Ford VSG-413 - Service Manual

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Power

Products

VSG-411 I41 3

ENGINE

SERVICE

MANUAL

FPPO-194-264

REVISED OCT. ‘89

Main Page

Safety Notice2
CGS Gasoline Engine4
Basic Engine4
Engine Identification5
Lubrication Circuit5
Engine Description5
VSG-411 Sectional View6
Engine Ventilation System Diagram7
Lubrication Circuit Diagram7
Engine: Diagnosis and Testing8
Camshaft Lobe Lift8
Compression Test8
Flywheel Face Runout, Camshaft End Play8
Cylinder Head9
Reaming Valve Guides9
Refacing Valve Seats9
Quick Reference Compression Pressure Limit Chart9
Refacing Valves10
Select Fitting Valves10
Camshaft Repair10
Crankshaft10
Fitting Pistons11
Fitting Piston Rings11
Valve Rocker Arm And/Or Shaft Assembly12
Push Rods12
Cylinder Block12
Repairing Sand Holes or Porous Engine Castings12
Intake Manifold Cleaning and Inspection13
Exhaust Manifolds Cleaning and Inspection13
Push Rods Cleaning and Inspection13
Cylinder Heads Cleaning and Inspection13
Tappets Cleaning and Inspection14
Timing Chain and Sprockets Cleaning and Inspection14
Camshaft Cleaning and Inspection14
Crankshaft Cleaning and Inspection15
Flywheel Inspection15
Connecting Rods Cleaning and Inspection15
Pistons, Pins and Rings Cleaning and Inspection15
Main and Connecting Rod Bearings Cleaning and Inspection16
Cylinder Block Cleaning and Inspection16
Oil Pan Cleaning and Inspection17
Oil Pump Cleaning and Inspection17
Valve Rocker Arm Cover, Rocker Arm And/Or Shaft Removal and Installation18
Intake Manifold Removal and Installation18
Exhaust Manifold Removal and Installation18
Cylinder Head Removal and Installation18
Valve Spring, Retainer and Stem Seal Cylinder Head Removed Removal and Installation20
Cylinder Head Installed Removal and Installation20
Water Pump Removal and Installation21
Cylinder Front Cover and Timing Chain, or Crankshaft Sprockets Removal and Installation21
Adjusting Valve Clearances22
Crankshaft Front Oil Seal Removal and Installation22
Camshaft And/Or Valve Lifters Removal and Installation23
Camshaft Bearings Removal and Installation24
Oil Pump Removal and Installation24
Oil Pan Removal and Installation24
Crankshaft Rear Oil Seal Removal and Installation25
Pistons and Connecting Rods Removal and Installation25
Oil Filter Removal and Installation26
Engine Assembly Disassembly and Assembly26
Oil Pump Disassembly and Assembly28
Ignition System - Breaker Point29
Distributor Identification Number29
Ignition System Diagnosis and Testing30
Spark Intensity Tests30
Primary Circuit, Secondary Circuit30
Battery to Coil Voltmeter Test30
Distributor Tests - on Engine31
Starting Ignition Circuit Voltmeter Test31
Coil to Ground Voltmeter Test31
Secondary (High Tension) Wires Resistance Test31
Breaker Point Alignment32
Dwell Angle/Breaker Point Gap Adjustment32
Dwell Angle Check32
Distributor Spark Advance Test32
Breaker Points And/Or Condenser Removal and Installation33
Initial Ignition Timing33
Spark Plug Wire Removal and Installation34
Spark Plugs Removal and Installation34
Distributor Removal and Installation34
Vacuum Diaphragm Removal and Installation35
Spark Plugs Cleaning and Inspection35
Distributor Cleaning and Inspection35
Ignition Coil Cleaning and Inspection35
Spark Plug Inspection - Illustration37
Ignition System - Solid State38
Primary Circuit Diagnosis and Testing39
Secondary Circuit Diagnosis and Testing39
Engine Cranks but will Not Start40
Initial Timing Check41
Initial Ignition Timing Adjustments41
Distributor Removal and Installation (Solid State)42
Spark Plugs Removal and Installation (Solid State)42
Distributor Cleaning and Inspection (Solid State)43
Distributor Cap and Rotor Cleaning and Inspection (Solid State)43
Ignition Wires Inspection43
Ignition Coil Cleaning and Inspection (Solid State)43
Spark Plug Inspection - Illustration (Solid State)44
Ignition System - Distributorless45
Cranking Mode46
Run Mode46
Transient Mode46
Overspeed Mode46
Ignition Coil Removal and Installation (Distributeless)47
Engine Speed Sensor Removal and Installation (Distributeless)47
Engine Coolant Temperature Sensor Removal and Installation (Distributeless)48
DIS Diagnosis Equipment49
DIS Diagnosis Procedure49
DIS Engine Harness Checks (UESC Harness Connector Removed All Sensor Connected to Harness)50
Codes - Temperature Sensor Characteristics Chart (TSCC)50
Engine Coolant Sensor Characteristics51
DIS Coil Connector for Engine Harness - Diagram52
VSG Distributorless Ignition System (DIS) Wiring Diagram Reference (E8JL-12A200-AD)53
VSG Distributorless Ignition System (DIS) Wiring Diagram Reference (E8JL-12A200-AD)54
VSG Distributorless Ignition System (DIS) Wiring Diagram Reference (E9JL-12A200-AB)55
VSG Distributorless Ignition System (DIS) Wiring Diagram Reference (E9JL-12A200-AC)56
VSG Distributorless Ignition System (DIS) Wiring Diagram Reference (E9JL-12A200-CA)57
VSG Distributorless Ignition System (DIS) Wiring Diagram Reference (E9JL-12A200-CB)58
VSG Distributorless Ignition System (DIS) Wiring Diagram Reference (E9JL-12A200-CC)59
Vacuum Line to Vacuum Port on Top of 4 Cyl Runner of Intake Manifold - Diagram60
Crankshaft Pulley - 2 Groove62
Rear Engine Plates Diagram63
Fuel System General Description64
Fuel System Identification64
Fuel System Diagnosis and Testing64
Air Cleaner Description and Operation64
Removal/Air Filter Element Replacement65
Fuel Pump Description66
Fuel Pump Diagnosis and Testing66
Fuel Pump Capacity (Volume) Test66
Fuel Pump Assembly Removal and Installation66
Facet Carburetor Disassembly67
Facet Carburetor Cleaning and Inspection67
Assembly of Air Intake / Assembly of Fuel Bowl67
Sideraft 87-Model Carburetor Description67
Facet Carburetor Exploded View68
Fuel Supply System Operation69
Idle System Operation69
High Speed (Main Metering) System Operation69
Choke System Operation70
Disassembly of Throttle Body70
Disassembly of Fuel Bowl70
Removal and Replacement of Throttle Shaft Bushings70
Assembly of Fuel Bowl71
Assembly of Throttle Body71
Assembly of Bowl to Throttle Body71
Fuel System Adjustments71
Sidecraft Model Carburetor Exploded View72
Variable Venturi Carburetor Description73
Fuel Input System73
Float Chamber Vent System74
Air Control74
Main Fuel Control System75
Idle System75
Throttle Operation76
Accelerator Pump76
Idle System Diagram76
Manual Choke Operation77
Pump Back Bleed77
Vacuum Break Air Hole77
Choke Fuel Supply and Control / Choke Air Supply and Control77
Choke Pull down System78
Two Extreme Conditions of Choke Operation - Diagrams78
Air Supply System in Operation - Diagram78
Air Supply System Closed down - Diagram78
Electric Choke Control Operation79
Electric Choke Control Assembly Diagram79
Choke Open, Engine Warm - Diagram79
VV Carburetor Diagnostic Checks and Adjustments80
Idle Fuel Mixture and Idle Speed80
Anti-Dieseling Valve80
Carburetor Removal and Installation81
Accelerator Pump - Vacuum Diaphragm Removal and Installation82
Needle Valve Removal and Installation82
Manual Choke Assembly Removal and Installation82
Carburetor Control Diaphragm Removal and Installation83
Charging System Diagnosis and Testing84
Alternator Operation84
Battery Testing84
Capacity Test85
Charging System Tests85
No Load, Load85
Over Voltage85
Control Voltage86
Output86
Diodes Bench Test86
Field Diodes Bench Test86
Stator Coil Open or Grounded Bench Test87
Rotor Open or Short Circuit Bench Test87
Alternator Overhaul87
Fan, Pulley and Associated Components Diagram87
Disassembled Alternator Diagram88
Alternator Assembly89
Starting System Description and Operation90
Starting System Testing90
Starter Circuit Test90
Starter Load Test90
Starter Cranking Circuit Tests - Diagram91
Starter Load Test - Diagram91
Starter Solenoid Test92
Starter No-Load Bench Test92
Armature Open Circuit Test92
Armature and Field Grounded Circuit Test92
Starter Removal and Installation93
Starting System Ovehaul93
Starting System Cleaning and Inspection93
Starter Motor Exploded View94
Starter Motor Assembly95
Pinion and Ring Gear Wear Patterns Diagram95
Sliding Armature in Its Bearings - Diagram96
Solenoid Diagram96
Governor Description and Operation97
Governor Adjustments97
Oil Level97
Belt Tension97
Throttle Control Rod98
RPM Adjustments98
Spread or Sensitivity98
Increas Spread98
Decrease Spread99
Governor Removal and Installation99
Low Speed99
No-Load Surge99
Cooling System Description and Operation100
Drive Belt Adjustment100
Specifications101

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Ford VSG-413 Specifications

General

Brand	Ford
Model	VSG-413
Category	Engine
Language	English

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