DEMO - 1956 Ford Car Shop Manual

Transcription

19 5 6
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FORD
M
DIVISION
O
T
O
COMPANY
Copyright © 2009, Forel Publishing Company, LLC, Woodbridge, Virginia
All Rights Reserved. No part of this book may be used or reproduced in any manner whatsoever
without written permission of Forel Publishing Company, LLC. For information write to Forel
Publishing Company, LLC, 3999 Peregrine Ridge Ct., Woodbridge, VA 22192
1956 Ford Car Shop Manual
EAN: 978-1-60371-006-0
ISBN: 1-60371-006-X
Forel Publishing Company, LLC
3999 Peregrine Ridge Ct.
Woodbridge, VA 22192
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Motor Company. No further reproduction or distribution of the Ford Motor Company material is
allowed without the express written permission of Ford Motor Company.
Note from the Editor
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been made to use the original scanned images, however, due to the condition of the material;
some pages have been modified to remove imperfections.
Disclaimer
Although every effort was made to ensure the accuracy of this book, no representations or
warranties of any kind are made concerning the accuracy, completeness or suitability of the
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should be used as general information only. The author and Forel Publishing Company, LLC
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19 5 6
Copyright 1955
FORD MOTOR COMPANY
DEARBORN, MICHIGAN
All
September, 1955
rights reserved
'Reproduced under License #5008
trom Ford Motor
Company
FORD
FORD
-
February
2002.
DIVISION
MOTOR
COMPANY
FOREWORD
This
proper
The
has been
manual
servicing
manual
be kept
should
The
reference at all times.
illustrations
of some of
The
of
the
following
for
by
Disassembled
main parts as
views
listed in the Table
pages.
ignition, fuel,
which are
conventional
and
axle, etc.)
and cooling.
information
-CHASSIS -includes
(clutch,
brakes,
Service
available
accompanied
be readily
service operations.
is divided into five
the
on
train
rear
sion,
will
car units are also given.
TWO
Part
line,
it
where
information for the
provide
the 1956 Ford Thunderbird.
service procedures are
the
their related systems,
power
and
ONE POWER PLANT is composed of the various engines
Part
the
on
entire
transmission, Overdrive, drive
the running
(frames,
gear
suspen
springs,
tires, steering gear, steering linkages, etc.).
for the Fordomatic transmission are published
wheels,
procedures
a separate manual.
Part THREE
all
of
many
manual
Contents
and
in
of
to
prepared
1956 Ford Cars
of
of
the
electrical
of
all
and
ELECTRICAL AND ACCESSORIES
-
the
BODIES
nance and repair of all
of
alignment
Part FIVE
includes
Ford
all
matter
page
mainte
glass
adjustments
part.
specifications
headings,
covered.
The
indicates the
right-hand
AND SPECIFICATIONS
-
lubrication information, and
necessary for properly servicing
and
in
Ford Division
without
heading
of
on
the
each
of
models
and
specifications
Ford Motor
notice and
and
any time,
without
was
incurring
even-numbered
heading
contained
reserves
change
subject
on
each
section covered.
approved
Company
or
or
the
indicates the
the time the book
at
left-hand
chapter
or odd-numbered page
effect at
continue
throughout the manual, designate the
name
The descriptions
were
the
adjustment and
cars.
The
page
on
including
fenders. Window
and
maintenance
the
information
components,
-MAINTENANCE
complete
contains
contains
body
doors, hoods,
included in this
are also
covers
(except the ignition system)
(except the Overdrive and Fordomatic).
systems and units
accessories
Part FOUR
-
in this
for
manual
printing.
the
right
specifications
or
The
to dis
design,
obligation.
SERVICE
FORD
FORD
DEPARTMENT
DIVISION
MOTOR
COMPANY
TABLE OF CONTENTS
Page
Foreword
.
2
.
Part ONE-POWER PLANT
CHAPTER
I GENERAL
ENGINE OVERHAUL, INSPECTION, AND REPAIR
âge
Page
Section 1
Troubleshooting.
2
Tune-Up
3
Engine Removal and Installation
Intake and Exhaust Manifolds
Rocker Mechanism, Cylinder Head, Valves,
Valve Lash Adjustment, and Valve Timing.
4
3
Manifolds
4
Cylinder Heads
5
Crankshaft Damper...
-
6
..
Rest.
36
and
III 8-CYLINDER
IV
CHAPTER
Section 1
2
3
4
.
Ignition System
Distributor Minor Repair and Adjustments.
Distributor Overhaul
Carburetor Operation and Adjustments
Single and Dual Carburetors.
Single Barrel Carburetor Overhaul.
Dual Carburetor Overhaul
....
.
....
.
6
39
Main Bearings
and
and
Bearings, Pistons, Pins,
Qil pilter
and
44
oil p
45
.
9
54
io
55
11
and Timing Chain, Camshaft and
Bearings, and Tappets
Flywheel, Crankshaft, and Main Bearings
Connecting Rods and Bearings, Pistons, Pins,
56
60
and Rings
Oil Pan, Oil Filter,
Exhaust System
62
64
66
Sprockets
.
..
and
Oil Pump.
.
.
...
.
IGNITION, FUEL, AND COOLING SYSTEMS
.
5
8
51
Crankshaft Oil Seal
30
ENGINES
Section 7
49
,
Valves
and
29
42
Exhaust System
10
49
Cylinder Front Cover
25
...
Rings
Qil p
g
37
.
'.''..,
,
Connecting Rods
and
47
Engine
Flywheel, Crankshaft,
8
33
36
General Information.
2
and
32
....
CHAPTER
22
ENGINE
Section 7
31
.
Steady
10
20
Camshaft
Main Bearings.
and
.
.15
....
Section 1
8
Sprockets
Flywheeel, Crankshaft and
Cylinder Block, Pistons, Piston Rings,
Connecting Rods and Bearings
Oil Pan and Oil Pump
Exhaust System
9
Engine Steady Rest.
Manifolds
Cylinder Head and Valves.
Crankshaft Damper.
Cylinder Front Cover and Crankshaft Oil Seal
sprocket and Timing Chain, Camshaft and
Bearings, and Tappets
.
10
Timing Chain,
7
II 6-CYLINDER
CHAPTER
Section
Section 6
14
...
5
5
8
69
74
Section 7
78
8
9
84
10
.89
92
Four-Barrel Carburetor Operation,
Adjustments, and Overhaul
11
Fuel Pumps, Vacuum Booster,
Fuel Tanks and Lines.
Fans and Belts.
Water Pumps
12
Radiator, Hose,
.
and
95
Fuel Filter
.
and
Thermostat
.
108
110
Ill
112
115
Part TWO-CHASSIS
CHAPTER
Section 1
2
3
4
Trouble Shooting
Clutch
I
CLUTCH, TRANSMISSION, AND GEAR SHIFT LINKAGE
119
Housing Alignment.
Transmission Cleaning and Inspection
123
Flywheel
124
II REAR
CHAPTER
2
Trouble Shooting.
Cleaning and Inspection.
3
Banjo
Section 1
Housing Hypoid
.
.
.
.
.
Rear Axle
Trouble
Shooting
2
Wheel Alignment.
3
Frames.
4
Front Suspension
5
Rear Suspension.
.
.
.
CHAPTER
Section 1
2
3
Power
and
163
164
168
10
IV POWER
.
.
187
Troubleshooting.
206
2
Adjustments.
3
Hydraulic System
4
Brake Assemblies.
207
208
212
.
Gear Shift Linkage
Section 6
7
8
9
CHAPTER V
Section 1
7
.
138
.
Integral Housing Hypoid Rear Axle.
Drive Lines.
152
158
RUNNING GEAR
159
161
186
Maintenance
Steering System Operation.
129
Section 4
5
183
Troubleshooting
Inspection
Overdrive Transmission
143
CHAPTER III
Section 1
125
6
AXLES AND DRIVE LINES
141
142
.
Conventional 3-Speed Transmission.
Section 5
117
.
.
Shock Absorbers.
Steering Gear
.
169
.
Steering Linkage
170
175
178
181
.
.
Wheels and Tires.
Hubs and Bearings
STEERING
Section 4
5
6
7
and Fluid Reservoir
Control Valve Assembly.
Power Cylinder Assembly
Pump
Steering Linkage
.
Assembly
.
.
190
194
200
202
BRAKES
Section 5
Brake Drums
213
6
Vacuum Booster
214
7
Brakes.
216
Parking
Part THREE-ELECTRICAL AND ACCESSORIES
CHAPTER I-GENERATING SYSTEM AND BATTERY
Page
Page
Section 1
2
Trouble Shooting
Generator
.
217
.
221
CHAPTER
Section 1
2
Section 1
2
II STARTING
Trouble Shooting
Starter and Circuit
235
238
CHAPTER
Trouble
Shooting
Lighting
System
III
2
Trouble
Radio
3
Heater
245
247
Shooting
3
I BODY
Construction Details
and
Sealer Application.
.
.
and
271
278
279
II-
Quarter Trim Panels.
.
.
TRIM,
289
.
Headlining Replacement
292
3
Ventilator
294
and
Division Bar
CHAPTER
3
III REMOVABLE
Door Replacement and Alignment
Door Locking Mechanism
Luggage Compartment Door
Replacement and Alignment
Luggage Compartment Door
Locking Mechanism
CHAPTER
Section 1
2
3
Section 3
244
Starter Drive
Section 3
4
252
253
Horns
Instruments
Section 4
5
268
269
Windshield Wiper
Miscellaneous Accessories
Section 4
5
6
Fibre Glass Repair Thunderbird
General Body Maintenance
Paint Refinishing
Hardtop
....
281
282
284
UPHOLSTERY, AND WINDOW GLASS
2
Section 1
2
SYSTEM
CONSTRUCTION AND MAINTENANCE
Alignment
Quarter Panel Repair
Door
226
232
FOUR BODIES
Body
CHAPTER
Section 1
Battery
.
265
CHAPTER
2
.
IV ACCESSORIES
257
260
Part
Section 1
Generator Regulator
LIGHTING SYSTEM, HORNS, AND INSTRUMENTS
CHAPTER
Section 1
Section 3
4
313
317
320
Section 4
5
6
7
Door Glass and Regulator Replacement
Door Glass Adjustments
Quarter Glass
Windshield and Rear Window
296
299
303
307
SHEET METAL ASSEMBLIES
Section 5
Grille
and
Hood
324
6
Hood Alignment
7
Thunderbird Grille
8
Front Fenders
and
Lock Adjustment
and
Hood
326
328
329
323
IV POWER
INSTALLATIONS AND SPECIAL ITEMS
331
Power Windows
Power Seats
Convertible Top
337
342
Section 4
5
6
Thunderbird Top Adjustments
Care of Country Squire Paneling
Crown Victoria Transparent Top
347
349
350
Part FIVE-MAINTENANCE AND SPECIFICATIONS
CHAPTER I-MAINTENANCE
Section 1
353
Preventive Maintenance
CHAPTER
Wheels
2
Brakes
3
Wheel Alignment
4
Rear Axles
5
Frame
6
Engines
7
Clutch
and
357
and
and
and
Steering
Lubrication
355
II SPECIFICATIONS
357
Tires
Section 1
Section 2
358
358
Springs
359
Transmission
362
360
Section 8
9
10
11
12
13
14
15
Cooling
Fuel System
Generating System
Starting System
Ignition
Fuse and Bulb Chart
Paint
Tools and Equipment
353
353
354
354
354
365
365
355
Part ONE
POWER PLANT
Chapter
i
Genera/ Engine
Overhaul, Inspection,
Section
Page
1
Trouble Shooting
2
Tune-Up
3
Engine Removal
4
Intake
5
Rocker
5
8
10
Installation
and
14
Exhaust Manifolds
and
Mechanism, Cylinder Head, Valves,
Timing Chain, Sprockets, and Camshaft
6
7
8
Cylinder Block, Pistons, Piston Rings,
and Oil Pump
9
10
of
component
in this
20
22
Connecting Rods
and
parts;
the
in the
or
and overhaul
have been
parts
case of a
trouble in a particular
trouble
shooting,
trouble,
such
gine, loose
as;
an
that may cause
definite
of a
the
in this
or
unit.
the
When
causes
any
other
item
affect power plant operation
the
or
the
on
can
be
attributed
that tend to
car
to the
harder
work
Engine
tion,
which
will
performance
correctly timed
pression,
result
ignition,
and an unobstructed
can cause
in
depends
under
not
tery
order
or
other
most
starter.
listed,
of exhaust gases.
and
remedies
probable
Perform
until
are
(d)
or replace
the
them as necessary.
become
badly burned
so
from cranking the
wiring may be at fault. Repair
starter
Part
THREE,
"Electrical
that
engine.
as nec
Ac
and
the
Starter or Starter Drive. If the
and
engaging the
not
and make
rare
starter or starter
the trouble is prob
fault,
drive. If the
flywheel,
starter
remove
starter
This
be
can
releasing the
drive may lock up
corrected
starter
drive. If the
drive. In
with
by loosening
run
the starter
the necessary repairs to the starter
cases, the
is
the
fly
the starter
starter
does
not
operate, remove it and make the necessary repairs.
turns it
causes
battery,
the starter, relay,
at
tighten
the
to
Check
ably in the
wheel.
dis
lights. If
or
as necessary.
seldom
prevent
Refer
ning, but
headings.
turn the engine over, or
to start, the
to
fuel distribu
WILL NOT CRAISK. If the
ENGINE
(1)
does
appropriate
engine
normal and uniform com
Engine troubles, their causes,
cussed
the
poor performance.
on proper
flow
to
Starter Relay Circuit. The relay
the
surfaces
will
the horn
Try
above components are not at
motion.
For example, dragging brakes
refer
cessories."
its
retard
Clean,
Check
contact
they
performance
to forces
If it is only
chapter.
individual part,
Battery Cables. Check for loose
the
connections
corroded
and ground.
essary.
engine
or
an
properly, test the battery. Recharge
battery
Check
(b)
However,
Poor
install
Battery.
the
not operate
or replace
(c)
section.
Check
they do
of
Engine.
engine
engine
applicable
remove or
applicable section.
(a)
pro
a wet or cold en
or
in the
desired to
temporary defect.
a
factors that
various
tained
TROUBLE SHOOTING
obvious
tank,
gas
empty
disconnected wiring,
or
are outlined
first look for the
the engine has been disassembled.
instruc-
removed
and eliminate
system
after
To completely disassemble or assemble an engine,
follow all the removal or installation instructions con-
complete overhaul
Trouble shooting is the application
cedure, in a logical sequence, to locate
a.
25
Bearings
and
instruc-
overhaul
1.
of
inspection,
the cleaning,
chapter.
after
apply only
from the engine,
The
Timing
30
are covered
cause
Valve
Exhaust System
The cleaning, inspection, repair,
tions
and
29
repair
tions
and
Valve Lash Adjustment,
15
Oil Pan
Trouble shooting; tune-up;
and
Repair
and
are
over
a
following
the trouble is located.
too slowly
defective bat
checks
(2)
starter
in the
The
or
ENGINE CRANKS. BUT WILL NOT START.
trouble probably lies in either the
the
fuel
system.
which system
is
at
The
following
test
ignition
will
system
determine
fault:
Remove the ignition
wire
from
one spark
plug,
and
Chapter
1 General
insert a piece of proper sized metal
rod so
from the insulator. With the ignition
turning
the
engine
hold
over,
end
Ii there is
follow
is
spark,
"a"
steps
a good
no
if there is
or
"b"
or
with
No Spark. Follow the
(a)
the cause,
and
is
whichever
spark, proceed
the
make
a
weak
spark,
"c."
below to determine
steps
repairs
or
replace
ments.
(1)
for
Pull the
inch from the
316
on
the
a
On
Fordomatic
good
Make
repairs
or
or
coil and
was
or
no
distributor,
weak
dry,
in
an
electrical
the
replace
the
spark
crank
the
the
coil
a weak
Test the
points.
it if
and replace
"jumper"
the
and
on
a
check
for
a spark at
"jumper"
now
a
spark
(b)
and
must
spurt
or
If there is
for
a
and
switch
be
"DIST"
for
check
no
spark,
terminals
and
spark, install
battery
at
or
to
a
terminal
the points. If
or switch
repaired
replace
may be
it if
weak.
coil
a
wiring
the
Check the
wires.
condition of
The
wires
following
checks
in
Test the
battery,
then
a suitable
to
and
Severely
regulator
inlet line
carburetor
to
container
at
the
fuel,
the
catch
if fuel is reaching the inlet fitting.
see
Repair the
the trouble is in the
fitting,
carburetor
If
necessary.
as
no
adjust, clean,
condition.
fuel pump inlet line
to
remove
start
the
any
(3)
air
into the line
Connect the line
does
engine
repair
not
or
check
start,
replace
try to
and
the
the
pump
ENGINE STARTS BUT FAILS TO KEEP RUN
NING. Check the fuel
has
cause
for
run
first. The ignition
system
trouble, but it is usually
time
some
is
and
at
system
after
the
operating
temperature.
(a) Check the fuel supply at the tank.
(b) Try to start the engine. If the engine
ate
with
and
adjust
system
as
If the fuel
engine still
outlined
system
in
oper
speed
(2)
foot throttle,
under
these components,
is operating correctly
operating
and replace
check
(c).
stalls, it may be due to the coil
down
breaking
will
the idle
the choke adjustment.
will not operate with constant
the fuel
(c)
foot throttle,
constant
check
If it
and
the
or condenser
temperature.
Check
them as necessary.
ENGINE CONTINUALLY MISSES AT IDLE.
When the
engine
continually
misses on
the same
cylin
the fault generally lies in the ignition system.
(a)
Isolate the
miss
time from the
inspect,
is improperly
(b)
and
or
(c)
adjust
by
pulling
plug
cable
Remove the plugs, then clean,
them. Replace those that are badly
plugs.
spark
corrosion
and
plug
wires
replace
and
replace
them
as
for
signs of
deteriora
them as necessary.
Remove the distributor cap
inspect,
one spark
burned.
Check the
tion and
fully
If the
engine.
Blow
pump.
necessary.
fouled
and
the
at
obstructions.
fuel pump pressure, then
pitted points
be clean, dry,
a
Remove the fuel tank filler cap, then disconnect the
at a
the rotor, distributor cap,
must
engine
collapsed
(4)
replaced.
necessary.
points as necessary.
the
crank
engine
closed, then install
the
spark
usually indicate that the voltage
set or the condenser is faulty.
plug
Using
sometimes can
spark, replace the
no
Remove the distributor cap,
or replace
this point, disconnect the
at
ders,
( ) The battery
and
should
pump discharge nozzle. If there is
fuel at this point, the engine is probably flooded or
there is water in the fuel system. If no fuel is observed
accelerator
at
listed:
order
(3)
Each time the throttle is actuated, fuel
or
the
then
coil
carburetor
times.
spark
terminal. Replace the coil
Weak Spark. Perform the
1
charge,
a
carburetor.
by hand
Adjust
a
If there is
primary
battery
check
points.
distributor,
other
exists, the ignition
is defective
(2)
the
and
are
points are
the
spark.
between the
the coil, then
the
of
one
"breaking"
between
wire.
the dis
remove
If there is
a
coil
(2),
the
at
occurs
necessary.
engine until
if there is
in
points
the points. If there is
at
"jumper"
the
as
to distributor primary
coil
of
if the
spark
install
of
spark
no
see
points
points;
terminal
a
was
and
cleaner,
throat while working the throttle
as
If there
(3)
look down the
and
carburetor.
necessary.
tributor cap,
the fuel tank.
at
to see if fuel is reaching the
air
perform
given.
several
between
wire
Adjust the
necessary.
order
fuel is reaching the inlet fitting, the trouble is in the
fuel pump or the fuel pump inlet line is clogged.
the
clean
arcing.
probably
spark,
NOTE: Check the flexible fuel pump inlet line for
the check. If
persists, test the coil,
spark
fuel
the fuel supply
good
in the
a
checks
system
either
defective.
and not
(1),
repeat
are
it if
condenser and replace
if
(c)
the following
(1) Check
(2) Check
Make
as necessary.
spark
then
points
wires.
plug
the high tension
replace
exists, the
spark
make
cars,
and re
necessary.
If fuel is reaching the inlet
spark
replacements
If there
(2)
a
and
over, check
is obtained, the trouble lies in
spark
tower socket,
the
equipped
these components are clean,
sure
turning
"/V."
lever is in
selector
distributor cap, rotor,
the
head,
cylinder
engine
persists, test the coil,
spark
weak
Good Spark. If there is
carburetor.
CAUTION:
If
the
and
distributor.
the
of
spark.
sure
If
from the top
coil wire
wire
ignition
the
a
it if
from the
Hold the
with
If the
(4)
Remove the
step
cor
or
roded wires.
place
cars,
Repair
and
in the terminals. Replace any damaged
seated
rod
applicable. If there
the necessary
make
starter
"N."
lever is in
the selector
protrudes
the
of
approximately 3/16 inch from the block.
CAUTION: On Fordomatic equipped
sure
it
on and
the
Engine Overhaul, Inspection,
and
rotor, then clean,
necessary.
1 Trouble
Section
If the
(d)
do
above steps
check the compression to
determine if it is satisfactory
(5) ENGINE MISSES
miss of this type
ERRATICALLY AT IDLE.
may be
following
(a) Carburetor, including
ture setting,
(c)
Valve
a
(6)
faults in the ignition
of
be
in
ing
(a)
by
caused
the
and
exhaust system.
Check the follow
operation
the
of
exhaust
gas
control
If it is sticking, free it up or replace it as necessary.
Check the paint on the intake manifold heat
(b)
be
If the
is
not
the
the
passage
Inspect,
plugs.
spark
clean,
and
that are defective
plugs
or
lobes,
shaft
replacements.
make
and
replacements
repairs
or
as
necessary.
they
and
coil
condenser.
carburetor
and
linkage.
test,
sion
replacements
Lack
POWER.
made.
the choke
has
not
NOT
valve
repairs
or
caused
preliminary
the throttle
FULL
DEVELOP
is usually
some
by
a
Check
system.
with
Show the
fuel
fuel
of
Time
internal
how improper
to
be
exces
carburetion
poor
malfunctions,
repair
be
will
in
only
by
saved
is
it is
one system
a
complete
a visual
inspec
for leaking gaskets or casting
the carburetor bowl. If the flooding stops,
carburetor
Tap
needle
was
held
Remove the
by foreign
open
persists, follow the
flooding
(a)
equipment
overhaul.
the
defects.
dragging.
consumption.
CARURETOR FLOODS. Make
the inlet
accelerator
are
consumption
to try to
advisable
test
customer
affect
shows
combination
not
of
choke oper
the
if the brakes
the carburetor. Since
carburetor.
(2)
steps
cleaner
air
Check the fuel
(b)
buretor float,
and
level,
material.
If
below:
and
the
check
choke
the car
of
needle and seat.
Replace
parts.
the
needle and
the condition
the fuel inlet
Check fuel pump
(c)
excessive,
pump
was
pressure.
forcing
If the
fuel
pressure
past
the pump should be rebuilt
checks should
opens all
the way,
and
Cooling
c.
or
the
is
inlet
replaced.
This
will
indicate
whether
regulate
a
short
checks
including
within
limits,
initial timing
and
check
distri
engine
engine
system
is thermostatically
operating temperature
controlled to
and
provide
for
warm-up period.
(1) ENGINE OVERHEATS. Usually, engine over
heating is the result of insufficient coolant supply. Check
coolant
level first. Make
certain
that the cause
of
trouble is not anti-freeze evaporation.
(a)
are operating properly.
System.
The cooling
the
compression
operation.
see
car will
If the test
carburetor
poor
open.
components
If the
preliminary
make certain
complaint
car.
the
rebuild
usually
tion
the
in the
operation of
usually
fuel
checks
carburetor.
(a) Verify
compres
lash. Check the
height. Make
compression.
the ignition system,
butor
a
been located:
the internal
(b)
perform
After preliminary checks are
the following operations if the trouble
Check the
(a)
power
sure
remains
perform
made,
valve
DOES
of
Make
and
adjustment,
Adjust the
(b)
Faulty
excessive
necessary.
However,
compression.
be
as
persists,
assembled
ENGINE
(7)
the
check
and
rates
spring
still
problem
and
following
Check for fuel leaks in the
stalled
for
made:
any defective
If the
(g)
However,
problems.
system
possible.
as
responsible
the
foreign
other
CONSUMPTION.
FUEL
usually
and
operation.
Check the fuel pump pressure and adjust the
fuel level. Check the accelerator pump action
(f)
be
ation and
Replace them if
defective.
are
is
clean
as
fuel
of
source
major
a
components
consumption.
should
the
Check the
(e)
repairs.
the fuel tank, fuel pump,
consists of
EXCESSIVE
(1)
cam
points.
deterioration,
of
the
of
Make the necessary repairs or
Check the high tension wiring for signs
the
and
condition
clearance,
the point
and check
Make the necessary
connecting lines. Dirt
and
are
all
in the
Remove the distributor cap,
(d)
material
sive,
lead-fouled.
gap, distributor
system
carburetor,
from
carburetor
fuel.
the gap. Replace any
adjust
burned off, the
preventing
vaporizing the
Remove
(c)
paint
obstructed
properly
The fuel
linkage is free. Check to
Check the
riser passage.
and valve timing.
carburetion
necessary.
sequence.
valve.
fuel pump pressure.
If the problem still exists, a check of mechanical
components must be made. Check the valve lash, cam
(d)
test if
is usually a combina
fuel system, but also
malfunction
carburetion
b. Fuel System.
ENGINE MISFIRES OR HESITATES ON AC
CELERATION. This
may
as
including
are
system
and
spark
compression
the ignition
and
the fuel system,
check
satisfactory,
Keep
Perform
the miss persists. Repair the engine
can
the
with
compression
mix
repairs.
operation.
If the
(c)
lobe lift,
operation, idle
choke
ignition system, starting
necessary
(d)
tion
a combination of
sequence:
Make the necessary repairs.
The vacuum lines and fittings for leaks. Make
plugs.
any
in
fuel level.
and
The
by
caused
things. Check the
(b)
the condition,
the intake manifold passages for obstructions.
and check
A
not correct
Shooting
If the supply is
low,
check
for leaks in the
cooling
system, then make the necessary repairs.
(b)
and
Check the
adjust
water pump belt for
it if it is loose.
proper
tension
8
1 General
Chapter
(c)
dirt,
Inspect the
(d) Using
NOTE:
by
clogged.
replacements
as
are
between
the temperature
sending
or
the
check
sometimes
caused
head casting and
element. Make repairs
unit
the
block if
heat
If it is defective
range.
it.
replace
Make
operation
and
the wrong heat range,
or of
is
thermostat
the
sure
proper
correctly
installed.
Check the
radiator
it if
and adjust
for
necessary.
flow. Flush it if
proper
necessary.
for
block
the
passage
water
the
replace
or
passages
the
replace
necessary.
ENGINE FAILS TO REACH NORMAL OPER
(2)
ATING TEMPERATURE. Generally this is
the thermostat sticking
being
or
operating temperature,
reach
ing
Make
passage
water
or
passages
unit
Replace any defective
not
gauge and send
thermometer installed in the
a
with
the
range.
does
still
engine
check
by
caused
the wrong heat
of
Check the thermostat first. If the
(f ) Check the ignition timing
(g)
the
out
for
head(s)
head(s) if necessary.
(j) Check the cylinder
Clean
defec
necessary.
as
out
a
obstruction.
passage
cylinder
Clean
obstructions.
for
check
and
pump
water
a
Check the
obstructions.
necessary.
Check the thermostat for
(e)
or
water
replacements
or
repairs
(i)
readings
clearance
impeller
Repair
and
Remove the
(h)
tive
accuracy.
Inaccurate
insufficient
(bugs,
obstructions
thermometer in the radiator,
a
reading for
gauge
fins for
radiator
Clean it if it is
etc.).
Engine
radiator.
parts.
2. TUNE-UP
Regular
maintenance
necessary for
tain satisfactory performance,
should
A
used
be
made,
hoses,
services
In addition, to
are
main
tune-up
a periodic engine
made.
a
cooling
of
engine
test equipment
inspection
visual
of
the wiring,
hoses, heater hoses,
system
be
should
the tests. As the checks and tests
perform
make
A
are
vacuum
be
should
A reading
Minor Tune-Up.
Perform the
following
INSPECT
(1)
CABLES,
IGNITION
all
insulation. Make
the distributor cap
Inspect the
for
Inspect the
firmly
wires are
to
case
for
fault,
and
cracks
low,
Brush the
a
the
repeat
leakage
compression
the
past
rings
compression
battery
the battery.
for corrosion,
and
cable connectors with
further corrosion, then tighten the
con
the
are
original
rings.
TEST CYLINDER COMPRESSION. Be
During
climb
a
sure
the
steadily
successive
Note the
obtain
cylinder.
of
strokes, or fails to
cates a
to
engine
obtain
the
or
oil will
same
are at
valves
the piston,
and
temporarily
seal
on
oil
reading is obtained,
are
leaking. If
or
more over
pounds
past
test, if the
the
climbs
same
during
higher
during
climb
pressure
the
on
fails to
the first two
the succeeding
entire
test, it indi
or stuck valve.
sticky
Install
a compression
reading
engine
and
compression
until
record
strokes
be
sure
gauge
in
the gauge
the
clean, file the
gap.
Test the
Install the
Repeat the test
the
a
on
to
reading
on
in
tips
an
electrodes.
or
spark
chipped
Replace
the
porcelain
adjust the
and
approved
for broken
spark plugs and
wipe
plugs,
flat,
all
spark
plug tester-
porcelain
defective
and
plugs.
tighten them to the specified
torque.
(4) CHECK THE DISTRIBUTOR. Remove
cylinder,
same number of strokes as was
maximum
plugs
spark
reading.
required
each
electrode
plugs
badly burned
tributor
reading.
cranking the
cylinder.
wide open position and
Crank the
maximum
this
required
wide open.
number
The
If the
and remains
strokes, but
Inspect the
all spark plugs.
Set the throttle in the
a
heavy
test.
compression
Remove
registers
checked
it indicates there is leakage
PLUGS. Sandblast the
1
be
rings.
(2)
battery is good. Operate the engine until normal operat
ing temperature is reached. Turn the ignition switch off.
number
cylinders
adjacent
should
(3) CLEAN, ADJUST, AND INSTALL THE SPARK
nectors securely.
the choke is
the rings
of
has increased 10
reading,
indi
normal
or valves.
satisfactory, but the valves
the
the
leaks. Make
below
rings or valves.
whether
tablespoon
in
make a
recharge
put
terminal
seated
and
To determine
the
cable connections
necessary.
retard
dam
corrosion.
battery
battery
if
clean. them
worn or
that the terminals
test. If the charge is
charge
grease
the
wires
capacity test. If unsatisfactory,
battery
given.
BATTERY
WIRES,
ignition
sure
and
free from
sockets are
a
order
AND CHECK THE CONDITION OF THE
BATTERY. Inspect
aged
in the
cylinder.
pounds
leak. This
gasket
indi
above normal
in two
compression
head
a
10
than
is
cylinders
all
of
pounds.
than 10 pounds
before condemning the
operations
10
the head gasket, rings,
at
even
indicates
a.
of more
leakage
specified pressure
compression
lead deposits in the
cates carbon or
cates
the
However,
of more
from
pounds
uniform within
A low
etc.
10
variation of
satisfactory.
A reading
type
reliable
to
inspection
and
proper car operation.
number
1
pitting
and
cap
and
and
rotor.
Inspect the breaker
burning. Replace defective
install the distributor cap
(5)
and
the dis
points
points.
for
Clean
rotor.
CHECK IGNITION TIMING. Disconnect the
dis-
2 Engine
Section
tributor
Check
line. Operate the
vacuum
the
necessary
line.
timing
with
timing light
a
(6) CHECK MANIFOLD VACUUM
CARBURETOR IDLE. Check
If the
If the
idle
manifold vacuum at
Set the
of
idle
engine
speed and
air cleaner
passenger
On
a
the specified
filter
fuel pump
a
drive belts (fan,
and power steering).
conditioning,
tester. Inspect the
defective
Install the
Make the
bolts
TEST COIL AND CONDENSER. If the
(7)
satisfactory, it
intensity (3) is
coil
the test unit
not
POINTS
BREAKER
for pits,
and
transfer,
excessive metal
or
b. Major Tune-Up.
vacuum
as
BATTERY. Remove the
(1)
Clean the
battery
battery
the
spect
terminals
case
test. If the
to
from the battery.
cable
and
cracks
is low,
charge
Replace deteriorated
worn
for
cables
and
connectors.
connectors
insulation. Brush the
further
retard
battery
a
burned
Connect the
cables
to the
CHECK THE GENERATOR AND REGULA
(2)
TOR. Follow the
procedures outlined
in Part
THREE,
and
from
each
plug
wire will
jump
a
inch gap,
3/16
as
Remove
in
adapter
Run the
the
spark
plug wire,
wire
engine
at
regularly.
If the
trouble
one
terminal.
approximately
adapter
the gap
spark
exists
is
idle
3/16
and
install
a
Hold
the
end
inch from the
speed.
The
Repeat the test
unsatisfactory
in the coil,
in the distributor,
circuit.
operate
head.
should
jump
spark
condenser,
or
cylinder
on each
at
in the
all
the
lead.
spark
adjustment
is
rotor or
external
(12)
primary
an
idle
at
and make
and
other
damage. Re
housing
sockets.
speed.
and
carburetor
Check the timing
the necessary adjustments.
vacuum
check
the valve lash
at
line
ignition
after
advance
completing
as
the
en
after
the
engine
is thoroughly
is lower than specified, check for leak
lines and intake manifold. Check the
idle
adjustment.
be
is
still below normal or is
erratic, it
bad rings, sticky valves, weak valve
leaking head gasket. If this condition exists,
vacuum
or a
should
mani
the specified idle speed.
vacuum
indication
springs,
it
or
distributor
the
engine
vacuum
the
If the
is
cracks
TEST MANIFOLD VACUUM. Check the
If the
plugs,
lubricant.
up.
vacuum
age at
cam
CHECK AND ADJUST VALVE LASH. Check
and adjust
fold
assembly is defec
accelerated.
carburetor
cap, inter
the
timing light
(11)
terminal
of
between
Connect the distributor
the
gap
point
Lubricate the distribu
from the terminal
corrosion
line
warmed
follows:
nally
and
the
CHECK IGNITION TIMING. Disconnect the
(10)
TEST SPARK INTENSITY. Determine if the
(3)
all
vacuum
gine
Accessories."
"Electrical
spark
move
point
check
to specifications, the
point
parts.
distributor
with
spots.
CLEAN AND INSPECT THE DISTRIBUTOR
(9)
with a
battery.
lightly
cam
defective
all
not
the
or
points
adjustments,
Set the
required.
is
angle
worn
CAP. Inspect the cap for
that have
cables
cable connectors with grease
corrosion.
tor
is
cam
tive. Replace
a
the "battery.
recharge
and
In
leaks. Make
capacity test. If unsatisfactory, make
battery
charge
in the
distributor
TEST
AND
distributor
make
and
advance
replacements
dwell. If the dwell
order given.
of
manufacturer.
THE DISTRIBUTOR. Inspect
Test the
to deter
parts on a test unit
the
neces
be necessary to
the spark is
is defective. Follow the instructions
INSPECT
(8)
will
spark
However, if
condenser.
and
satisfactory, test these
not
repairs,
operations
plugs
to 23-28
and nuts
to specifications. After setting the gap,
following
gap.
plugs
badly burned
and
plugs.
adjustments.
Perform the
the
adjust
and
porcelain
and exhaust manifold
mine which one
all
porcelain
foot-pounds torque.
element.
of
all
SPARK
the
wipe
plugs,
flat,
tips
an approved
chipped
INSTALL
CHECK MANIFOLD BOLT TORQUE. Tighten
test the
the fuel line filter. Install
BELTS. Check the deflection
sary
viscosity.
element.
clean
(6)
If
element.
to the indicated
CHECK THE DEFLECTION OF THE DRIVE
(8)
air
the
and oil
in
or
Replace
electrodes.
the intake
AND THE FUEL
bath-type, fill
electrode
plugs
broken
spark
and tighten them to the specified torque.
remove and clean the
cars,
new
Thunderbirds,
filter
cleaner,
oil
with engine oil of
bowl. Install
new
air
is the
clean, file the
for
AND
CLEAN, ADJUST,
PLUGS. Sandblast the
the carburetor idle fuel
(7) CLEAN THE AIR CLEANER
FILTER. Clean the
valve
weak
in Chapter IV.
adjustment as outlined
On
is erratic, it is
normal or
not all of
Tune-Up."
"a. Minor
procedure under
Test the
below
still
bad rings, sticky valves,
head gasket leak.
or a
springs,
is
some, but
at
distributor cap is corroded.
the
(4) TEST CYLINDER COMPRESSION. Follow
(5)
adjustment.
is unsatisfactory
spark
the spark plug wires, the trouble is in the wire itself,
the wire is not seated in the housing socket, or the
speed.
vacuum
indication
level
AND ADJUST
vacuum
carburetor
the
the
vacuum
is lower than specified, check for leak
the vacuum lines and intake manifold. Check the
age at
an
the
If the
speed.
make
and
Connect the distributor
adjustments.
the specified idle
idle
engine at
Tune-Up
of
reported
to the customer.
10
500
static
pressure
The capacity
r.p.m.
500
Engine
TEST FUEL PUMP PRESSURE AND CAPAC
(13)
ITY. The
at
1 General
Chapter
be 3.5-5.5
should
should
be 1
in 30
pint
seconds
r.p.m.
BOOSTER
PUMP
VACUUM.
INSPECT AND CLEAN THE FUEL FILTER.
On
passenger
bowl. Install
On
new
filter
Thunderbirds,
filter
and clean
(17)
fuel pump
the
clean
and
the fuel line filter. Install
clean
a
equipped
muffler
Disassemble
level,
oil
accessories.
fill to the indicated level
Separate
procedures
car
for the
given
are
oil
engine
of
conventional
The following
apply to
procedures
Differences in the
cars.
the
when
equipped
cars
noted
they
when
The
with
Remove the
then
REMOVAL. If the
(1)
ard
overdrive
or
(c). If the
steps
(a)
(b)
for the
it impractical to
gine with the transmission
car
remove
and
peculiar
engine
are
engine
only,
Remove the
toler
install the
or
remove
en
car
is
equipped with a stand
(a) and
Fordomatic, follow
with
Disconnect the
clutch
retaining the
equalizer
the
remove
accelerator
with
a
linkage
jack,
housing
then
spring.
release
Remove the two flywheel
bolts. Remove the flywheel
transmission
bar
support
support
at
housing
cover,
and
Drain
the
cooling
bolts. Jack up the front of the
transmission
safety stands. Support the
system
remove
the remaining
converter
housing
and
blower
Remove the
ground
flex fuel line
at
cable
perature
sending
wire.
at
unit
wire,
starter cable at
Disconnect the
to
jack,
engine
bolts.
Disconnect the
manifold.
hoses,
block,
then
the
and
wire
at
the starter, then
air
hose,
tem
the oil pressure sending
ground
cable
the
coil.
remove
from the
choke
inlet
cable
at
the
rear
cleaner, then tape the
accelerator
muffler
vacuum
wiper
primary
Disconnect the
Disconnect the
cylinder
and
Disconnect the
closed.
lower
and
pump.
horn
retor.
the
windshield
engine
then
heater
the
and
Remove the fan. Disconnect the
the fuel
Disconnect the
unit
cylinder
filter.
upper
radiator
radiator.
to
position
pan,
motor.
the two
and
oil
the crankcase. Remove the heater
the engine. Remove the
with a
from the
shield
splash
rubber
car
the transmission
hoses. Remove the heater inlet duct
starter.
upper
that
Engine Removal. Remove the hood. Drain the
Remove the
housing
at
then remove the oil
block,
and
remove
bracket
linkage
battery
the
the
level indicator tube to the
control
arm
converter
housing
sion
shaft,
the two
converter
the
the
then
Remove the idler
remove
so
plate
the tube assembly. Remove the transmis
at
plugs, then
the
Remove
oil
Disconnect the tube
tie the linkage to the dash
bracket. Fold back the floor mat,
from
90
drive
removed.
transmission.
upper
support
cross
180,
remove
the transmission throttle linkage
the
is
the transmission
secures
the
housing bolts.
Steps Peculiar To Fordomatic Disconnect
panel.
plate
removed
are
on
catch
not
will
remove
the remaining
remove
bolts
the
plate, turn the
engine
mani
the
flywheel
(b)
the
(c)
bushing. Disconnect the
crank.
drive
plates
cover, then
is in posi
access
drive
three bolts.
other
After
steps
(c).
to the flywheel housing, then
fold bell
flex
engine.
attached.
equipped
screws
owner.
without
compartment
Steps Peculiar To A Standard Or Overdrive
Transmission.
check
the three bolts. Turn the flywheel
the
CAUTION:
transmission, follow
is
final
car as a
lower
housing
converter
conventional
all
procedures
6-cylinder
or
Engine
attached.
air
additional service required
is delivered to the
remove
when
procedures given are
make
Recommend any
exist.
the transmission
ances
8
an
(fan,
Make the necessary
performed.
car
converter
to
drive belts
of all
power steering).
and
work
tion to
Conventional Passenger Car.
passenger
analyzers,
manufacturer.
turn the flywheel till the flywheel
the Thunderbird.
and
of
ENGINE REMOVAL AND INSTALLATION
3.
passenger
with
the
of
types
several
are
Also, notice the performance
transmission, axle, brakes, and any optional
If the
is the
there
as
ROAD TEST. Road test the
(21)
the
cleaner
left
adjustments.
the
air
exhaust
the
to
tube
CHECK THE DEFLECTION OF THE DRIVE
of
element.
the
dual
On
analyzer
BELTS. Check the deflection
on
the
ANALYSIS.
follow the instructions
air
and
en
adjustment
pipe.
outlet
Inasmuch
and check
operation.
pump
idle fuel
carburetor
connect
cars,
conditioning,
THE CARBURETOR.
the
in Chapter IV.
CLEAN THE AIR CLEANER. Clean the
bath-type,
a.
speed and
EXHAUST
(20)
the carburetor. Set the fuel
accelerator
cleaner
idle
(19)
element.
element.
CLEAN
(16)
the
remove
cars,
a new
viscosity.
ADJUST CARBURETOR IDLE. Set the
(18)
gine
The
booster pump vacuum should be 10.0 inches of mercury
at 500 r.p.m. The vacuum should not drop rapidly when
the engine is stopped.
(15)
specified
as outlined
TEST
(14)
the
at
p.s.i.
Repair
and
the
of
air
carbu
linkage.
pipes
at
the
exhaust
Section
3 Engine
Removal
11
Installation
and
Too/-T52L-6000-C
(SPLINED SHAFT)
Tool- 1 5 41-600 5-D
Tool T54L-6005-E
On 6-cylinder engines,
bracket bolts
at
the
Hook 6-Cylinder
Lifting
Engine
insulator,
the
engine
the transmission.
move
engine
the right
and
lifting hook(s) (fig.
left front
1
or
2). Re
aprons.
splash
On 8-cylinder engines, remove the
insulator from the engine front steady
Carefully
Do
safety
rest
to
spacer
bolts. Raise the
(2)
and
front
(b),
and
stands.
follow
steps
Remove
insulator
at
the
the
cap
screws
the
from
engine
the
left insula
engine
right
engine.
let the
pull
engine
it from
swing
the
of
out
engine
engine on a work stand
car
(fig. 3
is
against
or
4).
equipped
with
a
overdrive
(a), (c),
(d).
and
Engine Installation. Install the
lifting hook,
engine
remove
bracket
right
transmission, follow steps (a),
(d). If the car is equipped with Fordomatic,
or
position
(a)
tor.
car
engine
not
lift the
INSTALLATION. If the
standard
rest.
On 6-cylinder engines, loosen the two
steady
lower
the
and
the grille.
Install the
retainer and
left insulator to
the
slightly, then carefully
engine compartment.
Attach the
Engine
engine.
Raise the
J
Fig.
at
remove
6302
SHAFT)
3 Engine Mount 8 -Cylinder
Fig.
bolts
(KEYED
appropriate
then remove the engine
from the
work stand.
CAUTION:
sure
plate
the
will
On
Fordomatic
flywheel drive
not
Lower the
catch
engine
on
equipped
plate
the
is turned
so
the
flex
housing.
converter
carefully into the
make
cars,
engine
compart
ment.
On 8-cylinder engines, lower the
Tool-T53L-300-A
pump to oil
pan
line
clears
Start the transmission
the
main
engine
engine
drive
left
gear
until
the
oil
support.
into the
clutch
ToolT53L-6000-B
ToolT52T6005-CJD (Splined Sha
ToolT52T-^>005-KJD (Keyed Shaft)
6304
Fig.
2
Lifting Hooks
and Sling 8-Cylinder
Engine
6289
Fig.
4 Engine
Mount
Adapter 6-Cylinder
Engine
12
1 General
Chapter
disc. On Fordomatic units,
the converter
start
pilot
into
the crankshaft.
NOTE: On
with relation to
shaft
will
"hangs
or
units, it may be
overdrive
not
the engine
enter
up"
the
the
after
disc.
clutch
If
the
the
crank
it if
slowly (with the transmission in gear) until
the shaft splines mesh with the clutch disc splines.
Make
the
8-cylinder
and
muffler
inlet pipe(s)
the holes in the
block dowels
the
studs on
manifolds of
and
clutch
must
both the 6
the holes in the
engines are aligned with
the dowels in the block
housing
(on Fordomatic
the holes
engage
the
on
engage
units
housing).
NOTE: Level the
in
engine crosswise
installing
to the
relation
mounting bolts
the
or
the
steady rest.
On the 6-cylinder engine, install the left insulator to
bracket lockwashers and bolts and the right bracket to
lockwashers
bolts. Tighten the insulator to
and
bracket bolts to 45-50 foot-pounds torque. Tighten the
engine
pounds
front steady
rest
to spacer bolts to 30-35 foot
left
block,
the
insulator
the holes in the
align
insulator to
the insulator to
engine
torque.
sulator
Install the
to 50-60 foot-pounds
nuts
front steady
Tighten the
foot-pounds torque. Install the
right and
bolt to 23-28
left front
splash
manifold
Install the starter, then
rear
of
muffler
the
connect
Connect
Fordomatic).
cept
to the
(s)
the
inlet
starter
ground
oil pressure
sending
the ignition
switch wire
switch wire
to the
linkage
the
and
Connect the
wires, the
pipe(s).
cable
generator
(ex
Install the
Connect the
Connect the
engine clips.
(6-cylinder
line
windshield wiper
radiator
battery
cleaner.
heater inlet
Install
and
connect
ground cable
carburetor
the
to the
air
horn
Install the heater blower
and
duct,
the
then
connect
plate
holes
evenly to
and
housing
avoid
to
upper
engine
and
drive
six
bolts,
foot-pounds torque.
Install the starter, and tighten the bolts to 15-20
foot-pounds torque. Install the transmission oil level
indicator
tube
Install
assembly.
bracket. Tighten the idler
idler
the
bracket
arm
foot-pounds torque. Install the
and
arm
to 28-43
nuts
housing lower
converter
access covers.
necessary linkage
the
transmission
the
with
A, following
the
procedure.
recommeneded
Check Engine For Oil Or Coolant Leaks.
(d)
Run the
hose
Fill
Fluid Type
Automatic Transmission
and make
Remove the jack sup
adjustments.
transmission.
the
porting
the throttle linkage
and connect
fast idle
at
engine
connections
check
and
gaskets
all
and
for leaks.
Thunderbird.
b.
On Fordomatic
Remove
install the
motor
system
with
and
and
or
the
REMOVAL.
(1)
Thunderbird
Fordomatic
To
with
equipped
a
as
an
and
and
remove
assembly, follow
a
overdrive
remove
the
Fordomatic,
the engine and
steps
(c)
(d).
and
Steps Peculiar To A Standard Or Overdrive
Transmission. Disconnect the
Remove the
screws
to the flywheel
retaining the
housing,
clutch
Remove the flywheel
mission with a
then remove the
jack,
housing
then
release
equalizer
bushing. Remove the two flywheel
the
the transmission throttle linkage
bar
spring.
support
support
housing
cover,
remove
housing bolts.
(b)
or
(c). To
equipped with
(c). To
from
engine
standard
a
(a)
steps
Thunderbird
(b)
the
remove
the
upper
support
and
bolts.
the trans
the remaining flywheel
Steps Peculiar To Fordomatic. Disconnect
at
the cross shaft,
tie the linkage to the dash panel. Remove the
bar support,
engine
transmission
the
without
attached.
(a)
hoses.
Thunderbirds,
equipped
removed
steps
accelerator
engine.
be
follow
wires,
radiator
equalizer
and
foot-pounds torque.
the converter, then install the
them to 25-28
from
Connect Standard Or Overdrive Transmis
Install the bushings in the
with
and tighten
engine
the heater hoses.
hood. Fill the cooling
bolts,
Align the flywheel
pan plugs.
and
crankcase.
(b)
bolts,
the fuel pump
and
lower
engine
to 40-45
them
tighten
the
engine).
and
Install
pins.
converter
and
to the coil. Connect the ignition
choke wire
the tape from the
sion.
the dowel
on
Install the two
to
vacuum line. Connect the fuel pump flexible line. Install
the fan assembly, then adjust the fan belt.
air
binding
unit
cable
the engine, the temperature sending
unit
to
housing
NOTE: Tighten the bolts slowly
may
aprons.
Connect the
and adjust
lower in
rest
retainer
inches)
tighten them to 40-45 foot-pounds torque.
bolts. Tighten
and
bolts to 45-50 foot-pounds torque
engine
and retainer.
and
Install the
and nuts.
lockwashers
engine
the frame to insulator
and
bolts
then install the insulator to engine
the frame to insulator lockwashers
right
en
the mounting holes in
with
Check
transmission.
Transmission.
Fordomatic
converter
Install
support
spring.
release
clutch
free travel (lH-l3/8
Connect
the two
torque.
On the 8-cylinder engine,
gine
tighten
and
necessary.
Install the floor
frame before
engine
clutch pedal
(c)
the
converter
Connect the
cover.
Remove the jack supporting the
engine
enters, turn the
shaft
housing
shaft
sure
housing bolts,
them to 40-50 foot-pounds torque. Install the flywheel
the transmission input
if
housing. Install
the flywheel
support on
the transmission to flywheel
standard
to adjust the position
of the transmission
necessary
install the
then
Repair
and
idler
and
arm
bracket.
Jack up the front
of
the
car and position
safety
stands.
3 Engine
Section
Support the transmission
converter
housing
housing
lower
jack,
with a
Removal
then remove the
to engine bolts. Remove the
converter
cover, then turn the flywheel till
access
flywheel drive plate is in position so the three bolts
be removed. Turn the flywheel 180, then remove
the
can
the other three bolts.
CAUTION: After
converter
flex
the
bolts
are
drive plate,
turn
the
Drain
the
secures the
is
transmission.
transmission
and
remove
the tube
sion
control
linkage
(c)
system and
remove
the
90
plate
so
housing
oil
the
cleaner.
air
Remove the transmis
assembly.
splash
the
crankcase.
Disconnect the
the
battery
battery. Disconnect the
fuel inlet
to
Remove the fan, then
an assembly. Remove
engine
ground
battery
starter
vacuum
ground
wire
at
cable at
cable at
relay
line,
pump
the fuel pump. Disconnect the
at
and
the
the dash
at
wire
at
Remove the
wires.
unit
sending
and
Remove the heater blower
bracket
also serves as
Raise the
the
front
move the
mount
accelerator
stands.
safety
bolt,
nut,
engine right and
engine will clear
(this
Disconnect
lower insulator. Re
and
left steady
rest
bracket bolts
one side so
the
slightly, then carefully pull the
Carefully lift
the
engine
engine
from the trans
out
the
of
engine
Install the
engine on a work stand
in
step
(c),
perform
the
following
hooks,
at
ing
and
cap.
move
cable.
speedometer
plug the transmission
Remove the
converter
the bracket that
indicator tube to the
secures
remove
flywheel drive
the
will
not
engine.
on
catch
Lower the
the
equipped
is
plate
the
from the
engine
(a),
work
lifting
stand.
make sure
cars,
flex
plates
housing.
carefully into the
engine
engine
turned so the
converter
Start the transmission
drive
main
disc. On Fordomatic units,
engine compart
start
gear
into the
clutch
the converter pilot into
the crankshaft.
NOTE: On
standard
adjust
with relation
to the engine,
the clutch
enter
the
shaft
the
disc.
enters,
If
turn
the
with
Make
disc
clutch
the
sure
units, it may be
overdrive
or
necessary to
position
if
of the transmission
the input
the crankshaft
until
the
shaft will not
"hangs
the engine
up"
after
slowly (with
shaft splines mesh
splines.
studs
on
the manifolds are
the holes in the muffler inlet pipes, and the
with
in the block
engage
Fordomatic
units
on
the holes in the
car
front
dowels
housing
(on
must
engage
the
housing).
and position
support
aligned
clutch
block dowels
the
the converter
Raise the
engine
lower
safety
stands.
Install the
insulator, bolt, lockwasher,
Tighten the insulator mounting nut to 85-95
foot-pounds torque. Install the engine right and left
nut.
and
rest
NOTE:
adjust
shift
control
rod.
Remove the drive
duct
steps
ment.
additional
with an extension
air
(f). To install the
and
assembly, follow
as an
CAUTION : On Fordomatic
steady
car
the transmission and the throttle control
Disconnect the
shaft,
then
bracket bolts,
If
rest
the
hous
assembly.
Re
the transmission oil level
Disconnect the tube
at
the
rod
was
tighten the bolts to 45-50
and
assembly
disturbed
adjustment
during
the rod as outlined in
step
Connect the
Drain the transmission. Disconnect the
(a), (c), (e),
steps
Fordomatic
Thunder
equipped
Engine Installation. Install the
(a)
operations :
linkage
Fordomatic
a
(f). To in
and
(d),(e),and(f).
is
And Fordomatic As An Assembly. While the
raised
only in
a
overdrive
foot-pounds torque.
(fig. 3).
Removing The Engine
Steps Peculiar To
(d)
(a), (b), (e),
steps
in
engine
or
standard
a
with
equipped
engine
bird, follow
steady
compartment.
car.
the engine slightly,
To install the
INSTALLATION.
the
stall
holes
them upon removal.
Remove the safety stands and lower the car. Install
the engine lifting hooks (fig. 2). Raise the engine
mission.
lifting hooks. Raise
the transmission in gear)
the exhaust manifolds. Remove the
the engine, then turn the brackets to
at
block
the
at
rod,
the ignition cable bracket).
car and position
exhaust pipes at
engine
from the
Disconnect
assembly.
link bracket
disconnect the
wires
the temperature sending
the tachometer cable. Disconnect the
then
to coil
switch
the coil. Disconnect the two heater hoses. Re
pressure
unit.
Disconnect the ignition
the generator
move
oil
panel.
lower the
and
compartment.
engine
the
starter cable
as the
serves
Carefully
the starter solenoid, then remove the cable clamp
at
engine
engine and
shield.
the transmis
then carefully pull the engine and transmission forward.
lift the engine and transmission from the
radiator and shroud as
engine and
Remove the transmission jack
level indicator tube to the
oil pan
raise
assembly.
engine rear mount.
(2)
the transmission
bolt,
the cross member that
remove
Thunderbird
at
the tube
remove
engine rear mount
Remove the bracket that
the dash panel. Disconect the
the
drive
Engine Removal. Remove the hood. Drain the
cooling
sion, then
pan, then
oil
Remove the
removed.
Disconnect the tube
engine.
from the
removed
plates will not catch on the converter
when the engine
transmission
Install the
the
13
Installation
and
exhaust pipes
engine
of
either
removal,
(e).
to the exhaust manifolds.
Remove the safety stands and lower the car.
Connect the accelerator rod, then connect the accel
erator link bracket to the block. Connect the
tachometer
cable.
oil
Install the heater blower assembly. Install the
pressure
unit
wires.
sending
unit and
Connect the
the temperature sending
wires. Connect the
two heater hoses. Connect the ignition switch to
coil
generator
14
1 General
Chapter
Install the
bracket
arm
Install the
Install
the
Install the transmission
Install the idler
assembly.
idler
tighten the bolts to 15-20 foot
starter and
torque.
pounds
Repair
and
bracket. Tighten
arm and
housing lower
converter
and
connect
necessary
linkage
covers.
access
linkage,
throttle
the
make
and
Remove the jack
adjustments.
supporting the transmission. Fill the transmission
Automatic Transmission Fluid-Type
recommended
with
A, following
the
procedure.
Install The Engine And Fordomatic As An
(d)
Assembly. While the
following
the
the
foot-pounds torque.
28-43
to
nuts
filler tube
oil
Jack
additional
the
up
is
car
in step
raised
(a),
perform
operations:
Install
transmission.
the
rear
engine
Lower the transmission, then install the engine
mount bolt. Install the converter air duct assembly.
mount.
rear
Install the transmission
oil
Remove the
housing
extension
level indicator tube
install the drive
sion,
and
eter
cable.
Connect the
cap from the transmis
Connect the
shaft.
speedom
linkage
control
shift
assembly.
the
and
6512
throttle
5
Fig.
Adjustment Thunderbird
Rest
Steady
control
Fill the transmission
rod.
Transmission Fluid-Type A,
matic
Auto
with
following
the
recom
mended procedure.
wire.
Install the
starter
the
and connect
windshield wiper
the
battery
line
the flexible fuel line. Connect
and
Install the
engine ground wire.
radiator
and
system.
and
Fill the
crank
Install the bushings in the
then install the
support on
equalizer
bar support,
the flywheel housing. Install
the transmission to flywheel
housing bolts,
and
tighten
40-50 foot-pounds torque. Install the flywheel
them to
housing
Connect the
cover.
clutch
Engine Steady Rest Adjustment. If the
(e)
gine
steady
It is
good
the
rod
With the
loosen the
rod
each
the free play, if necessary.
of
(c)
Connect
Fordomatic
housing
converter
to
Transmission.
lower
engine
Install
bolts,
and
tighten them to 40-45 foot-pounds torque.
NOTE: Tighten the bolts slowly
binding on the dowel pins.
Install
tighten
flywheel
the
six
the
converter
40-45
them
to
and
drive
bolts,
plate
and
and
avoid
to
engine
bolts
foot-pounds
torque.
Align the
holes
tighten
with
them
and
the converter, install
to 25-28
engine
(at the
and
rest
up
foot-pounds
each
rod
assembly up
bracket. Tighten the
5. Turn the
the
rod
upper
assembly
nut
on
level
nut
adjustment
both steady
Turn
position.
and
insulator
(chassis)
and
insulator
the
against
measuring the
of
support
the
shown
at
top
support
in fig.
the
top
the engine support
to the dimension
the
at
engine
to the dimension
of
place
chassis),
to the dimension shown
against
assembly down
by
and
nut, washer, and insulator
bracket. Tighten the
top
shown
portion
over-all
of
in fig.
the
dimension
as
rod
in
dicated in fig. 5.
(f)
Check
The
Leaks. Run the
and
torque.
nut
rods are out of
brackets in
nuts
own
the lower
against
adjustment of
engine
upper
its
seek
result.
below:
assembly lower nut, washer,
5. Check the
housing
lower
rod
may
installation. The
rest support
steady
tightened
Turn the lower nut, washer,
of
evenly to
engine
steady
in fig. 5.
the
check
engine
procedure
bracket. Tighten the lower
release spring.
Remove the jack supporting the transmission. Check
the clutch pedal free travel (IVs-IVs inches). Adjust
the two
follow the
Let the
each
illustrated in fig. 5. If the
are
properly
rests.
and excessive engine vibration
at
en
properly adjusted, the engine
not
practice, therefore, to
adjustment
and
are
assemblies,
dimensions
the
rests
be tilted
will
grade of engine oil.
Connect Standard Or Overdrive Transmis
(b)
sion.
the correct quantity
air cleaner.
install the fan.
then
shroud,
Install the hood. Fill the cooling
case with
the dash panel,
on
clamp
to the starter. Connect the
ground cable and the starter solenoid cable.
Connect the
Install the
cable
starter cable
hose
Engine
engine at
connections
For
fast idle
Oil
Or
Coolant
and check all gaskets
for leaks.
4. INTAKE AND EXHAUST MANIFOLDS
a.
Cleaning
and
Wash grease, oil,
Inspection.
and
dirt from the
outside
of
the
exhaust manifolds.
Clean the mating
surfaces and check
4 Intake and
Section
15
Exhaust Manifolds
OPEN
OFF)
(HEAT
6338
OPEN
.
(HEAT
OFF)
Fig.
7 Exhaust
Valve Dual
Control
Exhaust System
6337
Fig.
6 Exhaust
Exhaust System
Valve Single
Control
them for damage. Repair
replace
or
the
manifolds
as
On the intake manifold, check the fuel-air and the
heat riser passages for foreign material. Inspect the
for
surfaces
replace
cracks
Remove
have
visible
other
or
the manifolds as
CAUTION:
that may
light finger
Rapidly
pressure
accelerate
opens.
momentarily
necessary.
or
engine
operated
trating
at
is
at
high
oil or
is
applied
the
The
valve
Free
r.p.m.
open
the
make
the
sure
is designed to
stuck
very
valve
open when
valves with
and
a
is
pene
and graphite mixture.
filings
the
foreign
and
manifolds
matter
result
a
as
of
CLOSED
work.
repair
when
counterweight.
normal
kerosene
to
engine
will
to
necessary.
all
entered
defects. Repair
the
valve
properly operating
a
ever,
(HEAT ON)
b. Exhaust Gas Control Valve.
Check the
valve
spring to
make sure
the stop pin. The spring stop is at the
housing
of
when
the valves
Check to
when
the
hand to
The
is
is
cold.
sure
it
closed
on
valve
action
the spring holds the valve closed
rotation
of
valve
the
of
valve
make sure
engine
90
top
is properly installed. The
in figs. 6, 7, and 8.
illustrated
is
the
make
mately
it is hooked
Actuate the
freely
moves
without
when
counterweight
through
by
approxi
binding.
the
6478
is
engine
and running
at
idle
at
normal
Fig.
speed. How-
8 Exhaust
Control
This
dures
and
section
applicable
valves.
valve
covers
lash
to the
the inspection and
rocker
In addition, the
and
to
check
mechanism,
methods used
valve
timing
repair
cylinder
to
are
head,
adjust
given.
AND VALVE TIMING
The
proce
Rocker Mechanism.
rocker mechanism parts are
individually
replace
able.
(1)
the
of
the
shaft
a.
Engine
VALVES,1
5. ROCKER MECHANISM, CYLINDER HEAD,
VALVE LASH ADJUSTMENT,
Valve 6-Cylinder
CLEANING AND INSPECTION. Check the I. D.
rocker arm
at
the
rocker arms
bore
location
for
and
of
the O.
the
grooved pads.
D.
rocker
of
the
arms.
Check the
rocker arm
Inspect the
rocker
adjust-
16
Chapter
1 General
Engine
(1) CLEANING
installed to
valves
to
fixture'
PUSH ROD
9 Push
Fig.
6263
Rod Runout Check
old
gasket
Check the head for
burrs,
nicks,
lock
screws and
the ball
and
for
nuts
the
end of
stripped or
for
screw
broken threads,
nicks and scratches or
excessive wear.
Inspect the
of
for
springs
are
Check the ball
drain tube for
cracks or other signs
nicks, grooves, roughness,
A
suitable
check
the
push rods
for
(2) REPAIRS. Replace
push
rods
be
can
at
any
discard
point,
straighten
0.020
the
rod.
Do
not
Remove
and
rocker
arms
the
rocker
arms.
severely
scored
Replace
all
or
scuffed
oil
and
and/or
rocker
Replace
minor nicks or scratches.
screws, lock nuts,
bores
scuffed
scored
Replace the
between the
shaft
is excessive, replace the shaft and/or
Replace all rocker arms that have
or
all
grooved
pads.
Dress up
shafts.
damaged adjusting
springs.
drain tube if it is
cracked
or
has
a
sharp bend.
to
use
is
heads, do
not
heads
off
are
the
the
if
material
excessive
surface
this
when
the
as
com
is
operation
dure is
the
leakage.
show signs of
HOLE ADAPTERS. If it is de
14
standard
spark
millimeter
The
18
the
reduces
which
millimeters.
millimeter
installation
adapter
an
plugs,
proce
follows:
as
Position
meter
that
plug
plug
gasket
a standard
on
install the plug in
and
plug
spark
spark
a
an
14
milli
Insert
adapter.
assembly into the 18
and adapter
milli
meter hole and tighten the plug to 25-30 foot-pounds
torque. This torque is sufficient to seal the adapter in
place
it
and
will
spark
back
not
Once the
out
adapters
plug
gap
when
the
plug is
spark
are
installed,
and
torque
14
standard
specifications
apply.
machined
remove
or
or scratches with an oil stone.
core plugs
available
hole to 14
removed.
b. Cylinder Heads.
protect
grind
gasket
altered
burrs
all
millimeter
To
the head if it cracked,
or
head
(3) SPARK PLUG
to
adapter
clearance
evidence
repair.
plane
is
ratio
Replace any
sired
If the
all,
performed.
inch,
attempt
it.
(2) REPAIRS.
not
cylinder
pression
they are installed in the engine by rotating them
(valve closed) or they can be checked between ball
and cup centers with a dial indicator (fig. 9).
runout of a push rod exceeds
the
made
while
If the total
Do
NOTE:
from
or excessive wear.
for bent
over
passages
sharp bends.
cracks or
end and socket end of
maximum
speci
leakage.
it is damaged beyond
oil
0.006 inch
0.003 in any six inches. Make sure all water
are open. Check the cylinder head core plug for
failure.
Inspect the
gasket surface
or
of
locating
with solvent
grease.
and
Check the
cracks.
to
careful not
for flatness (fig. 10). Service
and
fications for flatness
ing
brush. Be
dirt,
the
car
valve
and
chamber
combustion
sealer,
With
seats, remove
valve
the gasket surface. Clean the heads
remove
for
the
with a scraper and a wire
scratch
Holding
INSPECTION.
AND
protect
bon deposits from the
heads
Repair
and
the
surfaces
holding
of
the
fixtures
cylinder
while
the
Valve Mechanism.
c
Valve
engine.
guides
heads. Valves
replacements
with
integral
made
are
oversized
the
with
stems
available
are
if it becomes necessary to
cylinder
the
ream
as
valve
guides.
(1) CLEANING
brella-type
Scrape
stem
and/or
of
Remove
all
Fig.
10
Checking
Flatness
of
seals,
brush
varnish
carbon
from the
from the
valve
6601
Check the
the
valve
face for
valve
from the head
valve stems.
valve seat with a
for
stem
pits
for
um
and replace with new seals.
carbon
evidence
heavy discoloration, burning
the Cylinder Head Gasket
Surface Typical
wire
the valves and from the inside
Check the
(T), check diagonally
(5) CHECK ACROSS CENTER
AND INSPECTION. Discard
valve stem
face
runout
and
grooves.
or
of
of
and
guides.
Carefully
fine
wire
clean
brush.
imperfect seating,
erosion,
(fig. 11),
or
and
Inspect the
grooves or scores.
the
warpage.
also
ends
check
of
the
Section
5 Rocker
Mechanism, Cylinder Head, Valves,
Valve Lash Adjustment,
and
Valve
17
Timing
REFER TO
SPECIFICATIONS
6602
6266
11 Valve
Fig.
Inspect the
the
valve
valve springs
spring for
squareness (fig. 13).
valve
Check the
for
valve
wear or signs of
Check the
set
its
on
the
proper
signs
of
pressure
failure. Check
(fig.
12)
locks,
and sleeves
failure.
valve stem clearance of each valve
screw, then
and
tool
Position
guide.
the center
against
.as
permit
in fig. 14. Install the
shown
the
fully
in its
seated and
valve
the tool contacts the
to
drop
tighten the
away from
upper surface of
action
lifting
the
on a plane
from the
valve
Divide the indicator reading
to
tool)
Check the
a
by
flat tip
valve
that parallels
guide
upper
the
Move
stem.
normal
without
surface.
2 (division factor
of
the
the actual stem clearance.
obtain
as shown
with
spherical section of
take the indicator reading
and
tool
the
to the
approximately
rocker
Squareness Check
dial indicator
a
90
at
valve seat runout and the valve seat width
in figs. 15
and
16.
the
(2) REPAIRS.
locks,
Valve
Spring
portion of
the tool back and forth
valve stem until
seat until
for
spring retainers,
respective valve guide
tool
Fig. 7 3 Valve
Face Runout Check
Spring
(a)
Tester
retainers,
Discard any defective valves, springs,
or sleeves.
Refacing Valves. If the
excessive,
grind
Tool
-
the
S-8680
valve
face
valve
at
face
runout
is
45
a
angle
on
a
Dial Indicator
PRESSURE
READING
6267
6479
Fig.
12 Valve
Spring
Pressure Check
Fig.
14 Valve
Stem Clearance Check Typical
18
Chapter
1 General
Runout Gauge
,
Repair
and
Vn"
MINIMUM
MAXIMUM
REFER TO SPECIFICATIONS
FOR CORRECT DIAMETER
VALVE
FACE RUNOUT
0.002
CHECK FOR BENT STEM
L
Z
Tool-for
Removing
Installing Pilot
15 Valve
Fig.
and
6603
Seat Runout
Check Typical
valve
Follow the instructions
grinder.
equipment
manufacturer.
to
pits
remove
and
head is less than
Grind
inch thick
the
stem
enough
stock
able.
edge of the
valve
in
only
If the
grooves.
y32
off
after
replace
grinding,
the valve. If the runout still exceeds specifications
the
check
grinding,
equipment
used
in the
after
grinding
operation.
Grind
Do
end of
the
than 0.010 inch from
not remove more
The
of 0.003, 0.015, and 0.030 inch are avail
Occasionally the 0.003 inch oversize valve is used
critical
tolerances
of
the
valve are
illustrated in
in
production
valve
the diameter
determined
of
by
a
one or more positions.
to guide
the valve
new
be
cannot
valve
guide
stem
valve
is
on
excessive and
the lower limit (as
valve stem with a microm
with
a stem
diameter
use of standard valves
reduced
(fig.
is
stem clearance
measuring the
limit. If in the
upper
ance
valves with a
diameter
If the
the
stem.
the seats.
match
Select Fitting Valves. Oversize
eter), select
from the
all grooves or score marks
valve stem.
the
to
compound
of
Tolerances Typical
Valve
After refacing valves and seats, it is good practice to
lightly lap in the valves with a medium grade lapping
(c)
precision
6480
17 Critical
Fig.
to
20)
a
limit,
ream
oversize
valve
satisfactory
for the
next
the
on
the clear
stem.
fig. 17.
(b) Refacing
(fig. 18) to a true
to
clean
pits
up
Valve Seats. Grind the
45
angle.
or
specifications,
the
and/or
width
wheel
the
to
seat
bottom
edge
from the bottom
possible.
remove
as
near
stock
to
Remove only enough stock
If the valve seat width
valve
to
enough
the
of
30
a
of
to
seat
angle
the seat
center
check
the
of
on
the
the
from
stock
reduce
wheel
and a
from the top (fig.
the
Place Prussian Blue
install the
just
remove
to specifications. Use
move stock
seat
grooves.
exceeds
top
valve
60
to
the
d. Valve Lash Adjustment.
Reference is
(cold)
piston
valve
on
made
lash
top dead
compression
stroke.
in the
procedures
to
adjustment
center
(T.D.C.)
Number 1
for
a
preliminary
placing
at
piston
number
the end
is
on
1
the
of
T.D.C.
at
re
angle
19). Keep
face as
valve
valve
and
seat
point of contact.
30
ANGLE WHEEL
FOR BOTTOM OF SEAT
Seat Width Scale
60
ANGLE WHEEL
FOR TOP OF SEAT
6604
Fig.
16
Measuring
Valve Seat
Width Typical
6605
Fig.
18
Refacing
Valve
Seat Typical
Section
5 Rocker
Mechanism, Cylinder Head, Valves, Valve
Lash Adjustment,
Valve
and
19
Timing
REFER TO SPECIFICATIONS
VALVE SEAT
6292
Fig. J9-Va/ve Seat Width
the
the compression stroke
end of
closed and the
in line
timing
the
with
Step- type
timing
feeler
Valve lash is
lock
("go"
proper
the
on
valves are
"no go")
(fig. 21).
and
clearance
by
adjusted
located
nut
both
when
the crankshaft damper is
pointer.
gauges
to obtain the
used
mark on
It is very important that the lash of all valves be
held as close as possible to the correct specifications. If
the
lash is
engine
too close,
set
If the
performance can result.
valve
cessive,
formance
action
be
will
noise
lash is
valve
and
result,
poor
and
ment
specification
gines
is 0.019
cylinder
and
(intake
head
valve
adjust
exhaust) for
and
the
or
lash
all
has
mechanism
rocker
en
installed, it will be necessary to make
a preliminary (cold) valve lash adjustment before start
ing the engine. If the adjustment is made for the pur
been
removed and
(a)
and proceed with
the procedure for the
applicable engine.
tune-up,
pose of engine
(b)
(1) 6-CYLINDER
under
step
omit
step
ENGINE. Remove the
Remove the
rocker
Preliminary Adjustment. Make three
(a)
marks
the
on
damper.
crankshaft
90
apart so
that
Space
with
the
the
Va
around
turn
the crankshaft
of
or
lA
of
chalk
marks
timing
mark,
(90
the damper is divided into four equal parts
sents
final
ENGINES.
8-CYLINDER
(2)
approximately
per
engine
Reaming
Guides Typical
Valve
arm covers.
ex
affected.
NOTE: The preliminary
If the
will
idle
engine
rough
20
set screw and
the rocker arm.
push rod end of
539
Fig.
the
means of
be
can
repre
the distance
the damper circumference).
Rotate the
T.D.C.
at
timing
mark
crankshaft until
the
end
on
of
the
number
compression
the damper is
aligned
1
piston
stroke
with
is
and
the
near
the
timing
pointer.
Combination
Adjusting
Tool
rocker arm
cover.
on
the
120
the
apart so
V3
of
that
distance
the
the
with
into three
damper is divided
represents
two
damper. Space the
crankshaft
proximately
Make
Adjustment.
Preliminary
(a)
marks
chalk
marks
ap
timing mark,
(120
equal
around
parts
damper
the
circumference).
Rotate the
until
crankshaft
the
T.D.C.
at
intake
and exhaust valve
the
end of
Repeat this
the
turning
of
lash for
(b)
of
order
to
idling,
stroke.
number
1
is
near
Adjust the
cylinder.
for the remaining set of valves,
V3 turn at a time, in the direction
crankshaft
valves
in the
firing
order
(1-5-3-6-2-4).
Final Adjustment. Run the
mum
piston
procedure
rotation, while adjusting the
sequence
1
number
compression
30
stabilize
check
at
minutes
the
engine
valve
(fig. 21). Install the
engine
approximately
temperatures.
for
1200
a mini
r.p.m.
With the
in
engine
lash. Adjust the lash, if necessary
rocker arm
cover.
Step Type
Fig.
Feeler Gauge
21 Valve
Lash Adjustment Typical
6610
20
Chapter
1 General
Engine
is
engine performance
Dial Indicator
as
if the
mine
The
Remove
Back
Lobe Lift
No.
No.
4 Exhaust
180
T.D.C.)
the tappet is
the
and adjust
following
No.
4 Intake
No. 8-Exhaust
No.
5 Intake
Rotate the
puts number
3
3A
turn from
T.D.C.)
and adjust
270,
engine
piston on
or
on
(this
No. 7-Exhaust
No. 8-Intake
Final Adjustment. Run the
to
order
idling,
at
minutes
stabilize engine
check
the
engine
approximately
for
1200
temperatures. With the
point of
turning
the pulley
is in
rod
such a
engine
the
push
slowly
flywheel)
or
(at
until
lobe. Zero the dial
the engine slowly until
(Table 1). Compare the
with specifications.
1 Valve
Engine
and
side
the indicator
same plane as
the cam
obtained
push
dial indicator in
a
in the
of
the
sure
damper bolt
continue
adjusting screw,
Timing Specifications
Opens Crankshaft
Intake Valve
Degrees
at
Cam Lift
223
24
272, 292
12
arm
rocker
covers.
If the
for
timing
made
.016
Cam Lift
312
valve
timing is
the
mark on
is
not at
when
poor
not within
pulley, in the
crankshaft
fault,
sprocket, crankshaft
be
BTDC@
Cam Lift
specifications,
bent timing pointer. Bring the number 1
T.D.C. and see if the timing pointer is aligned
pointer
should
.016
a
T.D.C.
checks
BTDC@
in
engine
Valve Timing.
Valve
valve
a mini
r.p.m.
lash. Adjust the lash, if necessary
valve
(fig. 21). Install the
e.
rocker
Displacement)
No. 6-Intake
30
Make
(Cubic Inch
No. 3-Intake
-Exhaust
No. 3-Exhaust
of
mum
6-cylinder
the
the right
assembly to one
arm
the heel
on
and
and
(b)
crankshaft
Table
the follow
the
point
approximately
on
remove
(fig. 22). Turn the
desired lift is
degrees
valves :
No. 2
the
indicator
180
cover
arm
push rod socket and
2 Intake
number
in
lift.
cam
position.
movement
No.
the
to
equal
to have the actuating
as
No.
valves:
rocker
it in this
either
turn (this puts
V2
in
rocker
the
1 Intake
6 Exhaust
No.
ing
or
engine
rod
-Intake
is
lobe. At this
cam
the number 1 intake
off
manner
valves:
No. 7
-Exhaust
Rotate the
piston on
following
the
1 Exhaust
No. 5
4
on
to deter
engine
timing by using
cam
the tappet socket, then install
in the
Adjust the lash
the
1 intake
rotation
change
the
slide
secure
Fig.
used
cover.
then
6607
the
correct
the
correct with
engine.
Check Typical
checks
side of number
0.0004 inch
arm
timing is
crankshaft
of
be
procedure can
such
checks,
car.
procedure
opening
1
following
valve
in the
stalled
22 Camshaft
noted and all other
carburetion, ignition timing, etc., fail to
trouble. The
BE SURE
TO PLACE
INDICATOR TIP
IN CENTER
OF PUSH
ROD CUP
Repair
and
check
pulley
the
or
with
to
the
damper. If the
timing chain,
sprocket, camshaft,
check
piston
camshaft
and crankshaft
order of accessibility.
6. TIMING CHAIN, SPROCKETS, AND CAMSHAFT
To
the
of
Chain
Timing
a.
measure
slack
the
on
chain
timing
the left
by
shaft
from this
to move
side
deflection (fig.
(as
rotating the
direction. Establish
measure
chain
all
a
the
viewed
point
to the chain.
slack
23),
on
in
a
front)
clockwise
the block and
Rotate the
to the left
side.
move
crank
With the
the
chain
toward the original
reference
the distance between the reference
point
and
measure
point
and
the chain. If the difference between the two
take up
from the
crankshaft
reference
point
fingers,
Sprockets.
and
measurements
replace
(1)
the
(which is the slack)
timing
exceeds
y% inch,
chain and/or sprockets.
INSPECTION. Inspect the
damaged teeth. Inspect the
chain
sprockets
for
worn or
for broken links.
6
Section
(2) REPAIRS.
Replace the
Timing Chain, Sprockets,
sprockets or the
21
Camshaft
RIGHT SIDE OF CHAIN
REFERENCE POINT
deemed necessary by inspection. However, it is
chain as
recommended that all the components be
any
timing
and
item
one
replaced
if
needs replacement.
b. Camshaft.
The
camshaft
(intake
be
should
replaced
when
lobe
any
exhaust) is worn to such an extent that the
lift loss exceeds 0.005 inch. The tappet which mates
or
the
with
to
the
Loosen the
assembly to
Make
position.
socket
in the
and
same
plane
ment
(fig. 22). Rotate the
is
the heel
the
of
such a manner as
indicator in the
the
of
the push
as
engine
push
rod
the tappet
until
slowly
rod
fully
lobe. Zero the dial indicator,
cam
on
to
the
rotate
engine until
later step is
indicator
raised position.
the indicator
recorded
check
a
rod
move
then continue to rotate the engine slowly until the
is in the
slide
it in this
is in the tappet socket,
to have
sure the push rod
point
actuating
is
timing.
valve
one side and secure
dial indicator in
a
procedure
adjusting screw, then
valve rocker arm
then install
on
replaced.
for checking
procedure
rocker arm
the
be
must also
CAM LOBE LIFT CHECK. This
(1)
similar
the
lobe
worn
Compare the total lift
the indicator
the
of
original
Suspected
ure
the I. D.
are
excessive
replaced.
(3)
aged
the camshaft
the
cam
repair.
compared with a
correct.
Measure the
bearings. If the
cam
and/or
REPAIRS. Replace
with a microm
out-of-roundness.
and
Check the fuel pump
beyond
a
with
of
wear
be
should
diagnosis is
sure
journal diameter for
Check the lobes
lobes
worn
lobe to be
23
Timing
Chain
Deflection Typical
broken,
worn,
or scored
it
be necessary to
will
replace
the camshaft.
reading.
signs of abnormal wear.
good
Fig.
This
(2) INSPECTION. Thoroughly check the camshaft
for damage. Examine the lobes for pitting, scoring, and
eter.
WITH THE FINGERS AND MEASURE DISTANCE B. DEFLECTION
6608
IS A. MINUS B.
Continue
reads zero.
the accuracy
on
push
TAKE UP SLACK ON LEFT SIDE OF CHAIN. ESTABLISH A REFERENCE
THEN, TAKE UP SLACK ON
RIGHT SIDE OF CHAIN AND FORCE LEFT SIDE OF CHAIN OUT
POINT AND MEASURE DISTANCE A.
all camshafts
for
be
should
wear.
toward the
point
end of
zero,
END PLAY CHECK.
rear
against
a
Place
a
pull
the
camshaft
forward
with
and
release
specifications.
necessary.
or nicks
stone, then polish with crocus
the
wear characteristics
area
general
of
the nose
may
portion
in pitting in
the lobe. This
result
of
pitting is not detrimental to the operation of the cam if
the initial cam lobe lift loss has not exceeded 0.005 inch.
The camshaft will continue to operate satisfactorily for
the
life expectancy
normal
ably affecting
should not
the
be
excessive,
engine without notice
Therefore,
camshafts
the lobe lift loss exceeds
the tappet contact
face
shows
failure.
Normally if
it
the
replaced unless
above specification or
evidence of
of
engine performance.
the front journal to
can
be
assumed
bearing
clearance
that all bearings are
is
worn
and need replacement.
If any
of
the teeth
on
the distributor drive gear
are
it.
play is excessive, check the spacer for cor
installation. Replace the thrust plate and/or spacer
end
cloth.
The lobe
dial
the front
the camshaft assembly (fig. 24). Set the dial to
then
If the
if
the engine.
suitable surface on
Compare the dial reading
rect
of
Push the
that are dam
Remove light scuffs, scores,
hard Arkansas
camshaft
indicator
clearances
bearings
eccentric
Meas
CAMSHAFT
(4)
Fig.
24 Camshaft
End
Play
Check Typical
22
1 General
Chapter
Repair
and
7. FLYWHEEL, CRANKSHAFT, AND MAIN BEARINGS
Procedures for the inspection
and
components are given
here. In addition,
fitting
aligning the thrust
the
replacing
are
bearings,
main
rear
bearing
main
for
procedures
bearing,
and
oil
crankshaft
Heat the defective ring
these
of
repair
seal
not
off
hit the flywheel
the
on
the flywheel.
when
removing
gear.
given.
Heat the
a.
Do
CAUTION:
the ring
the gear, then knock it
of
side
engine
blow torch
gear with a
Flywheel.
The flywheel
enough
and
gear
ring
are
shrink
a
seated
fit
and
are
with
full forward
wheel
play
or
is excessive,
runout
the
of
runout
necessary
to
remove
the
the
(2)
gear
crankshaft
end
If the
runout.
and check
It
flange.
will
if the flange
for worn, chipped,
flange is
not
at
scored
0.045
be
fault,
inch
runout
replace
or
surface of
of
stock
from the
is
excessive
machine
the
the flywheel if
If it is necessary to
worn.
cracked
or
remove
original
ring
further use,
or
gear
if the
more
thickness,
the
When the
new
ring
a
the
heat any portion of the
500
F. // this
higher than
be
teeth.
gear expands
sure
not
will
form
the
on
check
runout
gear
is
shoulder.
exceeded, the temper
gear
until
removed
gear
to
limit
a
is
from the ring
is installed, per
and flywheel.
gear
the ring gear
b. Crankshaft.
end
crankshaft
Place
of
play in the
Check the
Push the
the
dial indicator
a
point against
on
manner:
rear
of
the
engine.
rear or
front
end
zero, then
push
the
the
forward. Compare the reading
crankshaft
on
the dial
INSPECTION.
(1) CLEANING AND
wash
crankshaft,
with
passages
the
Set the dial
crankshaft.
indicator
following
toward
it in
a
solvent,
compressed
air.
and
Remove the
blow
out
Examine the
the
shaft
oil
for
damage.
teeth
runout
are
damaged
is excessive,
and
unfit
replace
for
the ring
follows:
Fig.
evenly
the flywheel. Make
against
properly
temperature
re
the flywheel.
the
gear as
or
onto
gear
the
indicated in fig. 26.
gear runout as
REPAIRS. If the flywheel
the
replace
If
fly
flywheel,
crankshaft
flywheel. Machine the friction
than
to hold the
that
mounting
runout
machining.
teeth. Check the ring
it is
so
sure
flywheel
as
remove
crankshaft
Inspect the ring
and
rearward
be indicated
not
will
quires
Check the flywheel face
dial indicator (fig. 25). Be
a
to slip
ring
CAUTION: Do
replaceable as separate parts.
(1) INSPECTION.
new
25 Flywheel Runout Check Typical
Measure the diameter
places
to
condition
determine
of each
journal in
out-of-round,
taper,
at
or
least four
undersize
(fig. 27).
Fig.
26
Ring
Gear Runout
Check Typical
Section
(2) REPAIRS.
If the
end
7
play is excessive,
A VS B
C VS D
A VS C
replace
the thrust
bearing.
Replace the crankshaft if it
Dress minor nicks or scratches.
If the
pins or
use, the
journals
shaft should
bearing. Calculate
used as follows:
EXAMPLE: //
shows
signs
failure.
of
are out-of-round
beyond further
for the
next undersize
be
ground
the correct undersize
the main
bearing
bearing
journal
will
23
Main Bearings
and
=
VERTICAL TAPER
=
HORIZONTAL TAPER
B VS D
AND
OUT OF ROUND
=
CHECK FOR OUT-OF-ROUND AT EACH END OF JOURNAL
to be
"clean
before it is ground to 2.499
0.010 = 2.489
inches diameter, finish it to that diameter, and install
0.010 inch undersize bearings.
up9'
Always
result
in
existed originally.
Too
corners of
the
small a radius will
6517
bearing failure.
CAUTION:
excess
in the
reproduce the same radii
journals that
Never
grind
of 0.030 inch
journals
or
in
crankpins
Fig.
undersize.
After grinding, chamfer the oil holes, then polish the
journal with number 320 grit polishing cloth and
27
in the
or
workstand
Checking
Crankshaft Journal
car.
pin or
engine
ing
oil.
Crocus
cloth
may
also
be
used as
If the
polish
a
agent.
jack
small
Main Bearings.
c.
bearing fits
in the car,
against
available
on
for
main
in
service
bearings
bearings
must
clearance
proper
fit.
They
are
for
use
standard and undersizes
journals that have been
new
are select
reground.
be closely
between
The installation
checked
the
to
journals
maintain
and
of
the
bearing
joining
The
INSPECTION. Check the bearings for any dam
Examples of bearing failures
and
their causes are illustrated in
(2)
FITTING MAIN BEARINGS
METHOD. The
main
fig. 28.
bearings
SCRATCHES
following
with
the
procedure
engine
-
PLASTIGAGE
applies
either
to
installed
that
are
bolts just
on
a
not
enough
the
is
crankshaft
supported
counterweight
checked
by
a
the journal
and
checked.
to hold the
a
upward
bearings. Place the
main
being
engine
crankshaft with
for
thin
of
rubber
pad
two bearings
Tighten the
crankshaft
ad
clearance.
bearing
up
against
cap
the
bearings.
NOTE: It is necessary to
crankshaft
when
to
the
prevent
pressing the
support
main
checking
weight
of the
the
iveight
bearing
crankshaft
Plastigage, thereby
of the
clearances
from
com
an
erro
providing
neous reading.
LACK OF OIL
BY DIRT
be
being
the
the crankshaft
which
also
OVERLAY WIPED OUT
DIRT IMBEDDED
INTO BEARING MATERIAL
SCRATCHED
fitting
against
bearing
shaft can
upper
(1)
the
between the cap insert
surfaces.
age or excessive clearance.
to hold
the block half of the
the
checked with
weight of
positioned
jack to bear
The insert-type
to be
are
the
support
RADIUS RIDE
BRIGHT
(POLISHED) SECTIONS
IMPROPER SEATING
CRATERS OR POCKETS
OVERLAY GONE FROM ENTIRE SURFACE
RADIUS RIDE
TAPERED JOURNAL
Fig.
28
Bearing
Failures Typical
FATIGUE FAILURE
6491
24
Chapter
1 General
CLEARANCE
29
Place
bearing
shaft
cap,
journal if the
off center.
Plastigage, the full
bearing surface (or
of
the
on
1282
Plastigage Typical
Measuring
piece
a
engine
Install the cap
is
inverted)
width
crank
XA inch
about
bolts to
tighten the
and
the
of
the
on
6354
speci
Fig.
fications.
CAUTION:
Do
Plastigage is in
turn
not
the
at
the
crankshaft
while
the
widest
check
point
the
with
width
the
the Plasti
of
Plastigage
scale
(fig- 29).
If the
bearing
to
bring
the clearance
various
bearings
and/or
selective
and
limits,
fit
the desired limit.
increase
clearance;
clearance.
fit bearings do
the desired
journals
another selective
within
bearings decrease
clearance within
journal
is excessive, try
marked
marked
If the
fit
grind
install
not
the
bring
the
crankshaft
undersize
not
the
Pry Cap
main
bearing
journals
to
an
minimum
maximum
fitted
30
Pry
Crankshaft
is
to
diameter of the
minimum diam
clearance, interference may
re
an
early failure. It is not recommended
bearings be fitted to a crankshaft journal which
sult, causing
that
is
more
than
0.001 inch
out-of-round.
(3) THRUST BEARING ALIGNMENT. Install
main bearing caps, except the thrust bearing cap,
tighten
the
bolts
to
specifications.
Install
bearings.
Forward Typical
evenly
to the
16353
Fig.
wear
However, if a bearing
out-of-round journal, be sure
bearing to the
If the bearing is
with
Backward Typical
out-of-round.
fitted
journal.
31
Normally,
are
being
eter
clearance
NOTE: Red
blue
NOTE:
and
place.
Remove the cap, then
gage
Repair
Flattened Plastic
GRADUATED CONTAINER
Fig.
and
Fig.
32 Tighten Cap
Typical
the
the
and
thrust
Section
7
25
Main Bearings
and
Tool-T52L-6701-AGD
Tool T52L-670I-AGD
33 Oil
Fig.
bearing
crankshaft
rear
of
the thrust
will align
bearing. Retain
the
and
bearing
from the
new seal
the
both
edges
in the
installation
Coat the
cut
or
bearing
the
rear
seals
oil
specifica
sealer, install the
jecting
are
journal
Using
To
check
or
retainer
as shown
in
seals
Install the
cap
flush
without
new
journal
as shown
any
seal
may
or
cap
of
indicates
possible oil
NOTE: The
retainer and
bearing
for leaks,
side seals
cap
into the parting lines between
the cylinder block from the
and
compressed
block. If
the
oil.
this expansion.
of oil
retainer
dipped in
when
expand
the seals
air against
air
bubbles
from the
in the oil, it
appear
leakage.
in fig. 34. After
to block mating face
retainer
to
retainer or
Blow
The
use sealer on the side seals.
retard
few drops
a
inside
not
designed
sealer
outside.
the
in
in the
ends.
CAUTION: Do
the
block
oil,
Dip the retainer
immediately install
then
It may be necessary to tap the seals into place
for the last Vl inch of travel. Do not cut the seal pro
seals
flush.
seal
side seals
them
engine
squirt
cylinder
cut
overlapping.
seal
and
23-28 foot-pounds torque.
light
on
pressure
crankshaft
6374
Installation Typical
Seal to Retainer
grooves.
grooves.
seal
fig. 33. After installation,
retainer
block
cylinder
Clean the
cap.
Install the
with
the
REPLACING REAR MAIN BEARING CRANK
seals
in the
the
crankshaft end play.
SHAFT OIL SEALS. Remove the
frayed
the
of
surfaces of
forward
the
the cap bolts to
tighten
tions (fig. 32). Check the
oil
pry
bearing (fig. 30). While holding
forward, pry the thrust bearing cap to
the crankshaft,
(4)
then
surface
34 Oil
Fig.
the
of
(fig. 31). This
halves
thrust
the
against
|
J
bolts finger-tight,
the
forward
half
upper
Seal to Block
with
cap
crankshaft
I
6373
tighten the
bolts to
above
newly installed
allowed for the
test should
seals
seals
until
to
be
not
expand
into
performed on
time
sufficient
the
has been
seal grooves.
8. CYLINDER BLOCK, PISTONS, PISTON RINGS, AND
CONNECTING RODS AND BEARINGS
During
gine
parts
disassembly
the
overhaul,
to
help
of
the
cylinder
closely inspect the
diagnose the
cause
of
wear
block for
pattern
on
en
all
wear.
cracks.
Cylinder Block.
Clean
old gasket material
Remove the
all
passages
the
from
all machined surfaces.
passages and clean
pipe plugs which seal oil
thoroughly.
Minute
be detected
ture
a.
INSPECTION.
(1)
of
oxide
by
coating the
dry
and
dissolved in
the coating
Make
will
sure
and
apply
alcohol.
threads
area
75% light
become discolored
the
for
check
to the naked eye may
suspected
immediately
wood
thorough
a
cracks not visible
25% kerosene
part
Make
If
at
with
motor
a
coating
cracks are
the
a
oil.
mix
Wipe
of
zinc
present,
defective
area.
in the head bolt holes
are
26
Chapter
1 General
Engine
Repair
and
Tool T52L-6266-BGD
PLUGS-
CYLINDER BLOCK CORE
1271
37 Expansion-Type
Fig.
Fig.
35 Cylinder
NOTE: A 0.030 inch
Bore Measurement Typical
Rebore
clean.
in
a
and
Dirt in the threads
false torque
to
remove
Inspect the
roundness,
reading.
deposits if
tool
be
should
Inspect
Use
a
binding
and result
to true up threads
tap
necessary.
(fig. 35). Follow the instructions
manufacturer.
permitted
Only
experienced
of
expansion-type
plugs
for
evidence
of
the
a
To
Vi inch hole in
plug
as
shown
in
install it
until
surface
with
an
remove
the
36.
of
the flange
the flange is flush
expansion-type
center of
in fig.
thoroughly. Coat the flange
and
give
ing
equipment
be
should
satisfactory
Bore the
up
cylinder
by
bored for the
when
or
the plug
and remove
Clean the plug
the new plug
plug,
with
within
final step
sealer
and
out.
(fig. 37).
honing
pattern
instructions. This
If the
are
personnel
work
only.
first to deter
wear
cylinder will
replaced.
0.0015
approximately
of
new service
not
clean
maximum oversize piston recom
diameter. This
oversize
recess
Drive the plug
slightly below the casting
facing
to
cylin
performance.
the most
the proper oversize.
when
If the
excessive,
experienced
with
and
scored
BLOCK. Follow the bor
manufacturer's
performed
available.
are excessive.
and piston wear are not
mended, the block should be
(2) REPAIRS.
deeply
are
(3) BORING CYLINDER
mine
leakage.
drill
der bore
personnel
to take these measurements.
that
cylinders
plug is
oversize
taper and/or out-of-roundness
piston rings will
bores for scoring, taper, out of
Use a cylinder bore gauge to make
and wear.
all
cause
cylinder
the measurements
the
can
Plug
will
cylinder
required
stock
for the
the correct surface
so
Use
obtained.
the
of
allow enough
bores
the
Bore the
inch
a
finish
220-280
number
grit
hone for this
operation.
CAUTION:
Thoroughly clean the block to remove all
the boring and
honing operations,
after
particles
then
the
coat
bores
with
oil.
"GLAZE''
(4) CYLINDER BORE
Whenever piston rings are installed in a
the
remove
Take
all
"glaze"
on
hone
a
few times. Do
or glaze
the finish.
after
b.
in ring
removing tool through the
not
hone
Thoroughly
glaze
aid
cylinder,
seating.
precautions to catch the grit.
necessary
a
the bore to
REMOVAL.
used
than
the
clean
removal, then
Pistons, Pins,
more
oil
and
enough
cylinder
Pass
cylinder
bore
to rough-up
bore
and
block
the bores.
Rings.
(1) CLEANING AND INSPECTION. Remove
DRILL
Vi INCH HOLE IN PLUG
Fig.
CYLINDER
36 Expansion-Type
BLOCK
CORE PLUGS
Plug
carbon
6600
Removal Typical
deposits from the
grooves with a
the
oil
ring
ring
slots
(or
pistons.
Clean the
groove cleaner
holes)
the
piston
ring
(fig. 38). Make
sure
are clean.
Section
8 Cylinder
Block, Pistons, Piston Rings,
Connecting
and
Rods
27
Bearings
and
Groove Cleaning Tool
T52L-6 1 10-AAD
6097
38
Fig.
CAUTION: Do
Cleaning Ring Grooves
not use a caustic
solution or
cleaning
Inspect
for fractures
pistons
bosses,
and pin
for
and
eroded areas near
at
scuffed or
the edge of the
by detonation,
lands, skirt,
scored skirts. Spongy,
piston top are usually
or
bent connecting rod. The
is shown in fig. 39.
Inspect the
ing. Check the
pin
bushing. Check for
for
(2) REPAIRS.
Replace
lands, fractures
or
fit in the
piston and
rod
ring
of
signs
showing
side
NOTE: All
clearance, wavy
damage from detonation
or
pre-
piston pins
ing. Piston
or
pins
that
show
bushing
rod
signs of
showing
wear
or etch
fitted,
a piston
cylinder
pistons
are
the
to
can
be intermixed
only
the
without
cylinder
has been fitted, mark it
it was fitted.
which
same
oversize; therefore,
and
before trying another
hone the cylinder to the
weight, both
pistons
of
upsetting
or
stand
various sizes
engine
cylinders
balance.
which
re
it.
(4) FITTING PISTON RINGS. Select the proper
ring set for the size piston to be used. Before the rings
are
installed
on
the piston, check
each
ring for
proper
follows:
gap
Position
che
ring in the
cylinder
bore in
which
it is
fit loosely in the
Always re
or
be
should
fracture
be
When
ard
Rebore
Wear Pattern
calculations
can
none
for assembly in the
as
Replace
If
39 Normal
recheck
next size piston.
quire
ignition.
piston
pull,
piston.
or etch
pin retainer grooves.
pistons
or
fracture
signs of
in the
clearance
skirt
excessive
for
proper
wear
able
pre-ignition.
normal wear pattern of a piston
piston pins
Fig.
the ring
A shiny surface
on the thrust surface of the
piston, offset from the cen
terline between the piston pin holes, can be caused by a
caused
ring
NORMAL PISTON WEAR AREAS
6609
brush.
a wire
replaced.
place all piston pin retainers.
FITTING PISTONS.
(3)
0.040
and
Check the
engines.
To fit
a
the
to the
inch wide)
side of
the
of
the
parallel
out
to the
the
scale
piston
proper
for
bore,
bore
(fig.
provide
feeler
from the
the
crankshaft axis.
most
size
and
desired
attaching
ribbon
gauge
a
{Vi
feeler
on
hole. Invert
piston pin
piston and
35)
the
being fitted by
a
the
calculate
check
to
for
available.
sizes
thickness. Position the
piston
push
of
end
90
the piston, then
a
piston
size
Check the
scale
cylinder
0.020, 0.030,
of
available
are
catalogue
by taking
proper
clearance.
tension
a
Pistons
oversize
parts
in
piston
desired
piston
select
the
0.060 inch
feeler into the bore
Hold the
piston and pull
feeler ribbon, noting the reading
on
the
pull
(fig. 40).
If the
scale
allowable
pull,
proper size piston
piston,
obtain
try
a
is
reading
recheck
new
greater
calculations
than
the
to be
maximum
sure
for
that the
damaged
has been selected, check
piston, or hone the cylinder bore to
a
6490
the proper fit.
If the
scale
reading is
less than the minimum
allow-
Fig.
40
Fitting
Piston Typical
28
Chapter
1 General
Repair
and
according to the instructions
the ring
check
freely
gauge should slide
move
(5)
"glaze"
be
F). Standard
If the
to the size
Fig.
41
Measuring
Piston
Ring
Gap Typical
the
going to be
of
is
a
to
piston
square with
operation
Push the ring down into the bore area
ring wear is not encountered. Use the head
used.
position
the ring in the bore
the cylinder wall. Use caution
to avoid damage to the ring
so
the ring
during
or cylinder
Measure the gap between the ends of the ring
gauge (fig. 41). The gap should be from
feeler
this
bore.
with
a
bore, immediately install them on the piston,
identify them with the piston and cylinder in which
cylinder
they
are
to be installed.
After the
rings
have been installed in the ring
the
blue)
Pins
0.002 inch
and
reamer.
Set the
then expand the
bore. Take
pin
to
nearest size
ream
reamer
light
a
cut.
maintain align
hole size, using the
expand
the
reamer
slightly
the
and make
fit
proper
for fit in the
pin
piston
bushing if
bushing. Ream the
rod
new piston pin.
until
procedure
Check the fitted
necessary
pin.
Install the
in the
piston pin
retainers are
in the
Always
at normal temperature
installed,
grooves
piston
Install
and rod.
a
the pin to hold it in place. When
make sure
they
in the
provided
are
properly
bore.
pin
piston
use new retainers.
0.010-
0.027 inch. If the gap is less than the lower limit, try
another ring set. After the rings have been fitted in the
or
the
retainer at each end of
the
fit
pin
piston
be reamed, use an ex
Place the reamer in a vise
bore,
the
Repeat the
cut.
to fit the
seated
explained.
previously
The
re
cylinder,
must
pin
ream
reamed
obtained.
respective
where normal
a used
the bores.
another
is
ring
are available.
piston around
of
If the bore is small,
6485
piston
coded
yellow)
a pilot sleeve of
Check the
W
(color
hole
pin
trial
and
ment of
ft
The
entire
as
fit
press
piloted reamer.
the
and revolve
slightly
coded
piston
pansion-type,
Use
gauge.
the
piston pins are color coded green.
oversize
(color
oversize
er
the bore
on
light thumb
a
0.001 inch
of
feeler
FITTING PISTON PIN.
should
(70
a
to be installed in
rings are
the
around
ring package,
piston
with
binding.
circumference without
If the
the
on
clearance
side
Rod.
Connecting
c.
The connecting
fully inspected
cations.
by
rods and related parts should
Various forms
these
for
and checked
parts can
be
to
conformance
care
specifi
of engine wear which are caused
be readily identified
as
follows:
grooves
A shiny
on
surface
usually indicates that
piston
hole is
pin
skirt and
ring
not
grooves
the
a
in
by
improperly
a
proper
the
piston
is bent
relation
rod
bearing
bent connecting rod,
machined,
of
side
rod
the
or
to the
piston
(fig. 42).
Abnormal connecting
either
boss
pin
connecting
or a
wear can
a
be
crankshaft
caused
journal
tapered connecting rod
bore
(fig. 43).
Twisted connecting rods will not create
identifiable wear pattern, but badly twisted
disturb the
action
assembly that may
(1)
and
solution.
PISTON WEAR CAUSED BY BENT ROD
OR MISALIGNED PISTON PIN HOLE
Fig.
42 Wear
Pattern
on Piston Piston
and
6371
Pin Boss Surface
in
of
bearing failures
Make
result
solvent.
again), then
the back
sure
the
will
the entire piston, rings, and
in
rod
excessive oil consumption.
Never
Remove the bearings
used
easily
rods
CLEANING AND INSPECTION. Clean
passages
to be
of
an
use
a
(identify
thoroughly
all parts
caustic
cleaning
them if
they
clean the rod
are
bore
the bearings. For the different types
and
their causes,
oil squirt
holes
refer
are open.
to Section
of
7.
Section
8 Cylinder
Block, Pistons, Piston Rings,
Connecting
and
Rods
and
29
Bearings
BEARING WEAR CAUSED BY BENT ROD OR
6372
IMPROPER GRINDING OF CRANKSHAFT JOURNAL
43 Wear
Fig.
Inspect the
Pattern
rods
the bore for
check
for
deep
Rod
Connecting
on
nicks,
signs of
Bearing
fractures,
and
out-of-roundness.
Check the connecting rod bolts and nuts for damage.
After the connecting rods are assembled to the pistons,
check
the
ment
fixture.
for bend
rods
twist
or
Follow the
on
a
instructions
align
suitable
the
of
fixture
manufacturer.
is excessive,
clearance
for the
piston
ream
should
rod
bushing
the rod
rod
be
is twisted
bushing
and piston
bent
Rods
than specified, it
more
with
deep
more
rod nuts and/or
of
nicks, signs
out-of-round
fractures,
the
should
be
tive fit
a
piece
width of
blue
Rod Bearings
gage
measure
the
bearing
bearing caps
use
to file or lap the
bearing clearance.
of
bearing
bearing,
and tighten
marked
If the
Plastigage
the
on
the
the
rod
bearing
XA inch
about
surface,
off center.
bolts to 45-50 foot
turn the
with
crankshaft
the Plasti
to
not
bring
satisfactory,
to clearance
marked
try
another selec
within
bearings increase
bearings decrease
various selective
the desired
the clearance,
the clearance.
fit bearings do
not
bring
the
desired limit, it will be necessary to
the crankshaft journals and install undersize
regrind
bearings.
Rotate the
not
is
clearance
crankshaft
to be sure the
after
bearing is
not
the
bearing
is installed
too tight.
place.
Remove the
to
of
to
the
clearance within the
torque.
NOTE: Do
in
to
or
to adjust the
NOTE: Red
Install the cap
pounds
recommended
not
sure
limit.
Plastigage Method.
Place
It is
of any type,
order
If the
bolts.
or with
0.0004 inch
than
Fitting Connecting
the full
Check Typical
straightened or replaced.
replaced.
d.
crankpin.
in
Clearance
Connecting Rod Side
// the crankpin is out-of-round, be
bearing to the maximum diameter
fit the
shims
or
Replace defective connecting
bore
to
pin
next oversize pin.
If the
44
NOTE:
REPAIRS. If the
(2)
Fig,
the
bearing
cap,
width of
and use
the Plastigage
the flattened
e.
scale
piece of plastic at
Connecting
Rod Side Clearance.
After the connecting rods are installed,
feeler stock (fig. 44).
measure
the
side clearance with
widest point.
9. OIL PAN AND OIL PUMP
a.
baffle
Oil Pan.
Check the
Scrape any dirt or metal particles from the inside of
the pan. Scrape all old gasket material from the gasket
surface.
Be
sure
Wash the
all
plate.
pan
foreign
in
a solvent and
matter
is
dry it
removed
thoroughly.
from below the
threads,
a
pan
for cracks,
loose baffle,
and
holes, damaged drain
a nicked
or
plug
warped gasket
surface.
Repair any damage,
cannot be made.
or
replace
the
pan
if
repairs
30
Chapter
1 General
Engine
b. Oil Pump.
Wash
Use
all parts
brush to
a
the pressure
body
in
relief
cator or
the inside
the pump
Be
valve chamber.
Remove
Check the
housing
sure
and
dirt
all
and
from the
old gasket material
body
and
the
gear
the
Remove
as
the
and
is
dial indi
as
follows:
then place Plasti
in fig. 45,
shown
cover
method
housing,
the
gasket on
gears
teetn ior damage
gear end clearance with a
Plastigage. The Plastigage
on
cover.
of
them thoroughly.
and cover.
Position the
gage
dry
a solvent and
clean
Inspect the pump
or wear.
Repair
OIL PUMP GEARS
chips are removed.
pump
and
and
install the
the
Plastigage
rotation.
Check the
check
reading.
Check the
gears
for freedom
compression of the oil pressure
the
check
clearance
of
the
of
relief
relief
valve
valve
in the
Plastigage
and
spring
valve
chamber.
6497
Fig.
10.
The
exhaust system must
sive vibration.
in
some
pipe
Leaks
a
cases,
connections.
can
be free
of
leaks
and exces
All the
may be heard
noise
parts
of
the
system
at
are
inches,
or
To
the
the
re
signs
of
muffler
the
passage
inlet
all
various sections of
leaking
burning
outlet
either
pipes, respectively.
case
should
not
be
Date
Gear End
and
pipe
outlet
sections
and
by
the
broken
or
improperly
13A
clamps
as
necessary.
than
as
may be
connections,
previously
signs
restricted.
of
position
outlined.
burning
Re
through.
interference between the
outlet
the outlet pipe in the muffler.
However,
greater
pipes
gases
muffler
the floor pan. If the clearance is in
reposition
Exhaust
the
that show
possible
"kick-up"
sufficient,
exhaust
at
be blocked
SERVICE
Letter No.
for
system
through. The slots in the
and outlet extensions should
and
overlap in
or
the exhaust
of
leakage
Check for
inlet
inlet
as
correct
place
placeable.
Check the
Checking
Play Typical
EXHAUST SYSTEM
usually be detected visually,
whistling
45
system
vibrations
are
usually
aligned clamps.
Align
caused
or
LETTER REFERENCE
Subject
by
replace
Changes Information
on Page No.
Part ONE
POWER PLANT
Chapter
n
6-Cylinder Engine
Page
Section
Engine
Manifolds
3
Cylinder Head
4
Crankshaft Damper
5
Cylinder Front Cover
6
Sprockets
Rest
Steady
32
and
33
Valves
36
and
36
Crankshaft Oil Seal
Timing Chain, Camshaft and Bearings, and
Connecting Rods and Bearings, Pistons, Pins, and Rings
Oil Pan, Oil Filter, and Oil Pump
7
8
9
10
and
37
Tappets
39
42
44
45
Exhaust System
This
chapter
sembly,
and
parts of the
the removal,
contains
installation
6-cylinder
procedures
the component
covered
parts
disassembly,
for the
and
and
engine
repair
shooting
component
procedures
overhaul
and
tune-up
and
In
addition,
are covered
engine
trouble
in Chapter I.
The Cylinder, EBP engine (fig. 1) has a bore of
3.62 inches, a stroke of 3.6 inches, and an 8.0:1 com-
for
pression ratio.
instructions
in Chapter I, "General Engine
Repair."
Inspection,
as-
engine.
The cleaning, inspection,
are
31
1
2
This
engine
is
available
in
all car models
(except the
Thunderbird).
Overhaul,
1. ENGINE STEADY REST
The
engine
engine weight
steady
and,
as
rest
its
(fig.
name
2)
does
not support
any
implies, it functions
as a
rest.
a.
spacer
bolts from the left
stabilizer only.
~
Remove the
bolt that
retains
the insulators
in the bracket. Remove the insulators. Remove the two
side
,
Removal.
of
the
side and
engine
block,
the one bolt from the
then
remove
the
right
bracket
assembly.
Remove the two clamp bolts
at
the front
of
the steady
BRACKET
LOCKWASHER
LOCKNUT
BOLT
FLAT WASHER
SPACER
LOCKWASHER
RETAINER
SHOULDER BOLT
6615
/r;g< J 223 Cubic Inch
Engine
6199
Fig.
% Right Front View
31
2
Steady
Rest Disassembled
32
Chapter
1 General
b. Installation.
Before
the steady rest, inspect all the
for defects. Replace defective
ponents
bracket
installing
the
on
foot-pounds torque. Install, but do
sulators,
bolts,
Install the
block. Tighten the bolts to 23-28
cylinder
spacer
parts.
com
tighten,
not
the in
clamp bolts. If necessary,
and
cen
ter the
spacer
engine
front
tighten
Make
the
Repair
and
bolt in the frame bracket
in
mounts
spacer
being
not
transferred to the
then tighten the clamp bolts to
insulators,
rest
steady
is
Then,
foot-pounds torque.
bolt to 20-25
sure engine weight
shifting the
by
brackets.
frame
their
2. MANIFOLDS
A
chamber
fold
center
manifold
(heat riser) is
section
are
attached.
valve, located in the
into this
gases
quired
A
fuel
and
thermostatically
exhaust
to
into the intake
carburetor
mani
exhaust
controlled
manifold, directs
re
in vaporizing the
assist
the
mixture.
exhaust
placement
the
cotter
Remove the
Disconnect the
fastening
the
assembly
then
separate
manifolds
is
the
the
inlet
muffler
Remove the
sleeves.
bolt
manifold
bell
carburetor.
Remove the bolts
and
Remove
nuts and
the
the
pipe.
head,
to the
head.
manifolds.
shown
at
air cleaner and
manifold
from
lift the
the
joining
manifold
gaskets
and
the manifolds,
A disassembled
view of
the
control
of
damage to the
valve
and
rosion
and
shaft
the
sene
and
bearing bores
and
valve
position
original
valve
is located in the
of
valve
the
plate.
plate.
Use
The
Insert the
is in the
valve
over
to
occurred.
oil
new
kero
or
in the
the
valve
"up"
(heat
normal
to the shaft in the
shaft and valve are stainless steel
damage
outlet of
WASHER
the
caution
shaft through
shaft
by
excessive
Install the thermostat spring in the shaft
the spring 3A turn and hook the open end
LOCK
Using
cut
Lubricate the
penetrating
Rotate the
minimize corrosion and/or
NUT-*-
shaft.
the manifold,
necessary.
with a
(fig. 4). Weld the
manner.
end of
any damage that may have
and graphite mixture.
bearings
Re
and
bearing bores. Remove the
Clean the bearing bores of cor
pieces.
repair
position
valve plate.
shaft
Replace the bearings if
shaft
to
exhaust
sides
inside
plate until the counterweight
in fig. 3.
Exhaust Gas Control Valve
The
to the
shield, washer, stop spring
pin,
avoid
on)
b.
assembly, note the
relation
torch in the
both
on
shaft
Disconnect the throttle linkage
crank.
valve
thermostat spring from the front
Removal.
exces
damage.
the counterweight in
move
not require re
it becomes inoperative due to
Before removing the
of
an acetylene
a.
Normally, it does
manifold.
unless
sive corrosion or
exhaust
the necessary heat
provide
the intake manifold to
by
incoming
area
cast
the
where
slot.
of
heat.
Tighten
the spring
The thermostat spring should hold the
position (i.e. in the
in the closed or "heat
the stop
pin.
on"
valve
NUT
proper
LOCK WASHER -î
riser).
GASKET
STUD
pin.
INTAKE
MANIFOLD.
to direct the flow
Lubricate the
valve
tPLUG
position
of gases
Install the stop spring, shield,
manually to
shaft
bearings
replace original
performing the welding
into the heat
washer and
while
cotter
operating the
lubricant lost through
operation.
WINDSHIELD
WIPER
CONNECTOR
*gj?
EXHAUST
CLOSED
MANIFOLD
(HEAT ON)
SHIELD
/ SPRING
k
THERMOSTAT
SPRING
BUSHING
BOLT
LOCK WASHER
^tfPL
GASKET
Fig.
3 Manifold
"\VBL
ÎB'S?'1
STUD
Disassembled
Fig.
4 Exhaust
Control Valve
Section
Installation.
c.
cylinder
Place the intake manifold over the studs on the ex
haust manifold. Install the lock washers, nuts and bolt,
then tighten them finger tight. Clean the
mating surface
of the cylinder heads. Inspect and repair
any damage at
the mating surfaces. Install new gaskets
using new
sleeves, if necessary, in the
Coat the mating
then
surfaces
port
lightly
with
the manifold assembly in
place
the cylinder head.
of
graphite
grease,
position against
33
2 Manifolds
the
head.
head
and that none
of the
steel gaskets
become dislodged.
Tighten the bolts to 23-28 foot-pounds torque, tighten
ing from the center to the ends. Tighten the bolt and
nuts
the intake
joining
foot-pounds torque. Install
the
gasket, and
position
Install the
nuts and
assembly
the port openings in the
sure
are
aligned with
the
port
manifold
openings
in the
to 23-28
and exhaust manifolds
a new exhaust outlet
muffler
inlet
pipe over
the
flange
studs.
then tighten the nuts
lockwashers,
to 23-28 foot-pounds torque.
Connect the throttle linkage. Install the
NOTE: Make
have
and
the
connect
carburetor
carburetor
Install
the
air
and move
it to
one
linkage.
cleaner.
3. CYLINDER HEAD AND VALVES
The
and
cylinder
head
carries the valves and valve rocker
mechanism, the
arm
the
manifold
assembly, ignition coil,
water outlet.
Valve
rotating-type
Remove the
coil
from the head
spark
and
integral
exhaust
part of
valve
incorporate
which
the cylinder head.
assemblies are
umbrella-type
the
valve
stem seals.
Disconnect the fuel line
pump.
Cylinder Head Removal.
buretor
and
the
vacuum
line
at
Remove the
Drain the cooling system. Remove the radiator upper
hose and heater hose. Remove the air cleaner, then tape
the
carburetor
cable
wiper
at
the
vacuum
perature
air
horn
cylinder
line,
sending
closed.
accelerator
unit
Disconnect the
head. Disconnect the
wire, and
battery
windshield
rod, choke cable, tem
oil pressure
sending
unit
the carburetor
at
Disconnect the distributor
the
vacuum
and
line
at
distributor. Disconnect the
the
manifold
then remove the three
a.
plug
wires and remove
spark
plugs.
guides are an
Both the intake
Disconnect the
side.
lines
and at
the fuel
the
car
manifold
the booster pump,
as an assembly.
rocker arm cover.
Remove the cap
screw
clip from the number 6 rocker arm support bracket.
Pull the oil feed line out of the bracket, then pull it out
of the block with pliers (fig. 5). Be careful not to
and
damage the line.
Loosen
valve
all rocker arm
adjusting
spring load from the
rocker
screws
to
remove
the
arms, then remove the
rocker arm shaft assembly.
wire.
Remove the
them so
they
valve
can
push
rods
in
sequence.
be installed in their
Identify
original positions
(fig. 6).
REMOVE SCREW
PRY UP OIL LINE WITH PLIERS
Fig.
5 Oil
Line Removal
6499
6612
Fig.
6 Valve
Push Rod Removal
34
II 6-Cylinder
Chapter
Engines
BOLT BRACKETS TO INTAKE PORTS
TIGHTEN
SCREWJ^^
SECURELY
-
Tool-T52P-6085-DAD
7 Cylinder
Fig.
Head
1276
Holding Fixture
1234
Remove the
head bolts, and pull the
manifold assembly away from the head. Brace the as
sembly so the inlet pipe will not be damaged.
Install the
in
venience
surfaces
bly
cylinder
lifting
holding fixtures
for
con
the head and to protect the gasket
all
cylinder
the
head bolts. Install the
(fig. 8). Lift the
cylinder
9 Valve
Fig.
support
the
Stem Lock Removal
bracket. Remove the
rocker
arm
shaft,
Installation
or
cotter pins at each end of
and remove
Remove
washers.
spring
guide studs
off
head
(fig. 7).
Remove
head
to
manifold
the
the flat washers and
plugs
at
each
of
end
the shaft.
cylinder
head
assem
NOTE: The
plugs are an
drill
the plugs,
engine.
interference fit. To
or pierce
use a steel rod to
knock
the plug
out
the
on
plug
one
on
remove
end, then
the
opposite
7/1614x6"
BOLT
_
CUT OFF HEAD, TAPER END AND SLOT
FOR SCREW DRIVER AS SHOWN
i
Slide the
Be
rocker
sure
Clean the
b.
lease the
8 Cylinder
carbon
not
pry between the head
and
and
brackets
off
the
the parts.
out
of
the combustion
chambers
seal,
drain line
and
clip
out of
valve stem seals.
Identify
all valve parts.
d. Rocker Shaft Assembly.
Oil
the
and valve.
block
become damaged.
Rocker Shaft Disassembly.
oil
the
out
Remove the sleeve, spring retainer,
spring.
stem
spring,
Head Guide Studs
the gasket surfaces may
Pull the
knock
end,
before removing the valves. Compress the valve springs
(fig. 9), then remove the valve retainer locks and re
rz.-
CAUTION: Do
arms, springs,
identify
to
Discard the
as
open
Cylinder Head Disassembly.
c.
Fig.
the
plug.
remaining
shaft.
m
from
Working
end.
number
1
all
or
side
out, in
each
COVER RETAINING
ROCKER ARM
parts with engine oil.
moving
large diameter
tool
end of
STUD^
pin
the
Using
punch, install
rocker shaft.
LOCKNUT
a
blunt
a
plug, cup
Install a flat
FLAT WASHER
ADJUSTING SCREW
FLAT WASHER
/OOO
t
COTTER
PIN
SPRING
WASHER
/
PLUG
ROCKER
6614
SHAFT
Fig.
10 Rocker
Mechanism Disassembled
3 Cylinder
Section
washer, spring washer,
brackets,
port
Complete
and springs
the assembly
washers with
flat washer,
another
pin on one end of the shaft.
Install the
in the
the spring
and a cotter
UNDERSIDE OF SPRING RETAINER
arms, sup
shown in fig. 10.
the remaining flat
between them,
washer
35
Valves
and
rocker
order
by installing
Head
in
and
the cotter key.
stall
Cylinder Head Assembly.
e.
Install
each
in the
valve
it
removed or to which
the
seal on
coil
and
valve
head spring pad to the
shown in fig. 11. If the
height is
lx%6 inches
bring
to
spring
cylinder
head
the
dimension
mended
greater, install the
or
spacer
valve
and/or
71
ring
install the bolt. Tighten
install
not
spacers
necessary.
Use of
will
result
will
spacers in excess
of recommendations
in overstressing the valve springs which
lead to excessive load loss and spring breakage.
Apply
Use the brush furnished to
gasket.
over
the
the
entire gasket
head
cylinder
over
Before
carefully.
the threads
the
bolt
each
of
resistant sealer.
the
with
and
coating
a
of
the
spread
of
new
sealer
block. Lift the
cylinder
cylinder
a
Install two bolts
head to hold the head
sides
guides and slide
installing
a
surface. Position the gasket
the
on
studs
guide
from
Inspect the head for
both
to
sealer
gasket
perature
hose
the
head down
in
head
bolts,
Connect the
sending
holding fixtures. The
head
tightening
procedure
tighten the
First,
(cold) in the
steps.
them
is
position.
65
to
sequence.
the
Remove
the heater hoses. Install
and
Position
the
valve
on
the
the
number
shaft
the
rocker
then install the oil drain
in their
rods
arm
line,
progressive
vacuum
hose. Connect the
and
run
it for
approximately 1200
the tem
wires and
radiator upper
the, accelerator
lines
and
battery
pedal
the fuel line
cable
on
wind
to the head.
a
r.p.m.
minimum
With the
30
of
minutes
engine warmed
at
up,
tighten the cylinder head
bolts, in proper sequence, to
75 foot-pounds torque (hot), then check the valve lash
with the engine idling and adjust it if necessary.
After
NOTE:
the
cylinder
head
bolts
specifications, the bolts
tightened to
Coat
one side of
resistant
in
making
in
the
sure
have
should
been
not
be
are
retaining
the cemented side
Install the
gasket seats
rubber seals on
centered
nuts
rocker arm cover gasket with oil
lay
cover.
that the
head. Install the
they
the
sealer, and
place
in the
to 2.0-2.5
cover
rocker
evenly
the
of
the gasket
arm
cover,
all around
studs
openings.
making
the
sure
Tighten the
foot-pounds torque.
and
hole. Position the
head,
retaining
screw
the
oil
sockets.
the
assembly
sure
~~
25
proper sequence.
in the tappet
clip,
1 bracket. Make
locating
engine
in fig. 12, then tighten
torque (cold) in the same
push rods
end of
plug
Connect the
shown
foot-pounds
Position the lower
head bolt
bolts to 55 foot-pounds torque
sequence
Install the
cylinder
in three
performed
spark
unit wire.
and
coat
the guides, then install the remaining bolts. Remove the
cylinder
valve
disturbed.
at opposite ends of
gasket
(cold)
preliminary
assembly, the ignition coil,
manifold
Position the two
rod.
amount of water
small
bolts to 45-55
Fill the cooling system. Remove the tape from the car
buretor air horn, then connect the choke wire. Start the
and gasket sealer residue
gasket surfaces.
and repair as necessary.
head
cylinder
over
block
and
any damage
evenly
deposits
carbon
a
the engine, then connect the lines. Connect the
f. Cylinder Head Installation.
Clean
the retaining
adjustment.
shield wiper
the head
all
the oil
of
end
supply counterbore, then
recom
Install the
unless
oil
valve
spark plugs.
CAUTION: Do
the lower
sure
is in the
seal
foot-pounds torque. Perform
inches.
12%2-11%6
"O"
line
Height-
Valve Spring Assembled
Typical
Checking
6 bracket. Make
number
lash
height to the
assembled
of
the
pad and
spring
be
spacers
6504
SURFACE OF SPRING PAD
and
height from the
assembled
spring
necessary 0.030 inch thick
tween the
valve
Fig.
retainer contact surface as
assembled
the closed
with
spring
was
new stem
Compress the spring,
sleeve.
machined surface of the cylinder
spring
a
locks (fig. 9).
retainer
Measure the
valve
it
which
head surface, then install the
the
spring retainer,
install the
Install the
valve.
against
from
port
fitted. Install
was
on
oil
line
feed line
B
~
Z^Z
OTi flph
rtor
Moot)oo(?og)o9oo9ooôJ
enters
on
the
55
if
1225
Fig.
12 Cylinder
Head Bolt
Tightening Sequence
Engines
II 6-Cylinder
Chapter
36
4. CRANKSHAFT DAMPER
A
single sheave crankshaft
is
bly
retained
threaded holes
and
with
a
cap
are provided
the
Install the tool
crankshaft.
move the
crank
shown
in fig. 13
and re
damper.
Two
washer.
and
screw
the
assem
pulley
The assembly is keyed to
standard.
shaft and
damper
in the damper to facilitate
b. Installation.
removal.
Lubricate the
On
cars equipped with power
steering,
is bolted to the
single sheave pulley
an
damper
crankshaft
power
damper
Removal.
Remove the
On
cars
two bolts
radiator.
equipped
with
power
steering,
crankshaft
pounds
the
remove
lockwashers that fasten the
and
pump pulley to the
ing
Remove the drive belts.
On
Fig.
and
power
damper
washer
13 Damper
the
the damper
oil
white
lead
surface
with
and
and remove
from the
of
end
rubbing
then
with
on
the
the
key
shaft.
on
the
Press the
(fig. 14). Install the lockwasher
shaft
tighten
torque. Install
cars
equipped
and
bolt
the
the
adjust
with
on
the
foot
85-95
generator
steering,
power
steering pump pulley
to
belt.
install
crankshaft
the
damper.
Tighten the retaining bolts to 23-28 foot-pounds torque.
Install
screw
and start
power steer
the pulley.
Remove the cap
on
capscrew,
and
oil seal
Align the damper keyway
steering pump.
crankshaft,
a.
lubricate the
and
mixture
grease.
to drive the
an
with
crankshaft
additional
and adjust
Install the
power
steering pump belt.
radiator.
Fig.
Removal
the
14 Damper
Installation
OIL SEAL
5. CYLINDER FRONT COVER AND CRANKSHAFT
The
block
cylinder
by
front
ten pan head
cover
screws and
hex head bolts. Two dowels
ignition
on the block. The
the
is fastened to the
to the
are used
timing
cylinder
oil pan
by
to locate the
is
pointer
two
Cylinder Front Cover Removal.
a.
Remove the radiator, the
cover
welded
pan.
oil
to
and
Remove the
cover
crankshaft
damper,
and
the
retaining screws, the cover,
the gasket.
cover.
b. Oil Seal Replacement.
NOTE:
seal
It is
each
good
time the
practice
cylinder
to
replace
front
the front
cover
is
oil
removed.
Drive
out
the
out
the
recess
old seal with a pin
in the
cover.
Coat
punch, then clean
a new seal with
grease,
5 Cylinder
Section
then install the
is
fully
seated
(fig. 15). Drive the
seal
in the
Check the
recess.
Front Cover
in
seal
seal after
until
and
37
Crankshaft Oil Seal
it
installa
Tool
tion to be sure the
spring is properly
in the
positioned
T52L-6700-BEE
seal.
Cylinder Front Cover Installation.
c.
Clean the
front
cylinder
block
the cover
and
gasket
sealer, then
with
block. Place the
gasket on the
the
cover and
the cylinder block. Coat the
of
gasket surface
surface
position
cover on
the
of
new
a
the block
and
install the retaining screws. Tighten the screws to 6-9
foot-pounds torque. Install the oil pan. Install the crank
shaft damper and belt.
On
cars
equipped
with
power
power
Install the radiator.
and
CYLINDER FRONT COVER
install the
steering,
belt.
6549
15 Oil
Fig.
Seal
6. SPROCKETS AND TIMING CHAIN, CAMSHAFT AND BEARINGS,
AND TAPPETS
The
is
camshaft
babbitt insert-type bearings
driven
by
sprocket
the
the
on
by
trolled
The
shaft.
fuel
The
into the block. It is
chain
mesh with a
the shoulder
and
integral
in
con
thrust plate located between
is bolted to the front
plate
made
eccentric,
the
sprocket
steel-backed
Camshaft thrust is
crankshaft.
a spacer and a
camshaft
pressed
timing
a sprocket and
four
by
supported
the
with
the
on
low
are
car.
If the
installation
and
engine
the
when
applicable
is removed,
engine
is
stalled
eliminate
be
given
procedures
cylinder
front cover,
crankshaft
damper,
and radiator.
On
power
cars
equipped
with
power
and
steering,
install the
belt.
b. Camshaft.
operates
camshaft,
pump.
removal
Install the
belt,
cam
the block. An
of
bolt. Tighten the bolt to 45-50 foot-pounds torque.
in the
not
steps
any
The
camshaft and related parts are shown
(1)
REMOVAL. Remove the
radiator,
cover,
and
the
radiator grille
radiator
in fig. 17.
support
assembly, cylinder
bar,
front
and oil pan.
applicable.
CAMSHAFT SPROCKET TIMING MARK
Sprockets
a.
The
the
to,
is
a
slip fit on,
der front
the
cover.
and
is keyed
camshaft.
REMOVAL. Remove the
(1)
on
the
Chain.
Timing
sprocket
camshaft
end of
and
12 PINS BETWEEN MARKS
Crank the
sprockets
radiator and
engine until
and chain
the
the
timing
cylin
marks
are positioned as shown
in
fig. 16.
Remove
the
camshaft
Slide both
washer.
ward and remove
(2)
the
slots
chain
timing
sprockets
them as
retaining
the
and
timing
Be
are
on
the
and
sure
crankshaft
the
timing
positioned
chain
link
and
chain on
timing
as
pins
bolt
and
chain
for
an assembly.
INSTALLATION. Place the keys in
sprockets
shaft.
sprocket
the
marks
shown
camshaft.
position
in
Position the
camshaft and crank
on
the
sprockets
in fig. 16. There
between the timing
and
are
marks on
12
the
DRIVING SIDE OF CHAIN
sprockets.
Install the
camshaft
sprocket
washer
and
retaining
Fig.
16
CRANKSHAFT SPROCKET TIMING MARK
1244
Aligning Timing Marks
38
II 6-Cylinder
Chapter
BEARING (FRONT
AND INT.)
DRIVE CHAIN
Engines
REAR BEARING
INT.
CAMSHAFT
\
BEARING-*,
SPROCKET
SPACER
REWORK CLOTHESPIN
CAMSHAFT
THRUST PLATE
5HERA
3/i6 INCH
LOCKWASHER
SCREW
6298
Fig.
17 Camshaft and
Remove the
tion
arm
to
switch
the
remove
rocker
coil
arm
Related Parts
cover.
Disconnect the igni
from the
wire
push rod chamber cover.
then
assembly,
the
remove
engine
Remove the
push
valve
rods
the
camshaft
engine until the
timing
marks on
are positioned as shown
tor cap,
and scribe a
block to
cylinder
the
Crank
on
the
sprocket and chain
the distributor
the
of
position
housing
the
(2) INSTALLATION. Oil the camshaft
fully slide it through the bearings. Install
then
remove
the
the
thrust plate,
Turn the
clear
spring-type
with
spring
clips
Carefully
the front
of
(fig.
the
of
remove
the
18),
and
the
key,
or
pins
Remove the
Check the
be lifted
with
fingers. Raise the
lobes,
or
can
and
secure
window
them
regulator
19).
camshaft
by
the
the
Exercise the necessary
the camshaft bearings.
caution
to
Install the hub
avoid
and
Install
guides
a
tributor
cap
gasket
to the
cover.
Tighten
pounds
with
lash
rod
the
crankshaft
cover,
pump, radiator,
install the
the
using
the
rods, then
push
chamber
housing;
Cement the
cleaner.
cover
screws
as
make
Install the dis
adjustment.
air
lines
scribed
rotor and
retaining
engine
the
fast idle
at
engine
leaks. Make
the
Check
sprocket
install the
and
inch-
15-20
to
torque.
Run the
coolant
push
ex
Install
necessary.
camshaft
front
carburetor
and
if
play is
end
installation. Re
blades, fuel
and
position
valve
preliminary
If the
correct
assembly.
arm
to properly
foot-pounds
camshaft.
and radiator grille.
distributor,
the
journal
pan.
oil
fan
and
bar,
rocker
Magnetic Tappet Lifter
12-15
chain,
cylinder
Release the tappets
install the
to
and/or spacer
timing
and
and
radiator support
for
spacer
bolt,
drive
belts,
damper,
pulling it toward
engine.
camshaft
play.
end
camshaft
sprockets
the
in the
key
woodruff
the thrust plate
washers
inside of the
on
bolts
retaining
cessive, inspect the
place
faces
or
is installed.
torque. Install the
and spacer.
the
CAUTION:
damaging
chain.
the tappets
camshaft
clothes
(figs. 18
timing
woodruff
camshaft until
magnet
a
either
tappets
sprockets and
care
thrust
the
the
chamfer
rear
spacer
Tighten
Remove the
the
sure
is to the
spacer
and
distributor.
camshaft
Be
NOTE:
and
rotor
and
plate and spacer.
when
housing for installation,
distributor
Retainers
in
in fig. 16. Remove the distribu
line
mark
bolt.
sprocket
19 Tappet
Fig.
rocker
sequence.
Remove
6329
then
clips,
a
final
(hot)
valve
idling. Install the
ignition
timing
and
for
check
and
lash
rocker
adjust
oil
and
adjustment
arm
the
cover.
timing if
necessary.
c
Tappet Replacement.
Remove the
install
Fig.
18
Lifting
and
Securing
Valve Tappets
one
camshaft as outlined
tappet
at
block. A flexible-type
a
in
"b."
Remove
time through the bottom
holding
tool
can
be
used
of
and
the
if desired.
6 Sprockets and
Section
As
tappet is
each
installed,
it
should
be
Timing Chain,
secured
Camshaft
Bearings,
and
Adapter
in the
39
Tappets
and
Too\T52i-626l-CEEl
up position.
After the tappets
in
as outlined
d.
Bearing
It
replace
available
for
remove
camshaft
to size
0.015 inch
standard and
bearing
is
not
the
engine
from the
bearings. The bearings
camshaft
pre-finished
Number 3
the
Replacement.
be necessary to
will
to
car
installed, install
are
"b."
and
require
undersize
no
are
reaming
journal diameters.
interchangeable
the
with
other
bearings.
Remove the
flywheel
of
and
camshaft as outlined
Knock
way.
Push the
crankshaft.
the cylinders to
move
hole in the plug
and
the tool
shown
bearing
must
front face
of
rods out of the
bore plug
a Vi inch
drill
shown
Clean
Lightly
out
the plug
coat
the
Install the plug
Install the
crankshaft
with
rim
a
camshaft
new
then
plug
rear
bore.
sealer.
with
in fig. 22.
shown
"b."
in
outlined
as
flywheel,
in fig. 20 to
of
the tool
camshaft
and
in the
recess
outer
install the
Install the
in the
engine
camshaft
bearings
with
in fig. 21.
bearing
at
the tool
place with
or
top
21 Camshaft Bearings Removal or Installation
car.
the plug. Remove the
in
to the
bearing
rear
the tool
use
Remove the
pistons
bearing bore,
remove
Position the
"b."
the connecting
the camshaft
out
working from the front
in
Fig.
be
the
the
shown
pressed
bearing bore,
it
cam
in 0.005-0.025 inch below the
bearing bore. Press
ings in sufficiently to
and press
in fig. 21. Number 1
align
the remaining bear
the oil supply holes.
ToolT52L-6266-BGD
CYLINDER BLOCK CORE
CYLINDER BLOCK
Vi INCH HOLE IN PLUG
DRILL
CORE PLUGS
Fig.
PLUGS"
20 Camshaft
Bore
Plug
1271
6600
Fig.
Removal
22 Camshaft
Bore
Installation
Plug
7. FLYWHEEL, CRANKSHAFT, AND MAIN BEARINGS
The
The
in fig. 23.
crankshaft and related parts are shown
procedure
covered
for replacing the
clutch pilot
bushing
is
in Part TWO.
On
mission, the
surface
wheel
a.
on
the
crankshaft
bolted to the
bolt holes
shrink
fit
are
on
can
piloted on a shoulder and
by
six
crankshaft
unequally
the flywheel.
is
spaced.
one
in the
be
can
as
gear
the
is
two laminated
the flywheel is used as
by
engaged
and
the
clutch
installed
a
trans
friction
disc. The
with
the
fly
engine
car.
used on
Fordomatic
spring-steel
180
outer edge
of
removed
The flywheel
position
The ring
be
is
retained
bolts. The flywheel
in only
face
rear
which
mounted
Flywheel.
The flywheel is
cars equipped with a standard or overdrive
apart, to
drive
which
equipped cars
plates
has
riveted to the
the converter
cover
is
attached.
a
(1)
REMOVAL
-
STANDARD
OR
OVERDRIVE
40
II 6-Cylinder
Chapter
Engines
REAR OIL SEAL
CRANKSHAFT SPROCKET
FRONT OIL SEAL
SCREW
WASHER
SCREW
CLUTCH PILOT
BEARING
LOCKWASHER
FLYWHEEL ASSEMBLY
JR
~gL
SCREW
FRONT AND INTERMEDIATt
BEARING CAP
BEARING CAP
SIDE OIL SEALS
Fig.
6502
23 Crankshaft and
TRANSMISSION. Remove the transmission. Remove
the flywheel housing dust cover. Mark the clutch assem
it
be
bly
so
the
clutch release
can
in the
replaced
rod, spring,
clutch pressure plate and
same position.
and
Remove
bearing. Remove the
disc (Tool-7563). Remove the
flywheel retaining bolts and pry the flywheel
crankshaft. Remove the flywheel through the
lower
the
off
housing
Related Parts
tion
jack
a
the transmission. Remove the trans
under
bolts. Remove
mission support
bolts
the
securing
engine
block. Move
the flex drive
clear
torque
frame
the
cross member
Remove the two lower
at the rear of the transmission.
housing
converter
the transmission back
plate.
far
Secure the torque
CAUTION:
not
get
grease
or
oil
the
on
clutch
to
converter
to the housing.
access opening.
CAUTION: Do
the
to
enough
will slide
//
the torque
converter
is
not
secured, it
off the splines.
components.
Remove the flex drive
INSTALLATION
(2)
DRIVE
the
TRANSMISSION.
crankshaft
flange
and
STANDARD
OR
Position
flywheel
align
the
bolt
the
holes,
then
install the mounting bolts. Tighten the bolts in sequence
from each other to 75-85 foot-pounds torque.
Using a pilot shaft (Tool-6392-N) to locate the clutch
disc, install the pressure plate and disc. Install the
clutch release rod, bearing, spring, and hub. Install the
flywheel housing dust cover. Install the transmission.
flex drive
holes,
REMOVALFORDOMATIC.
verter
front
the car and
transmission control
access
edge.
position
safety
converter
converter
until
shaft.
converter
inlet shield,
plate. Turn the
converter air
front
access
the drain plug is
Drain the transmission
Remove the drive
Remove the
stands.
linkage shield, the torque
plate, the torque
the torque
and
torque
and
torque
at
the
converter
the flex
housing
housing
to
plate
and
dowel
to
holes,
engine
converter
block lower bolts. Install
bolts. Install the frame
speedometer
from the starter, then remove
Remove the transmission oil level indicator
Remove the
starter.
battery
cable
tube.
Install the drain plug in the torque
converter.
cross
rear
bolts.
control
the
linkage,
torque
converter
linkage shield, torque
cover, the torque
and
the
control
inlet
air
lower
access
cover,
the
cable.
control
shield,
housing front
converter
converter
linkage,
speedometer
access
and
the
transmission oil level indicator tube.
Install the starter, then
connect
the
battery
cable
to
the starter. Install the drive shaft. Remove the safety
converter.
Disconnect the
Install
pilot
converter
install the torque
then
Connect the transmission throttle
manual
the bolt
align
bolts. Tighten the bolts
Remove the jack. Install the transmission
member.
the lower
cable and transmission control rod at the transmission.
the
crankshaft
plugs
of
lower
the
to 75-85 foot-pounds torque. Align the
and
Remove the two
from the floor pan, then remove the con
housing to engine block upper bolts. Raise the
on
plate
then install the mounting
support
(3)
crankshaft.
INSTALLATION FORDOMATIC. Position the
(4)
on
across
rubber
from the
plate
OVER
Posi
stands
to
and
engine
tion the
lower the
car.
Install the
block bolts. Install the
floor
converter
housing
rubber plugs and posi
mat.
Fill the transmission
with
fluid. Start the
engine
to
fill the torque converter, then add fluid until the proper
level is reached on the oil level indicator. Check for
7
Section
leaks. Check
switch,
and adjust the manual
the throttle
and
control, the
neutral
linkage.
Tighten the
caps.
Install the
Install the
The
is precision-molded, alloy iron with
integral counterweights and is statically and dynami
crankshaft
cally balanced. Oil distribution holes
the shaft to pressure lubricate the
drilled through
are
main and
connecting
bearings.
NOTE:
Handle
possible
fractures
the
crankshaft
damage
or
(1) REMOVAL.
with
finished
to the
Remove the
to
care
it
be installed in the
Remove the
install it
timing
oil
pump
Make
sure
top
Remove the
installation
crankshaft
the
on
of
out
cap to block
bearing
and
connecting
journals.
same
the block
and
so
crankshaft
front cover,
pan, the
crankshaft
On
seal
rear
the
them
for
journal
and
cap,
and
Install
the
sur
the
into
not
careful
and
the
journal
cap.
Care
place.
damage
to
the
bearing
surfaces.
Check
clearance
of
bearing
main
each
(Chapter I). After the
checked and
the
clearance
found to be satisfactory, apply
to the
bearing
(Chapter
Check the
journals
caps
except
crankshaft
Check
the
end
are
the steel-backed, copper-lead,
play is
end
by
controlled
the
number
3
has been removed, new bearings can
be readily fitted. However, the bearings can be fitted
with the engine in the chassis as follows:
If the
crankshaft
Remove the
oil
NOTE: Replace
a
(Chapter I). After the
clearance,
clearance
and
leaving
time,
a
ings
cap to
to be fitted. Insert the
are
(Tool
Rotate the
rotation
bearing
main
6-331)
in the
crankshaft
to force the
oil
in the
bearing
upper
bearing
hole in the
opposite
out of
new
which
bear
removal
crankshaft.
direction to
engine
the block.
NOTE: When replacing standard bearings with new
bearings, it is good practice to first try to obtain the
proper clearance with
of
the
upper
two
blue
main
bearing
bearing,
bearing over the shaft
Using the same tool,
on
the block.
halves.
place
the
light
seats
itself. Remove the tool. Replace the
coat
the
bearings securely fastened.
other
in the direction
Clean the
bearing
the
locking tang
rotate
journal
and
the crank
bearing
bearing cap.
of engine rotation until
crankshaft
the plain
the
bearings. Check
the
using Plastigage (Chapter I). After
has been checked and found to be satis
clearance
clearance
factory, apply a light coat of engine oil to the journals
bearings, then install the bearing cap. Tighten the
and
bolts to 95-105 foot-pounds torque.
original posi
Plastigage
checked and
a
light
coat
bearings,
then
install the
at
oil pump.
shaft
specifications.
using
has been
bearing
one
the
remove
has been
play (Chapter I).
in their
pan, then
side of
the
rod caps
bearing
to the journals
oil pressure and oil
bearing flanges.
main
end
then install
and
I). Tighten the cap bolts to
Install the connecting
tions.
bearings
main
using
bearings,
thrust bearing cap.
Install new side seals when the rear main bearing cap
is installed. Install the thrust bearing cap and draw the
cap bolts up lightly, then align the thrust bearing
engine
oil
Fill the crankcase, then
leaks.
car.
lead-babbitt insert-type.
To install the
the
Plastigage
The
Remove the
a new rear
bearing
main
rear
crankshaft
Be
the
Main Bearings.
c.
or
install
steering,
belt.
and
for
engine and check
oil
and
assembly
belt.
power
in the
engine
screen
and
with
Install the
chain.
timing
pump
damper,
install
and
springs,
Install the flywheel hous
and
the
start
oil
equipped
Install the
plate
oil seal
remove
the bearings
sure
are clean.
in the block
lower the
cars
power
tool
journals
CAUTION:
oil
cylinder
or
disc (Tool-6392-N),
clutch
pressure
sprockets
Install the flywheel
plate.
assembly.
plate
ing. Install the
side seals.
INSTALLATION. Be
(2)
push
Carefully lift
thrust bearing
the
bearing
rear
mark
caps, and
damaged. Remove the
are not
rod
the cylinders.
of
main
from the block
fully
the
rear
clutch
Crankshaft
(main
caps
to intermix the caps, then
care not
pistons to the
oil
oil pan and
marked so they can be installed in their
locations. Remove the connecting rod bearing
caps, using
connecting
each
of
play
Align the
plate.
the
assembly.
bearing
all
end
engine
the pressure
front cover,
cylinder
Remove the
are
rod)
original
faces
damper,
chain.
housing
screen
the flywheel.
same position on
crankshaft
sprockets and
all
compress
a work stand.
can
of
flex drive
surfaces.
and
engine
avoid
Remove the flywheel housing, clutch
assembly, flywheel or flex drive plate, and the engine
rear plate. Mark the clutch pressure plate
assembly so
on
tighten them to 3-4 foot-pounds
(Chapter I).
b. Crankshaft.
rod
pal nuts and
torque.
foot-pounds
45-50
to
nuts
Check the
torque.
41
Main Bearings
and
of
engine
rod
If the
journal
rear
main
oil seals and
Install the
oil
bearing is
pump
and oil pan.
then start the engine and check
leaks.
replaced,
replace
the
the side seals.
for
Fill the crankcase,
42
II 6-Cylinder
Chapter
Engines
8. CONNECTING RODS AND BEARINGS, PISTONS, PINS, AND RINGS
The
piston and
rod
connecting
disassem
shown
are
b. Piston
bled in fig. 24.
Piston
a.
Disassembly.
ing
carbon
assemblies,
deposits from the
bores. Move the
piston
place a cloth on
the
Remove the
Never
the
any
head to
cylinder
the
bore,
cylinder
is
when
the
at
travel
in
area
its
from the connecting
crankshaft until
and
stroke
of
the
cylinder with
the handle
cylinder wall when
Remove the
Repeat this
glaze
to
end of a
being
rod
the hex head
assembly
the
removing the
from the
procedure
for
out
off
the
the
top
into
1
to
6 from
numbers
same
on
side
connecting
cylinder
and
the
the
bearing
rod and
the
the
front to the
crankpin
rod and
when
rod
cap is
bearing
is
ever
Be
cap
to another,
rod should
new cylinder
new
be
bearings
numbered
to
be
The
the
on
bore.
one
should
piston and push
at
If
block
be
the
by
spiraling them into
install the
the bearings
replace
contained
in the
piston
ring
piston rings.
and
journals
the connecting
are clean.
If it is
bearings,
replace
rod
this time.
Rod
Connecting
and
piston
rings, pistons,
and cylinder walls with
engine oil.
from
engine.
must
from
sure
Oil the
cylinder
in the
Installation.
(Chapter I).
numbered
of the
transposed
in
the fingers. Do not use pliers.
Follow the instructions
package and
d. Piston
assembly.
installed in the
rod with
shown
the
or
piston and rod.
rear
rod
new piston pin retainers
piston with
light
NOTE: Each
connecting
rod positioned as
place.
necessary to
hammer.
cylinder wall
each
retainers.
engine oil.
piston and
hole in the
Position the connecting
them
Avoid damage
CAUTION:
light
carefully
bolts. Pull the cap
piston
the
Rod Assembly.
Connecting
all parts with
oil squirt
Insert
pal nuts and
rod
rod, then push the rod and
from
piston rings.
fig. 26.
the connecting
until
crankshaft
is down. Remove the
same cylinder
(fig. 25). Discard
cutter
pin
of
and
NOTE: Assemble the
the
Turn the
nuts
Piston
c.
the
the
remove
then turn the
top
with
retainers, then drive the pin
pin
piston
the piston and rod
Lubricate
remove the cloth with the cuttings.
removed
out of
Follow
ridges.
removing
they
assembly
assure
Remove the
were removed.
Remove the
to
installation in the
same rod and
which
pins
and
pistons
and
cuttings.
the tool manufacturer.
has been removed,
ridge
position
by
remov
its travel
of
collect
the
and/or
the
of
end
into the ring
cut
of 1/32 inch
from the
upper
ridge
cylinder ridge with a ridge cutter.
CAUTION:
After the
remove
to the bottom
piston
the instructions furnished
excess
head. Before
oil pan and cylinder
piston
Mark the
Rod Removal.
Connecting
and
Remove the
the
Rod
Connecting
and
a
or
fitted,
correspond with
NOTE:
cylinder
they
sure
from
were
Make
the
Be
install the
they
were
pistons
in the
removed,
or
to
same
which
fitted.
sure
the ring
circumference
compressor on
hammer (fig.
number.
to
which
the
27)
of
gaps are
the
properly
piston.
Install
piston and push
until
spaced around
a
piston
the piston in
ring
with a
it is slightly below the top
OIL
of
RING
ASSEMBLY
SPRING SPACER
COMPRESSION RINGS
CONNECTING ROD CAP
STEEL RAILS
Fig.
24 Pisfon and
Connecting
Rod Disassembled
6385
Section
the cylinder. Be
avoid
damaging
NOTE: Install
piston
head
Check
sure
to
8
Rods
Connecting
the connecting
guide
and
rods
Bearings, Pistons, Pins,
and
43
Rings
to
the crankshaft journals.
the piston with the indentation in the
toward the front of the
the
bearing
clearance
engine.
Plastigage
using
(Chapter I). After the clearance has been checked, and
found satisfactory, apply a light coat of engine oil to the
journals
bottom
down
and
of
until
bearings. Turn
the crankshaft throw to the
its stroke, then
push
the
seats on
rod
bearing
the
piston all the
way
POSITION OIL SQUIRT
HOLE TO RIGHT WITH
PISTON DOT FORWARD
the crankpin. Install
the rod cap, then tighten the bolts to 45-50 foot-pounds
torque. Install the
pounds
pal nuts and tighten them
to 3-4 foot
torque.
After
the
all
installed,
piston
and
rod
the end play
check
have been
assemblies
of
the connecting
6387
rods
(Chapter I).
26 Correcf
Fig.
Install the
oil pan and cylinder
head. Fill the
case with the proper grade and amount of
the cooling system. Run the
sure there
is
Check for
Connecting
If the
bearings
can
engine
is
oil and coolant
Rod
Remove the
oil
leaks.
However,
removing the
pan, then
remove
the
crankshaft
bearing
the bearings
engine as
follows:
remove the oil pump.
the upper
and
lower bearings.
fit has been
a
light
then
new
journal,
blue
two
coat of engine
rod cap.
rod
halves.
and
cap.
Check
bearing
Tighten the bolts to 45-50 foot
pal
nuts,
and
tighten them
to 3-4 foot-pounds torque. Repeat the procedure for the
remaining bearings that
all
pump
need
replacing.
bearings have been replaced, install the
oil pan. Fill the
crankcase, then operate
the
and
leaks.
TIGHTEN COMPRESSOR
Tool FLM-
FRONT OF ENGINE
Pin Removal
upper
oil to the journals and
bearings,
torque. Install the
INSTALL PISTON WITH
INDENTATION TOWARD
6386
the
and
bearing
bearings in the
the engine and check for
Piston Pin Remover
the cap,
bore.
checked and
install the
pounds
oil
25 Piston
Oil Squirt Hole
the fit using Plastigage (Chapter I). After the
After
Fig.
of
NOTE: When replacing standard bearings with new
bearings, it is good practice to first try to obtain the
Install the
stand, the
Remove the connecting rod bearing caps to which
new bearings are to be fitted. Push the piston
up in the
cylinder, then
of
Replacement.
removed and mounted on a
without
does
Clean the
half
proper clearance with
Bearing
be readily fitted.
can
be fitted
lubricant. Fill
fast idle. Make
sufficient oil pressure and the engine
not overheat.
e.
engine at
Position
crank
SECURELY
6149
INSTALL RING COMPRESSOR WITH RETAINER TOWARD SKIRT
1259
Fig.
27 Pisfon
/nsfa//afion
44
Chapter
II 6-Cylinder
Engines
9. OIL PAN, OIL FILTER, AND OIL PUMP
Procedures for the
removal
and
installation
the
of
below.
above components are presented
Remove the flywheel
move the oil pan
inspection
housing
retaining
cover.
the
screws and remove
the block
and
Coat the block
pan
place
Make
are
the
the gasket
the
block
at each end of
ing
then
tighten
oil pan.
Hold the
install
and
a
the pan. Install the
the
screw,
remain
from the
screws
center
in each direction to 12-15 foot-pounds torque.
Install the flywheel housing inspection cover. Install
the engine right and left front splash aprons.
Install the
proper
level indicator. Fill the
oil
grade
and
and
of
quantity
for
check
crankcase with
engine
oil.
Run the
The full flow-type
the pump before the
of
lubrication
filter
located
to
and
element
outer
is
it,
the
oil
no
dirty
the
great
the
parts
in
bolt
center
enough
open.
in
and
consists
thereby maintaining
is
of
making
Install
spring.
element over
a
the
new
the
behind
enough
the
holes in the
flow
of
valve
the spring pressure,
emergency supply
of oil
to the
Fig.
filter
gasket and a new
Check to
if the two elong
back diaphragm
see
anti-drain
in the up position as shown in fig. 29. Clean the
block filter recess, then install a new gasket.
are
cylinder
not
over
tighten the center
Refill the
the
crankcase with oil
at
engine
fast
bolt.
are
oper
for leaks. If
check
oil
the necessary repairs to cor
the leakage.
rect
c.
evident,
idle,
perform
if necessary, then
and
Oil Pump.
A
case
gear-type
in line
oil
with
pump is
mounted
inside the
crank
the distributor.
The pump is driven by means
shaped drive shaft. The shaft is
of an
intermediate hex
pinned
into the
end of
the distributor drive shaft.
(1) REMOVAL.
indicator,
and
the
Remove the distributor,
pan. Remove the two
oil
from the mounting
(2) DISASSEMBLY. Remove
GASKET
ADAPTER
FITTING
FILTER ELEMENT
ANTI -DRAIN
oil
level
nuts
and
pad on
the block
Filter Disassembled
the
retaining screws, the screen assembly,
screen
assembly
move
the
and
gasket.
6080
Re
cover
retaining screws, cover, and gasket.
Push the pump drive shaft and drive gear assembly
from the pump housing. Remove the driven
BACK'
DIAPHRAGM
28 Oil
the
lockwashers retaining the pump to the cylinder block.
Remove the pump and gasket. Thoroughly clean the
RETAINER
NEOPRENE
BY-PASS VALVE
engaged
bolt.
filter
oil
are
and pump.
GASKET
VALVE
SPRING
tangs
neoprene
center
old gasket material
BY- PASS
the
on
valve.
FILTER HOUSING
RETAINER
seat
(4) INSTALLATION.
ated
clean and oil
the inner face of the valve
f
gasket
bolt,
.SPRING
SPRING
fiber
on
sure
a
difference between the
overcome
^XV^SPRING
new
in the
is
ENTER TUBE BOLT
FIBER GASKET
a
case
Oil then by-passes the element,
an
in the
openings
tainer. Install the spring and spring seat assembly
leaks
difference between the
to
Wash
gaskets.
all
the
then place the bolt through the filter con
bolt,
center
and
all
from the
are clean.
ASSEMBLY. Install
(3)
ate
pressure
acting
sure
gasket
entire
by-pass
the valve is not great
on
element
Make
solvent.
the fiber
neo
center
engine
system
The
element
pressure
of
pressure
will
all
and
the
remove
the
and will not permit a sufficient
If
valve
container
seat, then
filter assembly slightly, in each direction, to make sure
gasket is seated evenly. Tighten the center bolt to
flows through the by-pass. When the
drops.
the
to the
bolt
center
spring
oil pressure
faces is
enters
clogged.
When the
faces
oil, the
the
becomes
valve.
overcome
Therefore,
28) filters
oil
provides oil
in the hollow
flow through
inner
gasket, spring,
CAUTION: Do
element
spring loaded
will
and
the
system.
A built in by-pass
the
filter (fig.
oil
the filter. Remove
the filter assembly
Place the filter assembly in position, and thread the
center bolt into the adapter finger-tight. Rotate the
leaks.
oil
b. Oil Filter.
output
drip pan under
bolt, then remove
a
DISASSEMBLY. Remove the filter element,
(2)
bolt from the
surfaces
source of restriction
and gasket.
Re
outward
engine
the car. Place
pan
free from burrs.
and
gasket on
the
against
finger tight,
screws,
sure
clean
the
corrected.
REMOVAL. Remove the filter from the bottom
the filter center
surface and oil pan gasket surface with
sealer and position
the
oil
bolt. Discard the filter
(2) INSTALLATION.
in
flow is
prene
and gasket.
pan
system until
of
(1) REMOVAL. Drain the crankcase. Remove the
oil level indicator. Remove the engine left and right
front splash aprons.
of
lubrication
normal
(1)
Oil Pan.
a.
engine
to the
move
the
oil pressure relief valve chamber
and plunger.
gear.
Re
plug, spring,
9 Oil
Section
TOP
Pan, Oil Filter,
CYLINDER BLOCK
Oil
and
45
Pump
GASKET
NUT
SCREW
LOCKWASHER
HOUSING
PLUG
GEAR
DRIVEN
COVER
COVER
GASKET
SCREW
STRAINER FLANGE
GASKET
SCREW
SCREEN-
6081
SNAP
29 Oil
Fig.
Filter Anti-Drain Back Diaphragm Position
Remove the snap
and remove
screen
and
moving
wire
screen
Apply
a
pump
light
to
gear
Apply
valve
the
cover, but do
gasket on
end
a
The
exhaust
pipe,
are
system
and
the
pump.
screws.
as
provided
of
inlet
individual
a
muffler
a
(fig. 31). These
service
When
system, loosen
to
relieve
replacing
all
the
in
twists
any
part
of
system,
then
it
secure
the
with
the
and
screen
the pump cover. Tighten
make
a
sure
it turns freely.
new
gasket
nuts.
bolts, slide the pump mounting flange
bolts, and install the lock washers
stall
Tighten the
the
on
retaining
over
and
to 30-35 foot-pounds torque. In
nuts
the distributor.
Install the
grade and
Fill the
oil pan.
crankcase with
the
proper
of oil.
quantity
Run the
fast idle
engine at
and check
for
oil pressure
leaks.
and oil
at
the
rear
muffler,
the
parts.
the
by
muffler
of
the muffler. Separate the
sliding the
inlet
pipe
muffler.
pipe
outlet
clamp
and
Separate the
outlet pipe and
to the
Loosen
rear.
the clamp away
slide
muffler
exhaust
frame attaching bracket
the
on
hand to
by
shaft
from the
NOTE:
and
EXHAUST SYSTEM
muffler,
pipe
Install
cover
INSTALLATION. Place
retaining
the
Install the pump
retaining
consists
muffler
a
of
the pump cover gasket,
10.
outlet
play
screen
Install the inlet tube gasket,
the retaining screws to 12-15 foot-pounds torque. Rotate
dial indicator (Chapter
of
tighten the
not
into the
assembly
Check the
gear.
using Plastigage or
sealer to both sides
position
shaft
and
6331
Pump Disassembled
inlet tube assembly
and
coat of engine oil
in the
screen
retainer.
(4)
housing. Install the driven
the gears
the
the pump
relief
pressure
Slide the drive
parts
oil
plunger, spring, and
Tighten the plug to 33-38 foot-pounds torque.
plug.
then
pump screen,
parts.
Install the
I).
retaining the
from the housing. The
disassembled in fig. 30.
shown
are
ASSEMBLY.
(3)
all
the
30 Oil
Fig.
WIRE-
from the inlet
pipe, then remove the muffler.
clamps
tighten
the
(2) INSTALLATION.
clamp
clamps.
the
on
inlet
Position the
pipe.
Slide the
new
muffler
muffler
and
forward
on
the inlet pipe until the slots in the muffler extension are
Muffler Replacement.
a.
Extra
available
(1)
rear
heavy,
for
double-wall
mufflers
are
then
pipe
more
the inlet
service.
REMOVAL.
clamp,
blocked. However, do
constructed
Loosen
remove
the
the
outlet
pipe
lower half
of
than
pipe
l3/4
the muffler
on
the inlet
muffler.
clamp downward approximately
frame
the
clamp opening
the clamp
the
slots
to
not slide
inches. Align the
in the
is
muffler
not
positioned
extension.
directly
Rotate
45
so
opposite
46
II 6-Cylinder
Chapter
Engines
CARRIAGE BOLT
BOLT
6501
Fig. 31
Slide the
forward into the
outlet pipe
sion until
the slots in the muffler
However,
do
not
slide
the
into the
pipe
l3/4 inches. Connect, but do
than
half
the clamp
of
possible
sary.
the rear
of
pan.
Tighten the
outlet
Reposition the
outlet
pipe
muffler
The
if
pipe
neces
clamps.
sound
deadening
exhaust noises
frame,
or
pipe
but
is
attached
materials
from
being
also relieve
bending
to the
passage
which
not
conducted through
the
rear
of
the muffler, then
support.
Separate the
more than
outlet
support.
pipe and
the
slide
connect, but do
rear of
the clamp
rear
clamp
outlet
pipe
pipe.
into
the
muffler extension
\3A inches. Slide the
Connect, but do
the clamp at the
not
and
outlet
the slots in the
blocked. However, do
muffler
the
the chassis
of
the
remove
muffler
INSTALLATION. Slide the
muffler extension until
are
necessary.
the
to the muffler,
of
the
is designed to
pipe
exhaust
manifolds
muffler
the exhaust
direct through
the
over-all
exhaust system.
inlet
to the rear, then
Remove the inlet
outlet
pipe
clamps
Remove the two
pipe clamp.
the inlet pipe to the
muffler
give
a
thereby increasing
REMOVAL. Loosen the
tening
pipe.
the
exhaust manifold.
the muffler
separate
pipe
and
nuts
and
fas
Slide the
and
inlet
gasket.
stresses.
the
(2)
the
from twisting
exhaust system
REMOVAL. Remove the lower half
from its
prevent
only
(1)
at
by flexible
frame
inlet
muffler
leaving
gases
(1)
outlet
if
pipe
outlet
Inlet Pipe Replacement.
c.
efficiency
The
the
outlet pipe clamps.
more
Outlet Pipe Replacement.
b.
Reposition
pan.
"kick-up"
pipe
outlet
floor
Tighten the
the lower
tighten,
not
exten
blocked.
are
the muffler. Check for
the floor
and
at
muffler
extension
Exhaust System
pipe
rear
into the
clamp
not tighten
on
it to its
tighten, the lower half of
the muffler. Check for possible
not
"kick-up"
outlet
pipe
and
the
INSTALLATION. Slide the clamp on the new
slide the inlet pipe into the muffler
(2)
inlet pipe, then
extension
until
However,
do
slide
manifold outlet
the
exhaust
in the
the
\3A inches. Install
than
to
the slots
not
a
pipe
new
are
extension
into the
gasket
blocked.
muffler
on
more
the exhaust
flange studs, then connect the inlet pipe
manifold. Tighten the bolts to
23-28
foot-pounds torque. Position the muffler, then tighten
the
outlet
pipe
clamps.
Rotate the inlet
downward approximately 45 degrees
ing is
not
muffler
positioned
directly
so
opposite
extension, then tighten the
pipe
the clamp
the
clamp.
slots
clamp
open
in the
LITHO IN U.S.A.
7098-56

DEMO - 1956 Ford Car Shop Manual

Transcription

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