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351
PCM 351 User Manual
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2
Table of Contents
Index
2
Model Identification
4
Electrical Theory/Refresher
5
Electricity and Magnetism, Terms
5
Electrical Source
6
Electromagnets
7
Generating Electric Current
7
Voltage Regulator
9
Battery
9
Ignition Coil Operation and Construction
10
Engine Accessories, Test and Tune
11
Starter Motor Principle
11
Alternator, Regulator and Wiring Harness
11
General Wiring Diagram
12
Alternator Group Exploded View
12
Regulator Check
12
Carburetor and Fuel Pump
13
Electrical System
14
Overhaul of Carburetor
14
Circuit Breaker
14
Battery Specifications
15
Ignition Coil and Resistor
16
Distributor and Spark Cables
16
Engine Timing and Ignition
16
Firing Order - Cylinder Numbering/Engine Rotation
16
Prestolite Distributors (Marine Engines) Description and Operation
17
Adjustments and Repairs - Breaker Points And/Or Condenser
17
Centrifugal Advance Mechanism View
17
Weights, Spring and Cam Installed View
17
Breaker Plate and Sub-Plate Removal and Installation
18
Cam and Centrifugal Advance Weights Removal and Installation
18
Distributor Removal and Installation
18
Conventional Ignition System Distributor
19
Bench Assembly - Original Shaft and Gear
19
Bench Assembly - New Shaft and Gear
19
Distributor Assembly (Conventional) Exploded View
20
Oil Coolers
21
Starter and Relay
22
Cooling System, Raw Water Cooled Models
23
Troubleshooting the Cooling System
23
Overheating
23
Internal Leaks
23
Water in Crankcase
24
External Leaks (Not Evident)
24
Sherwood Raw Water Supply Pump - Exploded View
24
Cooling System - Fresh Water Cooled Models
25
Water Pump, Circulating
25
Water Pump, Raw Water Supply
26
Flywheel Housing, Drive Damper, Flywheel
26
Senders, Oil Pressure and Temperature
26
Holley Carburetor Repair and Diagnostic Procedures
28
Holley Two-Barrel Carburetor - Model 2300 Description
30
Main Body (Carburetor Model 2300)
30
Throttle Body
30
Carburetor Systems
31
Metering Block
31
Fuel Bowl Assembly
31
Fuel Inlet System
31
Idle Fuel System
32
Main Metering System
32
Carburetor Adjustments (Model 2300)
33
Power Fuel System
33
Accelerating Pump System
33
Float or Fuel Level Adjustments
33
Dry Adjustment - Externally Adjusted Float
34
Wet Adjustment - Externally Adjusted Float
34
Dry Adjustment - Internally Adjusted Float
35
Checking Fuel Level - Internally Adjusted Float
35
Accelerating Pump Override Spring Adjustment
35
Accelerating Pump Stroke Adjustment
36
Electric Automatic Choke Plate Clearance (Pulldown) Adjustment
36
Dechoke Clearance Adjustment
36
Carburetor Disassembly
37
Automatic Choke Thermostatic Spring Housing Adjustment
37
Idle Speed Adjustment
37
Idle Fuel Mixture Adjustment
37
Carburetor Assembly
39
Fuel Bowl and Metering Block
40
Model 2300C Carburetor Exploded View
41
Model 2300C Carburetor Nomenclature
42
Hollwy Four-Barrel Carburetors - Models 4150 and 4160 Description
43
Fuel Inlet System (4150/4160)
43
Idle Fuel System (4150/4160)
44
Main Metering System (4150/4160)
44
Secondary Metering Block 4160
45
Primary Metering Block 4150, 4160
45
Secondary Metering Block 4150
45
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 Procedures
51
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 Disassembly
52
Carburetor Models 4150 and 4160 Assembly
55
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 Seat
57
Assembling Main Body (4150, 4160)
57
Model 4160 Assembly
57
Primary Bowl and Metering Body Assembly (4160)
57
Model 4150 Secondary Bowl and Metering Body Assembly
58
Assembling Secondary Diaphragm
58
Externally Adjusted Needle and Seat Exploded View
59
Carburetors Models 4150 and 4160 Nomenclature
60
Carburetors Models 4150 and 4160 Troubleshooting
61
Carburetor Assembly - 4150 with Governor, Diagram
61
Carburetor Specifications
63
Holley Carburetor Problem Diagnosis
64
Rochester Carburetor Repair and Diagnostic Procedures
66
Model 4MV Carburetor - General Description
68
Model 4MV Carburetor View
69
Model 4MV Carburetor Identification
69
Model 4MV Carburetor Systems Diagrams
70
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 Carburetor
76
Model 4MV Carburetor On-Engine Service
77
4MV Carburetor Adjustments
77
Checking Carburetor Choke (4MV)
77
Idle Mixture Adjustment (4MV)
78
Carburetor Replacement (4MV)
78
Model 4MV Carburetor Disassembly
78
Air Horn Disassembly (4MV)
79
Float Bowl (4MV)
80
Float Bowl Disassembly (4MV)
81
Throttle Body Disassembly (4MV)
81
4MV Carburetor Cleaning and Inspection
81
4MV Carburetor Assembly
82
Float Level (4MV)
82
Air Horn to Bowl Assembly (4MV)
83
4MV Carburetor Torque Specifications
84
Rochester Carburetor Diagnosis
85
Engine Cranks Normally - will Not Start
85
Engine Starts - will Not Keep Running
85
Engine Starts Hard (Cranks Normally)
86
Engine Idles Abnormally (too Fast or too Slow)
87
Engine Diesels (after Run) Upon Shut off
87
Engine Hesitates on Acceleration
88
Engine Has Less than Normal Power at Normal Accelerations
88
Less than Normal Power on Heavy Acceleration or at High Speed
89
Engine Surges
89
Excessive Fuel Consumption
90
Engine Feels Like It Is Running out of Gas - Surging Occurs
91
Engine Starts but will Not Continue to Run
91
Fuel Starvation
91
Ford Engine Starting System Repair and Diagnostic Procedures
92
Ford Engine Starting System Description and Operation
93
Positive Engagement Starter
93
Solenoid Actuated Starter
93
Solenoid Operation
94
Connector Link
95
Booster Battery Testing
95
On Vehicle Testing Solenoid Starter
95
Starter Cranking Circuit Test
95
Starter Solenoid Test
96
Bench Tests - Starter No-Load Test
96
Armature Open Circuit Test
97
Armature and Field Grounded Circuit Test
97
Starting System On-Vehicle Testing
98
Starter Drive and Starter Test
98
Alternate Starter Drive Test
98
Positive Engagement - Starter Cranking Circuit Test
98
Starter Load Test
99
Starter No-Load Test - Bench Test
99
Armature Open Circuit Test - on Test Bench
99
Armature and Field Grounded Circuit Test - on Test Bench
99
Starter Removal and Installation
100
Overhaul Positive Engagement
100
Starter Disassembly
100
Solenoid Actuated Starter Disassembly
101
Starter Cleaning and Inspection
102
Assembly Positive Engagement Starter
102
Assembly Solenoid Starter
103
Starter Drive Replacement
103
Brush Replacement - Positive Engagement Starter
104
Brush Replacement - Solenoid Starter
104
Armature Replacement
105
Starter Terminal Removal
105
Starter Terminal Installation
105
Starting System Specifications
106
Delco Starter Systems Repair and Diagnostic Procedures
107
Delco Starter System General Description
108
Starter Motor Construction
108
Armature
108
Drive Mechanism
108
Solenoid
109
Starting Motor Cross Section View
109
Typical Cranking System
109
Delco Starter System Diagnosis
110
No Cranking Action
110
Cranking Speed Abnormally Low
110
Voltage Test of Starting System and Solenoid Switch
111
Amperage Test of Solenoid Switch Windings
111
Delco Starter System on Vehicle Service
112
Delco Starter System Lubrication
112
Starting Motor Replacement/Bench Test
112
Checking Pinion Clearance
112
Starting Motor Disassembly - Except Diesel
113
Starting Motor Cleaning and Inspection
113
Starting Motor Parts Layout
114
Armature Test for Shorts
115
Armature Test for Ground
115
Field Coil Test for Open Circuit/Field Coil Test for Ground
115
Field Coil Replacement
115
Delco Starting Motor Assembly
116
Loose Electrical Connections
116
Turning the Commutator
116
Brush Holder Replacement/Overrunning Clutch
116
Pinion Clearance Check
117
Starting Solenoid Removal
118
Replacement of Contacts (Starting Solenoid)
118
Starting Solenoid Installation
118
Starter (Diesel Engine) Disassembly
119
Starter (Diesel Engine) Cleaning, Inspection and Tests
120
Solenoid Switch
120
Starter (Diesel Engine) Assembly
120
Pinion Clearance
121
Delco-Remy - Enclosed Shift Lever Type Cranking Motors
122
Cranking Motor Lubrication
122
Troubleshooting the Cranking Circuit
122
Cranking Motor Tests
123
Magnetic Switch or Solenoid and Control Switches
123
No-Load Test
123
Cranking Motor Disassembly
124
Cranking Motor Component Inspection and Repair
124
Typical Cranking Motor Circuits View
125
Basic Solenoid Circuit
125
Connections for Checking Solenoid
125
Cranking Motor Reassembly
126
Cranking Motors and Miscellaneous DC Motors - No-Load Test
128
Starting Motor Specifications
128
Ford Engines Repair and Diagnostic Procedures
129
Ford Engine Index
130
460 Engines Description and Operation
131
Manifolds
131
Cylinder Heads/Cylinder Block
131
Valve Train
131
Lubrication System
132
Positive Crankcase Ventilation System
133
Carburetors
133
Distributors
133
302 And 351 Engines Description and Operation
134
Engine Overhaul
136
Manifold Vacuum Diagnosis and Testing
136
Camshaft Identification
137
Valve Spring Color Code
137
Rear Main Seal Color Code - All Engines
137
Engine Water Pump Identification
137
Camshaft Lobe Lift Diagnosis and Testing
138
Compression Test
138
Compression Gauge Check
138
Hydraulic Valve Lifter
139
Positive Closed-Type Ventilation System
139
Air Intake Test
139
Crankcase Ventilation Regular Valve Test
140
Crankshaft End Play
140
Flywheel Face Runout
140
Camshaft End Play
140
Timing Chain Deflection
141
Intake Manifold Cleaning and Inspection
141
Exhaust Manifolds Cleaning and Inspection
141
Valver Rocker Arm Assembly Cleaning and Inspection
141
Bush Rods Cleaning and Inspection
142
Cylinder Heads Cleaning and Inspection
142
Hydraulic Valve Lifters Cleaning and Inspection
143
Crankshaft Vibration Damper and Sleeve Cleaning and Inspection
143
Timing Chain and Sprockets Cleaning and Inspection
144
Camshaft Cleaning and Inspection
144
Crankshaft Cleaning and Inspection
144
Flywheel Inspection
145
Connecting Rods Cleaning and Inspection
145
Pistons, Pins and Rings Inspection
145
Main and Connecting Rod Bearings Cleaning and Inspection
146
Cylinder Block Cleaning and Inspection
146
Oil Pan Cleaning and Inspection
147
Oil Pump Cleaning and Inspection
147
Positive Closed-Type Crankcase Ventilation System Cleaning
148
Cylinder Head Overhaul
148
Reaming Valve Guides
148
Refacing Valve Seats
148
Refacing Valves
149
Select Fitting Valves
149
Camshaft Repair/Crankshaft
150
Refinishing Journals
150
Fitting Main or Connecting Rod Bearings with Plastigage
150
Fitting Pistons
150
Valve Rocker Arm
151
Push Rods
151
Cylinder Block - Refinishing Cylinder Walls
151
Fitting Piston Rings/Fitting Piston Pins
151
Repairing Sand Holes or Porous Engine Castings
152
Valve Clearance Adjustments
153
Crankcase Ventilation System Removal and Installation
155
Valve Rocker Arm Cover and Rocker Arm Removal and Installation
155
Valve Spring, Retainer and Stem Seal Removal and Installation
156
Intake Manifold Removal and Installation
157
Valve Lifter Removal and Installation
158
Cylinder Heads Removal and Installation
160
Exhaust Manifold Removal and Installation
161
Water Pump Removal and Installation
161
Cylinder Front Cover and Timing Chain Removal and Installation
161
Front Oil Seal Removal and Installation
163
Core Plugs Removal and Installation
163
Typical Core Plugs and Installation Tools View
164
Camshaft and Related Parts View
164
Cup Type Core Plugs - Installation
165
Expansion Type Core Plugs - Installation
165
Camshaft Removal and Installation
165
Camshaft Rear Bearing Bore Plug Removal and Installation
166
Oil Pan Removal and Installation
166
Oil Pump Removal and Installation
166
Crankshaft Rear Oil Seal Removal and Installation
167
Main Bearing Removal and Installation
167
Connecting Rod Bearings Removal and Installation
169
Pistons and Connecting Rods Removal and Installation
170
Cranksharft Removal and Installation
171
Camshaft Bearings Removal and Installation
173
Oil Filter (Spin-On Type) Removal and Installation
174
Valve Lifter Disassembly and Assembly
175
Cylinder Heads Disassembly and Assembly
175
Oil Pump Disassembly and Assembly
176
Pistons and Connecting Rods Disassembly and Assembly
177
Cylinder Assembly Disassembly and Assembly
178
Cylinder Block Disassembly and Assembly
178
Specifications - Ford Engines
179
Chervolet Engines Repair and Diagnostic Procedures
189
Chevrolet "V" Block General Description
190
Engine Lubrication
191
Oil Filter Type and Capacity
192
Crankcase Capacity
192
Recommended Viscosity
192
Checking Oil Level
192
Chevrolet "V" Block - in Boat Service
193
Exhaust Manifold Removal and Installation (Chevrolet)
193
Rocker Arm Cover Removal and Installation
193
Small V-8 Engine Lubrication - Diagram
194
Valve Mechanism Removal, Installation and Adjustment
196
Intake Manifold Torque Sequence - V-6
196
454 Engine
197
Valve Stem Oil Seal And/Or Valve Spring Removal and Installation
197
Valve Lifters
198
Locating Noisy Lifters
198
Valve Lifters Removal and Installation
199
Valve Lifters Disassembly
199
Valve Lifters Cleaning and Inspection
199
Valve Lifters Assembly
199
Cylinder Head Assembly Removal/Disassembly/Cleaning/Inspection
200
Cylinder Head Assembly Assembly
201
Cylinder Head Assembly Installatoin
203
Rocker Arm Studs Replacement
204
Valve Guide Bores
204
Valve Seats
204
Valves
204
Valves Reconditioning
205
Torsional Damper Removal and Installation
205
Crankcase Front Cover Removal and Installation
206
Oil Seal (Front Cover) Replacement
207
Camshaft - Measuring Lobe Lift
207
Camshaft Removal, Inspection and Installation
208
Camshaft Bearings Removal
208
Camshaft Bearings Installation
209
Oil Pan Removal and Installation
209
Oil Pump Removal and Disassembly
209
Oil Pump Cleaning and Inspection (Chevrolet)
210
Oil Pump Assembly
210
Oil Pump Installation
210
Connecting Rod Bearings
210
Connecting Rod Bearings Inspection and Replacement
211
Main Bearings Inspection/Checking Clearance
212
Main Bearings Replacement
213
Oil Seal (Rear Main) Replacement
214
Connecting Rod and Piston Assemblies Removal and Disassembly
215
Connecting Rod and Piston Assemblies Cleaning and Inspection
215
Connecting Rod and Piston Assemblies Assembly
216
Connecting Rod and Piston Assemblies Installation
218
Cylinder Block Cleaning and Inspection (Chervolet)
219
Cylinder Block Conditioning
219
Cylinder Block Boring and Honing
219
Oil Filter Bypass Valve Inspection and Replacement
220
Piston Selection
220
Crankshaft Removal, Cleaning and Inspection
220
Sprocket or Gear Replacement
220
Chevrolet "V" Block Specifications
222
Velvet Drive
224
Identification Markings for Warner Gear Division Marine Gears
226
10-17 and 10-18 Units Service Instructions
227
Selecting a Proper Velvet Drive
228
Engine Rotation
228
Transmission Rotation
228
Hydraulic Pump Indexing
228
Propeller Selection
229
Propeller Rotation
229
Transmission Ratio Selection
229
Installation Drawing for In-Line Transmissions
230
In-Line Transmissions General Performance Data/Dimensions
230
Identification of Velvet Drive In-Line Models 70C, 71C, 72C and 73C
231
Installation Drawing for V-Drive Transmissions
232
V-Drive Transmissions General Specifications
232
V-Drive Assemblies
233
Installation Drawing for Drop-Center Transmissions
234
Drop-Center Transmissions General Specifications
234
CR2 (Drop Center Assemblies)
235
Adapter Housing
236
Transmission Installation
236
Transmission Fluid
236
Checking Oil Level (Transmission)
236
Typical Timing Gear End Installation - Diagram
237
Typical Flywheel End Installation - Diagram
237
Transmission Operation
238
Filling and Checking the Hydraulic System
238
Neutral/Forward/Reverse
238
Freewheeling
238
Propeller Shaft Couplings
239
Coupling to Shaft Assembly
239
Transmission Coupling to Propeller Shaft Coupling Alignment
239
Use of Flexible Couplings
239
Shift Lever
240
Mounting Brackets
240
Transmission Painting
240
Coolers
241
Transmission Cooling Requirements
241
Recommendations for Sizing Coolers
241
Water Flow Rate/Water Temperature to Cooler
241
Connecting Cooler to Transmission
242
Cooler out Location
243
Cooler Return Location
243
Mounting Cooler
243
Testing Cooler Circuit
244
Water Drain Plug
244
Cooling Problems
244
Vibration Dampers
245
Transmission Requirements
245
Dampers Selection
245
Damper Application and Damper Assemblies Chart
246
Damper Installation
247
Spline Engagement
247
Early Damper Splines
247
Damper Problems
247
Neutral Switch Kit
248
Transmission Alarm Kits
248
Routine Checks and Maintenance
249
Matching Engine, Transmission and Propeller Rotation
250
Engine Rotation/Transmission Shaft Rotation Described
250
To Index Pump for Opposite Hand Rotation
250
Typical Timing Gear End Installation
251
Typical Flywheel End Installation
251
Single Prop Installation
251
Warner Gear Repair and Diagnostic Procedures
252
71C-72C Direct Drive and Reduction Rations 1.5:1 - 2.91:1
253
List of Drive-Direct and Reduction Models Covered in the Manual
254
List of Figures
257
List of Tables
257
71C and 72C Transmissions Description
258
71C and 72C Transmissions Specifications
258
71C and 72C Transmissions Typical Installation - Diagram
259
Forward Power Flow Diagram
259
Reverse Power Flow Diagram
259
Hydraulic Circuit Schematic (Model 72C Direct-Drive Shown)
260
71C and 72C Transmissions Scheduled Inspections
261
71C and 72C Transmissions Maintenance
263
71C and 72C Transmissions - Changing Oil
264
71C and 72C Transmissions Troubleshooting
265
71C and 72C Transmissions Overhaul
269
71C and 72C Transmissions Disassembly
269
71C and 72C Transmissions Cleaning and Inspection
269
71C and 72C Transmissions Repair
269
71C and 72C Transmissions Assembly
270
71C and 72C Transmissions Installation
285
71C and 72C Transmission Assembly Exploded View
286
Model Chart 71C and 72C Transmissions
292
Optional Drive Gear Alarm Kits
293
71C and 72C Transmissions - Bolt and Fastener Torques
294
71C and 72C Transmissions - Spring Dimensions
294
71C and 72C Transmissions - Test Pressures
295
1.523:1 Reduction Units Description
296
1.523:1 Reduction Units Overhaul
296
1.523:1 Reduction Units Exploded View
302
1.88:1 and 1.91:1 Reduction Units Description
305
1.88:1 and 1.91:1 Reduction Units Overhaul
305
1.88:1 and 1.91:1 Reduction Units Exploded View
311
2.57:1 and 2.91:1 Reduction Units Description
315
2.57:1 and 2.91:1 Reduction Units Overhaul
315
2.57:1 and 2.91:1 Reduction Units Exploded Views
321
2.10:1 Reduction Unit Description
325
2.10:1 Reduction Unit Overhaul
325
2.10:1 Reduction Unit Exploded Views
331
4
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PCM 351 Specifications
General
Configuration
V8
Ignition
Electronic
Starting System
Electric
Engine Type
Gasoline
Cooling System
Water-cooled
Fuel System
Fuel injection
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