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ESG-642 4.2 LITER

INDUSTRIAL ENGINE SERVICE MANUAL

FPP-194-309

April, 2001

Ford Power Products

28333 Telegraph Rd., Suite 300 Southfield, MI 48034 248 945 4500 (Fax) 248 945 4501

Ford Power Products, LTD

20/586 Arisdale Avenue South Ockendon

Essex, RM 15 5TJ England 44 1708 672 415

(Fax) 44 1708 672 815

Ford Power Products, GmbH

Stolberger Str. 313 D-50933 K?ln, Germany

49 221 94700 551 (Fax) 49 221 94700 560

HEALTH & SAFETY

! WARNING: THE FOLLOWING HEALTH AND SAFETY RECOMMENDATIONS SHOULD BE CAREFULLY OBSERVED.

CARRYING OUT CERTAIN OPERATIONS AND HANDLING SOME SUBSTANCES CAN BE DANGEROUS OR HARMFUL TO THE OPERATOR IF THE CORRECT SAFETY PRECAUTIONS ARE NOT OBSERVED. SOME SUCH PRECAUTIONS ARE RECOMMENDED AT THE APPROPRIATE POINTS IN THIS BOOK.

WHILE IT IS IMPORTANT THAT THESE RECOMMENDED SAFETY PRECAUTIONS ARE OBSERVED, CARE NEAR MACHINERY IS ALWAYS NECESSARY, AND NO LIST CAN BE EXHAUSTIVE. ALWAYS BE CAUTIOUS TO AVIOD POTENTIAL SAFETY RISKS.

The following recommendations are for general guidance:

1. Always wear correctly fitting protective clothing which should be laundered regularly. Loose or baggy clothing can be extremely dangerous when working on running engines or machinery. Clothing which becomes impregnated with oil or other substances can constitute a health hazard due to prolonged contact with the skin even through underclothing.

2. So far as practicable, work on or close to engines or machinery only when they are stopped. If this is not practicable, remember to keep tools, test equipment and all parts of the body well away from the moving parts of the engine or equipment--fans, drive belts and pulleys are particularly dangerous. The electric cooling fan used on some installations is actuated automatically when the coolant reaches a specified temperature. For this reason, care should be taken to ensure that the ignition/isolating switch is OFF when working in the vicinity of the fan as an increase in coolant temperature may cause the fan suddenly to operate.

3. Avoid contact with exhaust pipes, exhaust manifolds and silencers when an engine is, or has recently been running; these can be very hot and can cause severe burns.

4. Many liquids used in engines or vehicles are harmful if taken internally or splashed into the eyes. In the event of accidentally swallowing gasoline (petrol), oil, diesel fuel, antifreeze, battery acid etc, DO NOT ENCOURAGE VOMITING AND OBTAIN QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY.

Wear protective goggles when handling liquids which are harmful to the eyes; these include ammonia and battery acid. If any of these substances are splashed in the eyes, wash out thoroughly with clean water and OBTAIN QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY.

! WARNING: !

The Engine Exhaust from this product contains chemicals known to the State

of California to cause cancer, birth defects or other reproductive harm.

IMPORTANT SAFETY NOTICE

Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all industrial engines as well as the personal safety of the individual doing the work. This Service Manual provides general directions for accomplishing service and repair work with tested, effective techniques. Following them will help assure reliability.

Section 01 ESG-642 Section 02 ENGINE - 4.2L

Section 03 IGNITION

Section Index

FUEL Section 04 Section 05 COOLING

Section 06 CHARGING

Reproduction in any manner, in whole or in part, is prohibited without the express permission in writing from:

Ford Power Products, Marketing Department

Ford Power Products policy is one of continuous improvement and while every effort is made to ensure that this publication is up to date and correct in all respects, the right to change prices, specifications and equipment at any time without notice is reserved. Accordingly this publication is not to be regarded as a final description of any individual engine.

Section 07 STARTER

Section 08

ELECTRONICS & DIAGNOSTIC TROUBLE CODES

Section 09 METRICS

Section 10 DEALERS

INDEX

SUBJECT

ESG-642 PAGE SUBJECT

01

PAGE

Description ................................................................... 01-3 Introduction .................................................................. 01-3 Engine Identification Nameplate ................................. 01-3

Safety Notices .............................................................. 01-5 Notes, Cautions and Warnings ................................... 01-5 General Warnings ........................................................ 01-5

Battery Handling And Charging .................................. 01-6

Foreward ....................................................................... 01-7 Engine Identification .................................................... 01-7

Diagnosis And Testing (Continued) Valves and Cylinder Head ......................................... 01-22 Valve Train Analysis ? Dynamic ................................. 01-22 Rocker Arm ................................................................ 01-22 Push Rods ................................................................. 01-22 Positive Rotator and Valve Spring Retainer Keys ..... 01-22 Valves and Cylinder Head ......................................... 01-22 Camshaft Lobe Lift ..................................................... 01-22 OHV Engines ............................................................. 01-22 Typical Engine With Push Rods ................................. 01-22 Hydraulic Valve Tappet .............................................. 01-23 Leakdown Testing ...................................................... 01-23

European Service Identification Plate ........................ 01-8

U.S.A. Engine Identification Decal .............................. 01-9

Description And Operation ........................................ 01-10 Engine System ........................................................... 01-10

Diagnosis And Testing ............................................... 01-11 Engine System ........................................................... 01-11 Special Tools .............................................................. 01-11 Inspection and Verification ......................................... 01-11 Symptom Chart .......................................................... 01-11 Component Tests ....................................................... 01-14 Engine Oil Leaks ....................................................... 01-14 Fluorescnt Oil Aditive Method .................................... 01-14 Pressure Method ....................................................... 01-15 Testing Procedure ...................................................... 01-15 Leakage Points .......................................................... 01-15 Under Engine ............................................................ 01-15 With Transmission and Flywheel Removed .............. 01-15 Compression Tests .................................................... 01-15 Test Results ................................................................ 01-16 Compression Pressure Limit Chart ........................... 01-16 Interpreting Compression Readings ......................... 01-16 Cylinder Leakage Detection ...................................... 01-17 Oil Leak and Valve Stem Seal Test ............................ 01-17 Intake Manifold Vacuum Test ..................................... 01-17 Interpreting Vacuum Gauge Readings ...................... 01-17 Excessive Engine Oil Consumption .......................... 01-19 Oil Consumption Test ................................................. 01-19 Oil Pressure Test ........................................................ 01-21 Valve Train Analysis ? Static (Engine Off) .................. 01-21 Valve Cover Removed ............................................... 01-21 Rocker Arm ................................................................ 01-21 Camshaft Roller Followers & Hydraulic Lash Adjusters, Overhead Camshaft ................................ 01-21 Camshaft ? Overhead Camshaft Engines ................. 01-21 Push Rods ................................................................. 01-21 Valve Springs ............................................................. 01-21 Valve Spring Retainer and Valve Spring Retainer Keys .......................................................... 01-22

General Service Procedures .................................... 01-25 Sprockets ................................................................... 01-25 Gears ......................................................................... 01-26 Camshaft Journal Diameter ....................................... 01-26 Camshaft Journal Clearance ? OHV Engines .......... 01-27 Camshaft Lobe Surface ............................................. 01-27 Camshaft Lobe Lift ..................................................... 01-28 Camshaft Runout ....................................................... 01-28 Crankshaft Main Bearing Journal Diameter .............. 01-29 Crankshaft Main Bearing Journal Taper .................... 01-29 Crankshaft Main Bearing Journal Clearance ............ 01-30 Bearing Inspection ..................................................... 01-31 Crankcase End Play .................................................. 01-31 Cylinder Bore Taper ................................................... 01-33 Cylinder Bore Out-of-Round ...................................... 01-33 Piston Inspection ....................................................... 01-33 Piston Diameter ......................................................... 01-34 Piston to Cylinder Bore Clearance ............................ 01-34 Piston Selection ......................................................... 01-35 Piston Ring End Gap ................................................. 01-35 Piston Ring-to-Groove Clearance ............................. 01-36 Crankshaft Connecting Rod Journal Diameter ......... 01-37 Crankshaft Connecting Rod Journal Taper ............... 01-37 Connecting Rod Cleaning ......................................... 01-38 Connecting Rod Larger End Bore ............................. 01-38 Piston Pin Diameter ................................................... 01-39 Connecting Rod Bushing Diameter .......................... 01-39 Connecting Rod Bend ............................................... 01-40 Connecting Rod Twist ................................................ 01-40 Connecting Rod Piston Pin Side Clearance ............. 01-41 Connecting Rod Journal Clearance ......................... 01-41 Bearing Inspection ..................................................... 01-42 Roller Follower Inspection ? OHC Engines .............. 01-43 Hydraulic Valve Tappet Inspection ? OHV Engines ... 01-43 Hydraulic Valve Tappet Leakdown Test ? OHV Engines ........................................................... 01-43

01-1

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