International C 549 Engine

⚠ Dwell remains constant and should not require adjustment for the service life of the distributor unless sensor is moved

Tools: Feeler gauge, Dwell meter (electronic ignition type)

1. Rotate trigger wheel until one tooth is aligned with centerline of sensor (tooth perpendicular to flat surface of sensor).
2. Using feeler gauge, measure air gap between sensor and end of tooth.
3. Move sensor to obtain specified air gap; tighten sensor mounting screw and recheck air gap.
4. Connect dwell meter to engine; operate engine at curb idle speed and observe dwell reading.
5. If dwell is not within specified limits, stop engine and adjust trigger wheel-to-sensor air gap.
6. Dwell decreases as sensor is moved closer to trigger wheel and increases as sensor is moved away.
7. Dwell is affected approximately one-half degree per 0.025 mm (.001 in) of sensor movement.

⚠ Do not allow governor spring to twist, otherwise damage to spring may result

⚠ Do not use the bumper screw for speed adjustment

Tools: Tachometer, Screwdriver

1. Adjust speed control screw to dimension A (approximately 7/8 in) by turning speed control nut; hold screw from turning.
2. Adjust throttle rod: with governor lever in the weights-closed position, rod should just hold throttle lever wide open against internal stop; then shorten rod 1-1/2 to two turns.
3. Tighten rod locknuts; check for binding in both ball joints.
4. Set speed regulation adjustment screw to dimension B (approximately 1/2 in).
5. Set high idle by turning the speed control nut to produce the required high idle speed; dampen surge with bumper screw if needed.
6. Load engine to maximum rated power; adjust speed control nut to attain rated power speed.
7. Remove load and note high idle speed; back out or turn in speed regulation screw to correct regulation.
8. Load engine to maximum rating and reset speed nut if required; run engine through varying step load values.

⚠ Never exceed engine speed of 4,000 rpm

Tools: Tachometer

1. Bring engine to normal operating temperature.
2. Check governor setting against an accurate tachometer (use master tachometer of known accuracy).
3. Turn governor adjusting screw clockwise to decrease speed; counterclockwise to increase speed.

⚠ Idle speed and fuel mixture adjustments must be made with air cleaner in place

⚠ Where engine is used in a vehicle the transmission must be in neutral with the parking brake applied

⚠ Do not idle engine continuously for more than three minutes at one time

Tools: Tachometer (expanded scale 400-800 or 0-1000 rpm)

1. Connect tachometer (expanded scale 400 to 800 or 0 to 1000 rpm, 1 to 2% accuracy).
2. Remove limiter caps; file or grind away side of cap, do not pry cap off.
3. Operate engine until it reaches normal operating temperature.
4. Gently seat idle mixture screws.
5. Carefully adjust idle mixture screws (equal number of turns) to produce maximum idle speed.
6. Adjust curb idle speed screw to give engine speed higher than midpoint of idle speed range per specifications.
7. Adjust idle mixture screw(s) in until midpoint of idle speed range specification is obtained.
8. Install new plastic (service) limiter caps with tab in mid position.

⚠ Under no circumstances should governor be set faster than settings shown under Specifications

⚠ Never exceed engine speed of 4,000 rpm

Tools: Sharp punch, Compressed air, Tachometer

1. Pry out metal cover carefully with a sharp punch; lift out filter felt and inner cover; wash felt in cleaning solvent and dry.
2. Blow out stabilizer cylinder and piston by directing compressed air in sudden bursts through the atmospheric hole in the air filter chamber.
3. Install inner cover; replace felt in governor body; install outer cover (bend/flatten cover as needed).
4. Bring engine to normal operating temperature.
5. Remove seal from adjusting screw cap.
6. Check governor setting against an accurate tachometer.
7. Turn adjusting screw clockwise to decrease speed; counterclockwise to increase speed.

⚠ Do not use a test lamp to check continuity of the distributor sensor unit

⚠ Do not connect distributor sensor or tester switch SE-2503 to a 12 volt circuit

⚠ Mark or tag wires to assure correct reconnection

Tools: DC Voltmeter, Jumper wire 12-18 inches long with clip at each end, Tester Switch SE-2503, Insulated pliers for handling high tension cable, Dwell meter, Timing light

1. Inspect wiring: sensor connectors, ignition primary circuit, dash panel terminals, secondary cables, routing, and control (module) mounting bolts.
2. Test battery voltage; record (spec 12-13V).
3. Test primary voltage between coil positive terminal and ground; turn ignition ON and record (spec 12-13V).
4. Test spark at plug: hold cable terminal about 1/2 inch from engine and crank.
5. Test spark at distributor cap center terminal using jumper wire.
6. Test sensor: disconnect distributor from harness, plug in tester switch, turn ignition ON, press tab and observe spark.
7. Test sensor wiring circuit through ignition control (module).
8. Test ignition control and coil; coil negative terminal voltage spec 5-8V, switched voltage spec 12-13V.
9. Retest spark at plug after replacement of components; disconnect test equipment.
10. Check dwell; record (spec 26-32); adjust if necessary.
11. Check timing at idle speed with distributor vacuum hose disconnected and plugged.

⚠ Use only a corrosion inhibitor that is compatible with aluminum

1. Run engine until it reaches operating temperature; stop engine and drain cooling system.
2. Fill cooling system with clean coolant.
3. Add a flushing compound compatible with aluminum to the cooling system per the compound instructions.
4. Start engine and flush system as directed by the compound instructions.
5. After flushing and cleansing of the compound, refill with clean coolant.

⚠ Drain cooling system immediately after stopping engine while most of the sediment is in suspension

1. Remove radiator cap.
2. Open radiator and crankcase drain valves.
3. LIQUEFIED PETROLEUM GAS ENGINES ONLY: open water drain valve.
4. Allow system to drain completely; be sure drain outlets do not plug up.
5. Close all drain outlets.

⚠ Never use a fast charger as a booster to start the engine

⚠ Never unhook a battery terminal while engine is running

⚠ Never disconnect alternator cable while engine is running

Tools: Jumper lead

1. Delco-Remy: connect the integral charging system to the battery in a normal manner.
2. Delco-Remy: momentarily connect a jumper lead from the battery positive post to the integral charging system relay terminal.
3. IH: connect alternator to battery (positive to positive and negative to negative).
4. IH: attach a jumper wire to the alternator ground stud.
5. IH: insert the other end of the jumper wire into the hole in the end cover to energize the field coil and re-establish the magnetic field.

1. Remove drain plug in bottom of filter and drain oil. Reinstall drain plug.
2. Loosen filter body retaining bolt and remove filter body and element.
3. Check condition of filter body to base gasket. Replace if necessary.
4. Wash filter body in cleaning fluid, making sure all sediment is removed inside.
5. Position new filter element with large hole end toward filter base; seat element on pilot on base.
6. Install filter body and bolt with spring assembly to filter; be sure body seats on gasket seal in base.
7. Tighten retaining bolt to 41-47 N.m (30-35 ft. lbs.) torque.

⚠ Do not over tighten the filter

1. Remove oil filter assembly by turning counterclockwise with hands or suitable tool. Clean filter mounting pad.
2. Coat gasket on new filter with a film of grease.
3. Place new filter on center tube (threaded); hand tighten 1/2 to 3/4 of a turn after gasket first contacts base.
4. Do not over tighten.
5. Refill engine crankcase to proper oil level with recommended type and grade of oil.
6. Start engine and run at least five minutes to warm oil and check for leaks.
7. Recheck and add oil to bring level between the Add and Full marks on the dipstick.

⚠ Gasoline tank and carburetor should be completely drained of fuel when out of service more than two weeks due to gum deposits

1. Thoroughly wash or clean the engine.
2. Run engine long enough to warm the oil; drain crankcase, change lubricating oil filter element and refill crankcase.
3. Completely lubricate the rest of the engine.
4. Drain fuel from the fuel tank and carburetor and replace the fuel pump filter.
5. Remove spark plugs; pour one tablespoonful of Grade-30 lubricating oil into each cylinder; crank engine two or three times; reinstall spark plugs.
6. Remove valve housing cover; flush valves, rocker arms and push rods with Grade-30 oil; coat inside of cover; reinstall cover.
7. If equipped with oil cooler or heat exchanger, fill system with antifreeze then drain, or blow out residual water with compressed air.
8. Remove and clean the crankcase ventilator metering valve (if equipped).
9. Completely service the air cleaner.
10. Remove the air cleaner intake cap and store in a clean dry place; cover or plug the exhaust pipe and air cleaner pipe.
11. Remove battery and store in a cool dry place above freezing (+32 F); keep battery fully charged; check liquid level monthly.