TABLE OF CONTENTS
SAFETY NOTICE .................................................................................... III
INTRODUCTION ................................................................................... IV
GENERAL INFORMATION.......................................................................................... IV
ENGINE EMISSIONS INFORMATION ............................................................................ IV
ENGINE IDENTIFICATION NUMBER (E.I.N.) .................................................................... IV
TIGHTENING TORQUES ........................................................................................... IV
ARRANGEMENT OF THIS MANUAL, ILLUSTRATIONS AND PROCEDURES ............................. V
01 ENGINES (1503 4-TEC)
01 – LEAK TEST ...................................................................................................... 1
PROCEDURES .................................................................................................. 1
PREPARATION ........................................................................................................ 1
PROCEDURE .......................................................................................................... 2
DIAGNOSIS............................................................................................................ 3
POSSIBLE ENGINE LEAKAGE AREA................................................................................ 3
ASSEMBLY . . .. ... .... .. . .. .. . .. .. . .. .. . . . .. . . . .. .. . .. .. . .. . . . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . . . .. . . . .. . .. .. . .. . 4
02 – INTAKE MANIFOLD AND SUPERCHARGER............................................................... 5
INSPECTION (PARTS ASSEMBLED). . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. . . . .. .. . . . .. . . . .. .. . .. .. . .. .. . .. .. . .. 10
REMOVAL ............................................................................................................ 12
DISASSEMBLY .. . .. .. .. . . . .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . . . .. .. . .. .. . .. .. . .. . . . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. 17
INSPECTION (PARTS DISASSEMBLED) . . .. .. . . . .... . . . .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. 20
ASSEMBLY . . .. .. . .. .. . . . .. .. . .. .. . .. .. . .. .. . . . .. .. . .. .. . .. .. . .. . . . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . . . .. . . . .. . .. 21
INSTALLATION ....................................................................................................... 26
03 – PTO HOUSING AND MAGNETO .......................................................................... 29
GENERAL...................................................................................................... 31
PROCEDURES ................................................................................................ 31
PTO HOUSING ....................................................................................................... 31
PTO SEAL............................................................................................................. 34
COUPLING............................................................................................................ 35
STATOR ............................................................................................................... 35
ROTOR AND TRIGGER WHEEL .................................................................................... 36
RING GEAR........................................................................................................... 37
STARTER DRIVE ASS'Y.............................................................................................. 38
OIL SPRAY NOZZLE ... . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. ... .. . . . .. .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. 39
04 – LUBRICATION SYSTEM..................................................................................... 41
GENERAL...................................................................................................... 45
PROCEDURES ................................................................................................ 45
ENGINE OIL PRESSURE............................................................................................. 45
PTO OIL STRAINER.................................................................................................. 46
SUCTION PUMP OIL STRAINER.................................................................................... 47
ENGINE OIL PRESSURE REGULATOR............................................................................. 49
OIL PRESSURE PUMP............................................................................................... 51
OIL SUCTION PUMP................................................................................................. 54
OIL SEPARATOR COVER............................................................................................ 57
TOPS VALVE.......................................................................................................... 58
OIL COOLER ......................................................................................................... 58
05 – COOLING SYSTEM .......................................................................................... 61
GENERAL...................................................................................................... 63
PROCEDURES ................................................................................................ 63
COOLANT PUMP .................................................................................................... 63
COOLANT PUMP IMPELLER ....................................................................................... 64
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