1957 Ford Car and Thunderbird Shop Manual

Transcription

FORD
DIVISION
FORD MOTOR 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
1957 Ford Car and Thunderbird Shop Manual
EAN: 978-1-60371-007-7
ISBN: 1-60371-007-8
Forel Publishing Company, LLC
3999 Peregrine Ridge Ct.
Woodbridge, VA 22192
Email address: webmaster@ForelPublishing.com
Website: http://www.ForelPublishing.com
This publication contains material that is reproduced and distributed under a license from Ford
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
This product was created from the original Ford Motor Company’s publication. Every effort has
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
information, either expressed or implied. As a result, the information contained within this book
should be used as general information only. The author and Forel Publishing Company, LLC
shall have neither liability nor responsibility to any person or entity with respect to any loss or
damage caused, or alleged to be caused, directly or indirectly by the information contained in
this book. Further, the publisher and author are not engaged in rendering legal or other
professional services. If legal, mechanical, electrical, or other expert assistance is required, the
services of a competent professional should be sought.
INDEX
PART
ENGINES
IGNITION, FUEL, AND
COOLING SYSTEMS
CLUTCH, TRANSMISSION,
AND REAR AXLE
CHASSIS SUSPENSION
AND FRAMES
STEERING
AND
BRAKES
GENERATING AND
STARTING SYSTEMS
LIGHTS, INSTRUMENTS,
AND ACCESSORIES
BODY MAINTENANCE
AND REPAIR
DOORS, DECK LID, AND
FRONT SHEET METAL
INTERIOR TRIM,
AND WINDOWS
SEATS,
Copyright 1956
FORD MOTOR COMPANY
DEARBORN. MICHIGAN
All
rights
reserved
BODY INSTALLATION
DRAWINGS
Permission
Reprinted with Ford Motor Company's
FORD DIVISION
FORD MOTOR COMPANY
FORM 7098-57
MAINTENANCE AND
LUBRICATION
SEPTEMBER
1956
FOREWORD
This
proper
The
has been
manual
servicing
manual
of
prepared
1957 Ford Cars
be kept
should
to
and
it
where
provide
information for the
the 1957 Ford Thunderbird.
will
be readily
available
for
reference at all times.
The
page.
manual
A title
is divided into 13
page
is
also
lists the
chapters and
on each
left-hand
the
included
heading
indicates the
section covered.
The descriptions
effect at
Ford Division
continue
without
of
models
notice
the
in the
on
the title
of each part
The
part.
indicates the
that
heading
name of
the
on each right-hand or odd-numbered page
and
specifications
the time the book
Ford Motor
at
designated
beginning
or even-numbered page
the
in
at
sections contained
chapter and
were
parts as
any time,
and without
was approved
Company
or
contained
reserves
change
incurring
in this
for
manual
printing.
the
right
specifications
or
The
to dis
design,
obligation.
SERVICE
DEPARTMENT
FORD DIVISION
FORD
MOTOR
COMPANY
1957
SHOP
FORD
CAR
MANUAL
PARTI
ENGINES
Chapter 1
GENERAL ENGINE SERVICE
Page
Section
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
General Engine Trouble
Shooting
1-8
Tune-up
Manifolds and Exhaust Gas Control
Valve
Rocker Arm Assembly, Push Rods, and
Cylinder Heads
Valve Mechanism
Timing Chain, and Camshaft and
Bearings
Crankshaft and Main Bearings
Flywheel
Connecting Rods and Bearings
Pistons, Pins, and Rings
Cylinder Block
Oil Pan and Oil Pump
Exhaust System
Engine Dimensions, and Clearance and
Adjustment Specifications
Chapter 2
1-4
1-10
1-11
1-14
1-18
1-19
1-23
1-23
1-25
1-27
1-29
1-30
1-30
6-CYUNDER ENGINE
Section
1.
2.
3.
4.
5.
6.
8.
Description
Engine Removal and Installation
Engine Supports
Valve
Cylinder Head and Valves
Crankshaft Damper, Cylinder Front
Cover, and Crankshaft Oil Seal
Sprockets and Timing Chain, Camshaft,
1-35
1-38
1-40
Bearings, and Tappets
Flywheel, Crankshaft,
1-46
and
10.
11.
12.
1 -43
1-45
Main
Bearings
9.
1-41
1-48
Connecting Rods and Bearings, Pistons,
Pins, and Rings
Oil Pan, Oil Filter, and Oil
Exhaust System
General Specifications
Chapter 3
Pump
1-51
1-53
1-55
1-56
8-CYLINDER ENGINES
Section
1
.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11
.
12.
Description
Engine Removal and Installation
Engine Supports
Valve
Cylinder Heads and Valves
Crankshaft Damper, Cylinder Front
Cover, and Crankshaft Oil Seal
Sprockets and Timing Chain, Camshaft,
Bearings, and Tappets
Flywheel, Crankshaft, and Main
Bearings
Connecting Rods and Bearings, Pistons,
Pins, and Rings
Oil Pan, Oil Filter, and Oil Pump
Exhaust System
1-58
1-61
1-64
1-66
1-67
1-70
1-72
1-75
1-77
1-79
1-81
1-83
i
1-4
Part 1
-
ENGINES
Chapter 1
GENERAL ENGINE SERVICE
Page
Section
1-
4
1-
8
1
2
Tune-Up
3
Manifolds
4
Rocker Arm
5
Valve Mechanism
6
Timing Chain,
7
Crankshaft
8
Flywheel
1-23
9
1-23
10
Connecting Rods and Bearings
Pistons, Pins, and Rings
11
Cylinder Block
1-27
12
Oil Pan
13
Exhaust System
14
Engine
The
apply to
the
after
and
1-18
Bearings
1-19
Main Bearings
1-25
1-29
Pump
1-30
and
Clearance
in
contained
procedures
this
the
of
chapter
have
case
of
a
been
removed
engine
complete
and
parts
engine
component
1-30
and
The cleaning, inspection, repair,
parts
in the
or
engine,
Camshaft
Dimensions,
the
1-1 1
Cylinder Heads
and
1-14
and
Oil
procedures
after
apply
Assembly, Push Rods,
and
all engines.
overhaul
1-10
Exhaust Gas Control Valve
and
and
service
Shooting
To completely disassemble or assemble an engine,
follow all the removal or installation procedures in the
applicable
from the
individual part,
overhaul,
in the
To
chapter.
engine
to the
refer
remove
section
install
or
covering the
an
part
applicable engine chapter.
has been disassembled.
engine
1. GENERAL ENGINE TROUBLE SHOOTING
Poor
nosis
by
or
parts,
will
be
can
performance
tune-up, by
engine
general
a
of
engine
indicate the
of a
need
or
the need
The five
formance
trouble
good
complete engine
up, individual adjustments, part(s)
haul,
diag
tune-
speed
performance;
engine
overheats;
operation
of a complete engine overhaul.
major
in restoring
steps
good
engine
by
the
if possible, if any
could
owner
work
be the
actually
has been
cause of
the
sure
exists.
that
Deter
performed
present
re
trouble.
2. ISOLATE THE CAUSE IN THE PROPER SYS
TEM. Trace the
cause of
it has been isolated in
ignition, fuel,
the trouble to the point
one
of
engine, cooling,
following
the
where
systems:
in
a
refers
in the
not
listed.
has been corrected,
the
work
Engine
one
of
crank;
the
road
test the car
as a
final
check on
performance
complaints
usually
following basic headings:
engine
cranks
normally,
but
fall
engine
will
under
will
not
not
start;
poor
or
the engine
acceleration;
fails to
reach normal
trouble shooting
troubles
of
procedures
the
the
and
checks
the trouble
reference after each
check
covers, in
detail,
to be
corrections
as
When
definite
which
cause of
manual which
as well
systems.
a
The
chart
procedures
with
help isolate
system.
order of
cases, the
a
particular
system
by
a
checks
be
should
made
test, to
for testing
and
they
and several checks
save
time,
check
are not
later
the
calls
are
can
check,
listed
therefore, in
in the
order
be
given
should
spark
plugs
the cause
for
made
trouble
simple
their probable occurrence;
Some consideration, however,
to logical order. For example, if the
removed
runs,
full power, or has poor high
fuel consumption;
excessive
general
engine
various
trouble,
performed.
idle;
the possible systems that could be at fault
4. CORRECT THE TROUBLE.
that the trouble
a
be traced to
most
deciding
engine
engine
running;
develop
to that part
checking
keep
temperature.
particular
3. LOCATE THE CAUSE IN THE SYSTEM.
5. ROAD TEST. Before
not
to be performed to
in the
or exhaust.
rough
Table 1 is
per
lists basic
as stated
which
starts, but fails to
engine
but misses;
engine does
are:
the trouble
cently
need
replacement or over
1. ESTABLISH THE TROUBLE. Make
mine,
the
gradual wear of engine
failure. A
a sudden parts
by
caused
of
are
the
a compression
compression
while
the
spark plugs are out.
A
separate
trouble shooting
chart
is included in the
Section
ignition, fuel,
1- General
Engine Trouble
and
cooling system chapters. These charts
list the basic troubles listed in Table
1, but cover only
the items
relating to the particular
system
under
Shooting Chart
tion
con-
For example, in Table 1 under Poor Acceleration, the ignition system is listed as a probable
sideration.
Table J
These items
next
Poor Acceleration,
under
items that
system
to the
System Trouble
the trouble. In the Ignition
of
cause
'"*
Shooting
be
should
probable
acceleration
affect
system
the
are
listed in Table 1.
Shooting
Engine Will Not Crank
The
cause of this
If the starting
plugs, then
water
is
fault,
not at
to
attempt
into the
leaking
Also
is
system
spark
cracks.
trouble is usually in the starting
the engine
crank
for
block for
-Chapter
hydrostatic lock
a
the starter. If the
with
Remove the
cylinders.
examine the cylinder
check
(Part 7
system
cylinder
head
2).
or a seized engine.
engine
Remove the
cranks, it indicates that
head for
gasket and /or
inspect the
and
cracks.
Engine Cranks Normally, But Will Not Start
Check the fuel
If there is
supply.
sufficient
fuel in the tank, the
lies in
the trouble probably
cause of
either
the ignition
or
the fuel system.
To isolate
the cause:
Remove the ignition
insulator
so
from
wire
one spark
and
plug,
insert
a piece of proper sized metal rod
that it protrudes from the insulator. With the ignition
engine, hold the
If there is
approximately 3/16 inch from the
end of the rod
no spark or a weak
spark, the cause
of
on and
cylinder
the
starter
in the
cranking the
block.
the trouble is in the ignition
system
(Part
2
Chapter 1).
If the
spark
If the
spark plugs are not at
If the fuel
is good,
is
system
the
check
not
spark plugs
(Part
2 Chapter
1).
fault, check the fuel system (Part 2 Chapter 2).
at fault, check the valve timing (page 1-17).
Engine Starts, But Fails To Keep Running
If the
engine starts and runs
Fuel
system
Ignition
for
a
few seconds, then stops,
check
the:
(Part 2 -Chapter 2).
(Part
system
2 Chapter
1).
Engine Runs, But Misses
First, determine if
the miss
engine at various speeds under
is steady
load.
or erratic and at what speed
MISSES STEADY AT ALL SPEEDS. Isolate the
firing. This is done
time,
until all cylinders
If the
power
by
by
have been
engine with
checked.
being
shorted out.
cylinder not
Ignition
Engine
system
delivering
(Part
compression
If
Ground the
in the
no change
before
power
2 Chapter
to determine
spark
being
is
running the
wire
plug
shorted
by
running the
from
one spark
plug
at
a
wire removed.
shorted
out,
occurs
engine with one cylinder not
removed
out, that cylinder was
engine operation
check
is evident, the
delivering
miss was caused
the:
1).
which mechanical component of
MISSES ERRATICALLY AT ALL SPEEDS. If the
check
by
the ignition
particular cylinder
engine speed changes when a
before
that
running the
miss
the miss
miss cannot
the
engine
be isolated in
is
at
fault (page 1-9).
a particular
cylinder,
the:
Exhaust
Ignition
Fuel
gas control valve
system
system
Engine
(Part 2
(page 1-10).
(Part 2-Chapter 2).
compression
to determine
system
for
Cooling
system
for internal leaks
restrictions
which mechanical component of
the engine is at
fault (page 1-9).
(page 1-30).
Exhaust
normal
1).
-Chapter
operating temperature (Part
and/or
for
2 Chapter
a condition
3).
that prevents the engine
igni-
listed.
before proceeding
checked
all
all
from reaching
1-6
1 General
Chapter
1 General
Table
Engine Runs, But Misses
Engine Service
Engine Trouble
Shooting
(cont'd)
(cont'd)
MISSES AT IDLE ONLY. Check the:
Fuel
(Part 2-Chapter 2).
system
Ignition
2 Chapter
(Part
system
Vacuum booster pump, lines
Valve lash
Engine
fittings for leaks.
and
(page 1-15).
adjustment
for low
compression
1).
compression
(page 1-9).
MISSES AT HIGH SPEED ONLY. Check
Ignition
Fuel
1).
(Part 2-Chapter 2).
system
Cooling
2 Chapter
(Part
system
the:
system
for overheating
or
internal leakage (Part
2 Chapter
3).
Rough Engine Idle
Valve lash (page 1-15).
Exhaust
gas control valve
(page 1-10).
Vacuum booster pump (Part
2 Chapter
Ignition System (Part
Leaking
Fuel
system
Loose
brake
power
vacuum
2).
1).
booster (Part
6 Chapter
2).
(Part 2-Chapter 2).
engine mounts
Improper
2 Chapter
(Part
1 Chapter
2
or
3).
head bolt torque.
cylinder
Poor Acceleration
Ignition
Fuel
system
system
Exhaust
(Part
2 Chapter
(Part 2-Chapter 2).
gas control valve
Valve lash
1).
(page 1-10).
(page 1-15).
adjustment
Dragging brakes (Part 6 Chapter
Slipping clutch (Conventional and
Improper
adjustment of
1).
Overdrive
Transmission)
(Part
3 Chapter
1).
the Fordomatic transmission.
Engine Does Not Develop Full Power, Or Has Poor High Speed Performance
Determine if the trouble
engine
exists when
the
engine
is cold,
at normal
operating temperature,
temperatures.
ENGINE COLD
Exhaust
Fuel
gas control valve
system
Cooling
(page 1-10).
(Part 2-Chapter 2).
system
if the
engine reaches
operating temperature slowly (Part
ENGINE AT NORMAL OPERATING TEMPERATURE
Exhaust
Fuel
gas control valve
system
(page 1-10).
(Part 2-Chapter 2).
ALL ENGINE TEMPERATURES
Engine
compression
Ignition
Fuel
system
system
Valve lash
(page 1-9).
2 Chapter
(Part
1).
(Part 2-Chapter 2).
adjustment
(page 1-15).
Cam lobe lift (page 1-19).
Valve timing (page 1-17).
Cooling
system
if the
engine overheats
(Part
2 Chapter
3).
2 Chapter
3).
or at all
Section
Table
1 General
? General
Engine Trouble
Engine Trouble
'"'
Shooting
Shooting
(cont'd)
Engine Does Not Develop Full Power, Or Has Poor High Speed Performance (cont'd)
Excessive back
in the
pressure
Torque
converter stall speed.
Torque
converter
Brake
Tire
fails to lock up
Excessive
4 Chapter
(Part
in
carbon
high
at
speeds.
(Part 6-Chapter 1).
adjustment
pressure
exhaust system.
3).
engine.
Excessive Fuel Consumption
Determine
the
actual
fuel
consumption with
If the test indicates that the fuel
improper driving habits
If the test indicates that the fuel
below before proceeding to the fuel
equipment
consumption
fuel
will affect
test
is
not
installed in the
car.
excessive, demonstrate to the
Wheel
4 Chapter
alignment
(Part
consumption
and
ignition
is excessive,
make
the preliminary
systems.
3).
4 Chapter
1).
Brakes (Part 6-Chapter 1).
Exhaust
gas control valve
Odometer
calibration
Ignition timing (Part
(page 1-10).
(Part
8 Chapter
2 Chapter
1).
1).
Valve lash (page 1-15).
FUEL SYSTEM
(Part 2-Chapter
IGNITION SYSTEM
2)
(Part 2-Chapter
ENGINE COMPRESSION (page
1)
1-9)
COOLING SYSTEM (Part 2-Chapter
3)
TORQUE CONVERTER STALL SPEED
TORQUE CONVERTER CONTINUES TO CONVERT AT LOCKUP SPEED
Engine Overheats
Temperature sending
Temperature
Exhaust
unit
(Part
gauge
gas control valve
(Part
8 Chapter
8 Chapter
1).
1).
(page 1-10).
Cylinder head bolt torque (Part 1-Chapter 2
Cooling
system
(Part
2 Chapter
or
3).
3).
Ignition timing (Part 2-Chapter 1).
Valve timing (page 1-17).
Valves (page 1-14).
Exhaust
Brake
system
(page 1-30).
adjustment
(Part 6-Chapter 1).
Engine Fails To Reach Normal
Temperature sending
Temperature
Cooling
gauge
system
unit
Operating Temperature
(Part 8-Chapter 1).
(Part 8-Chapter 1).
(Part 2-Chapter 3).
how
consumption.
PRELIMINARY CHECKS
Tires (Part
owner
checks
listed
1-8
Chapter 1
General Engine Service
2. TUNE-UP
A tune-up is
rious
engine
a
components,
them
within
engine
efficiency
The
systematic
procedure
if
and,
recommended
for testing
bringing
necessary,
specifications
va
to
restore
Tune-Up Schedule (Table 2) is
Table
Perform
for
applicable
on
Operation
2
Major
X
cables.
series re
X
and capacity.
X
drop
voltage
at
resistor.
TIMING
Check
and
output.
X
wiring.
X
X
Part 7
Chapter 1
ignition
adjust
X
X
X
X
X
X
Test fuel pump
pressure.
X
Test fuel pump
capacity.
X
CARBURETOR
Clean carburetor
filter.
X
SPARK PLUGS
X
X
Part 2
Chapter
Part 2
Chapter 1
Part 2
Chapter 1
Part 2
Chapter 1
Page 1-9
Part 2
Chapter 2
X
Part 1
Chapter 2
or 3
Page
and
X
air
cleaner
X
X
1
Clean
INTAKE MANIFOLD
Check and adjust manifold
bolt torque.
VALVE LASH
Check and adjust intake
exhaust valve lash.
Procedure
Page 1-9
each cylinder.
test.
vacuum.
FUEL PUMP
Clean fuel pump bowl.
Part 7
Chapter 1
Recom
X
VACUUM
Check manifold
X
ENGINE COMPRESSION
Take compression reading of
and
Major
X
current and voltage.
adjust,
on
mended
timing.
REGULATOR
Visually inspect
Clean,
the
X
the
listed.
Minor
Check the
X
the
describes,
be followed. Perform
COIL AND RESISTOR
Check coil output.
Part 7
Chapter 1
which
manual
Operation
sistance,
cracks
state of charge.
GENERATOR
Check generator
Check
X
by
Tune-Up Schedule
Procedure
worn
for
sequence
governed
reference after each opera
the
to
procedure
in the
operations
of
as
Perform
X
Grease battery
the
detail,
The
part
CONDENSER
Check for leakage,
terminals.
Inspect cables for
insulation.
the engine.
to that
refers
tune-up
major
or
Recom
BATTERY AND CABLES
Clean cables, connectors, and
battery
tion
mended
Minor
Check
minor
a
condition of
in
and performance.
Inspect battery
and leaks.
either
1-15
carburetor
Adjust float
fuel bowl.
setting.
Check fuel level (Holley
Ford Carburetors).
Adjust
X
engine
idle
X
Part 2
Chapter 2
and
X
speed.
X
X
X
X
X
Adjust idle fuel
mixture.
DISTRIBUTOR
Check
arm
Check
and
spring tension.
of
condition
FUEL FILTER
Clean fuel line filter.
breaker
adjust
X
EXHAUST ANALYSIS
Perform an exhaust gas
contact
X
points.
X
X
Page 1-10
an
alysis.
Check
Check
and adjust point
and
adjust
dwell.
X
Part 2
X
Chapter 1
IGNITION SYSTEM RE
SISTANCE TEST
Perform a primary circuit
and
Check
and adjust mechanical
advance
(8-cyl.
Test distributor
cap
and
and
X
re
test.
X
COOLING SYSTEM
Check and adjust the tension
of the drive belts.
Check
inspect distributor
and rotor.
circuit
Part 2
Chapter 1
X
point resistance.
Clean
secondary
sistance
engines).
circuit
X
X
vacuum
advance.
Part 2
Chapter 2
X
X
condition of
radiator cap.
hoses
X
X
Part 2
Chapter 3
and
X
X
-Tune-Up
Manifold Vacuum Test
A
test
of
determining
manifold
ing to locate the
Engine Compression Test
is
vacuum
the condition
a
valuable
in
of an engine and also
1. Be
in
aid
for
help
cause of poor engine performance.
To
V2 hour
off, then
switch
for
engine
a
minimum
V^-hour
of
4-barrel carburetor)
at
1200
at
plugs.
spark
throttle
in the
choke
engine
Turn the igni
rpm.
the
(primary
and
Operate the
good.
remove all
2. Set the throttle
1200 rpm.
plates
posi
open
wide
on
only
tion.
2. Install
an
accurate, sensitive vacuum gauge
fuel pump end of the fuel
pump vacuum line.
3. Run the engine at recommended idle rpm.
4. Check the
vacuum
reading
on
carburetor
adjustment,
valves,
cylinder
the
3. Install
the
the
mum
is
affected
by
condition
of
5. Repeat
to
cylinder.
Note the
obtain
the
maxi
a
registers
gauge
reading.
strokes required
head
cylinder
test
the
each
on
the same number
engine
of
number
maximum
for
of strokes
to
required
obtain
maximum
a
the
cranking
cylinder,
as
each cylinder
the
was
or
the
and record the
reading
in No. 1
gauge
until
engine
of compression
leakage
and
compression,
manifold, carburetor,
a compression
4. Crank the
gauge.
vacuum
timing,
valve
on
reading.
TEST CONCLUSIONS. Manifold
the
battery is
the
sure
a minimum of
tion
test manifold vacuum:
1. Operate the
1-9
2
Section
No.
on
reading
1
gaskets.
cylinder.
Because
abnormal
than
more
has been
trouble
and
each
possible
not
3
lists
causes.
a
firm
Allowance
on
the
with
so
as
It is
from
For example,
item may
one
10
to indicate that the
necessary in
of
This table is merely
a
guide,
dicates
reading.
increase in
of
more
A
their
low
The
for the
affect
engine vacuum
of
will
decrease
fault,
head
in the
altitude.
Table
Gauge
3 Manifold
pounds
However,
uniform
the
within
above
below
in two
or
indi
normal
valves.
cylinders
adjacent
be
should
checked
the
rings
of
tablespoon
a
then
chamber,
the valves
or
crank
of
are
heavy
Engine Condition
18-20 inches (6-cylinder engine)
19-20 inches (8-cylinder engine)
Normal
Low
Loss
and
steady
Very low
Needle fluctuates steadily
as speed
increases.
of
power
or valve
leakage
around the piston
carburetor,
A
or
partial
weak
reading
at
engine
idle.
caused
by
gasket,
a
valve
a
or
drifting
of
the
needle.
manifold
of compression
due to
rings.
loss
head
gasket
leak.
of
power
in
leaking
valve,
leaking head
one
or
more
or
a
spring.
occasional
Improper
loss
by late
possibly
defect in the ignition system,
exhaust system.
loss
of
defect in the ignition
Slow fluctuation
or
or cylinder
complete
Restriction in the
An
Intermittent fluctuation
timing,
Manifold,
manifold
drop in
all cylinders caused
ignition
cylinders
Gradual
in
idle
gasket
power
system or a
mixture
leak,
possibly
or
caused
sticking
adjustment,
possibly late
at
oil
the engine to
Vacuum Gauge Readings
Reading
in
rings or valves.
whether
combustion
normal
cylinder.
leak. This
gasket
the equivalent
squirt
pounds
than 10 pounds
compression
To determine
altitude
10
the head gasket, rings,
at
even
a
than
before condemning the
made
be
should
10
of
satisfactory.
cylinders
of more
leakage
indicates
however,
is
deposits in the
excessive
A reading
to
standard.
be
all
variation
pounds.
cates
and
readings
of
A reading
the trouble.
of
types
order
A
pressure
specified
compression
reading be investigated
abnormal
various
of
CONCLUSIONS.
TEST
exercise
important, therefore,
conducted where
should
gauge
an
correction
enough
an
fault,
at
abnormal reading.
corrected.
of
may indicate that
factors is
the correct diagnosis
at
Table
and
cause
further tests
arrive
an
vacuum
readings
above
is low, the
vacuum
increase the
that
the
of
in analyzing
caution
if the
one
gauge
by
a
valve.
carburetor
valve
or
timing.
1-10
distribute
oil
will
the
oil
the
the
valves
has increased
During
a
10
and
are
strokes, but
successive
fails to
ceeding strokes,
it indicates a sticking
or
Exhaust Gas Analysis
An
the
the
over
pressure
same
during
climb
higher
during
on
the
is
analysis
air
and
a
the
entering
it
ever
As there
fails to
be
cannot
are
instructions
the
of
first
system, install the
the
suc
the
test,
control
entire
the
of
analyzer
the
How
carburetor.
a
On
in the
that
system
and
analyzers, follow the
of
a
dual
outlet
pipe
manufacturer.
analyzer
the
carburetor.
calibrate
the
contains
For example, if the
valve.
side, install the
or stuck valve.
to
types
various
the
side
used
testing
cylinders,
the
of
performance
and
of
method
com
adjustment
more
the
climbs
fuel
of
ratio
the
gas
exhaust
rings are
past the rings.
test, if
remains
or
Engine Service
If ap
rings.
leaking. If
pounds
is leakage
compression
steadily
the
past
reading is obtained, the
original reading, there
climb
leakage
seal
same
satisfactory, but
pression
the compression test. The
and repeat
temporarily
proximately
two
1 General
Chapter
is
valve
in the left
exhaust
opposite
exhaust
the
on
gas
right
muffler outlet pipe.
3. MANIFOLDS AND EXHAUST GAS CONTROL VALVE
Hot
exhaust gases are
fold to
diverted into the intake
mani
the heat necessary to vaporize the in
provide
coming fuel-air
mixture and
to
and carburetor
icing during
cold engine operation.
hot
by
directed into the intake
exhaust gases are
thermostatically
a
minimize engine
controlled
valve
stalling
The
manifold
located in the
exhaust manifold.
a
chamber
the intake manifold
exhaust
All
manifold
8-cylinder
through
the
through
which
an
riser
are
where
Blow
cylinder
sure
intake
section
the hot
exhaust
On
intake
gases
the
are
carburetor,
directed.
with
from the
compressed
center
in
a
air.
exhaust
suitable
Scrape
passage
solvent, then
three
tube
a vacuum
inches
with
all
carbon
below the
a
of
deposits
carburetor
used
fresh
the
check
pump to
moistened
Inspect the
Replace
manifolds
make
would
all
Make
air.
choke
Block
studs
that
four-barrel
tube
that
car
passes
follows:
a
off
steady reading
one
opening
then connect the
a
of
the
of
vacuum
If the pump does
opening.
the tube should be
fects that
as
obtain
finger,
other
heat
air
steady reading there is
a
8-
the
otherwise
a
with
for leaks,
vacuum.
pump hose to the
dry
hot
the
of
compressed
with
completely open,
manifolds
through the manifold
passage
as
acts
be impaired.
and
and
manifolds
are
the carburetor
under
and
manifolds
buretor,
a
of
action
passages
choke
automatic
the passages
maintain
them
the
out
into
contain
heating
carbon
exhaust gases.
Adjust
manifolds
This
manifolds.
insulator restricting the
cast
which
is
are
attached.
intake
center
(heat riser)
section
gases
exhaust
Manifolds
Clean the
the intake
of
operation will
On the 6-cylinder engine, the hot
directed into
heat
not
leak in the tube
replaced.
for cracks, leaks,
them
are
or
other
for further
unfit
stripped
or
de
service.
otherwise
dam
aged.
Remove
CLOSED (HEAT ON)
have
all
entered
filings
the
foreign
and
manifolds
as
a
matter
result
of
that
may
repairs.
Check
the
thermostatic
spring
to
make
sure
it
is
CLOSED
(HEAT
ON)
OPEN (HEAT OFF)
1001
Fig.
7 Exhaust
Gas Control
Valve 8-Cylinder
-A
Engines
Fig.
2 Exhaust
Gas Control
Valve 6-Cylinder
Engine
Section
hooked
The
the stop pin. The
spring stop is
on
the valve
housing
action of
Check to
hand to
ly
the valves is
make sure the
top
illustrated in Figs. 1
spring holds the
Actuate the
cold.
it
make sure
the
at
of
the valve is properly installed.
when
the engine is
when
3 Manifolds and
freely
moves
2.
and
valve closed
by
counterweight
through approximate
1-11
operating temperature
a
ever,
Rapidly
is
pressure
is
engine
at
counterweight.
the
sure
The
binding.
rotation without
is
valve
4.
closed
and
operating temperature
is
engine
at
normal
trating
high
Free
rpm.
stuck
pene
a
with
valves
is
oil or graphite mixture.
ROCKER ARM ASSEMBLY, PUSH RODS, AND CYLINDER HEADS
Rocker Arm
Clean
the
when
at
operated
valve
open when
90
of
very
when
open
make
How
speed.
is designed to
valve
normal
idle
the
to
to
engine
The
opens.
momentarily
will
valve
applied
the
accelerate
at
running
properly operating
light finger
the
and
Assembly
the parts thoroughly. Make
all
that
sure
all
oil passages are open.
Check the
the
checking the I. D.
by
shaft
the O. D.
and
arm
limit),
replace
shaft
shaft.
each
rocker
the
rocker
of
If the
arm
and
bore
arm
between any
clearance
the
shaft and/or
the
scuffs.
rocker
valves are
for
pad
the
at
If the
grooved radius.
a
rocker
Do
arm.
valve
pad
attempt
not
the
of
end
rocker
arms
is grooved,
replace
true this
surface
to
the
the
of
adjusting
for
arms
rocker
ball
the
and
rocker
stripped
the
of
end
and
screws
or
the push
broken threads,
for
screw
adjusting
rod
nicks,
or excessive wear.
scratches,
Check for broken
drain tube for
the
or
not
and
springs
and
inspect the
oil
sharp bends.
rods
cylinder
scratches
with
they
the
between ball
3). If the
cup
not attempt
0.020 inch
to
for
push
wear.
excessive
head
more
gasket
an
with
to
solvent
re
and
the
surface
gasket
cracked.
0.010 inch from
than
Remove
surface.
all
burrs
stone.
oil
Check the flatness
of
the
cylinder
head
or
are
gasket
sur
0.006 inch
0.003 inch in any 6 inches.
Valve Seat Runout
Check the
straight-
all,
valve
seat
runout
with
(Fig. 5). Follow the instructions
engine
by
rotating
facturer. The total
can
be
checked
inch (wear limit).
also
centers with a
the
of
end
checked
They
closed.
valve
and
or
installed in the
runout exceeds
Do
rod.
are
grind
or
plane
with a
grease.
face (Fig. 4). Specifications for flatness
socket
be visually
can
rods
push
while
them
the
the
for nicks, grooves, roughness,
The
ness
and
and
bores
Replace the head if it is
nicks.
maximum over
end
dirt,
sealer,
Check the head for cracks,
Do
guide
valve
cleaning tool. Use cleaning
move old gasket
Push Rods
Check the ball
the
Cylinder Head Flatness
locating
cracks or
Runout Typical
Rod
clean
removed,
guide
for burrs
Check the
end
valve
by
grinding.
3 Push
Fig.
arm
hone.
Inspect the
10O3-A
Inspect
rocker arm.
bore for nicks, scratches,
Dress up minor surface defects with a
the
PUSH ROD
fixture'
Holding
the shaft approaches 0.006 inch (wear
and
and
or
scores,
the
of
rocker
the
between
clearance
runout
should
an
of
accurate
the
not
gauge
exceed
gauge
manu
0.0025
dial indicator (Fig.
at
any point, discard
straighten
push
rods.
Cylinder Heads
To
head, do
is
off
the
to
stalled
a
scratch
the
surfaces
the
cylinder
while
the head
of
holding fixtures
engine.
AND INSPECTION. With the
protect
from the
posits
machined
not remove
CLEANING
with
the
protect
scraper
the
the
valve
combustion
and
a
cylinder
wire
head
seats,
brush. Be
gasket
carbon
remove
chambers
and
valves
valve
careful
surface.
in
de
heads
not
to
After the
0(3) CHECK
(5) CHECK
Fig.
DIAGONALLY
ACROSS CENTER
4 Cylinder
Head Flatness
1O04-A
1-12
1 General
Chapter
Engine Service
Runout Gauge
1005- A
Fig.
5 Valve
Seat
Runout Typical
valve
seat
exhaust
width
valve
the
valve
seat
limits
width
seat width
(Fig. 6). The intake
0.060-0.080 inch
are
limits
are
and
the
(Fig.
ream a valve guide
oversize
stem,
following
the
inch O.S.
a
to install
reaming kit is
reamer
pilot
and
0.030-inch
reamer
reamer
with
with
When going from
valve,
always
a
a
a valve with an
combinations:
0.003-
a
0.015-inch O.S.
standard
size
use the reamers
in
and
a
to
over
an
sequence.
Always
the
valve
seat
after
the
valve
guide
is
reamed.
correct
measure
seats
of
should
the
valve
valve
face
VALVE
SEATS.
Refacing
of
the
be
centered.
This is important
tight
compression
wheels are proper
the
If the
remove
of
a
it
bring
clean
seat
seat
limits.
width
exceeds
to
up pits, grooves,
the
from the top
the
reduce
angle
from the bottom
to
wheel
(lower the
seat).
The finished
valve
or
seat
maximum
edge and/or
width
to
of
grinding
the
remove
wheel
(raise the
seat
stock
limit,
bottom
specifications
30
a
(Fig. 8).
angle
After the
within
enough stock
angle
to
45
true
is ground,
(Fig. 6). Narrow the seat, if
width
seat
(Fig. 8). Use
stock
a
valve seat runout.
valve
the
to
seat
to
remove
seat).
from the top
of
Use
the
valve
be closely coordinated with the refacing
face so the finished seat will match the
and
good
a
grinding
enough stock
the
necessary to
seat
REFACING
refacer
valve
60
grind
have
dressed.
edge
pilot
valve
to
Valve Guides
Reaming
will
seat
that the
sure
Remove only
a 0.015-
diameter pilot,
0.003-inch O.S. pilot,
a
ly
and
Grind the
available which contains
reamer with a standard
inch O.S.
size
7)
valve
fit. Be
0.070-0.090 inch.
REAMING VALVE GUIDES. If it becomes necessary
to
7
Fig.
Valve Seat Width
Measure the
007-A
so
that
mate
the
valve seat contacts
blue,
Seat Width Scale
center of
then
set
the
seat
valve
the
should
the
face. To determine
face,
valve
contact
in
coat
place.
TO REMOVE STOCK
FROM TOP OF SEAT,
WHEEL
USE
the seat
where
with
Rotate the
approxi
the
Prussian
valve with
TO REMOVE STOCK
FROM BOTTOM OF SEAT,
USE
WHEEL
30
60
VALVE SEAT WIDTH:
INTAKE
0.0600.080
EXHAUST 0.0700.090
1006- A
fig,
6 Valve
Seat Width
1008- A
Fig.
8 Valve
Seat
Refacing
Section
4 Rocker
Arm
Assembly, Push Rods,
and
1-13
Cylinder Heads
Tool-T52T-6135-CJD
Tool T53L-200-A
\
Tool
T53P-33623-A
(Handle)
(Adapter)
1009- A
9 Water
Fig.
Outlet
Installation
Plug
8-Cylinder Engines
light
of
pressure.
the valve
If the blue is transferred to the
the contact is
face,
center
If the blue
satisfactory.
is transferred to the top edge of the valve face, lower
the valve seat. If the blue is transferred to the bottom
edge
the
of
face,
valve
After refacing the
lightly lap
in the
compound.
Remove
and
seat
after
WATER
engine
the
are
other,
valve
the
a
the
head
practice
grade
8-
lapping
from the
plug
is
installed
outlet
at
EN
rear
sending
opening
at
cylinder
heads do
the
of
the
unit
rear
either right or
right
adapter
of
the
have
not
installed; therefore, they
head
a
water
is installed in the
left
either
can
and
head.
tem
water
Replacement
the plug
be readily
or
adapter
adapted
for
left installations.
bank to
in the
water
Water Outlet
Plug
Install the plug (Fig. 9). Clean the plug
oughly.
DRILL
the
perature
valve
CYLINDER
cylinder
Unit Adapter Installation
to
assemblies of each particular
one
Sending
8-Cylinder Engines
operation.
interchangeable from
a
good
compound
1 Temperature
Fig. 7
seat.
medium
CONNECTION
cylinder
provided
valve
it is
seat,
with
lapping
OUTLET
GINES. The
valve
all
the
raise
101 1-A
Coat the flange
of
the plug
recess
thor
with water resistant
Vi INCH
HOLE IN
PLUG
INSTALL TOOL
INTO ADAPTER
1010-A
f/g.
10 Water
Outlet
Plug
Removal
8-Cylinder Engines
Fig.
12 Temperature
Sending
Unit Adapter Removal
8-Cylinder Engines
1-14
install it
sealer and
plug in
casting
To
1 General
Chapter
flange
facing
Drive the
out.
slightly below the
or
surface.
remove
center
the
flange is flush
the
until
with
the
water
plug, drill
Vfe-inch hole in
a
it
the
ter
The sending
resistant
sealer
toward the inside
adapter
To
adapter recess thoroughly.
water
with
the
in Fig. 10.
as shown
in
it is flush
until
the
is installed
unit adapter
in Fig.
as shown
adapter
slide
with
head. Drive
cylinder
the casting
with
the
surface.
adapter, thread the impact hammer
the
remove
install it
and
the
of
Coat the adap
handle into the adapter, then tighten the lock
Unit Adapter
Sending
11. Clean the
undercut
the plug and remove
of
Engine Service
(Fig. 12). Remove the
adapter
nut against
by
using the
hammer.
5. VALVE MECHANISM
The
valve
inspection
critical
points
tolerances
and
illustrated in Fig. 13. Both the intake
are
exhaust valves are the
rotating type
the
of
and
incorporate
which
Remove
a
fine
carbon
all
brush
wire
Inspection
and
Inspect the
or
and
varnish
buffing
burning
as
that
Inspect
locks,
are
with
the
defects. Inspect
the
of
head for
valve
valve
cracking.
stem
signs of
Defects,
such
Discard
removed.
severely damaged.
the
and
valve
of
the end
pits, grooves, etc., may be
minor
valves
and
erosion, warpage, and
or
edge
other
or
Check the
grooves or scores.
valve
against
the
valve
springs,
normal
rocker
without
lifting
retainers,
spring
Position
tool)
The
limits
at
and
action
forth
obtain
the
0.0023-0.0037 inch. The
are
inch. If the
clearance
approaches
(Fig. 14). The
recommended
inch total indicator
inch total indicator
reading.
limit for
The
runout
proper
SPRING
pressure
guide
valve
with
the
of
limit is 0.0045
clearance
stem
limit is 0.0065
wear
pressure
of
71-79
145
when
pounds).
Check
PRESSURE.
(Fig. 16). The
pounds
compressed
limit, try
a
when
Weak
to
valve
springs
the
spring
should
compressed
exert
to
or a pressure of
for
a
1.780
161-177
1.390 inches (wear limit
springs
cause
poor
engine
is 0.0015
reading.
clearance
guide
runout
clearance
limit is 0.002
wear
Model TV-2 Runout Gauge
VALVE STEM CLEARANCE. Check the
valve
face
valve
wear
the
upper sur
new valve.
pounds
VALVE FACE RUNOUT. Check the
wear
limits
parallels
clearance.
valve
exhaust
that
stem
valve
recommended
valve stem.
(division factor
stem
inch. The
spherical sec
guide
by 2
0.001-0.0024 inch. The
with
indicator reading
valve
actual
intake
plane
a
the
take
and
inches (wear limit 64 pounds)
parts.
on
the tool from the
to
the
to the
approximately
recommended
are
dial indicator
center portion of
face. Divide the indicator reading
the
a
90
the tool
of
VALVE
for defects. Discard any defective
sleeves
flat tip
tion
of
the
and
head for pits, grooves, scores,
the stem for a bent condition
for
from the
wheel.
face
valve
a
valve guide.
Move the tool back
umbrella-type valve stem seals.
Cleaning
the
surface of
each
tool
in its
valve
in
shown
valve
Fig.
stem
to
respective
15
or
its
equivalent.
Install the tool
and tighten
the
away from its
-
Va"
set
on
the
valve
stem
until
screw, then permit the
seat
until
the tool
fully
valve
contacts
seated
to
the
drop
upper
MINIMUM
REFER TO SPECIFICATIONS
FOR CORRECT DIAMETER
z
i
f/g.
DO NOT REMOVE MORE THAN 0.010 INCH
1015-A
101 4- A
73 Critical
Valve Tolerances
Fig.
14 Valve
Face Runout
5 Valve
Section
performance; therefore, if the
approaches the wear
limit,
pressure
the
replace
of
surface
against
valve
speed engine
the spring
of
the engine should be measured (Fig. 17).
Use dividers to
underside
Dial Indicator
S-8680-A
-
spring.
spring load is necessary for efficient high
operation; therefore, the assembled height
the
Tool
any spring
VALVE SPRING ASSEMBLED HEIGHT. Correct
installed in
1-15
Mechanism
the
the assembled height from
head spring pad to the
the spring retainer. Check the dividers
of
of
a
measure
cylinder
If
scale.
the
assembled
height is 113/16
install
the
greater,
necessary 0.030-inch thick
between
the
cylinder head spring pad and
spacer(s)
inches
the
or
valve
spring to
recommended
install
spacers
excess
of
ing
the
loss
bring
dimension
unless
the assembled height to the
of
12%2
inches. Do
113/16
-
Use of
necessary.
lead
valve springs which will
not
Fig.
in
spacers
in
recommendations will result
1016-A
load
to excessive
Valve Lash Adjustment
Reference is
VALVE SPRING SQUARENESS. Check
squareness
a
using
steel
square
and
spring for
each
a
plate
surface
(Fig. 18). Stand the spring and square on end on the
surface plate. Slide the spring
up to the square. Revolve
the
spring slowly
top
coil
out
of
and
the
observe
the spring and the
of
If the spring is
square.
y16 inch,
than
square more
between the
space
(cold)
pression
closed
The
Valves
valve
is in line
ordinated
finished
that the
have
refacer
pits
valve
and
face
up the
runout
stock
enough
y32
mcn
will
valve
face
match
will
that the
so
the
valve and seat
tight fit. Be
sure
to
the
with
timing
the
obtain
that the
run
to
valve
to
a
correct
If the
after
true
the
to
too hot in the
head
arm.
fit in the
threads.
rocker
is
the
on
on
com
at
the
valves
are
damper
crankshaft
pointer.
adjusted
located
threads
"no go")
and
clearance
by
means
the
on
which
of
push
screw
not
has
the
self
rod
end
an
until
threads
are
locking
the
of
interference
are
the
lead
center
in full
con-
remove
the
to
valve
replace
Valve
Spring
Tester
the
engine.
m
Grind
the
of
off
all
valve
more
remove
or
grooves
stem, then
chamfer
than 0.010 inch
lap in
the
pound
to
match
compound
with
valves
the
from the
as
seats.
valve
Be
grade
to
sure
and
seat
Do
not
lightly
lapping com
to
remove
after
the
all
If the
the
be
wear
lapping
PRESSURE
Valves
to
valve stem
limit, it is
for the
with
oversize
inch
are
stem
available
seat when
SCALE
READING
Fitting
reamed
LENGTH
the
operation.
Select
...
end
stem.
good practice
medium
a
necessary.
from the
After refacing the valves, it is
from the
marks
score
be
integral hex
provide an
reached
screw
can
(Fig. 19).
The first three threads
the adjusting
piston
the
T.D.C.
both
("go"
arm.
of
end
when
gauges
Interference is
of
the
at
stroke
The adjusting
and special
1
angle.
of
grinding,
timing
preliminary
to placing No.
piston
mark
a
45
runout or
edge
rocker
1
the proper
screw
adjusting
portion
excessive and/or
and grooves.
pits
the
as
is
the
grind
head is less than
valve
so
operation
refacing
valve
co
properly dressed.
wheels are
grooves,
Remove only
clean
the
angle of
be closely
should
seat
good compression
a
grinding
If the
valve
This is important
valve seat.
will
the
with
compression
for
procedure
(T.D.C.)
Number
Valve lash is
operation
refacing
and
in the
adjustment
center
stroke.
the
of
end
used
Refacing
lash
valve
top dead
on
made
Step-type feeler
it.
replace
Stem Clearance
overstress-
spring breakage.
and
15 Valve
the
valve guide clearance approaches
recommended
next
oversized
diameters
for
of
service.
valve guide
is
that the valve guide
valve
stem.
0.003, 0.015,
Always
reamed.
Valves
and
0.030
grind the valve
1017-A
Fig.
76 Valve
Spring Pressure
1-16
1 General
Chapter
Engine Service
UNDERSIDE OF SPRING RETAINER
SURFACE OF SPRING PAD
Fig.
tact
with
17 Valve
101 8-A
Spring
the threads in the
Assembled Height
rocker arm.
interference is reached, it
of
should
When the
take
minimum
a
3 foot-pounds (36 inch pounds) to turn the
further.
screw
of
It is very important that the
close as possible
is
set
to the correct
too close, the
valve will
valve
lash be held
specifications.
open
point
Step-Type Feeler Gauge
as
If the lash
too early
and
late, thereby, resulting in rough engine idle. Also,
burning and warping of the valve will occur because
they cannot make firm contact with the seats long
to
the
cause
cool
valve
causing
valve
lobe is
likely
the
pattern
contact
tions
If the lash is excessive, it
properly.
to
too
open
and
close
will
too early
bounce. In addition, damage to the cam
because the tappet foot will not follow
of
the
cam
lobe, thereby
between these two
are
late
given
parts.
causing
Valve lash
a
shock
specifica
If the
been
a
preliminary
ing
head
cylinder
the
(cold)
engine.
tune-up, follow
the
or
installed, it
removed and
mechanism
be necessary to
is
for
made
start
an engine
adjustment procedure.
numbered
are
cylinders
from front to rear, 1-2-3-4-5-6. The
valves are arranged
from front to rear, E-I-I-E-I-E-E-I-E-I-I-E.
in Table 4.
Preliminary Adjustment
the
all
noted, then
than
check
the torque
adjusting
replace
the
screw.
arm
rocker
Make two
that
with
the
and
adjusting
on
screw
the
equal
marks
timing
the damper
Rotate the
the end
of
Table
damper
apart
xh
of
the distance
circumference).
No. 1
lash for No. 1
4 Valve
piston
is
near
T.D.C.
Adjust the intake
cylinder.
Lash Specifications
Intake & Exhaust
Final (Hot)
Intake & Exhaust
6-Cylinder Engine
0.019
0.019
8-Cylinder Engines
0.020
0.019
Preliminary (Cold)
Engine
1019-A
18 Valve
Spring
Squareness
self
unsatisfactory,
approximately
compression stroke.
and exhaust valve
new
mark, the damper is divided into
crankshaft until
the
is less
screw.
crankshaft
represents
parts
a
screw
120
Vfc"
at
a
still
(120
around
NOT MORE
to turn the
to turn
If this is
marks
chalk
(Fig. 20). Space the
three
required
required
interference is
until
3 foot-pounds (36 inch pounds), try
locking
so
screws
adjusting
further. If the torque
Fig.
has
make
before
adjustment
adjustment
final
the
lash
valve
If the
rocker
will
6-CYLINDER ENGINE. The
Turn
THAN
Adjustment Typical
Lash
close
too
enough
79 Valve
Fig.
1020- A
Section
Repeat this
turning
tion
the crankshaft
of
for the remaining
procedure
rotation,
order sequence
while
Vz
turn
set of
5 Valve
adjusting the
in the
valves
Rotate the
valves,
time, in the direc
at a
firing
at
the
end
following
for
engine
approximately 1200
tures.
With the
a
minimum
minutes
idling,
check
the
lash.
valve
4
from front to
The
valves
rear-right
are
cylinders
are
numbered
bank, 1-2-3-4; left bank,
from front to
arranged
rear
5-6-7-8.
both
on
banks, E-M-E-E-I-I-E.
Preliminary
Turn
all
then
noted,
screws
adjusting
check
the
torque
required
to
turn
the
further.
screw
to turn the
required
screw
is less than
3 foot-pounds (36 inch pounds), try a new self locking
adjusting screw. If this is still unsatisfactory, replace the
rocker arm and
Make three
adjusting
chalk
(Fig. 21). Space the
that
with
the
equal
marks
marks
timing mark,
parts
the
around
on
the crankshaft damper
90
approximately
the damper
Va
represents
damper
No.
2 Intake
No.
5 Exhaust
No.
7 Intake
Rotate the
crankshaft
180'
T.D.C.),
on
SET
NO. 1
STROKE
STEP 4
STEP 2
apart so
is divided into
of
the
distance
adjust
the
(this
following
No. 8-Exhaust
No. 5-Intake
No.
puts
valves:
180
(this
puts
lowing
270, or 3A turn from
on T.D.C.), then adjust the fol
crankshaft
No. 3
piston
valves:
3Intake
No. 2-Exhaust
No.
No. 3-Exhaust
No. 6-Intake
No. 7-Exhaust
No. 8-Intake
Final Adjustment
for
engine
approximately 1200
With
tures.
the
minimum
a
to
rpm
engine
of
minutes
engine
stabilize
idling,
30
the
check
at
tempera
lash.
valve
Adjust the lash if necessary (Fig. 19).
Valve
The
Timing
timing
valve
is
performance
should
be
checked when poor engine
noted and all other
buretion, ignition timing,
etc.
checks,
such as
fail to locate the
car-
cause of
the trouble.
circumference).
valve
timing is checked,
check
for
a
bent
PISTON ON T.D.C. AT END OF COMPRESSION
ADJUST NO.
1
INTAKE & EXHAUST
STEP
1
SET
-
NO.
STROKE
STEP 3
NO. 5
-ADJUST
1
PISTON
-ADJUST
ON T.D.C. AT END OF COMPRESSION
NO. 1, 4, 5, EXHAUST & NO. 1,
2, 7 INTAKE
NO. 3
INTAKE & EXHAUST
INTAKE & EXHAUST
STEP 6
STEP 3 ADJUST NO. 2
-ADJUST
NO. 4
INTAKE & EXHAUST
INTAKE & EXHAUST
Fig.
then
turn
No. 4-Intake
Rotate the
ADJUST NO. 6 INTAKE & EXHAUST
-ADJUST
Vz
or
No. 6-Exhaust
Before the
STEP 1
the
adjust
4 Exhaust
piston
T.D.C.
screw.
(90
four
stroke, then
No.
Run the
If the torque
near
1 Intake
interference is
until
is
No.
Adjustment
the
compression
piston
1 Exhaust
Adjust the lash if necessary (Fig. 19).
8-CYLINDER ENGINE. The
the
of
No. 1
No.
at
to stabilize engine tempera
rpm
engine
30
of
crankshaft until
valves:
(1-5-3-6-2-4).
Final Adjustment.
Run the
1-17
Mechanism
STEP 2
STEP 3
-
-
ADJUST NO. 6 & 8 EXHAUST & NO. 4 & 5
INTAKE
2, 3, 7 EXHAUST & NO. 3, 6, 8 INTAKE
ADJUST NO.
1021-A
20 Preliminary
Valve Lash
6-Cylinder Engine
Adjustment
1022- A
Fig.
27
Preliminary Valve
Lash Adjustment
8-Cylinder Engine
1-18
Chapter
timing
compression
stroke
aligned
the
with
If the
the
valve
the
check
T.D.C.
in the car,
Install
proceed
a
quadrant
the No. 1 intake
rocker
arm
position.
as
then install
a
the
Engine Service
the
actuating
to T.D.C.
timing
on
the
is
pointer
the damper.
on
not within
specifications,
check
timing
installed
the engine
follows:
the
on
valve
damper. Back
adjusting screw, then
one
side
and
secure
slide
the push
the
of
it in this
rod
Table
5 Valve
cam
lobe. At this
the
the dial indicator
on
the heel
point the push rod will
be in its
Compare
the
is checked,
opening
the
check
Cam
Lift
Crankshaft
Degrees
Cam
Lift
0.016
8-Cylinder
18
B.T.D.C.
0.015
58
0.015
66
0.013
A.B.D.C.
or
the
sprockets
all parts
air.
in
worn
wise
be
SIDE OF CHAIN
point on
the left
side of
the block
the
the
of
the
to the
should
not
should
DISTANCE A. TAKE UP SLACK ON RIGHT SIDE
SIDE OUT WITH THE FINGERS AND MEASURE
LEFT
AND FORCE
1024-A
DISTANCE B. DEFLECTION IS A. MINUS B.
Fig.
Timing
Chain Deflection
ment
INSPECTION.
of
signs
result
with
a
Check the
by
of
point
to the
opposite
side of
the
chain out with
the
the
right
Clean the
reference
circle
lobes for
cam
wear.
Lobe
pit
wear
general area
detri
not
therefore, the cam
the cam lobe lift loss has
the cam,
of
and
suspected
over
the
worn
top
lobes
of
the
subtracting the measure
diameter (Fig. 23).
journal to
measuring the diameter
exceeds
camshaft
This pitting is
measuring
micrometer
camshaft
a reference
in the
in pitting in the
until
replaced
the base
Establish
abnormal
the lobe.
operation
checked
to take up the
front)
dry. Inspect the
0.005 inch. The lift
be
of
be
a clock
chain and/or sprockets.
AND
may
in
crankshaft
If the deflection
Bearings
and
mental
lobe
timing
nose portion of
exceeded
22
com
needs replacement.
the
and
and wipe
solvent
characteristics
AND MEASURE
the
The deflection is the difference
the
replace
ting, scoring,
REFERENCE POINT
side of
Vz inch,
in
A
all
distance between the
the
chain.
on
slack
measurements.
CLEANING
ESTABLISH
that
crankshaft
between the two
Camshaft
SIDE.
0.016
A.T.D.C.
from this
measure
and
and measure
and
point
LEFT
item
chain.
(Fig. 22). Rotate the
fingers
ON
one
from the
viewed
direction to take up the
chain, then force the left
UP SLACK
10
recommended
if any
replaced
direction (as
chain
TAKE
0.019
9A.T.D.C.
DEFLECTION CHECK. Rotate the
Inspect the
for cracks,
RIGHT
POINT
Cam
Lift
sol
slack on
REFERENCE
B.B.D.C.
damaged teeth. It is
ponents
and
to
CHAIN, CAMSHAFT AND BEARINGS
Chain
for broken links
valve
engine
Crankshaft
Degrees
61B.B.D.C.
chain
the
on
Closes
Crankshaft
Degrees
compressed
the
rotate
Opens
0.019
with
indicated
Timing Specifications
53A.B.D.C.
them
lobe
cam
closing.
valve
0.016
dry
to
continue
B.T.D.C.
and
of rotation
(Table 5). After the
quadrant with specifications
17
vent
continue
and
specified
degrees
crankshaft
Cam
Lift
CLEANING AND INSPECTION. Clean
the
registers
6-Cylinder
Timing
the tappet is
until
lift (Table 5).
Closes
6. TIMING
move
Exhaust Valve
Opens
Crankshaft
Degrees
rod
damper slowly in
crankshaft
slowly in the direction
crankshaft
push
the push rod
Zero the dial indicator
Intake Valve
Engine
as
plane
same
rotation
of
position.
turning
the
is in the tappet socket,
dial indicator in such a manner as to have
sure
the direction
until
crankshaft
in the
indicator in the
the
of
point
(Fig. 24). Turn the
lowest
order of accessibility.
with
and
socket
ment
sprocket, crankshaft sprocket,
in the
assembly to
Make
piston
if
mark
camshaft
valve
1
see
and crankshaft
camshaft,
off
and
timing is
timing chain,
To
the No.
Bring
pointer.
1 General
of
the
bearing
journals
clearances
and
the
I.D.
by
of
Section
6
Timing Chain, Camshaft
and
1-19
Bearings
Dial Indicator
BE SURE
TO PLACE
INDICATOR TIP
IN CENTER
OF PUSH
ROD CUP
1026- A
:o.v.w>.-i;...'...
LOBE UFT
A-B
timing. Loosen the valve
Lobe Lift Measurement
then
the
bearings. The
recommended
0.001-0.003 inch. The
clearance
journals
camshaft
placed.
be
are
for
undersize
the
bearings
secure
gear
for broken
it in this
or
size
nicks
the
to the
similar
procedure
dial indicator in
such
to have the actuating point
in the
rod
push
for
push
rod
socket
in the
and
for checking
of
same
the indicator
plane
24). Turn the
(Fig.
movement
the
as
crankshaft
damper slowly in the direction of rotation
tappet is on the heel of the cam lobe. At this
push rod will
be in its lowest
until
the push rod is in the
pare
the total lift recorded
fications.
valve
until
the
point
the
Set the dial indi
position.
zero, then continue to rotate the damper slowly
fully
cam
CAMSHAFT LOBE LIFT (CAMSHAFT INSTALLED). This
is
a
re
shaft machined surfaces with a smooth oilstone.
procedure
and
side
is in
or chipped
from the
one
push rod
the
sure
a manner as
cator on
or
Make
the tappet socket, then install
teeth.
Remove light scuffs, scores,
position.
adjusting screw,
assembly to
arm
rocker
arm
rocker
are
journal diameters.
undersize
Check the distributor drive
to
pre-finished
the
slide
camshaft
the bearings should be
available
0.015-inch
and
limit,
wear
and/or
replaced,
Bearings
standard
the
ground
limits
clearance
limit is 0.006 inch. If the
wear
approaches
should
Lobe Lift
102 5- A
23 Camshaft
Fig.
24 Camshaft
Fig.
'/...
=
Continue
indicator
reads
accuracy
of
to
raised position.
the indicator
on
the
rotate
Com
with speci
engine
the
until
This later step is a check
the original indicator reading.
zero.
the
on
7. CRANKSHAFT AND MAIN BEARINGS
The
crankshaft
8-cylinder
is
and
engines
6-cylinder
engine.
controlled
by
by five
supported
by
four
Crankshaft
the No. 3
play in
bearing
bearings in
bearings in the
main
end
main
main
all engines
is
flanges.
Handle
fractures
or
damage
with
to the
care
finished
to
avoid possible
surfaces.
main
blow
an
journals
are:
inch),
out
all
oil
crankshaft
passages with
and
connecting
oilstone.
scores.
rod
Dress
com
Regrind severely
Measure the diameter
of each
journals for cracks,
minor
imperfections
marred
journal in
journals.
at
be
should
0.00025-inch
main
and
out-of-round
undersize
connecting
(wear limit
0.0005-inch taper (wear limit 0.001
and
reground
CRANKSHAFT
toward the
the
scratches, grooves, or
with
limits for
recommended
or
the
approach
to
for
size
wear
the
limits, they
next
undersize
bearing.
air.
Inspect
determine out-of-round, taper,
(Fig. 25).
inch). If the journals
crankshaft
solvent, then
pressed
The
0.005
CLEANING AND INSPECTION. Clean the
with
to
condition
rod
Crankshaft
the
places
least four
END
rear of
PLAY.
the engine.
contact point rests against
the indicator
axis
26). Set the dial
forward
limits
and note
are
is
Force
Install
a
the
crankshaft
dial indicator
the crankshaft
flange
parallel to the crankshaft axis
on
zero,
then
the reading
push
so
and
(Fig.
the crankshaft
the dial. The end
play
0.004-0.008 inch for the 6-cylinder
engine
on
1-20
Chapter
A VS B
=
Engine Service
VERTICAL TAPER
I. FORCE CRANKSHAFT FORWARD, RELEASE PRESSURE
HORIZONTAL TAPER
2.
=
C VS D
A VS C
1 General
AND
B VS D
INDICATOR
INSTALL DIAL
OUT OF ROUND
CHECK FOR OUT-OF-ROUND AT EACH END OF JOURNAL
=
4.
^-MTmm
mm
*
(wear limit 0.012
8-cylinder
If the
end
inch)
thrust bearing. If the
limit, inspect
nicks,
dirty, they
the
end
the thrust
the
wear
bearing faces
probably
bearing
thrust
not
were
and
align
procedure, then
recommended
limit,
replace
aligned
the
not
faces
recheck
or
Install
following
Crocus
The
the
require
give
the
proper clearance with
the
the
to
two
with
clearance
able,
replace
Always
that
maximum
bear
the
existed originally.
of
the
bearing failure
After grinding,
undersize
same
bearing
proper
Too
due to
the
oil
Red
then
be
used as a
engine
and
polishing
agent.
marked
use
to
Standard bearings
by
a
daub
are
not
journals that have been
on
proper
service
in
"blue"
"red"
of
or
the clearance;
clearance.
selective
or
divided into
are
bearings increase
bearings decrease the
which
for
available
not
file
not
the
obtain
do
and
installation. Do
are
identified
fit
are selective
shims
use
bearings
marked
CLEANING
in
inserts
and
Inspect
the bearing.
holes,
cloth
fit,
are
Under
available
reground.
radius
a radius will result
radius ride of
chamfer
shoulder
also
Play
polishing
size upon
sizes only.
bearings,
size
small a radius will result
Too large
shaft.
blue
avail
for
journal
DIRT IMBEDDED
SCRATCHES
to give the
crankshaft.
reproduce
fatigue failure
in
the
the
"clean
will not
fit
sizes and are
paint.
ing. If the journal
grit
bearing inserts
reaming to
Selective
journal
next undersize
up"
may
lap bearing caps or
bearing clearance.
the end play.
Regrind
cloth
main
standard
JOURNALS.
REFINISHING
No. 320
a
End
Main Bearings
burrs,
defective
properly.
with
26 Crankshaft
the
minimum
for scratches,
are
journal
oil.
play is less than the
dirt. If the thrust faces
or
Fig.
0.002-0.006 inch for the
and
approaches
play
1029- A
Journal Measurements
(wear limit 0.010 inch).
engine
NOTE INDICATOR READING
1028-A
25 Crankshaft
Fig.
REAR, RELEASE PRESSURE
FORCE CRANKSHAFT TO
polish
the
scored,
OVERLAY WIPED OUT
AND
INSPECTION.
Clean
the
bearing
cap thoroughly.
each
chipped,
bearing
or
carefully.
worn
surface
Bearings that have
should
be
a
replaced.
S
INTO BEARING MATERIAL
SCRATCHED
LACK
BY DIRT
OF OIL
IMPROPER SEATING
J2
OVERLAY
GONE
PROM ENTIRE SURFACE
TAPERED JOURNAL
Fig.
RADIUS RIDE
CRATERS OR POCKETS
RADIUS RIDE
FATIGUE FAILURE
27
Bearing
Failures
1030- A
Section
Typical
are
examples
bearing failures
of
in Fig. 27. Check the
shown
that appear to be
satisfactory
bearings following the
7 Crankshaft and
their causes
and
bearings
clearance of
Plastigage. Fit
with
recommended
1-21
Main Bearings
new
procedure.
CHECKING MAIN BEARING CLEARANCE
Engine On Workstand
If the
engine,
crankshaft
leaving
been
not
the clearance
check
the
has
of
removed
bearing
one
from the
at
time
a
bearings securely fastened.
other
1. Invert the engine, remove one
bearing cap, then
wipe all oil from the journal and bearing.
2. Place
nal
Plastigage
a piece of
the full
width of
the
bearing
the crankshaft jour
on
and about
cap
Va inch
(Fig. 28).
off center
3. Install the cap and tighten the bolts to specifica
tions. Do not turn the crankshaft while the Plastigage
is in
place.
4. Remove the cap, then using the Plastigage scale
(Fig. 28) check the width of the Plastigage at the
widest
in
point
Check the Plastigage
get
two
to get the
order
the
at
minimum
narrowest point
clearance.
in
order
is the taper. If the
limits,
fit
select
not within
bearing.
new
a
is
clearance
To Block Installation
which
is
more
than
0.001 inch
out-of-round.
Engine On Workstand
bearing
clearance of one
time, leaving
at a
1. Support the crankshaft so its weight
the
29 Seal
ference may result, causing an early failure. It is not
recommended that bearings be fitted to a crankshaft
journal
Engine In Car
Check the
Fig.
to
the maximum clearance. The difference between the
readings
1032-A
Tool T 521-6701 -AGD
If the
crankshaft
has
not
been
removed
from the
other
press
the Plastigage
Position
weight
a small
and
jack
so
2. Follow
2-4
steps
Plastigage
on
on
the
it
will
bearing
adjoining the
Clearance Engine
provide an
under
bear
engine,
replace one
bearing
at a
time
leaving
the
other
erroneous reading.
against
the
counter
1. Invert the engine,
remove
the
bearing
cap
and
the
is
being checked.
"Checking Main Bearing
which
Workstand."
bearing
will not com
surface
In step 2,
instead
place
of
on
the
the
journal.
FITTING NEW BEARINGS.
journals
ever,
if
wear
a
evenly
bearing is
journal, be
sure
to
being
fit
minimum
Tool-T521-6701- AGD
an
out-of-round
clearance,
MEASURING
and
inter-
CHECK WIDTH OF PLASTIGAGE
0.002"
PLASTIGAGE
Installing
fitted to
How
bearing to the maximum
If the bearing is fitted to the
of journal about
Va inch off center
28
bearing
the
PLACE PLASTIGAGE FULL WIDTH
Fig.
main
and are not out-of-round.
diameter of the journal.
minimum diameter with
INSTALLING
Normally,
CLEARANCE
PLASTIGAGE
1031-A
Measuring Plastigage
1033-A
Fig.
30 Seal
To Retainer
InstallationTypical
1-22
1 General
Chapter
Engine Service
034-A
31
Fig.
half
upper
of
the
bearing
to
bearings
which new
are
to
bearing inserts and check the
When replacing standard bearings, it is
ance.
first try to obtain
blue bearing halves.
two
3. If the
try
two
the
to
practice
with
new
clearance
good
clearance
proper
specified
limits,
within
then
Bearing
Oil Seal Replacement
seal
retainer
bearing
or
2. Install the
standard
the desired
install
bearings do
limits,
undersize
not
bring
the
clearance
grind the crankshaft
one
time
ings securely fastened. Follow
New Bearings Engine On
leaving
steps
the
2-4
Workstand."
journal
new
sealer, install the
other
under
bear
"Fitting
Remember to
5.
Dip
the
travel.
use
to
expand
not
on
when
leaks
seals
cut
the
any
retainer or
bear
by
outside.
a
not
of
be
until sufficient
Backward
bearing
for the last Vi inch
ends.
The
are
oil.
oil, then
It may be
projecting
seals
Using
cap,
all
of
Do
not
designed
sealer
may
re
compressed
seals
side
for
into the parting
the cylinder block
air against
air
bubbles
leakage. The
on
has been
cap
oil
or retainer and
possible oil
time
the
appear
for
in
above test
newly installed
allowed
seals
seals
the seals to
seal grooves.
the
and
bearing
the block. If
Bearing
1. Install
or
performed
into the
Thrust
:**
seal
engine
grooves.
place
few drops
Blow
the oil, it indicates
iiiuiiii
into
seals.
retainer
from the inside
expand
in light
in the
dipped in
squirting
from the
should
the
side
lines between the cap
035-A
bolts to
expansion.
6. Check the
Pry Cap
without
tighten the
retainer and
them
the
tap
Do
sealer
tard this
32
in the
seal
retainer side seals
immediately install
of
Fig.
flush
seals
(Fig.
block
cylinder
23-28 foot-pounds torque.
necessary to
f^
the
seal grooves.
cut the seals flush.
cap (Fig. 30). After installation
4. Coat the rear oil seal retainer to block mating face
with
at a
cut
and
ing
bearings.
bearing
in the
seal
new
Clean the
cap.
block
cylinder
overlapping.
edges
3. Install the
journal,
Engine In Car
Replace
frayed
from the
oil seals
29). After installation,
4. If the
clearance of
bearings.
new
Rear Main
or a combination of red and
blue.
Cap
checking the
when
crankshaft
1. Remove the
is less than the
bearing halves
red
clear
the
support
the
be fitted.
2. Install the
33 Tighten
Fig.
Crankshaft Forward
Pry
Alignment
main
bearing
tighten the
2. Install the thrust
caps,
bolts to
bearing
cap
except
the thrust
specifications.
with
the bolts finger-
7 Crankshaft and
Section
tight,
then
pry the crankshaft forward against the
thrust surface of the upper half of the
bearing (Fig. 31).
3. Hold the crankshaft forward and
pry the thrust
bearing cap to the rear (Fig. 32). This will align the
1-23
Main Bearings
thrust
surfaces of
both halves
4. Retain the forward
and
8.
FLYWHEEL
and
are
the bearing.
pressure
tighten the cap bolts to
5. Check the
of
crankshaft end
on
the
crankshaft,
(Fig. 33).
specifications
play (page 1-19).
Conventional Flywheel
The flywheel
and
gear
ring
are
a
fit
shrink
replaceable as separate parts.
INSPECTION. Inspect the flywheel for cracks, heat
check, or other defects that would make it unfit for
further service. Machine the friction surface of the fly
if it is
wheel
0.045 inch
more than
ness,
If it is necessary to
scored or worn.
replace
of
from the
stock
for worn, chipped,
gear
damaged,
are
With the flywheel installed
the flywheel face
the face
the
sure
making
end
play
inch,
the
of
runout
flange. Replace the flywheel
will
runout.
remove
mounting flange. If
crankshaft
so
that it is full
crankshaft
machine
or
flywheel face if the mounting flange
the
runout
fly
the
for burrs between the flywheel
the
check
exist,
dial indicator
the flywheel face
against
0.010
exceeds
check
of
a
that crankshaft
so
flywheel
as
runout
and
wheel
flywheel,
rearward
be indicated
the
check
runout.
(Fig. 34). Turn the
If
cracked
the crankshaft,
on
that the indicator point bears
not
or
the ring gear.
replace
FLYWHEEL FACE RUNOUT. Install
or
thick
original
the flywheel.
Inspect the ring
teeth. If the teeth
forward
remove
no
1049- A
and
Fig.
burrs
crankshaft
is
excessive.
seated
a
blow torch
then knock it
when
off
enough
new
to slip
onto
not
side of
the gear,
hit
flywheel
the
gear.
expands
the flywheel. Make sure the gear is
of the
portion
If
removed
Runout Typical
this
from
gear
to
a
Do
heat any
temperature higher than
the shoulder.
not
limit is exceeded, the temper
will
be
the ring gear teeth.
Converter Drive Plate
The
evenly until the gear
gear
ring
engine
Do
the flywheel.
removing the ring
Heat the
the
on
against
properly
500F.
with
Face
mounting
RING GEAR REPLACEMENT. Heat the defective ring
gear
34 Flywheel
procedure
for Fordomatic
Fordomatic
for checking the
equipped
cars
is
converter
covered
drive
plate
in the 1957
Shop Manual.
9. CONNECTING RODS AND BEARINGS
The connecting
inspected
carefully
specifications.
these parts
A shiny
and
can
pin
skirt and
hole is
the
on
a
not
either a
of
should
be
conformance
to
caused
by
engine wear
grooves
pin
boss
connecting
in
proper
of
side
rod
the
is bent
relation
to the
piston
or
the
bearing wear can be caused
rod, an improperly machined
rod
bent connecting
tapered connecting
rod bore (Fig. 36).
Twisted connecting rods will not create an
easily
identifiable wear pattern, but badly twisted rods will
disturb the action of the entire piston,
rings, and rod
crankpin,
assembly
or a
and
may
be
the
cause
of
excessive
oil
consumption.
piston
(Fig. 35).
Abnormal connecting
by
for
parts
be readily identified.
surface
ring
related
checked
Various forms
usually indicates that
piston
and
rods
Cleaning
and
Inspection
Remove the bearings from the
them if
they
are
rod and
to be used again).
cap
Clean the
(identify
connect-
1-24
Chapter
1 General
Engine Service
PISTON WEAR CAUSED BY BENT ROD
OR MISALIGNED PISTON PIN HOLE
Fig.
ing
of
35 Wear
rod
Pattern On Piston Pin Boss Surface
in solvent,
the inserts. Do
Blow
out
all
ing bores for
maximum
not
rods
limit for
fractured,
the
signs
it
Check the
exceeds
should
be
piston pin
and
taper. The
out-of-round
worn
solution.
taper are 0.0004
and
these limits
and/or
if the
rod
replaced.
Inspect
have
ent
Rod Side Clearance
Connecting
bushing clear
bushing is so
rod
an
a
bearing
each
types
of
lowing
the
Fit
new
their
and
clearance of
For the differ
bearings that
bearings
where
refer
to
appear
to
causes
necessary, fol
recommended procedure.
After the connecting
over
or worn surface.
bearing failures
satisfactory.
Replace bearings that
carefully.
scored, chipped,
Fig. 27. Check the
be
to connecting
37
Fig.
the bear
recommended
Replace the connecting rod if the
that it cannot be reamed or honed for
ance.
the back
air.
fractures
of
and
cleaning
compressed
with
for
bore
rod
use a caustic
out-of-round and
inch. If the bore
is
including
passages
Inspect the
1045-A
check
the
ment
fixture.
rods are assembled
for bend
rods
twist
or
on
a
to the piston,
align
suitable
size pin.
Replace defective connecting
Inspect
each
connecting
cracks, scratches, grooves,
fections
with
out-of-round,
should
rod
taper,
be
or undersize.
and/or
reground
crankshaft
or scores.
a smooth oilstone.
the maximum limits
they
rod nuts and
to
Check
journal for
minor
each
imper
journal for
If the journals
if they
size
Dress
bolts.
The
manufacturer.
instructions
the
bend total difference using
on each side. If the bend
an
inch
8-inch
and/cr
exceed
be
of
the
maximum
recommended
twist total difference is 0.012
rod should
are
Follow
and
fixture
limit for
0.004 inch for
arbor and measured
twist is excessive, the
straightened or replaced.
severely marred,
for the
next undersize
Checking Connecting
Bearing Clearance
bearing.
1. Wipe
2. Place
surface
all oil
a
from the journal
piece
the full
Rod
Plastigage
of
width
of
the cap
bearing.
and
on
the lower
and about
bearing
Va inch
off
center.
3. Install the cap
and
foot-pounds torque. Do
the
Plastigage is in
tighten the
not
rod
bolts to 45-50
turn the crankshaft while
place.
4. Remove the cap, then using the Plastigage
check
in
the
to
order
Plastigage
IMPROPER GRINDING OF CRANKSHAFT JOURNAL
Fig.
36 Wear
Pattern On
1046-A
Connecting Rod Bearing
readings
limits,
get
at
of
the Plastigage
the
minimum
at
the widest point
clearance.
Check the
the narrowest point in order to get the
The difference between the two
is the taper. If the clearance is not within
maximum
BEARING WEAR CAUSED BY BENT ROD OR
width
scale
clearance.
select
fit
a new
bearing.
9
Section
Fitting
New Bearings
The connecting
m
standard
bearings
rod
sizes
and
red
for
are available
clearance; blue
use
If the
bearing
is
or
to the maximum diameter
not recommended to use
to file
bearing
it is
bearings increase
marked
is out-of-round, be
crankpin
lap
or
the
bearing
When replacing
practice to first try to
clearance.
good
clearance with two
blue
bearing
rod
cap, then
1. Remove the
from the cap
any type,
to
the
adjust
bearings,
the bearing
the connecting
from the
oil
foreign
or other
matter
inserts. In time, the dirt may distort the
and cause bearing failure.
4. Check the
5. If the
bearing
clearance.
specified
limit try two
or a combination of red and
6. If the
standard
the desired
within
blue.
bearings do
limits,
bearing halves is
red bearing halves
two blue
with
clearance
grind
not
bring
the
clearance
the crankpin, then in
bearings.
stall undersize
standard
obtain
halves.
the bearings
remove
journal,
crankshaft
bearing bores.
3. Install the upper bearing into
the rod assembly down firmly on the
Checking Connecting
Rod
Side Clearance
and rod.
2. Clean the
bearing
the crankpin. It
order
dirt
When instal
cap.
rod
the
less than the
to fit the
shims of
in
not get
in the
clearance.
sure
of
bearing
caps
color
are
bearing
do
ling bearings,
journals
on
bearings decrease
marked
service
1-25
Bearings
and
under
for
undersizes
blue. Red
and
Rods
Install the lower
that have been reground. Standard bearings
coded
Connecting
and
rod
After the connecting rods are installed,
clearance between the connecting rods on
(Fig. 37). The
6-cylinder
the rod, then
pull
journal.
crankshaft
inch)
engines are
the
side
each crankpin
clearance
limits for
0.003-0.009 inch (wear limit 0.012
0.006-0.016 inch
or
side
recommended
check
on
8-cylinder
(wear
engines
limit 0.019 inch).
10. PISTONS, PINS, AND RINGS
Cleaning
Remove
from the
varnish
solvent.
with a
Do
scored
grooves
to
clean
and
pistons.
surface on
from the
be
If the
ring
side clearance.
with
eroded
(Fig. 38). Make
bosses,
lower
ring
interfere
sure
the
oil
for scuffed, rough,
and
inner
portion
the
operation
the
the ring
at
ring
the
piston.
The step
cause
excessive
and
edge of
by detonation,
of
or
and/ or
Check the
or
the
piston
scale
following
holes,
pin
can
a
wear, wavy ring
damage from detonation
piston
and
to cylinder
ribbon
piston pins
and/or wear.
and rod
piston
offset
and
bore
the
or
lands, frac
pre-ignition.
clearance
ring
side
with
a
clearance
the recommended procedures.
Replace
ing
between the
show signs of excessive
tures,
the piston,
surface of
bent connecting rod. The normal wear
piston is shown in Fig. 39. Replace pistons
by
caused
tension
replace
areas near
caused
cleaning solution or a
Clean the ring grooves
the thrust
centerline
and rings with
pins,
the pistons for fractures
have high steps,
usually
gum or
are clean.
pin
will
are
head. Clean
piston
caustic
a
use
holes)
skirts.
Spongy,
piston surfaces and
that
not
(or
skirt,
piston
skirt,
groove cleaner
ring
shiny
pattern of a
piston
Carefully inspect
lands,
the
of
underside
from the
slots
Inspection
deposits from the
carbon
brush
wire
ring
and
showing
Check the
signs of
piston pin
fracture
or etch
fit in the
piston
bushing.
Replace
all
rings that
are
scored, chipped,
or cracked.
top
pre-ignition.
A
TOOL 7 521-61 10- A AD
NORMAL WEAR AREAS
1040- A
Fig.
38
Cleaning Ring
Grooves Typical
Fig.
39 Normal
Piston Wear Pattern
1041-A
1-26
Chapter
1 General
Engine Service
are
for
available
most
logue for
sizes available.
The
and
piston
temperature
block
cylinder
(70F)
Check the
engines.
the
when
be
should
room
at
fit is
piston
cata
parts
checked.
After any refinishing operation, allow the cylinder
bore to cool before the piston fit is checked.
Calculate
the size piston to be used
(Fig. 45), then
check
provide the
desired
Make
the
sure
dry. Attach
the proper size piston to
select
bore
piston and cylinder
ribbon that is free
should
be Vi-inch
bore
a
clearance.
tension
a
by taking
to the
scale
dents
of
or
wide and of
are clean and
feeler
end of a
burrs. The feeler
the
for the existing condition.
Position the ribbon in the bore
gauge
ribbon
thick
recommended
ness
length
entire
the
of
piston
location. Invert the
that the
1042- A
top
of
the
end of
is
the block and the
from the
at
pin
piston
install it in the bore
piston and
piston
that it extends the
so
90
1 Vi inches below the
about
piston
so
pin
is
to the
parallel
crankshaft axis.
Fig.
40
Checking
Hold the
Piston Fit
line
Check the
end
gap
and side clearance.
tice to always install new rings
engine.
piston
Rings
to
should
another
not
when
It is
good prac
be transferred from
regardless
one
If the
the
satisfactory.
scale
reading is
Pistons
Pistons
oversizes
Pistons
for
of
use
in
for
service
cylinders
0.020, 0.030, 0.040,
in
standard sizes and
aged
and
0.060-inch
oversize
piston, then try
If the
that have been rebored.
able
recheck
pull,
piston.
If
check
dam
a
fitted,
minimum allow
before trying
calculations
be
none can
for
a new piston.
reading is less than the
scale
remove
to be sure that the
has been selected,
proper size piston
are available
to
required
than the maximum
greater
recheck calculations
pull,
a straight
limits for the existing condition,
within
fit is
piston
allowable
Fitting
is
pull
in
scale
(Fig. 40).
ribbon
If the
mileage.
of
the
pull
slowly
the ribbon, noting the pull
with
the feeler
overhauling the
piston and
refinish
another
the cylinder for the
next size piston.
When
a
has been
piston
fitted,
it for
mark
sembly in the cylinder to which it was fitted.
If the taper and out-of-round conditions of the
der bore
are
satisfactory
cylinder
bore is
The
cylinder
piston
as
used
a
the
cylinder wall
proper
rings must
bore
and
grooves.
set
ring
be
First,
where
head
avoid
Fig.
41
Measuring
Piston
Ring
10*
Gap Typical
the
used.
normal
rings
for
size
piston
check
in the
are
to
each
ring for
to be
gap in the
proper
proper side clearance
in the
proper
gap
which
it is
down into the bore
area
square
damage
cylinder
Push the
ring
of a piston
ring is
WD
new
give
follows:
going to be
:.
will
"glaze."
for the
checked
for the
rings
cylin
that has not been re
cylinder
Position the ring in the
)
the
piston
piston clearance
limits. If the
within
remove
Select the
used.
new
service provided
be installed in
finished,
limits,
within
as
to
with
wear
ring
is
position
the
encountered.
(Fig. 41). The gap
0.010-0.027 inch for both
wall.
Use
or cylinder
ends
Use the
the ring in the bore
cylinder
to the ring
gap between the
not
bore in
of
the
ring
be
so
caution
the
to
bore. Measure
with
a
feeler
gauge
should
within
the limits
of
compression rings
(223, 272,
10
Section
292
inch engines)
The gap of the
cubic
engines).
be
should
0.012-0.029 (312
or
steel rail sections of
cubic
1-27
Rings
and
inch
the oil ring
0.015-0.062 inch.
If the gap is less than the lower
limit, try
ring
Pistons, Pins,
within
another
set.
After the gap has been checked, install the rings on
the piston
according to the instructions on the piston
ring package using the
side
clearance
42).
the compression rings
of
inserted between
gauge
Any
the ring
that occurs
wear
portion of
the lower land.
steps, the
piston should
freely
slide
the
around
binding. Because
out
If
be
the
the
piston
fit
pin
blue)
Pins
circumference with
ring
to the
refer
be
of
0.002 inch
and
hole in the
pin
expansion-type, piloted
and
the
to
reamer
slightly
light
cut.
the
revolve
reamer
tain
gauge should
limits
specifications
light thumb
a
0.001 inch
oversize
pins
piston
1044- A
(color
oversize
(color
fit
press
42
Checking Ring
cut.
Repeat the
Fig.
coded yel
Side
Clearance Typical
are available.
If the
vise
The
(70F). Standard
temperature
normal
low)
lower lands have high
recommended clearance
should
are color coded green.
coded
the inner
at
step
Piston Pins
Fitting
at
feeler
a
limits.
proper
The
a
replaced.
entire
with
ring
its lower land (Fig.
and
form
will
vary according to the engine,
for the
tool. Check the
approved
Use
reamer.
piston around
trial
and
bore,
ream
the
a pilot sleeve of
the
alignment of
the
reamer.
then
Set the
expand
the
bore. Take
pin
nearest size
to
is
bushing
main
to fit the
Install the
new piston pin.
If the
and
make
reamer
slightly
piston
pin
retainers
seated
fit
proper
for fit in the
ream
or
hone the
pin.
pin
in the
a new retainer at each end of
properly
the
pin
piston
bushing. If necessary,
rod
respective
until
procedure
Check the fitted
obtained.
When the
the
expand
another
a
bores.
Check the hole size, using the
bore is small,
the
pin
the
of
size
be reamed, use an
Place the reamer in a
piston must
the
grooves
and
rod.
Install
to hold it in
pin
installed,
are
in the
piston
make
sure
provided
place.
they
in the
are
piston
bore.
11. CYLINDER BLOCK
of
the
cylinder
overhaul, closely inspect the
engine
parts
disassembly
the
During
to
help diagnose
the
for
block
wear pattern on all
ent, the coating
area.
cause of wear.
Cleaning
Thoroughly
gasket
pipe
the
material
compressed
are
and result
threads
from
which
plugs
passages.
holes
clean
Blow
air.
and
a
to
oil
seal
passages, then
bolt
out all p? ssages,
sure
false torque
clean
for
cracks.
reading.
Use
a
Minute
may be detected by
mixture of 25% kerosene
Wipe the
part
dry
all
recommended
for the
and
and
Replace
binding
of
to the
naked
suspected area with
75% light
immediately
apply
a
motor
coating
oil.
of
at
the defective
for
burrs,
nicks,
imperfections
with
the cylinder block
of
the procedure and specifications
cylinder
head (page 1-11).
that show evidence
all expansion-type plugs
leakage.
To
an
remove
hole in the
expansion
center of
flange
of
install it
plug in
casting
the
with
until
new
type plug, drill
the plug
in Fig. 43. Clean the plug
make a
minor
Check the flatness
following
tap to true-up
cracks not visible
coating the
stone.
Remove
gasket surface
the threads in the head bolt
cause
oil
and scores.
cracks are pres
cracked.
gasket surfaces
all
any deposits.
eye
a
out
an
etc. with
After the block has been thoroughly cleaned,
check
old
Remove
holes,
Dirt in the threads may
remove
Remove
solvent.
If
become discolored
machined
all
scratches,
machined surfaces.
all
Make
clean.
in
the block in
will
wood alcohol.
Replace the block if it is
Check
Inspection
and
dissolved in
zinc oxide
plug
the flange
and remove
recess
with
it
a
as
V2-inch
shown
thoroughly. Coat the
water resistant sealer
facing
out
the flange is flush
and
(Fig. 44). Drive the
or
slightly below the
surface.
Inspect the
cylinder
walls
for scoring, roughness
or
1-28
1 General
Chapter
Engine Service
CENTERLINE OF ENGINE
A
A-AT
RIGHT ANGLE
TO CENTERLINE
OF ENGINE
B"
PARALLEL TO
CENTERLINE OF
ENGINE
DRILL V2 INCH HOLE IN PLUG
43 Expansion-Type
Fig.
Check the
other signs of wear.
and
gauge
following
bottom
and
parallel
Rebore
that
out-of-round and/or
If the
cylinder
tions, but
the
it may be
possible
ing
the
rings
the
taper
to
wall
providing the
the
deeply
have
walls
of
bore
the
at
wear
surface
the
grade of
CYLINDER BORE AND THE A MEASUREMENT AT BOTTOM
Fig.
is
is determined by the
imperfec
coarse
leave
Honing
only
when
is
the
walls
the
Cylinder
light scuffs, scratches,
etc.
The
cylinder walls
imperfections,
grade of
that
honing
If
operation,
be
can
marks
is
which
severly
limits
such
used
to
obtain
marred and/or worn
should
be
Before
rebored.
hone to be
used
boring
bearing bores
the
clean
up
will not
therefore,
cylinder with
bored for the
when
cylinder
finish
and pattern are obtained.
For the
personnel
of
should
After the final
ing
TOOLT54L-6015-A
ALL CORE PLUGS ON 8-CYLINDER BLOCK
methods
piston
vent
dry. Check the
Installation
to
be
correspond
for this
the
allowed
operation
described
remove
all
of
honing
in
piston
boring
to
wash
clean
equipment
Only
perform
either of
the
will allow
the correct
so
Use
sharp
follow
experienced
this
work.
the two
above and prior
abrasive
piston
not
operation.
the manufacturer.
fit, thoroughly
to
of
use
proper
the instructions
8-CYL. CAM BEARING BORE PLUG
ALL PLUGS ON 6-CYLINDER BLOCK
diameter. This
surface
grit
will
approximately 0.0015
within
for the final step
No. 220-280
first to deter
maximum oversize
stock
of
be
block.
oversize
required
can
cylinder
enough
hones
TOOLT52L-6266-BGD
to
and
standard
most wear
If the
oversize.
maximum
the
the
it.
balance.
engine
upsetting
require
pistons
sized
various
without
Rebore the
of
that the
so
that
weight, both
same
recommended, replace the
inch
be
caps must
become distorted from
cylinder or cylinders
the
are
pistons
mine
bearing
main
operation.
Rebore only the
All
all
to the proper torque
place and tightened
the
as
is rebored,
cylinder
Rebore the
Plug
the
manufacturer.
that all hone
so
are
specified
intermixed
44 Expansion-Type
start
finishing hone
the
walls
beyond the
oversize;
f/g.
hone
operation.
in
for refinishing
minor
the
removed.
proper piston clearance.
crankshaft
have
material
enough
removed with
limits.
Cylinder Walls
recommended
to
used
are
stones
of
to be
metal
of
amount
Follow the instructions
limits.
any
Refinishing
Bore Out-Of-Round And Taper
(Fig. 45).
within
for this
stone
45 Cylinder
are within
clearance
honing
1039-A
top,
limits,
remove the imperfections by hon
and installing new service piston
taper
DIFFERENCE BETWEEN A AND B
=
DIFFERENCE BETWEEN THE A MEASUREMENT AT TOP OF
=
manufacturer.
engine
minor
and
piston
OUT-OF-ROUND
TAPER
accurate
scored and/or when
approach
out-of-round
cylinder
Use the finest
are
1.
2.
OF CYLINDER BORE
the
of
an
out-of-
gauge placed at right angles
to the centerline
cylinders
with
of each cylinder
with
bore for
cylinder
the instructions
Measure the diameter
and
Removal
Plug
taper. Measure the bore
round
middle,
1037-A
refinish
to checking the
cylinder walls with sol
particles, then
thoroughly
fit (page 1-26). Mark the
to the cylinders in
which
they
pistons
are
to be
Section 1
installed. When
the
refinishing
it has been
require
thoroughly
clean
completed
the
bearing bores,
Coat the
cylinder walls with oil.
When
all
and
block to
entire
from the
Cylinder Wall
of
"Glaze"
new piston rings are
fitted,
pistons
has
1-29
Block
not
been
refinished,
cylinder
walls
to
in ring
aid
the
remove
from
glaze
Take
holes,
Removal
installed in
that
fine
Pass
a
bore
a
rough
a cylinder
all
etc.
and
the necessary
grit
hone
up the finish.
block
after
not
hone
Thoroughly
the
to
precautions
or glaze removal
few times. Do
glaze
the
seating.
remove all particles
passages, head bolt
oil
that
cylinders
all
1 Cylinder
the
grit.
tool through the
than
more
clean
catch
the
enough
to
cylinder walls
is removed, then
oil
the
walls.
12. OIL PAN AND OIL PUMP
Oil Pan
Scrape any dirt or metal particles from the inside of
the pan. Scrape all old gasket material from the gasket
surface.
Wash the
oughly.
Be
below
sure
Check the
threads,
a
dry it
and
is
matter
thor
from
removed
plate.
for cracks,
pan
loose
solvent
a
foreign
all
baffle
the
in
pan
.
baffle,
damaged drain plug
holes,
and
nicked
a
or
warped
gasket
surface.
Repair any
not be made.
damage,
Rotor-Type Oil
or replace
the
pan
if
repairs can
Pump
(8-Cylinder Engine)
Wash
Use
the
a
all parts
brush to
in
dry
a solvent and
the inside
clean
of
Be
sure
housing
and
dirt
and
all
chips are removed.
race and rotor
cover
for damage
Measure the
46). The
With
housing
the pump
and
Check
defective,
the
relief
replace
valve
in the bore. The
the
outer
0.0015-0.0029 inch.
for
wear.
Gear-Type Oil
cover
is worn, scored,
straight
or
grooved,
edge and
the
Clearance
the
spring.
for
piston
specified
scores
free
and
piston clearance
is
Pump
(6-Cylinder Engine)
outer
as
an
are
(Fig.
in
Wash
Use
a
rotor
clearance
brush to
the pressure
housing,
the
assembly
between
all parts
and
the
are
in
clean
relief
dry
a solvent and
the inside
of
the pump
valve chamber.
removed.
the
Remove
old
them thoroughly.
Be
housing
and
dirt
and
sure all
gasket
material
from
straight
(Fig. 47). The
Straight Edge
recom
0.001-0.0035.
race,
shaft
and
rotor
are
replaceable
assembly.
Check the drive
shaft
measuring the O. D.
housing
clearance
chips
rotor and outer race
limits
mended
installed
the
over
the
housing
be from 0.006-0.009 inch.
assembly
edge
Measure
to
race
should
rotor
housing.
only
surface of
outer
clearance
the
a
The
Housing
or excessive wear.
surface
mating
Race To
the cover.
replace
place
the pump
of
Check the mating
If the
the spring is
operation
Check the inside
46 Outer
them thoroughly.
the pump
chamber.
valve
relief
pressure
Fig.
bearing. The
of
to
housing bearing
the
shaft
and
clearance
the I. D.
clearance
recommended
by
of
the
limits
are
0.0015-0.0029 inch.
Inspect the
relief valve
spring for
a collapsed or worn
condition.
Check
should
the
exert
If the spring
relief
a
valve
pressure
tension
is
of
spring
9.2-10.4
not within
tension.
The spring
pounds at
1048- A
0.80 inch.
specifications
and/or
Fig.
47 Rotor
End
Play
1-30
the pump
or
1 General
Chapter
body
and cover.
gage
Inspect the pump body and the gear teeth for damage
wear. Check the gear end clearance with a dial indi
cator or
Plastigage. The Plastigage
Position the
gasket on
Engine Service
the
method
is
as
follows:
then place Plasti
housing,
on
the gears
cover and
check
Check the
the
the Plastigage
gears
the
pression of
for freedom
the
relief
Remove the
cover.
reading.
Check the
of rotation.
oil pressure relief valve
of
clearance
install the
and
valve
spring
in the
com
and check
valve chamber.
13. EXHAUST SYSTEM
The
and excessive vibration.
heard
at
system
in
or
visually,
the
are
of
some
pipe
a
cases,
restrictions, leaks
usually be detected
can
connections.
may be
noise
whistling
All the
parts
the
of
13A inches. To
tions,
the
leaking
or
inlet
and
by
inlet
and
burning
outlet
outlet
the
for
through. The slots in the
extensions
pipes,
the overlap in either case
exhaust system
respectively.
should
not
be
pipe
However,
greater
than
burning
possible
"kick-up"
and
insufficient,
Exhaust
broken
or
system
Replace
connec
as outlined
all sections
interference between the
floor
the
If the
pan.
outlet pipe
are
vibrations
improperly
the muffler
in
that
through.
the
reposition
at
and outlet pipes
respective engine chapter.
show signs of
be blocked
should
leakage
correct
the inlet
position
Check for
various sections of
muffler
the
Leaks
of
replaceable.
Check the
signs
be free
exhaust system must
aligned
in the
clearance
is
muffler.
usually
clamps.
outlet
Align
caused
by
or replace
clamps as necessary.
14. ENGINE DIMENSIONS, AND CLEARANCE AND ADJUSTMENT SPECIFICATIONS
NOTE: All
specifications are given
in inches
unless otherwise noted.
Engine Cubic Inch Displacement
Item
272
223
292
312
CYLINDER HEAD
0.003 in any 6 inches
Gasket Surface Flatness
Valve Guide Bore Diameter (Int. & Exh.)
Valve Seat Width
or
0.006 inch
overall
0.3433-0.3440
Int.
0.060-0.080
Exh.
0.070-0.090
45
Valve Seat Angle
Valve Seat
Runout-Maximum
Valve Seat
Runout Wear
0.002
0.0025
Limit
VALVE MECHANISM
Valve Lash
(Cold) Int. & Exh.
(Hot) Int. & Exh.
Valve Stem
Diameter Standard
Valve Lash
0.019
0.019
Int.
0.3416-0.3423
Exh.
0.3403-0.3410
0.003, 0.015, 0.030
Oversize Valves Available (Int. & Exh.)
Valve Stem Diameter 0.003 O.S.
Int.
0.3445-0.3455
Int.
0.3565-0.3575
Valve Stem to Valve Guide
Clearance
Valve Stem to Valve Guide
Clearance Wear
Limit
Valve Head Diameter
Int.
0.3566-0.3573
0.3555-0.3565
Exh.
0.3446-0.3453
0.3435-0.3445
Exh.
0.020
0.3715-0.3725
0.3716-0.3723
Exh.
0.3705-0.3715
Int.
0.001-0.0024
Exh.
0.0023-0.0037
Int.
0.0045
Exh.
0.0065
Int.
Exh.
1.775-1.785
1.920-1.930
1.505-1.515
Section 1
4 Engine
Dimensions,
and
Clearance
and
1-31
Item
223
292
272
VALVE
MECHANISM (Cont'd)
Valve Seat Face Runout (Int. 65
Maximum
Exh.)
0.0015
Valve Seat Face Runout (Int. 6b
Wear Limit
Int. Valve
(Opens) Tappet
Lift
Exh.)
0.002
@
Degrees B.T.C.
Int. Valve
17
(Closes)
Tappet Lift
53
Exh. Valve (Opens) Tappet Lift
Degrees B.B.C.
@
Exh. Valve (Closes) Tappet Lift
Degrees A.T.C.
@
Int. Valve
(Opens) Tappet
Lift
61
9
25
(Closes) Tappet
Lift
0.019
@
0.016
@
0.019
@
0.100
@
0.100
@
0.100
@
0.100
58
66
10
22
11
Exh. Valve (Opens) Tappet Lift
Degrees B.B.C.
@
Exh. Valve (Closes) Tappet Lift
Degrees B.T.C.
@
21
33
18
27
29
Valve
i
Spring Free Length (Approximate)
Valve Spring Out of Square (Maximum)
Valve Spring Pressure (Lbs.) @ Specified
Length (Valve Closed)
Wear Limit
Length (Valve Closed)
Length (Valve Open)
Length (Valve Open) Wear Limit
Valve Tappet Diameter
71-79
@
@
64
0.015
@
0.013
@
0.016
@
0.100
@
0.100
@
0.100
@
0.100
145
1.780
1.780
@
161-177
@
1.390
1.390
7.98
0.020
0.4989-0.4995
Valve Tappet to Tappet Bore Clearance
0.0005-0.0021
Clearance-
0.0026
Rocker Arm to Rocker Shaft Clearance
Rocker Arm to Rocker Shaft
@
0.062
(Maximum)
(Standard)
Valve Tappet to Tappet Bore
Wear Limit
0.015
2.09
9.62
Valve Push Rod Length
Valve Push Rod Runout
@
@
Degrees A.B.C.
j
@
18
@
Degrees A.T.C.
Int. Valve
0.016
@
Degrees A.B.C.
!
@
0.002-0.004
Clearance-
0.006
Wear Limit
Rocker Arm Shaft O.D.
0.780-0.781
Rocker Shaft Bore Diameter
0.783-0.784
CAMSHAFT AND TIMING CHAIN
Journal Diameter
:
Journal Runout
1.9255-1.9265
(Standard)
0.005
(Maximum)
Journal to
Bearing Clearance
Journal to
Bearing
Clearance Wear
0.001-0.003
Limit
Undersize
Bearing Available
0.015
Camshaft
Runout
Timing Sprocket Front Face
(Assembled) Maximum
0.008
Timing
V2
Chain Deflection
Camshaft Lobe Lift
Int.
0.273
0.272
Exh.
0.273
0.285
Max. Allowable Lobe Lift Loss Int. & Exh.
1
0.006
0.005
312
1-32
Chapter
1 General
En<gine Service
Item
223
272
292
312
FLYWHEEL
Con. and Overdrive Trans. Assembled
Flywheel Clutch Face Runout (Max.)
CRANKSHAFT
Main Bearing Journal Dia.
(Standard)
Runout Maximum
Main
Bearing Journal
Main Bearing Journal Runout Wear Limit
Connecting Rod and Main Bearing Journal
Out-of-Round
Connecting Rod
Out-of-Round
2.4980-2.4988
2.6235-2.6243
0.002
0.001
0.004
0.003
Maximum
0.00025
Main Bearing Journal
Wear Limit
and
Rod and Main
Maximum
Connecting
Taper
0.010
Connecting Rod and Main
Taper
Wear Limit
Bearing
Journal
Bearing
Journal
0.0005
0.0005
0.001
Thrust
Bearing Journal Length
Main Bearing Journal Thrust Face Runout
Connecting Rod Journal Diameter
Crankshaft Free End Play
Wear Limit
Crankshaft Free End Play
Crankshaft (Flywheel Contact Face)
Runout (Maximum)
1.359-1.361
1.124-1.126
0.001
2.2980-2.2988
2.1880-2.1888
0.004-0.008
0.002-0.006
0.012
0.010
0.002
Crankshaft Sprocket Contact Face
Runout (Maximum)
0.001
MAIN BEARINGS
0.010, 0.020, 0.030,
Undersize Bearings Available
Journal Clearance (Copper
0.010, 0.020, 0.030
0.0005-0.0025
Lead)
Wear Limit
(Copper Lead)
Bearing Wall Thickness
0.040
0.006-0.0032
0.0008-0.0026
Journal Clearance
Copper Lead
0.0035
0.0042
0.0036
Red
0.0958-0.0963
0.0955-0.0960
0.0951-0.0956
Blue
0.0962-0.0967
0.0959-0.0964
0.0955-0.0960
1.353-1.355
1.120-1.122
1.118-1.120
Thrust Bearing Flange Length
(Copper Lead)
Journal Clearance (Lead
0.0005-0.0021
Babbit)
Journal Clearance (Lead Babbit)
0.0031
Wear Limit
Bearing
Wall Thickness
(Lead Babbit)
Thrust Brg. Flange
Width Lead
CONNECTING ROD
Piston Pin Bushing I.D.
Red
0.09585-0.09625
0.09555-0.09595
Blue
0.09625-0.09665
0.09595-0.09635
1.353-1.355
1.120-1.122
Babbit
0.9122-0.9125
(Standard)
Bushing Out-of-Round
(Maximum)
Piston Pin Taper (Maximum)
Piston Pin
0.0003
0.0003
2.4230-2.4238
Bearing Bore
Diameter
Bearing Bore
Out-of-Round
0.0004
(Maximum)
0.0004
Bearing Bore Taper (Maximum)
Bearing Bore Length
Connecting Rod Length (Center
Connecting
Rod Twist
Rod Bend
(Maximum)*
0.871-0.873
1.244-1.245
to
Center)
6.258-6.262
6.320-6.324
Total Difference
0.012
(Maximum)*
Connecting
2.3120-2.3128
Total Difference
0.004
6.320-6.324
Section 1 4 Engine Dimensions,
and
Clearance
and
1-33
Item
223
CONNECTING ROD (Cont'd)
Connecting Rod Assembly (Assembled
312
292
272
to
Crankshaft) Side Clearance
Connecting Rod Assembly (Assembled to
Crankshaft) Side Clearance Wear Limit
0.006-0.016
0.003-0.009
0.019
0.012
*Pin bushing and crankshaft
bearing bore must be parallel
8 inches long bar measured 4 inches on each side of rod.
and
in the
same vertical plane within
the
specified
total difference at
ends of
CONNECTING ROD BEARINGS
Undersize Bearings Available
Bearing
Bearing
to
Crankpin Clearance
Crankpin
Wear Limit
Bearing
0.010, 0.020, 0.030
to
0.0004-0.0023
0.0008-0.0027
0.0033
0.0037
0.0007-0.0026
Clearance-
Wall Thickness--Red
0.0036
0.07495-
0.06166-
0.06205
0.07545
0.06095-0.06145
0.07535-
0.06195-
Blue
0.07585
0.06135-0.06185
0.06245
PISTON
Piston Dia. St 'd Spread for 8
3.7491-3.7515
3.6241-3.6265
grades
Oversize Pistons Available
3.7990-3.8014
0.020, 0.030,
0.020, 0.030, 0.040, 0.060
0.040
Piston to Bore Clearance
Piston to Bore Clearance
Wear Limit
Top
of
Piston to
Bottom
Bottom
of
of
Skirt
0.0009-0.0015
Skirt
0.0045
Top of Cylinder Bore
@ T.D.C.)
Clearance (Piston
0.019-0.031
0.0235-0.0415
Gauge Size
Fitting New Piston
in New Bore
0.0015
Pounds Pull
Piston
in Used Bore
Pounds Pull
Fitting Used Piston
Gauge Size
in Used Bore
0.5
5-10
Gauge Size
Fitting New
x
0.010-0.026
0.002-0.5
5-10
0.0025
Pounds Pull
x
0.5
5-10
PISTON PIN
Piston Pin Diameter Standard
(Color Coded Green)
0.9120-0.9123
Oversize Pins Available
0.001, 0.002
Piston Pin Diameter 0.001 O.S.
(Color Coded Blue)
0.9130-0.9133
Piston Pin Diameter 0.002 O.S.
(Color Coded Yellow)
0.9140-0.9143
3.016-3.030
Piston Pin Length
Piston Pin to Piston Clearance
(Loose)
0.0001-0.0003
Piston Pin to Piston Clearance (Loose)
Wear Limit
Piston Pin to Connecting Rod
Clearance (Loose)
0.0008
Bushing
0.0001-0.0003
Piston Pin to Connecting Rod Bushing
Clearance (Loose) Wear Limit
0.0008
PISTON RINGS
Ring
Side
Width Compression
1Upper
0.0930-0.0935
1 l,ower
0.0930-0.0935
Clearance Compression
Upper
Lower
0.0775-0.0780
0.0775-0.0780
0.0930-0.0940
0.002-0.0035
0.002-0.0035
0.001-0.003
1-34
Chapter
1 General
Engine Service
Item
PISTON
RINGS
(Cont'd)
Side Clearance
Compression
Upper & Lower
Wear Limit
0.006
Piston Ring Gap Width
Compression
(Upper and Lower)
Standard Bore
Piston
312
292
272
223
Ring Gap
Width Oil
0.012-0.029
0.010-0.027
(Steel Rails)
0.015-0.062
Oversizes Available
0.020, 0.030, 0.040, 0.060
0.020, 0.030,
0.040
CYLINDER BLOCK
Cylinder Bore Diameter
spread
for 8
Standard,
3.6250-3.6274
grades
Minimum Cyl. Wall Thickness Std. Bore
3.7500-3.7524
3.8000-3.8024
0.145
0.170
Cylinder Bore Out-of-Round Maximum
New Bore
0.0005
Cylinder Bore Out-of-Round
Wear Limit
Cylinder Bore Taper Maximum
Cylinder Bore Taper
Wear Limit
0.005
New Bore
0.001
Maximum
0.008
Maximum Allowable O.S. Cyl. Bore
Head Gasket Surface Flatness
OIL PUMP (ROTOR TYPE)
Relief Valve Spring Tension
0.003 in any 6 inches
or
9.2-10.4
@
0.006 inch
(lbs) @
Specified Length
Drive Shaft to
0.040
0.060
Housing Bearing Clearance
0.80
0.0015-0.0029
Assembly End Clearance
(Pump Assembled)
Rotor
Outer Race to
Housing
Radial Clearance
Drive Shaft Length (Rotor
to Shaft End)
3.36-3.38
(lbs.) @
Housing Bearing Clearance
Gears End Clearance (Pump Assembled)
Drive Shaft to
Driven Gear to Shaft Clearance
Housing
Clearance
0.006-0.009
Assembly Face
OIL PUMP (GEAR TYPE)
Relief Valve Spring Tension
Specified Length
Gear to
0.001-0.0035
9.76-9.84
@
1.56
0.0015-0.0029
0.003-0.006
0.001-0.002
0.0015-0.006
overall
1-35
1- ENGINES
Part
Chapter 2
6-CYLINDER ENGINE
Section
Page
1
Description
2
Engine Removal
3
Engine Supports
1-40
4
Manifolds
1-41
5
Cylinder Head
6
Crankshaft Damper, Cylinder Front Cover, and Crankshaft Oil Seal
Sprockets and Timing Chain, Camshaft, Bearings, and Tappets
7
8
1-35
and
1-38
Installation
and
and
1-43
Valves
1-46
1-48
10
Flywheel, Crankshaft, and Main Bearings
Connecting Rods and Bearings, Pistons, Pins,
11
Exhaust System
1-55
12
1-56
9
and
The removal, disassembly, assembly, and installation
procedures for the component parts of the 6-cylinder
engine are covered
in this
3.62 inches
sion
ratio
The
3, 4, 5,
3.6 inches. The
compres
cylinders
and
are
6. The
numbered
firing
order
from front to
cylinder
The cleaning, inspection,
gine overhaul instructions
arm
the
head
ii.m
i
rear
is 1-5-3-6-2-4. The
rear
carries
.i
from front to
1, 2,
mechanism,
water
are cast
lent
is 8.6: 1.
are arranged
The
and a stroke
1-53
repair
are
procedures,
covered
and
in Chapter
en-
1,
Service."
DESCRIPTION
.
The 6-cylinder, overhead valve engine (Figs. 1 and
2) has a displacement of 223 cubic inches with a bore
of
1-5 1
Rings
"General Engine
chapter.
1
of
1-45
manifold
assembly, ignition coil, and
outlet, thermostat
integral in the head.
and
housing. Valve
Wedge-shaped,
combustion chambers provide a
ture for
guides
high turbu
homogeneous
mix
efficient combustion.
valves
E-I-I-E-I-E-E-I-E-I-I-E.
the
valves, valve
rocker
a
^RimmmJJmmfr-
1053-A
Engine-3/4 Right Front View
Fig. 1-223 Cubic Inch
1054- A
Fig. 2223 Cubic Inch Engine % Left Sectional View
1-36
Both the intake
rotating-type
and
2 6-Cylinder
Chapter
which
The
closes.
and exhaust valve assemblies are
rotate
rotation
each
time the
permits
self
valve
opens
action
cleaning
better seating, minimizes valve warpage, wear,
sticking. Umbrella-type valve stem seals fit over
and
top
the
of
valve
the
guide
valve
The
by
self
block
trolled
shaft
a
on
by
a
is
the
fuel
timing
crankshaft.
thrust
and
made
pump.
and
pressed
valve
The tappets
are
at
are
a
one-piece
surround
temperatures.
steel-backed
chain
in
of
bab
mesh with a
the
solid
con
cam
camshaft.
the camshaft,
the
room-type.
operates
steel,
mush
They
block tappet
from the
lar
steel
The
oil
located in bores in the
are
and
chamber
gallery.
with
The bearings
The
is
lubricated
are
push
supported
four
by
the steel-backed,
are
by
overflow
tubu
one-piece
are
rods
cylinder
sockets.
cushioned
oil
crankshaft
bearings.
main
copper
lead
or
lead
babbitt, insert-type. Crankshaft end thrust is controlled
by the No. 3 main bearing flanges. Oil slingers are pro
vided to prevent leakage
by directing the oil away
from the front
assembled
Camshaft thrust is
with
coil
into the block. It is
the front journal
integral
of
lash is
located between the
washer
the
action
completely
by four
the
of
equal
valve
uniform cylinder
supported
sprocket
sprocket
An eccentric,
the
positive
water passages
to provide
camshaft
sprocket
have
crankcase
and
top
and
lubrication
control
springs
more
the
over
Easy maintenance of
locking adjusting screws.
Full length
by
seals
valve
bitt insert-type bearings
driven
extend
speed.
each cylinder
The
The
provides
cylinder
casting.
and
The
stems.
engine
afforded
stems
opening.
which
spacing
high
valve
the
Engine
and
to the
rear
The front
seals.
oil
between the damper
crankshaft
crankshaft sprocket and
throws the
chain, then into the
pan.
integral
with
the
trough
slinger
which
to the
crankshaft.
additional
On
cars
surface
cars
rear
face
which
is
rear
assembly
with
oil
and
made
into the
pan.
A
is keyed
steer
power
pulley is bolted to the
steering
pump.
conventional
of
oil
is
timing
is
slinger
deflects the
equipped
a
the
onto
back into the
sheave
with
oil
pulley
power
equipped
transmission, the
friction
and
single
damper to drive the
On
empties
damper
sheave
an
The
crankshaft and
single
ing,
oil
slinger
or
the flywheel is
engaged
by
the
overdrive
used
clutch
as a
disc.
1055-A
Fig.
3 Engine
Lubrication System
The flywheel assembly is piloted
bolted to the crankshaft. The
on
is
gear
ring
a
used on
rocker
arm
fit
rocker
arm.
shrink
laminated
outer
Fordomatic
equipped cars
drive
riveted
spring-steel
plates
has
apart, to
the converter
which
rod
rocker shaft
is
ing
and
cover
The forged steel, "I" section
connecting rods contain
a bronze piston pin bushing. The
connecting rod bear
ings are the steel-backed, copper-lead, two piece-type.
each
tons
the
are of
controlled
design. This design
autothermic
piston
fits
piston
top
alloy, three ring, flat head-type
expansion
which
binding
without
or
excessive
ring is chrome-plated
compression
tion against wear and scuffing.
consists
of
a
serrated
The
overflow
oil
tappet
and
exhausts excess oil
from
lubricating
tube
the
to lubricate the distributor lower bush
No.
arm
1
through
The
push
an
in the
push
cylinder
chamber
rod
opening
from
oil
chamber
rod
head.
drains back into
the back
at
tube is
overflow
bracket. The
support
drains into the
provided
in the
gears.
the block.
of
Crankcase Ventilation
Ventilating
the lower
nation
extra
as
ring
two
oil
protec
chrome-
the
maze
air
filler
(Fig.
provided
by
the
combi
breather cap located on the front
arm cover. The filler cap contains a
and
valve rocker
filtering
is
4)
element.
From the filler cap the filtered air flows into the
front section of the valve rocker arm chamber. There
plated steel rails.
Engine
rocker
pan
in
down the rotating
friction. The
control
and
spring
initial
of
oil
the
through holes
the
assists
spirals
oil
the
of
end
provides
closer
and
ring is phosphate-coated for
compression
sembly
allows
pis
the valve and ball
distributor drive
at
The
and
excess
An
the
located
aluminum
and
push rod seat.
attached.
The
The
to the
180
edge
bushing
and
push
The flywheel
two
shoulder
flywheel.
the
on
a
1-37
1 Description
Section
Lubricating
System
are
few
this point
gases at
and
the air has
a chance
to
its temperature before contacting contami
nating vapors originating in the crankcase. This warm
ventilating air minimizes the formation of crankcase
normalize
Oil from the
lubricating
sure-feed
pump
mounted
driven
by
by
inside
the
the
relief
an
valve
in the pump limits
The
oil
is directed back to the intake
valve
is
pump
intermediate drive
pressure of the system.
maximum
The
crankcase.
the distributor through
A spring loaded
shaft.
the
sump is forced through the pres
system
(Fig. 3) by a gear- type
oil pan
relieved
of
side
the
pump.
integral
relief
oil enters
The
entire
the engine.
output
front
the
of
section
front
of
of
the
the
crankcase
engine
cylinder
block
camshaft sprocket chamber.
then
rotating
directed into the
action of
The
road
wall
air
through
to ventilate
from the
draft
holes in
the
crankcase
outlet
tube
by
the crankshaft.
The filter has
back diaphragm
anti-drain
valve,
gasket.
mounting
filter filters the
oil
the pump before the
an
rods
is
A full flow-type
The ventilating air moves down past the push
into the engine crankcase. Air is diverted from the
sludge.
and
to bypass
relief valve permits oil
becomes clogged, thereby main
taining an emergency supply of oil to the engine lubrica
tion system at all times. The anti-drain diaphragm pre
the filter if the
vents
reverse
a
The
main
main
oil
bearing
The
flow
flat
through a
supplies oil
gallery
the No. 1
on
to
all
the
stopped.
camshaft
in
passage
each
rod
lubricated
are
sprockets
bearing.
cam
pistons and piston pins are
drilled hole
connecting
is
engine
drilled
a
and
chain
Cylinder walls,
a
the
when
web.
timing
through
of oil
bearings through
main
and
element
on
the
indexes
which
crankpin
a
with
lubricated
end
of
each
drilled hole in the
crankpin.
Oil
assembly
block
at
through
cylinder
into the hollow
arm
support.
drilled
holes
The
in
pressure
drilled
a
the No. 3
hole in the
oil
reduced
under
cam
rocker shaft
each
passage
bearing
head. An
oil
is fed to the
from
rocker
oil
in
which
the
arm
cylinder
indexes
with
a
feed tube directs the
through the
the
rocker
shaft
arm
to
No. 6
rocker
flows through
lubricate
each
1057-A
Fig.
4 Crankcase
Ventilating System
1-38
2 6-Cylinder
Chapter
Engine
System
Cooling
The
is drawn from the lower
coolant
by
radiator
to the
the
coolant
Upon reaching the
is directed
coolant
it
the
cools
its
seats on
past
the
the
tank
of
through a pipe
pump for
056-A
Fig. 5
Engine
out
given
procedures
transmission
the
tolerances
for the
attached.
it impractical to
make
the
with
engine
are
transmission
engine
Engine
only,
with
compartment
remove
or
install the
attached.
9. Turn
position
can
flywheel
the
be removed, then
Fordomatic Equipped Cars
REMOVAL
and
3. Remove the
battery
air
Remove the
tension
crank rod and
Remove the
the
the
and
system
crankcase.
ground cable at
the
battery
the
bell
Disconnect
accelerator
from
flex
the
to
crank
the
carburetor
starter
lower
bell
carburetor.
intake manifold, then tie the bracket to the dash
matic
manifold, the
generator
ground
engine
strap
starter
fuel line
cable at
the
at
the
the
oil
pressure
exhaust
and
housing.
hose
and
starter.
at
the
sending unit
and
coil
and
dis
the
converter
removed.
to
housing
the left
remove
lower
engine
splash
rear
shield.
insulator
retaining
bolts
cooler
and
right
engine
and
the
remove
Fordo
a
with
left insulator to
jack. Remove
bracket
support
bolts.
the
starter.
retaining
the
bolts,
Remove the remaining
bolts
the
and
13. Attach the
the
upper
starter
then
plate
rear
engine
housing
converter
remove
to
engine
bolts.
engine
converter
wire
is
flywheel
turn the
filler tube bracket.
upper
the fuel pump, and disconnect
7. Disconnect the primary
connect
converter
windshield wiper vacuum
6. Disconnect the
the flexible
from the
from the generator,
wires
at
pipe
Turn the fly
lines retaining clip from the
bracket. Remove the
support
12. Remove
inlet
a
bolts
converter
catch on
11. Support the transmission
the
is in
three bolts. Secure
other
will not
converter
and
oil
right
accelerator
the
the
the
engine
10. Remove the
engine
air
linkage bracket assembly from
muffler
radiator
plate
the bolts.
flex plates,
the
plates
the
when
horn
then tape the
cleaner,
choke control cable at
5. Disconnect the
the
removed
Remove
accelerator
spring.
pressurized
assembly in the housing. After the bolts
retaining bolts
panel.
the
are
housing
radiator.
4. Remove the
lever
converter
so
disconnect the heater hoses.
closed.
the
90
flywheel to
remove
remove
and
flex
one
until
that the three
so
wheel
2. Disconnect the
water
lower retaining bolts.
plate
180
1. Drain the cooling
is
pressure-type
a
of
use
to the
coolant
entire system
bypassed
is
ENGINE REMOVAL AND INSTALLATION
2.
The
the
outlet
cap.
System
Cooling
The
water
if it is open, into
coolant
the
returns
which
with
psi
the
of
valve
If the thermostat is
radiator.
recirculation.
13-15
to
the
and
engine.
thermostat
water
the
where
valves,
flows into the
coolant
block,
head
cylinder
the
of
of each cylinder
cylinder
chambers,
portion
small
a
closed,
into the
to the front
connection
the
of
rear
combustion
return
length
entire
upward
At this point, the
upper
coolant
it travels through
block,
the
enters
to cool the
cored passages
wall.
delivers the
which
pump
the
of
block (Fig. 5).
cylinder
As the
water
tank
lifting hook (Fig. 6). Raise
engine
slightly,
then
housing. Lift the
compartment, then
pull
carefully
install it
engine
on
a
out
from
it
of
the
workstand
the
engine
(Fig. 7).
the tempera
INSTALLATION
ture sending unit wires.
8. Remove the
plate
and
the
converter
cover
housing
assembly.
lower
Remove the
access cover
engine rear
1. Install the
engine
from the
engine
work
lifting hook,
stand.
Place
a
then
new
remove
gasket
the
over
2 Engine
Section
the exhaust manifold to inlet
flywheel is
the
catch on
turned
2. Lower the
are aligned with
the
the holes in the
housing. Start
verter
Tool-T52L-6000-C
com
engine
the exhaust manifold
studs on
dowels in the block
1-39
Installation
plates will not
carefully into the
the
sure
and
sure
housing.
engine
Make
partment.
flex
that the
so
the converter
threads. Make
pipe
Removal
inlet
muffler
pipe and
the holes in the
engage
the converter pilot into the
con
crank
shaft.
3. Install
the
to
engine
bolts. Position the
housing
converter
starter and
install, but do
upper
not tighten
the upper retaining bolts.
4. Remove
left
engine
the
transmission
insulator to
and right
housing,
is in
then
the flywheel
position
torque.
securing the
retainer
converter
until
bolts. Tighten
the bolts
Turn the flywheel
plate
converter
1060- A
to
install the
then
180,
in the
flex
one
to install the three flywheel to
position
the
bracket bolts.
support
Tighten the bolts to 45-50 foot-pounds
5. Remove the
Install
support.
other
three
Fig.
bolts.
6. Install the
housing
cover
lower
converter
plate.
Install the
rear
and
plate
splash
shield
bolts. Position the Fordomatic filler tube bracket
install
the
starter
lower retaining
bolts,
and
7. Position the Fordomatic
install the
engine
tubes bracket
cooler
bracket to
support
right
lockwashers
retaining
and
bolt.
engine
nuts, then tighten the
nuts
muffler
the
9. Install
intake
ground
engine
the
manifold.
Install the
tension
Connect the
bell
accelerator
Connect the
spring.
linkage
the
connect
ture sending
to
crank
choke
starter
them
the
12. Install the
Fill the cooling
quantity
buretor
of
air
the
hose
starter
the
upper
battery
radiator
battery
radiator.
closed.
lever
cleaner, then tape the
air
Disconnect the
accelerator
the
clutch
bracket spring
the
clutch
bracket. Disconnect the
at
horn
linkage. Disconnect
and release
rod, then remove
choke cable rod and
the carburetor.
5. Disconnect the
manifold, the
the
air
muffler
generator
engine ground
inlet
wires
pipe
from the
exhaust
from the generator,
strap from the
and
engine.
windshield
primary
wire
and
the tempera
retaining
bolts
and
ground cable.
and connect
the heater hoses.
system.
crankcase
engine
horn,
14. Run the
and
the
cable.
the
and
ground cable at
15-20 foot-pounds torque. Install the
to
cable and
13. Fill
and
coil
crank rod.
carburetor
control
unit
sending
bell
the
on
battery
the crankcase.
unit wires.
11. Install
tighten
pressure
oil
bracket
accelerator
hose. Connect the
vacuum
3. Remove the
bushing
10. Connect the flexible fuel line
wiper
generator wires
strap.
accelerator
and
system
disconnect the heater hoses.
4. Remove the
pipe
to
to 23-28 foot-pounds torque. Install the
and
1. Drain the cooling
and
inlet
manifold
exhaust
REMOVAL
and
Tighten the bolt to 45-50 foot-pounds torque.
8. Install the
Transmission
2. Disconnect the
them to
Conventional Or Overdrive
and
tighten
then
Hook
Lifting
the
lower
to engine lower retaining
housing
converter
cover
engine rear
retaining bolts. Position the left
install the
access
6 Engine
oil.
with
the
proper
grade
Remove the tape from the
and
car
then install the air cleaner.
engine at
connections
fast idle
for leaks.
Tool T52T 6005-CJD
(Splined
Shaft)
ToolT52T6005-KJD (Keyed Shaft)
1061-A
and check all gaskets
Fig.
7 Engine
Mount
1-40
2 6-Cylinder
Chapter
6. Disconnect the
hose
windshield wiper vacuum
Engine
3. Install the flywheel
and
the flexible fuel line at the fuel
pump, and disconnect
them to
the
wheel
starter cable at
the starter.
7. Disconnect the primary
wire
the oil pressure sending unit
connect
ture sending
the coil
at
dis
and
the tempera
and
unit wires.
8. Remove the
housing upper bolts.
10. Remove the flywheel housing cover, then remove
the flywheel housing lower bolts. Remove the engine
left insulator to
and
11. Attach the
the
engine
slightly, then carefully
Lift the
mission.
install it
then
hook
lifting
engine
the
engine out of
on
pull
it from the trans
engine
foot-pounds
from the
engine
transmission
the
up
sion
with
input
shaft
crankshaft
the
until
are
will not
the
the
shaft
(with
splines
sure
the
the
if
the dowels in the block
the
on
studs
engage
the transmis
disc.
If
the
enters, turn the
the
disc
clutch
exhaust
manifold
inlet
pipe and
muffler
the holes in the flywheel
crankcase
and
the
mission extension
located
on
ground
at
cable
housing.
The
procedures
given
installation. If only
not
disturb the
to
support
is
shown
either
a
in Fig. 8.
right
or
left
is to be removed, do
other support.
insulator to frame
nuts
and
lock
the
bracket
to
engine
bolts
and
lock
re
only the insulator is to be replaced,
the insulator to bracket bolts and lockwashers.
//
3. Raise the front
bracket
the
and
clutch
and/or
of
insulator
the
engine, then
assembly.
engine
accelerator
carburetor
air
choke
bracket spring
and
linkage. Remove the
horn,
install the
then
the
battery
radiator.
air
proper
engine
at
and
ground cable.
13. Fill the cooling
the
Connect the heater hoses
grade
fast idle
and
system.
quantity
Fill the
of
and check all
crankcase
engine
oil.
gaskets and
with
Run the
hose
con
for leaks.
INSTALLATION
1. Position
bracket
the
insulator
and/or
remove
the
assembly
place.
engine slightly.
Install, but do
not tighten
the bracket lockwashers
bolts (or the insulator to bracket lockwashers
and
bolts if only the insulator was removed). If both sup
ports
have been removed, install the bolts on the
opposite
side
before proceeding
with
step 4.
install, but do
not
tighten
and nuts.
5. Tighten the bracket bolts to 45-50 foot-pounds
torque (or the insulator to bracket bolts to
2. Remove
move
the
and
the
the insulator to frame lockwashers
the
to 23-28
bracket. Connect the
clutch
4. Lower the engine, then
washers.
washers.
rod,
12. Install the
3.
support
wires
generator
bushing,
2. Lower the
REMOVAL
1. Remove
nuts
pipe
cleaner.
in
apply
one
inlet
muffler
nuts, then tighten the
the
tape from the
and
left front
to
manifold
exhaust
the
and
rod
release
the trans
(Engine In Chassis)
engine
and
strap.
11. Install
the
Engine Front Supports
The
wires,
hose
vacuum
wiper
windshield
and
10. Connect
nections
of
side
each
is located
support
rear
unit
ENGINE SUPPORTS
3.
are
the temperature sending
and
pressure
oil
starter cable.
lockwashers
in gear)
housing. Remove the jack from the transmission.
supports
primary wire, the
coil
8. Connect the
disc. It
of the trans
clutch
with
mesh
the
start
transmission
the
holes in the
aligned with the
The front
the
and
com
engine
clutch
position
enter
after
shaft
the
to the engine
up"
slowly
Make
splines.
remove
then
into the
gear
adjust
relation
"hangs
engine
torque.
foot-pounds torque.
transmission,
drive
main
may be necessary to
mission
then
carefully into the
engine
then
bolts,
upper
the flexible fuel line.
work stand.
Jack
partment.
lifting hook,
housing
9. Install the
engine
2. Lower the
flywheel
the
unit
sending
INSTALLATION
1. Install the
45-50 foot
to
them
tighten
then
insulator to sup
6. Install the starter, then tighten the bolts to 15-20
compartment,
(Fig. 7).
a workstand
right
and
torque.
7. Connect the
(Fig. 6). Raise
left
engine
bolts,
tighten them to
bracket bolts.
support
fly
cover.
bracket
5. Install
9. Remove the flywheel
right
housing
pounds
starter.
and tighten
40-50 foot-pounds torque, then install the
4. Install the
port
lower bolts
housing
pounds
torque)!/ both
install the
ceeding
bolts
with
on
50-60 foot
have been removed,
opposite side before pro
supports
the
step 6.
6. Tighten the insulator to frame
pounds torque.
nuts
to 45-50
foot
Section
3 Engine
1-41
Supports
BOLT
RETAINER
RETAINER
SUPPORT ASSEMBLY
SUPPORT BRACKET
FRAME BRACKET
/
-*-^.
su^
_
1059-A
SUPPORT RETAINING BOLTS
INSULATOR
Fig.
1058-A
the pressure
on
the
4. Remove the
Fig. 8-Engine Front Support
9 Engine
Rear Support
support assembly.
retainer and support assembly.
INSTALLATION
Engine Rear Support
1. Jack up the
(Engine In Chassis)
The
engine rear support
tion the support assembly and
is
shown
to
support retainer
and
washers,
extension
housing
assembly to frame nuts, lock
bolts.
3. Jack up the
manifold
to
5. Tighten the
pounds
housing
extension
slightly to
relieve
assembly is
shown
support
and tighten
torque
extension
assembly
housing.
bolts to 23-28 foot
retainer
the
support
support
assembly
nuts
to
EXHAUST GAS CONTROL VALVE
MANIFOLDS AND
4.
The
Install, but do not tighten the
frame bolts, lockwashers, and nuts.
4. Remove the jack from the
support
posi
Install, but do not tighten the support retainer to
extension housing flat washers, lockwashers, and bolts.
and washers.
2. Remove the
to
retainer.
3.
1. Remove the
enough
2.
in Fig. 9.
REMOVAL
bolts
housing just
extension
3. Disconnect the
in Fig. 10.
muffler
inlet
pipe
from the
exhaust
manifold.
4. Remove the bolts
Manifolds
A
chamber
fold
center
(heat riser) is
section
valve, located in the
gases
quired
into this
by
incoming fuel
to
into the intake
carburetor
head,
and
lift the
Remove the
then
re
in vaporizing the
separate
air
horn
vacuum
line
intake
2. Disconnect the
bell
crank.
cleaner, then tape the carburetor
Remove the
at the
joining
the manifolds,
INSTALLATION
1. Place the intake
them
closed.
bolt
the manifolds.
2. Install the
REMOVAL
air
and
manifold
over
the studs
on
the
exhaust manifold.
mixture.
1. Remove the
nuts
exhaust
the necessary heat
assist
assembly from the head.
controlled
manifold, directs
to
manifold
gaskets and sleeves.
5. Remove the
provide
manifold
mani
the manifold to the
exhaust
and
thermostatically
exhaust
area
the intake
the
A
attached.
are
manifold
where
cast
fastening
carburetor.
Disconnect the
manifold.
throttle
linkage
the
manifold
3. Clean the mating
Inspect
in the
nuts and
bolts,
then tighten
finger tight.
and
4. Install
at
lockwashers,
repair
5. Coat
of
any damage
at
the mating surfaces.
new
sleeves, if necessary,
new gaskets
ports of
the cylinder
surface
using
heads.
the cylinder head.
the
mating
surfaces
lightly
with
graphite
1-42
2 6-Cylinder
Chapter
Engine
NUT
CLOSED
LOCKWASHER
(HEAT
ON)
GASKET
INTAKE
MANIFOLD
WINDSHIELD
WIPER
CONNECTOR
LOCKWASHER
EXHAUST
MANIFOLD
BOLT
-A
^A* VALVE
^Mi\ ^^
COUNTERWEIGHT
SHAFT ASSEMBLY
002 -A
CLAMP
WASHER
Fig. 7
2. Before
position
BUSHING
THERMOSTAT
SPRING
3.
10 Manifold
fold,
Using
the head.
against
manifold
gaskets
the
the
cut
caution
Assembly
manifold
Make
cylinder
the
sure
are
assembly
ings in the
assembly
head
6. Install the attaching
with
and
the port
open
that none of the
steel
washers and
bolts,
then tighten
ends.
7. Tighten the bolt
if
8. Install
position
a
nuts
joining
the intake
damage
to avoid
new
the muffler inlet pipe
over
and
lockwashers,
flange gasket, and
the studs. Install the
then tighten the
nuts
the
Install the
manifold.
carburetor
in the inside
and
7. Insert the
of
of
carburetor
ner.
linkage.
carburetor
air
repair
and
any
bushings
are
installed,
there
23/s inches from the inside
edge
bushings
with a pene
shaft
in
bushings
the
the
valve
"up"
and
plate
until
(heat on)
normal
valve
the
position
The
to the
valve
shaft
in the
shaft and valve are stainless steel
and/or
damage
by
excessive
man
to minimize
heat.
9. Install the thermostat spring in the
of
the spring
should
is located in the
original
outlet
Normally, it does not require
it becomes inoperative due to exces
over
hold the
hook the
and
open end
The thermostat spring
in the closed or "heat
position
the stop
pin.
on"
valve
proper
into the heat
shaft slot.
position
to direct the flow
of
gases
riser).
manifold.
unless
sive corrosion or
damage.
1. Remove the
intake
bores.
horn,
air cleaner.
exhaust gas control valve
replacement
bearing
Use
Replace the bushings
occurred.
through
is in the
8. Weld the
and
(i.e. in the
exhaust
plate.
vacuum
Replacement
the
mani
pieces.
corrosion
new shaft and
shaft
Rotate the
to 23-28
of
shaft
shaft
10. Wind the spring 3A turn
The
the valve
sides of
the
of
oil and graphite mixture.
corrosion
install the
shaft.
(Fig. 11).
10. Remove the tape from the
then
the
reamer.
counterweight
9. Connect the throttle linkage. Connect the
connect
end of
to the
new
distance
a
6. Lubricate the
trating
foot-pounds torque.
line to the intake
front
one
plate.
nuts
be
y16-inch
outlet
exhaust
valve
When
necessary.
and
to 23-28 foot-pounds torque.
manifolds
and
bushing to the inside edge of the other bushing.
The bushing should be equally spaced within the
counterbores. After installation, ream the bushings with
a
and
both
shaft on
damage that may have
should
bolts to 23-28 foot-pounds torque, tightening from
exhaust
valve
pin, shield, stop spring
5. Clean the bushings
in the
have become dislodged.
the center to the
to the
relation
position
openings
port
aligned
in
of
the
cotter
an acetylene torch
4. Remove the
place
in
counterweight
the
note
assembly,
>
GASKET
grease, then
valve
thermostat spring from the
LOCK WASH
Fig.
the
Gas Control Valve
the
removing
Remove the
plate.
BOLT^
of
1 Exhaust
manifold
11. Install the stop spring, shield,
12. Lubricate the
assembly
and exhaust manifolds.
and
separate
the
valve
manually to
the welding
shaft
replace
operation.
bushings
and
while
the original
cotter pin.
operating the
lubricant lost
by
5 Cylinder
Section
5.
Head
1-43
Valves
and
CYLINDER HEAD AND VALVES
Cylinder Head Removal
1. Drain the cooling system. Remove the
upper hose and heater hose. Disconnect the
cable at the cylinder
ture sending
head
battery
disconnect the tempera
and
unit wire.
2. Remove the
cleaner, then tape the
air
Disconnect the
closed.
radiator
accelerator
rod
the
and
horn
air
choke
cable.
3. Disconnect the
tributor
vacuum
carburetor
line,
and
the
carburetor
fuel inlet
the manifold
line,
the dis
vacuum
line
at
the fuel pump.
4. Disconnect
carburetor, the distributor
tor,
vacuum
and the manifold vacuum
remove
the three lines
5. Disconnect the
one side.
spark
Remove the
plugs.
an
as
coil
fuel inlet line
line
line
at
the distribu
the manifold, then
1064- A
assembly.
from the head
and move
plug wires, then
spark
Remove the
at
the
at
rocker
it to
remove
arm cover.
the
bracket,
(Fig. 12). Be
7. Loosen
then
pull
careful not
it
out of
the block
with pliers
to damage the line.
remove
the valve spring load from the rocker arms, then
remove
the
rocker
rods
in
in their
arm
shaft
sequence.
original
adjusting
assembly.
Identify
positions
screws
Remove the
them so
they
can
manifold
manifold
the
head
cylinder
(Fig.
the
head
pipe
and pull
the
will
not
and
to
protect
as
be damaged. Install
the
convenience
gasket
in
surfaces
14).
9. Remove
cylinder
all
der head
guide studs
be installed
assembly
off
and
bolts,
holding fixtures for
valve push
(Fig. 13).
to head
assembly away from the head. Brace the
sembly so the inlet
lifting
to
all rocker arm
Push Rod Removal
13 Valve
8. Remove the
6. Remove the cap screw and clip from the No. 6
rocker arm support bracket. Pull the oil feed line out
of
Fig.
the
block
head bolts. Install the
(Fig. 15). Lift the
the
engine.
as
the
Do
cylinder
head
pry between the head
not
gasket
cylin
surfaces
become
may
damaged.
Rocker Arm Mechanism
REMOVE SCREW
1. Pull the
support
drain line
oil
clip
out
of
the No.
1
bracket.
2. Remove the
arm
and
Disassembly
shaft,
and
cotter pins at each end of
remove
the
flat
washers
the rocker
and
spring
washers.
BOLT BRACKETS TO INTAKE PORTS
PRY UP OIL LINE WITH PLIERS
Flgm
12 Oil
Line Removal
Too/-T52P-6085-DAD
1063-A
1065- A
Fig.
14 Cylinder
Head
Holding Fixture
1-44
Chapter
6"
7/1614 X
|
BOLT
2 6-Cylinder
Engine
CUT OFF HEAD, TAPER END
AND CUT SLOT FOR
SCREWDRIVER, AS SHOWN
Tool
6513-EE
1066- A
15 Cylinder
Fig.
Head Guide Studs
1067- A
3. Remove the plugs
plugs
are
each
end
interference fit. To
an
drill
or
pierce
rod
to
knock
Working
ing plug.
at
the plug
the
out
from
on one
the open end,
remove
the plugs,
end, then
use a steel
the
on
plug
the shaft. The
of
knock
opposite
the
out
end.
Fig. 7
Cylinder Head
removed
shaft.
Be
rocker
to
sure
Cylinder Head
1. Clean the
2. Compress the
retainer
valve
install the
spring
Using
install
a
a
(Fig. 16), then
locks
and release
stem
seals.
remove
stem
Identify
seal,
all
and valve.
parts.
valve
Assembly
parts
side
with
or
engine
a
out, in
each
end
the
valve
fitted. Install
was
it
which
a
new
was
stem
install the
then
spring,
valve
Compress the spring, and
locks (Fig. 16). Measure the valve
and
retainer
sleeve.
height.
carbon
from the head
pin
punch,
the
rocker
and
deposits
block
head for any damage
Apply
a
sides of
the
new
a
and
gasket over
support
brackets,
17). Install the remaining flat
between them,
and
the
and
another
shaft.
install the
Install
springs
washers with
cotter
flat
(Fig.
3. Lift the
head
bolts,
amount
opposite
the spring
in
key.
ing
of
gasket sealer
to
Use the brush furnished to
over
the
entire
the guide
the threads
water
ends
gasket surface.
studs on
the cylinder
over
of
resistant
of
the guides and slide
installing
each
sealer.
bolt
the cylinder
with
a
small
Install two bolts
at
the head to hold the head and gasket
Remove the guides, then install the remain
bolts. Remove the cylinder head holding fixtures.
position.
FLAT WASHER
STUD^
COTTER PIN
ROCKER SHAFT
Arm Mechanism
ADJUSTING
^
J
17 Rocker
Inspect the
necessary.
head
cylinder
head
cylinder
coat
MOUNTING BRACKET
Fig.
as
residue
block.
COVER RETAINING
ROCKER ARM
sealer
surfaces.
repair
gasket.
evenly
gasket
gasket
and
of
coating
sealer
Position the
of
flat washer, spring washer,
arms,
from
valve.
1. Clean
both
oil.
large diameter
and a cotter pin on one end of
rocker
washer
port
the head down carefully. Before
3. Install
the
it
in the
Cylinder Head Installation
the spring. Remove
shaft.
washer,
valve
valves.
blunt tool
plug, cup
Installation
Assembly
which
assembled
spread
2.
to
spring retainer,
the combustion chambers
valve springs
moving
each
2. Install
Rocker Arm Mechanism
all
or
the
seal on
2.
1. Oil
or
the parts.
the sleeve, spring retainer, spring,
Discard the
off
Disassembly
carbon out of
before removing the
the valve
identify
brackets
and
arms, springs,
Stem Lock Removal
remain
1. Install
4. Slide the
the
6 Valve
L
SCREW
9
^^
FLAT WASHER
5 Cylinder
Section
4. The
head bolt tightening
cylinder
in three
performed
and
1-45
Valves
is
procedure
First,
progressive steps.
Head
0)
ffl
ZM
Q!)
tighten the
bolts to 55 foot-pounds torque
(cold) in the proper
sequence (Fig. 18), then tighten them to 65 foot-pounds
torque
again
in the
(cold)
after
the
push
Position the lower
then
valve
rocker
the shaft
line,
No. 1 bracket. Make
sockets.
the
on
assembly
clip, and retaining
sure
the
line
oil
enters
Connect
Make
sure
then install the air
in the
oil
13. Start the
feed line
oil
the lower
end of
the
No. 6 bracket.
the
on
"O"
line
oil
seal
ring
is
supply counterbore, then install the bolt.
8. Tighten
all
bolts to 45-55 foot-pounds
the retaining
Perform
a
(cold)
preliminary
lash
valve
ad
justment.
9. Install
the
manifold
head
to
bolts
tighten
and
minutes
10. Position the two
Connect the
the
on
lines
engine,
then
11. Install the ignition
nect
the
spark
plug
12. Install the
and
the
carburetor
lines.
the
connect
the choke cable.
the
coil and
spark plugs.
Con
wires.
radiator
hose
and
heater hose.
and
engine
the
valve
lash
the
with
necessary.
After the
tightened
to
horn,
1200
a minimum of
rpm.
With the
idling
engine
proper
check
it if
adjust
head bolts have been
cylinder
the
specifications,
and
30
bolts
not
should
be
disturbed.
oil
one side of
resistant
in
cover,
making
place
the
in the
the
the head. Install the
around
sure
they
are
Tighten the retaining
the
gasket
rubber
centered
nuts
cemented
side
Install the
cover.
that
sure
rocker arm cover gasket with
lay
and
sealer,
gasket
power
Crankshaft Damper
it for
run
engine
CRANKSHAFT DAMPER, CYLINDER FRONT
AND CRANKSHAFT OIL SEAL
6.
cooling
air
carburetor
in
up, tighten the cylinder head bolts,
sequence to 75 foot-pounds torque (hot), then
making
upper
the
cleaner.
approximately
14. Coat
vacuum
accelerator rod and
at
Fill
cable.
ground
warmed
them to 23-28 foot-pounds torque.
fuel inlet line
battery
the
Remove the tape from the
system.
locating hole.
7. Position the
torque.
drain
oil
Head Bolt Tightening Sequence
18 Cylinder
Fig.
sequence.
the rods in the tappet
install the
screw on the
proper
arm
13).
(Step
up
end of
6. Position the
head,
warmed
in their
rods
the bolts
1069- A
the engine has been
5. Install
Tighten
same sequence.
in the
to 2.0-2.5
evenly
on
cover
the
the
arm
rocker
seats
seals
of
all
studs
openings.
foot-pounds torque.
COVER,
steering pump pulley
on
the crankshaft
damper.
Tighten the retaining bolts to 23-28 foot-pounds torque.
REMOVAL
Install
1. Remove the
2. On
radiator
and
the drive belts.
cars equipped with power
two bolts
and
steering,
lockwashers that fasten the
pump pulley to the
crankshaft
damper,
adjust
4. Install the
remove
power
and
the
power
steering pump belt.
radiator.
the
steering
then remove the
pulley.
of
3. Remove the cap
screw
the crankshaft, then
remove
washer
and
from the
end
the damper (Fig. 19).
INSTALLATION
1. Lubricate
lead
mixture
the
and
crankshaft
lubricate the
with
oil
an
seal
oil
and
rubbing
white
surface
with grease.
2. Align the damper keyway
crankshaft, and
damper
and
on
the
start
the damper
shaft
3. On
cars
Install
on
the
the
key
shaft.
on
the
Press the
(Fig. 20). Install the lockwasher
tighten the
capscrew, then
pounds torque.
with
and
equipped
capscrew
adjust
with
to
the drive
85-95 foot
belt.
070-A
power
steering, install the
Fig. 7
9 Damper
Removal
1-46
2 6-Cylinder
Chapter
Engine
Tool
-
T52L-6700-BEE
1071-A
20 Damper
Fig.
Installation
107 2- A
Cylinder Front Cover
Oil Seal
It is
each
good
time the
CYLINDER
to
practice
cylinder
FRONT
Crankshaft
and
front
cover
COVER
front
the
replace
is
oil
IN
removed.
(ENGINE
IN
of
the
cylinder
the cylinder
of
surface
the block
and
front
cover
and
block. Coat the
the cover
with
the
gasket
sealer, then
gasket
surface
position
the block.
a new gasket on
the gasket.
cover and
2. Place the
OIL SEAL REPLACEMENT
taining
1. Drive
out
the
old seal with a pin
punch, then clean
cover
on
the block and install the
Tighten the
screws.
screws
re
to 6-9 foot-pounds
torque.
the recess in the cover.
2. Coat
a
new
seal
(Fig. 21). Drive the
the
(ENGINE
CHASSIS)
1. Clean
REMOVAL
Seal Installation
CYLINDER FRONT COVER INSTALLATION
seal
CHASSIS). Remove the radiator, the crankshaft damper,
and the oil pan. Remove the cover retaining screws, the
out
27 Oil
Fig.
recess.
in
seal
Check the
grease, then install the
with
it is
fully
seated
installation to be
after
seal
the spring is properly
until
positioned
in the
3. Install the
oil
seal
in
drive belt. On
the
power
the
crankshaft
sure
4. Install the
seal.
pan,
and
damper,
and
steering, install
belt.
radiator.
7. SPROCKETS AND TIMING CHAIN, CAMSHAFT,
BEARINGS, AND TAPPETS
Sprockets And
Timing
INSTALLATION
Chain
(Engine In Chassis)
1. Place the keys in
position
in the
slots on
the crank
shaft and camshaft.
The
to, the
is
camshaft sprocket
end of
the
a
slip fit on,
and
is keyed
2. Position the
camshaft
the
REMOVAL
1. Remove the
sprockets
radiator and
engine
the
cylinder
front
until
the
timing
marks
and chain are positioned as shown
3. Remove the
washer.
timing
and
camshaft
Slide both
ward and remove
sprocket
sprockets
them as
and
an assembly.
timing
crankshaft.
22. There
are
cover.
on
the
in Fig. 22.
retaining bolt
the
and
chain
and
for
Be
sure
the
chain
timing
12 timing
the
marks on
chain
link
pins
on
the
marks on
sprockets and chain are positioned as shown
timing
2. Crank the
sprockets
camshaft.
in Fig.
between the
sprockets.
3. Install the
camshaft sprocket washer and
4. Install the
cylinder
retaining
bolt. Tighten the bolt to 45-50 foot-pounds torque.
(power
belt(s),
steering
and
front cover, crankshaft damper,
pump pulley, if applicable) drive
radiator.
7 Sprockets and
Section
CAMSHAFT SPROCKET TIMING MARK
DRIVING SIDE OF CHAIN
12
Timing Chain, Camshaft, Bearings,
Fig.
CRANKSHAFT SPROCKET TIMING MARK
1073-A
24
Aligning Timing
Marks
Lifting
line
a
der block to
22
1-47
Tappets
PINS BETWEEN MARKS
5. Scribe
Fig.
and
the distributor
on
the
mark
Securing Valve
and
position of
housing for installation,
utor
Tappets
housing
the
then
rotor
and cylin
and
remove
distrib
dis
the
tributor.
Camshaft (Engine In Chassis)
The
6. Remove
in Fig. 23.
camshaft and related parts are shown
with
1. Remove
the
cleaner
air
Remove the distributor
disconnect the
spark
horn
air
plug
wires.
coil
clips, then
engine
push
Remove the
Remove the fuel
rods
the
radiator
radiator,
and
cylinder
front cover,
and
the
push
radiator
grille
wire
rod
support
assembly.
the oil
pan
from
valve
bar,
8.
sprocket
and
Remove the
Carefully
to
until
engine
chain
Remove the
to cylinder block
the
camshaft sprocket
SPROCKET
timing
marks
are positioned as shown
/
the fingers. Raise
lobes
them
and secure
of
avoid
on
and
remove
the
pins
clothes
or
window
regulator
25).
the
engine.
camshaft
by
pulling it toward
Exercise the necessary
damaging
the
camshaft
cau
bearings.
1. Oil the
camshaft and
carefully
bearings. Install the thrust
Be
sure
the
faces
chamfer
the
on
camshaft
washer
slide
it through the
and
woodruff
the thrust washer
key.
is to the
journal.
the
in Fig. 22.
bolt.
INT.
INT.)
camshaft
or
be lifted
INSTALLATION
rear or
BEARING (FRONT AND
CAMSHAFT
tion
the
two front bolts.
4. Crank the
the
spring clips (Figs. 24
chamber
mechanism, the
arm
in sequence, the
to coil
switch
remove
rocker
clear of
washer.
the tappets can
(Fig. 24),
magnet
a
spring-type
the front
3. Disconnect the ignition
cover.
the tappets
with
from the
wire
pump.
the
either
the
chain,
cap.
2. Disconnect the high tension
and
the
tape
and
thrust
camshaft until
timing
and
sprockets
and camshaft
7. Turn the
REMOVAL
closed.
key
woodruff
the
N.
BEARING
v
REAR
BEARING
REWORK CLOTHESPIN
^U
^^
WASHER
SCREW
KEY
3/i6 INCH
CAMSHAFT
THRUST WASHER
DRIVE CHAIN
1074-A
LOCKWASHER
Fig.
23 Camshaft and
Related Parts
1076-A
Fig.
25 Tappet
Retainers
1-48
2 6-Cylinder
Chapter
Adapter
Tool T52L-626I
Engine
11. Run the
-GEE
and
cover.
if
and
sprockets
bolt. Tighten
replace
3. Install the
timing chain,
and
the
bolt to 45-50
sprocket
front cover, the oil pan to
the drive belts and fan assembly.
radiator
grille
a
install the
and
preliminary
to properly
install the
rods, then
push
position
gasket
lash
using the
the
to the
and
rotor
lines
scribed
as
spark
plug
push rod chamber cover
Install
the
wires and
switch
to
distributor
coil
on
wire
the
Connect the
cap.
the coil high tension
wire.
Install
crankshaft
27. The
covered
carburetor
air
horn,
air cleaner.
clutch
other
and
pilot
and
the
2. Position the
it in
place
camshaft
bearing
at
camshaft
bearing
rear
bearings (Fig. 26).
the
(Fig. 26). Number 1
bearing bore
and press
bearing
cam
must
be
in 0.005-0.020 inch below the front face of
the bearing bore. Press the remaining bearings in
pressed
sufficiently to
align
the
supply holes. Install the
oil
Tappet Replacement (Engine
1. Remove the
camshaft.
2. Remove the
oil pan.
3. Remove
install
and
tappet
at a
time through
the block. A flexible-type
the
bottom
of
can
be
if desired. As
used
one
each
tappet
holding tool
is installed, secure
position.
4. After the tappets
are
installed, install
the
cam
shaft.
FLYWHEEL, CRANKSHAFT, AND MAIN BEARINGS
8.
The
1. Remove the camshaft, the
it in the up
10. Remove the tape from the
install the
the
with
to
screws
the fuel pump.
then
journal diameters.
interchangeable
not
reaming for
in Chassis)
housing.
Tighten the retaining
cover.
9. Connect the ignition
clip.
bearing is
are
adjustment.
15-20 inch-pounds torque.
engine
size and require no
undersize
from the
engine
camshaft.
valve
distributor,
8. Cement the
and
and
rocker arm assembly.
7. Install the
guides
assembly, radiator,
bar.
5. Release the tappets
6. Perform
timing
sprocket
cylinder
4. Install the
install the
the
The bearings
bearings.
0.015-inch
and
bore plug,
bolts,
radiator support
to
the
remove
camshaft
available pre-finished
Number 3
foot-pounds torque.
block two front
arm
rocker
and adjust
ad
bearings.
2. Install the
washer
lash
valve
oil
Replacement
be necessary to
will
standard
Bearing Replacement
(hot)
idling. Install the
engine
Check the ignition timing
to
car
26 Camshaft
final
a
for
check
and
necessary.
It
Fig.
the
with
Bearing
1077-A
fast idle
at
leaks. Make
coolant
justment
engine
related
bushing
parts
are
shown
in Fig.
replacement procedure
is
2. Remove the
mission
extension
speedometer
housing
3. Disconnect the
in Part 3.
gear
from the trans
cable
and secure
shift
rods
it
on
and
the frame.
transmission
levers.
4. On
Flywheel
nor and solenoid
The flywheel is
on
fit
the
on
crankshaft
piloted on a shoulder and
by
six
bolts. The ring
gear
is
retained
is
a shrink
the flywheel.
CONVENTIONAL
(ENGINE IN
the wiring harness clip from the transmission.
nect
OR
OVERDRIVE
TRANSMISSION
the engine
taining bolts
shaft
extension.
and
install tool 7657 in
rear
support.
and
install
pilots
1. Remove the drive
remove
6. Remove the transmission to flywheel
Removal
Discon
the overdrive manual control cable assembly.
5. Support the engine, then
CHASSIS)
the transmission
transmissions, disconnect the gover
wires at the bullet connectors. Remove
overdrive
clear
the
flywheel housing.
re
in the lower holes.
housing
8. Slide the transmission far
housing
cover.
enough
to the
rear
to
Section
9. Mark the
stalled
release
the
clutch
position, then
rod, spring, and bearing.
same
10. Remove
the
clutch
Flywheel Crankshaft,
that it
so
assembly
8
remove
can
be in
the
clutch
11. On
transmissions,
overdrive
and solenoid wires at
wiring harness clip
pressure
plate
disc
and
1-49
Main Bearings
and
governor
Install the
connectors.
the transmission. Connect the
on
control
manual
overdrive
the bullet
the
connect
assembly.
cable
(Tool-7563).
FORDOMATIC TRANSMISSION
retaining bolts and pry the
flywheel off the crankshaft. Remove it through the
housing
on
lower
access opening.
Do
Removal
not get grease or oil
1. Remove
the clutch components.
upper
Installation
1. Position
and align
the bolt
flywheel
holes,
Tighten the bolts in
the
on
crankshaft
converter
across
from
each
at
Using a pilot shaft (Tool-6392-N) to locate the
clutch disc, install the pressure plate and disc. Tighten
3. Install the
bearing,
rod,
sion control rod at
and
install the transmission to flywheel
Remove the
the pilots
on
housing
upper
engine
jack supporting the
6. Connect
the
rear
9. Position
support, then remove the
7. Install the
speedometer
8. Install the
clutch
rods
and
cable
transmission
drive
and
retracting spring
housing
and
install the drive
level
dip
jack
under
stick.
converter.
the transmission.
support
bolts.
cross member at
the
rear of
the
13. Move the transmission back far
enough
to clear
the flex drive plate. Secure the torque converter to the
housing.
cover.
10. Remove the tool from the transmission
housing
oil
12. Remove the two lower bolts securing the torque
converter housing to the engine block.
gear.
and adjust
remove
the transmission.
free travel (lV8-l3/8 inches).
a
11. Remove the frame
shift
transmis
and
cable
from the starter, then
cable
10. Remove the transmission
levers.
pedal
speedometer
8. Install the drain plug in the torque
engine.
gear
shaft.
bolts.
bolts. Tighten the bolts to 45-50 foot-pounds torque.
5. Install the
the drain plug is
the starter.
and
install the lower retaining
pilot studs and
converter until
the transmission
6. Remove the
hub.
4. Slide the transmission forward
the torque
and
the lower edge. Drain the transmission and torque
5. Disconnect the
spring,
linkage shield,
control
access plate.
4. Remove the drive
foot-pounds torque.
clutch release
block
converter.
2.
the retaining bolts to 17-20
front
3. Turn the torque
other
engine
bolts.
converter
then install the mounting bolts.
sequence
to
housing
the torque converter lower access plate,
flange
to 75-85 foot-pounds torque.
clutch
the
the
(ENGINE IN CHASSIS).
slide
extension
If
the torque converter
is
not
14. Remove the flywheel from the
shaft.
REAR OIL SEAL
CRANKSHAFT SPROCKET
secured, it
will
off the splines.
v^^
CRANKSHAFT
crankshaft.
LOCKWASHER
ITU
FRONT OIL SEAL
REAR OIL SLINGER
SCREW
\]
WASHER
KEY
SCREW
BEARING INSERT
(FRONT AND INTERMEDIATE)
DAMPER
THRUST BEARING
INSERT
FRONT
G/
REAR BEARING
INSERT
IV^-REAR
\J
OIL
SLINGER
OIL
SEAL
CLUTCH PILOT
BEARING
REAR MAIN
BEARING CAP
LOCKWASHER
SCREW
I
FRONT AND INTERMEDIATE
BEARING CAP
BEARING CAP
SIDE OIL SEALS
Fig.
27 Crankshaft and
Related Parts
FLYWHEEL ASSEMBLY
(CONVENTIONAL OR
OVERDRIVE
TRANSMISSION)
1078- A
1-50
2 6-Cylinder
Chapter
Installation
3.
1. Position the flywheel
the bolt
the crankshaft
on
and
align
install the mounting bolts. Tighten
the bolts to 75-85 foot-pounds torque.
holes,
then
2. Align the
holes,
converter
install the
then
pilot
housing
the
and
to engine block
housing
converter
dowel
lower bolts.
Engine
4. Check the
5. After the
to converter bolts.
plate
4. Install the frame
cross
journals
the
7. Connect the transmission throttle
the manual
8. Install the
front
linkage,
control
access
transmission
linkage,
linkage shield, converter housing
the lower access cover, and the
control
cover,
oil
control
the speedometer cable.
and
level
dip
connect the starter cable.
14. Start the
fluid
the
until
proper
fluid.
with
the
level is
cap is installed.
bearing
rear main
bolts up lightly, then
7. Tighten
the
torque. Check the
when
new side seals
bearing
the thrust bearing.
align
bolts
cap
draw the cap
and
cap
foot-pounds
95-105
to
crankshaft end play.
8. Install the connecting
in their
caps
rod
original
9. Check the
and
checked and
found
coat of engine oil
to the
has been
clearance
to be satisfactory, apply
journals
bearing.
clearance of each
light
a
then install the
bearings,
rod caps.
Tighten
the nuts to 45-50 foot-pounds torque.
to fill the converter, then
engine
to the
bearings, then install all the bearing caps
thrust bearing cap. Tighten the cap bolts to
10. After the
11. Remove the safety stands and lower the car.
12. Install the converter housing to engine bolts.
13. Fill the transmission
coat of engine oil
positions.
stick.
9. Install the starter, then
10. Install the drive shaft.
found
checked
and
6. Install the thrust
bolts.
rear support
light
bearing.
and
has been
a
Be
place.
surfaces.
main
each
of
clearance
bearing
the
clearance
into
crankshaft
95-105 foot-pounds torque. Install
member.
5. Remove the jack from the transmission.
6. Install the transmission
the
damage
to
not
careful
except
3. Install the flex
lower
Carefully
the
reached on
dip
add
stick.
11. Install
the
pal
to
3-4
connecting
rod.
them
tighten
and
nuts
foot-pounds torque.
15. Check for leaks.
16. Check
switch,
and
and adjust
the manual control, the neutral
the throttle linkage.
12. Check the
side clearance of each
13. Install the
engine rear plate.
14. Install the flywheel.
15. On
Crankshaft
the
REMOVAL
engine and
2. Remove the
flywheel,
3. Remove
the
cover, sprockets
ing
timing
damper,
rod)
oil pan and
top
the
oil
they
caps
pump
can
(main
screen
the
rear
bearing
cap,
and
connecting
compress
the
sprockets
18. Install the
cylinder
and
19. On
clutch
plate
pressure
covers.
timing
and
oil
pan,
front cover,
the
chain.
oil
crankshaft
pump
screen
damper,
and
bearing
rod
push
20. Install
caps,
using
the pistons to
bearing
journal
and
reground, install the
system and
of
for
the
not
oil
of
the block
engine oil.
pressure
cap to block
journals have been
bearing inserts.
the crankshaft
journals
Main
bearing
cap.
and
the
proper grade and
engine at
check
all
fast idle
hose
and
connections
for leaks.
Bearing
oil seal
in the block
and
Replacement
(Engine in Chassis)
Replace
one
oil
pan, then
bearing
at
a
remove
time,
the oil pump.
leaving
the other
2. Remove
bearings
are clean.
journal
Run the
Fill the cooling
so
from the block
the
correct undersize
a new rear
crankcase with
car.
damaged.
seal
remove
and
in the
engine
fill the
oil
and gaskets
out
crankshaft
the bearings
and
caps.
crankshaft
are
steering, install the
drive belt.
quantity
INSTALLATION. If the
2. Install
housing
17. Install the
1. Remove the
sure
install the
and
springs,
origi
side seals.
rear main
6392-N),
power
surfaces
9. Remove the
1. Be
(Tool
align
assembly.
check
main
Carefully lift
thrust bearing
rear
cars,
hous
the cylinders.
7. Remove the
8.
plate
assembly
be installed in their
to intermix the caps, then
of
equipped
drive belt.
bearing
sure all
are marked so
care not
overdrive
chain.
6. Remove the connecting
and
front
cylinder
locations.
nal
the
rear plate.
assembly.
5. Make
the
on a work stand.
the engine
and
crankshaft
and
4. Remove the
install it
disc
clutch
pressure
1. Remove the
or
standard
are
oil
main
bearing
cap
to
which
new
to be fitted.
3. Insert the
in the
the
upper
hole in the
bearing
removal
crankshaft.
tool (Tool
Rotate the
6331)
crankshaft
8
Section
in the opposite direction to
bearing
out of
it is
good
the
ing
bearing,
upper main
bearing over the shaft on
Using the same tool,
in the direction
shaft
seats
bear
with new
first try to obtain
two blue bearing halves.
the block.
side of
to force the
to
practice
4. To install the
of
bearings
standard
proper clearance with
end
engine rotation
the block.
When replacing
ings,
Flywheel, Crankshaft,
the
locking tang
rotate
the
crank
the bear
of engine rotation until
itself. Remove the tool.
5. Clean the
9.
bearing
7. After the
clearance
and
clearance.
light
a
journals
then
and
bearings,
and
found
coat of engine oil
to the
has been
8. If the
journal
checked
install
bearings.
bearing is
main
rear
oil seals and
the
bearing
the
cap.
oil
10. Fill the
crankcase
of engine
for
replace
replaced,
the
side seals.
9. Install the
quantity
journal
crankshaft
6. Check the
Tighten the bolts to 95-105 foot-pounds torque.
place the plain
the
1-51
Main Bearings
and
pump
and oil pan.
with
oil, then
the
start
grade
proper
and
engine and check
the
leaks.
oil pressure and oil
CONNECTING RODS AND BEARINGS,
PISTONS, PINS, AND RINGS
The
piston and
connecting
rod assemblies are shown
in Fig. 28.
7. Pull the cap
piston
handle
Piston
Rod Removal
Connecting
and
pin
oil pan.
2. Remove the
cylinder
of
the
of
its travel
cylinder
the
collect
excess
of
and
until
V32 inch
remove
piston
the
removed
cloth
when
the
on
is
top
the
piston
cylinder
the
its
end
head to
ridge
travel
with
a
in
area
ridges.
remove
then turn the
of
upper
to the bottom
has been removed,
bore,
at
piston
removing
cylinder
remove
assemblies,
into the ring
cut
cloth with
5. Turn the
a
Remove the
ridge
from the
the
place
Never
4. After the
cutter
bores. Move the
cuttings.
cutter.
ridge
piston
deposits from the
carbon
the
stroke and
carefully
rod
with
the
removing the
crank
piston
Each
6 from
bers
side
cylinder
and
the
the
new
bearing
front to the
the
connecting
Piston
the connecting
rod
being
rod
when
rod
is
and
cylinder wall.
ever
rod should
cylinder
cap is
assembly.
rear
of the
bearing
be
The
engine.
cap
must
be
cylinder
from
transposed
new
from 1 to
numbered
installed in the
to another,
and
1. Mark the
the
pal nuts and
the
from the
above procedure on each
rod and
on
same
glaze
bearings
on
bore.
one
should
num
the
If
block
be
a
or
fitted,
numbered to correspond with
number.
Connecting
Rod
Disassembly
is down.
the connecting
cylinder
and
crankshaft
cuttings.
crankshaft until
6. Remove the
when
wall
cylinder
9. Repeat the
head.
the
removing
and/or
ridge
the
the
of
rod
hammer. Avoid damage to the
8. Remove the
1. Remove the
any
or
top
the
push
and rod.
(Engine In Chassis)
3. Before
end of a
the
out
assembly
the rod, then
off
the hex head nuts from
pistons and pins
same rod and
which
they
installation in the
same cylinder
CONNECTING ROD CAP
COMPRESSION
STEEL RAILS
Fig.
28 Piston and
from
piston rings.
OIL RING ASSEMBLY
PAL NUT
with
were removed.
2. Remove the
bolts.
to assure assembly
Connecting Rod Assemblies
RINGS
1079-A
1-52
Chapter
2 6-Cylinder
Engine
5. Check the
6. Be
side clearance of
the bearings
sure
the
rings.
journals
and
If it
are clean.
'
is necessary to
replace
replace them at
this time.
Piston
Connecting
and
the
bearings,
rod
connecting
Rod Installation
(Engine In Chassis)
Be
from
install the
to
sure
they
which
1. Oil the
light
piston
the
guide
crankshaft
Pin Removal
tion
in
end
to
they
which
cylinder
walls
the
head
Install
the
push
a piston
piston
piston with
toward
sure
damaging
avoid
in
it is slightly
until
(Fig. 31). Be
to
rods
spaced
properly
piston.
hammer
a
journals. Install
piston
are
and
cylinder
connecting
the
the
of
piston
ot
the
of
gaps
ring
the
on
the handle
below the top
29 Piston
the
sure
compressor
with
Fig.
or
and
rings, pistons,
the circumference
around
080-A
removed,
engine oil.
2. Make
ring
were
cylinder
same
fitted.
were
with
in the
pistons
the
to
the
indenta
front of the
the
engine.
3. Remove the
the
pin out of
piston
4. Discard the
Piston
and
1. Lubricate
piston
pin
and rod
into
pin
ing
rod with
as shown
light
all parts with
the
rod
Assemble
oil squirt
and connect
piston
hole in
the
new piston
piston with
package and
journals
bearings.
5. Turn the
rod positioned
rod
bearing
crankshaft
push
pin
retainers
by
spiraling them
the fingers. Do not use pliers.
install the
contained
on
the
piston
piston rings.
the
seats on
6. Install the
rod
coat
throw
piston all
the
using Plastigage.
has been checked,
light
a
apply
and
clearance
clearance
of
engine
and
found
to
oil
to the bottom
of
the
its
the way down until the
crankpin.
cap, then tighten the
bolts
to 45-50
foot-pounds torque.
7. Install the
4. Follow the instructions
ring
piston and push
bearing
satisfactory,
stroke, then
engine oil.
in the
the
Assembly
in Fig. 30.
3. Insert
into the
Rod
Connecting
place.
3. Check the
4. After the
retainers.
2. Position the connecting
the
retainers, then drive the
(Fig. 29).
pounds
pal nuts and
tighten them to 3-4 foot
torque.
8. After
installed,
all
the
check
piston and rod assemblies
the
side
clearance
of
the
have been
connecting
rods.
INSTALL PISTON WITH
INDENTATION TOWARD
COMPRESSOR
SECURELY
TIGHTEN
FRONT OF ENGINE
T00/-FLM-
6749
POSITION OIL SQUIRT
HOLE TO RIGHT WITH
PISTON DOT FORWARD
1081-A
Fig.
30 Correct
Position
of
Oil Squirt Hole
INSTALL RING COMPRESSOR
Fig.
WITH RETAINER TOWARD SKIRT
31 Piston
Installation
1082- A
9
Section
9. Install the
and
11. Fill the
cylinder
head.
crankcase
quantity of engine oil.
12. Fill the cooling
13. Run the
Bearings, Pistons, Pins
4. Clean
oil pan.
10. Install the
upper
the
with
proper
grade
and
half
fast idle. Make
at
there is
sure
does
not overheat.
leaks.
oil and coolant
new
standard
bearings in the
6. Check the
7. After the
Connecting
Rod Bearing Replacement
(Engine In Chassis)
pan, then
oil
2. Remove the connecting
new bearings are to be fitted.
3. Push the
the
upper and
remove
rod
the
bearing
oil pump.
caps
to
bearings
remove
lower bearings.
10. Repeat the
11. After
oil
3. Remove
crankcase.
the
proper clear
bearings,
then
coat
of
found
and
oil
engine
install the
rod
to
cap.
for the
procedure
remaining
need replacing.
all
pump
above
the bearings
have been replaced, install
and oil pan.
oil
pump is
shown
in Fig. 32.
REMOVAL
dip
stick.
left
engine
1. Remove the
front
right
and
splash
distributor,
the pump to the
bar.
stabilizer
5. Remove the flywheel housing inspection
oil
level
dip
stick,
and
the
oil pan.
2. Remove the two
aprons.
4. Remove the
the
Pump
The
REMOVAL
level
bearings, it is
pounds torque.
Oil
oil
new
OIL PAN, OIL FILTER, AND OIL PUMP
Oil Pan
2. Remove the
light
a
When
8. Tighten the bolts to 45-50 foot-pounds torque.
9. Install the pal nuts, and tighten them to 3-4 foot
the
10.
1. Drain the
with
bearing fit using Plastigage.
bearing fit has been checked
and
bearings that
up in the cylinder, then
piston
which
the journals
the
and
rod and cap.
first try to obtain
blue bearing halves.
ance with two
cap,
bearing bore.
1. Remove the
the
journal,
crankshaft
the
of
1-53
Rings
and
good practice to
system.
engine
the
5. Install the
replacing
sufficient oil pressure and the engine
Check for
Rods
Connecting
nuts
cylinder
and
lockwashers retaining
block.
cover.
GASKET
6. Remove the
the
oil
pan
retaining
screws
and
remove
-f V
J^>
pan and gasket.
NUT
SCREW
LOCKWASHER
INSTALLATION
1. Make
the
sure
the block
of
surfaces
gasket
and
free from burrs.
pan are clean and
2. Coat the block
surface and
HOUSING
PLUG
SPRING
oil
gasket surface
pan
DRIVING GEAR
the
with sealer and position
3. Hold the
a screw,
in
finger tight,
4. Install
screws
pan
the
from the
gasket on
place against
at each
end
of
in
center outward
oil pan.
the block
screws,
remaining
the
the
install
pan.
then
each
and
tighten
direction to
12-
*
5. Install the flywheel housing inspection
stabilizer
7. Install the
engine right and
8. Install the
oil
quantity
oil
leaks.
of
level
dip
crankcase
engine
oil.
SCREW
cover.
SCREW
bar.
6. Install the
the
COVER GASKET
COVER
INLET TUBE GASKET
15 foot-pounds torque.
9. Fill
DRIVEN GEAR
the
left front
splash aprons.
COVER AND INLET
TUBE ASSEMBLY
stick.
with
the
Run the
proper
engine
and
grade
check
SCREEN
and
SNAP WIRE
for
Fig.
32 Oil
Pump
1085- A
1-54
2 6-Cylinder
Chapter
FILTER ADAPTER
Engine
ASSEMBLY
FILTER
1.
Apply
light
a
2. Install the
and plug.
ADAPTER
GASKET
1083-A
Fig.
33 Oil
Filter
the
Thoroughly
ket,
and gasket.
the mounting
the
clean
pad on
old
the block
gasket
play
of
gears.
Apply
then
to both
sealer
the
position
5. Install the
and pump.
sides of
the pump
the
gasket on
cover gas
Install the
pump.
tighten the retaining
not
screws.
the
with
in the
screen
screen
secure
and
cover
retainer.
6. Install the inlet tube gasket, and the inlet tube
assembly on the pump cover. Tighten the retaining
DISASSEMBLY
1. Remove the
cover
remove
move the cover
end
from
material
it
screws, then
Check the
gear.
Assembly
pump cover, but do
4.
assembly into the
shaft
and
gear
housing. Install the driven
4.
3. Remove the pump
plunger, spring,
torque.
foot-pounds
Tighten the plug to 33-38
valve
relief
pressure
3. Slide the drive
FITTING
to all moving parts.
coat of engine oil
inlet tube assembly retaining
the tube assembly,
retaining screws, cover,
and gasket.
Re
12-15 foot-pounds torque. Rotate the pump
to
screws
by hand
shaft
to
it turns freely.
make sure
and gasket.
INSTALLATION
2. Push the pump drive
bly from
shaft and
drive
gear assem
the pump housing. Remove the driven gear.
1. Place
3. Remove the
spring,
oil pressure relief valve chamber
plug,
install the lock
the
4. Remove the snap
and remove
the
wire
the
and
nuts.
washers
bolts,
retaining
oil
the
slide
Tighten the
and
nuts
to
and
pan.
retaining the pump screen,
2. Fill
from the housing.
screen
over
bolts,
foot-pounds torque. Install the distributor
30-35
and plunger.
flange
mounting
pump
the retaining
a new gasket on
quantity
POSITION OF OIL FILTER ADAPTER PLATE
for
the
of
oil.
Run the
oil pressure and oil
the
with
crankcase
engine
at
proper
and
grade
fast idle
and
check
the
car as
leaks.
Oil Filter Replacement
The
filter assembly is
oil
The filter is
shown
in Fig. 33.
from the bottom
removed
of
follows :
1. Place
from the
a
drip
cylinder
2. Check to
positioned
pan under
the filter. Unscrew the filter
block.
if the filter
see
adapter plate
(Fig. 34). Clean the
cylinder
is properly
block filter
recess.
3. Coat the
the
filter in
filter
until
advance
OIL FILTER ELEMENT
11 24- A
34 Oil
Filter Replacement
on
position
on
the filter
oil, then place
the block. Hand tighten the
with
the gasket contacts the adapter
face,
then
it V^-turn.
4. Operate the
leaks. If
Fig,
gasket
oil
engine
leaks
repairs
to
fill the
crankcase
correct
are
at
fast idle,
evident,
perform
and
necessary.
for
the necessary
the leakage. Check the oil
if
check
level
and
Section 1 1
outlet
parts
exhaust system consists of a
pipe,
are
and
a
muffler
provided
as
inlet
pipe
individual
proximately 45 degrees
muffler, a muffler
(Fig. 35). These
service
When
parts.
clamps after
the
directly
positioned
exhaust
and
the muffler inlet pipe clamp. Slide the muffler to the
Loosen the
rear, then separate the muffler
and
outlet
inlet
pipe
pipe.
away from the
to
the
manifold.
clamps
the
blocked. Do
muffler more than
3. Install
haust
the
the
slots
slide
pipe
into
the
connect
the
muffler on
directly
exhaust manifold out
sembly.
manifold.
4. Tighten the bolts to 23-28 foot-pounds torque.
until
extension
blocked. Do
5. Position the muffler, then tighten the outlet pipe
clamps. Rotate the inlet pipe clamp downward ap
than
clamp
forward
on
extension
to
it
outlet
pipe.
on
the inlet
the inlet pipe
are
until
blocked. Do
not
the inlet pipe more than 1 % inches.
pipe
clamp
outlet
the slots
not
and slide
muffler
muffler
and
clamp downward
opening
outlet pipe upper
Slide the
rear
muffler.
clamp
is
the slots in the muffler
opposite
5. Install the
ex
the
so
mately
muffler
muf
pipe
outlet
from the
Remove the
muffler
45
the inlet pipe to the
new
muffler
in the
slots
the
of
to
outlet pipe
assembly from the inlet
4. Rotate the inlet
1 ZA inches.
a new gasket on
let flange studs, then
not slide
slide
Slide the
to
the
frame bracket from the frame.
and
muffler
3. Position the
pipe.
pipe
muffler.
clamp
Remove the
Remove
2. Slide the clamp on the new inlet pipe, then
the inlet pipe into the muffler extension until the
extension are
upper
pipe
the inlet pipe and gasket.
in the
outlet pipe
2. Loosen the inlet
pipe
of
the lower half
and
Separate the
clamp.
the inlet
muffler
clamp.
1. Remove the lower half
fastening
in the
slots
Muffler Replacement
Inlet Pipe Replacement
nuts
the
opposite
not
part
fler clamp,
1. Remove the two
is
the clamp opening
so
extension, then tighten the
replacing any part of the exhaust system, loosen all
the frame
attaching bracket clamps to relieve twists
in the system, then tighten the
is installed.
]-55
System
EXHAUST SYSTEM
11.
The
Exhaust
slide
pipe
positioned
extension.
clamp
and
frame
forward into the
in the
the
not
approxi
pipe
muffler
into the
as
muffler
extension
muffler
are
more
13A inches.
:-r.~
\
MUFFLER OUTLET PIPE
MUFFLER
INLET PIPE
REAR BRACKET
INTERMEDIATE BRACKET
10 86- A
.
Fig.
35 Exhaust
System
1-56
6.
Connect, but do
outlet
pipe
front
7. Check for
pipe
pipe
2 6-Cylinder
Chapter
and
and
the
of
the
outlet pipe.
3. Slide the
clamps.
outlet
sion
the floor pan. Reposition the
outlet
However, do
Tighten the
necessary.
the lower half
tighten,
rear
possible
"kick-up"
if
not
Engine
until
the
slots
not
nect, but do
Outlet Pipe Replacement
5.
1. Remove the lower half
the
muffler, then
remove
the clamp
of
the
rear
at
slide
the
rear
clamp from its
not
Connect,
clamp
at
the
rear
support.
but do
rear of
6. Check for
pipe
muffler and outlet
pipe, then
12.
remove
pipe
not
the
into the
pipe
blocked.
more
muffler
necessary.
on
the
it to its
outlet
pipe
and
con
support.
tighten, the lower half
of
muffler.
outlet
the floor pan. Reposition the
outlet
Tighten the
outlet pipe clamps.
GENERAL SPECIFICATIONS
6-CYLINDER ENGINE
Note: The
engine
fits, tolerances,
and adjustment specifications are
listed
at
the
end of
Chapter
1 GENERAL
ENGINE SERVICE.
All
in inches
specifications are given
Piston Displacement
Bore
and
(cubic
unless otherwise noted.
223
inches)
3.62
stroke
Compression Ratio
Engine Fuel Requirements
Brake Horsepower
Torque
at
@ Cranking
Speed
150
rpm
Specified Engine
rpm
Firing Order
@
4200
212
@
2400
E-I-I-E-I-E-E-I-E-M-E
Rear)
Taxable Horsepower
31.54
rpm:
Conventional & Overdrive Transmission
475-500
Fordomatic
475-500
(Neutral)
Fordomatic (Drive
Engine Idle Manifold
425-450
range)*
Vacuum Inches of
Mercury @ Specified Engine Idle
Initial Ignition
rpm
(Sea
18-19
Level)
Timing (B.T.D.C.)
Conventional & Overdrive Transmission
4
(Maximum
6)
6
(Maximum
8)
Fordomatic
Oil
Capacity
(psi)
@
2000
45-50
rpm
SAE 20-20W
+32 F
+32F to
Below
Hot
Viscosity @ Specified Ambient Temperature:
Recommended Oil
Above
4
(Quarts)**
Oil Pressure
SAE
-10F
Engine
Final
Add 1
idle
quart with
10W
of
MM
Lubricating Oils
engine
10-
SAE 5W
-10F
Recommended Minimum A.P.I. Classification
**
144
1-5-3-6-2-4
Valve Arrangement (Front to
*
3.60
Regular
Specified
@
(Foot-Pounds)
Engine Idle
x
8.6:1
Compression Pressure-Sea Level
rpm
filter
to be
change
checked
in drive
range and
readjusted
to
the
possible
and
if
clamp
tighten
"kick-up"
2. Separate the
muffler extension are
the
exten
muffler
than 13A inches.
outlet pipe clamps.
4. Slide the
of
in the
into the
pipe
outlet
new
specifications
if necessary
Section 1
TORQUE LIMITS
Main
2 General Specifications 6-Cylinder
1-57
Engine
(Foot-Pounds)
Bearing Cap
Bolts
95-105
Cylinder Head Bolts (Hot)
75
Oil Pan to Cylinder Block
12-15
Flywheel
75-85
Crankshaft
to
Exhaust Manifold
to Cyl. Hd.
23-28
Intake Manifold to Cyl. Hd.
23-28
Oil
Pump
30-35
Oil
Pump Cover Plate
to Cyl. Block
12-15
Cyl. Front Cover
Water Outlet
6-9
Housing
23-28
Rocker Arm Cover
2.0-2.5
Cam Sprocket to Cam
45-50
Damper
Crankshaft
85-95
Rod Nuts
45-50
to
Connecting
Connecting Rod
Pal Nuts
3-4
Rocker Shaft Support to Cyl. Hd.
45-55
Valve Rocker Arm Adj. Screw
(Self
Locking)
Minimum Torque to Rotate
3
Push Rod Chamber Cover
Water
Fuel
Pump
Pump
to
12-15
Cyl. Block
to Cyl. Block
or
(Inch-Pounds)
23-28
Cyl. Front Cover
12-15
Crankcase Vent Adapter to Cyl. Block
8-10
Engine Front Support
45-50
Bracket to Engine Bolts
Insulator
Assembly
to Engine Bracket
Insulator
Assembly
to Frame Nuts
Bolts
50-60
45-50
Engine Rear Support
Support Retainer to Extension
Housing Bolts
50-60
23-28
Support to Frame Nuts
TORQUE
LIMITS
CAUTION:
FOR
In the
above
Size
Size
event
limits
(Inches)
Torque
(Foot-Pounds)
(Inches)
Torque
VARIOUS
(Foot-Pounds)
SIZE BOLTS
that any of the
below limits
are
in disagreement
with
any
of
those listed above, the
prevail.
i/4-20
i/4-28
5/i6-18
5/ie-24
%-16
%-24
6-9
6-9
12-15
15-18
23-28
30-35
7/i6-14
7/ie-20
i/2-13
i/2-20
9/i6-18
%-18
45-50
50-60
60-70
70-80
85-95
130-145
1-58
1- ENGINES
Part
Chapter 3
8-CYLINDER ENGINES
Section
Page
1
Description
2
Engine Removal
3
Engine Supports
1-64
4
Manifolds
1-66
5
Cylinder Heads
6
Crankshaft Damper, Cylinder Front Cover, and Crankshaft Oil Seal
Sprockets and Timing Chain, Camshaft, Bearings, and Tappets
1-70
1-75
10
Flywheel, Crankshaft, and Main Bearings
Connecting Rods and Bearings, Pistons, Pins,
11
Exhaust System
1-81
12
1-83
7
8
9
1-58
Installation
and
1-61
and
Valves
and
1-67
and
the
are
same
in this
covered
for
all
8-cylinder
the
The
chapter.
1-79
wise noted.
The cleaning,
procedures are
engines
unless
1-77
Rings
The removal, disassembly, assembly, and installation
procedures for the component parts of the 8-cylinder
engine
1-72
engine
inspection,
instructions
overhaul
are
procedures
repair
and
in Chapter
covered
1,
Service."
"General Engine
other
and
1. DESCRIPTION
All the 8-cylinder
The
various
engine
placement, bore
have the
engines
models
same
basic design.
differ only in
diameter, length
of
stroke,
The
dis
piston
the
is
engine
2. The differences between the
application are
The
and
are
2, 3,
firing
8. The
arranged
and
their
and
4
and
is
order
from front to
on
rear on
the left bank
5, 6, 7,
1-5-4-8-6-3-7-2. The
both banks
rear on
An
the
valves
stem
The
provides
1 Engine
The
valve
valve
and
The
valve
more
rotate
each
guides
and
an
are
time the valve
rotation permits self
umbrella-type
stem.
Valve
mechanism.
and exhaust valve assemblies are
which
guide opening.
E-I-I-E-
E-I-I-E.
Table
arm
minimizes
the valve
the valves
assemblies contain
the head.
part of
and closes.
seating,
from front to
rocker
rotating-type
listed in Table 1.
bank 1,
right
engine models and
cylinders are numbered
head
Both the intake
in Figs. 1
shown
valve
integral
compression
ratio, power output, and carburetor equipment.
A typical 8-cylinder
cylinder
warpage,
stem
extends
seal
over
seal controls
springs
positive
cleaning
have
fits
the
top
lubrication
equal
valve
over
coil
action
better
sticking.
the
of
of
top
of
the valve
the
spacing
at
opens
and
and
wear,
the
high
valve
which
engine
Model Application
Engine
Prefix
Piston
Displacement
(Cubic Inches)
Compression
Ratio
Type
Transmission
Carburetor
Fuel
Required
Car Model
Application
EGG
272
8.6:1
All
2-Barrel
Regular
Custom
EDB
292
9.1:1
All
2-Barrel
Regular
Fairlane, Station Wagons,
Type
Thunderbird*
ECJ
312
9.7:1
All
4-Barrel
Premium
All**
ECJ
312
9.7:1
All
Dual 4-Barrels
Premium
Fairlane, Station Wagons,
Thunderbird and
Police Interceptor
Available
Available
**
on
on
Thunderbird
Thunderbird
with
conventional
with
Overdrive
transmission
and
only.
Fordomatic Transmissions
only.
LITHO IN U.S.A.
FORM 7098-57

1957 Ford Car and Thunderbird Shop Manual

Transcription

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