PCM 302 - Engine Overhaul; Manifold Vacuum Diagnosis and Testing

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Index2
Model Identification4
Electrical Theory/Refresher5
Electricity and Magnetism, Terms5
Electrical Source6
Electromagnets7
Generating Electric Current7
Voltage Regulator9
Battery9
Ignition Coil Operation and Construction10
Engine Accessories, Test and Tune11
Starter Motor Principle11
Alternator, Regulator and Wiring Harness11
General Wiring Diagram12
Alternator Group Exploded View12
Regulator Check12
Carburetor and Fuel Pump13
Electrical System14
Overhaul of Carburetor14
Circuit Breaker14
Battery Specifications15
Ignition Coil and Resistor16
Distributor and Spark Cables16
Engine Timing and Ignition16
Firing Order - Cylinder Numbering/Engine Rotation16
Prestolite Distributors (Marine Engines) Description and Operation17
Adjustments and Repairs - Breaker Points And/Or Condenser17
Centrifugal Advance Mechanism View17
Weights, Spring and Cam Installed View17
Breaker Plate and Sub-Plate Removal and Installation18
Cam and Centrifugal Advance Weights Removal and Installation18
Distributor Removal and Installation18
Conventional Ignition System Distributor19
Bench Assembly - Original Shaft and Gear19
Bench Assembly - New Shaft and Gear19
Distributor Assembly (Conventional) Exploded View20
Oil Coolers21
Starter and Relay22
Cooling System, Raw Water Cooled Models23
Troubleshooting the Cooling System23
Overheating23
Internal Leaks23
Water in Crankcase24
External Leaks (Not Evident)24
Sherwood Raw Water Supply Pump - Exploded View24
Cooling System - Fresh Water Cooled Models25
Water Pump, Circulating25
Water Pump, Raw Water Supply26
Flywheel Housing, Drive Damper, Flywheel26
Senders, Oil Pressure and Temperature26
Holley Carburetor Repair and Diagnostic Procedures28
Holley Two-Barrel Carburetor - Model 2300 Description30
Main Body (Carburetor Model 2300)30
Throttle Body30
Carburetor Systems31
Metering Block31
Fuel Bowl Assembly31
Fuel Inlet System31
Idle Fuel System32
Main Metering System32
Carburetor Adjustments (Model 2300)33
Power Fuel System33
Accelerating Pump System33
Float or Fuel Level Adjustments33
Dry Adjustment - Externally Adjusted Float34
Wet Adjustment - Externally Adjusted Float34
Dry Adjustment - Internally Adjusted Float35
Checking Fuel Level - Internally Adjusted Float35
Accelerating Pump Override Spring Adjustment35
Accelerating Pump Stroke Adjustment36
Electric Automatic Choke Plate Clearance (Pulldown) Adjustment36
Dechoke Clearance Adjustment36
Carburetor Disassembly37
Automatic Choke Thermostatic Spring Housing Adjustment37
Idle Speed Adjustment37
Idle Fuel Mixture Adjustment37
Carburetor Assembly39
Fuel Bowl and Metering Block40
Model 2300C Carburetor Exploded View41
Model 2300C Carburetor Nomenclature42
Hollwy Four-Barrel Carburetors - Models 4150 and 4160 Description43
Fuel Inlet System (4150/4160)43
Idle Fuel System (4150/4160)44
Main Metering System (4150/4160)44
Secondary Metering Block 416045
Primary Metering Block 4150, 416045
Secondary Metering Block 415045
Power Fuel System (4150, 4160)46
Secondary Operation - Vacuum Systems (4150, 4160)46
Accelerator Pump (4150, 4160)47
Float or Fuel Level Adjustments (4150, 4160)48
Dry Adjustments/Wet Adjustments (4150, 4160)48
Checking Fuel Level - Internally Adjusted Float (4150, 4160)49
Accelerating Pump Override Spring Adjustment (4150, 4160)49
Accelerating Pump (4150, 4160)50
Secondary Throttle Stop Adjustment (4150, 4160)50
Choke Plate Clearance (Pulldown) Adjustment (4150, 4160)50
Dechoke Clearance Adjustment (4150, 4160)50
Carburetor Models 4150 and 4160 Service Procedures51
Automatic Choke Thermostatic Spring Housing Adjustment (4150, 4160)51
Idle Speed Adjustment (4150, 4160)51
Idle Fuel Mixture Adjustment (4150, 4160)51
Carburetor Models 4150 and 4160 Disassembly52
Carburetor Models 4150 and 4160 Assembly55
Assembling Primary Metering Body (4150, 4160)55
Assembly Fuel Bowls (Primary) (4150, 4160)56
Secondary Fuel Bowl (External Needle and Seat) (4150, 4160)56
Fuel Bowls with Internal Fuel Inlet Needle and Seat57
Assembling Main Body (4150, 4160)57
Model 4160 Assembly57
Primary Bowl and Metering Body Assembly (4160)57
Model 4150 Secondary Bowl and Metering Body Assembly58
Assembling Secondary Diaphragm58
Externally Adjusted Needle and Seat Exploded View59
Carburetors Models 4150 and 4160 Nomenclature60
Carburetors Models 4150 and 4160 Troubleshooting61
Carburetor Assembly - 4150 with Governor, Diagram61
Carburetor Specifications63
Holley Carburetor Problem Diagnosis64
Rochester Carburetor Repair and Diagnostic Procedures66
Model 4MV Carburetor - General Description68
Model 4MV Carburetor View69
Model 4MV Carburetor Identification69
Model 4MV Carburetor Systems Diagrams70
Float Level Adjustment (4MV)71
Pump Adjustment (4MV)71
Choke Rod (Fast Idle Cam) Adjustment - Angle Gauge Method (4MV)72
Air Valve Rod Adjustment (4MV)72
Vacuum Break Adjustment - Angle Gauge Method (4MV)73
Automatic Choke Coil Rod Adjustment (4MV)73
Unloader Adjustment - Angle Gauge Method (4MV)74
Secondary Closing Adjustment (4MV)74
Secondary Opening Adjustment (4MV)75
Air Valve Spring Adjustment (4MV)75
Idle Speed Adjustment - Without Solenoid (4MV)75
Andle Degree to Decimal Conversion - Model 4MV Carburetor76
Model 4MV Carburetor On-Engine Service77
4MV Carburetor Adjustments77
Checking Carburetor Choke (4MV)77
Idle Mixture Adjustment (4MV)78
Carburetor Replacement (4MV)78
Model 4MV Carburetor Disassembly78
Air Horn Disassembly (4MV)79
Float Bowl (4MV)80
Float Bowl Disassembly (4MV)81
Throttle Body Disassembly (4MV)81
4MV Carburetor Cleaning and Inspection81
4MV Carburetor Assembly82
Float Level (4MV)82
Air Horn to Bowl Assembly (4MV)83
4MV Carburetor Torque Specifications84
Rochester Carburetor Diagnosis85
Engine Cranks Normally - will Not Start85
Engine Starts - will Not Keep Running85
Engine Starts Hard (Cranks Normally)86
Engine Idles Abnormally (too Fast or too Slow)87
Engine Diesels (after Run) Upon Shut off87
Engine Hesitates on Acceleration88
Engine Has Less than Normal Power at Normal Accelerations88
Less than Normal Power on Heavy Acceleration or at High Speed89
Engine Surges89
Excessive Fuel Consumption90
Engine Feels Like It Is Running out of Gas - Surging Occurs91
Engine Starts but will Not Continue to Run91
Fuel Starvation91
Ford Engine Starting System Repair and Diagnostic Procedures92
Ford Engine Starting System Description and Operation93
Positive Engagement Starter93
Solenoid Actuated Starter93
Solenoid Operation94
Connector Link95
Booster Battery Testing95
On Vehicle Testing Solenoid Starter95
Starter Cranking Circuit Test95
Starter Solenoid Test96
Bench Tests - Starter No-Load Test96
Armature Open Circuit Test97
Armature and Field Grounded Circuit Test97
Starting System On-Vehicle Testing98
Starter Drive and Starter Test98
Alternate Starter Drive Test98
Positive Engagement - Starter Cranking Circuit Test98
Starter Load Test99
Starter No-Load Test - Bench Test99
Armature Open Circuit Test - on Test Bench99
Armature and Field Grounded Circuit Test - on Test Bench99
Starter Removal and Installation100
Overhaul Positive Engagement100
Starter Disassembly100
Solenoid Actuated Starter Disassembly101
Starter Cleaning and Inspection102
Assembly Positive Engagement Starter102
Assembly Solenoid Starter103
Starter Drive Replacement103
Brush Replacement - Positive Engagement Starter104
Brush Replacement - Solenoid Starter104
Armature Replacement105
Starter Terminal Removal105
Starter Terminal Installation105
Starting System Specifications106
Delco Starter Systems Repair and Diagnostic Procedures107
Delco Starter System General Description108
Starter Motor Construction108
Armature108
Drive Mechanism108
Solenoid109
Starting Motor Cross Section View109
Typical Cranking System109
Delco Starter System Diagnosis110
No Cranking Action110
Cranking Speed Abnormally Low110
Voltage Test of Starting System and Solenoid Switch111
Amperage Test of Solenoid Switch Windings111
Delco Starter System on Vehicle Service112
Delco Starter System Lubrication112
Starting Motor Replacement/Bench Test112
Checking Pinion Clearance112
Starting Motor Disassembly - Except Diesel113
Starting Motor Cleaning and Inspection113
Starting Motor Parts Layout114
Armature Test for Shorts115
Armature Test for Ground115
Field Coil Test for Open Circuit/Field Coil Test for Ground115
Field Coil Replacement115
Delco Starting Motor Assembly116
Loose Electrical Connections116
Turning the Commutator116
Brush Holder Replacement/Overrunning Clutch116
Pinion Clearance Check117
Starting Solenoid Removal118
Replacement of Contacts (Starting Solenoid)118
Starting Solenoid Installation118
Starter (Diesel Engine) Disassembly119
Starter (Diesel Engine) Cleaning, Inspection and Tests120
Solenoid Switch120
Starter (Diesel Engine) Assembly120
Pinion Clearance121
Delco-Remy - Enclosed Shift Lever Type Cranking Motors122
Cranking Motor Lubrication122
Troubleshooting the Cranking Circuit122
Cranking Motor Tests123
Magnetic Switch or Solenoid and Control Switches123
No-Load Test123
Cranking Motor Disassembly124
Cranking Motor Component Inspection and Repair124
Typical Cranking Motor Circuits View125
Basic Solenoid Circuit125
Connections for Checking Solenoid125
Cranking Motor Reassembly126
Cranking Motors and Miscellaneous DC Motors - No-Load Test128
Starting Motor Specifications128
Ford Engines Repair and Diagnostic Procedures129
Ford Engine Index130
460 Engines Description and Operation131
Manifolds131
Cylinder Heads/Cylinder Block131
Valve Train131
Lubrication System132
Positive Crankcase Ventilation System133
Carburetors133
Distributors133
302 And 351 Engines Description and Operation134
Engine Overhaul136
Manifold Vacuum Diagnosis and Testing136
Camshaft Identification137
Valve Spring Color Code137
Rear Main Seal Color Code - All Engines137
Engine Water Pump Identification137
Camshaft Lobe Lift Diagnosis and Testing138
Compression Test138
Compression Gauge Check138
Hydraulic Valve Lifter139
Positive Closed-Type Ventilation System139
Air Intake Test139
Crankcase Ventilation Regular Valve Test140
Crankshaft End Play140
Flywheel Face Runout140
Camshaft End Play140
Timing Chain Deflection141
Intake Manifold Cleaning and Inspection141
Exhaust Manifolds Cleaning and Inspection141
Valver Rocker Arm Assembly Cleaning and Inspection141
Bush Rods Cleaning and Inspection142
Cylinder Heads Cleaning and Inspection142
Hydraulic Valve Lifters Cleaning and Inspection143
Crankshaft Vibration Damper and Sleeve Cleaning and Inspection143
Timing Chain and Sprockets Cleaning and Inspection144
Camshaft Cleaning and Inspection144
Crankshaft Cleaning and Inspection144
Flywheel Inspection145
Connecting Rods Cleaning and Inspection145
Pistons, Pins and Rings Inspection145
Main and Connecting Rod Bearings Cleaning and Inspection146
Cylinder Block Cleaning and Inspection146
Oil Pan Cleaning and Inspection147
Oil Pump Cleaning and Inspection147
Positive Closed-Type Crankcase Ventilation System Cleaning148
Cylinder Head Overhaul148
Reaming Valve Guides148
Refacing Valve Seats148
Refacing Valves149
Select Fitting Valves149
Camshaft Repair/Crankshaft150
Refinishing Journals150
Fitting Main or Connecting Rod Bearings with Plastigage150
Fitting Pistons150
Valve Rocker Arm151
Push Rods151
Cylinder Block - Refinishing Cylinder Walls151
Fitting Piston Rings/Fitting Piston Pins151
Repairing Sand Holes or Porous Engine Castings152
Valve Clearance Adjustments153
Crankcase Ventilation System Removal and Installation155
Valve Rocker Arm Cover and Rocker Arm Removal and Installation155
Valve Spring, Retainer and Stem Seal Removal and Installation156
Intake Manifold Removal and Installation157
Valve Lifter Removal and Installation158
Cylinder Heads Removal and Installation160
Exhaust Manifold Removal and Installation161
Water Pump Removal and Installation161
Cylinder Front Cover and Timing Chain Removal and Installation161
Front Oil Seal Removal and Installation163
Core Plugs Removal and Installation163
Typical Core Plugs and Installation Tools View164
Camshaft and Related Parts View164
Cup Type Core Plugs - Installation165
Expansion Type Core Plugs - Installation165
Camshaft Removal and Installation165
Camshaft Rear Bearing Bore Plug Removal and Installation166
Oil Pan Removal and Installation166
Oil Pump Removal and Installation166
Crankshaft Rear Oil Seal Removal and Installation167
Main Bearing Removal and Installation167
Connecting Rod Bearings Removal and Installation169
Pistons and Connecting Rods Removal and Installation170
Cranksharft Removal and Installation171
Camshaft Bearings Removal and Installation173
Oil Filter (Spin-On Type) Removal and Installation174
Valve Lifter Disassembly and Assembly175
Cylinder Heads Disassembly and Assembly175
Oil Pump Disassembly and Assembly176
Pistons and Connecting Rods Disassembly and Assembly177
Cylinder Assembly Disassembly and Assembly178
Cylinder Block Disassembly and Assembly178
Specifications - Ford Engines179
Chervolet Engines Repair and Diagnostic Procedures189
Chevrolet "V" Block General Description190
Engine Lubrication191
Oil Filter Type and Capacity192
Crankcase Capacity192
Recommended Viscosity192
Checking Oil Level192
Chevrolet "V" Block - in Boat Service193
Exhaust Manifold Removal and Installation (Chevrolet)193
Rocker Arm Cover Removal and Installation193
Small V-8 Engine Lubrication - Diagram194
Valve Mechanism Removal, Installation and Adjustment196
Intake Manifold Torque Sequence - V-6196
454 Engine197
Valve Stem Oil Seal And/Or Valve Spring Removal and Installation197
Valve Lifters198
Locating Noisy Lifters198
Valve Lifters Removal and Installation199
Valve Lifters Disassembly199
Valve Lifters Cleaning and Inspection199
Valve Lifters Assembly199
Cylinder Head Assembly Removal/Disassembly/Cleaning/Inspection200
Cylinder Head Assembly Assembly201
Cylinder Head Assembly Installatoin203
Rocker Arm Studs Replacement204
Valve Guide Bores204
Valve Seats204
Valves204
Valves Reconditioning205
Torsional Damper Removal and Installation205
Crankcase Front Cover Removal and Installation206
Oil Seal (Front Cover) Replacement207
Camshaft - Measuring Lobe Lift207
Camshaft Removal, Inspection and Installation208
Camshaft Bearings Removal208
Camshaft Bearings Installation209
Oil Pan Removal and Installation209
Oil Pump Removal and Disassembly209
Oil Pump Cleaning and Inspection (Chevrolet)210
Oil Pump Assembly210
Oil Pump Installation210
Connecting Rod Bearings210
Connecting Rod Bearings Inspection and Replacement211
Main Bearings Inspection/Checking Clearance212
Main Bearings Replacement213
Oil Seal (Rear Main) Replacement214
Connecting Rod and Piston Assemblies Removal and Disassembly215
Connecting Rod and Piston Assemblies Cleaning and Inspection215
Connecting Rod and Piston Assemblies Assembly216
Connecting Rod and Piston Assemblies Installation218
Cylinder Block Cleaning and Inspection (Chervolet)219
Cylinder Block Conditioning219
Cylinder Block Boring and Honing219
Oil Filter Bypass Valve Inspection and Replacement220
Piston Selection220
Crankshaft Removal, Cleaning and Inspection220
Sprocket or Gear Replacement220
Chevrolet "V" Block Specifications222
Velvet Drive224
Identification Markings for Warner Gear Division Marine Gears226
10-17 and 10-18 Units Service Instructions227
Selecting a Proper Velvet Drive228
Engine Rotation228
Transmission Rotation228
Hydraulic Pump Indexing228
Propeller Selection229
Propeller Rotation229
Transmission Ratio Selection229
Installation Drawing for In-Line Transmissions230
In-Line Transmissions General Performance Data/Dimensions230
Identification of Velvet Drive In-Line Models 70C, 71C, 72C and 73C231
Installation Drawing for V-Drive Transmissions232
V-Drive Transmissions General Specifications232
V-Drive Assemblies233
Installation Drawing for Drop-Center Transmissions234
Drop-Center Transmissions General Specifications234
CR2 (Drop Center Assemblies)235
Adapter Housing236
Transmission Installation236
Transmission Fluid236
Checking Oil Level (Transmission)236
Typical Timing Gear End Installation - Diagram237
Typical Flywheel End Installation - Diagram237
Transmission Operation238
Filling and Checking the Hydraulic System238
Neutral/Forward/Reverse238
Freewheeling238
Propeller Shaft Couplings239
Coupling to Shaft Assembly239
Transmission Coupling to Propeller Shaft Coupling Alignment239
Use of Flexible Couplings239
Shift Lever240
Mounting Brackets240
Transmission Painting240
Coolers241
Transmission Cooling Requirements241
Recommendations for Sizing Coolers241
Water Flow Rate/Water Temperature to Cooler241
Connecting Cooler to Transmission242
Cooler out Location243
Cooler Return Location243
Mounting Cooler243
Testing Cooler Circuit244
Water Drain Plug244
Cooling Problems244
Vibration Dampers245
Transmission Requirements245
Dampers Selection245
Damper Application and Damper Assemblies Chart246
Damper Installation247
Spline Engagement247
Early Damper Splines247
Damper Problems247
Neutral Switch Kit248
Transmission Alarm Kits248
Routine Checks and Maintenance249
Matching Engine, Transmission and Propeller Rotation250
Engine Rotation/Transmission Shaft Rotation Described250
To Index Pump for Opposite Hand Rotation250
Typical Timing Gear End Installation251
Typical Flywheel End Installation251
Single Prop Installation251
Warner Gear Repair and Diagnostic Procedures252
71C-72C Direct Drive and Reduction Rations 1.5:1 - 2.91:1253
List of Drive-Direct and Reduction Models Covered in the Manual254
List of Figures257
List of Tables257
71C and 72C Transmissions Description258
71C and 72C Transmissions Specifications258
71C and 72C Transmissions Typical Installation - Diagram259
Forward Power Flow Diagram259
Reverse Power Flow Diagram259
Hydraulic Circuit Schematic (Model 72C Direct-Drive Shown)260
71C and 72C Transmissions Scheduled Inspections261
71C and 72C Transmissions Maintenance263
71C and 72C Transmissions - Changing Oil264
71C and 72C Transmissions Troubleshooting265
71C and 72C Transmissions Overhaul269
71C and 72C Transmissions Disassembly269
71C and 72C Transmissions Cleaning and Inspection269
71C and 72C Transmissions Repair269
71C and 72C Transmissions Assembly270
71C and 72C Transmissions Installation285
71C and 72C Transmission Assembly Exploded View286
Model Chart 71C and 72C Transmissions292
Optional Drive Gear Alarm Kits293
71C and 72C Transmissions - Bolt and Fastener Torques294
71C and 72C Transmissions - Spring Dimensions294
71C and 72C Transmissions - Test Pressures295
1.523:1 Reduction Units Description296
1.523:1 Reduction Units Overhaul296
1.523:1 Reduction Units Exploded View302
1.88:1 and 1.91:1 Reduction Units Description305
1.88:1 and 1.91:1 Reduction Units Overhaul305
1.88:1 and 1.91:1 Reduction Units Exploded View311
2.57:1 and 2.91:1 Reduction Units Description315
2.57:1 and 2.91:1 Reduction Units Overhaul315
2.57:1 and 2.91:1 Reduction Units Exploded Views321
2.10:1 Reduction Unit Description325
2.10:1 Reduction Unit Overhaul325
2.10:1 Reduction Unit Exploded Views331

PCM 302 - Engine Overhaul; Manifold Vacuum Diagnosis and Testing

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