

1. Spark plug Removed and grounded against block

Conditions: • Engine not cranking • Ignition on 2. Ignition coil and spark plug (Test both coil)

Condition; • Engine cranking • Pulser coil disconnected

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11 - 7

TROUBLESHOOTING

DIAGNOSIS

Test/Check Point 5. Compression Test

Normal Compression above 1171 kPa (170 psi). Maximum difference between cylinders 97 kPa (14 psi)

If Not Normal Compression OK: See carbureted or fuel injected fuel system diagnosis. Compression low: Add oil to cylinders and retest. No Change in Compression: Check valve adjustment cylinder head, gasket, valves and valve springs. Change in Compression: Check piston, cylinder and rings

PERFORMANCE DIAGNOSIS ENGINE HARD TO START Test/Check Point

Normal

If Not Normal

1. Spark plugs

Not oil or wet

Check the following: • Spark plugs. • High tension wire & ignition coil(s) • One faulty pulser • Check air cleaner for plugging or for intake leaks. • Compression See carburetor or fuel injection system diagnosis.

2. Lubrication system

Correct oil level and viscosity Oil not contaminated with coolant or gasoline.

Correct oil level Change oil and determine cause for contamination.

3. Muffler

Little to no smoke. No sound of restriction.

Excessive black smoke: • Check for plugged air cleaner. • Too much oil in crankcase. • Defective breather valve. • Excessive carbon in exhaust port or muffler. See carbureted or fuel injection system diagnosis.

11 - 8

4/7/95

TROUBLESHOOTING

DIAGNOSIS

COMPRESSION TEST

CRANKCASE VACUUM TEST

REASON:

Reason:

To determine the condition of pistons, rings, cylinder walls and valves

To check operation of breather and condition of seals, gaskets, rings, piston and cylinders walls.

Equipment:

Equipment:

• JDM59 Compression Gauge

• JTO5701 Hose Clamp • JTO5703 Barb Fitting • JTO5699 Line • JTO5698 U-Tube Manometer Procedure: 1. Park machine on level surface, key switch OFF, transmission in NEUTRAL, and LOCK park brake.

B

M56385

1. Remove both spark plugs and install compression gauge. 2. Ground high tension leads or disconnect positive lead from ignition coil. 3. Hold throttle shaft open.

A C

M57357

IMPORTANT: DO NOT overheat starting motor during test. Starter duty is 5 seconds on, 10 seconds off. 4. Crank engine for three to five compression strokes. 5. Record pressure readings for each cylinder.

2. Put small end of barb fitting (A) into line (B) and fasten with hose clamp (C). 3. Install large end of barbed fitting into dipstick tube.

Compression Specifications Minimum . . . . . . . . . . . . . . . . . . . 1171 kPa (170 psi) Minimum difference between cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 kPa (14 psi)

B

D

Results: • Above specification, adjust valves and check fuel and intake air systems. Check exhaust for restriction. • Below specification, squirt clean engine oil into cylinders and repeat test. • Pressure increases significantly, check piston rings and cylinder walls for wear or damage, • Pressure does NOT increase after retest, check for leaking valves, valve seeats or cylindwer head gaskets. 6. Reconnect ignition coils and install spark plugs 4/7/95

M56365

IMPORTANT: DO NOT make connection between manometer (D) and engine line (B) BEFORE engine is running or fluid in manometer could be drawn into crankcase. DO NOT turn engine OFF until line (B) has been disconnected from manometer (D).

11 - 9

TROUBLESHOOTING

DIAGNOSIS

4. START and run engine at SLOW idle. 5. Connect line (B) to U-Tube Manometer Kit (D). 6. Run engine at FAST idle. 7. Record crankcase vacuum reading. Manometer should show a minimum vacuum of 25 mm (1.0 in.) of water. 8. Run engine at SLOW idle. DO NOT TURN ENGINE OFF! 9. Disconnect clear tube (B) from manometer. 10. Turn engine OFF. 11. Remove barbed fitting and install dipstick.

E

C

D

M56384

OIL PRESSURE TEST 4. Install JT03349 Connector (C). 5. Connect JT03017 Hose Assembly (D) and JT05577 Pressure Gauge Assembly (E). 6. Crank engine and check oil pressure. No oil pressure, determine cause before starting engine.

Reason: To determine condition of lubrication system. Equipment:

IMPORTANT: If pressure reading is below 69 kPa (10 psi), STOP ENGINE IMMEDATELY and determine cause.

• JT05577 Pressure Gauge Assembly • JT03017 Hose Assembly • JT03349 Connector Procedure: 1. Check engine oil level, bring level to full mark..

c CAUTION Engine components are HOT. Be careful not to touch, especially the exhaust pipe or muffler, while making adjustments. Wear protective eye glasses and clothing.

Results: If oil pressure is BELOW specifications, inspect or replace the following: • Oil pressure relief valve for broken or worn spring • Oil pressure relief valve for stuck or damaged valve. • Worn or damaged oil pump. • Oil pump suction screen or oil passages plugged. • Excessive wear of connecting rod and main bearing journals.

B

A

Results: M56383

2. Disconnect oil pressure switch wiring lead (A). 3. Remove oil pressure switch (B).

11 - 10

7. Run engine at FAST idle and check. Minimum oil pressure 276 kPa (40 psi). 8. Run engine at FAST idle until at operating temperature. 9. Install oil pressure switch and switch wiring lead. Use John Deere Pipe Sealant with TEFLON (medium strength), or equivalent, on switch threads.

If crankcase vacuum is LESS than specification, check the following: • Breather reed valve clearance and condition, • Seals and gaskets for leakage, • Valve cover gasket for leakage, • Valve and valve seats for wear or damage. • Head warpage. • Rings, piston, and cylinder walls for wear or damage.

4/7/95

COMPONENT ANALYSIS

CONTENTS

CONTENTS Page

COMPONENT ANALYSIS VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 RING WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 PISTON WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

CRANKSHAFT AND CONNECTING ROD WEAR . . . . . . . . . . . . . . . . . 4

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12 - 1

NOTES

12 - 2

COMPONENT ANALYSIS

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COMPONENT ANALYSIS

ANALYZE VALVES

ANALYZE VALVES Lead deposits on the intake valve are caused by exhaust gas leakage past the valve. This indicates that the valve is not seating properly.

Valve Margin

Valve Face

Grind intake valve and reface the seat to correct this condition. NOTE: Be sure to reset valve clearance after grinding valves.

M30024

IMPORTANT: Do not run the engine with blower housing removed. Lead Deposits

M29934

Poor engine cooling due to dirt or obstructions is a common cause for overheating an engine and the valves. Remove blower housing and clean the engine cooling fins. Other causes for valves running hot are worn valve guides or valve springs, incorrect valve clearance, lean fuel-air mixture and incorrect or overheated spark plug.

Valve stem corrosion is caused by moisture in the engine. Moisture in the fuel-air-mixture can condense inside the engine when the engine is stopped and cools down. Valve corrosion can also occur during storage. Fogging or pouring oil in the combustion chamber before storing, helps prevent valve corrosion.

Using old or stale gasoline is a common cause for sticky valves. This gummy deposit can be seen on the valve. When this condition exists, the carburetor may also contain gum deposits and will require a complete cleaning. Always use fresh gasoline and drain fuel tank, lines, and carburetor before storing machine.

Corroded or pitted valves collect deposits and may cause sticking valves. Replace badly corroded or pitted valves.

Gummy (Sticky) Deposit

Valve Stem Corrosion

M29936

M5563

Exhaust valves are designed to function in temperatures exceeding 2760°C (5000°F). However, when operating at high temperatures for long periods of time, valve burning may occur. Valves running too hot will show a dark discoloration of the valve stem into the area protected by the valve guide. Another indication is distortion of the valve margin and valve face. Valve inserts may also begin to burn away.

4/7/95

Exhaust valves are designed to function in temperatures exceeding 2760°C (5000°F). However, when operating at high temperatures for long periods of time, valve burning may occur. Valves running too hot will show a dark discoloration of the valve stem into the area protected by the valve guide. Another indication is distortion of the valve margin (A) and valve face (B). Valve inserts may also begin to burn away. Other causes for valves running hot are worn valve guides or valve springs, incorrect valve clearance, lean fuel-air mixture and incorrect or overheated spark plug.

12 - 3

COMPONENT ANALYSIS

ANALYZE PISTON RING WEAR

ANALYZE PISTON RING WEAR Rings of the wrong size or rings having improper end gap will not conform to the shape of the cylinder. This results in high oil consumption and excessive blow-by.

Varnish, Lacquer or Carbon Deposits

Ring end gaps should be staggered on the piston during installation. End gaps in alignment can also cause oil consumption and blow-by. Light scuffing or scoring of both rings and piston occurs when unusually high friction and combustion temperatures approach the melting point of the piston material. When this condition exists, it is due to one or more of the following probable causes: • Dirty cooling shroud and cylinder head. • Lack of cylinder lubrication. • Improper combustion. • Wrong bearing or piston clearance. • Too much oil in crankcase causing fluid friction.

M29944

Vertical scratches across the piston rings are due to an abrasive in the engine. Abrasives may be airborne, may have been left in the engine during overhaul or may be loose lead and carbon deposits. When this condition exists, check for one or more of the following: • Damaged, collapsed or improperly installed air filter. • Loose connection or damaged gasket between air cleaner and carburetor. • Air leak around carburetor-to-cylinder block gasket. • Air leakage around throttle shaft. • Failure to properly clean cylinder bore after reconditioning engine.

M29943

Vertical Scratches

The engine operating at abnormally high temperatures may cause varnish, lacquer or carbon deposits to form in the piston grooves making the rings stick. When this happens, excessive oil consumption and blow-by will occur. Engine overheating and ring sticking is usually caused by one or more of the following: • Overloading • Incorrect ignition timing. • Lean fuel mixture. • Dirty cooling fins. • Incorrect oil. • Low oil supply. • Stale fuel.

M29945

Abrasive particles in engine oil causes scratches on side rails of oil control ring. Inner spacer wear or distortion may cause: • High oil consumption. • Increased deposits in combustion chamber. • Sticking compression rings. Increased oil consumption may be caused by: • Worn side rails with low tension. • Worn or distorted inner spacer.

12 - 4

4/7/95

COMPONENT ANALYSIS

ANALYZE PISTON RING WEAR . Damaged Area

Side Rails Spacer

M30039 M38101

Check rod and piston alignment when piston shows a diagonal wear pattern extending across the skirt of the piston. Contact with the cylinder wall shows on bottom of skirt at left and ring lands on the right.

ANALYZE PISTON WEAR Detonation, is abnormal combustion causing excessive temperature and pressure in the combustion chamber. Commonly called carbon knock, spark knock or timing knock, detonation occurs as the compressed fuel-air mixture ignites spontaneously to interrupt the normal ignition.

A cylinder bored at an angle to the crankshaft can also give improper ring contact with cylinder causing: • Rapid piston wear. • Uneven piston wear. • Excessive oil consumption.

The following is a list of possible causes for detonation: • Lean fuel mixture. • Low octane fuel. • Advanced ignition timing. • Engine lugging. • Build-up of carbon deposits on piston or cylinder head, causing excessive compression. • Wrong cylinder head or milling of head increasing compression ratio.

Diagonal Wear Pattern M29948

A broken retaining ring caused the damage shown. Retaining rings loosen or break due to:

M29947

• Rod misalignment. • Excessive crankshaft end play. • Crankshaft journal taper. • Weak retaining rings. • Incorrectly installed retaining rings. Inertia can cause a broken retaining ring to beat out the piston and cylinder, causing extensive damage.

Pre-ignition is the igniting of the fuel-air mixture prior to regular ignition spark. Pre-ignition causes internal shock, resulting in pings, vibration, detonation and power loss. Severe damage to piston rings and valves results from pre-ignition. Check the following for causes of pre-ignition: • Internal carbon deposits. • Incorrect spark plug (high heat range). • Broken ceramic in spark plug. • Sharp edges on valves.

4/7/95

Damaged Area

M29949

12 - 5

COMPONENT ANALYSIS

ANALYZE CRANKSHAFT AND CONNECTING ROD WEAR

ANALYZE CRANKSHAFT AND CONNECTING ROD WEAR Check connecting rod and cap for damage or unusual wear patterns. Lack of lubrication or improper lubrication can cause the connecting rod and cap to seize the crankshaft. When the rod and cap seize to the crankshaft, the connecting rod and piston may both break causing other internal damage. Inspect block carefully before rebuilding engine. Crankshaft and connecting rod damage can result from: • Engine run low on oil or without oil. • Oil not changed regularly. • Bearing cap installed incorrectly.

12 - 6

4/7/95

INDEX A Air Cleaner Service 3 - 2 Analyze Crankshaft & Connecting Rod Wear 12 - 6 Analyze Piston Ring Wear 12 - 4 Analyze Piston Wear 12 - 5 Analyze Starter Condition 10 - 5 Analyze Valves 12 - 3

B Basic Engine Specifications 2 - 3 Breather Operation 3 - 4 Breather Repair 3 - 4 Breather Service 3 - 4

C Camshaft Bearing Inspection 7 - 4 Camshaft Installation 7 - 4 Camshaft Removal 7 - 4 Camshaft Service 7 - 4 Camshaft Specifications 7 - 4 Camshaft, Crankshaft & Flywheel Specifications 7 - 3 Carburetor Operation 4 - 4 Carburetor Serial Number Locations 2 - 5 Carburetor Specifications 4 - 3 Clean and Rebuild Carburetor 4 - 8 Component Location 2 - 18 Compression Test 11 - 9 Connecting Rod & Piston Assembly 6 - 14 Connecting Rod Bearing Specifications 6 - 13 Connecting Rod Inspection 6 - 13 Coolant Pump Removal & Installation 9 - 8 Coolant Pump Repair 9 - 9 Coolant Pump Service 9 - 8 Coolant Pump Specifications 9 - 9 Cooling System Components 9 - 5 Cooling System Operation 9 - 4 Cooling System Repair 9 - 6 Cooling System Specifications 2 - 5, 9 - 3 Crankcase Disassembly 6 - 6 Crankcase Vacuum Test 11 - 9 Crankshaft Inspection 7 - 5 Crankshaft Installation 7 - 6 Crankshaft Journal Bushing & Seal Replacement 6 - 9 Crankshaft Plain Bearings Inspection & Replacement6 - 8 Crankshaft Removal 7 - 5 Crankshaft Service 7 - 5 Cylinder Block, Piston & Rod Components 6 - 7 Cylinder Block, Piston & Rod Specifications 6 - 3 Cylinder Bore Specifications 6 - 10 Cylinder Head & Valve Specifications 5 - 3 Cylinder Head Cleaning and Inspection 5 - 4 Cylinder Head Removal 5 - 4 Cylinder Head Service 5 - 4 Cylinder Head Specifications 5 - 3 Cylinder Initial Rebore Specifications 6 - 11 Cylinder Inspection6 - 10

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D Deglaze Cylinder Bores . . . . . . . . . . . . . . . . . . . . 6 - 10 Down Draft Carburetor Repair . . . . . . . . . . . . . . . . 4 - 7

E Electrical System Specifications . . . . . . . . . . . . . . 10 - 3 Engine Applications . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3 Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 17 Engine Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 7 Engine Oil Specifications . . . . . . . . . . . . . . . . . . . 2 - 17 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 - 5

F FD440/501V Engine Repair Specifications . . . . . . . 2 - 6 FD440V/501V Cooling System Repair . . . . . . . . . . 9 - 6 FD440V/501V/590V Engine Component Locations . . . . . . . . . . . . . . . 2 - 18 FD440V/FD501V Cylinder Block, Piston & Rod Specifications . . . . . . . . . . . . 6 - 3 FD440V/FD501V/FD590V Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2 FD590D Altitude Compensation Switch Circuit Operation . . . . . . . . . . . . . . . . . . . 10 - 9 FD590D Fuel INjection Throttle Sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 9 FD590V Cooling System Repair . . . . . . . . . . . . . . . 9 - 7 FD590V Cylinder Block, Piston & Rod Specifications . . . . . . . . . . . . . . . . . . . . . . . 6 - 4 FD590V Engine Repair Specifications . . . . . . . . . . . 2 - 9 FD590V Engine Throttle Body Repair . . . . . . . . . . 4 - 14 FD620D Cooling Fan & Bracket . . . . . . . . . . . . . . 9 - 10 FD620D Cooling Fan Belt Adjustment . . . . . . . . . 9 - 10 FD620D Cylinder Block, Piston & Rod Specifications . . . . . . . . . . . . . . . . . . . . . . . 6 - 5 FD620D Engine Air Cleaner . . . . . . . . . . . . . . . . . . 3 - 2 FD620D Engine Component Locations . . . . . . . . . 2 - 22 FD620D Engine Repair Specifications . . . . . . . . . 2 - 12 FD620D Engine Throttle Body Repair . . . . . . . . . . 4 - 14 FD620D Fuel Injection Air Pressure Sensor Operation . . . . . . . . . . . . . . . . . . . 10 - 9 Float Level Adjustment . . . . . . . . . . . . . . . . . . . . . . 4 - 8 Fuel Injection Air Temperature Sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 8 Fuel Injection System Operation . . . . . . . . . . . . . . 4 - 11 Fuel Injection System Service . . . . . . . . . . . . . . . . 4 - 11 Fuel Injection Temperature Sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 8 Fuel Injector Operation . . . . . . . . . . . . . . . . . . . . . 4 - 11 Fuel Injector Repair . . . . . . . . . . . . . . . . . . . . . . . . 4 - 12 Fuel Injector Test . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 8 Fuel Pressure Regulator Operation . . . . . . . . . . . 4 - 12 Fuel Pressure Regulator Repair . . . . . . . . . . . . . . 4 - 13 Fuel Pressure Regulator Service . . . . . . . . . . . . . 4 - 12 Fuel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 16 Fuel System Troubleshooting . . . . . . . . . . . . . . . . . 4 - 3 Fuel/Air System Specifications . . . . . . . . . . . . . . . . 2 - 5

G Gasoline Specifications . . . . . . . . . . . . . . . . . . . . . Governor Operation . . . . . . . . . . . . . . . . . . . . . . . Governor Repair . . . . . . . . . . . . . . . . . . . . . . . . . . Governor Service . . . . . . . . . . . . . . . . . . . . . . . . .

2 - 16 4 - 10 4 - 10 4 - 10

INDEX - 1

INDEX

H

R

Handling Asbestos . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4 Rebore Cylinder Block . . . . . . . . . . . . . . . . . . . . . . 6 - 10 Head and Valve Components . . . . . . . . . . . . . . . . . 5 - 4 Repair Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6 Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6 Ring End Gap Specifications . . . . . . . . . . . . . . . . . 6 - 11 Ring Land Side Clearance Specifications . . . . . . . 6 - 12 I Rocker Arm Specifications . . . . . . . . . . . . . . . . . . . . 5 - 3 Ignition Coil Replacement . . . . . . . . . . . . . . . . . . . 10 - 4 S Ignition Module Replacement . . . . . . . . . . . . . . . . . 10 - 5 Intake Manifold Installation . . . . . . . . . . . . . . . . . . . . 3 - 3 Safe Chemical Handling . . . . . . . . . . . . . . . . . . . . . . 1 - 2 Intake Manifold Removal . . . . . . . . . . . . . . . . . . . . . 3 - 3 Safe Fluid Handling . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2 Intake Manifold Service . . . . . . . . . . . . . . . . . . . . . . 3 - 3 Serial Number Plate Locations . . . . . . . . . . . . . . . . . 2 - 4 Internal Engine Components . . . . . . . . . . . . . . . . . 2 - 20 Side Draft Carburetor Repair . . . . . . . . . . . . . . . . . . 4 - 6 Solenoid Shift Starter Inspection . . . . . . . . . . . . . . 10 - 6 L Starter Armature Test . . . . . . . . . . . . . . . . . . . . . . . 10 - 7 Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . 2 - 17 Starter Field Windings Test . . . . . . . . . . . . . . . . . . 10 - 6 Lubrication System Components . . . . . . . . . . . . . . . 8 - 4 Starter Service Parts Kits . . . . . . . . . . . . . . . . . . . . 10 - 5 Lubrication System Operation . . . . . . . . . . . . . . . . . 8 - 4 Starter Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . 10 - 7 Lubrication System Specifications . . . . . . . . . . . . . . 8 - 3 Starting Motor Diagnosis . . . . . . . . . . . . . . . . . . . . 11 - 6 M Stator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 4 Manual Fuel Pump Repair . . . . . . . . . . . . . . . . . . . . 4 - 9 Stator Replacement . . . . . . . . . . . . . . . . . . . . . . . . 10 - 4 Mechanical Fuel Pump Operation . . . . . . . . . . . . . . 4 - 9 Synthetic Lubricants . . . . . . . . . . . . . . . . . . . . . . . . 2 - 17 Mechanical Fuel Pump Service . . . . . . . . . . . . . . . . 4 - 9 T Metric Torque Valves . . . . . . . . . . . . . . . . . . . . . . . 2 - 15 Tappet Removal & Installation . . . . . . . . . . . . . . . . .7 - 5 Model Configuration Changes . . . . . . . . . . . . . . . . . 2 - 4 Test & Adjustment Specifications . . . . . . . . . . . . . . . 2 - 5 Muffler Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3 Thermostat Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 8 O Thermostat Specifications . . . . . . . . . . . . . . . . . . . . 9 - 8 Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 17 Thermostat Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 8 Oil Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 10 Throttle Body Service . . . . . . . . . . . . . . . . . . . . . . 4 - 13 Oil Pump Disassembly & Assembly . . . . . . . . . . . . . 8 - 5 Trhottle Body Operation . . . . . . . . . . . . . . . . . . . . . 4 - 13 Oil Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 3 Oil Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 5 V Oil Pump Specifications . . . . . . . . . . . . . . . . . . . . . . 8 - 6 Valve & Spring Specifications . . . . . . . . . . . . . . . . . 5 - 3 P Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . 5 - 5 Performance Diagnosis . . . . . . . . . . . . . . . . . . . . . 11 - 8 Valve, Valve Seat and Guide Inspection . . . . . . . . . 5 - 5 Piston & Piston Pin Specifications . . . . . . . . . . . . . 6 - 12 Valve, Valve Seat and Guide Service . . . . . . . . . . . 5 - 5 Piston Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 12 Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 8 Piston Ring End Gap Check . . . . . . . . . . . . . . . . . . 6 - 11 Piston Rings Removal and Installation . . . . . . . . . . 6 - 11 Proper Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3 Proper Waste Disposal . . . . . . . . . . . . . . . . . . . . . . . 1 - 2 Proper Welding Procedures . . . . . . . . . . . . . . . . . . . 1 - 4 Proper Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3 Protective Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3 Pulser Coil Replacement . . . . . . . . . . . . . . . . . . . . 10 - 4 Push Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6 Push Rod Specifications . . . . . . . . . . . . . . . . . . . . . 5 - 3

INDEX - 2

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