DEMO - 1956 Ford Car Shop Manual

19 5 6

FORD M

DIVISION O

T

O

COMPANY

Copyright © 2009, Forel Publishing Company, LLC, Woodbridge, Virginia All Rights Reserved. No part of this book may be used or reproduced in any manner whatsoever without written permission of Forel Publishing Company, LLC. For information write to Forel Publishing Company, LLC, 3999 Peregrine Ridge Ct., Woodbridge, VA 22192

1956 Ford Car Shop Manual EAN: 978-1-60371-006-0 ISBN: 1-60371-006-X Forel Publishing Company, LLC 3999 Peregrine Ridge Ct. Woodbridge, VA 22192 Email address: [email protected] 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.

19 5 6

Copyright 1955

FORD MOTOR COMPANY DEARBORN, MICHIGAN All

September, 1955

rights reserved

'Reproduced under License #5008

trom Ford Motor

Company

FORD FORD

-

February

2002.

DIVISION

MOTOR

COMPANY

FOREWORD This proper

The

has been

manual

servicing

manual

be kept

should

The

reference at all times.

illustrations of some of

The of

the

following

for

by

Disassembled

main parts as

views

listed in the Table

pages.

ignition, fuel,

which are

conventional

and

axle, etc.)

and cooling.

information

-CHASSIS -includes

(clutch,

brakes,

Service

available

accompanied

be readily

service operations.

is divided into five

the

on

train

rear

sion,

will

car units are also given.

TWO

Part

line,

it

where

information for the

provide

the 1956 Ford Thunderbird.

service procedures are

the

their related systems,

power

and

ONE POWER PLANT is composed of the various engines

Part

the

on

entire

transmission, Overdrive, drive

the running

(frames,

gear

suspen

springs,

tires, steering gear, steering linkages, etc.). for the Fordomatic transmission are published

wheels,

procedures

a separate manual.

Part THREE all

of

many

manual

Contents

and

in

of

to

prepared

1956 Ford Cars

of

of

the

electrical

of

all

and

ELECTRICAL AND ACCESSORIES

-

the

BODIES

nance and repair of all of

alignment

Part FIVE includes Ford

all

matter

page

mainte

glass

adjustments

part.

specifications

headings,

covered.

The

indicates the

right-hand

AND SPECIFICATIONS

-

lubrication information, and necessary for properly servicing and

in

Ford Division

without

heading of

on

the

each

of

models

and

specifications

Ford Motor

notice and

and

any time, without

was

incurring

even-numbered

heading

contained

reserves

change

subject

on

each

section covered.

approved

Company or

or

the

indicates the

the time the book

at

left-hand

chapter

or odd-numbered page

effect at

continue

throughout the manual, designate the

name

The descriptions were

the

adjustment and

cars.

The

page

on

including

fenders. Window

and

maintenance

the

information

components,

-MAINTENANCE

complete

contains

contains

body

doors, hoods,

included in this

are also

covers

(except the ignition system) (except the Overdrive and Fordomatic).

systems and units

accessories

Part FOUR

-

in this

for

manual

printing.

the

right

specifications

or

The

to dis

design,

obligation.

SERVICE

FORD FORD

DEPARTMENT

DIVISION

MOTOR

COMPANY

TABLE OF CONTENTS Page

Foreword

.

2

.

Part ONE-POWER PLANT CHAPTER

I GENERAL

ENGINE OVERHAUL, INSPECTION, AND REPAIR âge

Page

Section 1

Troubleshooting.

2

Tune-Up

3

Engine Removal and Installation Intake and Exhaust Manifolds Rocker Mechanism, Cylinder Head, Valves, Valve Lash Adjustment, and Valve Timing.

4

3

Manifolds

4

Cylinder Heads

5

Crankshaft Damper...

-

6

..

Rest.

36

and

III 8-CYLINDER

IV

CHAPTER Section 1 2 3 4

.

Ignition System Distributor Minor Repair and Adjustments. Distributor Overhaul Carburetor Operation and Adjustments Single and Dual Carburetors. Single Barrel Carburetor Overhaul. Dual Carburetor Overhaul ....

.

....

.

6

39

Main Bearings

and

and

Bearings, Pistons, Pins,

Qil pilter

and

44

oil p

45

.

9

54

io

55

11

and Timing Chain, Camshaft and Bearings, and Tappets Flywheel, Crankshaft, and Main Bearings Connecting Rods and Bearings, Pistons, Pins,

56 60

and Rings Oil Pan, Oil Filter, Exhaust System

62 64 66

Sprockets

.

..

and

Oil Pump.

.

.

...

.

IGNITION, FUEL, AND COOLING SYSTEMS

.

5

8

51

Crankshaft Oil Seal

30

ENGINES

Section 7

49 ,

Valves

and

29

42

Exhaust System

10

49

Cylinder Front Cover

25

...

Rings

Qil p

g

37

.

'.''..,

,

Connecting Rods and

47

Engine

Flywheel, Crankshaft,

8

33 36

General Information.

2

and

32

....

CHAPTER

22

ENGINE

Section 7

31

.

Steady

10

20

Camshaft Main Bearings.

and

.

.15

....

Section 1

8

Sprockets

Flywheeel, Crankshaft and Cylinder Block, Pistons, Piston Rings, Connecting Rods and Bearings Oil Pan and Oil Pump Exhaust System

9

Engine Steady Rest. Manifolds Cylinder Head and Valves. Crankshaft Damper. Cylinder Front Cover and Crankshaft Oil Seal sprocket and Timing Chain, Camshaft and Bearings, and Tappets .

10

Timing Chain,

7

II 6-CYLINDER

CHAPTER

Section

Section 6

14

...

5

5 8

69 74

Section 7

78

8 9

84

10

.89

92

Four-Barrel Carburetor Operation, Adjustments, and Overhaul

11

Fuel Pumps, Vacuum Booster, Fuel Tanks and Lines. Fans and Belts. Water Pumps

12

Radiator, Hose,

.

and

95 Fuel Filter

.

and

Thermostat

.

108 110 Ill

112

115

Part TWO-CHASSIS CHAPTER Section 1 2

3 4

Trouble Shooting Clutch

I

CLUTCH, TRANSMISSION, AND GEAR SHIFT LINKAGE 119

Housing Alignment. Transmission Cleaning and Inspection

123

Flywheel

124 II REAR

CHAPTER

2

Trouble Shooting. Cleaning and Inspection.

3

Banjo

Section 1

Housing Hypoid

.

.

.

.

.

Rear Axle

Trouble

Shooting

2

Wheel Alignment.

3

Frames.

4

Front Suspension

5

Rear Suspension.

.

.

.

CHAPTER Section 1 2

3

Power

and

163 164 168

10

IV POWER

.

.

187

Troubleshooting.

206

2

Adjustments.

3

Hydraulic System

4

Brake Assemblies.

207 208 212

.

Gear Shift Linkage

Section 6 7 8 9

CHAPTER V Section 1

7

.

138

.

Integral Housing Hypoid Rear Axle. Drive Lines.

152

158

RUNNING GEAR

159 161

186

Maintenance

Steering System Operation.

129

Section 4 5

183

Troubleshooting Inspection

Overdrive Transmission

143

CHAPTER III Section 1

125

6

AXLES AND DRIVE LINES

141 142

.

Conventional 3-Speed Transmission.

Section 5

117

.

.

Shock Absorbers. Steering Gear .

169

.

Steering Linkage

170 175 178 181

.

.

Wheels and Tires. Hubs and Bearings

STEERING

Section 4 5 6 7

and Fluid Reservoir Control Valve Assembly. Power Cylinder Assembly

Pump

Steering Linkage

.

Assembly .

.

190 194 200

202

BRAKES Section 5

Brake Drums

213

6

Vacuum Booster

214

7

Brakes.

216

Parking

Part THREE-ELECTRICAL AND ACCESSORIES CHAPTER I-GENERATING SYSTEM AND BATTERY Page

Page

Section 1 2

Trouble Shooting Generator

.

217

.

221

CHAPTER

Section 1 2

Section 1 2

II STARTING

Trouble Shooting Starter and Circuit

235 238

CHAPTER Trouble

Shooting

Lighting

System

III

2

Trouble Radio

3

Heater

245 247

Shooting

3

I BODY

Construction Details

and

Sealer Application.

.

.

and

271

278 279

II-

Quarter Trim Panels.

.

.

TRIM,

289

.

Headlining Replacement

292

3

Ventilator

294

and

Division Bar

CHAPTER

3

III REMOVABLE

Door Replacement and Alignment Door Locking Mechanism Luggage Compartment Door Replacement and Alignment Luggage Compartment Door Locking Mechanism CHAPTER

Section 1 2 3

Section 3

244

Starter Drive

Section 3 4

252 253

Horns Instruments

Section 4 5

268 269

Windshield Wiper Miscellaneous Accessories

Section 4 5 6

Fibre Glass Repair Thunderbird General Body Maintenance Paint Refinishing

Hardtop

....

281 282 284

UPHOLSTERY, AND WINDOW GLASS

2

Section 1 2

SYSTEM

CONSTRUCTION AND MAINTENANCE

Alignment Quarter Panel Repair

Door

226 232

FOUR BODIES

Body

CHAPTER Section 1

Battery

.

265

CHAPTER

2

.

IV ACCESSORIES

257 260

Part

Section 1

Generator Regulator

LIGHTING SYSTEM, HORNS, AND INSTRUMENTS

CHAPTER

Section 1

Section 3 4

313 317 320

Section 4 5 6

7

Door Glass and Regulator Replacement Door Glass Adjustments Quarter Glass Windshield and Rear Window

296 299 303 307

SHEET METAL ASSEMBLIES Section 5

Grille

and

Hood

324

6

Hood Alignment

7

Thunderbird Grille

8

Front Fenders

and

Lock Adjustment

and

Hood

326 328

329

323

IV POWER

INSTALLATIONS AND SPECIAL ITEMS 331

Power Windows Power Seats Convertible Top

337 342

Section 4 5 6

Thunderbird Top Adjustments Care of Country Squire Paneling Crown Victoria Transparent Top

347 349 350

Part FIVE-MAINTENANCE AND SPECIFICATIONS CHAPTER I-MAINTENANCE Section 1

353

Preventive Maintenance

CHAPTER Wheels

2

Brakes

3

Wheel Alignment

4

Rear Axles

5

Frame

6

Engines

7

Clutch

and

357

and

and

and

Steering

Lubrication

355

II SPECIFICATIONS

357

Tires

Section 1

Section 2

358 358

Springs

359

Transmission

362

360

Section 8 9 10 11 12

13 14 15

Cooling Fuel System Generating System

Starting System Ignition Fuse and Bulb Chart Paint Tools and Equipment

353 353 354 354 354 365 365 355

Part ONE

POWER PLANT Chapter

i

Genera/ Engine

Overhaul, Inspection,

Section

Page

1

Trouble Shooting

2

Tune-Up

3

Engine Removal

4

Intake

5

Rocker

5 8 10

Installation

and

14

Exhaust Manifolds

and

Mechanism, Cylinder Head, Valves, Timing Chain, Sprockets, and Camshaft Flywheel, Crankshaft, and Main Bearings

6

7 8

Cylinder Block, Pistons, Piston Rings, and Oil Pump

9 10

of

component

in this

20 22

Connecting Rods

and

parts;

the

in the

or

and overhaul

have been

parts

case of a

trouble in a particular

trouble

shooting,

trouble,

such

gine, loose

as;

an

that may cause

definite

of a

the

in this

or

unit.

the

When

causes

any

other

item

affect power plant operation

the

or

the

on

can

be

attributed

that tend to

car

to the

harder

work

Engine

tion,

which

will

performance

correctly timed

pression,

result

ignition,

and an unobstructed

can cause

in

depends

under

not

tery order

or

other

most

starter.

listed,

of exhaust gases.

and

remedies

probable

Perform

until

are

(d)

or replace

the

them as necessary.

become

badly burned

so

from cranking the wiring may be at fault. Repair starter

Part

THREE,

"Electrical

that

engine. as nec

Ac

and

the

Starter or Starter Drive. If the

and

engaging the

not

and make rare

starter or starter

the trouble is prob

fault,

drive. If the

flywheel,

starter

remove

starter

This

be

can

releasing the

drive may lock up

corrected

starter

drive. If the

drive. In

with

by loosening

run

the starter

the necessary repairs to the starter

cases, the

is

the

fly

the starter

starter

does

not

operate, remove it and make the necessary repairs.

turns it

causes

battery,

the starter, relay,

at

tighten

the

to

Check

ably in the

wheel.

dis

lights. If

or

as necessary.

seldom

prevent

Refer

ning, but

headings.

turn the engine over, or

to start, the

to

fuel distribu

WILL NOT CRAISK. If the

ENGINE

(1) does

appropriate

engine

normal and uniform com

Engine troubles, their causes, cussed

the

poor performance.

on proper

flow

to

Starter Relay Circuit. The relay

the

surfaces

will

the horn

Try

above components are not at

motion.

For example, dragging brakes

refer

cessories."

its

retard

Clean,

Check

contact

they

performance

to forces

If it is only

chapter.

individual part,

Battery Cables. Check for loose

the

connections

corroded

and ground.

essary.

engine or

an

properly, test the battery. Recharge

battery

Check

(b)

However, Poor

install

Battery.

the

not operate

or replace

(c)

section.

Check

they do

of

Engine.

engine

engine

applicable

remove or

applicable section.

(a)

pro

a wet or cold en

or

in the

desired to

temporary defect.

a

factors that

various

tained

TROUBLE SHOOTING

obvious

tank,

gas

empty

disconnected wiring,

or

are outlined

first look for the

the engine has been disassembled.

instruc-

removed

and eliminate

system

after

To completely disassemble or assemble an engine, follow all the removal or installation instructions con-

complete overhaul

Trouble shooting is the application cedure, in a logical sequence, to locate

a.

25

Bearings

and

instruc-

overhaul

1.

of

inspection,

the cleaning,

chapter.

after

apply only

from the engine,

The

Timing

30

are covered

cause

Valve

Exhaust System

The cleaning, inspection, repair, tions

and

29

repair

tions

and

Valve Lash Adjustment,

15

Oil Pan

Trouble shooting; tune-up; and

Repair

and

are

over

a

following

the trouble is located.

too slowly

defective bat checks

(2)

starter

in the

The or

ENGINE CRANKS. BUT WILL NOT START.

trouble probably lies in either the

the

fuel

system.

which system

is

at

The

following

test

ignition will

system

determine

fault:

Remove the ignition

wire

from

one spark

plug,

and

Chapter

1 General

insert a piece of proper sized metal rod so

from the insulator. With the ignition

turning

the

engine

hold

over,

end

Ii there is

follow is

spark,

"a"

steps

a good

no

if there is

or

"b"

or

with

No Spark. Follow the

(a)

the cause,

and

is

whichever

spark, proceed

the

make

a

weak

spark,

"c."

below to determine

steps

repairs

or

replace

ments.

(1)

for

Pull the

inch from the

316 on

the a

On

Fordomatic

good

Make

repairs

or

or

coil and

was

or

no

distributor,

weak

dry, in

an

electrical

the

replace

the

spark

crank

the

the

coil

a weak

Test the points.

it if

and replace

"jumper"

the

and

on

a check

for

a spark at

"jumper"

now

a

spark

(b)

and

must

spurt

or

If there is

for

a

and

switch

be

"DIST"

for

check

no

spark,

terminals

and

spark, install

battery

at

or

to

a

terminal

the points. If

or switch

repaired

replace

may be

it if

weak.

coil

a

wiring

the

Check the wires.

condition of

The

wires

following

checks

in

Test the

battery,

then

a suitable

to

and

Severely

regulator

inlet line

carburetor

to

container

at

the

fuel,

the

catch

if fuel is reaching the inlet fitting.

see

Repair the

the trouble is in the

fitting,

carburetor

If

necessary.

as

no

adjust, clean,

condition.

fuel pump inlet line to

remove

start

the

any

(3)

air

into the line

Connect the line does

engine

repair

not

or

check

start,

replace

try to

and

the

the

pump

ENGINE STARTS BUT FAILS TO KEEP RUN

NING. Check the fuel has

cause

for

run

first. The ignition

system

trouble, but it is usually time

some

is

and

at

system

after

the

operating

temperature.

(a) Check the fuel supply at the tank. (b) Try to start the engine. If the engine ate

with

and

adjust

system

as

If the fuel

engine still

outlined

system

in

oper

speed

(2)

foot throttle,

under

these components,

is operating correctly

operating

and replace

check

(c).

stalls, it may be due to the coil

down

breaking

will

the idle

the choke adjustment.

will not operate with constant

the fuel

(c)

foot throttle,

constant

check

If it

and

the

or condenser

temperature.

Check

them as necessary.

ENGINE CONTINUALLY MISSES AT IDLE.

When the

engine

continually

misses on

the same

cylin

the fault generally lies in the ignition system.

(a)

Isolate the

miss

time from the

inspect,

is improperly

(b)

and

or

(c)

adjust

by

pulling

plug

cable

Remove the plugs, then clean, them. Replace those that are badly

plugs.

spark

corrosion

and

plug

wires

replace

and

replace

them

as

for

signs of

deteriora

them as necessary.

Remove the distributor cap

inspect,

one spark

burned.

Check the

tion and

fully

If the

engine.

Blow

pump.

necessary.

fouled

and

the

at

obstructions.

fuel pump pressure, then

pitted points

be clean, dry,

a

Remove the fuel tank filler cap, then disconnect the

at a

the rotor, distributor cap,

must

engine

collapsed

(4)

replaced.

necessary.

points as necessary.

the

crank

engine

closed, then install

the

spark

usually indicate that the voltage set or the condenser is faulty.

plug

Using

sometimes can

spark, replace the

no

Remove the distributor cap,

or replace

this point, disconnect the

at

ders,

( ) The battery

and

should

pump discharge nozzle. If there is fuel at this point, the engine is probably flooded or there is water in the fuel system. If no fuel is observed accelerator

at

listed:

order

(3)

Each time the throttle is actuated, fuel

or

the

then

coil

carburetor

times.

spark

terminal. Replace the coil

Weak Spark. Perform the

1

charge,

a

carburetor.

by hand

Adjust a

If there is

primary

battery

check

points.

distributor,

other

exists, the ignition

is defective

(2)

the

and

are

points are

the

spark.

between the

the coil, then

the

of

one

"breaking"

between

wire.

the dis

remove

If there is

a

coil

(2), the

at

occurs

necessary.

engine until

if there is

in

points

the points. If there is

at

"jumper"

the

as

to distributor primary

coil

of

if the

spark

install

of

spark

no

see

points

points;

terminal a

was

and

cleaner,

throat while working the throttle

as

If there

(3)

look down the

and

carburetor.

necessary.

tributor cap,

the fuel tank.

at

to see if fuel is reaching the

air

perform

given.

several

between

wire

Adjust the

necessary.

order

fuel is reaching the inlet fitting, the trouble is in the fuel pump or the fuel pump inlet line is clogged.

the

clean

arcing.

probably

spark,

NOTE: Check the flexible fuel pump inlet line for

the check. If

persists, test the coil,

spark

fuel

the fuel supply

good

in the

a

checks

system

either

defective.

and not

(1),

repeat

are

it if

condenser and replace

if

(c) the following (1) Check (2) Check

Make

as necessary.

spark

then

points

wires.

plug

the high tension

replace

exists, the

spark

make

cars,

and re

necessary.

If fuel is reaching the inlet

spark

replacements

If there

(2)

a

and

over, check

is obtained, the trouble lies in

spark

tower socket,

the

equipped

these components are clean,

sure

turning

"/V."

lever is in

selector

distributor cap, rotor,

the

head,

cylinder

engine

persists, test the coil,

spark

weak

Good Spark. If there is

carburetor.

CAUTION:

If

the

and

distributor.

the

of

spark.

sure

If

from the top

coil wire

wire

ignition

the

a

it if

from the

Hold the with

If the

(4)

Remove the

step

cor

or

roded wires.

place

cars,

Repair

and

in the terminals. Replace any damaged

seated

rod

applicable. If there

the necessary

make

starter

"N."

lever is in

the selector

protrudes

the

of

approximately 3/16 inch from the block. CAUTION: On Fordomatic equipped sure

it

on and

the

Engine Overhaul, Inspection,

and

rotor, then clean,

necessary.

1 Trouble

Section If the

(d)

do

above steps

check the compression to

determine if it is satisfactory

(5) ENGINE MISSES miss of this type

ERRATICALLY AT IDLE.

may be

following (a) Carburetor, including

ture setting,

(c)

Valve

a

(6)

faults in the ignition

of

be in

ing (a)

by

caused

the

and

exhaust system.

Check the follow

operation

the

of

exhaust

gas

control

If it is sticking, free it up or replace it as necessary. Check the paint on the intake manifold heat

(b)

be

If the

is

not

the

the

passage

Inspect,

plugs.

spark

clean,

and

that are defective

plugs

or

lobes,

shaft

replacements.

make

and

replacements

repairs

or

as

necessary.

they

and

coil

condenser.

carburetor

and

linkage.

test,

sion

replacements

Lack

POWER.

made.

the choke

has

not

NOT

valve

repairs

or

caused

preliminary

the throttle

FULL

DEVELOP

is usually

some

by

a

Check

system.

with

Show the

fuel

fuel

of

Time

internal

how improper

to

be

exces

carburetion

poor

malfunctions,

repair

be

will

in

only

by

saved

is

it is

one system

a

complete

a visual

inspec

for leaking gaskets or casting the carburetor bowl. If the flooding stops,

carburetor

Tap

needle

was

held

Remove the

by foreign

open

persists, follow the

flooding

(a)

equipment

overhaul.

the

defects.

dragging.

consumption.

CARURETOR FLOODS. Make

the inlet

accelerator

are

consumption

to try to

advisable

test

customer

affect

shows

combination

not

of

choke oper

the

if the brakes

the carburetor. Since

carburetor.

(2)

steps

cleaner

air

Check the fuel

(b)

buretor float,

and

level,

material.

If

below:

and

the

check

choke

the car

of

needle and seat.

Replace

parts.

the

needle and

the condition

the fuel inlet

Check fuel pump

(c)

excessive,

pump

was

pressure.

forcing

If the

fuel

pressure

past

the pump should be rebuilt

checks should

opens all

the way,

and

Cooling

c.

or

the

is

inlet

replaced.

This

will

indicate

whether

regulate a

short

checks

including

within

limits,

initial timing

and

check

distri

engine

engine

system

is thermostatically

operating temperature

controlled to

and

provide

for

warm-up period.

(1) ENGINE OVERHEATS. Usually, engine over heating is the result of insufficient coolant supply. Check coolant

level first. Make

certain

that the cause

of

trouble is not anti-freeze evaporation.

(a)

are operating properly.

System.

The cooling

the

compression

operation.

see

car will

If the test

carburetor

poor

open.

components

If the

preliminary

make certain

complaint

car.

the

rebuild

usually

tion

the

in the

operation of

usually

fuel

checks

carburetor.

(a) Verify

compres

lash. Check the

height. Make

compression.

the ignition system,

butor

a

been located:

the internal

(b)

perform

After preliminary checks are the following operations if the trouble

Check the

(a)

power

sure

remains

perform

made,

valve

DOES

of

Make

and

adjustment,

Adjust the

(b)

Faulty

excessive

necessary.

However,

compression.

be

as

persists,

assembled

ENGINE

(7)

the

check

and

rates

spring

still

problem

and

following

Check for fuel leaks in the

stalled

for

made:

any defective

If the

(g)

However,

problems.

system

possible.

as

responsible

the

foreign

other

CONSUMPTION.

FUEL

usually

and

operation.

Check the fuel pump pressure and adjust the fuel level. Check the accelerator pump action

(f)

be

ation and

Replace them if

defective.

are

is

clean

as

fuel

of

source

major

a

components

consumption. should

the

Check the

(e)

repairs.

the fuel tank, fuel pump,

consists of

EXCESSIVE

(1)

cam

points.

deterioration,

of

the

of

Make the necessary repairs or Check the high tension wiring for signs

the

and

condition

clearance,

the point

and check

Make the necessary

connecting lines. Dirt

and

are

all

in the

Remove the distributor cap,

(d)

material

sive,

lead-fouled.

gap, distributor

system

carburetor,

from

carburetor

fuel.

the gap. Replace any

adjust

burned off, the

preventing

vaporizing the

Remove

(c)

paint

obstructed

properly

The fuel

linkage is free. Check to

Check the

riser passage.

and valve timing.

carburetion

necessary.

sequence.

valve.

fuel pump pressure. If the problem still exists, a check of mechanical components must be made. Check the valve lash, cam

(d)

test if

is usually a combina fuel system, but also

malfunction

carburetion

b. Fuel System.

ENGINE MISFIRES OR HESITATES ON AC

CELERATION. This

may

as

including

are

system

and

spark

compression

the ignition

and

the fuel system,

check

satisfactory,

Keep Perform

the miss persists. Repair the engine

can

the

with

compression

mix

repairs.

operation.

If the

(c)

lobe lift,

operation, idle

choke

ignition system, starting

necessary

(d)

tion

a combination of

sequence:

Make the necessary repairs. The vacuum lines and fittings for leaks. Make

plugs.

any

in

fuel level.

and

The

by

caused

things. Check the

(b)

the condition,

the intake manifold passages for obstructions.

and check

A

not correct

Shooting

If the supply is

low,

check

for leaks in the cooling

system, then make the necessary repairs.

(b) and

Check the

adjust

water pump belt for it if it is loose.

proper

tension

8

1 General

Chapter

(c) dirt,

Inspect the

(d) Using NOTE:

by

clogged.

replacements

as

are

between

the temperature sending or

the

check

sometimes

caused

head casting and element. Make repairs

unit

the

block if

heat

If it is defective

range.

it.

replace

Make

operation

and

the wrong heat range,

or of

is

thermostat

the

sure

proper

correctly

installed.

Check the

radiator

it if

and adjust

for

necessary.

flow. Flush it if

proper

necessary.

for

block

the

passage

water

the

replace

or

passages

the

replace

necessary.

ENGINE FAILS TO REACH NORMAL OPER

(2)

ATING TEMPERATURE. Generally this is the thermostat sticking

being

or

operating temperature,

reach

ing

Make

passage

water

or

passages

unit

Replace any defective

not

gauge and send

thermometer installed in the

a

with

the

range.

does

still

engine

check

by

caused

the wrong heat

of

Check the thermostat first. If the

(f ) Check the ignition timing

(g)

the

out

for

head(s)

head(s) if necessary. (j) Check the cylinder Clean

defec

necessary.

as

out

a

obstruction.

passage

cylinder

Clean

obstructions.

for

check

and

pump

water

a

Check the

obstructions.

necessary.

Check the thermostat for

(e)

or

water

replacements

or

repairs

(i)

readings

clearance

impeller

Repair

and

Remove the

(h) tive

accuracy.

Inaccurate

insufficient


(bugs,

obstructions

thermometer in the radiator,

a

reading for

gauge

fins for

radiator

Clean it if it is

etc.).

Engine

radiator.

parts.

2. TUNE-UP Regular

maintenance

necessary for

tain satisfactory performance, should

A used

be

made,

hoses,

services

In addition, to

are

main

tune-up

a periodic engine

made.

a

cooling

of

engine

test equipment

inspection

visual

of

the wiring,

hoses, heater hoses,

system

be

should

the tests. As the checks and tests

perform

make

A

are

vacuum

be

should

A reading

Minor Tune-Up. Perform the

following

INSPECT

(1) CABLES,

IGNITION

all

insulation. Make

the distributor cap

Inspect the

for

Inspect the

firmly

wires are

to

case

for

fault,

and

cracks

low,

Brush the

a

the

repeat

leakage

compression

the

past

rings

compression

battery

the battery.

for corrosion,

and

cable connectors with

further corrosion, then tighten the

con

the

are

original

rings.

TEST CYLINDER COMPRESSION. Be

During climb

a

sure

the

steadily

successive

Note the obtain

cylinder.

of

strokes, or fails to cates a

to

engine obtain

the

or

oil will

same

are at

valves

the piston,

and

temporarily

seal

on

oil

reading is obtained, are

leaking. If

or

more over

pounds

past

test, if the the

climbs

same

during

higher

during

climb

pressure

the

on

fails to

the first two

the succeeding

entire

test, it indi

or stuck valve.

sticky

Install

a compression

reading

engine and

compression

until

record strokes

be

sure

gauge

in

the gauge

the

clean, file the gap.

Test the

Install the

Repeat the test the a

on

to

reading

on

in

tips an

electrodes.

or

spark

chipped

Replace

the

porcelain

adjust the

and

approved

for broken

spark plugs and

wipe

plugs,

flat,

all

spark

plug tester-

porcelain

defective

and

plugs.

tighten them to the specified

torque.

(4) CHECK THE DISTRIBUTOR. Remove

cylinder,

same number of strokes as was

maximum

plugs

spark

reading.

required

each

electrode

plugs

badly burned

tributor reading.

cranking the

cylinder.

wide open position and

Crank the

maximum

this

required

wide open.

number

The

If the

and remains

strokes, but

Inspect the

all spark plugs.

Set the throttle in the

a

heavy

test.

compression

Remove

registers

checked

it indicates there is leakage

PLUGS. Sandblast the

1

be

rings.

(2) battery is good. Operate the engine until normal operat ing temperature is reached. Turn the ignition switch off.

number

cylinders

adjacent should

(3) CLEAN, ADJUST, AND INSTALL THE SPARK

nectors securely.

the choke is

the rings

of

has increased 10

reading,

indi

normal

or valves.

satisfactory, but the valves

the the

leaks. Make

below

rings or valves.

whether

tablespoon

in

make a

recharge

put

terminal

seated

and

To determine

the

cable connections

necessary.

retard

dam

corrosion.

battery

battery if

clean. them

worn or

that the terminals

test. If the charge is

charge

grease

the

wires

capacity test. If unsatisfactory,

battery

given.

BATTERY

WIRES,

ignition

sure

and

free from

sockets are

a

order

AND CHECK THE CONDITION OF THE

BATTERY. Inspect aged

in the

cylinder.

pounds

leak. This

gasket

indi

above normal

in two

compression

head

a

10

than

is

cylinders

all

of

pounds.

than 10 pounds

before condemning the operations

10

the head gasket, rings,

at

even

indicates a.

of more

leakage

specified pressure

compression

lead deposits in the

cates carbon or

cates

the

However, of more

from

pounds

uniform within

A low

etc.

10

variation of

satisfactory.

A reading

type

reliable

to

inspection

and

proper car operation.

number

1

pitting and

cap and

and

rotor.

Inspect the breaker

burning. Replace defective

install the distributor cap

(5)

and

the dis

points

points.

for

Clean

rotor.

CHECK IGNITION TIMING. Disconnect the

dis-

2 Engine

Section tributor

Check

line. Operate the

vacuum

the

necessary line.

timing

with

timing light

a

(6) CHECK MANIFOLD VACUUM CARBURETOR IDLE. Check If the

If the

idle

manifold vacuum at

Set the

of

idle

engine

speed and

air cleaner

passenger

On

a

the specified

filter

fuel pump

a

drive belts (fan,

and power steering).

conditioning,

tester. Inspect the

defective

Install the

Make the

bolts

TEST COIL AND CONDENSER. If the

(7)

satisfactory, it

intensity (3) is coil

the test unit

not

POINTS

BREAKER

for pits,

and

transfer,

excessive metal

or

b. Major Tune-Up.

vacuum

as

BATTERY. Remove the

(1)

Clean the

battery battery

the

spect

terminals case

test. If the

to

from the battery.

cable and

cracks

is low,

charge

Replace deteriorated worn

for

cables

and

connectors.

connectors

insulation. Brush the

further

retard

battery

a

burned

Connect the

cables

to the

CHECK THE GENERATOR AND REGULA

(2)

TOR. Follow the

procedures outlined

in Part

THREE,

and

from

each

plug

wire will

jump

a

inch gap,

3/16

as

Remove

in

adapter

Run the

the

spark

plug wire,

wire

engine

at

regularly.

If the trouble

one

terminal.

approximately

adapter

the gap

spark

exists

is

idle

3/16

and

install

a

Hold

the

end

inch from the

speed.

The

Repeat the test unsatisfactory

in the coil,

in the distributor,

circuit.

operate

head.

should

jump

spark

condenser, or

cylinder

on each

at

in the

all

the

lead. spark

adjustment

is

rotor or

external

(12)

primary

an

idle

at

and make

and

other

damage. Re

housing

sockets.

speed.

and

carburetor

Check the timing

the necessary adjustments.

vacuum

check

the valve lash

at

line

ignition

after

advance

completing as

the

en

after

the

engine

is thoroughly

is lower than specified, check for leak lines and intake manifold. Check the

idle

adjustment.

be

is

still below normal or is erratic, it bad rings, sticky valves, weak valve leaking head gasket. If this condition exists,

vacuum

or a

should

mani

the specified idle speed.

vacuum

indication

springs,

it

or

distributor

the

engine

vacuum

the

If the

is

cracks

TEST MANIFOLD VACUUM. Check the

If the

plugs,

lubricant.

up.

vacuum

age at

cam

CHECK AND ADJUST VALVE LASH. Check

and adjust

fold

assembly is defec

accelerated.

carburetor

cap, inter

the

timing light

(11)

terminal of

between

Connect the distributor the

gap

point

Lubricate the distribu

from the terminal

corrosion

line

warmed

follows:

nally

and

the

CHECK IGNITION TIMING. Disconnect the

(10)

TEST SPARK INTENSITY. Determine if the

(3)

all

vacuum

gine

Accessories."

"Electrical

spark

move

point

check

to specifications, the

point

parts.

distributor

with

spots.

CLEAN AND INSPECT THE DISTRIBUTOR

(9)

with a

battery.

lightly

cam

defective

all

not

the

or

points

adjustments,

Set the

required.

is

angle

worn

CAP. Inspect the cap for

that have

cables

cable connectors with grease

corrosion.

tor

is

cam

tive. Replace

a

the "battery.

recharge and

In

leaks. Make

capacity test. If unsatisfactory, make

battery charge

in the

distributor

TEST

AND

distributor

make

and

advance

replacements

dwell. If the dwell order given.

of

manufacturer.

THE DISTRIBUTOR. Inspect Test the

to deter

parts on a test unit

the

neces

be necessary to the spark is

is defective. Follow the instructions

INSPECT

(8)

will

spark

However, if

condenser.

and

satisfactory, test these

not

repairs,

operations

plugs

to 23-28

and nuts

to specifications. After setting the gap,

following

gap. plugs

badly burned

and

plugs.

adjustments.

Perform the

the

adjust

and

porcelain

and exhaust manifold

mine which one

all

porcelain

foot-pounds torque.

element.

of

all

SPARK

the

wipe

plugs,

flat,

tips

an approved

chipped

INSTALL

CHECK MANIFOLD BOLT TORQUE. Tighten

test the

the fuel line filter. Install

BELTS. Check the deflection

sary

viscosity.

element.

clean

(6)

If

element.

to the indicated

CHECK THE DEFLECTION OF THE DRIVE

(8) air

the

and oil

in

or

Replace

electrodes.

the intake

AND THE FUEL

bath-type, fill

electrode

plugs

broken

spark

and tighten them to the specified torque.

remove and clean the

cars, new

Thunderbirds,

filter

cleaner,

oil

with engine oil of

bowl. Install new

air

is the

clean, file the

for

AND

CLEAN, ADJUST,

PLUGS. Sandblast the

the carburetor idle fuel

(7) CLEAN THE AIR CLEANER FILTER. Clean the

valve

weak

in Chapter IV.

adjustment as outlined

On

is erratic, it is

normal or

not all of

Tune-Up."

"a. Minor

procedure under

Test the

below

still

bad rings, sticky valves, head gasket leak.

or a

springs,

is

some, but

at

distributor cap is corroded. the (4) TEST CYLINDER COMPRESSION. Follow

(5)

adjustment.

is unsatisfactory

spark

the spark plug wires, the trouble is in the wire itself, the wire is not seated in the housing socket, or the

speed.

vacuum

indication

level

AND ADJUST

vacuum

carburetor

the

the

vacuum

is lower than specified, check for leak the vacuum lines and intake manifold. Check the

age at

an

the

If the

speed.

make

and

Connect the distributor

adjustments.

the specified idle

idle

engine at

Tune-Up

of

reported

to the customer.

10

500

static

pressure

The capacity

r.p.m.

500

Engine


TEST FUEL PUMP PRESSURE AND CAPAC

(13)

ITY. The at

1 General

Chapter

be 3.5-5.5

should

should

be 1

in 30

pint

seconds

r.p.m.

BOOSTER

PUMP

VACUUM.

INSPECT AND CLEAN THE FUEL FILTER.

On

passenger

bowl. Install On new

filter

Thunderbirds,

filter

and clean

(17)

fuel pump

the

clean

and

the fuel line filter. Install

clean

a

equipped muffler

Disassemble

level,

oil

accessories.

fill to the indicated level

Separate

procedures

car

for the

given

are

oil

engine

of

conventional

The following

apply to

procedures

Differences in the

cars.

the

when

equipped

cars

noted

they

when

The

with

Remove the

then

REMOVAL. If the

(1) ard

overdrive

or

(c). If the steps

(a)

(b)

for the

it impractical to

gine with the transmission

car

remove

and

peculiar

engine

are

engine

only,

Remove the

toler

install the

or

remove

en

car

is

equipped with a stand

(a) and Fordomatic, follow

with

Disconnect the

clutch

retaining the

equalizer

the

remove

accelerator

with

a

linkage

jack,

housing

then

spring.

release

Remove the two flywheel

bolts. Remove the flywheel transmission

bar

support

support

at

housing

cover,

and

Drain

the

cooling

bolts. Jack up the front of the transmission safety stands. Support the

system

remove

the remaining

converter

housing

and

blower

Remove the

ground

flex fuel line

at

cable

perature

sending

wire.

at

unit

wire,

starter cable at

Disconnect the

to

jack,

engine

bolts.

Disconnect the

manifold.

hoses,

block,

then

the

and

wire

at

the starter, then

air

hose,

tem

the oil pressure sending

ground

cable

the

coil.

remove

from the

choke

inlet

cable

at

the

rear

cleaner, then tape the

accelerator

muffler

vacuum

wiper

primary

Disconnect the

Disconnect the

cylinder

and

Disconnect the

closed.

lower

and

pump.

horn retor.

the

windshield

engine

then

heater

the

and

Remove the fan. Disconnect the

the fuel

Disconnect the

unit

cylinder

filter.

upper

radiator

radiator.

to

position

pan,

motor.

the two

and

oil

the crankcase. Remove the heater

the engine. Remove the

with a

from the

shield

splash

rubber

car

the transmission

hoses. Remove the heater inlet duct

starter.

upper

that

Engine Removal. Remove the hood. Drain the

Remove the

housing

at

then remove the oil

block,

and

remove

bracket

linkage

battery

the

the

level indicator tube to the

control

arm

converter

housing

sion

shaft,

the two

converter

the

the

then

Remove the idler

remove

so

plate

the tube assembly. Remove the transmis

at

plugs, then

the

Remove

oil

Disconnect the tube

tie the linkage to the dash

bracket. Fold back the floor mat,

from 90

drive

removed.

transmission.

upper

support

cross

180,

remove

the transmission throttle linkage

the

is

the transmission

secures

the

housing bolts. Steps Peculiar To Fordomatic Disconnect panel.

plate

removed

are

on

catch

not

will

remove

the remaining

remove

bolts

the

plate, turn the

engine

mani

the

flywheel

(b)

the

(c)

bushing. Disconnect the crank.

drive

plates

cover, then is in posi

access

drive

three bolts.

other

After

steps

(c).

to the flywheel housing, then

fold bell

flex

engine.

attached.

equipped

screws

owner.

without

compartment

Steps Peculiar To A Standard Or Overdrive

Transmission.

check

the three bolts. Turn the flywheel

the

CAUTION:

transmission, follow

is

final

car as a

lower

housing

converter

conventional

all

procedures

6-cylinder

or

Engine

attached.

air

additional service required

is delivered to the

remove

when

procedures given are

make

Recommend any

exist.

the transmission ances

8

an

(fan,

Make the necessary

performed.

car

converter

to

drive belts

of all

power steering).

and

work

tion to

Conventional Passenger Car.

passenger

analyzers,

manufacturer.

turn the flywheel till the flywheel

the Thunderbird.

and

of

ENGINE REMOVAL AND INSTALLATION

3.

passenger

with

the

of

types

several

are

Also, notice the performance transmission, axle, brakes, and any optional

If the

is the

there

as

ROAD TEST. Road test the

(21) the

cleaner

left

adjustments.

the

air

exhaust

the

to

tube

CHECK THE DEFLECTION OF THE DRIVE

of

element.

the

dual

On

analyzer

BELTS. Check the deflection

on

the

ANALYSIS.

follow the instructions

air

and

en

adjustment

pipe.

outlet

Inasmuch

and check

operation.

pump

idle fuel

carburetor

connect

cars,

conditioning,

THE CARBURETOR.

the

in Chapter IV.

CLEAN THE AIR CLEANER. Clean the

bath-type,

a.

speed and

EXHAUST

(20)

the carburetor. Set the fuel

accelerator

cleaner

idle

(19)

element.

element.

CLEAN

(16) the

remove

cars,

a new

viscosity.

ADJUST CARBURETOR IDLE. Set the

(18) gine

The

booster pump vacuum should be 10.0 inches of mercury at 500 r.p.m. The vacuum should not drop rapidly when the engine is stopped.

(15)

specified

as outlined

TEST

(14)

the

at

p.s.i.

Repair

and

the

of

air

carbu

linkage. pipes

at

the

exhaust

Section

3 Engine

Removal

11

Installation

and

Too/-T52L-6000-C

(SPLINED SHAFT)

Tool- 1 5 41-600 5-D Tool T54L-6005-E

On 6-cylinder engines,

bracket bolts at

the

Hook 6-Cylinder

Lifting

Engine

insulator,

the

engine

the transmission.

move

engine

the right

and

lifting hook(s) (fig.

left front

1

or

2). Re

aprons.

splash

On 8-cylinder engines, remove the insulator from the engine front steady

Carefully Do

safety

rest

to

spacer

bolts. Raise the

(2)

and

front

(b),

and

stands.

follow

steps

Remove

insulator

at

the

the

cap

screws

the

from

engine

the

left insula

engine

right

engine.

let the

pull

engine

it from

swing

the

of

out

engine

engine on a work stand car

(fig. 3

is

against

or

4).

equipped

with

a

overdrive

(a), (c),

(d).

and

Engine Installation. Install the

lifting hook,

engine remove

bracket

right

transmission, follow steps (a), (d). If the car is equipped with Fordomatic, or

position

(a)

On 8-cylinder engines, tor.

car

engine

not

lift the

INSTALLATION. If the

standard

rest.

On 6-cylinder engines, loosen the two steady

lower

the

and

the grille.

Install the

retainer and

left insulator to

the

slightly, then carefully

engine compartment.

Attach the

Engine

engine.

Raise the J

Fig.

at

remove

6302

SHAFT)

3 Engine Mount 8 -Cylinder

Fig.

bolts

(KEYED

appropriate

then remove the engine

from the

work stand.

CAUTION: sure plate

the will

On

Fordomatic

flywheel drive not

Lower the

catch

engine

on

equipped

plate

the

is turned

so

the

flex

housing.

converter

carefully into the

make

cars,

engine

compart

ment.

On 8-cylinder engines, lower the

Tool-T53L-300-A

pump to oil

pan

line

clears

Start the transmission

the

main

engine

engine

drive

left

gear

until

the

oil

support.

into the

clutch

ToolT53L-6000-B

ToolT52T6005-CJD (Splined Sha ToolT52T-^>005-KJD (Keyed Shaft)

6304

Fig.

2

Lifting Hooks

and Sling 8-Cylinder

Engine

6289

Fig.

4 Engine

Mount

Adapter 6-Cylinder

Engine

12

1 General

Chapter

disc. On Fordomatic units,


the converter

start

pilot

into

the crankshaft.

NOTE: On

with relation to shaft

will

"hangs

or

units, it may be

overdrive

not

the engine

enter

up"

the

the

after

disc.

clutch

If

the

the

crank

it if

slowly (with the transmission in gear) until the shaft splines mesh with the clutch disc splines.

Make

the

8-cylinder

and

muffler

inlet pipe(s)

the holes in the

block dowels

the

studs on

manifolds of

and

clutch

must

both the 6

the holes in the

engines are aligned with

the dowels in the block

housing

(on Fordomatic

the holes

engage

the

on

engage

units

housing). NOTE: Level the

in

engine crosswise

installing

to the

relation

mounting bolts

the

or

the

steady rest. On the 6-cylinder engine, install the left insulator to bracket lockwashers and bolts and the right bracket to lockwashers

bolts. Tighten the insulator to

and

bracket bolts to 45-50 foot-pounds torque. Tighten the engine pounds

front steady

rest

to spacer bolts to 30-35 foot

left

block,

the

insulator

the holes in the

align

insulator to

the insulator to

engine

torque. sulator

Install the

to 50-60 foot-pounds

nuts

front steady

Tighten the

foot-pounds torque. Install the

right and

bolt to 23-28

left front

splash

manifold

Install the starter, then

rear

of

muffler

the

connect

Connect

Fordomatic).

cept

to the

(s)

the

inlet

starter

ground

oil pressure

sending

the ignition

switch wire

switch wire

to the

linkage

the

and

Connect the

wires, the

pipe(s).

cable

generator

(ex

Install the

Connect the

Connect the

engine clips.

(6-cylinder

line

windshield wiper

radiator

battery

cleaner.

heater inlet

Install

and

connect

ground cable carburetor

the

to the

air

horn

Install the heater blower

and

duct,

the

then

connect

plate

holes

evenly to

and

housing

avoid

to

upper

engine

and

drive

six

bolts,

foot-pounds torque.

Install the starter, and tighten the bolts to 15-20 foot-pounds torque. Install the transmission oil level indicator

tube

Install

assembly.

bracket. Tighten the idler

idler

the

bracket

arm


and

arm

to 28-43

nuts

housing lower

converter

access covers.

necessary linkage

the

transmission

the

with

A, following

the

procedure.

recommeneded

Check Engine For Oil Or Coolant Leaks.

(d)

Run the

hose

Fill

Fluid Type

Automatic Transmission

and make

Remove the jack sup

adjustments.

transmission.

the

porting

the throttle linkage

and connect

fast idle

at

engine

connections

check

and

gaskets

all

and

for leaks.

Thunderbird.

b.

On Fordomatic

Remove

install the

motor

system

with

and

and

or

the

REMOVAL.

(1)

Thunderbird

Fordomatic

To

with

equipped

a

as

an

and

and

remove

assembly, follow

a

overdrive

remove

the

Fordomatic,

the engine and

steps

(c)

(d).

and

Steps Peculiar To A Standard Or Overdrive

Transmission. Disconnect the Remove the

screws

to the flywheel

retaining the

housing,

clutch

Remove the flywheel mission with a

then remove the

jack,

housing

then

release

equalizer

bushing. Remove the two flywheel

the

the transmission throttle linkage

bar

spring.

support

support

housing

cover,

remove

housing bolts.

(b)

or

(c). To

equipped with

(c). To

from

engine

standard

a

(a)

steps

Thunderbird

(b)

the

remove

the

upper

support

and

bolts.

the trans

the remaining flywheel

Steps Peculiar To Fordomatic. Disconnect at

the cross shaft,

tie the linkage to the dash panel. Remove the

bar support,

engine

transmission

the

without

attached.

(a)

hoses.

Thunderbirds,

equipped

removed

steps

accelerator

engine.

be

follow

wires,

radiator

equalizer

and

foot-pounds torque.

the converter, then install the

them to 25-28

from

Connect Standard Or Overdrive Transmis

Install the bushings in the

with

and tighten

engine

the heater hoses.

hood. Fill the cooling

bolts,

Align the flywheel

pan plugs.

and

crankcase.

(b)

bolts,


the fuel pump

and

lower

engine

to 40-45

them

tighten

the

engine).

and

Install

pins.

converter

and

to the coil. Connect the ignition

choke wire

the tape from the

sion.

the dowel

on

Install the two

to

vacuum line. Connect the fuel pump flexible line. Install the fan assembly, then adjust the fan belt.

air

binding

unit

cable

the engine, the temperature sending unit

to

housing

NOTE: Tighten the bolts slowly

may

aprons.

Connect the

and adjust

lower in

rest

retainer

inches)

tighten them to 40-45 foot-pounds torque.

bolts. Tighten

and

bolts to 45-50 foot-pounds torque

engine

and retainer.

and

Install the

and nuts.

lockwashers

engine

the frame to insulator

and

bolts

then install the insulator to engine

the frame to insulator lockwashers right

en

the mounting holes in

with

Check

transmission.

Transmission.

Fordomatic

converter

Install

support

spring.

release

clutch

free travel (lH-l3/8

Connect

the two

torque.

On the 8-cylinder engine, gine

tighten

and

necessary.

Install the floor

frame before

engine

clutch pedal

(c)

the

converter

Connect the

cover.

Remove the jack supporting the

engine

enters, turn the

shaft

housing

shaft

sure

housing bolts,

them to 40-50 foot-pounds torque. Install the flywheel

the transmission input

if

housing. Install

the flywheel

support on

the transmission to flywheel

standard

to adjust the position of the transmission

necessary

install the

then

Repair

and

idler

and arm

bracket. Jack up the front

of

the

car and position

safety

stands.

3 Engine

Section Support the transmission converter

housing

housing

lower

jack,

with a

Removal

then remove the

to engine bolts. Remove the

converter

cover, then turn the flywheel till

access

flywheel drive plate is in position so the three bolts be removed. Turn the flywheel 180, then remove

the can

the other three bolts.

CAUTION: After converter

flex

the

bolts

are

drive plate,

turn

the

Drain

the

secures the

is

transmission.

transmission

and

remove

the tube

sion

control

linkage

(c)

system and

remove

the

90

plate

so

housing

oil

the

cleaner.

air

Remove the transmis

assembly.

splash

the

crankcase.

Disconnect the the

battery

battery. Disconnect the fuel inlet

to

Remove the fan, then an assembly. Remove

engine

ground

battery starter

vacuum

ground

wire

at

cable at

cable at

relay

line,

pump

the fuel pump. Disconnect the

at

and

the

the dash

at

wire

at

Remove the

wires.

unit

sending

and

Remove the heater blower

bracket

also serves as

Raise the the

front

move the

mount

accelerator

stands.

safety

bolt,

nut,

engine right and

engine will clear

(this

Disconnect

lower insulator. Re

and

left steady

rest

bracket bolts

one side so

the

slightly, then carefully pull the

Carefully lift

the

engine

engine

from the trans

out

the

of

engine

Install the

engine on a work stand

in

step

(c),

perform

the

following

hooks,

at

ing

and

cap.

move

cable.

speedometer

plug the transmission

Remove the

converter

the bracket that

indicator tube to the

secures

remove

flywheel drive

the will

not

engine.

on

catch

Lower the

the

equipped

is

plate

the

from the

engine

(a),

work

lifting

stand.

make sure

cars,

flex

plates

housing.

carefully into the

engine

engine

turned so the

converter

Start the transmission

drive

main

disc. On Fordomatic units,

engine compart

start

gear

into the

clutch

the converter pilot into

the crankshaft.

NOTE: On

standard adjust

with relation

to the engine,

the clutch

enter

the

shaft

the

disc.

enters,

If

turn

the

with

Make

disc

clutch

the

sure

units, it may be

overdrive

or

necessary to

position

if

of the transmission

the input

the crankshaft until

the

shaft will not

"hangs

the engine

up"

after

slowly (with

shaft splines mesh

splines.

studs

on

the manifolds are

the holes in the muffler inlet pipes, and the

with

in the block

engage

Fordomatic

units

on

the holes in the

car

front

dowels

housing

(on

must

engage

the

housing).

and position

support

aligned

clutch

block dowels

the

the converter

Raise the engine

lower

safety

stands.

Install the

insulator, bolt, lockwasher,

Tighten the insulator mounting nut to 85-95 foot-pounds torque. Install the engine right and left nut.

and

rest

NOTE:

adjust

shift

control rod.

Remove the drive

duct

steps

ment.

additional

with an extension

air

(f). To install the

and

assembly, follow

as an

CAUTION : On Fordomatic

steady

car

the transmission and the throttle control

Disconnect the shaft,

then

bracket bolts,

If rest

the

hous

assembly.

Re

the transmission oil level

Disconnect the tube

at

the

rod

was

tighten the bolts to 45-50

and

assembly

disturbed

adjustment

during

the rod as outlined in step

Connect the

Drain the transmission. Disconnect the

(a), (c), (e),

steps

Fordomatic

Thunder

equipped

Engine Installation. Install the

(a)

operations :

linkage

Fordomatic

a

(f). To in

and

(d),(e),and(f).

is

And Fordomatic As An Assembly. While the raised

only in

a

overdrive

foot-pounds torque.

(fig. 3).

Removing The Engine

Steps Peculiar To

(d)

(a), (b), (e),

steps

in

engine

or

standard

a

with

equipped

engine

bird, follow

steady

compartment.

car.

the engine slightly,

To install the

INSTALLATION.

the

stall

holes

them upon removal.

Remove the safety stands and lower the car. Install the engine lifting hooks (fig. 2). Raise the engine mission.

lifting hooks. Raise

the transmission in gear)

the exhaust manifolds. Remove the

the engine, then turn the brackets to

at

block

the

at

rod,

the ignition cable bracket).

car and position

exhaust pipes at

engine

from the

Disconnect

assembly.

link bracket

disconnect the

wires

the temperature sending

the tachometer cable. Disconnect the then

to coil

switch

the coil. Disconnect the two heater hoses. Re

pressure

unit.

Disconnect the ignition

the generator

move oil

panel.

lower the

and

compartment.

engine

the

starter cable

as the

serves

Carefully

the starter solenoid, then remove the cable clamp

at

engine

engine and

shield.

the transmis

then carefully pull the engine and transmission forward. lift the engine and transmission from the


radiator and shroud as

engine and

Remove the transmission jack

level indicator tube to the oil pan

raise

assembly.

engine rear mount.

(2)

the transmission

bolt,

the cross member that

remove

Thunderbird

at

the tube

remove

engine rear mount

Remove the bracket that

the dash panel. Disconect the the

drive

Engine Removal. Remove the hood. Drain the

cooling

sion, then

pan, then

oil

Remove the

removed.

Disconnect the tube

engine.

from the

removed

plates will not catch on the converter

when the engine

transmission

Install the

the

13

Installation

and

exhaust pipes

engine

of

either

removal,

(e).

to the exhaust manifolds.

Remove the safety stands and lower the car. Connect the accelerator rod, then connect the accel erator link bracket to the block. Connect the tachometer cable. oil

Install the heater blower assembly. Install the

pressure

unit

wires.

sending

unit and

Connect the

the temperature sending

wires. Connect the two heater hoses. Connect the ignition switch to coil generator

14

1 General

Chapter

Engine Overhaul, Inspection, Install the

bracket

arm

Install the Install the

Install the transmission

Install the idler

assembly.

idler

tighten the bolts to 15-20 foot

starter and

torque.

pounds

Repair

and

bracket. Tighten

arm and

housing lower

converter

and

connect

necessary

linkage

covers.

access

linkage,

throttle

the

make

and

Remove the jack

adjustments.

supporting the transmission. Fill the transmission

Automatic Transmission Fluid-Type recommended

with

A, following

the

procedure.

Install The Engine And Fordomatic As An

(d)

Assembly. While the

following

the

the

foot-pounds torque.

28-43

to

nuts

filler tube

oil

Jack

additional

the

up

is

car

in step

raised

(a),

perform

operations:

Install

transmission.

the

rear

engine

Lower the transmission, then install the engine mount bolt. Install the converter air duct assembly.

mount. rear

Install the transmission

oil

Remove the

housing

extension

level indicator tube

install the drive

sion,

and

eter

cable.

Connect the

cap from the transmis

Connect the

shaft.

speedom

linkage

control

shift

assembly.

the

and

6512

throttle 5

Fig.

Adjustment Thunderbird

Rest

Steady

control

Fill the transmission

rod.

Transmission Fluid-Type A,

matic

Auto

with

following

the

recom

mended procedure.

wire.

Install the

starter

the

and connect

windshield wiper

the

battery

line

the flexible fuel line. Connect

and

Install the

engine ground wire. radiator

and

system.

and

Fill the

crank

Install the bushings in the

then install the

support on

equalizer

bar support,

the flywheel housing. Install

the transmission to flywheel

housing bolts,

and

tighten

40-50 foot-pounds torque. Install the flywheel

them to

housing

Connect the

cover.

clutch

Engine Steady Rest Adjustment. If the

(e) gine

steady

It is

good

the

rod

With the

loosen the

rod

each

the free play, if necessary.

of

(c)

Connect

Fordomatic

housing

converter

to

Transmission.

lower

engine

Install

bolts,

and

tighten them to 40-45 foot-pounds torque.

NOTE: Tighten the bolts slowly binding on the dowel pins. Install tighten

flywheel the

six

the

converter

40-45

them

to

and

drive

bolts,

plate

and

and

avoid

to

engine

bolts

foot-pounds

torque.

Align the

holes

tighten

with

them

and

the converter, install

to 25-28

engine

(at the

and

rest

up

foot-pounds

each

rod

assembly up

bracket. Tighten the 5. Turn the the

rod

upper

assembly

nut

on

level

nut

adjustment

both steady Turn

position.

and

insulator

(chassis)

and

insulator the

against

measuring the

of

support

the

shown

at

top

support

in fig.

the

top

the engine support

to the dimension

the

at

engine

to the dimension

of

place

chassis),

to the dimension shown

against

assembly down

by

and

nut, washer, and insulator

bracket. Tighten the

top

shown

portion

over-all

of

in fig.

the

dimension

as

rod

in

dicated in fig. 5.

(f)

Check

The

Leaks. Run the and

torque.

nut

rods are out of

brackets in

nuts

own

the lower

against

adjustment of

engine

upper

its

seek

result.

below:

assembly lower nut, washer,

5. Check the

housing

lower

rod

may

installation. The

rest support

steady

tightened

Turn the lower nut, washer,

of

evenly to

engine

steady

in fig. 5.

the

check

engine

procedure

bracket. Tighten the lower

release spring.

Remove the jack supporting the transmission. Check the clutch pedal free travel (IVs-IVs inches). Adjust

the two

follow the

Let the

each

illustrated in fig. 5. If the

are

properly

rests.

and excessive engine vibration

at

en

properly adjusted, the engine

not

practice, therefore, to

adjustment

and

are

assemblies,

dimensions

the

rests

be tilted

will

grade of engine oil.

Connect Standard Or Overdrive Transmis

(b) sion.

the correct quantity

air cleaner.

install the fan.

then

shroud,

Install the hood. Fill the cooling case with

the dash panel,

on

clamp

to the starter. Connect the

ground cable and the starter solenoid cable.

Connect the Install the

cable

starter cable

hose

Engine

engine at

connections

For

fast idle

Oil

Or

Coolant

and check all gaskets

for leaks.

4. INTAKE AND EXHAUST MANIFOLDS a.

Cleaning

and

Wash grease, oil,

Inspection. and

dirt from the

outside

of

the

exhaust manifolds.

Clean the mating

surfaces and check

4 Intake and

Section

15

Exhaust Manifolds

OPEN

OFF)

(HEAT

6338 OPEN

.

(HEAT

OFF)

Fig.

7 Exhaust

Valve Dual

Control

Exhaust System

6337

Fig.

6 Exhaust

Exhaust System

Valve Single

Control

them for damage. Repair

replace

or

the

manifolds

as

On the intake manifold, check the fuel-air and the heat riser passages for foreign material. Inspect the for

surfaces replace

cracks

Remove

have

visible

other

or

the manifolds as

CAUTION: that may

light finger

Rapidly

pressure

accelerate

opens.

momentarily

necessary.

or

engine

operated

trating

at

is

at

high

oil or

is

applied

the

The

valve

Free

r.p.m.

open

the

make

the

sure

is designed to

stuck

very

valve

open when

valves with

and

a

is

pene

and graphite mixture.

filings

the

foreign

and

manifolds

matter

result

a

as

of

CLOSED

work.

repair

when

counterweight.

operating temperature

normal

kerosene

to

engine

will

to

necessary.

all

entered

defects. Repair

the

valve

properly operating

a

ever,

(HEAT ON)

b. Exhaust Gas Control Valve. Check the

valve

spring to

make sure

the stop pin. The spring stop is at the

housing of

when

the valves

Check to when

the

hand to

The

is

is

cold.

sure

it

closed

on

valve action

the spring holds the valve closed

rotation

of

valve

the

of

valve

make sure

engine

90

top

is properly installed. The in figs. 6, 7, and 8. illustrated is the

make

mately

it is hooked

Actuate the

freely

moves without when

counterweight

through

by

approxi

binding.

the

6478

is

engine

and running operating temperature

at

idle

at

normal

Fig.

speed. How-

8 Exhaust

Control

This dures and

section

applicable

valves.

valve

covers

lash

to the

the inspection and rocker

In addition, the and

to

check

mechanism,

methods used

valve

timing

repair

cylinder

to

are

head,

adjust

given.

AND VALVE TIMING The

proce

Rocker Mechanism.

rocker mechanism parts are

individually

replace

able.

(1)

the of

the

shaft

a.

Engine

VALVES,1

5. ROCKER MECHANISM, CYLINDER HEAD, VALVE LASH ADJUSTMENT,

Valve 6-Cylinder

CLEANING AND INSPECTION. Check the I. D. rocker arm

at

the

rocker arms

bore

location

for

and

of

the O.

the

grooved pads.

D.

rocker

of

the

arms.

Check the

rocker arm

Inspect the

rocker

adjust-

16

Chapter

1 General

Engine

Overhaul, Inspection, (1) CLEANING installed to

valves

to fixture'

PUSH ROD

9 Push

Fig.

6263

Rod Runout Check

old

gasket

Check the head for

burrs,

nicks,

lock

screws and

the ball

and

for

nuts

the

end of

stripped or

for

screw

broken threads,

nicks and scratches or

excessive wear.

Inspect the of

for

springs

are

Check the ball

drain tube for

cracks or other signs

nicks, grooves, roughness,

A

suitable

check

the

push rods

for

(2) REPAIRS. Replace

push

rods

be

can

at

any

discard

point,

straighten

0.020

the

rod.

Do

not

Remove

and

rocker

arms

the

rocker

arms.

severely

scored

Replace

all

or

scuffed

oil

and

and/or

rocker

Replace

minor nicks or scratches.

screws, lock nuts,

bores

scuffed

scored

Replace the

between the

shaft

is excessive, replace the shaft and/or Replace all rocker arms that have

or

all

grooved

pads.

Dress up

shafts.

damaged adjusting

springs.

drain tube if it is

cracked

or

has

a

sharp bend.

to

use

is

heads, do

not

heads

off

are

the

the

if

material

excessive

surface

this

when

the

as

com

is

operation

dure is

the

leakage.

show signs of

HOLE ADAPTERS. If it is de 14

standard

spark

millimeter

The

18

the

reduces

which

millimeters.

millimeter

installation

adapter

an

plugs,

proce

follows:

as

Position meter

that

plug

plug

gasket

a standard

on

install the plug in

and

plug

spark

spark

a

an

14

milli

Insert

adapter.

assembly into the 18

and adapter

milli

meter hole and tighten the plug to 25-30 foot-pounds torque. This torque is sufficient to seal the adapter in place

it

and

will

spark

back

not

Once the

out

adapters

plug

gap

when

the

plug is

spark

are

installed,

and

torque

14

standard

specifications

apply.

machined

remove

or

or scratches with an oil stone.

core plugs

available

hole to 14

removed.

b. Cylinder Heads. protect

grind

gasket

altered

burrs

all

millimeter

To

the head if it cracked,

or

head

(3) SPARK PLUG

to

adapter

clearance

evidence

repair.

plane

is

ratio

Replace any

sired

If the

all,

performed.

inch,

attempt

it.

(2) REPAIRS.

not

cylinder

pression

they are installed in the engine by rotating them (valve closed) or they can be checked between ball and cup centers with a dial indicator (fig. 9). runout of a push rod exceeds

the

made

while

If the total

Do

NOTE:

from

or excessive wear.

for bent

over

passages

sharp bends.

cracks or

end and socket end of

maximum

speci

leakage.

it is damaged beyond oil

0.006 inch

0.003 in any six inches. Make sure all water are open. Check the cylinder head core plug for

failure. Inspect the

gasket surface

or

of

locating

with solvent

grease.

and

Check the

cracks.

to

careful not

for flatness (fig. 10). Service

and

fications for flatness

ing

brush. Be

dirt,

the car

valve

and

chamber

combustion

sealer,

With

seats, remove

valve

the gasket surface. Clean the heads

remove

for

the

with a scraper and a wire

scratch

Holding

INSPECTION.

AND protect

bon deposits from the

heads

Repair

and

the

surfaces

holding

of

the

fixtures

cylinder

while

the

Valve Mechanism.

c

Valve

engine.

guides

heads. Valves replacements

with

integral

made

are

oversized

the

with

stems

available

are

if it becomes necessary to

cylinder

the

ream

as

valve

guides.

(1) CLEANING brella-type Scrape stem

and/or

of

Remove all

Fig.

10

Checking

Flatness

of

seals,

brush

varnish

carbon

from the

from the valve

6601

Check the the

valve

face for

valve

from the head

valve stems.

valve seat with a

for

stem

pits

for

um

and replace with new seals. carbon

evidence

heavy discoloration, burning

the Cylinder Head Gasket

Surface Typical

wire

the valves and from the inside

Check the

(T), check diagonally (5) CHECK ACROSS CENTER

AND INSPECTION. Discard

valve stem

face

runout

and

grooves.

or

of

of

and

guides.

Carefully fine

wire

clean

brush.

imperfect seating,

erosion,

(fig. 11),

or

and

Inspect the

grooves or scores.

the

warpage.

also

ends

check

of

the

Section

5 Rocker

Mechanism, Cylinder Head, Valves,

Valve Lash Adjustment,

and

Valve

17

Timing

REFER TO

SPECIFICATIONS

6602

6266 11 Valve

Fig.

Inspect the the

valve

valve springs

spring for squareness (fig. 13). valve

Check the

for

valve

wear or signs of

Check the

set

its

on

the

proper

signs

of

pressure

failure. Check (fig.

12)

locks,

and sleeves

failure.

valve stem clearance of each valve

screw, then

and

tool

Position

guide.

the center

against

.as

permit

in fig. 14. Install the

shown

the

fully

in its

seated and

valve

the tool contacts the

to

drop

tighten the

away from

upper surface of

action

lifting

the

on a plane

from the

valve

Divide the indicator reading to

tool)

Check the

a

by

flat tip

valve

that parallels

guide

upper

the

Move

stem.

normal without

surface.

2 (division factor

of

the

the actual stem clearance.

obtain

as shown

with

spherical section of

take the indicator reading

and

tool

the

to the

approximately

rocker

Squareness Check

dial indicator

a

90

at

valve seat runout and the valve seat width

in figs. 15

and

16.

the

(2) REPAIRS. locks, Valve

Spring

portion of

the tool back and forth

valve stem until

seat until

for

spring retainers,

respective valve guide

tool

Fig. 7 3 Valve

Face Runout Check

Spring

(a)

Tester

retainers,

Discard any defective valves, springs,

or sleeves.

Refacing Valves. If the

excessive,

grind

Tool

-

the

S-8680

valve

face

valve at

face

runout

is

45

a

angle

on

a

Dial Indicator

PRESSURE

READING

6267

6479

Fig.

12 Valve

Spring

Pressure Check

Fig.

14 Valve

Stem Clearance Check Typical

18

Chapter

1 General


Runout Gauge

,

Repair

and

Vn"

MINIMUM

MAXIMUM

REFER TO SPECIFICATIONS FOR CORRECT DIAMETER

VALVE

FACE RUNOUT 0.002

CHECK FOR BENT STEM

L

Z Tool-for

Removing Installing Pilot

15 Valve

Fig.

and

6603

Seat Runout

Check Typical

valve

Follow the instructions

grinder.

equipment

manufacturer.

to

pits

remove

and

head is less than

Grind

inch thick

the

stem

enough

stock

able.

edge of the

valve

in

only

If the

grooves.

y32

off

after

replace

grinding,

the valve. If the runout still exceeds specifications

the

check

grinding,

equipment

used

in the

after

grinding

operation.

Grind

Do

end of

the

than 0.010 inch from

not remove more

The

of 0.003, 0.015, and 0.030 inch are avail Occasionally the 0.003 inch oversize valve is used

critical

tolerances

of

the

valve are

illustrated in

in

production

valve

the diameter

determined

of

by a

one or more positions.

to guide

the valve

new

be

cannot

valve

guide

stem

valve

is

on

excessive and

the lower limit (as

valve stem with a microm

with

a stem

diameter

use of standard valves

reduced

(fig.

is

stem clearance

measuring the

limit. If in the

upper

ance

valves with a

diameter

If the

the

stem.

the seats.

match

Select Fitting Valves. Oversize

eter), select

from the

all grooves or score marks

valve stem.

the

to

compound

of

Tolerances Typical

Valve

After refacing valves and seats, it is good practice to lightly lap in the valves with a medium grade lapping

(c) precision

6480

17 Critical

Fig.

to

20)

a

limit,

ream

oversize

valve

satisfactory

for the

next

the

on

the clear

stem.

fig. 17.

(b) Refacing (fig. 18) to a true to

clean

pits

up

Valve Seats. Grind the 45

angle. or

specifications,

the

and/or

width

wheel

the

to

seat

bottom

edge

from the bottom

possible.

remove

as

near

stock

to

Remove only enough stock If the valve seat width

valve

to

enough

the

of

30

a of

to

seat

angle

the seat

center

check

the

of

on

the

the

from

stock

reduce

wheel

and a

from the top (fig.

the

Place Prussian Blue

install the

just

remove

to specifications. Use

move stock

seat

grooves.

exceeds

top

valve

60

to

the

d. Valve Lash Adjustment. Reference is

(cold) piston

valve on

made

lash

top dead

compression

stroke.

in the

procedures

to

adjustment center

(T.D.C.)

Number 1

for

a

preliminary

placing at

piston

number

the end

is

on

1

the

of

T.D.C.

at

re

angle

19). Keep face as

valve valve

and

seat

point of contact.

30

ANGLE WHEEL FOR BOTTOM OF SEAT

Seat Width Scale

60

ANGLE WHEEL FOR TOP OF SEAT

6604

Fig.

16

Measuring

Valve Seat

Width Typical

6605

Fig.

18

Refacing

Valve

Seat Typical

Section

5 Rocker

Mechanism, Cylinder Head, Valves, Valve

Lash Adjustment,

Valve

and

19

Timing

REFER TO SPECIFICATIONS

VALVE SEAT

6292

Fig. J9-Va/ve Seat Width the

the compression stroke

end of

closed and the

in line

timing

the

with

Step- type

timing

feeler

Valve lash is lock

("go"

proper

the

on

valves are

"no go") (fig. 21).

and

clearance

by

adjusted

located

nut

both

when

the crankshaft damper is

pointer.

gauges

to obtain the

used

mark on

It is very important that the lash of all valves be held as close as possible to the correct specifications. If the

lash is

engine

too close,

set

If the

performance can result. valve

cessive,

formance

action

be

will

noise

lash is

valve and

result,

poor

and

ment

specification

gines

is 0.019 cylinder

and

(intake

head

valve

adjust

exhaust) for

and

the

or

lash

all

has

mechanism

rocker

en

installed, it will be necessary to make a preliminary (cold) valve lash adjustment before start ing the engine. If the adjustment is made for the pur been

removed and

(a)

and proceed with

the procedure for the

applicable engine.

tune-up,

pose of engine

(b) (1) 6-CYLINDER under

step

omit

step

ENGINE. Remove the

Remove the

rocker

Preliminary Adjustment. Make three

(a) marks

the

on

damper.

crankshaft 90

apart so

that

Space

with

the

the

Va

around

turn

the crankshaft

of

or

lA

of

chalk marks

timing

mark,

(90

the damper is divided into four equal parts sents

final

ENGINES.

8-CYLINDER

(2)

approximately per

engine

Reaming

Guides Typical

Valve

arm covers.

ex

affected.

NOTE: The preliminary

If the

will

idle

engine

rough

20

set screw and

the rocker arm.

push rod end of

539

Fig.

the

means of

be

can

repre

the distance

the damper circumference).

Rotate the

T.D.C.

at

timing

mark

crankshaft until

the

end

on

of

the

number

compression

the damper is

aligned

1

piston

stroke with

is

and

the

near

the

timing

pointer.

Combination

Adjusting

Tool

rocker arm

cover.

on

the

120

the

apart so

V3

of

that

distance

the

the

with

into three

damper is divided

represents

two

damper. Space the

crankshaft

proximately

Make

Adjustment.

Preliminary

(a) marks

chalk

marks

ap

timing mark, (120

equal

around

parts

damper

the

circumference).

Rotate the

until

crankshaft

the

T.D.C.

at

intake

and exhaust valve

the

end of

Repeat this the

turning of

lash for

(b)

of

order

to

idling,

stroke.

number

1

is

near

Adjust the cylinder.

for the remaining set of valves, V3 turn at a time, in the direction

crankshaft

valves

in the

firing

order

(1-5-3-6-2-4).

Final Adjustment. Run the

mum

piston

procedure

rotation, while adjusting the

sequence

1

number

compression

30

stabilize

check

at

minutes

the

engine

valve

(fig. 21). Install the

engine

approximately temperatures.

for

1200

a mini

r.p.m.

With the

in

engine

lash. Adjust the lash, if necessary

rocker arm

cover.

Step Type

Fig.

Feeler Gauge

21 Valve

Lash Adjustment Typical

6610

20

Chapter

1 General

Engine


is

engine performance

Dial Indicator

as

if the

mine

The

Remove

Back

Lobe Lift

No.

No.

4 Exhaust

180

T.D.C.)

the tappet is

the

and adjust

following

No.

4 Intake

No. 8-Exhaust

No.

5 Intake

Rotate the puts number

3

3A

turn from

T.D.C.)

and adjust

270,

engine

piston on

or

on

(this

No. 7-Exhaust

No. 8-Intake

Final Adjustment. Run the

to

order

idling,

at

minutes

stabilize engine

check

the

engine

approximately

for

1200

temperatures. With the

point of

turning

the pulley

is in

rod

such a

engine

the

push

slowly

flywheel)

or

(at

until

lobe. Zero the dial

the engine slowly until

(Table 1). Compare the

with specifications.

1 Valve

Engine

and

side

the indicator

same plane as

the cam

obtained

push

dial indicator in

a

in the

of

the

sure

damper bolt

continue

adjusting screw,

Timing Specifications Opens Crankshaft

Intake Valve Degrees

at

Cam Lift

223

24

272, 292

12

arm

rocker

covers.

If the

for

timing

made

.016

Cam Lift

312

valve

timing is

the

mark on

is

not at

when

poor

not within

pulley, in the

crankshaft

fault,

sprocket, crankshaft

be

BTDC@

Cam Lift

specifications,

bent timing pointer. Bring the number 1 T.D.C. and see if the timing pointer is aligned pointer

should

.016

a

T.D.C.

checks

BTDC@

in

engine

Valve Timing. Valve

valve

a mini

r.p.m.

lash. Adjust the lash, if necessary

valve

(fig. 21). Install the

e.

rocker

Displacement) No. 6-Intake

30

Make

(Cubic Inch

No. 3-Intake

-Exhaust

No. 3-Exhaust

of

mum

6-cylinder

the

the right

assembly to one

arm

the heel

on

and

and

(b)

crankshaft

Table

the follow

the

point

approximately

on

remove

(fig. 22). Turn the

desired lift is

degrees

valves :

No. 2

the

indicator

180

cover

arm

push rod socket and

2 Intake

number

in

lift.

cam

position.

movement

No.

the

to

equal

to have the actuating

as

No.

valves:

rocker

it in this

either

turn (this puts

V2

in

rocker

the

1 Intake

6 Exhaust

No.

ing

or

engine

rod

-Intake

is

lobe. At this

cam

the number 1 intake

off

manner

valves:

No. 7

-Exhaust

Rotate the piston on

following

the

1 Exhaust

No. 5

4

on

to deter

engine

timing by using

cam

the tappet socket, then install

in the

Adjust the lash

the

1 intake

rotation

change

the

slide

secure

Fig.

used

cover.

then

6607

the

correct

the

correct with

On 8-cylinder engines,

engine.

Check Typical

checks

side of number

0.0004 inch

arm

timing is

crankshaft

of

be

procedure can

such

checks,

car.

procedure

opening 1

following valve

in the

stalled

22 Camshaft

noted and all other

carburetion, ignition timing, etc., fail to

trouble. The

BE SURE TO PLACE INDICATOR TIP IN CENTER OF PUSH ROD CUP

Repair

and

check

pulley

the

or

with

to

the

damper. If the

timing chain,

sprocket, camshaft,

check

piston

camshaft

and crankshaft

order of accessibility.

6. TIMING CHAIN, SPROCKETS, AND CAMSHAFT

To the of

Chain

Timing

a.

measure

slack

the

on

chain

timing

the left

by

shaft

from this

to move

side

deflection (fig.

(as

rotating the

direction. Establish measure

chain

all

a

the

viewed

point

to the chain.

slack

23),

on

in

a

front)

clockwise

the block and

Rotate the

to the left

side.

move

crank

With the

the

chain

toward the original

reference

the distance between the reference

point

and

measure

point

and

the chain. If the difference between the two

take up

from the

crankshaft

reference

point

fingers,

Sprockets.

and

measurements replace

(1)

the

(which is the slack)

timing

exceeds

y% inch,

chain and/or sprockets.

INSPECTION. Inspect the

damaged teeth. Inspect the

chain

sprockets

for

worn or

for broken links.

6

Section

(2) REPAIRS.

Replace the

Timing Chain, Sprockets,

sprockets or the

21

Camshaft

RIGHT SIDE OF CHAIN

REFERENCE POINT

deemed necessary by inspection. However, it is

chain as

recommended that all the components be

any

timing

and

item

one

replaced

if

needs replacement.

b. Camshaft. The

camshaft

(intake

be

should

replaced

when

lobe

any

exhaust) is worn to such an extent that the lift loss exceeds 0.005 inch. The tappet which mates or

the

with

to

the

Loosen the

assembly to

Make

position.

socket

in the

and

same

plane

ment

(fig. 22). Rotate the

is

the heel

the

of

such a manner as

indicator in the

the

of

the push

as

engine

push rod

the tappet

until

slowly

rod

fully

lobe. Zero the dial indicator,

cam

on

to

the

rotate

engine until

later step is indicator

raised position.

the indicator

recorded

check

a

rod

move

then continue to rotate the engine slowly until the

is in the

slide

it in this

is in the tappet socket, to have

sure the push rod

point

actuating

is

timing.

valve

one side and secure

dial indicator in

a

procedure

adjusting screw, then

valve rocker arm

then install

on

replaced.

for checking

procedure

rocker arm

the

be

must also

CAM LOBE LIFT CHECK. This

(1) similar

the

lobe

worn

Compare the total lift


the indicator

the

of

original

Suspected

ure

the I. D.

are

excessive

replaced.

(3) aged

the camshaft

the

cam

repair.

compared with a

correct.

Measure the

bearings. If the cam

and/or

REPAIRS. Replace

with a microm

out-of-roundness.

and

Check the fuel pump

beyond a

with

of

wear

be

should

diagnosis is

sure

journal diameter for

Check the lobes

lobes

worn

lobe to be

23

Timing

Chain

Deflection Typical

broken,

worn,

or scored

it

be necessary to

will

replace

the camshaft.

reading.

signs of abnormal wear.

good

Fig.

This

(2) INSPECTION. Thoroughly check the camshaft for damage. Examine the lobes for pitting, scoring, and eter.

WITH THE FINGERS AND MEASURE DISTANCE B. DEFLECTION 6608 IS A. MINUS B.

Continue

reads zero.

the accuracy

on

push

TAKE UP SLACK ON LEFT SIDE OF CHAIN. ESTABLISH A REFERENCE THEN, TAKE UP SLACK ON RIGHT SIDE OF CHAIN AND FORCE LEFT SIDE OF CHAIN OUT

POINT AND MEASURE DISTANCE A.

all camshafts

for

be

should wear.

toward the point

end of

zero,

END PLAY CHECK. rear

against

a

Place

a

pull

the

camshaft

forward

with

and

release

specifications.

necessary.

or nicks

stone, then polish with crocus

the

wear characteristics

area

general

of

the nose

may

portion

in pitting in the lobe. This

result of

pitting is not detrimental to the operation of the cam if the initial cam lobe lift loss has not exceeded 0.005 inch. The camshaft will continue to operate satisfactorily for the

life expectancy

normal

ably affecting should not

the

be

excessive,

engine without notice

Therefore,

camshafts

the lobe lift loss exceeds

the tappet contact

face

shows

failure.

Normally if it

the

replaced unless

above specification or

evidence of

of

engine performance.

the front journal to

can

be

assumed

bearing

clearance

that all bearings are

is

worn

and need replacement.

If any

of

the teeth

on

the distributor drive gear

are

it.

play is excessive, check the spacer for cor installation. Replace the thrust plate and/or spacer end

cloth.

The lobe

dial

the front

the camshaft assembly (fig. 24). Set the dial to

then

If the

if

the engine.

suitable surface on

Compare the dial reading

rect

of

Push the

that are dam

Remove light scuffs, scores,

hard Arkansas

camshaft

indicator

clearances

bearings

eccentric

Meas

CAMSHAFT

(4)

Fig.

24 Camshaft

End

Play

Check Typical

22

1 General

Chapter


Repair

and

7. FLYWHEEL, CRANKSHAFT, AND MAIN BEARINGS Procedures for the inspection

and

components are given

here. In addition,

fitting

aligning the thrust

the

replacing are

bearings,

main

rear

bearing

main

for

procedures

bearing,

and

oil

crankshaft

Heat the defective ring

these

of

repair

seal

not

off

hit the flywheel

the

on

the flywheel.

when

removing

gear.

given.

Heat the a.

Do

CAUTION: the ring

the gear, then knock it

of

side

engine

blow torch

gear with a

Flywheel. The flywheel

enough

and

gear

ring

are

shrink

a

seated

fit

and

are

with

full forward

wheel

play

or

is excessive,

runout

the

of

runout

necessary

to

remove

the

the

(2)

gear

crankshaft

end

If the

runout.

and check

It

flange.

will

if the flange

for worn, chipped,

flange is

not

at

scored

0.045

be

fault,

inch

runout

replace

or

surface of

of

stock

from the

is

excessive

machine

the

the flywheel if

If it is necessary to

worn.

cracked

or

remove

original

ring

further use,

or

gear

if the

more

thickness,

the

When the

new

ring

a

the

heat any portion of the 500 F. // this higher than

be

teeth.

gear expands

sure

not

will

form

the

on

check

runout

gear

is

shoulder.

exceeded, the temper gear

until

removed

gear

to

limit

a

is

from the ring

is installed, per and flywheel.

gear

the ring gear

b. Crankshaft. end

crankshaft

Place of

play in the

Check the Push the

the

dial indicator

a

point against on

manner:

rear

of

the

engine.

rear or

front

end

zero, then

push

the

the

forward. Compare the reading

crankshaft

on

the dial


INSPECTION.

(1) CLEANING AND wash

crankshaft,

with

passages

the

Set the dial

crankshaft.

indicator

following

toward

it in

a

solvent,

compressed

air.

and

Remove the

blow

out

Examine the

the

shaft

oil

for

damage. teeth

runout

are

damaged

is excessive,

and

unfit

replace

for

the ring

follows:

Fig.

evenly

the flywheel. Make

against

properly

temperature

re

the flywheel.

the

gear as

or

onto

gear

the

indicated in fig. 26.

gear runout as

REPAIRS. If the flywheel

the

replace

If

fly

flywheel,

crankshaft

flywheel. Machine the friction

than

to hold the

that

mounting

runout

machining.

teeth. Check the ring

it is

so

sure

flywheel

as

remove

crankshaft

Inspect the ring

and

rearward

be indicated

not

will

quires

Check the flywheel face

dial indicator (fig. 25). Be

a

to slip

ring

CAUTION: Do

replaceable as separate parts.

(1) INSPECTION.

new

25 Flywheel Runout Check Typical

Measure the diameter places

to

condition

determine

of each

journal in

out-of-round,

taper,

at or

least four undersize

(fig. 27).

Fig.

26

Ring

Gear Runout

Check Typical

Section

(2) REPAIRS.

If the

end

7


play is excessive,

A VS B C VS D A VS C

replace

the thrust

bearing. Replace the crankshaft if it Dress minor nicks or scratches. If the

pins or

use, the

journals

shaft should

bearing. Calculate used as follows:

EXAMPLE: //

shows

signs

failure.

of

are out-of-round

beyond further

for the

next undersize

be

ground

the correct undersize

the main

bearing

bearing

journal

will

23

Main Bearings

and

=

VERTICAL TAPER

=

HORIZONTAL TAPER

B VS D

AND

OUT OF ROUND

=

CHECK FOR OUT-OF-ROUND AT EACH END OF JOURNAL

to be

"clean

before it is ground to 2.499 0.010 = 2.489 inches diameter, finish it to that diameter, and install 0.010 inch undersize bearings. up9'

Always

result

in

existed originally.

Too

corners of

the

small a radius will 6517

bearing failure.

CAUTION: excess

in the

reproduce the same radii

journals that

Never

grind

of 0.030 inch

journals

or

in

crankpins

Fig.

undersize.

After grinding, chamfer the oil holes, then polish the journal with number 320 grit polishing cloth and

27

in the

or

workstand

Checking

Crankshaft Journal

car.

pin or

engine

ing

oil.

Crocus

cloth

may

also

be

used as

If the

polish

a

agent.

jack

small

Main Bearings.

c.

bearing fits

in the car,

against

available on

for

main

in

service

bearings

bearings

must

clearance

proper

fit.

They

are

for

use

standard and undersizes

journals that have been

new

are select

reground.

be closely between

The installation

checked

the

to

journals

maintain and

of

the

bearing

joining The

INSPECTION. Check the bearings for any dam Examples of bearing failures

and

their causes are illustrated in

(2)

FITTING MAIN BEARINGS

METHOD. The main

fig. 28.

bearings

SCRATCHES

following

with

the

procedure

engine

-

PLASTIGAGE

applies

either

to

installed

that

are

bolts just

on

a

not

enough

the

is

crankshaft

supported

counterweight

checked

by

a

the journal

and

checked.

to hold the

a

upward

bearings. Place the

main

being

engine

crankshaft with

for

thin of

rubber

pad

two bearings

Tighten the crankshaft

ad

clearance.

bearing

up

against

cap the

bearings.

NOTE: It is necessary to crankshaft

when

to

the

prevent

pressing the

support main

checking

weight

of the

the

iveight

bearing

crankshaft

Plastigage, thereby

of the

clearances

from

com

an

erro

providing

neous reading.

LACK OF OIL

BY DIRT

be

being

the

the crankshaft

which

also

OVERLAY WIPED OUT

DIRT IMBEDDED INTO BEARING MATERIAL

SCRATCHED

fitting

against

bearing

shaft can

upper

(1)

the

between the cap insert

surfaces.

age or excessive clearance.

to hold

the block half of the

the

checked with

weight of

positioned

jack to bear

The insert-type

to be

are

the

support

RADIUS RIDE

BRIGHT

(POLISHED) SECTIONS

IMPROPER SEATING

CRATERS OR POCKETS

OVERLAY GONE FROM ENTIRE SURFACE

RADIUS RIDE

TAPERED JOURNAL

Fig.

28

Bearing

Failures Typical

FATIGUE FAILURE

6491

24

Chapter

1 General

CLEARANCE


29

Place

bearing shaft

cap, journal if the

off center.

Plastigage, the full bearing surface (or

of

the

on

1282

Plastigage Typical

Measuring

piece

a

engine

Install the cap

is

inverted)

width

crank

XA inch

about

bolts to

tighten the

and

the

of

the

on

6354

speci

Fig.

fications. CAUTION:

Do

Plastigage is in

turn

not

the

at

the

crankshaft

while

the

widest

check

point

the

with

width

the

the Plasti

of

Plastigage

scale

(fig- 29). If the

bearing

to

bring

the clearance

various

bearings

and/or

selective

and

limits,

fit

the desired limit.

increase

clearance;

clearance.

fit bearings do

the desired

journals

another selective

within

bearings decrease

clearance within

journal

is excessive, try

marked

marked

If the

fit

grind

install

not

the

bring

the

crankshaft

undersize

not

the

Pry Cap main

bearing

journals

to

an

minimum

maximum

fitted

30

Pry

Crankshaft

is to

diameter of the minimum diam

clearance, interference may

re

an early failure. It is not recommended bearings be fitted to a crankshaft journal which

sult, causing that

is

more

than

0.001 inch

out-of-round.

(3) THRUST BEARING ALIGNMENT. Install main bearing caps, except the thrust bearing cap, tighten

the

bolts

to

specifications.

Install

bearings.

Forward Typical

evenly

to the

16353

Fig.

wear

However, if a bearing out-of-round journal, be sure

bearing to the If the bearing is

with

Backward Typical

out-of-round.

fitted

journal.

31

Normally,

are

being

eter

clearance

NOTE: Red

blue

NOTE: and

place.

Remove the cap, then gage

Repair

Flattened Plastic

GRADUATED CONTAINER

Fig.

and

Fig.

32 Tighten Cap Typical

the

the and

thrust

Section

7


25

Main Bearings

and

Tool-T52L-6701-AGD

Tool T52L-670I-AGD

33 Oil

Fig.

bearing

crankshaft rear

of

the thrust

will align

bearing. Retain

the

and

bearing

from the

new seal

the

both

edges

in the

installation

Coat the

cut

or

bearing

the

rear

seals

oil

specifica

sealer, install the

jecting

are

journal

Using To

check

or

retainer

as shown

in

seals

Install the cap

flush

without

new

journal

as shown

any seal

may

or

cap

of

indicates

possible oil

NOTE: The

retainer and

bearing

for leaks,

side seals

cap

into the parting lines between the cylinder block from the

and

compressed

block. If

the

oil.

this expansion.

of oil

retainer

dipped in

when

expand

the seals

air against

air

bubbles

from the

in the oil, it

appear

leakage.

in fig. 34. After

to block mating face

retainer

to

retainer or

Blow

The

use sealer on the side seals.

retard

few drops

a

inside

not

designed

sealer

outside.

the

in

in the

ends.

CAUTION: Do

the

block

oil,

Dip the retainer immediately install

then

It may be necessary to tap the seals into place for the last Vl inch of travel. Do not cut the seal pro

seals

flush.

seal

side seals

them

engine

squirt

cylinder

cut

overlapping.

seal

and

23-28 foot-pounds torque. light

on

pressure

crankshaft

6374

Installation Typical

Seal to Retainer

grooves.

grooves.

seal

fig. 33. After installation,

retainer

block

cylinder

Clean the

cap.

Install the

with

the

REPLACING REAR MAIN BEARING CRANK

seals

in the

the

crankshaft end play.

SHAFT OIL SEALS. Remove the

frayed

the

of

surfaces of

forward

the

the cap bolts to

tighten

tions (fig. 32). Check the

oil

pry

bearing (fig. 30). While holding forward, pry the thrust bearing cap to

the crankshaft,

(4)

then surface

34 Oil

Fig.

the

of

(fig. 31). This

halves

thrust

the

against

| J


bolts finger-tight,

the

forward

half

upper

Seal to Block

with

cap

crankshaft

I

6373

tighten the

bolts to

above

newly installed allowed for the

test should

seals seals

until

to

be

not

expand

into

performed on

time

sufficient

the

has been

seal grooves.

8. CYLINDER BLOCK, PISTONS, PISTON RINGS, AND CONNECTING RODS AND BEARINGS During gine parts

disassembly

the

overhaul,

to

help

of

the

cylinder

closely inspect the

diagnose the

cause

of

wear

block for

pattern

on

en

all

wear.

cracks.

Cylinder Block. Clean

old gasket material

Remove the all

passages

the

from

all machined surfaces.

passages and clean pipe plugs which seal oil

thoroughly.

Minute

be detected ture

a.

INSPECTION.

(1)

of

oxide

by

coating the

dry

and

dissolved in

the coating

Make

will

sure

and

apply

alcohol.

threads

area

75% light

become discolored

the

for

check

to the naked eye may

suspected

immediately wood

thorough

a

cracks not visible

25% kerosene

part

Make

If at

with

motor a

coating

cracks are

the

a

oil.

mix

Wipe

of

zinc

present,

defective

area.

in the head bolt holes

are

26

Chapter

1 General

Engine


Repair

and

Tool T52L-6266-BGD

PLUGS-

CYLINDER BLOCK CORE

1271

37 Expansion-Type

Fig.

Fig.

35 Cylinder

NOTE: A 0.030 inch

Bore Measurement Typical

Rebore clean.

in

a

and

Dirt in the threads

false torque to

remove

Inspect the roundness,

reading.

deposits if

tool

be

should

Inspect

Use

a

binding

and result

to true up threads

tap

necessary.

(fig. 35). Follow the instructions

manufacturer. permitted

Only

experienced

of

expansion-type

plugs

for

evidence

of

the

a

To

Vi inch hole in

plug

as

shown

in

install it

until

surface

with

an

remove

the

36. of

the flange

the flange is flush

expansion-type

center of

in fig.

thoroughly. Coat the flange and

give

ing

equipment

be

should

satisfactory

Bore the

up

cylinder

by

bored for the

when

or

the plug

and remove

Clean the plug

the new plug

plug,

with

within

final step

sealer

and

out.

(fig. 37).

honing

pattern

instructions. This

If the

are

personnel

work

only.

first to deter

wear

cylinder will

replaced.

0.0015

approximately

of

new service

not

clean

maximum oversize piston recom

diameter. This

oversize

recess

Drive the plug slightly below the casting

facing

to

cylin

performance.

the most

the proper oversize.

when

If the

excessive,

experienced

with

and

scored

BLOCK. Follow the bor

manufacturer's

performed

available.

are excessive.

and piston wear are not

mended, the block should be

(2) REPAIRS.

deeply

are

(3) BORING CYLINDER

mine

leakage.

drill

der bore

personnel

to take these measurements.

that

cylinders

plug is

oversize

taper and/or out-of-roundness

piston rings will

bores for scoring, taper, out of Use a cylinder bore gauge to make

and wear.

all

cause

cylinder

the measurements the

can


Plug

will

cylinder required

stock

for the

the correct surface

so

Use

obtained.

the

of

allow enough

bores

the

Bore the

inch

a

finish

220-280

number

grit

hone for this

operation.

CAUTION:

Thoroughly clean the block to remove all the boring and honing operations,

after

particles

then

the

coat

bores

with

oil.

"GLAZE'' (4) CYLINDER BORE Whenever piston rings are installed in a

the

remove

Take

all

"glaze"

on

hone

a

few times. Do

or glaze

the finish. after

b.

in ring

removing tool through the not

hone

Thoroughly

glaze

aid

cylinder, seating.

precautions to catch the grit.

necessary

a

the bore to

REMOVAL. used

than

the

clean

removal, then

Pistons, Pins,

more

oil

and

enough

cylinder

Pass

cylinder

bore

to rough-up

bore

and

block

the bores.

Rings.

(1) CLEANING AND INSPECTION. Remove DRILL

Vi INCH HOLE IN PLUG

Fig.

CYLINDER

36 Expansion-Type

BLOCK

CORE PLUGS

Plug

carbon

6600

Removal Typical

deposits from the

grooves with a

the

oil

ring

ring

slots

(or

pistons.

Clean the

groove cleaner

holes)

the

piston

ring

(fig. 38). Make

sure

are clean.

Section

8 Cylinder

Block, Pistons, Piston Rings,

Connecting

and

Rods

27

Bearings

and

Groove Cleaning Tool T52L-6 1 10-AAD

6097 38

Fig.

CAUTION: Do

Cleaning Ring Grooves

not use a caustic

solution or

cleaning

Inspect

for fractures

pistons

bosses,

and pin

for

and

eroded areas near

at

scuffed or

the edge of the

by detonation,

lands, skirt, scored skirts. Spongy, piston top are usually

or

bent connecting rod. The is shown in fig. 39. Inspect the ing. Check the

pin

bushing. Check for

for

(2) REPAIRS.

Replace

lands, fractures

or

fit in the

piston and

rod

ring

of

signs

showing

side

NOTE: All

clearance, wavy

damage from detonation

or

pre-

piston pins

ing. Piston or

pins

that

show

bushing

rod

signs of

showing

wear

or etch

fitted,

a piston

cylinder

pistons

are

the

to

can

be intermixed only

the

without cylinder

has been fitted, mark it it was fitted.

which

same

oversize; therefore,

and

before trying another hone the cylinder to the

weight, both

pistons

of

upsetting or

stand

various sizes

engine

cylinders

balance.

which

re

it.

(4) FITTING PISTON RINGS. Select the proper ring set for the size piston to be used. Before the rings are

installed

on

the piston, check

each

ring for

proper

follows:

gap Position

che

ring in the

cylinder

bore in

which

it is

fit loosely in the Always re

or

be

should

fracture

be

When

ard

Rebore

Wear Pattern

calculations

can

none

for assembly in the

as

Replace

If

39 Normal

recheck

next size piston.

quire

ignition.

piston

pull,

piston.

or etch

pin retainer grooves.

pistons

or

fracture

signs of

in the

clearance

skirt

excessive

for

proper

wear

able

pre-ignition.

normal wear pattern of a piston

piston pins

Fig.

the ring

A shiny surface on the thrust surface of the piston, offset from the cen terline between the piston pin holes, can be caused by a caused

ring

NORMAL PISTON WEAR AREAS 6609

brush.

a wire

replaced.

place all piston pin retainers.

FITTING PISTONS.

(3) 0.040

and

Check the

engines.

To fit

a

the

to the

inch wide) side of

the

of

the

parallel

out

to the

the

scale

piston

proper

for

bore,

bore

(fig.

provide

feeler

from the

the

crankshaft axis.

most

size

and

desired

attaching ribbon

gauge

a

{Vi

feeler

on

hole. Invert

piston pin

piston and

35)

the

being fitted by a

the

calculate

check

to

for

available.

sizes

thickness. Position the

piston push

of

end

90

the piston, then

a

piston

size

Check the

scale

cylinder

0.020, 0.030,

of

available

are

catalogue

by taking

proper

clearance.

tension

a

Pistons

oversize

parts

in

piston

desired

piston select

the

0.060 inch

feeler into the bore

Hold the

piston and pull

feeler ribbon, noting the reading

on

the

pull

(fig. 40).

If the

scale

allowable

pull,

proper size piston

piston, obtain

try

a

is

reading recheck

new

greater

calculations

than

the

to be

maximum

sure

for

that the

damaged

has been selected, check piston, or hone the cylinder bore to a

6490

the proper fit.

If the

scale

reading is

less than the minimum

allow-

Fig.

40

Fitting

Piston Typical

28

Chapter

1 General


Repair

and

according to the instructions the ring

check

freely

gauge should slide

move

(5)

"glaze"

be

F). Standard

If the

to the size

Fig.

41

Measuring

Piston

Ring

Gap Typical

the

going to be

of

is

a

to

piston

square with

operation

Push the ring down into the bore area ring wear is not encountered. Use the head

used.

position

the ring in the bore

the cylinder wall. Use caution

to avoid damage to the ring

so

the ring

during

or cylinder

Measure the gap between the ends of the ring gauge (fig. 41). The gap should be from

feeler

this

bore.

with

a

bore, immediately install them on the piston, identify them with the piston and cylinder in which

cylinder

they

are

to be installed.

After the

rings

have been installed in the ring

the

blue)

Pins

0.002 inch

and

reamer.

Set the

then expand the

bore. Take

pin

to

nearest size

ream

reamer

light

a

cut.

maintain align

hole size, using the

expand

the

reamer

slightly the

and make

fit

proper

for fit in the

pin

piston

bushing if

bushing. Ream the

rod

new piston pin.

until

procedure

Check the fitted

necessary

pin.

Install the

in the

piston pin

retainers are

in the

Always

at normal temperature

installed,

grooves

piston

Install

and rod.

a

the pin to hold it in place. When make sure

they

in the

provided

are

properly

bore.

pin

piston

use new retainers.

0.010-

0.027 inch. If the gap is less than the lower limit, try another ring set. After the rings have been fitted in the

or

the

retainer at each end of

the

fit

pin

piston

be reamed, use an ex Place the reamer in a vise

bore,

the

Repeat the

cut.

to fit the

seated

explained.

previously

The

re

cylinder,

must

pin

ream

reamed

obtained.

respective

where normal

a used

the bores.

another

is

ring

are available.

piston around

of

If the bore is small, 6485

piston

coded

yellow)

a pilot sleeve of

Check the

W

(color

hole

pin

trial

and

ment of

ft

The

entire

as

fit

press

piloted reamer.

the

and revolve

slightly

coded

piston

pansion-type,

Use

gauge.

the

piston pins are color coded green.

oversize

(color

oversize

er

the bore

on

light thumb

a

0.001 inch

of

feeler

FITTING PISTON PIN.

should (70

a

to be installed in

rings are

the

around

ring package,

piston

with

binding.

circumference without

If the

the

on

clearance

side

Rod.

Connecting

c.

The connecting

fully inspected cations.

by

rods and related parts should

Various forms

these

for

and checked

parts can

be

to

conformance

care

specifi

of engine wear which are caused

be readily identified

as

follows:

grooves

A shiny

on

surface

usually indicates that piston

hole is

pin

skirt and

ring

not

grooves

the a

in

by improperly

a

proper

the

piston

is bent

relation

rod

bearing

bent connecting rod, machined,

of

side

rod

the

or

to the

piston

(fig. 42).

Abnormal connecting either

boss

pin

connecting

or a

wear can

a

be

crankshaft

caused

journal

tapered connecting rod

bore

(fig. 43). Twisted connecting rods will not create identifiable wear pattern, but badly twisted disturb the

action

assembly that may

(1) and

solution.

PISTON WEAR CAUSED BY BENT ROD

OR MISALIGNED PISTON PIN HOLE

Fig.

42 Wear

Pattern

on Piston Piston

and

6371

Pin Boss Surface

in

of

bearing failures Make

result

solvent.

again), then

the back

sure

the

will

the entire piston, rings, and

in

rod

excessive oil consumption.

Never

Remove the bearings

used

easily

rods

CLEANING AND INSPECTION. Clean

passages

to be

of

an

use

a

(identify

thoroughly

all parts

caustic

cleaning

them if

they

clean the rod

are

bore

the bearings. For the different types and

their causes,

oil squirt

holes

refer

are open.

to Section

of

7.

Section

8 Cylinder

Block, Pistons, Piston Rings,

Connecting

and

Rods

and

29

Bearings

BEARING WEAR CAUSED BY BENT ROD OR 6372

IMPROPER GRINDING OF CRANKSHAFT JOURNAL 43 Wear

Fig.

Inspect the

Pattern

rods

the bore for

check

for

deep

Rod

Connecting

on

nicks,

signs of

Bearing

fractures,

and

out-of-roundness.

Check the connecting rod bolts and nuts for damage. After the connecting rods are assembled to the pistons, check

the

ment

fixture.

for bend

rods

twist

or

Follow the

on

a

instructions

align

suitable

the

of

fixture

manufacturer.

is excessive,

clearance

for the

piston

ream

should

rod

bushing

the rod

rod

be

is twisted

bushing

and piston

bent

Rods

than specified, it

more

with

deep

more

rod nuts and/or

of

nicks, signs

out-of-round

fractures,

the

should

be

tive fit

a

piece

width of

blue

Rod Bearings

gage

measure

the

bearing bearing caps use

to file or lap the bearing clearance.

of

bearing

bearing,

and tighten

marked

If the

Plastigage

the

on

the

the

rod

bearing

XA inch

about

surface,

off center.

bolts to 45-50 foot

turn the

with

crankshaft

the Plasti

to

not

bring

satisfactory,

to clearance

marked

try

another selec

within

bearings increase

bearings decrease

various selective

the desired

the clearance,

the clearance.

fit bearings do

not

bring

the

desired limit, it will be necessary to the crankshaft journals and install undersize

regrind

bearings. Rotate the

not

is

clearance

crankshaft

to be sure the

after

bearing is

not

the

bearing

is installed

too tight.

place.

Remove the to

of

to

the

clearance within the

torque.

NOTE: Do

in

to

or

to adjust the

NOTE: Red

Install the cap pounds

recommended

not

sure

limit.

Plastigage Method. Place

It is

of any type,

order

If the

bolts.

or with

0.0004 inch

than

Fitting Connecting

the full

Check Typical

straightened or replaced.

replaced.

d.

crankpin.

in

Clearance

Connecting Rod Side

// the crankpin is out-of-round, be bearing to the maximum diameter

fit the

shims

or

Replace defective connecting

bore

to

pin

next oversize pin.

If the

44

NOTE:

REPAIRS. If the

(2)

Fig,

the

bearing

cap,

width of

and use

the Plastigage

the flattened

e. scale

piece of plastic at

Connecting

Rod Side Clearance.

After the connecting rods are installed, feeler stock (fig. 44).

measure

the

side clearance with

widest point.

9. OIL PAN AND OIL PUMP a.

baffle

Oil Pan.

Check the

Scrape any dirt or metal particles from the inside of the pan. Scrape all old gasket material from the gasket surface.

Be

sure

Wash the all

plate.

pan

foreign

in

a solvent and

matter

is

dry it

removed

thoroughly.

from below the

threads,

a

pan

for cracks,

loose baffle,

and

holes, damaged drain a nicked

or

plug

warped gasket

surface.

Repair any damage, cannot be made.

or

replace

the

pan

if

repairs

30

Chapter

1 General

Engine


b. Oil Pump. Wash

Use

all parts

brush to

a

the pressure

body

in

relief

cator or

the inside

the pump

Be

valve chamber.

Remove

Check the

housing

sure

and

dirt

all

and

from the

old gasket material

body

and

the

gear

the

Remove

as

the

and

is

dial indi

as

follows:

then place Plasti

in fig. 45,

shown

cover

method

housing,

the

gasket on

gears

teetn ior damage

gear end clearance with a

Plastigage. The Plastigage

on

cover.

of

them thoroughly.

and cover.

Position the gage

dry

a solvent and

clean

Inspect the pump or wear.

Repair

OIL PUMP GEARS

chips are removed.

pump

and

and

install the

the

Plastigage

rotation.

Check the

check

reading.

Check the

gears

for freedom

compression of the oil pressure

the

check

clearance

of

the

of

relief

relief

valve

valve

in the

Plastigage

and

spring

valve

chamber.

6497

Fig.

10. The

exhaust system must

sive vibration.

in

some

pipe

Leaks a

cases,

connections.

can

be free

of

leaks

and exces

All the

may be heard

noise

parts

of

the

system

at are

inches,

or

To

the

the

re

signs

of

muffler

the

passage

inlet all

various sections of

leaking

burning

outlet

either

pipes, respectively.

case

should

not

be

Date

Gear End

and

pipe

outlet

sections

and

by the

broken

or

improperly

13A

clamps

as

necessary.

than

as

may be

connections,

previously

signs

restricted.

of

position

outlined.

burning

Re

through.

interference between the

outlet

the outlet pipe in the muffler.

However,

greater

pipes

gases

muffler

the floor pan. If the clearance is in

reposition

Exhaust

the

that show

possible

"kick-up"

sufficient,

exhaust

at

be blocked

SERVICE

Letter No.

for

system

through. The slots in the

and outlet extensions should

and

overlap in

or

the exhaust

of

leakage

Check for

inlet

inlet

as

correct

place

placeable.

Check the

Checking

Play Typical

EXHAUST SYSTEM

usually be detected visually,

whistling

45

system

vibrations

are

usually

aligned clamps.

Align

caused or

LETTER REFERENCE Subject

by

replace

Changes Information on Page No.

Part ONE

POWER PLANT Chapter

n

6-Cylinder Engine Page

Section

Engine

Manifolds

3

Cylinder Head

4

Crankshaft Damper

5

Cylinder Front Cover

6

Sprockets

Rest

Steady

32 and

33

Valves

36 and

36

Crankshaft Oil Seal

Timing Chain, Camshaft and Bearings, and Flywheel, Crankshaft, and Main Bearings Connecting Rods and Bearings, Pistons, Pins, and Rings Oil Pan, Oil Filter, and Oil Pump

7 8

9 10

and

37

Tappets

39

42 44 45

Exhaust System

This

chapter

sembly,

and

parts of the

the removal,

contains

installation

6-cylinder

procedures

the component covered

parts

disassembly,

for the

and

and

engine

repair

shooting

component

procedures

overhaul

and

tune-up

and

In

addition,

are covered

engine

trouble

in Chapter I.

The Cylinder, EBP engine (fig. 1) has a bore of 3.62 inches, a stroke of 3.6 inches, and an 8.0:1 com-

for

pression ratio.

instructions

in Chapter I, "General Engine

Repair."

Inspection,

as-

engine.

The cleaning, inspection,

are

31

1

2

This

engine

is

available

in

all car models

(except the

Thunderbird).

Overhaul,

1. ENGINE STEADY REST The

engine

engine weight

steady and,

as

rest

its

(fig.

name

2)

does

not support

any

implies, it functions

as a

rest.

a.

spacer

bolts from the left

stabilizer only. ~

Remove the

bolt that

retains

the insulators

in the bracket. Remove the insulators. Remove the two

side

,

Removal.

of

the

side and

engine

block,

the one bolt from the then

remove

the

right

bracket

assembly.

Remove the two clamp bolts

at

the front

of

the steady BRACKET

LOCKWASHER

LOCKNUT

BOLT

FLAT WASHER

SPACER LOCKWASHER

RETAINER

SHOULDER BOLT

6615

/r;g< J 223 Cubic Inch

Engine

6199

Fig.

% Right Front View

31

2

Steady

Rest Disassembled

32

Chapter

1 General


b. Installation. Before

the steady rest, inspect all the

for defects. Replace defective

ponents

bracket

installing the

on

foot-pounds torque. Install, but do sulators,

bolts,

Install the

block. Tighten the bolts to 23-28

cylinder

spacer

parts.

com

tighten,

not

the in

clamp bolts. If necessary,

and

cen

ter the

spacer

engine

front

tighten

Make

the

Repair

and

bolt in the frame bracket in

mounts

spacer

being

not

transferred to the

then tighten the clamp bolts to

insulators,

rest

steady

is

Then,

foot-pounds torque.

bolt to 20-25

sure engine weight

shifting the

by

brackets.

frame

their

25-30 foot-pounds torque.

2. MANIFOLDS A

chamber

fold

center

manifold

(heat riser) is

section

are

attached.

valve, located in the

into this

gases

quired

A

fuel

and

thermostatically

exhaust

to

into the intake

carburetor

mani

exhaust

controlled

manifold, directs

re

in vaporizing the

assist

the

mixture.

exhaust

placement

the

cotter

Remove the

Disconnect the

fastening

the

assembly

then

separate

manifolds

is

the

the

inlet

muffler

Remove the

sleeves.

bolt

manifold

bell

carburetor.

Remove the bolts

and

Remove

nuts and

the

the

pipe.

head,

to the

head.

manifolds.

shown

at

air cleaner and

manifold

from

lift the

the

joining

manifold

gaskets

and

the manifolds,

A disassembled

view of

the

control

of

damage to the

valve

and

rosion

and

shaft

the

sene

and

bearing bores

and

valve

position

original

valve

is located in the

of

valve

the

plate.

plate.

Use

The

Insert the

is in the valve

over

to

occurred.

oil

new

kero

or

in the

the

valve

"up"

(heat

normal

to the shaft in the

shaft and valve are stainless steel

damage

outlet of

WASHER

the

caution

shaft through shaft

by

excessive

Install the thermostat spring in the shaft the spring 3A turn and hook the open end LOCK

Using

cut

Lubricate the

penetrating

Rotate the

minimize corrosion and/or

NUT-*-

shaft.

the manifold,

necessary. with a

(fig. 4). Weld the

manner.

end of

any damage that may have

and graphite mixture.

bearings

Re and

bearing bores. Remove the Clean the bearing bores of cor

pieces.

repair

position

valve plate.

shaft

Replace the bearings if shaft

to exhaust

sides

inside

plate until the counterweight

in fig. 3.

Exhaust Gas Control Valve The

to the

shield, washer, stop spring

pin,

avoid

on)

b.

assembly, note the

relation

torch in the

both

on

shaft

Disconnect the throttle linkage crank.

valve

thermostat spring from the front

Removal.

exces

damage.

the counterweight in

move

not require re

it becomes inoperative due to

Before removing the of

an acetylene

a.

Normally, it does

manifold.

unless

sive corrosion or

exhaust

the necessary heat

provide

the intake manifold to

by

incoming

area

cast

the

where

slot. of

heat.

Tighten

the spring

The thermostat spring should hold the position (i.e. in the in the closed or "heat

the stop

pin.

on"

valve

NUT

proper

LOCK WASHER -î

riser).

GASKET STUD

pin.

INTAKE MANIFOLD.

to direct the flow

Lubricate the

valve

tPLUG

position

of gases

Install the stop spring, shield,

manually to

shaft

bearings

replace original

performing the welding

into the heat

washer and

while

cotter

operating the

lubricant lost through

operation.

WINDSHIELD

WIPER CONNECTOR

*gj?

EXHAUST

CLOSED

MANIFOLD

(HEAT ON) SHIELD

/ SPRING

k

THERMOSTAT SPRING

BUSHING

BOLT

LOCK WASHER

^tfPL GASKET

Fig.

3 Manifold

"\VBL

ÎB'S?'1

STUD

Disassembled

Fig.

4 Exhaust

Control Valve

Section

Installation.

c.

cylinder

Place the intake manifold over the studs on the ex haust manifold. Install the lock washers, nuts and bolt, then tighten them finger tight. Clean the mating surface of the cylinder heads. Inspect and repair any damage at the mating surfaces. Install new gaskets using new

sleeves, if necessary, in the

Coat the mating then

surfaces

port

lightly

with

the manifold assembly in

place

the cylinder head.

of

graphite

grease,

position against

33

2 Manifolds

the

head.

head

and that none

of the

steel gaskets

become dislodged. Tighten the bolts to 23-28 foot-pounds torque, tighten ing from the center to the ends. Tighten the bolt and nuts

the intake

joining


gasket, and

position

Install the

nuts and

assembly

the port openings in the

sure

are

aligned with

the

port

manifold

openings

in the

to 23-28

and exhaust manifolds

a new exhaust outlet

muffler

inlet

pipe over

the

flange studs.

then tighten the nuts

lockwashers,

to 23-28 foot-pounds torque.

Connect the throttle linkage. Install the

NOTE: Make

have

and

the

connect

carburetor

carburetor

Install

the

air

and move

it to

one

linkage.

cleaner.

3. CYLINDER HEAD AND VALVES The and

cylinder

head

carries the valves and valve rocker

mechanism, the

arm

the

manifold

assembly, ignition coil,

water outlet.

Valve

rotating-type

Remove the

coil

from the head

spark

and

integral exhaust

part of

valve

incorporate

which

the cylinder head.

assemblies are

umbrella-type

the

valve

stem seals.

Disconnect the fuel line pump.

Cylinder Head Removal.

buretor

and

the

vacuum

line

at

Remove the

Drain the cooling system. Remove the radiator upper hose and heater hose. Remove the air cleaner, then tape the

carburetor

cable wiper

at

the

vacuum

perature

air

horn

cylinder

line,

sending

closed.

accelerator

unit

Disconnect the

head. Disconnect the

wire, and

battery

windshield

rod, choke cable, tem oil pressure

sending

unit

the carburetor

at

Disconnect the distributor

the

vacuum

and

line

at

distributor. Disconnect the

the

manifold

then remove the three

a.

plug

wires and remove

spark

plugs.

guides are an

Both the intake

Disconnect the side.

lines

and at

the fuel the

car

manifold

the booster pump,

as an assembly.

rocker arm cover.

Remove the cap

screw

clip from the number 6 rocker arm support bracket. Pull the oil feed line out of the bracket, then pull it out of the block with pliers (fig. 5). Be careful not to and

damage the line. Loosen valve

all rocker arm

adjusting

spring load from the

rocker

screws

to

remove

the

arms, then remove the

rocker arm shaft assembly.

wire.

Remove the them so

they

valve

can

push

rods

in

sequence.

be installed in their

Identify

original positions

(fig. 6).

REMOVE SCREW

PRY UP OIL LINE WITH PLIERS

Fig.

5 Oil

Line Removal

6499

6612

Fig.

6 Valve

Push Rod Removal

34

II 6-Cylinder

Chapter

Engines

BOLT BRACKETS TO INTAKE PORTS

TIGHTEN

SCREWJ^^

SECURELY

-

Tool-T52P-6085-DAD 7 Cylinder

Fig.

Head

1276

Holding Fixture 1234

Remove the

head bolts, and pull the manifold assembly away from the head. Brace the as sembly so the inlet pipe will not be damaged. Install the in

venience surfaces

bly

cylinder

lifting

holding fixtures

for

con

the head and to protect the gasket

all

cylinder

the

head bolts. Install the

(fig. 8). Lift the

cylinder

9 Valve

Fig. support

the

Stem Lock Removal

bracket. Remove the

rocker

arm

shaft,

Installation

or

cotter pins at each end of

and remove

Remove

washers.

spring

guide studs

off

head

(fig. 7).

Remove head

to

manifold

the

the flat washers and

plugs

at

each

of

end

the shaft. cylinder

head

assem

NOTE: The

plugs are an

drill

the plugs,

engine.

interference fit. To

or pierce

use a steel rod to

knock

the plug

out

the

on

plug

one

on

remove

end, then

the

opposite

7/1614x6"

BOLT

_

CUT OFF HEAD, TAPER END AND SLOT FOR SCREW DRIVER AS SHOWN

i

Slide the Be

rocker

sure

Clean the

b.

lease the

8 Cylinder

carbon

not

pry between the head

and

and

brackets

off

the

the parts.

out

of

the combustion

chambers

seal,

drain line

and

clip

out of

valve stem seals.

Identify

all valve parts.

d. Rocker Shaft Assembly. Oil

the

and valve.

block

become damaged.

Rocker Shaft Disassembly. oil

the

out

Remove the sleeve, spring retainer,

spring.

stem

spring,

Head Guide Studs

the gasket surfaces may

Pull the

knock

end,

before removing the valves. Compress the valve springs (fig. 9), then remove the valve retainer locks and re

rz.-

CAUTION: Do

arms, springs,

identify

to

Discard the

as

open

Cylinder Head Disassembly.

c.

Fig.

the

plug.

remaining

shaft.

m

from

Working

end.

number

1

all

or

side

out, in

each

COVER RETAINING

ROCKER ARM

parts with engine oil.

moving

large diameter

tool

end of

STUD^

pin

the

Using

punch, install rocker shaft.

LOCKNUT

a

blunt

a

plug, cup Install a flat

FLAT WASHER

ADJUSTING SCREW

FLAT WASHER

/OOO

t

COTTER PIN

SPRING WASHER

/ PLUG

ROCKER

6614

SHAFT

Fig.

10 Rocker

Mechanism Disassembled

3 Cylinder

Section washer, spring washer,

brackets,

port

Complete

and springs

the assembly

washers with

flat washer,

another

pin on one end of the shaft.

Install the

in the

the spring

and a cotter

UNDERSIDE OF SPRING RETAINER

arms, sup shown in fig. 10.

the remaining flat

between them,

washer

35

Valves

and

rocker

order

by installing

Head

in

and

the cotter key.

stall

Cylinder Head Assembly.

e.

Install

each

in the

valve

it

removed or to which

the

seal on coil

and

valve

head spring pad to the shown in fig. 11. If the

height is

lx%6 inches

bring

to

spring

cylinder

head

the

dimension

mended

greater, install the

or

spacer

valve

and/or

71

ring

install the bolt. Tighten

install

not

spacers

necessary.

Use of

will

result

will

spacers in excess of recommendations in overstressing the valve springs which lead to excessive load loss and spring breakage.

Apply

Use the brush furnished to

gasket.

over

the

the

entire gasket

head

cylinder

over

Before

carefully.

the threads

the

bolt

each

of

resistant sealer.

the

with

and

coating a

of

the

spread

of

new

sealer

block. Lift the

cylinder

cylinder a

Install two bolts

head to hold the head

sides

guides and slide

installing

a

surface. Position the gasket

the

on

studs

guide

from

Inspect the head for

both

to

sealer

gasket

perature

hose

the

head down

in

head

bolts,

Connect the

sending

holding fixtures. The

head

tightening

procedure

tighten the

First, (cold) in the

steps.

them

is

position.

65

to

sequence.

the

Remove

the heater hoses. Install

and

Position

the

valve

on

the

the

number

shaft

the

rocker

then install the oil drain

in their

rods

arm

line,

progressive

vacuum

hose. Connect the

and

run

it for

approximately 1200

the tem

wires and

radiator upper

the, accelerator

lines

and

battery

pedal

the fuel line

cable

on

wind

to the head.

a

r.p.m.

minimum

With the

30

of

minutes

engine warmed

at

up,

tighten the cylinder head

bolts, in proper sequence, to 75 foot-pounds torque (hot), then check the valve lash with the engine idling and adjust it if necessary. After

NOTE:

the

cylinder

head

bolts

specifications, the bolts

tightened to

Coat

one side of

resistant

in

making

in

the

sure

have

should

been

not

be

are

retaining

the cemented side

Install the

gasket seats

rubber seals on

centered

nuts

rocker arm cover gasket with oil

lay

cover.

that the

head. Install the

they

the

sealer, and

place

in the

to 2.0-2.5

cover

rocker

evenly the

of

the gasket

arm

cover,

all around

studs

openings.

making

the

sure

Tighten the

foot-pounds torque.

and

hole. Position the

head,

retaining

screw

the

oil

sockets.

the

assembly

sure

~~

25

proper sequence.

in the tappet

clip,

1 bracket. Make

locating

engine

in fig. 12, then tighten torque (cold) in the same

push rods

end of

plug

Connect the

shown

foot-pounds

Position the lower

head bolt

bolts to 55 foot-pounds torque

sequence

Install the

cylinder

in three

performed

spark

unit wire.

and

coat

the guides, then install the remaining bolts. Remove the cylinder

valve

disturbed.

at opposite ends of

gasket

(cold)

preliminary

assembly, the ignition coil,

manifold

Position the two

rod.

amount of water

small

bolts to 45-55

Fill the cooling system. Remove the tape from the car buretor air horn, then connect the choke wire. Start the

and gasket sealer residue

gasket surfaces.

and repair as necessary.

head

cylinder

over

block

and

any damage

evenly

deposits

carbon

a

the engine, then connect the lines. Connect the

f. Cylinder Head Installation. Clean

the retaining

adjustment.

shield wiper

the head

all

the oil

of

end

supply counterbore, then

recom

Install the

unless

oil

valve

spark plugs.

CAUTION: Do

the lower

sure

is in the

seal

foot-pounds torque. Perform

inches.

12%2-11%6

"O"

line

Height-

Valve Spring Assembled Typical

Checking

6 bracket. Make

number

lash

height to the

assembled

of

the

pad and

spring

be

spacers

6504

SURFACE OF SPRING PAD

and

height from the

assembled

spring

necessary 0.030 inch thick tween the

valve

Fig.

retainer contact surface as

assembled

the closed

with

spring

was

new stem

Compress the spring,

sleeve.

machined surface of the cylinder

spring

a

locks (fig. 9).

retainer

Measure the

valve

it

which

head surface, then install the

the

spring retainer,

install the

Install the

valve.

against

from

port

fitted. Install

was

on

oil

line

feed line

B

~

Z^Z

OTi flph

rtor

Moot)oo(?og)o9oo9ooôJ

enters on

the

55 if

1225

Fig.

12 Cylinder

Head Bolt

Tightening Sequence

Engines

II 6-Cylinder

Chapter

36

4. CRANKSHAFT DAMPER A

single sheave crankshaft

is

bly

retained

threaded holes

and

with

a

cap

are provided

the

Install the tool

crankshaft.

move the

crank

shown

in fig. 13

and re

damper.

Two

washer.

and

screw

the

assem

pulley

The assembly is keyed to

standard.

shaft and

damper

in the damper to facilitate

b. Installation.

removal.

Lubricate the

On

cars equipped with power

steering,

is bolted to the

single sheave pulley

an

damper

crankshaft

power

damper

Removal. Remove the On

cars

two bolts

radiator.

equipped

with

power

steering,

crankshaft

pounds

the

remove

lockwashers that fasten the

and

pump pulley to the

ing

Remove the drive belts.

On

Fig.

and

power

damper

washer

13 Damper

the

the damper

oil

white

lead

surface

with

and

and remove

from the

of

end

rubbing

then

with

on

the

the

key

shaft.

on

the

Press the

(fig. 14). Install the lockwasher

shaft

tighten

torque. Install

cars

equipped

and

bolt

the

the

adjust

with

on

the

foot

85-95

generator

steering,

power

steering pump pulley

to

belt.

install

crankshaft

the

damper.

Tighten the retaining bolts to 23-28 foot-pounds torque. Install

screw

and start

power steer

the pulley.

Remove the cap

on

capscrew,

and

oil seal

Align the damper keyway

steering pump. crankshaft,

a.

lubricate the

and

mixture

grease.

to drive the

an

with

crankshaft

additional

and adjust

Install the

power

steering pump belt.

radiator.

Fig.

Removal

the

14 Damper

Installation

OIL SEAL 5. CYLINDER FRONT COVER AND CRANKSHAFT The block

cylinder

by

front

ten pan head

cover

screws and

hex head bolts. Two dowels ignition on the block. The the

is fastened to the to the

are used

timing

cylinder

oil pan

by

to locate the

is

pointer

two

Cylinder Front Cover Removal.

a.

Remove the radiator, the

cover

welded

pan.

oil

to and

Remove the

cover

crankshaft

damper,

and

the

retaining screws, the cover,

the gasket.

cover.

b. Oil Seal Replacement. NOTE: seal

It is

each

good

time the

practice

cylinder

to

replace

front

the front

cover

is

oil

removed.

Drive out

the

out

the

recess

old seal with a pin

in the

cover.

Coat

punch, then clean

a new seal with

grease,

5 Cylinder

Section then install the

is

fully

seated

(fig. 15). Drive the

seal

in the

Check the

recess.

Front Cover

in

seal

seal after

until

and

37

Crankshaft Oil Seal

it

installa Tool

tion to be sure the spring is properly

in the

positioned

T52L-6700-BEE

seal.

Cylinder Front Cover Installation.

c.

Clean the

front

cylinder

block

the cover

and

gasket

sealer, then

with

block. Place the

gasket on the

the

cover and

the cylinder block. Coat the

of

gasket surface

surface position

cover on

the

of

new

a

the block

and

install the retaining screws. Tighten the screws to 6-9 foot-pounds torque. Install the oil pan. Install the crank shaft damper and belt. On

cars

equipped

with

power

power

steering pump pulley Install the radiator.

and

CYLINDER FRONT COVER

install the

steering,

belt.

6549 15 Oil

Fig.

Seal


6. SPROCKETS AND TIMING CHAIN, CAMSHAFT AND BEARINGS, AND TAPPETS The

is

camshaft

babbitt insert-type bearings driven

by

sprocket

the

the

on

by

trolled

The

shaft.

fuel

The

into the block. It is

chain

mesh with a

the shoulder

and

integral

in

con

thrust plate located between

is bolted to the front

plate made

eccentric, the

sprocket

steel-backed

Camshaft thrust is

crankshaft.

a spacer and a

camshaft

pressed

timing

a sprocket and

four

by

supported

the

with

the

on

low

are

car.

If the

installation

and

engine

the

when

applicable

is removed,

engine

is

stalled

eliminate

be

given

procedures

cylinder

front cover,

crankshaft

damper,

and radiator.

On power

cars

equipped

with

power


and

steering,

install the

belt.

b. Camshaft.

operates

camshaft,

pump. removal

Install the

belt,

cam

the block. An

of

bolt. Tighten the bolt to 45-50 foot-pounds torque.

in the not

steps

any

The

camshaft and related parts are shown

(1)

REMOVAL. Remove the

radiator,

cover,

and

the

radiator grille

radiator

in fig. 17.

support

assembly, cylinder

bar, front

and oil pan.

applicable.

CAMSHAFT SPROCKET TIMING MARK

Sprockets

a.

The the

to,

is

a

slip fit on,

der front the

cover.

and

is keyed

camshaft.

REMOVAL. Remove the

(1) on

the

Chain.

Timing

sprocket

camshaft end of

and

12 PINS BETWEEN MARKS

Crank the

sprockets

radiator and

engine until

and chain

the

the

timing

cylin

marks

are positioned as shown

in

fig. 16. Remove

the

camshaft

Slide both

washer.

ward and remove

(2) the

slots

chain

timing

sprockets

them as

retaining

the

and

timing

Be are

on

the

and

sure

crankshaft

the

timing

positioned

chain

link

and

chain on

timing

as

pins

bolt

and

chain

for

an assembly.

INSTALLATION. Place the keys in

sprockets

shaft.

sprocket

the

marks

shown

camshaft.

position

in

Position the

camshaft and crank

on

the

sprockets

in fig. 16. There

between the timing

and

are

marks on

12 the DRIVING SIDE OF CHAIN

sprockets.

Install the

camshaft

sprocket

washer

and

retaining

Fig.

16

CRANKSHAFT SPROCKET TIMING MARK 1244

Aligning Timing Marks

38

II 6-Cylinder

Chapter BEARING (FRONT AND INT.)

DRIVE CHAIN

Engines

REAR BEARING INT.

CAMSHAFT

\

BEARING-*,

SPROCKET

SPACER REWORK CLOTHESPIN

CAMSHAFT THRUST PLATE

5HERA

3/i6 INCH LOCKWASHER

SCREW 6298

Fig.

17 Camshaft and

Remove the tion

arm

to

switch

the

remove

rocker coil

arm

Related Parts

cover.

Disconnect the igni

from the

wire

push rod chamber cover.

then

assembly,

the

remove

engine

Remove the push

valve

rods

the

camshaft

engine until the

timing

marks on

are positioned as shown

tor cap,

and scribe a

block to

cylinder

the

Crank

on

the

sprocket and chain

the distributor

the

of

position

housing

the

(2) INSTALLATION. Oil the camshaft fully slide it through the bearings. Install

then

remove

the

the

thrust plate,

Turn the

clear

spring-type

with

spring

clips

Carefully the front

of

(fig. the

of

remove

the

18),

and

the

key,

or

pins

Remove the

Check the

be lifted

with

fingers. Raise the

lobes, or

can

and

secure

window

them

regulator

19).

camshaft

by

the

the

Exercise the necessary the camshaft bearings.

caution

to

Install the hub

avoid

and

Install guides a

tributor

cap

gasket

to the

cover.

Tighten

pounds

with

lash

rod

the

crankshaft

cover,

pump, radiator,

install the

the

using the

rods, then

push

chamber

housing;

Cement the

cleaner. cover

screws

as

make

Install the dis

adjustment. air

lines

scribed

rotor and

retaining

engine

the

fast idle

at

engine

leaks. Make

the

Check

sprocket

install the

and

inch-

15-20

to

torque.

Run the coolant

push

ex

Install

necessary.

camshaft

front

carburetor

and

if

play is

end

installation. Re

blades, fuel

and

position

valve

preliminary

If the

correct

assembly.

arm

to properly

foot-pounds

camshaft.

and radiator grille.

distributor,

the

journal

pan.

oil

fan

and

bar,

rocker

Magnetic Tappet Lifter

12-15

chain,

cylinder

Release the tappets install the

to

and/or spacer

timing

and

and

radiator support

for

spacer

bolt, drive belts, damper,

pulling it toward

engine.

camshaft

play.

end

camshaft

sprockets

the

in the

key

woodruff

the thrust plate

washers

inside of the

on

bolts

retaining

cessive, inspect the place

faces

or

is installed.

torque. Install the

and spacer.

the

CAUTION:

damaging

chain.

the tappets

camshaft

clothes

(figs. 18

timing

woodruff

camshaft until

magnet

a

either

tappets

sprockets and

care

thrust

the

the

chamfer

rear

spacer

Tighten

Remove the

the

sure

is to the

spacer

and

distributor.

camshaft

Be

NOTE:

and

rotor

and

plate and spacer.

when

housing for installation,

distributor

Retainers

in

in fig. 16. Remove the distribu

line

mark

bolt.

sprocket

19 Tappet

Fig.

rocker

sequence.

Remove

6329

then

clips,

a

final

(hot)

valve

idling. Install the

ignition

timing

and

for

check

and

lash

rocker

adjust

oil

and

adjustment

arm

the

cover.

timing if

necessary.

c

Tappet Replacement. Remove the

install Fig.

18

Lifting

and

Securing

Valve Tappets

one

camshaft as outlined

tappet

at

block. A flexible-type

a

in

"b."

Remove

time through the bottom

holding

tool

can

be

used

of

and

the

if desired.

6 Sprockets and

Section As

tappet is

each

installed,

it

should

be

Timing Chain,

secured

Camshaft

Bearings,

and

Adapter

in the

39

Tappets

and

Too\T52i-626l-CEEl

up position.

After the tappets in

as outlined

d.

Bearing It

replace

available

for

remove

camshaft

to size

0.015 inch

standard and

bearing

is

not

the

engine

from the

bearings. The bearings

camshaft

pre-finished

Number 3

the

Replacement.

be necessary to

will

to

car

installed, install

are

"b."

and

require

undersize

no

are

reaming

journal diameters.

interchangeable

the

with

other

bearings. Remove the

flywheel of

and

camshaft as outlined

Knock

way.

Push the

crankshaft.

the cylinders to

move

hole in the plug

and

the tool

shown

bearing

must

front face

of

rods out of the

bore plug a Vi inch

drill

shown

Clean

Lightly

out

the plug

coat

the

Install the plug Install the crankshaft

with

rim

a

camshaft

new

then

plug

rear

bore.

sealer.

with

in fig. 22.

shown

"b."

in

outlined

as

flywheel,

in fig. 20 to

of

the tool

camshaft

and

in the

recess

outer

install the

Install the in the

engine

camshaft

bearings

with

in fig. 21.

bearing

at

the tool

place with

or

top

21 Camshaft Bearings Removal or Installation

car.

the plug. Remove the

in

to the

bearing

rear

the tool

use

Remove the

pistons

bearing bore,

remove

Position the

"b."

the connecting

the camshaft

out

working from the front

in

Fig.

be

the

the

shown

pressed

bearing bore,

it

cam

in 0.005-0.025 inch below the

bearing bore. Press

ings in sufficiently to

and press

in fig. 21. Number 1

align

the remaining bear

the oil supply holes.

ToolT52L-6266-BGD CYLINDER BLOCK CORE

CYLINDER BLOCK

Vi INCH HOLE IN PLUG

DRILL

CORE PLUGS

Fig.

PLUGS"

20 Camshaft

Bore

Plug

1271

6600

Fig.

Removal

22 Camshaft

Bore

Installation

Plug

7. FLYWHEEL, CRANKSHAFT, AND MAIN BEARINGS The

The

in fig. 23.

crankshaft and related parts are shown

procedure

covered

for replacing the

clutch pilot

bushing

is

in Part TWO.

On

mission, the surface wheel

a.

on

the

crankshaft

bolted to the bolt holes shrink

fit

are

on

can

piloted on a shoulder and

by

six

crankshaft

unequally

the flywheel.

is

spaced.

one

in the

be

can

as

gear

the

is

two laminated

the flywheel is used as

by

engaged

and

the

clutch

installed

a

trans

friction

disc. The

with

the

fly

engine

car. used on

Fordomatic

spring-steel

180

outer edge

of

removed

The flywheel

position

The ring

be

is

retained

bolts. The flywheel in only

face

rear

which

mounted

Flywheel. The flywheel is

cars equipped with a standard or overdrive

apart, to

drive

which

equipped cars

plates

has

riveted to the

the converter

cover

is

attached. a

(1)

REMOVAL

-

STANDARD

OR

OVERDRIVE

40

II 6-Cylinder

Chapter

Engines

REAR OIL SEAL

CRANKSHAFT SPROCKET FRONT OIL SEAL

SCREW

WASHER

SCREW

CLUTCH PILOT BEARING

LOCKWASHER FLYWHEEL ASSEMBLY

JR ~gL

SCREW

FRONT AND INTERMEDIATt

BEARING CAP

BEARING CAP

SIDE OIL SEALS

Fig.

6502

23 Crankshaft and

TRANSMISSION. Remove the transmission. Remove the flywheel housing dust cover. Mark the clutch assem it

be

bly

so

the

clutch release

can

in the

replaced

rod, spring,

clutch pressure plate and

same position.

and

Remove

bearing. Remove the

disc (Tool-7563). Remove the

flywheel retaining bolts and pry the flywheel crankshaft. Remove the flywheel through the lower

the

off

housing

Related Parts

tion

jack

a

the transmission. Remove the trans

under

bolts. Remove

mission support

bolts

the

securing

engine

block. Move

the flex drive

clear

torque

frame

the

cross member

Remove the two lower

at the rear of the transmission.

housing

converter

the transmission back plate.

far

Secure the torque

CAUTION: not

get

grease

or

oil

the

on

clutch

to

converter

to the housing.

access opening.

CAUTION: Do

the

to

enough

will slide

//

the torque

converter

is

not

secured, it

off the splines.

components.

Remove the flex drive

INSTALLATION

(2)

DRIVE the

TRANSMISSION.

crankshaft

flange

and

STANDARD

OR

Position

flywheel

align

the

bolt

the

holes,

then

install the mounting bolts. Tighten the bolts in sequence from each other to 75-85 foot-pounds torque.

Using a pilot shaft (Tool-6392-N) to locate the clutch disc, install the pressure plate and disc. Install the clutch release rod, bearing, spring, and hub. Install the flywheel housing dust cover. Install the transmission.

flex drive

holes,

REMOVALFORDOMATIC.

verter

front

the car and

transmission control access

edge.

position

safety

converter

converter

until

shaft.

converter

inlet shield, plate. Turn the

converter air

front

access

the drain plug is

Drain the transmission

Remove the drive

Remove the

stands.

linkage shield, the torque

plate, the torque

the torque

and

torque

and

torque

at

the

converter

the flex

housing housing to

plate

and

dowel to

holes,

engine

converter

block lower bolts. Install

bolts. Install the frame

speedometer

from the starter, then remove Remove the transmission oil level indicator

Remove the starter.

battery

cable

tube.

Install the drain plug in the torque

converter.

cross rear

bolts.

control

the

linkage,

torque

converter

linkage shield, torque cover, the torque

and

the

control

inlet

air

lower

access

cover,

the

cable. control

shield,

housing front

converter

converter

linkage,

speedometer

access

and

the

transmission oil level indicator tube.

Install the starter, then

connect

the

battery

cable

to

the starter. Install the drive shaft. Remove the safety

converter.

Disconnect the

Install

pilot

converter

install the torque

then

Connect the transmission throttle manual

the bolt

align

bolts. Tighten the bolts

Remove the jack. Install the transmission

member.

the lower

cable and transmission control rod at the transmission.

the

crankshaft

plugs

of

lower

the

to 75-85 foot-pounds torque. Align the and

Remove the two

from the floor pan, then remove the con housing to engine block upper bolts. Raise the

on

plate

then install the mounting

support

(3)

crankshaft.

INSTALLATION FORDOMATIC. Position the

(4)

on

across

rubber

from the

plate

OVER

Posi

stands

to

and

engine

tion the

lower the

car.

Install the

block bolts. Install the

floor

converter

housing

rubber plugs and posi

mat.

Fill the transmission

with

fluid. Start the

engine

to

fill the torque converter, then add fluid until the proper level is reached on the oil level indicator. Check for

7

Section leaks. Check switch,

and adjust the manual

the throttle

and


control, the

neutral

linkage.

Tighten the

caps.

Install the

Install the

The

is precision-molded, alloy iron with integral counterweights and is statically and dynami crankshaft

cally balanced. Oil distribution holes the shaft to pressure lubricate the

drilled through

are

main and

connecting

bearings.

NOTE:

Handle

possible

fractures

the

crankshaft

damage

or

(1) REMOVAL.

with

finished

to the

Remove the

to

care

it

be installed in the

Remove the

install it

timing

oil

pump

Make

sure

top

Remove the installation crankshaft

the

on

of

out

cap to block

bearing

and

connecting

journals.

same

the block

and

so

crankshaft

front cover,

pan, the

crankshaft

On

seal

rear

the

them

for

journal

and

cap,

and

Install

the sur

the

into

not

careful

and

the

journal

cap.

Care

place.

damage

to

the

bearing

surfaces.

Check

clearance

of

bearing

main

each

(Chapter I). After the

checked and

the

clearance

found to be satisfactory, apply to the

bearing

(Chapter Check the

journals

caps

except

crankshaft

Check

the

end

are

the steel-backed, copper-lead,

play is

end

by

controlled

the

number

3

has been removed, new bearings can be readily fitted. However, the bearings can be fitted with the engine in the chassis as follows: If the

crankshaft

Remove the

oil

NOTE: Replace

a

(Chapter I). After the

clearance,

clearance

and

leaving

time,

a

ings

cap to

to be fitted. Insert the

are

(Tool

Rotate the rotation

bearing

main

6-331)

in the

crankshaft

to force the

oil

in the

bearing

upper

bearing

hole in the

opposite out of

new

which

bear

removal

crankshaft.

direction to

engine

the block.

NOTE: When replacing standard bearings with new bearings, it is good practice to first try to obtain the proper clearance with

of

the

upper

two

blue

main

bearing

bearing,

bearing over the shaft Using the same tool, on

the block.

halves.

place

the

light

seats

itself. Remove the tool. Replace the

coat

the

bearings securely fastened.

other

in the direction

Clean the

bearing the

locking tang

rotate

journal

and

the crank

bearing bearing cap.

of engine rotation until

crankshaft

the plain

the

bearings. Check

the

using Plastigage (Chapter I). After has been checked and found to be satis

clearance

clearance

factory, apply a light coat of engine oil to the journals bearings, then install the bearing cap. Tighten the

and

bolts to 95-105 foot-pounds torque.

original posi

Plastigage

checked and

a

light

coat

bearings,

then

install the

found to be satisfactory, apply

at

oil pump.

shaft

specifications.

using

has been

bearing

one

the

remove

has been

play (Chapter I).

in their

pan, then

side of

the

rod caps

bearing

to the journals

oil pressure and oil

bearing flanges.

main

end

then install

and

I). Tighten the cap bolts to

Install the connecting tions.

bearings

main

using

bearings, thrust bearing cap. Install new side seals when the rear main bearing cap is installed. Install the thrust bearing cap and draw the cap bolts up lightly, then align the thrust bearing engine

oil

Fill the crankcase, then leaks.

car.

lead-babbitt insert-type.

To install the the

Plastigage

The

Remove the

a new rear

bearing

main

rear

crankshaft

Be

the

Main Bearings.

c.

or

install

steering,

belt.

and

for

engine and check

oil

and

assembly

belt.

power

in the

engine

screen

and

with

Install the

chain.

timing

pump

damper,

install

and

springs,

Install the flywheel hous

and


the

start

oil

equipped

Install the

plate

oil seal

remove

the bearings

sure

are clean.

in the block

lower the

cars

power

tool

journals

CAUTION:

oil

cylinder

or

disc (Tool-6392-N),

clutch

pressure

sprockets

Install the flywheel

plate.

assembly.

plate

ing. Install the

side seals.

INSTALLATION. Be

(2)

push

Carefully lift thrust bearing

the

bearing

rear

mark

caps, and

damaged. Remove the

are not

rod

the cylinders.

of

main

from the block

fully

the

rear

clutch

Crankshaft (main

caps

to intermix the caps, then

care not

pistons to the

oil

oil pan and

marked so they can be installed in their locations. Remove the connecting rod bearing

caps, using

connecting

each

of

play

Align the

plate.

the

assembly.

bearing

all

end

engine

the pressure

front cover,

cylinder

Remove the

are

rod)

original

faces

damper,

chain.

housing

screen

the flywheel.

same position on

crankshaft

sprockets and

all

compress

a work stand.

can

of

flex drive

surfaces.

and

engine

avoid

Remove the flywheel housing, clutch assembly, flywheel or flex drive plate, and the engine rear plate. Mark the clutch pressure plate assembly so

on

tighten them to 3-4 foot-pounds

(Chapter I).

b. Crankshaft.

rod

pal nuts and

torque.

foot-pounds

45-50

to

nuts

Check the

torque.

41

Main Bearings

and

of

engine

rod

If the

journal

rear

main

oil seals and

Install the

oil

bearing is

pump

and oil pan.

then start the engine and check

leaks.

replaced,

replace

the

the side seals.

for

Fill the crankcase, oil pressure and oil

42

II 6-Cylinder

Chapter

Engines

8. CONNECTING RODS AND BEARINGS, PISTONS, PINS, AND RINGS The

piston and

rod

connecting

disassem

shown

are

b. Piston

bled in fig. 24.

Piston

a.

Disassembly.

ing

carbon

assemblies, deposits from the

bores. Move the

piston

place a cloth on

the

Remove the

Never

the

any

head to

cylinder

the

bore,

cylinder

is

when

the

at

travel

in

area

its

from the connecting

crankshaft until and

stroke

of

the

cylinder with

the handle

cylinder wall when

Remove the Repeat this

glaze

to

end of a

being

rod

the hex head

assembly

the

removing the

from the

procedure

for

out

off

the

the

top

into

1

to

6 from

numbers

same

on

side

connecting cylinder

and

the

the

bearing

rod and

the the

front to the

crankpin

rod and

when rod

cap is

bearing

is

ever

Be

cap

to another, rod should

new cylinder

new

be

bearings

numbered

to

be

The the

on

bore.

one

should

piston and push

at

If

block be

the

by

spiraling them into

install the

the bearings replace

contained

in the

piston

ring

piston rings. and

journals

the connecting

are clean.

If it is

bearings,

replace

rod

this time.

Rod

Connecting

and

piston

rings, pistons,

and cylinder walls with

engine oil.

from

engine.

must

from

sure

Oil the

cylinder

in the

Installation.

(Chapter I).

numbered

of the

transposed

in

the fingers. Do not use pliers.

Follow the instructions package and

d. Piston

assembly.

installed in the

rod with shown

the

or

piston and rod.

rear

rod

new piston pin retainers

piston with

light

NOTE: Each

connecting

rod positioned as

place.

necessary to

hammer.

cylinder wall

each

retainers.

engine oil.

piston and

hole in the

Position the connecting

them

Avoid damage

CAUTION:

light

carefully

bolts. Pull the cap

piston

the

Rod Assembly.

Connecting

all parts with

oil squirt

Insert

pal nuts and

rod

rod, then push the rod and

from

piston rings.

fig. 26.

the connecting

until

crankshaft

is down. Remove the

same cylinder

(fig. 25). Discard

cutter

pin of

and

NOTE: Assemble the

the

Turn the

nuts

Piston

c.

the

the

remove

then turn the

top

with

retainers, then drive the pin

pin

piston

the piston and rod

Lubricate

remove the cloth with the cuttings.

removed

out of

Follow

ridges.

removing

they

assembly

assure

Remove the

were removed.

Remove the

to

installation in the

same rod and

which

pins

and

pistons

and

cuttings.

the tool manufacturer.

has been removed,

ridge

position

by

remov

its travel

of

collect

the

and/or

the

of

end

into the ring

cut

of 1/32 inch

from the

upper

ridge

cylinder ridge with a ridge cutter.

CAUTION:

After the

remove

to the bottom

piston

the instructions furnished

excess

head. Before

oil pan and cylinder

piston

Mark the

Rod Removal.

Connecting

and

Remove the the

Rod

Connecting

and

a or

fitted,

correspond with

NOTE: cylinder

they

sure

from

were

Make the

Be

install the

they

were

pistons

in the

removed,

or

to

same which

fitted.

sure

the ring

circumference

compressor on

hammer (fig.

number.

to

which

the

27)

of

gaps are

the

properly

piston.

Install

piston and push

until

spaced around a

piston

the piston in

ring

with a

it is slightly below the top OIL

of

RING

ASSEMBLY

SPRING SPACER

COMPRESSION RINGS

CONNECTING ROD CAP

STEEL RAILS

Fig.

24 Pisfon and

Connecting

Rod Disassembled

6385

Section the cylinder. Be avoid

damaging

NOTE: Install piston

head

Check

sure

to

8

Rods

Connecting

the connecting

guide

and

rods

Bearings, Pistons, Pins,

and

43

Rings

to

the crankshaft journals. the piston with the indentation in the

toward the front of the

the

bearing

clearance

engine.

Plastigage

using

(Chapter I). After the clearance has been checked, and found satisfactory, apply a light coat of engine oil to the

journals bottom down

and of

until

bearings. Turn

the crankshaft throw to the

its stroke, then

push

the

seats on

rod

bearing

the

piston all the

way

POSITION OIL SQUIRT HOLE TO RIGHT WITH PISTON DOT FORWARD

the crankpin. Install

the rod cap, then tighten the bolts to 45-50 foot-pounds

torque. Install the pounds

pal nuts and tighten them

to 3-4 foot

torque.

After

the

all

installed,

piston

and

rod

the end play

check

have been

assemblies

of

the connecting

6387

rods

(Chapter I).

26 Correcf

Fig.

Install the

oil pan and cylinder

head. Fill the

case with the proper grade and amount of

the cooling system. Run the sure there

is

Check for

Connecting If the

bearings can

engine

is

oil and coolant

Rod

Remove the

oil

leaks.

However,

removing the

pan, then

remove

the

crankshaft

bearing

the bearings

engine as

follows:

remove the oil pump.

the upper

and

lower bearings.

fit has been a

light

then

new

journal,

blue

two

coat of engine

rod cap.

rod

halves.

and

cap.

Check

bearing

Tighten the bolts to 45-50 foot pal

nuts,

and

tighten them

to 3-4 foot-pounds torque. Repeat the procedure for the

remaining bearings that all

pump

need

replacing.

bearings have been replaced, install the oil pan. Fill the crankcase, then operate

the

and

oil pressure and oil

leaks.

TIGHTEN COMPRESSOR

Tool FLM-

FRONT OF ENGINE

Pin Removal

upper

found to be satisfactory, apply oil to the journals and bearings,

torque. Install the

INSTALL PISTON WITH INDENTATION TOWARD

6386

the

and

bearing

bearings in the

the engine and check for

Piston Pin Remover

the cap,

bore.

checked and

install the

pounds

oil

25 Piston

Oil Squirt Hole

the fit using Plastigage (Chapter I). After the

After

Fig.

of

NOTE: When replacing standard bearings with new bearings, it is good practice to first try to obtain the

Install the stand, the

Remove the connecting rod bearing caps to which new bearings are to be fitted. Push the piston up in the cylinder, then

of

Replacement.

removed and mounted on a

without

does

Clean the half

proper clearance with

Bearing

be readily fitted.

can

be fitted

lubricant. Fill

fast idle. Make

sufficient oil pressure and the engine

not overheat.

e.

engine at

Position

crank

SECURELY

6149

INSTALL RING COMPRESSOR WITH RETAINER TOWARD SKIRT 1259

Fig.

27 Pisfon

/nsfa//afion

44

Chapter

II 6-Cylinder

Engines

9. OIL PAN, OIL FILTER, AND OIL PUMP Procedures for the

removal

and

installation

the

of

below.

above components are presented

Remove the flywheel move the oil pan

inspection

housing

retaining

cover.

the

screws and remove

the block

and

Coat the block

pan

place

Make

are

the

the gasket

the

block

at each end of

ing

then

tighten

oil pan.

Hold the

install

and

a

the pan. Install the

the

screw,

remain

from the

screws

center

in each direction to 12-15 foot-pounds torque. Install the flywheel housing inspection cover. Install the engine right and left front splash aprons.

Install the proper

level indicator. Fill the

oil

grade

and

and

of

quantity

for

check

crankcase with

engine

oil.

Run the

The full flow-type

the pump before the

of

lubrication filter

located

to

and

element

outer

is

it,

the oil

no

dirty

the

great

the

parts

in

bolt

center

enough

open.

in

and

consists

thereby maintaining

is

of

making

Install

spring.

element over

a

the

new

the

behind

enough

the

holes in the

flow

of

valve

the spring pressure,

emergency supply

of oil

to the

Fig.

filter

gasket and a new

Check to

if the two elong back diaphragm

see

anti-drain

in the up position as shown in fig. 29. Clean the block filter recess, then install a new gasket.

are

cylinder

not

over

tighten the center

Refill the the

crankcase with oil at

engine

fast

bolt.

are

oper

for leaks. If

check

oil

the necessary repairs to cor

the leakage.

rect

c.

evident,

idle,

perform

if necessary, then

and

Oil Pump. A

case

gear-type

in line

oil

with

pump is

mounted

inside the

crank

the distributor.

The pump is driven by means shaped drive shaft. The shaft is

of an

intermediate hex

pinned

into the

end of

the distributor drive shaft.

(1) REMOVAL. indicator,

and

the

Remove the distributor, pan. Remove the two

oil

from the mounting

(2) DISASSEMBLY. Remove

GASKET ADAPTER

FITTING

FILTER ELEMENT ANTI -DRAIN

oil

level

nuts

and

pad on

the block

Filter Disassembled

the

retaining screws, the screen assembly,

screen

assembly

move

the

and

gasket.

6080

Re

cover

retaining screws, cover, and gasket. Push the pump drive shaft and drive gear assembly

from the pump housing. Remove the driven

BACK'

DIAPHRAGM

28 Oil

the

lockwashers retaining the pump to the cylinder block. Remove the pump and gasket. Thoroughly clean the

RETAINER

NEOPRENE

BY-PASS VALVE

engaged

bolt.

filter

oil

are

and pump.

GASKET

VALVE SPRING

tangs

neoprene

center

old gasket material

BY- PASS

the

on

valve.

FILTER HOUSING

RETAINER

seat

(4) INSTALLATION. ated

clean and oil

the inner face of the valve

f

gasket

bolt,

.SPRING

SPRING

fiber

on

sure

a

difference between the

overcome

^XV^SPRING

new

in the

is

ENTER TUBE BOLT

FIBER GASKET

a

case

Oil then by-passes the element, an

in the

openings

tainer. Install the spring and spring seat assembly

leaks

difference between the

to

Wash

gaskets.

all

the

then place the bolt through the filter con

bolt,

center

and all

from the

are clean.

ASSEMBLY. Install

(3)

ate

pressure

acting

sure

gasket

entire

by-pass

the valve is not great

on

element

Make

solvent.

the fiber

neo

center

engine

system

The

element

pressure

of

pressure

will

all

and

the

remove

20-25 foot-pounds torque.

the

and will not permit a sufficient

If

valve

container

seat, then

filter assembly slightly, in each direction, to make sure gasket is seated evenly. Tighten the center bolt to

flows through the by-pass. When the

drops.

the

to the

bolt

center

spring

oil pressure

faces is

enters

clogged.

When the

faces

oil, the

the

becomes

valve.

overcome

Therefore,

28) filters

oil

provides oil

in the hollow

flow through

inner

gasket, spring,

CAUTION: Do

element

spring loaded will

and

the

system.

A built in by-pass the

filter (fig.

oil

the filter. Remove the filter assembly

Place the filter assembly in position, and thread the center bolt into the adapter finger-tight. Rotate the

leaks.

oil

b. Oil Filter. output

drip pan under bolt, then remove a

DISASSEMBLY. Remove the filter element,

(2)

bolt from the

surfaces

source of restriction

and gasket.

Re

outward

engine

the car. Place

pan

free from burrs.

and

gasket on

the

against

finger tight, screws,

sure

clean

the

corrected.

REMOVAL. Remove the filter from the bottom

the filter center

surface and oil pan gasket surface with

sealer and position

the

oil

bolt. Discard the filter

(2) INSTALLATION.

in

flow is

prene

and gasket.

pan

system until

of

(1) REMOVAL. Drain the crankcase. Remove the oil level indicator. Remove the engine left and right front splash aprons.

of

lubrication normal

(1)

Oil Pan.

a.

engine

to the

move

the

oil pressure relief valve chamber

and plunger.

gear.

Re

plug, spring,

9 Oil

Section TOP

Pan, Oil Filter,

CYLINDER BLOCK

Oil

and

45

Pump

GASKET

NUT

SCREW LOCKWASHER

HOUSING PLUG

GEAR

DRIVEN

COVER

COVER

GASKET

SCREW

STRAINER FLANGE GASKET

SCREW

SCREEN-

6081 SNAP

29 Oil

Fig.

Filter Anti-Drain Back Diaphragm Position

Remove the snap and remove screen

and

moving

wire

screen

Apply

a

pump

light

to

gear

Apply

valve

the

cover, but do

gasket on

end

a

The

exhaust

pipe, are

system

and

the

pump.

screws.

as

provided

of

inlet

individual

a

muffler

a

(fig. 31). These

service

When

system, loosen to

relieve

replacing all

the

in

twists

any

part

of

system,

then

it

secure

the

with

the

and

screen

the pump cover. Tighten

make a

sure

it turns freely.

new

gasket

nuts.

bolts, slide the pump mounting flange bolts, and install the lock washers

stall

Tighten the

the

on

retaining

over and

to 30-35 foot-pounds torque. In

nuts

the distributor.

Install the grade and

Fill the

oil pan.

crankcase with

the

proper

of oil.

quantity

Run the

fast idle

engine at

and check

for

oil pressure

leaks.

and oil

at

the

rear

muffler, the

parts.

the

by

muffler

of

the muffler. Separate the

sliding the

inlet

pipe

muffler.

pipe

outlet

clamp

and

Separate the

outlet pipe and

to the

Loosen

rear.

the clamp away

slide

muffler

exhaust

frame attaching bracket the

on

hand to

by

shaft

from the NOTE:

and

EXHAUST SYSTEM

muffler,

pipe

Install

cover

INSTALLATION. Place

retaining the

Install the pump

retaining

consists

muffler

a

of

the pump cover gasket,

10.

outlet

play

screen

Install the inlet tube gasket,

the retaining screws to 12-15 foot-pounds torque. Rotate

dial indicator (Chapter

of

tighten the

not

into the

assembly

Check the

gear.

using Plastigage or sealer to both sides

position

shaft

and

6331

Pump Disassembled

inlet tube assembly

and

coat of engine oil

in the

screen

retainer.

(4)

housing. Install the driven the gears

the

the pump

relief

pressure

Slide the drive

parts

oil

plunger, spring, and Tighten the plug to 33-38 foot-pounds torque.

plug.

then

pump screen,

parts.

Install the

I).

retaining the

from the housing. The disassembled in fig. 30.

shown

are

ASSEMBLY.

(3) all

the

30 Oil

Fig.

WIRE-

from the inlet

pipe, then remove the muffler. clamps

tighten

the

(2) INSTALLATION. clamp

clamps.

the

on

inlet

Position the

pipe.

Slide the

new

muffler

muffler

and

forward

on

the inlet pipe until the slots in the muffler extension are

Muffler Replacement.

a.

Extra available

(1) rear

heavy, for

double-wall

mufflers

are

then

pipe

more

the inlet

service.

REMOVAL.

clamp,

blocked. However, do

constructed

Loosen

remove

the

the

outlet

pipe

lower half

of

than

pipe

l3/4

the muffler

on

the inlet

muffler.

clamp downward approximately

frame

the

clamp opening

the clamp

the

slots

to

not slide

inches. Align the

in the

is

muffler

not

positioned

extension.

directly

Rotate 45

so

opposite

46

II 6-Cylinder

Chapter

Engines

CARRIAGE BOLT BOLT

6501

Fig. 31

Slide the

forward into the

outlet pipe

sion until

the slots in the muffler

However,

do

not

slide

the

into the

pipe

l3/4 inches. Connect, but do

than

half

the clamp

of

possible

sary.

the rear

of

pan.

Tighten the

outlet

Reposition the

outlet

pipe

muffler

The if

pipe

neces

clamps.

sound

deadening

exhaust noises

frame, or

pipe

but

is

attached

materials

from

being

also relieve

bending

to the

passage

which

not

conducted through

the

rear

of

the muffler, then

support.

Separate the

more than

outlet

support.

pipe and

the

slide

connect, but do

rear of


the clamp

rear

clamp

outlet

pipe

pipe.

into

the

muffler extension

\3A inches. Slide the

Connect, but do

the clamp at the

not

and

outlet

the slots in the

blocked. However, do

muffler

the

the chassis

of

the

remove muffler

INSTALLATION. Slide the

muffler extension until are

necessary.

the

to the muffler, of

the

is designed to

pipe

exhaust

manifolds

muffler

the exhaust

direct through the

over-all

exhaust system.

inlet

to the rear, then

Remove the inlet

outlet

pipe

clamps

Remove the two

pipe clamp.

the inlet pipe to the

muffler

give a

thereby increasing

REMOVAL. Loosen the

tening pipe.

the

exhaust manifold.

the muffler

separate

pipe

and

nuts

and

fas

Slide the and

inlet

gasket.

stresses.

the

(2)

the

from twisting

exhaust system

REMOVAL. Remove the lower half

from its

prevent

only

(1) at

by flexible

frame

inlet

muffler

leaving

gases

(1) outlet

if

pipe

outlet

Inlet Pipe Replacement.

c.

efficiency

The

the

outlet pipe clamps.

more

Outlet Pipe Replacement.

b.

Reposition

pan.

"kick-up"

pipe

outlet

floor

Tighten the

the lower

tighten,

not

exten

blocked.

are

the muffler. Check for


the floor

and

at

muffler

extension

Exhaust System

pipe rear

into the

clamp

not tighten

on

it to its

tighten, the lower half of the muffler. Check for possible not

"kick-up"

outlet

pipe

and

the

INSTALLATION. Slide the clamp on the new slide the inlet pipe into the muffler

(2)

inlet pipe, then extension

until

However,

do

slide

manifold outlet

the

exhaust

in the

the

\3A inches. Install

than

to

the slots

not

a

pipe new

are

extension

into the gasket

blocked.

muffler

on

more

the exhaust

flange studs, then connect the inlet pipe manifold. Tighten the bolts to 23-28

foot-pounds torque. Position the muffler, then tighten the

outlet

pipe

clamps.

Rotate the inlet

downward approximately 45 degrees

ing is

not

muffler

positioned

directly

so

opposite

extension, then tighten the

pipe

the clamp the

clamp.

slots

clamp open

in the

LITHO IN U.S.A.

7098-56

DEMO - 1956 Ford Car Shop Manual

DEMO - 1956 Ford Car Shop Manual

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