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BIG BLOCK M540000
Vanguard BIG BLOCK M540000 User Manual
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18.
Remove connecting rod and piston assembly from
cylinder bore.
19.
Repeat steps 17-18 on opposite cylinder.
20.
Remove crankshaft from crankcase.
21.
See the following topics under
SECTION 6 - SERVICE
ENGINE SUBASSEMBLIES:
•
PISTON AND CONNECTING ROD
•
FL
YWHEEL, CRANKSHAFT AND CAMSHAFT
•
CRANKCASE AND CRANKCASE COVER.
88
vanguardpower.com
86
88
Table of Contents
1 Section 1 - Safety and General Information
6
Table of Contents
6
Safety Information
7
Safety Alert Symbol and Signal Words
7
Hazard Symbols and Meanings
7
General Safety Messages
7
General Information
10
Engine Identification
10
Fuel Recommendations
10
Fuel Recommendations - Gaseous Engines
10
Oil Recommendations
10
Fuel Storage
11
2 Section 2 - Maintenance
12
Check Engine Oil Level/Change Engine Oil/Replace Oil Filter
13
Maintenance Schedule
13
Preliminary Instructions
13
Check Oil Guard Oil Level
15
Check/Change Engine Oil/Replace Oil Filter on Vanguard Oil Guard System
15
Clean/Replace Air Filter/Safety Filter
16
Clean/Replace Air Filter - Low Profile
17
Replace Fuel Filter
17
Clean/Gap/Replace Spark Plug
18
Clean/Inspect Muffler
18
Check/Adjust Valve Clearance
19
High Speed Adjustment - Mechanical Governor
20
Idle Speed Adjustment - Mechanical Governor
20
Clean Air Cooling System
21
Static Governor Adjustment - Mechanical Governor
21
3 Section 3 - Troubleshooting and Special Tools
23
Check Ignition System
25
Preliminary Instructions
25
Troubleshooting
25
Check Fuel System - Carbureted Engine
26
Check Fuel System - Fuel-Injected Engine (EFI)
26
Check Fuel System Pressure - EFI and EFI-ETC
27
Check Compression Components
28
Compression Test
28
Cylinder Leakdown Test
28
Cylinder Balance Test
29
Check Crankcase Breather
30
Troubleshooting Guide - Gasoline Fueled Engines
31
Troubleshooting Guide - Gaseous-Fueled Engines
34
Additional Troubleshooting Help
35
Alternator
36
Charging System Identification
36
Electrical Systems
36
System Diagnosis - Alternator
36
20 Amp Regulated Alternator
37
Output Test - 20 Amp Alternator
37
Output Test - 20/50 Amp Alternator
37
Regulator-Rectifier Test - 20 Amp
37
Regulator-Rectifier Test - 20/50 Amp
37
Testing Alternator Output
37
Anti-Afterfire Solenoid - Carbureted Engines
38
Battery Load Test
38
Battery Voltage Test
38
Testing the Battery
38
Test Engine Wire Harness Continuity
39
Test Engine Wiring
39
Test Engine Wiring Harness
39
Carbureted and Gaseous Engine Wire Harness Connector Pin-Out
40
Engine Wiring Harness Diagram
40
Conditions Affecting Starter Motor Performance
41
Oil Pressure
41
Starter Motor
41
Test Oil Pressure
41
Test Oil Pressure Switch
41
Starter Motor Solenoid Continuity Test
42
Troubleshooting - Starter Motor
42
Starter Motor Solenoid Load and Current Draw Test
43
Starter Motor Solenoid Voltage Test
43
Special Tools
45
Special Tools List
45
Special Tools Image Chart
46
4 Section 4 - Remove External Assemblies
47
Oil Filter
49
Preliminary Instructions
49
Relieve Fuel System Pressure - EFI and EFI-ETC
49
Remove External Assemblies
49
Oil Cooler
50
Oil Diverter Valve and Drip Tray
50
Oil Pressure Switch
50
Optional Oil Guard System
51
Air Cleaner Assembly - Cyclonic
52
Air Cleaner Assembly - Low Profile
52
Muffler
53
Engine Covers
54
Intake Elbow Cover
54
Key Switch Cover
54
Cylinder Air Guides
55
Throttle Control
55
Blower Housing
57
Voltage Regulator
57
Starter Motor
58
Electric Lift Fuel Pump
59
Fuel Filter
59
Fuel Pump - Carbureted Engine
59
Fuel Pump Module
61
Engine Control Module (ECM) - EFI
62
Crankshaft Position Sensor (CKP)
63
Optional Speed Sensor
63
Ignition Coil - EFI and EFI-ETC
64
Ignition Coil/Armature - Carbureted and Gaseous
64
Idle Air Control Valve (IAC) - EFI
65
Intake Elbow and Throttle Body Adapter - EFI
65
Throttle Position Sensor (TPS)
66
Throttle Position Sensor (TPS) - Early Style
66
Throttle Position Sensor (TPS) - Late Style
66
Carburetor and Spacers
67
Anti-Afterfire Solenoid
69
Mixer and Spacers - Gaseous
69
Fuel Rail and Fuel Injectors - EFI
70
Fuel Rail and Fuel Injectors - EFI-ETC
70
T-MAP Sensor - EFI
70
Intake Manifold
71
Wire Harness - EFI
72
Wire Harness - EFI-ETC
73
Wire Harness - Carbureted and Gaseous
76
Air Block Plate, Valley Air Guides, Speed Control Bracket
77
Governor Arm Bracket
78
5 Section 5 - Disassemble Engine
79
Preliminary Instructions
80
Top End Disassembly
80
Bottom End Disassembly
82
Flywheel Fan and Flywheel
82
Alternator and Guard Plate
84
Bottom End Disassembly
84
6 Section 6 - Service Engine Subassemblies
88
Cylinder Head
90
Disassembly
90
Preliminary Instructions
90
Cleaning
91
Cylinder Head
91
Inspection
91
Valve Guide Inspection
92
Valve Seat Inspection
92
Valves
92
Assembly
96
Intake Manifold Studs
96
Tappets, Push Rods, Adjuster Screws, and Rocker Arms
96
Valve Spring Retainers/Tapered Keepers Inspection
96
Valve Springs
96
Disassembly
98
Piston and Connecting Rod
98
Cleaning
99
Connecting Rod
99
Inspection
99
Piston
99
Piston and Pin
99
Connecting Rod
100
Assembly
101
Cleaning
103
Crankshaft
103
Flywheel
103
Flywheel, Crankshaft and Camshaft
103
Inspection
103
Camshaft
104
Crankcase and Crankcase Cover
104
Crankcase Cover
105
Governor Gear - Assembly
105
Governor Gear - Disassembly
105
Oil Guard Oil Supply Pump - Removal
106
Oil Pump - Horizontal Shaft Engines - Assembly
106
Oil Pump - Horizontal Shaft Engines - Disassembly
106
Oil Pump - Vertical Shaft Engines - Assembly
106
Oil Pump - Vertical Shaft Engines - Disassembly
106
Optional Oil Guard System - Disassembly
106
Oil Guard Oil Scavenge Pump - Removal
107
Oil Guard Oil Scavenge Pump - Install
108
Oil Guard Oil Supply Pump - Install
108
Optional Oil Guard System - Assembly
108
PTO Oil Bearing Seal - Assembly
109
PTO Oil Bearing Seal - Disassembly
109
Starter Motor
109
Starter Motor Solenoid - Disassembly
109
Efi and Efi-Etc System
110
EFI and EFI-ETC System Components
110
Starter Motor Solenoid - Assembly
110
Mixer - Gaseous Engines
116
7 Section 7 - Assemble Engine
117
Botom End Assembly
118
Bottom End Assembly
118
Preliminary Instructions
118
Alternator and Guard Plate
123
Flywheel Fan and Flywheel
124
Top End Assembly
125
Crankcase Breather
127
8 Section 8 - Install External Assemblies
129
Air Block Plate, Valley Air Guides, Speed Control Bracket
131
Governor Arm Bracket
131
Preliminary Instructions
131
Section 8 - Install External Assemblies
131
Wire Harness - EFI
133
Wire Harness - EFI-ETC
134
Wire Harness - Carburetor and Gaseous
137
Fuel Rail and Fuel Injectors - EFI
138
Intake Manifold
138
T-MAP Sensor - EFI
138
Carburetor and Spacers
139
Fuel Rail and Fuel Injectors - EFI-ETC
139
Anti-Afterfire Solenoid
141
Mixer and Spacers - Gaseous
141
Idle Air Control Valve (IAC) - EFI
142
Throttle Position Sensor (TPS) - Adjustment
142
Throttle Position Sensor (TPS) - Early Style
142
Throttle Position Sensor (TPS) - Late Style
142
Ignition Coil - EFI and EFI-ETC
143
Intake Elbow/Throttle Body Adaptor
143
Ignition Coil/Armature - Carbureted and Gaseous
144
Crankshaft Position Sensor (CKP)
145
Engine Control Module (ECM) - EFI
145
Optional Speed Sensor
145
Fuel Pump Module
146
Fuel Pump - Carbureted
147
Electric Lift Fuel Pump
148
Fuel Filter
149
Starter Motor
149
Voltage Regulator
150
Blower Housing
151
Cylinder Air Guides
152
Throttle Control
152
Engine Covers
153
Key Switch Cover
153
Intake Elbow Cover
154
Air Cleaner Assembly - Cyclonic
155
Muffler
155
Air Cleaner Assembly - Low Profile
157
Optional Oil Guard System
158
Oil Diverter Valve and Drip Tray
159
Oil Pressure Switch
159
Oil Cooler
160
Oil Filter
160
Final Instructions
161
Engine Specifications - 540000
163
Engine Specifications - 610000
163
Specifications
163
Engine Fluid and Sealant Specifications
164
Engine Parameter Specifications - 540000 and 610000
164
Torque Specifications
165
Standard and Reject Sizes
167
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Vanguard BIG BLOCK M540000 Specifications
General
Brand
Vanguard
Model
BIG BLOCK M540000
Category
Engine
Language
English
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