DEMO - 1957 Ford Car and Thunderbird Shop Manual

FORD

DIVISION

FORD MOTOR COMPANY

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

1957 Ford Car and Thunderbird Shop Manual EAN: 978-1-60371-007-7 ISBN: 1-60371-007-8 Forel Publishing Company, LLC 3999 Peregrine Ridge Ct. Woodbridge, VA 22192 Email address: [email protected] Website: http://www.ForelPublishing.com

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INDEX

PART

ENGINES

IGNITION, FUEL, AND COOLING SYSTEMS

CLUTCH, TRANSMISSION, AND REAR AXLE

CHASSIS SUSPENSION AND FRAMES

STEERING

AND

BRAKES

GENERATING AND STARTING SYSTEMS

LIGHTS, INSTRUMENTS, AND ACCESSORIES BODY MAINTENANCE AND REPAIR

DOORS, DECK LID, AND FRONT SHEET METAL INTERIOR TRIM, AND WINDOWS

SEATS,

Copyright 1956

FORD MOTOR COMPANY DEARBORN. MICHIGAN

All

rights

reserved

BODY INSTALLATION

DRAWINGS Permission Reprinted with Ford Motor Company's

FORD DIVISION FORD MOTOR COMPANY

FORM 7098-57

MAINTENANCE AND LUBRICATION

SEPTEMBER

1956

FOREWORD This proper

The

has been

manual

servicing

manual

of

prepared

1957 Ford Cars

be kept

should

to

and

it

where

provide

information for the

the 1957 Ford Thunderbird. will

be readily

available

for

reference at all times.

The page.

manual

A title

is divided into 13

page

is

also

lists the

chapters and

on each

left-hand

the

included

heading

indicates the

section covered.

The descriptions effect at

Ford Division continue without

of

models notice

the

in the

on

the title

of each part

The

part.

indicates the

that

heading

name of

the

on each right-hand or odd-numbered page

and

specifications

the time the book

Ford Motor at

designated

beginning

or even-numbered page

the

in

at

sections contained

chapter and

were

parts as

any time,

and without

was approved

Company or

contained

reserves

change

incurring

in this

for

manual

printing.

the

right

specifications

or

The

to dis

design,

obligation.

SERVICE

DEPARTMENT

FORD DIVISION FORD

MOTOR

COMPANY

1957

SHOP

FORD

CAR

MANUAL

PARTI

ENGINES

Chapter 1

GENERAL ENGINE SERVICE Page

Section 1. 2. 3. 4.

5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

General Engine Trouble

Shooting

1-8

Tune-up Manifolds and Exhaust Gas Control Valve Rocker Arm Assembly, Push Rods, and Cylinder Heads Valve Mechanism Timing Chain, and Camshaft and Bearings Crankshaft and Main Bearings Flywheel Connecting Rods and Bearings Pistons, Pins, and Rings Cylinder Block Oil Pan and Oil Pump Exhaust System Engine Dimensions, and Clearance and Adjustment Specifications

Chapter 2

1-4

1-10 1-11

1-14 1-18 1-19 1-23 1-23 1-25 1-27

1-29 1-30 1-30

6-CYUNDER ENGINE

Section 1. 2.

3. 4.

5. 6.

8.

Description Engine Removal and Installation Engine Supports Manifolds and Exhaust Gas Control Valve Cylinder Head and Valves Crankshaft Damper, Cylinder Front Cover, and Crankshaft Oil Seal Sprockets and Timing Chain, Camshaft,

1-35 1-38 1-40

Bearings, and Tappets Flywheel, Crankshaft,

1-46 and

10. 11.

12.

1 -43

1-45

Main

Bearings 9.

1-41

1-48

Connecting Rods and Bearings, Pistons, Pins, and Rings Oil Pan, Oil Filter, and Oil Exhaust System General Specifications

Chapter 3

Pump

1-51 1-53 1-55 1-56

8-CYLINDER ENGINES

Section 1

.

2. 3. 4.

5. 6.

7. 8. 9. 10. 11 .

12.

Description Engine Removal and Installation Engine Supports Manifolds and Exhaust Gas Control Valve Cylinder Heads and Valves

Crankshaft Damper, Cylinder Front Cover, and Crankshaft Oil Seal Sprockets and Timing Chain, Camshaft, Bearings, and Tappets Flywheel, Crankshaft, and Main Bearings Connecting Rods and Bearings, Pistons, Pins, and Rings Oil Pan, Oil Filter, and Oil Pump Exhaust System General Specifications

1-58 1-61 1-64

1-66 1-67 1-70 1-72

1-75

1-77 1-79 1-81 1-83

i

1-4

Part 1

-

ENGINES

Chapter 1

GENERAL ENGINE SERVICE Page

Section

1-

4

1-

8

1

General Engine Trouble

2

Tune-Up

3

Manifolds

4

Rocker Arm

5

Valve Mechanism

6

Timing Chain,

7

Crankshaft

8

Flywheel

1-23

9

1-23

10

Connecting Rods and Bearings Pistons, Pins, and Rings

11

Cylinder Block

1-27

12

Oil Pan

13

Exhaust System

14

Engine

The

apply to

the

after

and

1-18

Bearings

1-19

Main Bearings

1-25

1-29

Pump

1-30 and

Clearance in

contained

procedures

this

the

of

chapter

have

case

of

a

been

removed engine

complete

and

parts

engine

component

1-30

Adjustment Specifications

and

The cleaning, inspection, repair,

parts

in the

or

engine,

Camshaft

Dimensions,

the

1-1 1

Cylinder Heads

and

1-14

and

Oil

procedures

after

apply

Assembly, Push Rods,

and

all engines.

overhaul

1-10

Exhaust Gas Control Valve

and

and

service

Shooting

To completely disassemble or assemble an engine, follow all the removal or installation procedures in the applicable

from the

individual part,

overhaul,

in the

To

chapter.

engine

to the

refer

remove

section

install

or

covering the

an

part

applicable engine chapter.

has been disassembled.

engine

1. GENERAL ENGINE TROUBLE SHOOTING Poor

nosis

by

or

parts,

will

be

can

performance

tune-up, by

engine

general

a

of

engine

indicate the

of a

need

or

the need

The five formance

trouble

good

complete engine

up, individual adjustments, part(s)

haul,

diag tune-

speed

performance;

engine

overheats;

operation

of a complete engine overhaul.

major

in restoring

steps

good

engine

by

the

if possible, if any could

owner

work

be the

actually

has been

cause of

the

sure

exists.

that

Deter

performed

present

re

trouble.

2. ISOLATE THE CAUSE IN THE PROPER SYS

TEM. Trace the

cause of

it has been isolated in

ignition, fuel,

the trouble to the point

one

of

engine, cooling,

following

the

where

systems:

in

a

refers

in the not

listed.

has been corrected, the

work

Engine one

of

crank;

the

road

test the car

as a

final

check on

performance

complaints

usually

following basic headings:

engine

cranks

normally,

but

fall

engine will

under

will

not

not

start;

poor

or

the engine

acceleration;

fails to

reach normal

trouble shooting

troubles

of

procedures

the

the

and

checks

the trouble

reference after each

check

covers, in

detail,

to be

corrections

as

When

definite

which

cause of

manual which

as well

systems. a

The

chart

procedures

with

help isolate

system.

order of

cases, the

a

particular

system

by

a

checks

be

should

made

test, to

for testing

and

they

and several checks save

time,

check

are not

later the

calls

are

can

check,

listed

therefore, in in the

order

be

given

should spark

plugs

the cause

for

made

trouble

simple

their probable occurrence;

Some consideration, however, to logical order. For example, if the removed

runs,

full power, or has poor high fuel consumption; excessive

general

engine

various

trouble,

performed.

idle;

the possible systems that could be at fault

4. CORRECT THE TROUBLE. that the trouble

a

be traced to

most

deciding

engine

engine

running;

develop

to that part

checking

keep

temperature.

particular

3. LOCATE THE CAUSE IN THE SYSTEM.

5. ROAD TEST. Before

not

to be performed to

in the

or exhaust.

rough

Table 1 is

per

lists basic

as stated

which

starts, but fails to

engine

but misses; engine does

are:

the trouble

cently

need

replacement or over

1. ESTABLISH THE TROUBLE. Make

mine,

the

gradual wear of engine

failure. A

a sudden parts

by

caused

of

are

the

a compression

compression

while

the

spark plugs are out.

A

separate

trouble shooting

chart

is included in the

Section

ignition, fuel,

1- General

Engine Trouble

and

cooling system chapters. These charts list the basic troubles listed in Table 1, but cover only the items relating to the particular

system

under

Shooting Chart tion

con-

For example, in Table 1 under Poor Acceleration, the ignition system is listed as a probable

sideration.

Table J

These items next

General Engine Trouble

Poor Acceleration,

under

items that

system

to the

System Trouble

the trouble. In the Ignition

of

cause

'"*

Shooting

be

should probable

acceleration

affect

system

the

are

listed in Table 1.

Shooting

Engine Will Not Crank The

cause of this

If the starting plugs, then

water

is

fault,

not at

to

attempt

into the

leaking

Also

is

system

spark

cracks.

trouble is usually in the starting

the engine

crank

for

block for

-Chapter

hydrostatic lock

a

the starter. If the

with

Remove the

cylinders.

examine the cylinder

check

(Part 7

system

cylinder

head

2).

or a seized engine. engine

Remove the

cranks, it indicates that

head for

gasket and /or

inspect the

and

cracks.

Engine Cranks Normally, But Will Not Start Check the fuel If there is

supply.

sufficient

fuel in the tank, the

lies in

the trouble probably

cause of

either

the ignition

or

the fuel system.

To isolate

the cause:

Remove the ignition

insulator

so

from

wire

one spark

and

plug,

insert

a piece of proper sized metal rod

that it protrudes from the insulator. With the ignition

engine, hold the

If there is

approximately 3/16 inch from the

end of the rod

no spark or a weak

spark, the cause

of

on and

cylinder

the

starter

in the

cranking the

block.

the trouble is in the ignition

system

(Part

2

Chapter 1). If the

spark

If the

spark plugs are not at

If the fuel

is good,

is

system

the

check

not

spark plugs

(Part

2 Chapter

1).

fault, check the fuel system (Part 2 Chapter 2). at fault, check the valve timing (page 1-17).

Engine Starts, But Fails To Keep Running If the

engine starts and runs

Fuel

system

Ignition

for

a

few seconds, then stops,

check

the:

(Part 2 -Chapter 2). (Part

system

2 Chapter

1).

Engine Runs, But Misses

First, determine if

the miss

engine at various speeds under

is steady load.

or erratic and at what speed

MISSES STEADY AT ALL SPEEDS. Isolate the

firing. This is done

time,

until all cylinders

If the power

by

by

have been

engine with

checked.

being

shorted out.

cylinder not

Ignition Engine

system

delivering (Part

compression

If

Ground the in the

no change

before

power

2 Chapter

to determine

spark

being

is

running the wire

plug

shorted

by

running the

from

one spark

plug

at

a

wire removed.

shorted

out,

occurs

engine with one cylinder not

removed

out, that cylinder was

engine operation check

is evident, the

delivering

miss was caused

the:

1). which mechanical component of

MISSES ERRATICALLY AT ALL SPEEDS. If the check

by

the ignition

particular cylinder

engine speed changes when a

before

that

running the

miss

the miss

miss cannot

the

engine

be isolated in

is

at

fault (page 1-9).

a particular

cylinder,

the:

Exhaust Ignition

Fuel

gas control valve system

system

Engine

(Part 2

(page 1-10).

(Part 2-Chapter 2).

compression

to determine

system

for

Cooling

system

for internal leaks

restrictions

which mechanical component of

the engine is at

fault (page 1-9).

(page 1-30).

Exhaust

normal

1).

-Chapter

operating temperature (Part

and/or

for

2 Chapter

a condition

3).

that prevents the engine

igni-

listed.

before proceeding

checked

all

all

from reaching

1-6

1 General

Chapter

1 General

Table

Engine Runs, But Misses

Engine Service

Engine Trouble

Shooting

(cont'd)

(cont'd)

MISSES AT IDLE ONLY. Check the: Fuel

(Part 2-Chapter 2).

system

Ignition

2 Chapter

(Part

system

Vacuum booster pump, lines

Valve lash Engine

fittings for leaks.

and

(page 1-15).

adjustment

for low

compression

1).

compression

(page 1-9).

MISSES AT HIGH SPEED ONLY. Check Ignition Fuel

1).

(Part 2-Chapter 2).

system

Cooling

2 Chapter

(Part

system

the:

system

for overheating

or

internal leakage (Part

2 Chapter

3).

Rough Engine Idle Valve lash (page 1-15). Exhaust

gas control valve

(page 1-10).

Vacuum booster pump (Part

2 Chapter

Ignition System (Part

Leaking Fuel

system

Loose

brake

power

vacuum

2).

1).

booster (Part

6 Chapter

2).

(Part 2-Chapter 2).

engine mounts

Improper

2 Chapter

(Part

1 Chapter

2

or

3).

head bolt torque.

cylinder

Poor Acceleration Ignition

Fuel

system

system

Exhaust

(Part

2 Chapter

(Part 2-Chapter 2).

gas control valve

Valve lash

1).

(page 1-10).

(page 1-15).

adjustment

Dragging brakes (Part 6 Chapter Slipping clutch (Conventional and Improper

adjustment of

1).

Overdrive

Transmission)

(Part

3 Chapter

1).

the Fordomatic transmission.

Engine Does Not Develop Full Power, Or Has Poor High Speed Performance Determine if the trouble engine

exists when

the

engine

is cold,

at normal

operating temperature,

temperatures.

ENGINE COLD Exhaust

Fuel

gas control valve

system

Cooling

(page 1-10).

(Part 2-Chapter 2).

system

if the

engine reaches

operating temperature slowly (Part

ENGINE AT NORMAL OPERATING TEMPERATURE Exhaust Fuel

gas control valve

system

(page 1-10).

(Part 2-Chapter 2).

ALL ENGINE TEMPERATURES Engine

compression

Ignition Fuel

system

system

Valve lash

(page 1-9). 2 Chapter

(Part

1).

(Part 2-Chapter 2).

adjustment

(page 1-15).

Cam lobe lift (page 1-19).

Valve timing (page 1-17).

Cooling

system

if the

engine overheats

(Part

2 Chapter

3).

2 Chapter

3).

or at all

Section Table

1 General

? General

Engine Trouble

Engine Trouble

'"'

Shooting

Shooting

(cont'd)

Engine Does Not Develop Full Power, Or Has Poor High Speed Performance (cont'd) Excessive back

in the

pressure

Torque

converter stall speed.

Torque

converter

Brake

Tire

fails to lock up

Excessive

4 Chapter

(Part in

carbon

high

at

speeds.

(Part 6-Chapter 1).

adjustment

pressure

exhaust system.

3).

engine.

Excessive Fuel Consumption Determine

the

actual

fuel

consumption with

If the test indicates that the fuel

improper driving habits

If the test indicates that the fuel

below before proceeding to the fuel

equipment

consumption

fuel

will affect

test

is

not

installed in the

car.

excessive, demonstrate to the

Wheel

4 Chapter

alignment

(Part

consumption

and

ignition

is excessive,

make

the preliminary

systems.

3). 4 Chapter

1).

Brakes (Part 6-Chapter 1). Exhaust

gas control valve

Odometer

calibration

Ignition timing (Part

(page 1-10).

(Part

8 Chapter

2 Chapter

1).

1).

Valve lash (page 1-15).

FUEL SYSTEM

(Part 2-Chapter

IGNITION SYSTEM

2)

(Part 2-Chapter

ENGINE COMPRESSION (page

1)

1-9)

COOLING SYSTEM (Part 2-Chapter

3)

TORQUE CONVERTER STALL SPEED TORQUE CONVERTER CONTINUES TO CONVERT AT LOCKUP SPEED

Engine Overheats Temperature sending Temperature

Exhaust

unit

(Part

gauge

gas control valve

(Part

8 Chapter

8 Chapter

1).

1).

(page 1-10).

Cylinder head bolt torque (Part 1-Chapter 2

Cooling

system

(Part

2 Chapter

or

3).

3).

Ignition timing (Part 2-Chapter 1). Valve timing (page 1-17).

Valves (page 1-14). Exhaust

Brake

system

(page 1-30).

adjustment

(Part 6-Chapter 1).

Engine Fails To Reach Normal Temperature sending

Temperature

Cooling

gauge

system

unit

Operating Temperature

(Part 8-Chapter 1).

(Part 8-Chapter 1).

(Part 2-Chapter 3).

how

consumption.

PRELIMINARY CHECKS

Tires (Part

owner

checks

listed

1-8

Chapter 1

General Engine Service

2. TUNE-UP A tune-up is rious

engine

a

components,

them

within

engine

efficiency

The

systematic

procedure

if

and,

recommended

for testing

bringing

necessary,

specifications

va

to

restore

Tune-Up Schedule (Table 2) is

Table Perform

for

applicable

on

Operation

2

Major

X

cables.

series re X

and capacity.

X

drop

voltage

at

resistor.

TIMING Check

and

output.

X

wiring.

X

X

Part 7 Chapter 1

ignition

adjust

X

X

X

X

X

X

Test fuel pump

pressure.

X

Test fuel pump

capacity.

X

CARBURETOR Clean carburetor filter.

X

SPARK PLUGS X

X

Part 2 Chapter

Part 2 Chapter 1

Part 2 Chapter 1

Part 2 Chapter 1

Page 1-9

Part 2 Chapter 2

X

Part 1 Chapter 2 or 3

Page

and X

air

cleaner

X

X

1

Clean INTAKE MANIFOLD Check and adjust manifold bolt torque. VALVE LASH Check and adjust intake exhaust valve lash.

Procedure

Page 1-9

each cylinder.

test.

vacuum.

FUEL PUMP Clean fuel pump bowl.

Part 7 Chapter 1

Recom

X

VACUUM Check manifold

X

ENGINE COMPRESSION Take compression reading of

and

Major

X

current and voltage.

adjust,

on

mended

timing.

REGULATOR Visually inspect

Clean,

the

X

the

listed.

Minor

Check the

X

the

describes,

be followed. Perform

COIL AND RESISTOR Check coil output.

Part 7 Chapter 1

which

manual

Operation

sistance,

cracks

state of charge.

GENERATOR Check generator

Check

X

by

Tune-Up Schedule

Procedure

worn

for

sequence

governed

reference after each opera

the

to

procedure

in the

operations

of

as

Perform

X

Grease battery

the

detail,

The

part

CONDENSER Check for leakage,

terminals.

Inspect cables for insulation.

the engine.

to that

refers

tune-up

major

or

Recom

BATTERY AND CABLES Clean cables, connectors, and

battery

tion

mended

Minor

Check

minor

a

condition of

in

and performance.

Inspect battery and leaks.

either

1-15

carburetor

Adjust float

fuel bowl.

setting.

Check fuel level (Holley Ford Carburetors). Adjust

X

engine

idle

X

Part 2 Chapter 2

and X

speed.

X

X

X

X

X

Adjust idle fuel

mixture.

DISTRIBUTOR

Check arm

Check

and

spring tension. of

condition

FUEL FILTER Clean fuel line filter.

breaker

adjust

X

EXHAUST ANALYSIS Perform an exhaust gas

contact X

points.

X

X

Page 1-10

an

alysis.

Check Check

and adjust point

and

adjust

dwell.

X

Part 2 X

Chapter 1

IGNITION SYSTEM RE SISTANCE TEST Perform a primary circuit and

Check

and adjust mechanical

advance

(8-cyl.

Test distributor

cap

and

and X

re

test.

X

COOLING SYSTEM Check and adjust the tension of the drive belts. Check

inspect distributor

and rotor.

circuit

Part 2 Chapter 1

X

point resistance.

Clean

secondary

sistance

engines).

circuit

X

X

vacuum

advance.

Part 2 Chapter 2

X

X

condition of

radiator cap.

hoses

X

X

Part 2

Chapter 3

and X

X

-Tune-Up

Manifold Vacuum Test A

test

of

determining

manifold

ing to locate the

Engine Compression Test is

vacuum

the condition

a

valuable

in

of an engine and also

1. Be

in

aid

for

help

cause of poor engine performance.

To

V2 hour

off, then

switch

for

engine

a

minimum

V^-hour

of

4-barrel carburetor)

at

1200

at

plugs.

spark

throttle

in the

choke

engine

Turn the igni

rpm.

the

(primary and

Operate the

good.

remove all

2. Set the throttle

1200 rpm.

plates

posi

open

wide

on

only

tion.

2. Install

an accurate, sensitive vacuum gauge fuel pump end of the fuel pump vacuum line. 3. Run the engine at recommended idle rpm.

4. Check the

vacuum

reading

on

carburetor

adjustment,

valves,

cylinder

the

3. Install

the

the

mum

is

affected

by

condition

of

5. Repeat

to

cylinder.

Note the

obtain

the

maxi

a

registers

gauge

reading.

strokes required

head

cylinder

test

the

each

on

the same number

engine of

number

maximum

for

of strokes

to

required

obtain

maximum

a

the

cranking

cylinder,

as

each cylinder

the was

or

the

and record the

reading

in No. 1

gauge

until

engine

of compression

leakage

and

compression,

manifold, carburetor,

a compression

4. Crank the

gauge.

vacuum

timing,

valve

on

reading.

TEST CONCLUSIONS. Manifold

the

battery is

the

sure

a minimum of

tion

test manifold vacuum:

1. Operate the

1-9

2

Section

No.

on

reading

1

gaskets. cylinder.

Because

abnormal

than

more

has been

trouble

and

each

possible not

3

lists

causes. a

firm

Allowance on

the

with

so

as

It is

from

For example, item may

one

10

to indicate that the

necessary in

of

This table is merely

a

guide,

dicates

reading.

increase in

of

more

A

their

low

The

for the

affect

engine vacuum

of

will

decrease

fault,

head

in the

altitude.

Table

Gauge

3 Manifold

pounds

However, uniform

the

within

above

below

in two

or

indi

normal

valves.

cylinders

adjacent

be

should

checked

the

rings

of

tablespoon

a

then

chamber,

the valves

or

crank

of

are

heavy

Engine Condition

18-20 inches (6-cylinder engine)

19-20 inches (8-cylinder engine)

Normal

Low

Loss

and

steady

Very low Needle fluctuates steadily

as speed

increases.

of

power

or valve

leakage

around the piston

carburetor,

A

or

partial

weak

reading

at

engine

idle.

caused

by

gasket,

a

valve

a

or

drifting

of

the

needle.

manifold

of compression

due to

rings.

loss

head

gasket

leak.

of

power

in

leaking

valve,

leaking head

one

or

more or a

spring.

occasional

Improper

loss

by late

possibly

defect in the ignition system,

exhaust system.

loss

of

defect in the ignition Slow fluctuation

or

or cylinder

complete

Restriction in the An

Intermittent fluctuation

timing,

Manifold,

manifold

drop in

all cylinders caused

ignition

cylinders

Gradual

in

idle gasket

power

system or a

mixture

leak,

possibly

or

caused

sticking

adjustment,

possibly late

at oil

the engine to

Vacuum Gauge Readings

Reading

in

rings or valves.

whether

combustion

normal

cylinder.

leak. This

gasket

the equivalent

squirt

pounds

than 10 pounds

compression

To determine

altitude

10

the head gasket, rings,

at

even a

than

before condemning the made

be

should

10

of

satisfactory.

cylinders

of more

leakage

indicates

however,

is

deposits in the

excessive

A reading

to

standard.

be

all

variation

pounds.

cates and

readings

of

A reading

the trouble.

of

types

order

A

pressure

specified

compression

reading be investigated

abnormal

various

of

CONCLUSIONS.

TEST

exercise

important, therefore,

conducted where

should

gauge

an

correction

enough

an

fault,

at

abnormal reading.

corrected.

of

may indicate that

factors is

the correct diagnosis

at

Table

and

cause

further tests

arrive

an

vacuum

readings

above

is low, the

vacuum

increase the

that

the

of

in analyzing

caution

if the

one

gauge

by

a

valve.

carburetor valve

or

timing.

1-10 distribute oil

will

the

oil

the

the

valves

has increased

During

a

10

and

are

strokes, but

successive

fails to

ceeding strokes, it indicates a sticking or

Exhaust Gas Analysis An

the

the

over

pressure

same

during

climb

higher

during

on

the

is

analysis air

and

a

the

entering

it

ever

As there

fails to

be

cannot

are

instructions

the

of

first

system, install the

the

suc

the

test,

control

entire

the

of

analyzer

the

How

carburetor.

a

On

in the

that

system

and

analyzers, follow the

of

a

dual

outlet

pipe

manufacturer. analyzer

the

carburetor.

calibrate

the

contains

For example, if the

valve.

side, install the

or stuck valve.

to

types

various

the

side

used

testing

cylinders,

the

of

performance

and

of

method

com adjustment

more

the

climbs

fuel

of

ratio

the

gas

exhaust

rings are

past the rings.

test, if

remains

or

Engine Service

If ap

rings.

leaking. If

pounds

is leakage

compression

steadily

the

past

reading is obtained, the

original reading, there

climb

leakage

seal

same

satisfactory, but pression

the compression test. The

and repeat

temporarily

proximately

two

1 General

Chapter

is

valve

in the left

exhaust opposite

exhaust

the

on

gas

right

muffler outlet pipe.

3. MANIFOLDS AND EXHAUST GAS CONTROL VALVE Hot

exhaust gases are

fold to

diverted into the intake

mani

the heat necessary to vaporize the in

provide

coming fuel-air

mixture and

to

and carburetor

icing during

cold engine operation.

hot

by

directed into the intake

exhaust gases are

thermostatically

a

minimize engine

controlled

valve

stalling

The

manifold

located in the

exhaust manifold.

a

chamber

the intake manifold exhaust

All

manifold

8-cylinder

through

the

through

which

an

riser

are

where

Blow cylinder sure

intake

section

the hot

exhaust

On

intake

gases

the

are

carburetor,

directed.

with

from the

compressed

center

in

a

air.

exhaust

suitable

Scrape

passage

solvent, then

three tube

a vacuum

inches with

all

carbon

below the

a

of

deposits

carburetor

used

fresh

the

check

pump to

moistened

Inspect the

Replace

manifolds make

would

all

Make

air.

choke

Block

studs

that

four-barrel

tube

that

car

passes

follows: a

off

steady reading

one

opening

then connect the

a

of

the

of

vacuum

If the pump does

opening.

the tube should be

fects that

as

obtain

finger,

other

heat

air

steady reading there is

a

8-

the

otherwise

a

with

for leaks,

vacuum.

pump hose to the

dry

hot

the

of

compressed

with

completely open,

manifolds

through the manifold

passage

as

acts

be impaired.

and

and

manifolds

are

the carburetor

under

and

manifolds

buretor,

a

of

action

passages

choke

automatic

the passages

maintain

them

the

out

into

contain

heating

carbon

exhaust gases.

Adjust

manifolds

This

manifolds.

insulator restricting the

cast

which

is

are

attached.

intake

center

(heat riser)

section

gases

exhaust

Manifolds Clean the

the intake

of

operation will

On the 6-cylinder engine, the hot

directed into

heat

not

leak in the tube

replaced.

for cracks, leaks, them

are

or

other

for further

unfit

stripped

or

de

service.

otherwise

dam

aged.

Remove

CLOSED (HEAT ON)

have

all

entered

filings

the

foreign

and

manifolds

as

a

matter

result

of

that

may

repairs.

Exhaust Gas Control Valve Check

the

thermostatic

spring

to

make

sure

it

is

CLOSED (HEAT

ON)

OPEN (HEAT OFF)

1001

Fig.

7 Exhaust

Gas Control

Valve 8-Cylinder

-A

Engines

Fig.

2 Exhaust

Gas Control

Valve 6-Cylinder

Engine

Section hooked The

the stop pin. The spring stop is

on

the valve

housing

action of

Check to hand to

ly

the valves is

make sure the

top

illustrated in Figs. 1

spring holds the

Actuate the

cold.

it

make sure

the

at

of

the valve is properly installed.

when

the engine is

when

3 Manifolds and

freely

moves

2.

and

valve closed

by

counterweight

through approximate

1-11

Exhaust Gas Control Valve

operating temperature a

ever,

Rapidly

is

pressure

is

engine

at

counterweight.

the

sure

The

binding.

rotation without

is

valve

4.

closed

and

operating temperature

is

engine

at

normal

trating

high

Free

rpm.

stuck

pene

a

with

valves

is

oil or graphite mixture.

ROCKER ARM ASSEMBLY, PUSH RODS, AND CYLINDER HEADS

Rocker Arm Clean

the

when

at

operated

valve

open when

90

of

very

when

open

make

How

speed.

is designed to

valve

normal

idle

the

to

to

engine

The

opens.

momentarily

will

valve

applied

the

accelerate

at

running

properly operating

light finger

the

and

Assembly

the parts thoroughly. Make

all

that

sure

all

oil passages are open.

Check the the

checking the I. D.

by

shaft

the O. D.

and

arm

limit),

replace

shaft

shaft.

each

rocker

the

rocker

of

If the

arm

and

bore

arm

between any

clearance

the

shaft and/or

the

scuffs.

rocker

valves are

for

pad

the

at

If the

grooved radius.

a

rocker

Do

arm.

valve

pad

attempt

not

the

of

end

rocker

arms

is grooved,

replace

true this

surface

to

the

the

of

adjusting

for

arms

rocker

ball

the

and

rocker

stripped

the

of

end

and

screws

or

the push

broken threads,

for

screw

adjusting

rod

nicks,

or excessive wear.

scratches,

Check for broken drain tube for

the or

not

and

springs

and

inspect the

oil

sharp bends.

rods

cylinder

scratches

with

they the

between ball

3). If the

cup

not attempt

0.020 inch to

for

push

wear.

excessive

head

more

gasket

an

with

to

solvent

re

and

the

surface

gasket

cracked.

0.010 inch from

than

Remove

surface.

all

burrs

stone.

oil

Check the flatness

of

the

cylinder

head

or

are

gasket

sur

0.006 inch

0.003 inch in any 6 inches.

Valve Seat Runout Check the

straight-

all,

valve

seat

runout

with

(Fig. 5). Follow the instructions

engine

by

rotating

facturer. The total

can

be

checked

inch (wear limit).

also

centers with a

the

of

end

checked

They

closed.

valve

and

or

installed in the

runout exceeds

Do

rod.

are

grind

or

plane

with a

grease.

face (Fig. 4). Specifications for flatness

socket

be visually

can

rods

push

while

them

the

the

for nicks, grooves, roughness,

The ness

and

and

bores

Replace the head if it is

nicks.

maximum over

end

dirt,

sealer,

Check the head for cracks,

Do

guide

valve

cleaning tool. Use cleaning

move old gasket

Push Rods Check the ball

the

Cylinder Head Flatness

locating

cracks or

Runout Typical

Rod

clean

removed,

guide

for burrs

Check the end

valve

by

grinding.

3 Push

Fig.

arm

hone. Inspect the

10O3-A

Inspect

rocker arm.

bore for nicks, scratches, Dress up minor surface defects with a

the

PUSH ROD

fixture'

Holding

the shaft approaches 0.006 inch (wear

and

and

or

scores,

the

of

rocker

the

between

clearance

runout

should

an

of

accurate

the

not

gauge

exceed

gauge

manu

0.0025

dial indicator (Fig.

at

any point, discard

straighten

push

rods.

Cylinder Heads To

head, do is

off

the

to

stalled

a

scratch

the

surfaces

the

cylinder

while

the head

of

holding fixtures

engine.

AND INSPECTION. With the

protect

from the

posits

machined

not remove

CLEANING

with

the

protect

scraper

the

the

valve

combustion

and

a

cylinder

wire

head

seats,

brush. Be gasket

carbon

remove

chambers

and

valves

valve

careful

surface.

in de

heads

not

to

After the

0(3) CHECK (5) CHECK Fig.

DIAGONALLY

ACROSS CENTER

4 Cylinder

Head Flatness

1O04-A

1-12

1 General

Chapter

Engine Service

Runout Gauge

1005- A

Fig.

5 Valve

Seat

Runout Typical

valve

seat

exhaust

width

valve

the

valve

seat

limits

width

seat width

(Fig. 6). The intake

0.060-0.080 inch

are

limits

are

and

the

(Fig.

ream a valve guide

oversize

stem,

following

the

inch O.S.

a

to install

reaming kit is

reamer

pilot

and

0.030-inch

reamer reamer

with with

When going from valve,

always

a

a

a valve with an

combinations:

0.003-

a

0.015-inch O.S.

standard

size

use the reamers

in

and

a

to

over

an

sequence.

Always

the

valve

seat

after

the

valve

guide

is

reamed.

correct

measure

seats of

should

the

valve

valve

face

VALVE

SEATS.

Refacing

of

the

be

centered.

This is important

tight

compression

wheels are proper

the

If the remove of

a

it

bring

clean

seat

seat

limits.

width

exceeds

to

up pits, grooves,

the

from the top the

reduce

angle

from the bottom to

wheel

(lower the

seat).

The finished

valve

or

seat

maximum

edge and/or

width

to

of

grinding

the

remove

wheel

(raise the

seat stock

limit,

bottom

specifications

30

a

(Fig. 8).

angle

After the

within

enough stock

angle

to

45

true

is ground, (Fig. 6). Narrow the seat, if

width

seat

(Fig. 8). Use stock

a

valve seat runout.

valve

the

to

seat

to

remove

seat).

from the top

of

Use the

valve

be closely coordinated with the refacing face so the finished seat will match the

and

good

a

grinding

enough stock

the

necessary to

seat

REFACING

refacer

valve

60

grind

have

dressed.

edge

pilot

valve

to

Valve Guides

Reaming

will

seat

that the

sure

Remove only

a 0.015-

diameter pilot,

0.003-inch O.S. pilot,

a

ly

and

Grind the

available which contains

reamer with a standard

inch O.S.

size

7)

valve

fit. Be

0.070-0.090 inch.

REAMING VALVE GUIDES. If it becomes necessary to

7

Fig.

Valve Seat Width Measure the

007-A

so

that

mate

the

valve seat contacts

blue, Seat Width Scale

center of

then

set

the

seat

valve

the

should

the

face. To determine

face,

valve

contact

in

coat

place.

TO REMOVE STOCK FROM TOP OF SEAT, WHEEL USE

the seat

where

with

Rotate the

approxi

the

Prussian

valve with

TO REMOVE STOCK FROM BOTTOM OF SEAT, USE WHEEL 30

60

VALVE SEAT WIDTH: INTAKE

0.0600.080

EXHAUST 0.0700.090

1006- A

fig,

6 Valve

Seat Width

1008- A

Fig.

8 Valve

Seat

Refacing

Section

4 Rocker

Arm

Assembly, Push Rods,

and

1-13

Cylinder Heads

Tool-T52T-6135-CJD

Tool T53L-200-A

\

Tool

T53P-33623-A

(Handle)

(Adapter)

1009- A

9 Water

Fig.

Outlet

Installation

Plug

8-Cylinder Engines light of

pressure.

the valve

If the blue is transferred to the the contact is

face,

center

If the blue

satisfactory.

is transferred to the top edge of the valve face, lower the valve seat. If the blue is transferred to the bottom edge

the

of

face,

valve

After refacing the

lightly lap

in the

compound.

Remove

and

seat

after

WATER

engine

the

are

other,

valve

the

a

the

head

practice

grade

8-

lapping

from the

plug

is

installed

outlet

at

EN

rear

sending

opening

at

cylinder

heads do

the

of

the

unit rear

either right or

right

adapter of

the

have

not

installed; therefore, they

head

a

water

is installed in the left

either

can

and

head.

tem water

Replacement

the plug

be readily

or

adapter

adapted

for

left installations.

bank to

in the

water

Water Outlet

Plug

Install the plug (Fig. 9). Clean the plug oughly.

DRILL

the

perature valve

CYLINDER

cylinder

Unit Adapter Installation

to

assemblies of each particular one

Sending

8-Cylinder Engines

operation.

interchangeable from a

good

compound

1 Temperature

Fig. 7

seat.

medium

CONNECTION

cylinder

provided

valve

it is

seat,

with

lapping

OUTLET

GINES. The

valve

all

the

raise

101 1-A

Coat the flange

of

the plug

recess

thor

with water resistant

Vi INCH

HOLE IN

PLUG

INSTALL TOOL

INTO ADAPTER

1010-A

f/g.

10 Water

Outlet

Plug

Removal

8-Cylinder Engines

Fig.

12 Temperature

Sending

Unit Adapter Removal

8-Cylinder Engines

1-14

install it

sealer and

plug in casting

To

1 General

Chapter

flange

facing

Drive the

out.

slightly below the

or

surface.

remove

center

the

flange is flush

the

until

with

the

water

plug, drill

Vfe-inch hole in

a

it

the

ter

The sending

resistant

sealer

toward the inside

adapter

To

adapter recess thoroughly.

water

with

the

in Fig. 10.

as shown

in

it is flush

until

the

is installed

unit adapter

in Fig.

as shown

adapter

slide

with

head. Drive

cylinder

the casting

with

the

surface.

adapter, thread the impact hammer

the

remove

install it

and

the

of

Coat the adap

handle into the adapter, then tighten the lock

Unit Adapter

Sending

11. Clean the

undercut

the plug and remove

of

Engine Service

(Fig. 12). Remove the

adapter

nut against

by

using the

hammer.

5. VALVE MECHANISM The valve

inspection

critical

points

tolerances

and

illustrated in Fig. 13. Both the intake

are

exhaust valves are the

rotating type

the

of

and

incorporate

which

Remove a

fine

carbon

all

brush

wire

Inspection

and

Inspect the

or

and

varnish

buffing

burning as

that

Inspect

locks,

are

with

the

defects. Inspect the

of

head for

valve

valve

cracking.

stem

signs of

Defects,

such

Discard

removed.

severely damaged.

the

and

valve

of

the end

pits, grooves, etc., may be

minor

valves

and

erosion, warpage, and

or

edge

other

or

Check the

grooves or scores.

valve

against

the

valve

springs,

normal

rocker

without

lifting

retainers,

spring

Position

tool)

The limits

at

and

action

forth

obtain

the

0.0023-0.0037 inch. The

are

inch. If the

clearance

approaches

(Fig. 14). The

recommended

inch total indicator inch total indicator

reading.

limit for

The

runout

proper

SPRING

pressure

guide

valve

with

the

of

limit is 0.0045 clearance

stem

limit is 0.0065

wear

pressure

of

71-79

145

when

pounds).

Check

PRESSURE.

(Fig. 16). The pounds

compressed

limit, try

a

when

Weak

to

valve

springs

the

spring

should

compressed

exert

to

or a pressure of

for a

1.780

161-177

1.390 inches (wear limit

springs

cause

poor

engine

is 0.0015

reading.

clearance

guide

runout

clearance

limit is 0.002

wear

Model TV-2 Runout Gauge

VALVE STEM CLEARANCE. Check the valve

face

valve

wear

the

upper sur

new valve.

pounds

VALVE FACE RUNOUT. Check the

wear

limits

parallels

clearance.

valve

exhaust

that

stem

valve

recommended

valve stem.

(division factor

stem

inch. The

spherical sec

guide

by 2

0.001-0.0024 inch. The

with

indicator reading

valve

actual

intake

plane

a

the

take

and

inches (wear limit 64 pounds)

parts.

on

the tool from the

to

the

to the

approximately

recommended are

dial indicator

center portion of

face. Divide the indicator reading the

a

90

the tool

of

VALVE

for defects. Discard any defective

sleeves

flat tip

tion

of

the

and

head for pits, grooves, scores, the stem for a bent condition

for

from the

wheel.

face

valve

a

valve guide.

Move the tool back

umbrella-type valve stem seals.

Cleaning

the

surface of

each

tool

in its

valve

in

shown

valve

Fig.

stem

to

respective

15

or

its

equivalent.

Install the tool and tighten

the

away from its

-

Va"

set

on

the

valve

stem

until

screw, then permit the

seat

until

the tool

fully

valve

contacts

seated

to

the

drop

upper

MINIMUM

REFER TO SPECIFICATIONS FOR CORRECT DIAMETER

z

i f/g.

DO NOT REMOVE MORE THAN 0.010 INCH 1015-A

101 4- A 73 Critical

Valve Tolerances

Fig.

14 Valve

Face Runout

5 Valve

Section performance; therefore, if the approaches the wear

limit,

pressure

the

replace

of

surface

against

valve

speed engine

the spring

of

the engine should be measured (Fig. 17).

Use dividers to

underside

Dial Indicator

S-8680-A

-

spring.

spring load is necessary for efficient high operation; therefore, the assembled height

the

Tool

any spring

VALVE SPRING ASSEMBLED HEIGHT. Correct

installed in

1-15

Mechanism

the

the assembled height from

head spring pad to the the spring retainer. Check the dividers

of

of

a

measure

cylinder

If

scale.

the

assembled height is 113/16 install the greater, necessary 0.030-inch thick between the cylinder head spring pad and spacer(s)

inches the

or

valve

spring to

recommended

install

spacers

excess

of

ing

the

loss

bring

dimension unless

the assembled height to the

of

12%2

inches. Do

113/16

-

Use of

necessary.

lead

valve springs which will

not

Fig.

in

spacers

in

recommendations will result

1016-A

load

to excessive

Valve Lash Adjustment Reference is

VALVE SPRING SQUARENESS. Check squareness

a

using

steel

square

and

spring for

each

a

plate

surface

(Fig. 18). Stand the spring and square on end on the surface plate. Slide the spring up to the square. Revolve the

spring slowly

top

coil

out

of

and

the

observe

the spring and the

of

If the spring is

square.

y16 inch,

than

square more

between the

space

(cold)

pression

closed

The

Valves

valve

is in line

ordinated

finished

that the

have

refacer

pits

valve

and

face

up the

runout

stock

enough

y32

mcn

will

valve

face

match

will

that the

so

the

valve and seat

tight fit. Be

sure

to

the

with

timing

the

obtain

that the

run

to

valve

to

a

correct

If the

after

true

the

to

too hot in the

head

arm.

fit in the threads.

rocker

is

the

on

on

com

at

the

valves

are

damper

crankshaft

pointer.

adjusted

located

threads

"no go")

and clearance

by

means

the

on

which

of

push

screw

not

has

the

self

rod

end

an

until

threads

are

locking the

of

interference are

the

lead

center

in full

con-

remove

the

to

valve

replace

Valve

Spring

Tester

the

engine. m

Grind the

of

off

all

valve

more

remove

or

grooves

stem, then

chamfer

than 0.010 inch

lap in

the

pound

to

match

compound

with

valves

the

from the

as

seats.

valve

Be

grade

to

sure

and

seat

Do

not

lightly lapping com to

remove

after

the

all

If the the

be

wear

lapping

PRESSURE

Valves to

valve stem

limit, it is for the

with

oversize

inch

are

stem

available

seat when

SCALE

READING

Fitting

reamed

LENGTH

the

operation.

Select

...

end

stem.

good practice

medium

a

necessary.

from the

After refacing the valves, it is

from the

marks

score

be

integral hex

provide an

reached

screw

can

(Fig. 19).

The first three threads

the adjusting

piston

the

T.D.C.

both

("go"

arm.

of

end

when

gauges

Interference is of

the

at

stroke

The adjusting

and special

1

angle.

of

grinding,

timing

preliminary

to placing No.

piston

mark

a

45

runout or

edge

rocker

1

the proper

screw

adjusting

portion

excessive and/or

and grooves.

pits

the

as

is

the

grind

head is less than valve

so

operation

refacing

valve

co

properly dressed.

wheels are

grooves,

Remove only clean

the

angle of

be closely

should

seat

good compression

a

grinding

If the

valve

This is important

valve seat. will

the

with

compression

for

procedure

(T.D.C.)

Number

Valve lash is operation

refacing

and

in the

adjustment

center

stroke.

the

of

end

used

Refacing

lash

valve

top dead

on

made

Step-type feeler

it.

replace

Stem Clearance

overstress-

spring breakage.

and

15 Valve

the

valve guide clearance approaches

recommended

next

oversized

diameters

for

of

service.

valve guide

is

that the valve guide valve

stem.

0.003, 0.015,

Always

reamed.

Valves

and

0.030

grind the valve

1017-A

Fig.

76 Valve

Spring Pressure

1-16

1 General

Chapter

Engine Service

UNDERSIDE OF SPRING RETAINER

SURFACE OF SPRING PAD

Fig.

tact

with

17 Valve

101 8-A

Spring

the threads in the

Assembled Height

rocker arm.

interference is reached, it

of

should

When the

take

minimum

a

3 foot-pounds (36 inch pounds) to turn the further.

screw

of

It is very important that the close as possible

is

set

to the correct

too close, the

valve will

valve

lash be held

specifications.

open

point

Step-Type Feeler Gauge

as

If the lash

too early

and

late, thereby, resulting in rough engine idle. Also, burning and warping of the valve will occur because they cannot make firm contact with the seats long to

the

cause

cool

valve

causing

valve

lobe is

likely

the

pattern

contact

tions

If the lash is excessive, it

properly.

to

too

open

and

close

will

too early

bounce. In addition, damage to the cam because the tappet foot will not follow

of

the

cam

lobe, thereby

between these two

are

late

given

parts.

causing

Valve lash

a

shock

specifica

If the

been a

preliminary

ing

head

cylinder

the

(cold)

engine.

tune-up, follow

the

or

installed, it

removed and

mechanism

be necessary to

is

for

made

start

an engine

adjustment procedure.

numbered

are

cylinders

from front to rear, 1-2-3-4-5-6. The

valves are arranged

from front to rear, E-I-I-E-I-E-E-I-E-I-I-E.

in Table 4.

Preliminary Adjustment the

all

noted, then

than

check

the torque

adjusting

replace

the

screw. arm

rocker

Make two

that

with

the

and

adjusting

on

screw

the

equal

marks

timing

the damper

Rotate the the end

of

Table

damper apart

xh

of

the distance

circumference).

No. 1

lash for No. 1

4 Valve

piston

is

near

T.D.C.

Adjust the intake

cylinder.

Lash Specifications

Intake & Exhaust

Final (Hot) Intake & Exhaust

6-Cylinder Engine

0.019

0.019

8-Cylinder Engines

0.020

0.019

Preliminary (Cold) Engine

1019-A

18 Valve

Spring

Squareness

self

unsatisfactory,

approximately

compression stroke.

and exhaust valve

new

mark, the damper is divided into

crankshaft until

the

is less

screw.

crankshaft

represents

parts

a

screw

120

Vfc"

at

a

still

(120

around

NOT MORE

to turn the

to turn

If this is

marks

chalk

(Fig. 20). Space the

three

required

required

interference is

until

3 foot-pounds (36 inch pounds), try

locking

so

screws

adjusting

further. If the torque

Fig.

has

make

before

adjustment

adjustment

final

the

lash

valve

If the

rocker

will

6-CYLINDER ENGINE. The

Turn

THAN

Adjustment Typical

Lash

close

too

enough

79 Valve

Fig.

1020- A

Section Repeat this

turning tion

the crankshaft

of

for the remaining

procedure

rotation,

order sequence

while

Vz

turn

set of

5 Valve

adjusting the

in the

valves

Rotate the

valves,

time, in the direc

at a

firing

at

the

end

following

for

engine

approximately 1200 tures.

With the

a

minimum

minutes

idling,

check

the

lash.

valve

4

from front to The

valves

rear-right are

cylinders

are

numbered

bank, 1-2-3-4; left bank, from front to

arranged

rear

5-6-7-8. both

on

banks, E-M-E-E-I-I-E.

Preliminary Turn

all

then

noted,

screws

adjusting

check

the

torque

required

to

turn

the

further.

screw

to turn the

required

screw

is less than

3 foot-pounds (36 inch pounds), try a new self locking adjusting screw. If this is still unsatisfactory, replace the rocker arm and

Make three

adjusting chalk

(Fig. 21). Space the that

with

the

equal

marks

marks

timing mark,

parts

the

around

on

the crankshaft damper 90

approximately the damper

Va

represents

damper

No.

2 Intake

No.

5 Exhaust

No.

7 Intake

Rotate the

crankshaft

180'

T.D.C.),

on

SET

NO. 1

STROKE STEP 4

STEP 2

apart so

is divided into

of

the

distance

adjust

the

(this

following

No. 8-Exhaust

No. 5-Intake

No.

puts

valves:

180

(this

puts

lowing

270, or 3A turn from on T.D.C.), then adjust the fol

crankshaft

No. 3

piston

valves:

3Intake

No. 2-Exhaust

No.

No. 3-Exhaust

No. 6-Intake

No. 7-Exhaust

No. 8-Intake

Final Adjustment

for

engine

approximately 1200

With

tures.

the

minimum

a

to

rpm

engine

of

minutes

engine

stabilize

idling,

30

the

check

at

tempera

lash.

valve

Adjust the lash if necessary (Fig. 19).

Valve The

Timing timing

valve

is

performance

should

be

checked when poor engine

noted and all other

buretion, ignition timing,

etc.

checks,

such as

fail to locate the

car-

cause of

the trouble.

circumference).

valve

timing is checked,

check

for

a

bent

PISTON ON T.D.C. AT END OF COMPRESSION

ADJUST NO.

1

INTAKE & EXHAUST

STEP

1

SET

-

NO.

STROKE

STEP 3

NO. 5

-ADJUST

1

PISTON

-ADJUST

ON T.D.C. AT END OF COMPRESSION

NO. 1, 4, 5, EXHAUST & NO. 1,

2, 7 INTAKE

NO. 3

INTAKE & EXHAUST

INTAKE & EXHAUST

STEP 6

STEP 3 ADJUST NO. 2

-ADJUST

NO. 4

INTAKE & EXHAUST

INTAKE & EXHAUST

Fig.

then

turn

No. 4-Intake

Rotate the

ADJUST NO. 6 INTAKE & EXHAUST

-ADJUST

Vz

or

No. 6-Exhaust

Before the STEP 1

the

adjust

4 Exhaust

piston

T.D.C.

screw.

(90

four

stroke, then

No.

Run the

If the torque

near

1 Intake

interference is

until

is

No.

Adjustment

the

compression

piston

1 Exhaust

Adjust the lash if necessary (Fig. 19).

8-CYLINDER ENGINE. The

the

of

No. 1

No.

at

to stabilize engine tempera

rpm

engine

30

of

crankshaft until

valves:

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

Final Adjustment. Run the

1-17

Mechanism

STEP 2 STEP 3

-

-

ADJUST NO. 6 & 8 EXHAUST & NO. 4 & 5 INTAKE 2, 3, 7 EXHAUST & NO. 3, 6, 8 INTAKE

ADJUST NO.

1021-A

20 Preliminary

Valve Lash

6-Cylinder Engine

Adjustment

1022- A

Fig.

27

Preliminary Valve

Lash Adjustment

8-Cylinder Engine

1-18

Chapter

timing

compression

stroke

aligned

the

with

If the the

valve

the

check

T.D.C.

in the car, Install

proceed

a

quadrant

the No. 1 intake

rocker

arm

position.

as

then install

a

the

Engine Service

the

actuating

to T.D.C.

timing

on

the

is

pointer

the damper.

on

not within

specifications,

check

timing

installed

the engine

follows: the

on

valve

damper. Back

adjusting screw, then one

side

and

secure

slide

the push

the

of

it in this

rod

Table

5 Valve

cam

lobe. At this

the

the dial indicator

on

the heel

point the push rod will

be in its

Compare

the

is checked,

opening

the

check

Cam Lift

Crankshaft Degrees

Cam Lift

0.016

8-Cylinder

18

B.T.D.C.

0.015

58

0.015

66

0.013

A.B.D.C.

or

the

sprockets

all parts air.

in

worn

wise

be

SIDE OF CHAIN

point on

the left

side of

the block

the

the

of

the

to the

should

not

should

DISTANCE A. TAKE UP SLACK ON RIGHT SIDE SIDE OUT WITH THE FINGERS AND MEASURE LEFT AND FORCE 1024-A DISTANCE B. DEFLECTION IS A. MINUS B.

Fig.

Timing

Chain Deflection

ment

INSPECTION.

of

signs

result

with

a

Check the

by

of

point

to the

opposite

side of

the

chain out with

the

the

right

Clean the

reference

circle

lobes for

cam

wear.

Lobe

pit

wear

general area

detri

not

therefore, the cam the cam lobe lift loss has

the cam,

of

and

suspected over

the

worn

top

lobes

of

the

subtracting the measure

diameter (Fig. 23).

journal to

measuring the diameter

exceeds

camshaft

This pitting is

measuring

micrometer

camshaft

a reference

in the

in pitting in the

until

replaced

the base

Establish

abnormal

the lobe.

operation

checked

to take up the

front)

dry. Inspect the

0.005 inch. The lift

be

of

be

a clock

chain and/or sprockets.

AND

may

in

crankshaft

If the deflection

Bearings

and

mental

lobe

timing

nose portion of

exceeded

22

com

needs replacement.

the

and

and wipe

solvent

characteristics

AND MEASURE

the

The deflection is the difference

the

replace

ting, scoring,

REFERENCE POINT

side of

Vz inch,

in

A

all

distance between the

the

chain.

on

slack

measurements.

CLEANING

ESTABLISH

that

crankshaft

between the two

Camshaft

SIDE.

0.016

A.T.D.C.

from this

measure

and

and measure and

point

LEFT

item

chain.

(Fig. 22). Rotate the

fingers

ON

one

from the

viewed

direction to take up the chain, then force the left

UP SLACK

10

recommended

if any

replaced

direction (as

chain

TAKE

0.019

9A.T.D.C.

DEFLECTION CHECK. Rotate the

Inspect the

for cracks,

RIGHT

POINT

Cam Lift

sol

slack on

REFERENCE

B.B.D.C.

damaged teeth. It is

ponents

and

to

CHAIN, CAMSHAFT AND BEARINGS

Chain

for broken links

valve

engine

Crankshaft Degrees

61B.B.D.C.

chain

the

on

Closes

Crankshaft Degrees

compressed

the

rotate

Opens

0.019

with

indicated

Timing Specifications

53A.B.D.C.

them

lobe

cam

closing.

valve

0.016

dry

to

continue

B.T.D.C.

and

of rotation

(Table 5). After the

quadrant with specifications

17

vent

continue

and

specified

degrees

crankshaft

Cam Lift

CLEANING AND INSPECTION. Clean

the

registers

6-Cylinder

Timing

the tappet is

until

lift (Table 5).

Closes

6. TIMING

move

Exhaust Valve

Opens Crankshaft Degrees

rod

damper slowly in

crankshaft

slowly in the direction

crankshaft

push

the push rod

Zero the dial indicator

Intake Valve Engine

as

plane

same

rotation

of

position.

turning

the

is in the tappet socket, dial indicator in such a manner as to have sure

the direction

until

crankshaft

in the

indicator in the

the

of

point

(Fig. 24). Turn the

lowest

order of accessibility.

with

and

socket

ment

sprocket, crankshaft sprocket,

in the

assembly to

Make

piston

if

mark

camshaft

valve

1

see

and crankshaft

camshaft,

off

and

timing is

timing chain,

To

the No.

Bring

pointer.

1 General

of

the

bearing

journals

clearances

and

the

I.D.

by of

Section

6

Timing Chain, Camshaft

and

1-19

Bearings

Dial Indicator

BE SURE TO PLACE INDICATOR TIP

IN CENTER OF PUSH ROD CUP

1026- A

:o.v.w>.-i;...'...

LOBE UFT

A-B

timing. Loosen the valve

Lobe Lift Measurement

then the

bearings. The

recommended

0.001-0.003 inch. The clearance

journals

camshaft

placed.

be

are

for

undersize

the

bearings

secure

gear

for broken

it in this

or

size

nicks

the

to the

similar

procedure

dial indicator in

such

to have the actuating point

in the

rod

push

for

push

rod

socket

in the

and

for checking

of

same

the indicator plane

24). Turn the

(Fig.

movement

the

as

crankshaft

damper slowly in the direction of rotation tappet is on the heel of the cam lobe. At this push rod will

be in its lowest

until

the push rod is in the

pare

the total lift recorded

fications.

valve

until

the

point

the

Set the dial indi

position.

zero, then continue to rotate the damper slowly

fully

cam

CAMSHAFT LOBE LIFT (CAMSHAFT INSTALLED). This

is

a

re

shaft machined surfaces with a smooth oilstone.

procedure

and

side

is in

or chipped

from the

one

push rod

the

sure

a manner as

cator on

or

Make

the tappet socket, then install

teeth.

Remove light scuffs, scores,

position.

adjusting screw,

assembly to

arm

rocker

arm

rocker

are

journal diameters.

undersize

Check the distributor drive

to

pre-finished

the

slide

camshaft

the bearings should be

available

0.015-inch

and

limit,

wear

and/or

replaced,

Bearings

standard

the

ground

limits

clearance

limit is 0.006 inch. If the

wear

approaches

should

Lobe Lift

102 5- A

23 Camshaft

Fig.

24 Camshaft

Fig.

'/...

=

Continue

indicator

reads

accuracy

of

to

raised position.

the indicator

on

the

rotate

Com

with speci

engine

the

until

This later step is a check the original indicator reading. zero.

the

on

7. CRANKSHAFT AND MAIN BEARINGS The

crankshaft

8-cylinder

is

and

engines

6-cylinder

engine.

controlled

by

by five

supported

by

four

Crankshaft

the No. 3

play in

bearing

bearings in

bearings in the

main

end

main

main

all engines

is

flanges.

Handle fractures

or

damage

with

to the

care

finished

to

avoid possible

surfaces.

main

blow

an

journals

are:

inch),

out

all

oil

crankshaft

passages with

and

connecting

oilstone.

scores.

rod

Dress

com

Regrind severely

Measure the diameter

of each

journals for cracks, minor

imperfections

marred

journal in

journals. at

be

should

0.00025-inch

main

and

out-of-round

undersize

connecting (wear limit

0.0005-inch taper (wear limit 0.001

and

reground

CRANKSHAFT toward the the

scratches, grooves, or with

limits for

recommended

or

the

approach

to

for

size

wear

the

limits, they

next

undersize

bearing.

air.

Inspect

determine out-of-round, taper, (Fig. 25).

inch). If the journals

crankshaft

solvent, then

pressed

The 0.005

CLEANING AND INSPECTION. Clean the with

to

condition

rod

Crankshaft the

places

least four

END

rear of

PLAY.

the engine.

contact point rests against

the indicator

axis

26). Set the dial

forward

limits

and note

are

is

Force

Install

a

the

crankshaft

dial indicator

the crankshaft

flange

parallel to the crankshaft axis

on

zero,

then

the reading

push

so

and

(Fig.

the crankshaft

the dial. The end play 0.004-0.008 inch for the 6-cylinder engine on

1-20

Chapter A VS B

=

Engine Service

VERTICAL TAPER

I. FORCE CRANKSHAFT FORWARD, RELEASE PRESSURE

HORIZONTAL TAPER

2.

=

C VS D A VS C

1 General

AND

B VS D

INDICATOR

INSTALL DIAL

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

4.

^-MTmm

mm

*

(wear limit 0.012 8-cylinder If the

end

inch)

thrust bearing. If the

limit, inspect nicks,

dirty, they the

end

the thrust

the

wear

bearing faces

probably

bearing

thrust

not

were

and

align

procedure, then

recommended

limit,

replace

aligned

the

not

faces

recheck

or

Install

following

Crocus

The

the

require

give

the

proper clearance with

the

the

to

two

with

clearance

able,

replace

Always that

maximum

bear

the

existed originally. of

the

bearing failure After grinding,

undersize

same

bearing

proper

Too

due to

the

oil

Red

then

be

used as a

engine

and

polishing

agent.

marked

use

to

Standard bearings

by

a

daub

are

not

journals that have been

on

proper

service

in

"blue"

"red"

of

or

the clearance;

clearance.

selective

or

divided into

are

bearings increase

bearings decrease the which

for

available

not

file

not

the

obtain

do

and

installation. Do

are

identified

fit

are selective

shims

use

bearings

marked

CLEANING

in

inserts

and

Inspect

the bearing.

holes,

cloth

fit,

are

Under

available

reground.

radius

a radius will result

radius ride of

chamfer

shoulder

also

Play

polishing

size upon

sizes only.

bearings,

size

small a radius will result

Too large

shaft.

blue

avail

for journal

DIRT IMBEDDED SCRATCHES

to give the

crankshaft.

reproduce

fatigue failure

in

the

the

"clean

will not

fit

sizes and are

paint.

ing. If the journal

grit

bearing inserts

reaming to

Selective

journal

next undersize

up"

may

lap bearing caps or bearing clearance.

the end play.

Regrind

cloth

main

standard

JOURNALS.

REFINISHING

No. 320

a

End

Main Bearings

burrs,

defective

properly.

with

26 Crankshaft

the

minimum

for scratches,

are

journal oil.

play is less than the

dirt. If the thrust faces

or

Fig.

0.002-0.006 inch for the

and

approaches

play

1029- A

Journal Measurements

(wear limit 0.010 inch).

engine

NOTE INDICATOR READING

1028-A

25 Crankshaft

Fig.

REAR, RELEASE PRESSURE

FORCE CRANKSHAFT TO

polish

the

scored,

OVERLAY WIPED OUT

AND

INSPECTION.

Clean

the

bearing

cap thoroughly.

each

chipped,

bearing or

carefully.

worn

surface

Bearings that have should

be

a

replaced.

S

INTO BEARING MATERIAL

SCRATCHED

LACK

BY DIRT

OF OIL

IMPROPER SEATING

J2 OVERLAY

GONE

PROM ENTIRE SURFACE TAPERED JOURNAL

Fig.

RADIUS RIDE

CRATERS OR POCKETS

RADIUS RIDE

FATIGUE FAILURE

27

Bearing

Failures

1030- A

Section Typical are

examples

bearing failures

of

in Fig. 27. Check the

shown

that appear to be satisfactory

bearings following the

7 Crankshaft and

their causes

and

bearings

clearance of

Plastigage. Fit

with

recommended

1-21

Main Bearings

new

procedure.

CHECKING MAIN BEARING CLEARANCE Engine On Workstand If the engine,

crankshaft

leaving

been

not

the clearance

check

the

has

of

removed

bearing

one

from the at

time

a

bearings securely fastened.

other

1. Invert the engine, remove one bearing cap, then wipe all oil from the journal and bearing. 2. Place nal

Plastigage

a piece of

the full

width of

the

bearing

the crankshaft jour

on

and about

cap

Va inch

(Fig. 28).

off center

3. Install the cap and tighten the bolts to specifica tions. Do not turn the crankshaft while the Plastigage

is in

place.

4. Remove the cap, then using the Plastigage scale (Fig. 28) check the width of the Plastigage at the widest

in

point

Check the Plastigage get

two

to get the

order

the

at

minimum

narrowest point

clearance.

in

order

is the taper. If the

limits,

fit

select

not within

bearing.

new

a

is

clearance

To Block Installation

which

is

more

than

0.001 inch

out-of-round.

Engine On Workstand

bearing

clearance of one

time, leaving

at a

bearings securely fastened. 1. Support the crankshaft so its weight

the

29 Seal

ference may result, causing an early failure. It is not recommended that bearings be fitted to a crankshaft journal

Engine In Car Check the

Fig.

to

the maximum clearance. The difference between the readings

1032-A

Tool T 521-6701 -AGD

If the

crankshaft

has

not

been

removed

from the

other

press

the Plastigage

Position weight

a small

and

jack

so

2. Follow

2-4

steps

Plastigage

on

on

the

it

will

bearing

adjoining the

Clearance Engine

provide an

under

bear

engine,

replace one

bearing

at a

time

leaving

the

other

bearings securely fastened.

erroneous reading.

against

the

counter

1. Invert the engine,

remove

the

bearing

cap

and

the

is

being checked. "Checking Main Bearing

which

Workstand."

bearing

will not com

surface

In step 2, instead

place of

on

the the

journal. FITTING NEW BEARINGS.

journals ever,

if

wear

a

evenly bearing is

journal, be

sure

to

being

fit

minimum

Tool-T521-6701- AGD an

out-of-round

clearance,

MEASURING

and

inter-

CHECK WIDTH OF PLASTIGAGE 0.002"

PLASTIGAGE

Installing

fitted to

How

bearing to the maximum If the bearing is fitted to the

of journal about Va inch off center

28

bearing

the

PLACE PLASTIGAGE FULL WIDTH

Fig.

main

and are not out-of-round.

diameter of the journal. minimum diameter with

INSTALLING

Normally,

CLEARANCE

PLASTIGAGE 1031-A

Measuring Plastigage

1033-A

Fig.

30 Seal

To Retainer

InstallationTypical

1-22

1 General

Chapter

Engine Service

034-A

31

Fig.

half

upper

of

the

bearing

to

bearings

which new

are

to

bearing inserts and check the When replacing standard bearings, it is

ance.

first try to obtain blue bearing halves.

two

3. If the

try

two

the

to

practice

with

new

clearance

good

clearance

proper

specified

limits,

within

then

Bearing

Oil Seal Replacement seal

retainer

bearing

or

2. Install the

standard

the desired

install

bearings do

limits,

undersize

not

bring

the

clearance

grind the crankshaft

one

time

ings securely fastened. Follow New Bearings Engine On

leaving

steps

the

2-4

Workstand."

journal

new

sealer, install the

other

under

bear

"Fitting

Remember to

5.

Dip

the

travel.

use

to

expand

not

on

when

leaks

seals

cut

the

any

retainer or

bear

by

outside.

a

not

of

be

until sufficient

Backward

bearing

for the last Vi inch ends.

The

are

oil.

oil, then

It may be

projecting seals

Using

cap,

all

of

Do

not

designed

sealer

may

re

compressed

seals

side

for

into the parting the cylinder block

air against

air

bubbles

leakage. The

on

has been

cap

oil

or retainer and

possible oil

time

the

appear

for

in

above test

newly installed

allowed

seals

seals

the seals to

seal grooves.

the

and

bearing

the block. If

Bearing

1. Install

or

performed

into the

Thrust :**

seal

engine

grooves.

place

few drops

Blow

the oil, it indicates

iiiuiiii

into

seals.

retainer

from the inside

expand

in light

in the

dipped in

squirting

from the

should

the

side

lines between the cap

035-A

bolts to

expansion.

6. Check the

Pry Cap

without

tighten the

retainer and

them

the

tap

Do

sealer

tard this

32

in the

seal

retainer side seals

immediately install of

Fig.

flush

seals

(Fig.

block

cylinder

23-28 foot-pounds torque.

necessary to

f^

the

seal grooves.

cut the seals flush. cap (Fig. 30). After installation 4. Coat the rear oil seal retainer to block mating face

with

at a

cut

and

ing

bearings.

bearing

in the

seal

new

Clean the

cap.

block

cylinder

overlapping.

edges

3. Install the

journal,

Engine In Car Replace

frayed

from the

oil seals

29). After installation,

4. If the

clearance of

bearings.

new

Rear Main

or a combination of red and

blue.

Cap

checking the

when

crankshaft

1. Remove the

is less than the

bearing halves

red

clear

the

support

the

be fitted. 2. Install the

33 Tighten

Fig.

Crankshaft Forward

Pry

Alignment

main

bearing

tighten the

2. Install the thrust

caps,

bolts to

bearing

cap

except

the thrust

specifications.

with

the bolts finger-

7 Crankshaft and

Section tight,

then

pry the crankshaft forward against the thrust surface of the upper half of the bearing (Fig. 31). 3. Hold the crankshaft forward and pry the thrust bearing cap to the rear (Fig. 32). This will align the

1-23

Main Bearings

thrust

surfaces of

both halves

4. Retain the forward and

8.

FLYWHEEL

and

are

the bearing.

pressure

tighten the cap bolts to

5. Check the

of

crankshaft end

on

the

crankshaft,

(Fig. 33).

specifications

play (page 1-19).

Conventional Flywheel The flywheel

and

gear

ring

are

a

fit

shrink

replaceable as separate parts.

INSPECTION. Inspect the flywheel for cracks, heat check, or other defects that would make it unfit for further service. Machine the friction surface of the fly if it is

wheel

0.045 inch

more than

ness,

If it is necessary to

scored or worn.

replace

of

from the

stock

for worn, chipped,

gear

damaged,

are

With the flywheel installed the flywheel face

the face

the

sure

making

end

play

inch,

the

of

runout

flange. Replace the flywheel

will

runout. remove

mounting flange. If

crankshaft

so

that it is full

crankshaft

machine

or

flywheel face if the mounting flange

the

runout

fly

the

for burrs between the flywheel

the

check

exist,

dial indicator

the flywheel face

against

0.010

exceeds

check

of

a

that crankshaft

so

flywheel

as

runout

and

wheel

flywheel,

rearward

be indicated the

check

runout.

(Fig. 34). Turn the

If

cracked

the crankshaft,

on

that the indicator point bears

not

or

the ring gear.

replace

FLYWHEEL FACE RUNOUT. Install

or

thick

original

the flywheel.

Inspect the ring teeth. If the teeth

forward

remove

no

1049- A

and

Fig.

burrs

crankshaft

is

excessive.

seated

a

blow torch

then knock it when

off

enough

new

to slip

onto

not

side of

the gear,

hit

flywheel

the

gear. expands

the flywheel. Make sure the gear is

of the

portion

If

removed

Runout Typical

this

from

gear

to

a

Do

heat any temperature higher than

the shoulder.

not

limit is exceeded, the temper

will

be

the ring gear teeth.

Converter Drive Plate The

evenly until the gear

gear

ring

engine

Do

the flywheel.

removing the ring

Heat the

the

on

against

properly

500F. with

Face

mounting

RING GEAR REPLACEMENT. Heat the defective ring gear

34 Flywheel

procedure

for Fordomatic Fordomatic

for checking the

equipped

cars

is

converter covered

drive

plate

in the 1957

Shop Manual.

9. CONNECTING RODS AND BEARINGS The connecting inspected

carefully

specifications.

these parts

A shiny

and

can

pin

skirt and

hole is

the

on

a

not

either a

of

should

be

conformance

to

caused

by

engine wear

grooves

pin

boss

connecting

in

proper

of

side rod

the

is bent

relation

to the

piston

or

the

bearing wear can be caused rod, an improperly machined

rod

bent connecting

tapered connecting

rod bore (Fig. 36). Twisted connecting rods will not create an easily identifiable wear pattern, but badly twisted rods will disturb the action of the entire piston, rings, and rod

crankpin,

assembly

or a

and

may

be

the

cause

of

excessive

oil

consumption.

piston

(Fig. 35).

Abnormal connecting

by

for

parts

be readily identified.

surface

ring

related

checked

Various forms

usually indicates that piston

and

rods

Cleaning

and

Inspection

Remove the bearings from the them if

they

are

rod and

to be used again).

cap

Clean the

(identify connect-

1-24

Chapter

1 General

Engine Service

PISTON WEAR CAUSED BY BENT ROD

OR MISALIGNED PISTON PIN HOLE

Fig.

ing of

35 Wear

rod

Pattern On Piston Pin Boss Surface

in solvent,

the inserts. Do

Blow

out

all

ing bores for maximum

not

rods

limit for

fractured,

the

signs

it

Check the

exceeds

should

be

piston pin

and

taper. The

out-of-round

worn

solution.

taper are 0.0004

and

these limits

and/or

if the

rod

replaced.

Inspect

have ent

Rod Side Clearance

Connecting

bushing clear bushing is so

rod

an

a

bearing

each

types

of

lowing

the

Fit

new

their

and

clearance of

For the differ

bearings that

bearings

where

refer

to

appear

to

causes

necessary, fol

recommended procedure.

After the connecting

over

or worn surface.

bearing failures

satisfactory.

Replace bearings that

carefully.

scored, chipped,

Fig. 27. Check the be

to connecting

37

Fig.

the bear

recommended

Replace the connecting rod if the that it cannot be reamed or honed for

ance.

the back

air.

fractures

of

and

cleaning

compressed

with

for

bore

rod

use a caustic

out-of-round and

inch. If the bore

is

including

passages

Inspect the

1045-A

check

the

ment

fixture.

rods are assembled

for bend

rods

twist

or

on

a

to the piston, align

suitable

size pin.

Replace defective connecting

Inspect

each

connecting

cracks, scratches, grooves,

fections

with

out-of-round,

should

rod

taper, be

or undersize. and/or

reground

crankshaft

or scores.

a smooth oilstone.

the maximum limits

they

rod nuts and

to

Check

journal for

minor

each

imper

journal for

If the journals

if they size

Dress

bolts.

The

manufacturer.

instructions

the

bend total difference using on each side. If the bend

an

inch

8-inch

and/cr

exceed

be

of

the

maximum

recommended

twist total difference is 0.012

rod should are

Follow

and

fixture

limit for

0.004 inch for

arbor and measured

twist is excessive, the

straightened or replaced.

severely marred,

for the

next undersize

Checking Connecting Bearing Clearance

bearing.

1. Wipe 2. Place surface

all oil a

from the journal

piece

the full

Rod

Plastigage

of

width

of

the cap

bearing.

and on

the lower

and about

bearing

Va inch

off

center.

3. Install the cap

and

foot-pounds torque. Do the

Plastigage is in

tighten the

not

rod

bolts to 45-50

turn the crankshaft while

place.

4. Remove the cap, then using the Plastigage check

in

the

to

order

Plastigage

IMPROPER GRINDING OF CRANKSHAFT JOURNAL

Fig.

36 Wear

Pattern On

1046-A

Connecting Rod Bearing

readings

limits,

get

at

of

the Plastigage

the

minimum

at

the widest point

clearance.

Check the

the narrowest point in order to get the

The difference between the two is the taper. If the clearance is not within

maximum

BEARING WEAR CAUSED BY BENT ROD OR

width

scale

clearance.

select

fit

a new

bearing.

9

Section

Fitting

New Bearings

The connecting m

standard

bearings

rod

sizes

and

red

for

are available

clearance; blue

use

If the

bearing is or

to the maximum diameter

not recommended to use

to file

bearing it is

bearings increase

marked

is out-of-round, be

crankpin

lap

or

the

bearing

When replacing practice to first try to

clearance.

good

clearance with two

blue

bearing

rod

cap, then

1. Remove the

from the cap

any type,

to

the

adjust

bearings, the bearing

the connecting

from the

oil

foreign

or other

matter

inserts. In time, the dirt may distort the and cause bearing failure.

4. Check the

5. If the

bearing

clearance.

specified

limit try two

or a combination of red and

6. If the

standard

the desired

within

blue.

bearings do

limits,

bearing halves is red bearing halves

two blue

with

clearance

grind

not

bring

the

clearance

the crankpin, then in

bearings.

stall undersize

standard obtain

halves. the bearings

remove

journal,

crankshaft

bearing bores. 3. Install the upper bearing into the rod assembly down firmly on the

Checking Connecting

Rod

Side Clearance

and rod.

2. Clean the

bearing

the crankpin. It

order

dirt

When instal

cap.

rod

the

less than the to fit the

shims of

in

not get

in the

clearance.

sure

of

bearing caps

color

are

bearing

do

ling bearings,

journals

on

bearings decrease

marked

service

1-25

Bearings

and

under

for

undersizes

blue. Red

and

Rods

Install the lower

that have been reground. Standard bearings coded

Connecting

and

rod

After the connecting rods are installed, clearance between the connecting rods on (Fig. 37). The 6-cylinder

the rod, then

pull

journal.

crankshaft

inch)

engines are

the

side

each crankpin

clearance

limits for

0.003-0.009 inch (wear limit 0.012

0.006-0.016 inch

or

side

recommended

check

on

8-cylinder

(wear

engines

limit 0.019 inch).

10. PISTONS, PINS, AND RINGS

Cleaning Remove from the varnish solvent.

with a

Do

scored

grooves

to

clean

and

pistons.

surface on

from the

be

If the

ring

side clearance.

with

eroded

(Fig. 38). Make

bosses, lower

ring

interfere

sure

the

oil

for scuffed, rough,

and

inner

portion

the

operation

the

the ring

at

ring

the

piston.

The step

cause

excessive

and

edge of

by detonation,

of

or

and/ or

Check the

or

the

piston

scale

following

holes,

pin

can

a

wear, wavy ring

damage from detonation piston and

to cylinder

ribbon

piston pins

and/or wear.

and rod

piston

offset

and

bore

the

or

lands, frac

pre-ignition.

clearance

ring

side

with

a

clearance

the recommended procedures.

Replace

ing

between the

show signs of excessive

tures,

the piston,

surface of

bent connecting rod. The normal wear piston is shown in Fig. 39. Replace pistons

by

caused

tension

replace

areas near

caused

cleaning solution or a Clean the ring grooves

the thrust

centerline

and rings with

pins,

the pistons for fractures

have high steps,

usually

gum or

are clean.

pin

will

are

head. Clean

piston

caustic

a

use

holes)

skirts.

Spongy,

piston surfaces and

that not

(or

skirt,

piston

skirt,

groove cleaner

ring

shiny

pattern of a piston

Carefully inspect

lands,

the

of

underside

from the

slots

Inspection

deposits from the

carbon

brush

wire

ring

and

showing

Check the

signs of

piston pin

fracture

or etch

fit in the

piston

bushing.

Replace

all

rings that

are

scored, chipped,

or cracked.

top

pre-ignition.

A

TOOL 7 521-61 10- A AD

NORMAL WEAR AREAS

1040- A

Fig.

38

Cleaning Ring

Grooves Typical

Fig.

39 Normal

Piston Wear Pattern

1041-A

1-26

Chapter

1 General

Engine Service

are

for

available

most

logue for

sizes available.

The

and

piston

temperature

block

cylinder

(70F)

Check the

engines.

the

when

be

should

room

at

fit is

piston

cata

parts

checked.

After any refinishing operation, allow the cylinder bore to cool before the piston fit is checked.

Calculate

the size piston to be used

(Fig. 45), then

check

provide the

desired

Make

the

sure

dry. Attach

the proper size piston to

select

bore

piston and cylinder

ribbon that is free should

be Vi-inch

bore

a

clearance.

tension

a

by taking

to the

scale

dents

of

or

wide and of

are clean and

feeler

end of a

burrs. The feeler the

for the existing condition. Position the ribbon in the bore

gauge ribbon

thick

recommended

ness

length

entire

the

of

piston

location. Invert the that the 1042- A

top

of

the

end of

is

the block and the

from the

at

pin

piston

install it in the bore

piston and piston

that it extends the

so

90

1 Vi inches below the

about

piston

so

pin

is

to the

parallel

crankshaft axis.

Fig.

40

Checking

Hold the

Piston Fit

line Check the

end

gap

and side clearance.

tice to always install new rings engine. piston

Rings to

should

another

not

when

It is

good prac

be transferred from

regardless

one

If the the

satisfactory.

scale

reading is

Pistons

Pistons oversizes

Pistons

for

of

use

in

for

service

cylinders

0.020, 0.030, 0.040,

in

standard sizes and

aged

and

0.060-inch

oversize

piston, then try

If the

that have been rebored.

able

recheck

pull,

piston.

If

check

dam

a

fitted,

minimum allow

before trying

calculations

be

none can

for

a new piston.

reading is less than the

scale

remove

to be sure that the

has been selected,

proper size piston

are available

to

required

than the maximum

greater

recheck calculations

pull,

a straight

limits for the existing condition,

within

fit is

piston

allowable

Fitting

is

pull

in

scale

(Fig. 40).

ribbon

If the

mileage.

of

the

pull

slowly

the ribbon, noting the pull

with

the feeler

overhauling the

piston and

refinish

another

the cylinder for the

next size piston.

When

a

has been

piston

fitted,

it for

mark

sembly in the cylinder to which it was fitted. If the taper and out-of-round conditions of the

der bore

are

satisfactory cylinder

bore is

The

cylinder piston

as

used

a

the

cylinder wall

proper

rings must

bore

and

grooves.

set

ring

be

First,

where

head

avoid

Fig.

41

Measuring

Piston

Ring

10*

Gap Typical

the

used.

normal

rings

for

size

piston

check

in the are

to

each

ring for

to be

gap in the

proper

proper side clearance

in the

proper

gap

which

it is

down into the bore

area

square

damage

cylinder

Push the

ring

of a piston

ring is

WD

new

give

follows:

going to be

:.

will

"glaze."

for the

checked

for the

rings

cylin

that has not been re

cylinder

Position the ring in the

)

the

piston

piston clearance

limits. If the

within

remove

Select the used.

new

service provided

be installed in

finished,

limits,

within

as

to

with

wear

ring is

position

the

encountered.

(Fig. 41). The gap 0.010-0.027 inch for both

wall.

Use

or cylinder

ends

Use the

the ring in the bore

cylinder

to the ring

gap between the

not

bore in

of

the

ring

be

so

caution

the to

bore. Measure with

a

feeler

gauge

should

within

the limits

of

compression rings

(223, 272,

10

Section 292

inch engines) The gap of the

cubic

engines).

be

should

0.012-0.029 (312

or

steel rail sections of

cubic

1-27

Rings

and

inch

the oil ring

0.015-0.062 inch. If the gap is less than the lower limit, try

ring

Pistons, Pins,

within

another

set.

After the gap has been checked, install the rings on the piston according to the instructions on the piston ring package using the side

clearance

42).

the compression rings

of

inserted between

gauge

Any

the ring

that occurs

wear

portion of

the lower land.

steps, the

piston should

freely

slide

the

around

binding. Because

out

If

be

the

the

piston

fit

pin

blue)

Pins

circumference with

ring

to the

refer

be

of

0.002 inch

and

hole in the

pin

expansion-type, piloted and

the

to

reamer

slightly

light

cut.

the

revolve

reamer

tain

gauge should

limits

specifications

light thumb

a

0.001 inch oversize

pins

piston

1044- A

(color

oversize

(color

fit

press

42

Checking Ring

cut.

Repeat the

Fig.

coded yel

Side

Clearance Typical

are available.

If the

vise

The

(70F). Standard

temperature

normal

low)

lower lands have high

recommended clearance

should

are color coded green.

coded

the inner

at

step

Piston Pins

Fitting at

feeler

a

limits.

proper

The

a

replaced.

entire

with

ring

its lower land (Fig.

and

form

will

vary according to the engine,

for the

tool. Check the

approved

Use

reamer.

piston around

trial

and

bore,

ream

the

a pilot sleeve of

the

alignment of

the

reamer.

then

Set the

expand

the

bore. Take

pin

nearest size

to

is

bushing

main

to fit the

Install the

new piston pin.

If the

and

make

reamer

slightly

piston

pin

retainers

seated

fit

proper

for fit in the

ream

or

hone the

pin. pin

in the

a new retainer at each end of

properly

the

pin

piston

bushing. If necessary,

rod

respective

until

procedure

Check the fitted

obtained.

When the

the

expand

another

a

bores.

Check the hole size, using the

bore is small,

the

pin

the

of

size

be reamed, use an Place the reamer in a

piston must

the

grooves

and

rod.

Install

to hold it in

pin

installed,

are

in the

piston

make

sure

provided

place.

they

in the

are

piston

bore.

11. CYLINDER BLOCK of

the

cylinder

overhaul, closely inspect the

engine

parts

disassembly

the

During to

help diagnose

the

for

block

wear pattern on all

ent, the coating area.

cause of wear.

Cleaning

Thoroughly gasket

pipe

the

material

compressed

are

and result

threads

from

which

plugs

passages.

holes

clean

Blow

air.

and

a

to

oil

seal

passages, then

bolt

out all p? ssages, sure

false torque

clean

for

cracks.

reading.

Use

a

Minute

may be detected by mixture of 25% kerosene

Wipe the

part

dry

all

recommended

for the

and

and

Replace

binding

of

to the

naked

suspected area with

75% light

immediately

apply

a

motor

coating

oil.

of

at

the defective

for

burrs,

nicks,

imperfections

with

the cylinder block

of

the procedure and specifications

cylinder

head (page 1-11). that show evidence

all expansion-type plugs

leakage.

To

an

remove

hole in the

expansion

center of

flange

of

install it plug in casting

the with

until

new

type plug, drill

the plug

in Fig. 43. Clean the plug make a

minor

Check the flatness

following

tap to true-up

cracks not visible

coating the

stone.

Remove

gasket surface

the threads in the head bolt cause

oil

and scores.

cracks are pres

cracked.

gasket surfaces

all

any deposits.

eye

a

out

an

etc. with

After the block has been thoroughly cleaned, check

old

Remove

holes,

Dirt in the threads may

remove

Remove

solvent.

If

become discolored

machined

all

scratches,

machined surfaces.

all

Make

clean.

in

the block in

will

wood alcohol.

Replace the block if it is

Check

Inspection

and

dissolved in

zinc oxide

plug

the flange

and remove

recess

with

it

a as

V2-inch shown

thoroughly. Coat the

water resistant sealer

facing

out

the flange is flush

and

(Fig. 44). Drive the

or

slightly below the

surface.

Inspect the

cylinder

walls

for scoring, roughness

or

1-28

1 General

Chapter

Engine Service CENTERLINE OF ENGINE A

A-AT

RIGHT ANGLE

TO CENTERLINE OF ENGINE

B"

PARALLEL TO

CENTERLINE OF

ENGINE

DRILL V2 INCH HOLE IN PLUG

43 Expansion-Type

Fig.

Check the

other signs of wear. and

gauge

following

bottom

and

parallel

Rebore

that

out-of-round and/or

If the

cylinder

tions, but

the

it may be

possible

ing

the

rings

the

taper

to

wall

providing the

the

deeply

have

walls

of

bore

the

at

wear

surface

the

grade of

CYLINDER BORE AND THE A MEASUREMENT AT BOTTOM

Fig.

is

is determined by the

imperfec

coarse

leave

Honing only

when

is

the

walls

the

Cylinder

light scuffs, scratches,

etc.

The

cylinder walls

imperfections,

grade of

that

honing

If

operation,

be

can

marks

is

which

severly

limits

such

used

to

obtain

marred and/or worn

should

be

Before

rebored.

hone to be

used

boring

bearing bores

the

clean

up

will not

therefore,

cylinder with

bored for the

when

cylinder

finish

and pattern are obtained.

For the

personnel

of

should

After the final

ing

TOOLT54L-6015-A

ALL CORE PLUGS ON 8-CYLINDER BLOCK

methods

piston

vent

dry. Check the Installation

to

be

correspond

for this the

allowed

operation

described

remove

all

of

honing

in

piston

boring to

wash

clean

equipment

Only

perform

either of

the

will allow

the correct

so

Use

sharp

follow

experienced

this

work.

the two

above and prior

abrasive

piston

not

operation.

the manufacturer.

fit, thoroughly

to

of

use

proper

the instructions

8-CYL. CAM BEARING BORE PLUG ALL PLUGS ON 6-CYLINDER BLOCK

diameter. This

surface

grit

will

approximately 0.0015

within

for the final step

No. 220-280

first to deter

maximum oversize

stock

of

be

block.

oversize

required

can

cylinder

enough

hones

TOOLT52L-6266-BGD

to

and

standard

most wear

If the

oversize.

maximum

the

the

it.

balance.

engine

upsetting

require

pistons

sized

various

without

Rebore the of

that the

so

that

weight, both

same

recommended, replace the

inch

be

caps must

become distorted from

cylinder or cylinders

the

are

pistons

mine

bearing

main

operation.

Rebore only the

All

all

to the proper torque

place and tightened

the

as

is rebored,

cylinder

Rebore the

Plug

the

manufacturer.

that all hone

so

are

specified

intermixed

44 Expansion-Type

start

finishing hone

the

walls

beyond the

oversize;

f/g.

hone

operation.

in

for refinishing minor

the

removed.

proper piston clearance.

crankshaft

have

material

enough

removed with

limits.

Cylinder Walls

recommended

to

used

are

stones

of

to be

metal

of

amount

Follow the instructions

limits.

any

Refinishing

Bore Out-Of-Round And Taper

(Fig. 45).

within

for this

stone

45 Cylinder

are within

clearance

honing

1039-A

top,

limits, remove the imperfections by hon and installing new service piston taper

DIFFERENCE BETWEEN A AND B

=

DIFFERENCE BETWEEN THE A MEASUREMENT AT TOP OF

=

manufacturer.

engine

minor

and

piston

OUT-OF-ROUND TAPER

accurate

scored and/or when

approach

out-of-round

cylinder

Use the finest

are

1. 2.

OF CYLINDER BORE

the

of

an

out-of-

gauge placed at right angles

to the centerline

cylinders

with

of each cylinder

with

bore for

cylinder

the instructions

Measure the diameter

and

Removal

Plug

taper. Measure the bore

round

middle,

1037-A

refinish

to checking the

cylinder walls with sol

particles, then

thoroughly

fit (page 1-26). Mark the

to the cylinders in

which

they

pistons

are

to be

Section 1 installed. When

the

refinishing

it has been

require

thoroughly

clean

completed

the

bearing bores,

Coat the

cylinder walls with oil.

When

all

and

block to

entire

from the

Cylinder Wall

of

"Glaze"

new piston rings are

fitted,

pistons

has

1-29

Block

not

been

refinished,

cylinder

walls

to

in ring

aid

the

remove

from

glaze

Take

holes,

Removal

installed in

that

fine

Pass

a

bore

a

rough

a cylinder

all

etc.

and

the necessary grit

hone

up the finish.

block

after

not

hone

Thoroughly

the

to

precautions

or glaze removal

few times. Do

glaze

the

seating.

remove all particles

passages, head bolt

oil

that

cylinders

all

1 Cylinder

the

grit.

tool through the than

more clean

catch

the

enough

to

cylinder walls

is removed, then

oil

the

walls.

12. OIL PAN AND OIL PUMP

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

Wash the

oughly.

Be

below

sure

Check the

threads,

a

dry it

and

is

matter

thor

from

removed

plate.

for cracks,

pan

loose

solvent

a

foreign

all

baffle

the

in

pan

.

baffle,

damaged drain plug

holes,

and

nicked

a

or

warped

gasket

surface.

Repair any not be made.

damage,

Rotor-Type Oil

or replace

the

pan

if

repairs can

Pump

(8-Cylinder Engine) Wash Use the

a

all parts

brush to

in

dry

a solvent and

the inside

clean

of

Be

sure

housing

and

dirt

and

all

chips are removed.

race and rotor

cover

for damage

Measure the 46). The With

housing

the pump

and

Check

defective,

the

relief

replace

valve

in the bore. The

the

outer

0.0015-0.0029 inch.

for

wear.

Gear-Type Oil

cover

is worn, scored,

straight

or

grooved,

edge and

the

Clearance

the

spring.

for

piston

specified

scores

free

and

piston clearance

is

Pump

(6-Cylinder Engine)

outer

as

an

are

(Fig.

in

Wash

Use

a

rotor

clearance

brush to

the pressure

housing,

the

assembly

between

all parts

and

the

are

in

clean

relief

dry

a solvent and

the inside

of

the pump

valve chamber.

removed.

the

Remove

old

them thoroughly.

Be

housing

and

dirt

and

sure all

gasket

material

from

straight

(Fig. 47). The

Straight Edge recom

0.001-0.0035.

race,

shaft

and

rotor

are

replaceable

assembly.

Check the drive

shaft

measuring the O. D.

housing

clearance

chips

rotor and outer race

limits

mended

installed

the

over

the

housing

be from 0.006-0.009 inch.

assembly

edge

Measure

to

race

should

rotor

housing.

only

surface of

outer

clearance

the

a

The

Housing

or excessive wear.

surface

mating

Race To

the cover.

replace

place

the pump

of

Check the mating

If the

the spring is

operation

Check the inside

46 Outer

them thoroughly.

the pump

chamber.

valve

relief

pressure

Fig.

bearing. The

of

to

housing bearing

the

shaft

and

clearance

the I. D.

clearance

recommended

by

of

the

limits

are

0.0015-0.0029 inch.

Inspect the

relief valve

spring for

a collapsed or worn

condition.

Check should

the

exert

If the spring

relief

a

valve

pressure

tension

is

of

spring

9.2-10.4

not within

tension.

The spring

pounds at

1048- A

0.80 inch.

specifications

and/or

Fig.

47 Rotor

End

Play

1-30

the pump

or

1 General

Chapter

body

and cover.

gage

Inspect the pump body and the gear teeth for damage wear. Check the gear end clearance with a dial indi

cator or

Plastigage. The Plastigage

Position the

gasket on

Engine Service

the

method

is

as

follows:

then place Plasti

housing,

on

the gears

cover and

check

Check the

the

the Plastigage

gears

the

pression of

for freedom

the

relief

Remove the

cover.

reading.

Check the

of rotation.

oil pressure relief valve

of

clearance

install the

and

valve

spring

in the

com

and check

valve chamber.

13. EXHAUST SYSTEM The

and excessive vibration.

heard

at

system

in

or

visually,

the

are

of

some

pipe

a

cases,

restrictions, leaks

usually be detected

can

connections.

may be

noise

whistling

All the

parts

the

of

13A inches. To

tions, the

leaking

or

inlet

and

by

inlet

and

burning

outlet outlet

the

for

through. The slots in the

extensions

pipes,

the overlap in either case

exhaust system

respectively.

should

not

be

pipe

However,

greater

than

burning possible

"kick-up"

and

insufficient, Exhaust

broken

or

system

Replace

connec

as outlined

all sections

interference between the

floor

the

If the

pan.

outlet pipe

are

vibrations

improperly

the muffler

in

that

through.

the

reposition

at

and outlet pipes

respective engine chapter.

show signs of

be blocked

should

leakage

correct

the inlet

position

Check for

various sections of

muffler

the

Leaks

of

replaceable.

Check the signs

be free

exhaust system must

aligned

in the

clearance

is

muffler.

usually

clamps.

outlet

Align

caused

by

or replace

clamps as necessary.

14. ENGINE DIMENSIONS, AND CLEARANCE AND ADJUSTMENT SPECIFICATIONS NOTE: All

specifications are given

in inches

unless otherwise noted.

Engine Cubic Inch Displacement Item

272

223

292

312

CYLINDER HEAD 0.003 in any 6 inches

Gasket Surface Flatness

Valve Guide Bore Diameter (Int. & Exh.) Valve Seat Width

or

0.006 inch

overall

0.3433-0.3440

Int.

0.060-0.080

Exh.

0.070-0.090 45

Valve Seat Angle Valve Seat

Runout-Maximum

Valve Seat

Runout Wear

0.002

0.0025

Limit

VALVE MECHANISM

Valve Lash

(Cold) Int. & Exh. (Hot) Int. & Exh.

Valve Stem

Diameter Standard

Valve Lash

0.019 0.019

Int.

0.3416-0.3423

Exh.

0.3403-0.3410

0.003, 0.015, 0.030

Oversize Valves Available (Int. & Exh.) Valve Stem Diameter 0.003 O.S.

Int.

0.3445-0.3455

Int.

0.3565-0.3575

Valve Stem to Valve Guide Clearance

Valve Stem to Valve Guide Clearance Wear

Limit

Valve Head Diameter

Int.

0.3566-0.3573 0.3555-0.3565

Exh.

Valve Stem Diameter 0.030 O.S.

0.3446-0.3453

0.3435-0.3445

Exh.

Valve Stem Diameter 0.015 O.S.

0.020

0.3715-0.3725

0.3716-0.3723

Exh.

0.3705-0.3715

Int.

0.001-0.0024

Exh.

0.0023-0.0037

Int.

0.0045

Exh.

0.0065

Int. Exh.

1.775-1.785

1.920-1.930 1.505-1.515

Section 1

4 Engine

Dimensions,

and

Clearance

and

1-31

Adjustment Specifications

Engine Cubic Inch Displacement Item

223

292

272

VALVE

MECHANISM (Cont'd) Valve Seat Face Runout (Int. 65 Maximum

Exh.)

0.0015

Valve Seat Face Runout (Int. 6b Wear Limit Int. Valve

(Opens) Tappet

Lift

Exh.)

0.002

@

Degrees B.T.C. Int. Valve

17

(Closes)

Tappet Lift

53

Exh. Valve (Opens) Tappet Lift Degrees B.B.C.

@

Exh. Valve (Closes) Tappet Lift Degrees A.T.C.

@

Int. Valve

(Opens) Tappet

Lift

61

9

25

(Closes) Tappet

Lift

0.019

@

0.016

@

0.019

@

0.100

@

0.100

@

0.100

@

0.100

58

66

10

22

11

Exh. Valve (Opens) Tappet Lift Degrees B.B.C.

@

Exh. Valve (Closes) Tappet Lift Degrees B.T.C.

@

21

33

18

27

29

Valve

i

Spring Free Length (Approximate) Valve Spring Out of Square (Maximum) Valve Spring Pressure (Lbs.) @ Specified Length (Valve Closed) Valve Spring Pressure (Lbs.) @ Specified Wear Limit Length (Valve Closed) Valve Spring Pressure (Lbs.) @ Specified Length (Valve Open) Valve Spring Pressure (Lbs.) @ Specified Length (Valve Open) Wear Limit

Valve Tappet Diameter

71-79

@

@

64

0.015

@

0.013

@

0.016

@

0.100

@

0.100

@

0.100

@

0.100

145

1.780

1.780

@

161-177

@

1.390

1.390

7.98 0.020

0.4989-0.4995

Valve Tappet to Tappet Bore Clearance

0.0005-0.0021

Clearance-

0.0026

Rocker Arm to Rocker Shaft Clearance Rocker Arm to Rocker Shaft

@

0.062

(Maximum) (Standard)

Valve Tappet to Tappet Bore Wear Limit

0.015

2.09

9.62

Valve Push Rod Length Valve Push Rod Runout

@

@

Degrees A.B.C.

j

@

18

@

Degrees A.T.C. Int. Valve

0.016

@

Degrees A.B.C.

!

@

0.002-0.004

Clearance-

0.006

Wear Limit Rocker Arm Shaft O.D.

0.780-0.781

Rocker Shaft Bore Diameter

0.783-0.784

CAMSHAFT AND TIMING CHAIN

Journal Diameter :

Journal Runout

1.9255-1.9265

(Standard)

0.005

(Maximum)

Journal to

Bearing Clearance

Journal to

Bearing

Clearance Wear

0.001-0.003 Limit

Undersize

Bearing Available

0.015

Camshaft Runout

Timing Sprocket Front Face (Assembled) Maximum

0.008

Timing

V2

Chain Deflection

Camshaft Lobe Lift

Int.

0.273

0.272

Exh.

0.273

0.285

Max. Allowable Lobe Lift Loss Int. & Exh. 1

0.006

0.005

312

1-32

Chapter

1 General

En

pan and gasket.

NUT SCREW

LOCKWASHER

INSTALLATION

1. Make

the

sure

the block

of

surfaces

gasket

and

free from burrs.

pan are clean and

2. Coat the block

surface and

HOUSING PLUG SPRING

oil

gasket surface

pan

DRIVING GEAR

the

with sealer and position

3. Hold the a screw,

in

finger tight,

4. Install screws

pan

the

from the

gasket on

place against at each

end

of

in

center outward

oil pan.

the block

screws,

remaining

the

the

install

pan.

then

each

and

tighten

direction to

12-

*

5. Install the flywheel housing inspection stabilizer

7. Install the

engine right and

8. Install the

oil

quantity oil

leaks.

of

level

dip

crankcase

engine

oil.

SCREW

cover.

SCREW

bar.

6. Install the

the

COVER GASKET

COVER INLET TUBE GASKET

15 foot-pounds torque.

9. Fill

DRIVEN GEAR

the

left front

splash aprons.

COVER AND INLET TUBE ASSEMBLY

stick.

with

the

Run the

proper

engine

and

grade check

SCREEN

and

SNAP WIRE

for Fig.

32 Oil

Pump

1085- A

1-54

2 6-Cylinder

Chapter

FILTER ADAPTER

Engine

ASSEMBLY

FILTER

1.

Apply

light

a

2. Install the and plug.

ADAPTER

GASKET

1083-A

Fig.

33 Oil

Filter

the

Thoroughly

ket,

and gasket.

the mounting

the

clean

pad on

old

the block

gasket

play

of

gears.

Apply then

to both

sealer

the

position

5. Install the

and pump.

sides of

the pump

the

gasket on

cover gas

Install the

pump.

tighten the retaining

not

screws.

the

with

in the

screen

screen

secure

and

cover

retainer.

6. Install the inlet tube gasket, and the inlet tube assembly on the pump cover. Tighten the retaining

DISASSEMBLY

1. Remove the

cover

remove

move the cover

end

from

material

it

screws, then

Check the

gear.

Assembly

pump cover, but do

4.

assembly into the

shaft

and

gear

housing. Install the driven

4.

3. Remove the pump

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

relief

pressure

3. Slide the drive

FITTING

to all moving parts.

coat of engine oil

inlet tube assembly retaining

the tube assembly,

retaining screws, cover,

and gasket.

Re

12-15 foot-pounds torque. Rotate the pump

to

screws

by hand

shaft

to

it turns freely.

make sure

and gasket.

INSTALLATION

2. Push the pump drive

bly from

shaft and

drive

gear assem

the pump housing. Remove the driven gear.

1. Place

3. Remove the spring,

oil pressure relief valve chamber

plug,

install the lock

the

4. Remove the snap and remove

the

wire

the

and

nuts.

washers

bolts,

retaining

oil

the

slide

Tighten the

and

nuts

to

and

pan.

retaining the pump screen,

2. Fill

from the housing.

screen

over

bolts,

foot-pounds torque. Install the distributor

30-35

and plunger.

flange

mounting

pump

the retaining

a new gasket on

quantity

POSITION OF OIL FILTER ADAPTER PLATE

for

the of

oil.

Run the

oil pressure and oil

the

with

crankcase

engine

at

proper

and

grade

fast idle

and

check

the

car as

leaks.

Oil Filter Replacement The

filter assembly is

oil

The filter is

shown

in Fig. 33.

from the bottom

removed

of

follows : 1. Place from the

a

drip

cylinder

2. Check to positioned

pan under

the filter. Unscrew the filter

block. if the filter

see

adapter plate

(Fig. 34). Clean the

cylinder

is properly block filter

recess.

3. Coat the the

filter in

filter

until

advance

OIL FILTER ELEMENT

11 24- A

34 Oil

Filter Replacement

on

position

on

the filter

oil, then place the block. Hand tighten the with

the gasket contacts the adapter

face,

then

it V^-turn.

4. Operate the leaks. If

Fig,

gasket

oil

engine

leaks

repairs

to

fill the

crankcase

correct

are

at

fast idle,

evident,

perform

and

necessary.

for

the necessary

the leakage. Check the oil

if

check

level

and

Section 1 1

outlet

parts

exhaust system consists of a

pipe, are

and

a

muffler

provided

as

inlet

pipe

individual

proximately 45 degrees

muffler, a muffler (Fig. 35). These

service

When

parts.

clamps after

the

directly

positioned

exhaust

and

the muffler inlet pipe clamp. Slide the muffler to the

Loosen the

rear, then separate the muffler

and

outlet

inlet

pipe

pipe.

away from the

to

the

manifold.

clamps

the

blocked. Do

muffler more than

3. Install

haust

the

the

slots

slide

pipe

into

the

connect

the

muffler on

directly

exhaust manifold out

sembly.

manifold.

4. Tighten the bolts to 23-28 foot-pounds torque.

until

extension

blocked. Do

5. Position the muffler, then tighten the outlet pipe clamps. Rotate the inlet pipe clamp downward ap

than

clamp

forward

on

extension

to

it

outlet

pipe.

on

the inlet

the inlet pipe are

until

blocked. Do

not

the inlet pipe more than 1 % inches. pipe

clamp

outlet

the slots

not

and slide

muffler

muffler

and

clamp downward opening

outlet pipe upper

Slide the

rear

muffler.

clamp

is

the slots in the muffler

opposite

5. Install the

ex

the

so

mately

muffler

muf

pipe

outlet

from the

Remove the

muffler

45

the inlet pipe to the

new

muffler

in the

slots

the

of

to

outlet pipe

assembly from the inlet

4. Rotate the inlet

1 ZA inches.

a new gasket on

let flange studs, then

not slide

slide

Slide the

to

the

frame bracket from the frame.

and

muffler

3. Position the pipe.

pipe

muffler.

clamp

Remove the

Remove

2. Slide the clamp on the new inlet pipe, then the inlet pipe into the muffler extension until the extension are

upper

pipe

the inlet pipe and gasket.

in the

outlet pipe

2. Loosen the inlet pipe

of

the lower half

and

Separate the

clamp.

the inlet

muffler

clamp.

1. Remove the lower half

fastening

in the

slots

Muffler Replacement

Inlet Pipe Replacement nuts

the

opposite

not

part

fler clamp,

1. Remove the two

is

the clamp opening

so

extension, then tighten the

replacing any part of the exhaust system, loosen all the frame attaching bracket clamps to relieve twists in the system, then tighten the is installed.

]-55

System

EXHAUST SYSTEM

11. The

Exhaust

slide

pipe

positioned

extension.

clamp

and

frame

forward into the

in the

the

not

approxi

pipe

muffler

into the

as

muffler

extension

muffler

are

more

13A inches.

:-r.~

\

MUFFLER OUTLET PIPE

MUFFLER INLET PIPE REAR BRACKET

INTERMEDIATE BRACKET

10 86- A

.

Fig.

35 Exhaust

System

1-56

6.

Connect, but do

outlet

pipe

front

7. Check for pipe

pipe

2 6-Cylinder

Chapter

and

and

the

of

the

outlet pipe.

3. Slide the

clamps.

interference between the

outlet

sion

the floor pan. Reposition the

outlet

However, do

Tighten the

necessary.

the lower half

tighten,

rear

possible

"kick-up"

if

not

Engine

until

the

slots

not

nect, but do

Outlet Pipe Replacement

5. 1. Remove the lower half the

muffler, then

remove

the clamp

of

the

rear

at

slide

the

rear

clamp from its

not

Connect,

clamp

at

the

rear

support.

but do

rear of

6. Check for pipe

muffler and outlet

pipe, then

12.

remove

pipe

not

the

into the

pipe

blocked. more

muffler

necessary.

on

the

it to its

outlet

pipe

and

con

support.

tighten, the lower half

of

muffler. outlet

the floor pan. Reposition the

outlet

Tighten the

outlet pipe clamps.

GENERAL SPECIFICATIONS 6-CYLINDER ENGINE

Note: The

engine

fits, tolerances,

and adjustment specifications are

listed

at

the

end of

Chapter

1 GENERAL

ENGINE SERVICE.

All

in inches

specifications are given

Piston Displacement

Bore

and

(cubic

unless otherwise noted.

223

inches)

3.62

stroke

Compression Ratio

Engine Fuel Requirements

Brake Horsepower Torque

at

@ Cranking

Speed

150

rpm

Specified Engine

rpm

Firing Order

@

4200

212

@

2400

E-I-I-E-I-E-E-I-E-M-E

Rear)

Taxable Horsepower

31.54

rpm:

Conventional & Overdrive Transmission

475-500

Fordomatic

475-500

(Neutral)

Fordomatic (Drive Engine Idle Manifold

425-450

range)*

Vacuum Inches of

Mercury @ Specified Engine Idle Initial Ignition

rpm

(Sea

18-19

Level)

Timing (B.T.D.C.)

Conventional & Overdrive Transmission

4

(Maximum

6)

6

(Maximum

8)

Fordomatic

Oil

Capacity

(psi)

@

2000

45-50

rpm

SAE 20-20W

+32 F

+32F to

Below

Hot

Viscosity @ Specified Ambient Temperature:

Recommended Oil

Above

4

(Quarts)**

Oil Pressure

SAE

-10F

Engine

Final Add 1

idle

quart with

10W

of

MM

Lubricating Oils

engine

10-

SAE 5W

-10F

Recommended Minimum A.P.I. Classification

**

144

1-5-3-6-2-4

Valve Arrangement (Front to

*

3.60

Regular

Specified

@

(Foot-Pounds)

Engine Idle

x

8.6:1

Compression Pressure-Sea Level

rpm

filter

to be change

checked

in drive

range and

readjusted

to

the

interference between the

possible

and

if

clamp

tighten

"kick-up"

2. Separate the

muffler extension are

the

exten

muffler

than 13A inches.

outlet pipe clamps.

4. Slide the

of

in the

into the

pipe

outlet

new

specifications

if necessary

Section 1 TORQUE LIMITS Main

2 General Specifications 6-Cylinder

1-57

Engine

(Foot-Pounds)

Bearing Cap

Bolts

95-105

Cylinder Head Bolts (Hot)

75

Oil Pan to Cylinder Block

12-15

Flywheel

75-85

Crankshaft

to

Exhaust Manifold

to Cyl. Hd.

23-28

Intake Manifold to Cyl. Hd.

23-28

Oil

Pump

30-35

Oil

Pump Cover Plate

to Cyl. Block

12-15

Cyl. Front Cover Water Outlet

6-9

Housing

23-28

Rocker Arm Cover

2.0-2.5

Cam Sprocket to Cam

45-50

Damper

Crankshaft

85-95

Rod Nuts

45-50

to

Connecting

Connecting Rod

Pal Nuts

3-4

Rocker Shaft Support to Cyl. Hd.

45-55

Valve Rocker Arm Adj. Screw (Self

Locking)

Minimum Torque to Rotate

3

Push Rod Chamber Cover

Water Fuel

Pump

Pump

to

12-15

Cyl. Block

to Cyl. Block

or

(Inch-Pounds) 23-28

Cyl. Front Cover

12-15

Crankcase Vent Adapter to Cyl. Block

8-10

Engine Front Support

45-50

Bracket to Engine Bolts Insulator

Assembly

to Engine Bracket

Insulator

Assembly

to Frame Nuts

Bolts

50-60 45-50

Engine Rear Support Support Retainer to Extension

Housing Bolts

50-60 23-28

Support to Frame Nuts

TORQUE

LIMITS

CAUTION:

FOR

In the above

Size

Size

event

limits

(Inches)

Torque

(Foot-Pounds)

(Inches)

Torque

VARIOUS

(Foot-Pounds)

SIZE BOLTS

that any of the

below limits

are

in disagreement

with

any

of

those listed above, the

prevail.

i/4-20

i/4-28

5/i6-18

5/ie-24

%-16

%-24

6-9

6-9

12-15

15-18

23-28

30-35

7/i6-14

7/ie-20

i/2-13

i/2-20

9/i6-18

%-18

45-50

50-60

60-70

70-80

85-95

130-145

1-58

1- ENGINES

Part

Chapter 3

8-CYLINDER ENGINES Section

Page

1

Description

2

Engine Removal

3

Engine Supports

1-64

4

Manifolds

1-66

5

Cylinder Heads

6

Crankshaft Damper, Cylinder Front Cover, and Crankshaft Oil Seal Sprockets and Timing Chain, Camshaft, Bearings, and Tappets

1-70

1-75

10

Flywheel, Crankshaft, and Main Bearings Connecting Rods and Bearings, Pistons, Pins, Oil Pan, Oil Filter, and Oil Pump

11

Exhaust System

1-81

12

General Specifications

1-83

7 8

9

1-58

Installation

and

1-61

Exhaust Gas Control Valve

and

Valves

and

1-67

and

the

are

same

in this

covered

for

all

8-cylinder

the

The

chapter.

1-79

wise noted.

The cleaning,

procedures are

engines

unless

1-77

Rings

The removal, disassembly, assembly, and installation procedures for the component parts of the 8-cylinder engine

1-72

engine

inspection, instructions

overhaul

are

procedures

repair

and

in Chapter

covered

1,

Service."

"General Engine

other

and

1. DESCRIPTION All the 8-cylinder

The

various

engine

placement, bore

have the

engines

models

same

basic design.

differ only in

diameter, length

of

stroke,

The

dis

piston

the

is

engine

2. The differences between the application are

The

and are

2, 3, firing

8. The arranged

and

their

and

4

and

is

order

from front to

on

rear on

the left bank

5, 6, 7,

1-5-4-8-6-3-7-2. The both banks

rear on

An

the

valves

stem

The

provides

1 Engine

The

valve

valve

and

The

valve

more

rotate

each

guides

and an

are

time the valve

rotation permits self

umbrella-type

stem.

Valve

mechanism.

and exhaust valve assemblies are

which

guide opening.

E-I-I-E-

E-I-I-E.

Table

arm

minimizes

the valve

the valves

assemblies contain

the head.

part of

and closes.

seating,

from front to

rocker

rotating-type

listed in Table 1.

bank 1,

right

engine models and

cylinders are numbered

head

Both the intake

in Figs. 1

shown

valve

integral

compression

ratio, power output, and carburetor equipment.

A typical 8-cylinder

cylinder

warpage, stem

extends

seal

over

seal controls

springs

positive

cleaning

have

fits the

top

lubrication

equal

valve

over

coil

action

better

sticking.

the

of of

top

of

the valve

the

spacing

at

opens

and

and

wear,

the

high

valve which

engine

Model Application

Engine Prefix

Piston Displacement (Cubic Inches)

Compression Ratio

Type Transmission

Carburetor

Fuel Required

Car Model Application

EGG

272

8.6:1

All

2-Barrel

Regular

Custom

EDB

292

9.1:1

All

2-Barrel

Regular

Fairlane, Station Wagons,

Type

Thunderbird*

ECJ

312

9.7:1

All

4-Barrel

Premium

All**

ECJ

312

9.7:1

All

Dual 4-Barrels

Premium

Fairlane, Station Wagons, Thunderbird and Police Interceptor

Available Available

**

on on

Thunderbird Thunderbird

with

conventional

with

Overdrive

transmission

and

only.

Fordomatic Transmissions

only.

LITHO IN U.S.A.

FORM 7098-57