DEMO - 1959 Ford Thunderbird Shop Manual - ForelPublishing.com

1

FORD

FORD PORD

DIVISION

MOTOR

COMPANY

SHOP MAM

J

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

1959 Ford Thunderbird Shop Manual EAN: 978-1-60371-009-1 ISBN: 1-60371-009-4 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

IGNITION, FUEL, AND COOLING SYSTEMS

CLUTCH AND MANUAL-SHIFT TRANSMISSIONS

CRUISE-O-MATIC TRANSMISSIONS

THUNDERBIRD

REAR AXLE AND DRIVE LINE

WHEELS, TIRES, CHASSIS SUSPENSION, AND UNDERBODY

STEERING

BRAKES

GENERATING AND STARTING SYSTEMS

LIGHTS, INSTRUMENTS, AND ACCESSORIES

BODY MAINTENANCE AND REPAIR

DOORS, DECK LID, AND FRONT SHEET METAL

INTERIOR

TRIM, SEATS, AND WINDOWS

CONVERTIBLE TOP SE RVICE

DEPARTMENT

FORD

DIVISION

FORD

MOTOR

COMPANY

1958 FORD MOTOR COMPANY.

Reprinted with Ford Motor

DEARBORN. MICHIGAN

Company's Permission

MAINTENANCE, LUBRICATION, AND SPECIAL TOOLS

FOREWORD This

manual provides

information for the

Thunderbird. The descriptions manual were

in

effect at the

discontinue or

time the manual was approved

models at

design,

servicing of the 1959

and specifications contained

The Ford Division of Ford Motor to

proper

any time,

Company

for

in this

printing.

reserves the right

or change specifications

without notice and without

SERVICE

FORD FORD

incurring

obligation.

DEPARTMENT

DIVISION

MOTOR COMPANY

I THUNDERBIRD SHOP MANUAL

GROUP

ENGINES EXHAUST

AND

SYSTEM

PAGE

1-2

PART

1-1

PART

1

-2

THUNDERBIRD 352 SPECIAL V-8

1-23

PART

1-3


1-48

PART

1-4

EXHAUST SYSTEM

1-72

PART

1-5

SPECIFICATIONS

1-74

GENERAL ENGINE SERVICE

I

12

PART

The

service procedures

both

apply to

1-1

430 Special V-8

and


inspection,

cleaning,

ing

of the

apply

from

moved case

Page

Section

Page

1 Engine Trouble Diagnosis.

1-2

Exhaust Manifold

2

1-8

Valve Rocker Arm Shaft

Tune-Up

3 Tests and Adjustments (Engine Installed) Camshaft Lobe Lift

1-12

Push Rods

1-12

1-9

Cylinder Heads

1-12 1-13

Valve Clearance

1-9

Hydraulic Valve Lifters.

1-15

Manifold Vacuum Test.

1-10

Timing Chain

1-10

Camshaft

1-11

Connecting

1-11

Pistons, Pins,

Compression Test 4

Assembly 1-9

Cleaning, Inspection, Intake Manifold

ENGINE TROUBLE Poor caused

engine engine

plete

the

tune-up, parts,

failure. will

A

engine

justments, overhaul,

or

a

can

the

need

of

a

the

replacement

need of a

performance

isolate When

be

ad

the a

ENGINE

to

(and Vacuum Booster 430

listed

or

trouble

could

be

order

of

fault

at

that

These

can

checked

not

by

a

should

be

in

listed. For example,

under

ignition

the

celeration,

the

this

of

cause

NOT

fault, or

a

spark

the

for

check

seized

then

plugs,

engine

a

hydrostatic

with

Check the fuel

attempt

the

starter.

supply.

BUT

WILL

the

listed

in

the

cause

refer

to

that

and

var

part

of

detail.

For

refer

example,

for ignition

Part 2-1

system

to

items.

the

ignition

or

the fuel

To determine

fault, one

remove

spark

the

plug.

which

Insert

the

If there is

system wire a

cranks, it indicates that water

leaking into

move

the

spect

the

for

the

cylinder

cylinders.

head(s)

gasket(s)

Also

cracks.

der block for

and/or

examine

and

Rein-

head(s)

the

cylin-

cracks.

proper

metal

sized

that

it

rod

in the in from the

protrudes

cause

sulator so

either

insulator. With the ignition the

system.

ignition

engine

If the

fuel in the tank, the the trouble probably lies in

of

at

to crank

sufficient

NORMALLY, NOT START

in

is

is

lock

Remove

engine.

is

trouble

ENGINE

CRANKS

to

the manual which covers the system

Poor Ac

usually in the starting system. If the starting system is not

ENGINE

be

proceeding

GUIDE

The

WILL CRANK

ious systems,

order

system

are

all

corrections

cases, the items

most

checked

should

For the checking procedures to be made in the

their probable occurrence.

Therefore, in

complaints

items

guide.

listed in the

are

system

acceleration

affect

before

the

of

ignition

the

probable

next

items that

cause

probable

All

listed.

cause

possible

a

as

items

complete

DIAGNOSIS

1-22

Engine)

trouble.

help

to

the

of

definite

a

check, the

Guide."

TROUBLE

1-21 1-21

trouble.

performed

cause

particular

traced

simple

be

to

and checks

usually fall under one of the basic headings listed in the "Engine

Trouble Diagnosis

Transmissions Cylinder Block Oil Pan and Oil Pump

1-16

overhaul.

Engine

1-18

Manual-Shift

1-16

Guide,"

Diagnosis

com

tune-up, individual

Flywheel

In addition, the "Engine Trouble lists procedures

be

general

diagnosis

trouble

Connecting

and

DIAGNOSIS

by gradual wear of by a sudden parts

part(s) or

of

need

good

indicate

engine

performance

engine

by

Rings.

and

refer

1-3.

Rod Bearings

1-15

Rods

assem

,

Page

Main

1-15

Crankshaft

and

Reconditioning

disassembly

Section

1-15

Bearings.

and

after

overhaul,

installation procedures,

and

to Part 1-2 or

Valves

Timing

bly,

engine,

re

in the

or

has been disassembled.

For removal,

1-11

1-9

Valve

the

parts

have been

parts

complete

a

of

the engine

Section

the

The

engines.

and recondition component

various

after

in this Part

Thunderbird 352

the

is

at

from

piece

of

the

starter

end

on

and

cranking the engine,

hold

of

the

rod

3/16 inch from the

approximately block.

cylinder

\

CONTINUED ON NEXT PAGE

PART 1-1 ENGINE TROUBLE DIAGNOSIS GUIDE

ENGINE CRANKS NORMALLY, BUT WILL NOT START (CONT.)

(Cont.) Thermostatic

NO SPARK OR A WEAK SPARK AT THE SPARK PLUGS

justment. Fast idle

The cause of the trouble is in the ignition system. To determine if the cause is in the primary

of the

trouble

the

or

secondary circuit, remove the coil high tension lead from the top of the distributor and hold it

approxi

mately 3/16 inch from the

cylinder

head, the a

then with the ignition on and

engine

check

turning over,

for

If the

spark at the

high ten

coil

lead is good, the cause of the trouble is probably in the distributor cap, rotor, or the spark plug wires. sion

If there is

no

weak

a

or

spark

lead,

the cause of the trouble is probably in the primary circuit, coil to dis

high tension

tributor

lead,

or

the

fault,

check

the

spark

at

not

are

following

the

plugs

items:

Check the position of the choke If the engine is warm, the plate should be open. If the plate is not open, the engine will load up due to plate.

the excessively rich mixture and will not start. If the engine is cold, the

be closed, if the

plate should

operating properly,

lowing

items:

The

choke

check

is the fol plate

linkage for binding.

The fast idle

cam

FAILS TO KEEP RUNNING

fuel

Each time the throttle is fuel should spurt from the

celerating pump, the

flooded, item,

chanical

engine

is

there

or

fuel system,

the

such

ac

prob

water

in

me

engine

an

or

is

valves, is at

as

fault.

If fuel is

discharged by the disconnect the

not

pump,

accelerating

line

inlet

fuel

the

at

Use a suitable container to catch the fuel. Crank the en gine to see if fuel is reaching the

carburetor.

not

reaching the

carbu

check: pump.

fuel inlet line for

carburetor

obstructions.

The flexible fuel pump inlet line for a collapsed condition. The fuel tank line to flexible fuel line for obstructions.

check:

The fuel inlet

system

including,

the fuel inlet screen, the fuel needle

float

and

seat

assembly,

inlet

and

the

assembly.

Check for dirt in the carburetor, allowing fuel to enter or be dis charged from the idle system. not

Check the

needle(s)

not

speed set

valve

timing.

Fuel pump defective.

choke not

IGNITION SYSTEM

too low.

operating

properly.

Float setting incorrect.

inlet

system

not

operating

or

carburetor.

Breaker justed.

water

in

fuel

lines

or

points

Defective Open

properly.

Dirt

acceler

ating pump discharge nozzles. If fuel is discharged by the

Carburetor icing.

mixture

Engine idle

Fuel

actuated

adjusted.

properly

The

Work times.

ENGINE

for binding.

FUEL SYSTEM Idle

op

The fuel tank vent. If fuel is reaching the carburetor,

FUEL SYSTEM

STARTS, BUT

the

The fuel

plugs and

ignition timing. If the or the ignition timing

proper

carburetor).

throttle

The

good at the spark

the spark

check

plugs,

is

proper

Supply at Carburetor. by hand several

Fuel

retor,

A GOOD SPARK AT THE SPARK PLUGS spark

for

plate valve

(Ford

If fuel is

If the

for

screw

speed

ad

carburetor.

coil.

ENGINE

Choke eration

carburetor

the coil high tension

spark at

housing

spring

adjustment.

ably

spark.

not

1-3

ENGINE SERVICE

-GENERAL

not

properly

ad

spark plugs.

circuit at the resistor.

Leakage

in

the

high

tension

wiring.


GROUP 1

14

ENGINE TROUBLE DIAGNOSIS GUIDE

(Cont.)

Determine if the

ENGJNE RUNS, BUT MISSES

AND EXHAUST SYSTEM

-ENGINES

erratic

and

occurs

by

various

at

is steady

miss

or

the miss

speed

what

operating the engine under load.

This is done

by

one spark

Ground

the

firing. engine

wire removed

spark

wire

plug

re

moved.

If the a

engine speed changes when

is

particular cylinder

that

cylinder

being

change

in

that

shorted

the

the

evident,

being

power

If

out.

engine

miss

cylinder

before

shorted out,

delivering

was

before

no

operation

is

by

caused

was

delivering

not

ticular

is

miss

isolated in

cylinder,

lead

inder. If a

does

par spark

the cyl

of

not

occur,

is in the secondary

the trouble cuit

spark

a

a

perform

test on the ignition

good

cir

the system, check the:

of

Spark plug wire. Distributor cap. If a good spark occurs, check the spark plug. If the spark plug is not at

fault,

of

the

a

component

mechanical

is probably

engine

at

fault.

Perform termine nent of

a compression

which

test to de

mechanical

compo

Exhaust

operating tempera

normal

reaching ture. ENGINE

Perform

a

determine

test

compression

which

mechanical

ponent of the engine

is

to

com

fault.

at

MISSES AT IDLE ONLY Idle

fuel

mixture

needles

not

adjusted.

properly

IGNITION SYSTEM

Defective coil, condenser, breaker ignition wiring, or rotor,

points, spark

plugs.

Excessive play in the distributor shaft.

Worn distributor

cam.

VACUUM BOOSTER PUMP

Leaking

pump,

Perform determine

lines,

a

fittings.

or

IGNITION

inoper

SYSTEM

Breaker

points

not

ad

properly

mechanical

breaker

denser, secondary

is

to

com

fault.

at

points,

wiring,

con

coil,

or

clogged or

damaged

sure.

inlet

system

not

operating

properly.

COOLING SYSTEM

Engine

spark plugs.

valve

(Ford carburetor). Vacumeter not operating properly (Carter carburetor). Low or erratic fuel pump pres Fuel

justed. Defective

test

compression

which

ponent of the engine

Power

gas control valve

sticking (352 engine). Exhaust system restricted.

overheating.

SYSTEM

Engine idle

Idle

Check the cooling system for in leakage and/or for a condi tion that prevents the engine from ternal

FUEL SYSTEM

ative or

IDLE

or

MISSES AT HIGH SPEED ONLY

EXHAUST SYSTEM

ENGINE

lines

COOLING SYSTEM

the engine is at fault.

MISSES ERRATICALLY AT ALL SPEEDS

ROUGH

fuel

in

water

ENGINE

ENGINE

FUEL

or

FUEL SYSTEM

IGNITION SYSTEM

If the

Dirt

carburetor.

power

Check the:

shorted out.

properly.

from

time, until all been checked. a

at

have

cylinders

operating the

operating the

plug

the

cap.

Choke not operating properly. Float setting incorrect. Fuel inlet system not operating

cylinder not

ignition

with the

by

miss

across

distributor

or

FUEL SYSTEM

MISSES STEADILY AT ALL SPEEDS Isolate the

leakage

tension

at

speeds

engine with one

High

coil, rotor,

fuel

properly

speed set

mixture

too

low.

needle(s)

adjusted.

Float setting incorrect.

Air leaks between the not

and

the manifold

Fuel

leakage

and/or at

the

carburetor

fittings. carburetor

fuel bowl(s).


1-5

PART 1-1 -GENERAL ENGINE SERVICE ENGINE TROUBLE DIAGNOSIS GUIDE

(Cont.)

Idle fuel

system air

bleeds

fuel

or

passages restricted.

ROUGH ENGINE IDLE (Cont.)

Fuel

Exhaust

from the

bleeding

pump discharge

ing

accelerat-

(Ford

adjustment

sticking (352

or

erative

inop-

valve

control

gas

engine).

nozzle(s).

Throttle plates not closing. Improper secondary throttle stop

EXHAUST SYSTEM

BOOSTER PUMP

VACUUM plate

Leak"*

carburetor).

*.*.-

,

.

,

PumP>

,mes>

fittm8s-

or

ENGINE

SYSTEM

IGNITION

Improperly

or

defective

improperly

adjusted

adjusted

breaker points. Fouled or

Cylinder head bolts

Incorrect ignition timing. Spark plug misfiring.

Fouled

Leaky adjusted

Improperly breaker

adjusted

or

defective

not

leaking

(352

valve, gaskets, or

power

prop-

advancing

acac-

or

piston.

corrosion

or

in accelerating

system.

Distributor

points.

Distributor

manifold seals

celerating pump

Dirt

plugs.

spark

properly

celerating pump diaphragm

timing.

improperly

or

not

engine).

IGNITION SYSTEM Incorrect ignition

or

tightened.

Intake

spark plugs.

POOR ACCELERATION

Loose engine mounting bolts insulator.

worn

in

passages

vacuum

the carburetor blocked.

EXHAUST SYSTEM

erly.

Exhaust

FUEL SYSTEM ,

Inoperative accelerating pump

in-

gas

control

inop-

valve

v sticking & (352

or

erative

engine). e

let. Inoperative accelerating pump disball check. Accelerating pump diaphragm or

charge

defective.

piston

Float setting incorrect. Throttle linkage not properly

not

stroke

Clutch

slippage

Determine

(manual

shift

-

if the trouble exists is cold, at normal

temperature,

engine

or

at

all

adjustment

(auto-

transmissions).

Secondary

the engine

operating

Improper band matic

PRELIMINARY

SPEED

adjustment.

transmissions).

Accelerating pump properly adjusted.

when

Improper

tbammk~u..e*

SYSTEM

COOLING

TEMPERATURE SENDING UNIT AND GAUGE

ignition timing.

Incorrect

properly

ôperative.

SYSTEM

IGNITION

ENG(NE not

.

.

Water PumP

system.

Cylinder head bolts

bhW

'

engine).

tightened.

Low

ity

level

oil

incorrect

or

viscos-

Dragging brakes.

used.

oil

COOLING SYSTEM

SENDING UNIT AND GAUGE

TEMPERATURE

ENGINE FAILS TO REACH NORMAL OPERATING TEMPERATURE

makes ""*"

Unit

dicating

Thermostat inoperative, incorrect

defective,

gauge

or

in-

not

temperature.

correct

heat range,

Intake

COOLING SYSTEM

Leaking

LOSS OF COOLANT

Loose

radiator.

.

head

Qr

mtake

Water pump leaking. Radiator cap defective.

Temperature

Overheating.

Cracked or

Cylinder head

NOISY HYDRAULIC VALVE LIFTER

defective.

gasket

lifter

valve

the

operating

valve

Another

by

idle speed, hose near the and

the

this

er(s) has

The

one

operating

end of the

on

the

to

end

and

Repeat intake and

noise.

each

until

ear

the

noisy

lift-

been located.

most

draulic

engine

metallic

valve

exhaust

gum,

a

a

end of the valve stem

procedure

valve

or

filter

and

lems

because the internal

to

minimize

by dirt.

caused

Deposits cause

of

which

may

gum

and

in lifter

result

varnish

to

conditions

similar

exist

malfunc-

tion. If these

conditions are found be present, the lifter should be disassembled and cleaned in solvent

to

to remove all traces of deposits.

Air bubbles in the

by

low

oil

an

level,

deposits,

and

pick

up tube may

drawn into To

check

remove

a

lubricating

oil,

excessively high or may likewise cause

malfunction.

due to failure to

remove

intervals should be lifter prob-

change

lifter

bubbles. Dirt in the lifter assembly can prevent the disc valve from seating, or it may become lodged between the plunger and body surfaces. In either case, the lifter becomes inop-

block

or

lifter assembly and thoroughly clean it. Recommended engine oil

dirt,

air

block,

or

head

the

are

lifter troubles

head

cylinder

for lifter malfunction,

sible

caused

common causes of hy-

varnish, carbon

erative

leak-

longer free to function properly. When dirt is found to be respon-

the use of a piece

place

other

for

listen

identifying

of

method

at

unit

surface.

followed

hose. With the

of

can

engine

seats.

noisy lifter is

leak-

sending

cylinder

warpe(j

gasket

be located at idle speed and placing a finger on the face of the valve spring retainer. If the lifter is not functioning properly, a shock will be felt when the A noisy

plugs

ing.

ENGINE

by

core

.

cylinder

MtSm

manifold

block

Cylinder

..

f

of

tightening

connec-

Uom-

j

to cylinder head

manifold

Improper

.

,

damaged hose

in

not

defecê'

SasTket

or

thermostat

or

stalled.

the

damaged

allow

to

air

lubricating

for the valve

A

presence

rocker

oil

be

system. of

arm

air,

shaft

cover and note the condition of the oil

it flows from the

as

arm

shaft

assembly.

valve rocker

Perform

cor-

"pump-up,"

rective parts

are

no

air

action as required

from the

lubricating

to remove

oil.

GROUP 1

1-8

-ENGINES

AND EXHAUST SYSTEM

TUNE-UP A tune-up is a for testing

cedure

systematic various

is

if and, necessary, them within recommended

components,

bringing

to

specifications

ficiency

restore

engine

ef

and performance.

TABLE 1 -Tune-Up

Perform

on

ual

which

procedure

X

test.

X

ENGINE COMPRESSION Take compression reading

INTAKE MANIFOLD Check and tighten bolts.

the

operations

Part 2-1

in

the

sequence

X

Check and dwell. Check

Check

1-2,

Major Procedure

X

centrif

adjust

and

Recom

point

adjust

X

ugal advance.

Part 1-3

on

(Cont.)

DISTRIBUTOR

Part 2-1

and adjust vacuum

X

advance.

and

rotor.

X

X

X

X

Part 2-3 X

X FUEL SYSTEM Clean fuel pump filter bowl.

cables and

X

terminals.

X

cable clamps.

X

Part 9-1 Check fuel pump

X

terminals.

battery

filter

Replace fuel pump bowl strainer.

Part 2-2 pressure

X

and capacity.

Check

the

mended

Minor

Clean distributor cap

Grease

opera

followed. Perform

Perform

Part 1-1

X*

DRIVE BELTS Check and adjust the ten sion of all drive belts.

Tighten

each

describes, in detail, to be

Operation

X

of each cylinder.

BATTERY Clean battery

after

listed.

Major Procedure

SPARK PLUGS and

reference

tion refers to that part of the man

Recom mended

Minor

adjust,

Tune-Up

applicable

Schedule

Operation

Clean,

The

Schedule (Table 1) for either a minor or major tune-up. A minor tune-up is recommended each 6000 miles and a major tune-up is recommended each 12,000 miles. The

pro

engine

battery

state of

X

charge.

X

Clean

fuel bowls float setting.

carburetor

and adjust

X

ELECTRICAL

Check Check rent

Check

X

generator output.

starter

motor

draw.

X

coil output.

X

Perform

a

primary

resistance

ADJUSTMENTS Check and adjust ignition

Part 9-1

cur

timing.

Check idle

circuit

X

test.

of

Replace the breaker

points

X

and the condenser.

arm

cam. wick.

the

Oil the

X

!

breaker

spring tension.

Lubricate

mixture.

EXHAUST Free the exhaust gas control valve (352 engine).

the

Check the condition breaker points.

adjust

X

Part 2-1

COOLING SYSTEM Inspect the radiator, hoses, and engine for leaks. Add

distributor

lubricating

rust

inhibitor to

tributor

bushing

X

X

X

X

X

X

through

X *On 352

Part 1-4

radi

ator.

Lubricate the dis

the oil cup.

X Part 2-2

Adjust idle fuel

DISTRIBUTOR

and

X

engine

speed.

X

continuity test.

Check

adjust

X

Part 2-1

circuit t

Perform a secondary

and

Part 2-1 X

engine only.

Part 2-3

1-9

PART 1-1 -GENERAL ENGINE SERVICE

TESTS AND ADJUSTMENTS (ENGINE INSTALLED) CAMSHAFT LOBE LIFT 1. Remove the shaft

assembly

tappet-type

bore

push rod

the

of

valve

and

rocker arm

install a solid in the push rod

lobe to

camshaft

be

checked.

2. Make

sure

the push rod is in

the lifter push rod cup, then install a

dial indicator in such a manner as to have the actuating point of the indi cator in the push rod socket and in the same plane ment

as

the push rod move

(Fig. 1).

3. Rotate the

crankshaft slowly in direction of rotation until the lifter is on the base circle of the cam shaft lobe. At this point, the push rod will be in its lowest position. Zero the dial indicator, then continue to rotate the damper slowly until the push rod is in the fully raised position. Com pare the total lift recorded on the indicator with specifications.

the

4. Continue to shaft

until the

This is

a

on the

indicator

FIG. 1 Camshaft

reads zero.

valve

timing

Remove the shaft

when

poor

noted

and all other

engine

checked

performance

is

such

as

checks,

carburetion, ignition timing, etc. fail to locate the cause of the trouble.

specifications, check the

check

the valve

installed,

1. Install a shaft damper.

timing

proceed

as

quadrant on

the

follows:

the

(the

second

a solid tappet-

2. Make

sure

the lifter push

closing.

the push rod is in

rod

dial indicator in

cup, then install

VALVE CLEARANCE

such a manner as

A

(Fig. 1).

low) is

3. Rotate the crankshaft slowly in direction of rotation until the lifter is on the base circle of the cam shaft lobe. At this point the push rod will be in its lowest position. Zero the dial indicator and continue rotat ing the crankshaft slowly in the direc tion of rotation until the dial indicator registers

crank

the specified camshaft

Crankshaft Degrees

(BTDC)

lobe

rod

available

or a

push

rod

0.060-inch

(color coded for service to

yel pro

a

means

of

changes

22

22

Exhaust Valve Closes

Camshaft Lobe Lift

Crankshaft Degrees

(ABDC)

0.002

0.002

Opens

Camshaft Lobe Lift

Crankshaft Degrees

(BBDC)

(Inch)

(Inch)

430

shorter

white)

Timing Specifications

Opens

352

push

dimensional

Intake Valve

Engine

coded

compensating for in the valve mechanism. Valve stem to valve rocker arm clearance be should 0.078-0.218 inch (352 engine) or 0.126-0.226 inch (430 engine) with the hydraulic lifter completely col lapsed. Repeated valve recondition ing operations (valve and/or valve seat refacing) will decrease this clearvide

lift (Table 2).

TABLE 2 Valve

0.060-inch

(color longer

the

sprock

with

valve push rod

rod) and install

the same plane as the push rod move

order of accessibility.

To

4. Compare the crankshaft degrees indicated on the quadrant with speci fications (Table 2). After the valve opening is checked, continue to ro tate the damper to check the valve

the No.

type push rod in its place.

ment

et, camshaft, and crankshaft in the

engine

and remove

to have the actuating point of the in dicator in the push rod socket and in

timing chain,

sprocket, crankshaft

push

a

Before the valve timing is checked, bent timing pointer. check for a Bring the No. 1 piston to T.D.C. on the compression stroke and see if the timing pointer is aligned with the T.D.C. mark on the damper. If the valve timing is not within camshaft

Lift Typical

right valve rocker arm

assembly

1 intake

be

should

Lobe

of

accuracy

reading.

VALVE TIMING The

1748-B

the crank

rotate

indicator

check

the original

BE SURE TO PLACE Indicator TIP IN CENTER OF PUSH ROD SOCKET

68

68

0.005

0.005

Closes

Camshaft Lobe Lift

Crankshaft Degrees

(ATDC)

(Inch) 68

63

Camshaft Lobe Lift

(Inch)

0.002

22

0.002

27

0.005 0.005

MO

1- ENGINES

GROUP

AND EXHAUST SYSTEM

rod, it will be to remove valve rocker the necessary

To

replace a push

arm shaft assembly.

Upon rod

replacement of a valve push

and/ or

valve

assembly, the

arm

rocker

engine

cranked or rotated until the

shaft

not

should

be

hydraulic

lifters have had an opportunity to leak down to their normal operating position. The leak down rate can be accelerated by using the tool shown in Fig. 2 on the valve rocker arm, apply pressure in a direction to collapse the lifter.

MANIFOLD VACUUM TEST A

manifold

determining gine

and

cause

To test

also

in

helping

to locate the

engine

performance.

poor

of

test aids

vacuum

the condition of an en

manifold vacuum:

1. Operate the engine for a mini 30 minutes at 1200 rpm.

mum of

2. Install 1883-A

vacuum

Mb. 2 Valve ance

to the

lifter

point

for,

pensated

Clearance Typical

that if not com

hydraulic to function.

the

will cease

valve

The correct operating range of the hydraulic valve lifter plunger must be maintained because: If the plunger travel is excessive, the lifter pump-up time will be pro longed resulting in excessive valve train noise

following

engine start-up.

If the travel is insufficient to com pensate for normal expansion of the valve

operating

components,

the

be permitted to seat properly resulting in a rough engine and/or premature valve failure.

valve would not

To

the valve clearance:

check

1.

Position the crankshaft as out lined in Steps 2 and 3. Position the

hydraulic lifter

tool on

compressor

the rocker arm and slowly apply pres sure to bleed down the hydraulic

lifter

the plunger is completely bottomed (Fig. 2). Hold the lifter in

the

until

fully

On ance

352 engine, insert the clear gauge (Fig. 2) between the a

On

being a

430 engine, insert

inch feeler stem and

checked.

gauge

a

between the

the rocker

arm of

0.126 valve

the valve

being checked. If the first step (352 engine)

or

of the gauge enters

if the feeler

gauge

the standard push rod with a

0.060-inch shorter push rod. If the second step of the gauge enters (352 engine) or if a 0.226-inch feeler gauge enters (430 engine), the operating range of the lifter is ex cessive. This indicates that the incor rect push rod has been installed or severe wear has occurred at the push

intake

manifold

line.

4. Check the

engine

at

vacuum

recom

reading

on

the gauge. TEST CONCLUSIONS

Manifold carburetor

vacuum

is

adjustment,

affected

valve

by

timing,

the condition of the valves, cylinder

compression,

ifold,

and

leakage or

carburetor,

of the man

head

cylinder

gaskets.

Because abnormal gauge readings may indicate that more than one of the above factors is at fault, exercise in analyzing an abnormal For example, if the vacuum is low, the correction of one item may

caution

reading.

rod ends, rocker

In this case, it determine the and the

arm,

area

incorrect

or valve stem.

be necessary to

will

or

discrepancy

of

defective part(s)

increase the cate

If

all

the valve train components

except the push rod are within

install 2.

No. 1

a

0.060-inch longer

Rotate piston

the

is

on

push rod.

crankshaft

T.D.C.

limits,

at

until

the end

of the compression stroke. piston on

T.D.C,

check

With No. the follow

ing valves:

indi

has been

It

rected.

cor

is

important,

therefore,

that each cause of an abnormal read

ing be investigated

and

further tests

necessary in order the correct diagnosis of

conducted where

to arrive at

the trouble.

Table 3 lists various types of read ings and their possible causes. Allowance should be made for the effect of altitude on the gauge read

No. 1 Intake No. 3 Intake No. 7 Intake No. 8 Intake

No. 1 Exhaust No. 4 Exhaust No. 5 Exhaust No. 8 Exhaust

3. Position No. 6

piston on

and check the

vacuum enough to

that the trouble

replaced.

1

collapsed position.

valve stem and the rocker arm of the valve

(430 engine), a standard length may be used. If the first step of the gauge does not enter (352 engine) or if the feeler gauge does not enter (430 engine) re push rod

sensitive

accurate,

3. Operate the mended idle rpm.

enters

place

an

vacuum gauge on an

following

No. 2 Intake No. 4 Intake No. 5 Intake No. 6 Intake

T.D.C.

valves:

No. 2 Exhaust No. 3 Exhaust No. 6 Exhaust No. 7 Exhaust

ing. The with an

engine vacuum will

increase in

decrease

altitude.

COMPRESSION TEST 1. Be sure the battery is good. Operate the engine for a minimum of 30 minutes at 1200 rpm. Turn the ignition switch off, then remove all the

spark plugs.

2. Set the primary throttle

plates

Ml

PART 1-1 -GENERAL ENGINE SERVICE and the choke plate

in the

wide open

position.

3. Install a compression gauge in No. 1 cylinder. 4. Crank the engine several times

highest reading reg

record the

and

istered. Note the sion

number of compres

strokes required

highest reading. 5. Repeat the test

der, cranking number

on

Gauge

Engine Condition

Reading

19-20 inches (352 17-18 inches (430 Low

Vacuum Gauge Readings

engine).

Loss

and steady.

compression

to obtain the highest cylinder.

A

Very low.

However, inders

is

pressure

Manifold,

Needle fluctuates steadily increases.

as

speed

satisfactory.

the compression of all cyl

be

should

uniform within

10

A reading able

deposits in the cylinder. A reading of more than the allow able tolerance below normal indicates leakage at the cylinder head gasket, piston

rings, or valves.

A low

even

Gradual drop in reading idle.

in two

adjacent cylinders indicates a cylin der head gasket leak. This should be checked before condemning the rings or valves.

To determine

whether

the rings

fault,

squirt the

or the valves are at equivalent of a

tablespoon of

heavy

A

loss

partial or complete

more cylinders caused

head

gasket

in

one or

of power

by a leaking valve,

at

Excessive back

pressure

An

loss

in the

occasional

of power

by a defect in the ignition

cyl

exhaust system.

possibly caused sticking

system or a

valve.

Slow fluctuation

or

drifting

of the needle.

oil

compression

cylinder

engine

tolerance above normal indicates

excessive

carburetor, or

spring.

than the allow

of more

possibly

timing, or loss of due to leakage around the piston

inder head or intake manifold gasket leak, a defect in the ignition system, or a weak valve

Intermittent fluctuation.

pounds.

all cylinders caused or valve

leak.

20 pounds from

variation of

in

rings.

on each cylin

TEST CONCLUSIONS

specified

of power

by late ignition

to obtain the

the engine the same

No. 1

Normal.

engine).

times for each cylinder

of

as was required

reading

TABLE 3 Manifold

into the

combustion

Improper idle mixture adjustment, carburetor or intake manifold gasket leak, or possibly late valve timing.

chamber, then

there

reading,

is leakage

past

the

rings.

distribute the oil and repeat the compression test. The oil will temporarily seal leakage past the rings. If approximately the same reading is obtained, the rings are satisfactory, but the valves are leak ing. If the compression has increased 10 pounds or more over the original crank the engine to

During pressure

a

compression

fails to

remains the same

climb

during

successive strokes, on

but

test, if the

steadily

higher fails test, it in

climbs

the succeeding strokes,

to climb

during

dicates

sticking

a

and

the first two

the entire

or

or stuck valve.

CLEANING, INSPECTION, AND RECONDITIONING leaks,

INTAKE MANIFOLD Clean the

manifolds

dry

then

solvent, pressed

in

them

a suitable

with

com

air.

or

other

make them unfit

On the

defects that would for further service.

air heat chamber (Fig. 3). Make sure the air inlet and outlet holes are completely open and the cover does not leak. Blow out the

matic choke

right exhaust manifold of

the 352 engine, clean out the auto

On the 352 engine, scrape all car bon deposits from the center exhaust passage below the carburetor heat riser. This carbon acts as an insu

AIR

INLET'

lator restricting the heating action of the hot exhaust gases. Inspect the manifold for cracks, leaks, or other defects that would make it unfit for further service. Re place

all

otherwise

ings

and

entered

studs

that are

stripped

damaged. Remove

foreign the

matter

manifold

all

or

fil

that may have as a result of

repairs.

On the 352 engine,

check

plate on the underside of

fold for looseness maze screen is in any

varnish

and

be

the baffle

the

mani

sure

Clean

place.

the off

1S09-A

accumulation.

EXHAUST MANIFOLD

Inspect the

manifolds

FIG. 3 Automatic for cracks,

Engine

Choke Air Heat Chamber 352

M2

1-

GROUP

ENGINES AND EXHAUST SYSTEM

Runout Gauge

fixture'

Holding

PUSH ROD 1003-A

FIG. 4 Push

Runout Typical

Rod

73S-A

(D (3)

CHECK DIAGONALLY

(|)

CHECK ACROSS CENTER

FIG. 6Valve

1729-A

FIG. 5 Cylinder

Seat

Runout Typical

Head Flatness Typical CYLINDER HEAD FLATNESS

choke

automatic

compressed

heat tube

air

with

air.

for

checked are

installed in the

they

while

straightness

engine

by rotating They also

Check the flatness head

gasket surface

fications for flatness

them with the valve closed.

VALVE

can

ROCKER ARM

Clean Make

the

all

that

sure

thoroughly.

parts all

be

checked with a

(Fig. 4). If the

SHAFT ASSEMBLY

oil

passages

are

maximum

the

limit

Do

rod.

dial indicator

runout

at

to

maximum

between

clearance

rocker arm and

the shaft

by

the I.D. of the rocker arm

VALVE SEAT RUNOUT

Check the

the O.D. ance

of

the

shaft.

between any

checking

If the

clear

limit,

the

shaft

In

the rocker arm

and

bore for nicks, scratches, scores, or scuffs. Dress up minor surface defects with a

the

radius.

pad

rocker

If the

the rocker

at

pad

arm.

true this surface

the valve end

for

arms

a

grooved

is grooved, replace Do not attempt to

by

Check for broken

grinding.

locating

facturer. The exceed

With the

valves

installed to

from the

engine) and valve heads with a and a wire

brush. Be

RODS

Check the

ends

valves

the

push

for nicks, grooves, roughness,

rods

or ex

The

push

rods

can

be

visually

Do

and the exhaust

are

0.070-

If it becomes necessary to (Fig. 8) to install

ream a

valve

seat

width

limits

0.090 inch.

REAMING VALVE GUIDES

grease, and

valve guide

cylinder

Replace

cracked.

0.060-0.080 inch

the

head for cracks, for burrs

head

if

and

it

is

not plane or grind more

than 0.010 inch from the gasket surface.

(Fig. limits

clean

deposits.

Check the

valve seat width

valve seat width

removed,

cleaning tool. Use

ing solvent to remove dirt,

head

cessive wear.

gasket sur

are

Measure the 7). The intake are

to

the valve guide bores with a

valve guide

nicks. of

total runout should not

the wear limit.

VALVE SEAT WIDTH

scraper

careful not

the cylinder head

face. After the clean

(352

combustion chambers

and the gasket surface

PUSH

pro

tect the valve seats, remove deposits

other

springs.

(Fig. 6). Follow

CLEANING AND INSPECTION

scratch

hone.

Inspect the of

CYLINDER HEADS

replace

the shaft and/ or the rocker arm. spect

the

valve seat runout with gauge

accurate

the instructions of the gauge manu

and

rocker arm and

the wear

shaft exceeds

each

bore

0.006 inch

0.003 inch in

straighten

an

Check the

are

or

any 6 inches.

push rods.

open.

overall,

the cylinder

the

exceeds

any point, discard

not attempt

of

(Fig. 5). Speci

Remove

cylinder

all

or scratches with an oil stone.

burrs

with an oversize

is

available

lowing

which

reamer

a valve

stem, a reaming kit contains

and

tions: a 0.003-inch

pilot

O.S.

the fol

combina

reamer with

diameter pilot, a 0.015inch O.S. reamer with a 0.003-inch

a

standard

O.S. pilot, and a 0.030-inch reamer with a 0.015-inch O.S. pilot.

1-13


1736- A

FIG. 7

1737- A -Valve

Seat Width-Typical

FIG. 8 Reaming TO REMOVE STOCK FROM TOP OF SEAT, USE 60" WHEEL

Guides Typical

Valve

TO REMOVE STOCK FROM TOP OF

TO REMOVE STOCK FROM BOTTOM OF EXHAUST WHEEL SEAT, USE

TO REMOVE STOCK FROM BOTTOM OF SEAT, 30* USE WHEEL

INTAKE

30

SEAT, USE

15

WHEEL

TO REMOVE STOCK FROM TOP OF 60

EXHAUST SEAT, USE 15

OR

WHEEL

60

EXHAUST-352 AND 430 ENGINES AND INTAKE-430 ENGINE

1

JSt

1738- A

FIG. 10-lntake

1882-A

9 Valve

FIG.

430

Seat Refacing Exhaust 352 Intake 430

to

the

use

reamers

the

reface

valve,

always

in

sequence.

Always

valve seat after

has been

guide

a standard size

oversize

an

the valve face. To

and

When going from valve

and

the valve

reamed.

Refacing

the seat has been refaced, measure the seat width (Fig. 7). Narrow the

seat, if necessary to

limits. If the

be closely

facing ished

of

co-ordinated with the re

the valve

centered.

so that

the valve

a

good

the

fin face

This is important and seat will have tight

compression

Be

fit.

that the refacer grinding wheels

sure are

so

the valve

seat will match

be

and

face

properly dressed.

Grind the both

engines

exhaust

and

the

seats

intake

of

valve

the 430 engine to a true (Fig. 9). Grind the intake valve

seats of

seat of angle

stock

the 352 engine to a true

(Fig. 10). Remove only to clean up pits,

correct

or

seat

limits, remove top edge

the

edge of the

to

width

width

grooves, or to

the valve seat runout. After

within

On the engines

specifications

valve

enough

tory.

and/ or

the

(Fig. 9

exhaust valve seats of

both

intake

seats

and

the

430 engine,

of the

valve

use a

30

angle

grinding wheel to remove stock from the bottom of the seats (raise the and use a

remove

seats

stock

60

angle wheel to

from the top

(lower the

On the intake 352 engine, use a

of

valve 15

seats

contact

finished the

valve

of

the

angle

grinding from the top seat

approximate

to

face,

the

the

center

is

contact

of

the

satisfac

If the blue is transferred to

top

edge

lower the

the

of

valve

seat.

valve

face,

If the blue is

transferred to the bottom edge of the valve face, raise the valve seat.

After refacing the is

valve

seat,

it

good practice to

valve with a

lightly lap in the medium grade lapping

Remove from the valve

compound.

all

pound

and seat after

the

lapping

the

com

operation.

VALVES

the seats (lower the seats).

The

Rotate the valve If the blue is

place.

pressure.

the

seats).

wheel to remove stock of

in

light

with

exceeds

to reduce

seat

30

enough

it

bring

10).

seats) valve

45

angle

bottom the

where

face, coat Prussian blue, then set

the seat with the valve

transferred valve

from

stock

of the valve seats should

determine

the valve seat contacts the

the maximum REFACING VALVE SEATS

Valve Seat Refacing-352 Engi ne


Remove valve with a

ing should

center

of

wheel.

points are

and

all

fine The

deposits from the wire brush or buff critical

tolerances

of

inspection the valves

illustrated in Fig. 11.

1-14

GROUP 1

AND EXHAUST SYSTEM

-ENGINES

Model TV-2 Runout Gauge

MAXIMUM VALVE FACE RUNOUT 0.002

, REFER

TO SPECIFICATIONS

FOR CORRECT DIAMETER

CHECK FOR BENT STEM DO NOT REMOVE MORE THAN 0.010 INCH 45

45* 30*

MS. 11 Critical

EXHAUST -352 AND 430 ENGINES INTAKE-430 ENGINE INTAKE-352 ENGINE

1739-B

Valve Tolerances

1015-A

12Valve Face

FIG.

Runout

VALVE SPRING PRESSURE

Check the spring for proper pres (Fig. 14). Do not remove the damper spring from the 430 engine when checking the pressure. Weak sure

valve springs cause poor engine per

formance; therefore, if of

limit,

Inspect the

face and the head for pits, grooves, scores, or other defects. Inspect the stem for a bent condi tion and the end of the stem for grooves or scores. Check the valve head for signs of burning or ero sion, warpage, and cracking. De

fects, etc.

such

valve

as

minor

be

may

valves

valve

the

of

pits, grooves,

Discard

removed.

that are severely damaged.

Inspect

the

valve

spring retainers,

springs,

locks,

for defects. Discard

and

valve sleeves

any defective

VALVE FACE RUNOUT

Check the

12). The

face runout (Fig. limit is 0.002 inch

valve

wear

total indicator

until

fully

hs

or

equivalent

seated and

away from its seat contacts the upper valve guide. with

flat tip

a

portion

Position

of

the

a

the

valve

stem

valve

the

the

against

center

section

of

replace

it.

The should

vahre refacing operation be closely co-ordinated with

the valve seat refacing operation so that the finished angle of the valve

face will match the valve seat. This is important so that the valve and

90

to the the tool at approximately Move the tool back and

valve stem.

forth

on a plane that parallels nor

2 (division factor the

the tool) to

actual stem clearance.

clearance

limit, try

of

exceeds

a new valve.

seat

the

If

wear

have a good fit. Be sure that

wiD

tight

If the sive

valve

and/or

grooves,

the

refacer

properly dressed. face runout is exces

to

reface

remove

the

of

both

engines and

of

the

430 engine

angle.

compression

wheels are

grinding

take the

indicator reading without lifting the tool from the valve guide upper sur face. Divide the indicator reading

the

to

of

dial indicator

spherical

inch,

REFACM6 VALVES

drop

the tool

surface

and

stem

tighten the set

until

surface

Slide the spring up to the square. Revolve the spring slowly and ob serve the space between the top coil of the spring and the square. If the spring is out of square more than 1/16

the valve

on

screw, then permit the valve to

obtain

VALVE STEM CLEARANCE

Check

in Fig. 13

Install the tool

by

reading.

its

respective valve guide with the tool

mal rocker arm action and

parts.

in

guide clearance of each valve

a

the surface plate.

square on aid on

shown

squareness

(Fig. 15). Stand the spring

plate

edge

spring for

each

using a steel square and

Valve Stem Clearance

wear

SQUARENESS

Check 1740-A

the

replace the spring.

VALVE

FIG. 13 Typical

the pressure

approaches

any spring

and

valves

the intake valves to

a

Reface the intake

the 352 engine to a true

Remove only

pits

exhaust

true

45

valves 30

of

angle.

enough stock to correct

PART 1-1

ENGINE SERVICE

-GENERAL

M5

Valve

Spring

Teste

NOT MORE THAN W

PRESSURE READING

i

1017-A

FIG. 14-Valve

If the

grooves

marks

then

stem,

valve

pits

end

of

chamfer

as

Do not remove more inch from the stem.

after

as

hot in the

valve will run too

Remove all from the

1/32 inch the

replace

up the

CAMSHAFT AND BEARINGS

the

engine.

or

score

the

valve

necessary.

0.010

than

Clean the

After

the

refacing to

practice

valves,

lightly lap

valves with

a medium grade

compound

to

sure-

to

remove

from the

lapping

the

match

valve

the

all and

it is in the

lapping

seats.

Be

compound

seat

after

the

operation.

SELECT FITTING VALVES

If the clearance

the

ream

to valve guide

stem

valve

the

exceeds valve

guide

oversize valve stem.

limit,

wear

for the

Valves

next

the valve guide has been

The

lifter

reamed.

kept in can

position.

installed Inspect

separately

lifter place

should

proper sequence so that

be

internal

LIFTERS

assemblies

so

as

parts.

assembly

in

their

test

and not

needs

shows signs of

ing, Also,

or

The

pitting, scoring, gall

evidence

replace the

is

of

non-rotation.

assembly if free in the body.

entire

not

drop to the bot body by its own weight.

plunger should

tom of the

Assemble the lifter assembly and the assembly for freeness of

check

operation

by

push

cup.

rod

pressing down on the Also, the lifter as

be

they

clean

all

be

if any one item needs replacement. dry. Inspect the camshaft lobes for pitting, scoring, and signs of ab normal

istics

general

Lobe wear character in pitting in the

wear.

may

result

area

of

the nose portion of

lobe (Fig. 16). This pitting is not detrimental to the operation of the camshaft, therefore, the camshaft should not be replaced until the lobe lift loss has exceeded 0.005 inch. the

Check

bearing

the

journal

to

by measuring

the

camshaft

clearances

diameter of the journals I.D. of the bearings. If the

is 8-45 seconds. Follow the instructions of the test unit man

shaft

ufacturer.

exceeds

for

If

valve

and/or

have been refaced, it sary to

with

seat

be neces the clearance between

check

rocker

valve

arm

the

installed in the

pad

valve

will

and

the valve

train assembly

(Page 1-9).

engine

wear

limit,

should

the

and

clearance

the

be

bearings

undersized

shaft

ARM TO VALVE CLEARANCE

the

the

journals

cam

refinished

or the cam

bearings Bearings are available prefinished to size for standard and 0.015-inch undersize journal diameters. Check the distributor drive gear for broken or chipped teeth. Remove light scuffs, scores, or nicks from the camshaft machined replaced,

should

ROCKER

replaced

wipe

semblies can be tested with a hy draulic valve lifter tester to test the leak down rate. The leak down rate

specification

in

the parts

the components

all

be

and/or

the

replaced.

surfaces with

a

smooth

TIMING CHAIN

oilstone.

original

each

part

lifter

of

the

replacing, re

the entire assembly.

a

lint free cloth. Inspect the parts and discard the entire lifter assembly if any part

stem

to intermix the

If any

with

clean,

the

VALVE

Thoroughly that

with over

diameters of 0.003, 0.015, and 0.030 inch are available for service. Always reface the valve seat

HYDRAULIC


solvent and

clean solvent and wipe them

size stem

after

in

camshaft

the plunger good

Squareness Typical

edge of the valve

head is less than grinding,

Hll. 15 Valve Spring

Pres sure

Spring

the runout or to clean and grooves.

1019-B

Clean them

all parts

with

in

solvent and

compressed

the chain for

for cracks, damaged teeth. It is sprockets

air.

broken links and

dry

Inspect and

worn

the or

recommended

CRANKSHAFT CLEANING AND INSPECTION

Handle the

crankshaft

to avoid possible age

to

with

care

fractures or dam the finished surfaces. Clean

1-16

GROUP 1 -ENGINES AND EXHAUST SYSTEM

VERTICAL TAPER VS B VS D = HORIZONTAL TAPER OUT OF ROUND VS C AND B VS D CHECK FOR OUT-OF-ROUND AT EACH END OF JOURNAL

A C A

=

=

r. '

FIG. 17

1028-A

Journal Measurements

"-Crankshaft

1 749-A

FIG. 16 Camshaft the

crankshaft

blow

out

pressed

Lobe Lift

with

all oil

then

solvent,

passages with com

air.

Inspect

and

for

cracks,

scratches,

grooves, or scores. Dress perfections

with

rod

connecting

an

im Refin

minor

oilstone.

ish severely marred journals. Measure the diameter of each journal in at least four places to de termine

dersize

taper,

out-of-round,

limit, they

next

be

wear

to

bearing.

REFINISHING JOURNALS

Refinish the journal clearance

proper

connecting rod pin hole is not in

to

give

the

the next un

with

dersize bearing. If the journal will not "clean to give the proper up"

clearance with the maximum under

bearing

replace

available,

Abnormal

originally.

machined

or

crankpin, rod

an

that

radius

Too

small

a

existed

radius

by improperly a

tapered

a

badly

rods

will

twisted

not

wear

rods

will

and

and

sembly

oil

the

journal

holes,

oil

will

with

cloth

a

No.

may be

polish

320

engine

and

cloth

journals,

then

grit oil.

used also as a

agent.

connecting rod may be the cause

RODS

The connecting should

rods

as

check

the I. D.

bore is place

is

if the

the connecting rod

place

not within specifications.

pin

Re

the piston and pin if the pin

not within specifications.

interference fit

of

refer

connecting rod,

To

check

in the to Part 1-3. the pin

Replace defective connecting and bolts.

rod

nuts

After the connecting to the

tions of the

the

bend

the

fixture

and/or

are

as

them

check

suitable align

the

instruc If

manufacturer.

is excessive, should be

twist rod

connecting

straightened

rods

piston,

for bend or twist on a fixture. Follow ment

of

or replaced.

PISTONS, PINS, AND RINGS

vent,

bore

including a

caustic

all

out

connecting

sol rod

cleaning

passages

solution.

with

com

air.

pressed

signs

in

the back of the inserts. Do

and use

the

rod

of

connecting rods for fractures and the bearing the

related

be carefully inspected


Remove deposits from the piston and from the underside of

surfaces

the piston head. Clean gum or var nish

from

pins,

and rings with solvent.

the

use a caustic wire

piston

cleaning

brush to

clean

pistons.

be

fractures

replaced.

a

352 engine,

check

the piston

to connecting rod bushing clear ance. Replace the connecting rod if the

bushing is

so worn

that it cannot

ring

(Fig. 18). Make (or holes) are

slots

Carefully inspect and

pin

at

the

bosses,

Do

not

solution or a

the ring grooves with a cleaner

piston

skirt,

for out-of-round and taper. If the bore exceeds the recom limits and/or if the con mended necting rod is fractured, it should bores

pin and

430 engine,

consumption.

Clean the connecting

On CONNECTING

a

the connecting rod piston pin bore and the O. D. of the piston pin. Re

sembled

action of the entire pis

Inspect

After refinishing the

parts

bear

either

ton, rings,

bearing.

polishing

rod

disturb the

Blow

Crocus

ring

identifiable

easily

pattern, but

not

the

and

bore.

connecting Twisted connecting

jour

the same

in fatigue failure of the crank Too large a radius will result in bearing failure due to radius ride

polishing

caused an

result

chamfer

be

bent connecting rod,

shaft.

of the

proper re


reproduce

shoulder

nal

boss

pin

skirt

connecting

wear can

an oversize

the

crankshaft.

Always

On

the

excessive size

piston

honed for

reamed or

pin.

of

grooves.

create

be

these parts can

indicates is bent or the

lation to the

un

refinished

undersize

piston

of en

the piston usually

of

that a

ing

the

exceed

should

for the

or

(Fig. 17).

condition

If the journals size

by

be readily identified. A shiny surface on the side

to

conformance

Various forms

gine wear caused

main

journals

for

checked

and

specifications.

the

ring and

rough, or scored skirts.

ring

Clean groove

sure the oil clean. pistons

lands,

for

skirts,

for scuffed, If the lower

inner portion of the ring grooves have high steps, replace the piston.

1-1-

PART

1-17


Tool-RC-500

FIG. 18 Cleaning Ring The side

interfere

will

step

operation

and

cause

Grooves Typical with

ring

excessive

ring

clearance.

Spongy, edge

eroded

the

of

top

A shiny

pre-ignition.

thrust

surface

from the

are or

the

between the pis be caused by a Replace pis rod.

can

connecting

tons

that

show

wavy

of

signs

excessive

lands, fractures,

ring

damage from detonation

and /or

or

pre-ignition.

to cylinder bore

piston

with

a

tension

and

scale

the ring side clearance

and

the

following

pro

recommended

cedures.

Replace

piston pins

signs

showing

fracture or etching On a 352 engine, check the piston pin fit in the piston and rod bushing. To check the pin fit in the con and/ or wear.

of

rod

necting

of

a

430 engine,

refer

to Part 1-3. all rings that

Replace

chipped, or

gap

when

cracked.

are

to always install

overhauling the

should

not

piston

to

scored,

Check the

clearance.

side

and

practice

FIG. 19-Checking allow the cylinder bore to before the piston fit is checked. Calculate the size piston to be

eration, cool

used

by taking

(Fig. 25), then piston

Check the clearance

ribbon

1741-A

offset

piston,

centerline

bent wear,

piston

surface on

the

of

holes,

ton pin

the

near

the

by detonation,

caused

usually

areas

of

end

It is

good

new

rings

engine.

Rings

be transferred from

one

regardless

of

another

a cylinder

select

to provide the

the

bore

check

proper size

desired

clear

mately AVa

tension scale to the end of a

termined

feeler gauge ribbon that is free of dents or burrs. The feeler ribbon should be Vi inch wide and of one of the thick nesses listed in Table 4. Position the ribbon in the cyl inder bore so that it extends the entire length of the piston at 90 from the piston pin location. Invert install it in the bore is about 1 % inches below the top of the cylinder block and the piston pin is parallel to the crankshaft axis. Hold the piston and slowly pull the piston and

so that the end of the piston

the scale in a straight line with the

ribbon, noting the pull required to

in

standard

0.030, 0.040, size.

Standard

and

service

0.003, 0.020,

and

sizes

for

0.060-inch over divided

size pistons are

into two sizes and are identified by a daub of red or blue paint. Refer to the specification section for the avail able sizes.

The

piston

should

be

(70 F)

when

checked.

at

and

cylinder

room

the

After any

block

temperature

piston

fit

refinishing

is op-

Example 1. If a 0.0015-inch feeler ribbon is used and it takes approxi the feeler

remove

available

line to the right until it intersects the diagonal line representing the feeler ribbon. Read down the vertical line for the clearance.

Make sure the piston and cylinder bore are clean and dry. Attach a

FITTING PISTONS are

Fit Typical

ance.

mileage.

Pistons

Piston

The

the

piston

feeler ribbon (Fig. 19).

to cylinder bore clearance

be from 0.0011-0.0029 inch. The wear limit is 0.005 inch. In Table 4, the diagonal lines rep resent feeler ribbons of various thick should

pounds

ribbon,

to remove

pull

the clearance is ap

proximately 0.0008 inch. This is de

by locating

{AVa) in Table line to the

4

right

the pounds pull

following

and until

the

it intersects

the diagonal line representing 0.0015-inch feeler ribbon. Read down the vertical line for the clear ance (approximately 0.0008 inch). Example 2. If a 0.003-inch feeler ribbon is used and it takes approxi mately 9 pounds pull to remove the with

the

ribbon, the resultant clearance is ap

proximately 0.0015 inch. Example 3. If a 0.003-inch feeler ribbon is used and it takes approxi mately 4 pounds pull to remove the feeler ribbon, the resultant clearance is approximately 0.0026 inch. If the clearance is greater than the maximum

limit,

recheck calculations

to be sure that the proper size piston

has been selected,

check

aged

try

piston, then

a

for new

a

dam

piston.

If the clearance is less than the

nesses, the horizontal lines represent

minimum

the pounds pull, and the vertical

lines represent the clearances. To deter mine the clearance, locate the line

before trying can be fitted,

representing the pounds pull required to remove the feeler ribbon from the cylinder bore. Follow the horizontal

When a piston has been fitted, it for assembly in the cylinder to which it was fitted.

limit,

recheck calculations

another piston. refinish

If

none

the cylinder for

the next size piston.

mark

M8

1- ENGINES

GROUP

TABLE 4-

-Piston

Clearance

\

\\

13

AND EXHAUST SYSTEM

\

\

\

12

\

\

\

\

RIBBON

.0045

RIBBON

.004 .

.0035

> .0025

11

RIBBON

RIBBON

.003

RIBBON RIBBON

.002

.0015

RIBBON

10 (A

a

Z

9

3

o CL

z

\\ \ \ \ \ \\ \ \\ \ \ \ \. \ \ \\K\ \ \ \ K \\ \ \t \ \ \\\ \

_l

3 a.

7

Ul

\

O 3

< o

6

z

o ca

4'/4

y

5

5

POUNDS *

1

(EXAMPLE)

\

V

8

mJ

\

4

V.

s

3

4

POUNDS

\

2

1

v

1

^

\ 1

\

0 -.0

02

C

01

3+

.0

)2

01

)3

.0(

.004

.oc

.005

CLEA RANCI: IN IN CHES 1

326'

8'

.01

.000

(EX*MPLE)

(EXAM PLE)

If the taper ditions

of

in limits,

cylinder piston

new

satisfactory ton

and out-of-round con

the

are with will

in the

limits. If the

give

the pis

service provided

clearance

within

bore rings

cylinder

bore is

new rings are

gap between the ends of the ring a feeler gauge (Fig. 20).

with

If the gap is less than the recom lower limit, try another ring

"glaze."

cut.

Use

size

to

set.

bores. Check the hole size, using the new piston pin. If the bore is small,

FITTING PISTON PINS

The

piston pin

fit

fit

thumb press

for the The rings size piston to be used. must be checked for proper gap in

ture (70F). Standard

the

cylinder

proper

bore

in

side clearance

First, as

check each

ring

and

set

ring for

proper

(color

proper

gap

cylinder

it is going to be used. into the cylinder where normal ring wear is

which

Push the ring down

bore not

area

encountered.

piston

to

or

of a

the ring so that the with the cylinder wall.

position

ring is square Use caution to

ring

Use the head

avoid

cylinder

damage to the

bore. Measure the

tempera

piston pins are

0.001 -inch oversize (color blue) and 0.002-inch oversize of

coded

able

the nearest

alignment

another

cut.

slightly Repeat the

of

the

and make

procedure

fit

is obtained. for fit in the respective rod bushing. If necessary, ream or hone the bushing to fit the until

the

Check the

proper piston

pin

pin.

yellow) are available for

the 352 engine.

Oversize

Position the ring in the

bore in

Pins

grooves.

follows:

light

a

coded green.

coded

for the

the piston

be

normal

at

a pilot sleeve of maintain

expand the reamer

should

cylinder wall

Select the

then expand the reamer slightly and trial ream the pin bore. Take a light

mended

to

be installed in a used cylinder that has not been refinished, remove the

18S6-A

MAIN AND CONNECTING

piston pins are not avail

for the 430

pins are serviced

engine.

only

Piston

as an

and

assembly

ROD

BEARINGS


on this engine.

On in the

a

352 engine, if the

piston must

pin

be reamed,

expansion-type piloted reamer.

the

reamer

piston reamer

in

around

hole

use an

Place

a vise and revolve

the

reamer.

the

Clean the thoroughly. carefully.

scored,

Set the

should

bore,

amples

to the size of the pin

bearing inserts Inspect

Bearings

chipped,

be of

or

that worn

and caps

bearing have

a

surface

Typical ex failure and their

replaced.

bearing

each

1-19


1043-B

FIG. 20 Piston in Fig. 21. Check bearings that ap to be satisfactory with Plasti Fit new bearings following the

causes are shown

two

the

daub

clearance

pear

gage.

recommended

of

procedure.

sizes of

Ring

identified by a blue paint. Red

are

and

or

red

Gap Typical

bearings increase the

marked

fit,

which are not selective

BEARING REPLACEMENT able

The

bearing do

main

and

inserts

not require

installation. Do

ing

are

connecting fit

selective

reaming to not

file

caps or use shims

proper

bearing

lap

bear

obtain

the

are available

for service in standard sizes only. Standard bearings are divided into

DIRT IMBEDDED

SCRATCHES

use

on

are avail

journals that have

refinished.

evenly

and

However, if to

are

not

wear

a

of

the journal. If the bear

ing is fitted

to the minimum diam

eter

with minimum

clearance, inter

OVERLAY WJPED OUT

-

-

ance

with

two blue

bearing

When checking the

out-of-round.

bearing is being fitted an out-of-round journal, be sure fit the bearing to the maximum

diameter

bearings be fitted to a crankshaft journal which exceeds the maximum of out round specifications. When replacing standard bearings with new bearings, it is good practice to first try to obtain the proper clear

Plastigage, in

order

order

of the

the widest point

at

the narrowest point

to get the maximum clear

The

ance.

halves.

to get the minimum clear

Check

ance.

in

check at

width

difference between the is the taper.

two readings

BRIGHT

(POLISHED) SECTIONS

INTO BEARING MATERIAL LACK OF OIL

SCRATCHED BT DIRT

FIG. 21

for

Normally, bearing journals

to

clearance.

Selective fit bearings

been

and

size upon

or

to

rod

clear

ance; blue marked bearings decrease the clearance. Undersized bearings,

ference may result, causing an early failure. It is not recommended that

15VERLAY GONE FROM ENTIRE SURFACE

RADIUS RIDE

TAPERED JOURNAL

RADIUS RIDE

Typical

Bearing

Failures

IMPROPER SEATING

CRATERS OR POCKETS FATIGUE FAILURE

1030-A

1-20

GROUP

PLACE PLASTIGAGE FULL WIDTH OF JOURNAL ABOUT Va INCH OFF CENTER

1-


CHECK WIDTH OF PLASTIGAGE 0 002

PLACE Plastigage FULL WIDTH OF JOURNAL ABOUT Va INCH

CLEARANCE

OFF CENTER

INSTALLING PLASTIGAGE

CHECK WIDTH OF Plastigage

MEASURING PLASTIGAGE 1031-A

Mb. ZZ

Installing Engine

and

Measuring

Plastigage

Work Stand

on

0.0015"

CLEARANCE

MEASURING Plastigage

INSTALLING Plastigage

1558-B

23

FIG.

Installing

Plastigage

Measuring

and

Engine in Chassis

the Plasti

not compress

weight will

gage and provide an erroneous read

ing. Position

a

bear

the

against

small

jack

it

so

will

counterweight

ad

is being checked. Place a piece of Plastigage on the bearing surface the full width V* of the bearing cap and about

joining

inch

1049-8

specified

halves

is less than the

limits, try

two red

bearing

combination of red

or a

sired limits, refinish journal, then install

the crankshaft

bear

undersize

ings. get

not

foreign

distort

Main Bearings. The

is for

cedure

removed.

stand,

If

2-5. In step stand,

work

support engine

3

mat

and

place

the

will

pro

installed in

the crankshaft not

the engine

step 1

omit

following

the engine

with

chassis

shaft

bearing

the

bearing failure.

cause

the

under

In time the foreign

the inserts.

may

matter

3, if it is

and

is

on a work

1. Replace

leaving

crankshaft

ing

is

ing,

main

bearing

tool (tool

6331) in

the

hole in the

turn the crankshaft

the cap, then using the Plasti

place

the

6331

in

plain

the

rotate

opposite

rotation until

end

hole

oil

of

the

4. After

of

width

the

bearing has been

the

found to be satisfac tory, apply a light coat of engine oil to the journal and bearings, then and

checked

install the

bearing

cap bolts to

5. If the

rear main

bearing

of

in the

block)

The

be

new

and

connecting

connecting

Remove the tool. Replace the cap

Place

bearing. Clean the

lower

crankshaft

of so

its

on a

rod

the

piece

bearing

the cap

center.

and the

(in the

with the

Rod Bearings.

Connecting

firmly

re seal

installed.

rod

itself.

oil

cap

replaced

in

engine

bearing is

upper oil seal

cannot

crankshaft

Tighten the

lower

bearing

rear main

side seals.

1. Install the

seats

journal and bearings. 3. Support the crankshaft

the

replace

placed,

cap.

specifications.

in the

the crankshaft

direction the

the

check

scale,

crankshaft

bearing over the shaft on the lock ing tang side of the block. Using tool

gage

time,

at a

bearings securely

crankshaft Rotate in the direction of engine rotation to force the bearing out of the block. 2. To install the upper main bear

the

the

of on

bearing

one

other

removal

on a

22) instead

engine

not

Plastigage.

fastened. Remove the

is

the Plastigage on the crank

if the

cap to which new bearings are to be installed. Insert the upper bear

crankshaft,

be inverted. Also in step

journal (Fig.

the

steps

necessary to because the

surface

work stand.

follow

the engine not

bearing

on a

oil

Do ter

the

and

blue depending upon the condition. If the standard bearings do not bring the clearance within the de

Do

the Plastigage is in place. Re

move

clearance

tighten the bolts to specifi

cations.

while

If the

which

(Fig. 23). Install the

off center and

cap

Z4 Typical Flywheel Face Runout

bearing

the

bearings in the cap. Pull the down

assembly

journal.

crankshaft of

Plastigage

on

the

surface, the full width

and

about

Install the cap

V*

inch

and

off

tighten

1-21


CENTERLINE OF ENGINE

sages.

Blow

out

holes,

etc.

with

Make

sure

all

bolt

passages,

air.

compressed

the threads in

the

cyl

inder head bolt holes are clean. Dirt in the threads may cause binding and result in a false torque reading. Use a tap to true-up threads and to

A-AT

RIGHT ANGLE TO CENTERLINE OF ENGINE

any deposits. After the block

remove B"

PARALLEL TO

CENTERLINE OF

for

ENGINE

Minute

cracks.

to

the

by

coating the

light

If

OUT-OF-ROUND

2. TAPER

FIG.

=

the

shaft end

cations.

as

connecting rod nuts to specifi Do not turn the crankshaft while the Plastigage is in place. 2. Remove the cap, then using the Plastigage scale check the width

of

the Plastigage.

for the

procedure

remaining connecting

If the

runout

limit,

mum

rods

that re

wheel

or

Replace

knock it

wheel.

INSPECTION

removing the ring

replace

the

fly

Inspect the ring

gear

cracked

chipped,

or

teeth are

damaged,

for worn, If the

teeth.

replace

the

tion

the

of

With the flywheel installed

crankshaft, check the flywheel

face

runout.

dial indicator point

bears

sure

properly against Do not heat any por to

gear

temperature

a

exceeded,

the

temper

from the ring

will

gear

be

re

teeth.

During

the

disassembly

block for

closely inspect the all

parts

of

wear.

to

help

Thoroughly

so that the

against

the

flywheel face (Fig. 24). Turn the flywheel making sure that it is full forward or rearward so that crank

solvent.

engine

from all

wear

the

of

all

show

plugs

pattern on

Inspect

the

then

clean

the

out

cylinder

roughness,

of wear.

Check the

out-of-round

bore

plugs

leakage.

of

or

cylinder

and

with

walls

other

an

for signs

bore for Measure

taper.

accurate

gauge

instructions of the manufacturer. Measure the diam eter of each cylinder bore at the top, middle, and bottom with the gauge

following

placed

the

at

right

angles

and

parallel

to the centerline of the engine (Fig.

Refinish

cylinders that

and /or

scored

when

and/or taper exceed

If the surface

are

deeply

out-of-round

the wear limits.

cylinder walls

have

imperfections, but

minor

the

of-round and taper are within

out-

limits,

it may be possible to remove the imperfections by honing the cyl inder walls and installing new serv ice piston rings providing the piston

finest

is

within

grade of

limits. Use the stone for this

honing

REFINISHING CYLINDER WALLS

cause

Honing is recommended for re finishing cylinder walls only when the walls have minor imperfections,

block

in

old gasket material

which

for the

expansion-type

evidence

scoring,

the

procedure and

operation.

all machined surfaces.

pipe

sages,

Replace that

the

overhaul,

diagnose the

clean

Remove

of

alcohol.

head.

cylinder

clearance

CYLINDER BLOCK


FLYWHEEL FACE RUNOUT a

to

enough

higher than 500 F. If this limit is

cylinder on the

expands

evenly

seated

the shoulder.

dry

25). gear

ring

flywheel. Make

the

is

gear

fly

when

gear.

new

gear

onto

slip

side of

the

off

hit the flywheel

not

the

the

until

the ring

gear.

Install

Heat

moved

wheel.

indicator

Do

gear with

on the engine

TRANSMISSIONS Inspect the flywheel for cracks, heat check, or other defects that would make it unfit for further serv ice. Machine the friction surface of the flywheel if it is scored or worn. If it is necessary to remove more than 0.045 inch of stock from the

fly

the

RING GEAR REPLACEMENT

the gear, then

part

coating

recommended

crankshaft

Heat the defective ring

FLYWHEEL MANUAL-SHIFT

thickness,

the

flywheel face if the mounting flange runout is excessive.

blow torch

a

following

specifications

the flywheel and

machine

the

it is cracked. Check all machined gasket sur faces for burrs, nicks, scratches, and scores. Remove minor imperfec tions with an oil stone. Check the flatness of the cylinder block gasket

maxi

burrs

flange.

mounting

Wipe

apply dissolved in wood

the runout of the crankshaft

check

75%

cracks

surface

the

exceeds

between the fly face of the crankshaft mounting flange. If no burrs exist,

a

original

be indicated

not

remove

for

check

bearings.

quire new

Taper

play will flywheel runout.

with

and

will

wheel and the

After the bearing clearance has been checked and found to be satis factory, apply a light coat of engine oil to the journal and bearings, then install the connecting rod cap.

3. Repeat the

and

area

the coating are present, become discolored at the de fective area. Replace the block if

DIFFERENCE BETWEEN A AND B DIFFERENCE BETWEEN THE A MEASUREMENT AT TOP OF CYLINDER BORE AND THE A MEASUREMENT AT BOTTOM OF CYLINDER BORE 1039-A =

25 Cylinder Bore Out-Of-Round

may be detected

immediately

zinc oxide

1.

cracks not visible

suspected

oil.

motor

check

a

25% kerosene

a mixture of

and

eye

naked

been

has

make

thoroughly cleaned,

Remove

seal

oil

pas

all

the

pas

light scuffs, scratches, etc. of hone to be used is determined by the amount of metal to be removed. Follow the instruc such

The

as

grade

tions of the

hone

manufacturer.

If

1-22


coarse

stones

are

to start the

used

honing operation, leave enough ma terial so that all hone marks can be removed which

is

piston

clearance.

Cylinder marred

that

walls

limits

Before any

should

caps

not

be

refinished.

is refinished, all be in place torque

proper

so that the crankshaft

will

severely beyond the

must

tightened to the

and

are

worn

cylinder

bearing

proper

bearing bores

become distorted from the

refinishing

Refinish only the cylinder or cyl require it. All pistons are

the same weight, both standard and

oversize; therefore,

various sized pis

tons can be intermixed

without upset

ting engine balance. Refinish the If the

oversize piston

the

maximum

cylinder will not clean

when refinished

up

the most

cylinder with

first to determine the

oversize.

for the

maximum replace

recommended,

Refinish the

cylinder to within

proximately 0.0015 inch

diameter. This

oversize

honing

so the

of

thoroughly

the

to correspond

pistons

completed and all pistons clean the

oughly move

all

bores, holes,

oil

with

entire

from

passages,

Coat the

been

fitted,

cylinder

etc.

of all

thor

block to

particles

to

re

bearing

the

head bolt

OIL PAN AND OIL PUMP (AND VACUUM BOOSTER

Inspection. Check the inside

housing

rotor

for damage

OIL

grooved,

Measure the

surface.

foreign

all

Wash the

dry it

matter

Check the

Use

No. 220-280

will

clear

grit

in

pan

is

a

Be

thoroughly.

sol

from

removed

and

baffle, ket

for cracks, holes, a loose

Repair the pan

any

if

O.D.

finishing

structions of

damage,

gas

be

the

the manufacturer.

perform

Check

scribed

should

vent

in

Only

be

a

and

dry

brush to

in

a sol

them thoroughly. Use

clean

the

inside

I.D.

of

bearing. relief valve

spring for

replace

of

the

a

the

spring.

the relief valve piston

scores and

On

re

housing

measuring the

free

430

operation

engine

pump, inspect all

the vacuum pump parts

Replace the if any

part

for

in the bore. for damage.

complete vacuum

pump

is damaged.

al

this work. operation

two refinishing and

the

rotor

relief valve spring ten If the spring tension is not with in specifications and/ or the spring is

made.

for all parts

to

shaft

by

the shaft and the

housing

defective,

repairs can not

and

as an assembly.

Check the

replace

or

and

a collapsed or worn condition.

OIL PUMP

follow the

personnel

After the final of

of

use

equipment

experienced

lowed to

proper

clearance

of

rotor

sion.

a nicked or warped

and

only

Check the drive

the

the

shaft

race,

Inspect the

surface.

Cleaning. Wash the

edge

hous

between

(Fig. 27).

outer

bearing

plate.

pan

and the

the straight

this operation.

For

assembly

clearance

gas

sure

place a straight edge

ing. Measure the

are replaceable

vent and

assembly installed

rotor

Scrape any dirt or metal particles from the inside of the pan. Scrape ket

to hous

race

outer

(Fig. 26).

clearance

The

or

the cover.

replace

OIL PAN

from the

the

or excessive wear.

is worn, scored,

surface

mating

outer race

all old gasket material

of

race and

Check the mating surface of the pump cover for wear. If the cover

over the rotor

PUMP

AND OIL

PAN

the outer

and

in the housing,

ENGINE)

430

pump housing, (430 engine).

pump

ing

oil.

re

dirt

all

vacuum

vanes

and

pressure sure

removed.

are

Clean the rotor,

walls

cylinder

chips

and

to be

are

they

which

pump housing and the lief valve chamber. Be

fit.

piston

damaged drain plug threads,

for the final step correct surface finish

and pattern are obtained.

sharp hones

then

installed. When the refinishing has cylinders that require it

ap

the re

of

allow enough stock

of

Mark the

below the baffle

block.

quired

particles,

the walls. Check

dry

to remove all

walls with solvent

abrasive

the cyl

wash

With the

operation.

inders that

wear

inder

the cylinders in

and/or

specified

main

to obtain the

used

hone

finishing

the

with

fit, thoroughly

piston

prior

to

in

either

methods

checking

de

Straight Edge

the

Feeler Gauge

1742-A

FIG. 26 Outer

Race to

Housing

Clearance

1743- A

FIG. 27-Rotor

End

Play

1-23

Page

Section


1-2 Section

1

Page

Description

2

Engine Removal Installation

3

Section

1-23

Valve Rocker Arm Shaft.

and

Cylinder Heads 1-28

Assembly Removed)

Disassembly (Engine Removed) Disassembly and Assembly

4

Component Parts

of

Pistons

1-30 1-32

and

1-44

Installed) Engine Supports

1-44

Intake Manifold

1-45

Cylinder Heads

1-45

Crankshaft Damper

1-45

Page

Cylinder Front Cover

1-32

Timing Chain

1-45

Camshaft

1-46

Hydraulic Valve Lifter Replacement

1-46

1-34

.

1-36

Repair Operations (Engine

6

1-33

Hydraulic Valve Lifters.

Engine

(Engine

Engine

5

and

1-46

Flywheel

Connecting

Rods

1-35

Oil Filter Replacement.

Oil

1-35

Oil Pan

Pump

Oil Pump

and

.

.

...

1-47 1-47

DESCRIPTION The Thunderbird 352 Special V-8 (Figs. 1 and 2) has a 4.00-inch

engine

bore

and

a

3.50-inch

and

stroke

a

total piston displacement of 352 cubic

inches. It has a compression ratio of 9.6:1. The patent plate symbol for the "H."

is

engine

MANIFOLDS The intake manifold, ber cover,

hot

contains

the

through

center

passage

a

gases

exhaust

assist

in

gases

are

and

section

the carburetor, through

under

also

which

the valve push rod cham

as

serves

which

directed

are

to

vaporizing the incoming fuel charge (Fig. 3). The exhaust

valve

is located

right

exhaust

valve

is

(Fig. 4). The

at

the

position, part of the directed from the

more of right

flow

out

"heat

permitted

the

exhaust

fuel passages, each inlet connection to the

separate

the

(Fig. 5). The

carburetor

and

7

right

feeds Nos.

cylinders

feeds Nos. 2, 3,

and

5,

the

and

8

Valve sets

the own car

side

of

1, 4, 6, left

The

head

assemblies

head. The

an

in the head.

integral

valves rear

combus

on

part of

arranged

are

both banks

E-I-E-I-I-E-I-E (Fig. 6).

CYLINDER The

con-

3, 7,

rear on

and

4

and

8. The

and on

the right

from

bank 1, 2,

the left bank

firing

2-6-3-7-8. The oil pump,

front, is driven by

distributor through drive shaft. The

five

crankshaft

insert

Crankshaft

type

supported

by

bearings.

main

thrust is controlled

end

flanges

the

is

the

intermediate

an

of

the No.

3

main

bearing.

BLOCK

cylinders are numbered

front to

oil pan at the

by

side

HEADS

cylinder

guides are

from front to

cylinders.

The distributor is mounted at the left front of the intake manifold. CYLINDER

The

assembly.

tion chambers are cast

its

with

shaft

system

has two

manifold

352 Special V-8 Engine

tain the valves and the valve rocker

to

manner.

normal

buretor

FIG. 1 Thunderbird

mani

opens

are

1722-A

riser

arm

The intake of

heat

exhaust

valve

manifold

directly

in the

exhaust

right

the exhaust gases from

off,"

the

left

the

When the

the on"

gases

exhaust

the

through

to

passage,

When

in the "heat

or

closed

the

of

outlet

manifold.

are

fold.

con

thermostatically

a

trolled exhaust valve

manifold,

intake

into the

directed

by

manifold

order

is

5, 6, 1-5-4-

The sion

The

top

inside the

and

The

oil

two

one oil

compres

control ring.

ring is lower com

compression

chrome-plated pression

mounted

have

pistons

rings

and

ring is control

the

phosphated-coated.

ring assembly

con-

1-24

GROUP

1- ENGINES

AND EXHAUST SYSTEM

1723-A

FIG. 2

Sectional

View

of

Thunderbird 352 Special V-8 Engine

PART 1-2

1-25

352 SPECIAL V-8

-THUNDERBIRD

OPEN (HEAT OFF)

10O1-A

FIG.

4 Exhaust

Gas Control Valve

l-A

FIG. 3 Intake

Manifold Exhaust Gas Passages

1724-A

Flu.

0 Valve

Port Arrangement thrust button and spring located be tween and

the

bolt

sprocket

camshaft

the cylinder front cover. An ec

bolted to the front

centric, the

operates

camshaft,

end

of

the

fuel

are

used

pump.

Hydraulic which

valve zero

provide

minimize

valve

lifters

lash

valve

train

and

The

noise.

identification of lifters are shown in Fig. 7. When the valve is closed, the lifter assembly is on the base

operation and

parts

the hydraulic valve

circle

of

the camshaft lobe and the

valve push rod

tion.

With

the

is in its lowest posi lifter assembly in this

position, the plunger spring expands the plunger upward. This

1512-A

forcing

FIG. 5-lntake sists

of

a

Manifold Fuel Passages

serrated

chrome-plated

spring

steel

and

two

rails.

semblies

rotate

and

each

exhaust

valve

rotating-type

time

the

valve

as

which opens

closes.

The oil

and

are the

push rods are solid steel with

cushioned

is

with

hydraulic

valve

rocker

justing

VALVE TRAIN The intake

there

sockets.

Inasmuch

as

no

valve

lash

valve

arms

do

adjustment

lifters, not

the

have

ad

screws.

is supported by five insert-type bearings pressed into the block. It is driven by a sprocket and timing chain in mesh with a sprocket on the crankshaft. Cam The

shaft

camshaft

end

play

is

controlled

by

a

action

is

rocker

arm

until

transmitted

the

to

the valve

via

valve

push

there is solid contact

rod

betweer

the valve and the valve end of the rocker arm (zero valve lash). In this position, the oil hole in the lifter and plunger is indexed with

valve

the lifter oil gallery and oil is under

This

pressure creates

above and

high

a

into

pressure

below the

pressure

the

above

differential

valve

the

forced

plunger.

disc. The

valve

disc

1-26

1- ENGINES

GROUP

AND EXHAUST SYSTEM

VALVE OPEN LIFTER BODY VALVE

CLOSED

PUSH ROD CUP

PLUNGER

Mfl } PLUNGER SPRING

DISC VALVE

**&>

-*jp

DISC VALVE

SPRING

BASE CIRCLE

1717-B

7 Typical Hydraulic Valve Lifter Operation

FIG.

forces the

fills

oil

area

equalizing the of

the

the

tends

to

spring

expands

be

the

plunger

pushing the

the

of

parts

arm

rocker

valve

plunger

between

contact

solid

train

valve

mech

anism.

As

the

disc

comes

a

period

a

below

tates

point

past

forces the seats

oil

the

ram.

leakage

the

the valve

the valve.

below the

oil

lifter be

During oil

of

occurs.

camshaft

lifter,

the

The

As lobe

and

pressure on

is

this

from

push

lifter down

plunger

pres

forces the

the

and

plunger

on

raised

plunger

hydraulic

the

(valve

is

increase in

closed

slight

rotates

lifter

valve

sudden

below

sure valve

high

camshaft

the

opening) and

cycle

is

can

opens

that

so

be filled. This

for

each revolution

repeated

Oil from the oil pan sump, lo in the front of the oil pan, is forced through the pressure-type lu

cated

lief

Oil

(Fig. 8) by a rotorA spring loaded re

the

by

All

the

the

position

at

the

the

filter

if

engine.

permits

the

A

relief

oil

to

en

in

lower

element

the flow-

full

a

enters

mounted

in the filter the

by

is

of

clogged.

the pump.

filter

The

front

is directed

side of

through

the

system.

discharged

filter before it

type

the

of

the valve

oil

passes

pump

limits

pump

pressure

back to the intake

ro

the

in

relieved

vertical

relieved and

pump.

maximum

the

re

system

valve

gine.

rod

SYSTEM

a

left

valve

bypass

becomes

filter,

flows into

the oil

the main oil gallery which is located in the center of the valve push rod

floor. The

chamber

LUBRICATION

brication

From the

the

again

the camshaft.

type oil tht

disc

valve

chamber

between the

present,

is

the

of

clearance

and

all

the

plunger

pressure on each side

valve

there

and

disc.

valve

Whenever

until

disc open below the

valve

the

oil

gallery sup

individual

plies oil

to each

bearing,

through drilled passages in

the block.

Passages

each camshaft

bearing

ing

feeds No. 1

drilled from

are

bearing. Number 1

to

bearing

main

bearing,

etc.

main

crankshaft

bear

bearing,

main

camshaft

the

each main

camshaft

No. 2

flows through

camshaft

and

feeds No. 2

The

oil

then

notches or grooves

in

bearings to lubricate the

journals. A jiggle

pin

in

front plug allows air that be trapped in the any may oil to escape. The timing chain and the main oil gallery

sprockets

oil

are

splash

from the jiggle

The

crankshaft

lubricated

by

pin.

is drilled from the

bearings to the connecting rod bearings. The oil flow is as follows: main

1-27

PART 1-2 -THUNDERBIRD 352 SPECIAL V-8

NO. 2 SUPPORT, LEFT HEAD NO. 4 SUPPORT, RIGHT HEAD

CYLINDER HEAD BOLT BORE

FROM NO. 2 CAMSHAFT

BEARING TO LEFT CYLINDER

HEAD, AND FROM NO. 4 CAMSHAFT BEARING TO RIGHT CYLINDER HEAD.

1725-A

FIG. 9 Valve

Rocker Arm Shaft Lubrication

1514-A

FIG. 8 Lubrication

Syst em TO RADIATOR SUPPLY TANK

J$

i

/

i

1 770-A

FIG. 11 Cooling

FIG. 10 Crankcase

Ventilation System

System

No. 2 left

Main

Connecting Bearing

Rod

Bearing

No.

Serves Serves

Nos. 2

No.

Serves

Nos. 3

No.

Serves

Nos. 4

No.

Serves

No. 8

No.

A

small

connecting

groove rod

at

the

1

No.

ing

and

and

7

the cylinder wall.

cap contacts the connect This groove is used as an ing oil squirt hole for cylinder wall lu brication. Oil from the connecting rod.

site

cylinder wall.

nal

Oil

is located in the the mating face

hole lubricates the

hole in the connecting rod bear aligns with the hole in the jour causing a direct squirt of oil onto

5 6

and

where the

rod squirt

No. 1 connecting rod oils No. 5 cyl inder, etc. As the crankshaft turns,

oppo

For example, the

main

oil

are

drilled from the

gallery to each valve lifter Oil from here feeds the

oil

gallery.

valve at

passages

lifter

each

assemblies.

valve

oil so that oil

A

reservoir

lifter bore boss traps is available for valve

lifter lubrication

as

soon

as

the en

gine starts.

An

oil

camshaft

cylinder

6

and valve

cylinders rocker

is drilled from

web to the

(Fig. 9). The

to

arm

lubricate shaft

oil passage

the

assembly in the cyl

inder head is drilled from the cylin der head bolt bore to the No. 2 valve rocker arm shaft support.

The

oil

flows through the

rocker arm shaft

in

valve

through drilled holes

each valve rocker arm to

lubricate

the shaft bore and both ends of the

The excess oil down the rotating push rods

valve rocker arm.

spi

rals

and

lubricates the passage

bearing

head between Nos. 5

push

rod

seats.

right valve rocker arm shaft

The

assem-

1-28

GROUP

is similarly lubricated from No. 4 camshaft bearing via the No. 4

bly

valve rocker arm shaft support.

A baffle located rocker

arm

shaft

the valve

under

shields

assembly

the valve stems from oil splash. Excess

1- ENGINES

into the front push

AND EXHAUST SYSTEM

section

chamber

rod

of

where

the

valve

there are

up before contacting contaminating vapors originating in the crankcase.

passages to cool

CRANKCASE VENTILATION

the

crankcase

located at the The forward

tube

ventilation rear

the

of

motion

causes a partial vacuum to at the tube outlet.

This

engine.

the

of

is car

be formed

vacuum action

be drawn through the engine from the oil filler cap located at the front of the intake manifold (Fig. 10). The filler cap contains a filtering element which filters the in causes air to

coming air. From the filler cap, the

air

flows

pump

a

located

baffle,

intake

the front

the underside

on

manifold,

both

of

upward

valve

rocker

of

from the valve rocker arm from the crankcase and

flows into the rod chamber.

rear of the valve push

All

air

is

then

directed

combustion

The

coolant

is

drawn

The

it

where

the

into the

upward

the

cools

and

valves,

chambers,

coolant

to the front

return

from

into the top

open,

cylinder

each

the

of

radiator.

If the thermostat is closed, water

for

pump

is

system

entire

by

psi

is

the coolant

portion of

13-15 from the

of

head flows through the water pas and manifold sages in the intake past the water thermostat, if it is

The

SYSTEM

block,

cylinder

its

length

entire

the engine.

the

out the crankcase ventilation tube.

COOLING

heads

cylinder

valve seats on

chamber

water

Upon reaching

is directed

of

The baffle also directs air front of the lower crankcase into the timing chain chamber.

Air

the rear of the coolant

into

to the

the

wall.

cylinder

each

the

coolant travels through cored

arm

chambers.

and

The

by

radiator

delivers the coolant to block (Fig. 11).

the cylinder

Warm ventilating air minimizes the formation of crankcase sludge. The ventilating air is directed by

A

the

of

which

few contaminating vapors. Here, the incoming air has a chance to warm

is returned to the oil pan through drain back holes located at each end of the cylinder head and in the push rod chamber floor.

oil

bottom

a

a

small

returned

to

recirculation. pressurized

pressure-type

to

radia

tor cap.

ENGINE REMOVAL AND INSTALLATION The

procedures given are

for the

only without the transmission attached. If the engine and transmis

engine

sion are removed as an

stall

threads of

eye

standard

in

the

the exhaust

the

lifting bracket and bolts. The engine in is shown in Fig. 12. engine

stallation

eye

assembly, in

bolts

bosses

tach

sling to the

with

at the

manifolds.

Vi-IA

top

rear

Then

at

tery

hood,

1. Drain the cooling system the crankcase. Disconnect the

and

bat-

Re

engine.

the air

and

radiator,

cleaner.

2. Remove the

REMOVAL

the

ground cable at

move the

level

oil

dip

and the coil.

Disconnect the

sure

unit wire at the

sending

unit, the flexible fuel line

line,

tank

line

the

flexible

stick

oil pres

at

sending the fuel

windshield

the vacuum pump and position it out of the way. Remove

wiper

the wire

left

at

loom from the

the

clips on

valve rocker arm cover and posi

tion the wires out of the way.

On

a car with a windshield

disconnect washer

the

pump

washer,

lines

three

the

at

position them out

and

of the way.

On

a car with a manual-shift

mission,

Remove

disconnect the

the

trans

accelerator.

accelerator

retracting

spring.

On

a car with an automatic

mission, rod

and

disconnect cross

shaft

secure ihem to the

dash

a car with power

connect

trans

accelerator

the transmission rod at the

accelerator

On

the

the

power

bracket from the

bracket

steering, dis

steering

water

and

panel.

pump

pump, then

the power steering pump to the hood left hinge in a position that will

wire

prevent

On

the oil from

a car with

draining

power

brake line at the at the flexible line, then release the line from the brackets on the left valve rocker arm

connect the power 1884

FIG. 12-Thunderbird 352

Special V-8 Engine Installation

-A

out.

brakes, dis

intake

manifold

and

PART 1-2 Tool T53L300-A

1-29

352 SPECIAL V-8

-THUNDERBIRD

Tool 1009

Tool T58P-6000A

1728-A 1727-

Fib. 13 Engine Lifting

Brackets

and

the line. On a car with an air conditioner, disconnect the magnetic clutch wire. Isolate the compressor. cover and remove

3. Disconnect the heater hose the

water

pump

and

manifold, the generator

wires at the

the engine tempera

and

generator,

intake

the

at

ture sending unit wire at the sending unit. Remove the engine ground strap the

and

retaining bracket

starter cable

from the head.

rear

of

the

the rear of the right cylinder

at

head. Attach the engine lifting sling (Fig. 13). Raise the engine slightly and carefully pull it from the trans Lift the

mission.

out

engine

a work stand

the

of

install it

engine compartment and

on

of the car.

Re

the starter and dust seal (and

the automatic transmission

fluid filler

1. Position the valve, with a

exhaust gas control

new gasket on each

the right exhaust manifold

on

side,

studs.

Temporarily

manifolds, and the engine right and

Loosen the engine right and left sup port insulators at the chassis. Attach

left

insulators

support

On

at

the

engine.

a car with an automatic trans

mission, remove the converter hous

ing

lower

access cover and the cover

Remove the flywheel to Secure the converter assembly in the housing. Remove the assembly.

converter nuts.

converter

bolts,

housing

and remove

lower

engine

the oil cooler lines

from

clamp

retaining

to

the

engine

block. On

a car with a manual-shift trans

mission,

remove

inspection

cover and spring.

retracting clutch

izer the

the

release

5. Lower the car,

the

at

the

engine upper

transmission.

pedal

then

the

equal

the bracket

Remove

engine.

housing

the clutch

from

flywheel

bolts. support

Remove the

flywheel

housing

upper

a

new

gasket

lifting brackets

(Fig.

then

13),

from the

the

to

valve

the engine

over

remove

and

the

sling

engine

2. Lower the

engine

carefully into

the engine compartment. Make sure the

exhaust

manifolds

are

properly

inlet pipes and the dowels in the block engage the holes in the flywheel housing or converter housing. aligned

On

with

the muffler


trans

start the converter pilot

into

the crankshaft.

On

a car with a manual-shift

mission,

drive

start the transmission

gear

into the

be necessary to

clutch

adjust

trans main

disc. It may

the position of

the transmission in relation to the the

converter

retaining

3. Install the

housing

verter

tighten

the

engine

if the input

shaft will not enter

the clutch disc. If the engine "hangs after

in

mesh with

crankcase ventilation

tube and the flywheel

housing

bolts

or con

bolts,

upper

then

foot

45-50

to

torque.

pounds

4. Start the

engine right

insulator

support

the

to

left bolts.

and

engine

engine lifting sling lifting brackets.

5. Raise the front of the car. In the flywheel housing or con verter housing lower retaining bolts and tighten them to 45-50 foot torque.

pounds

On


the shaft enters, turn the

trans

mission, remove the retainer securing the converter in the housing, then

install the flywheel to converter lock Tighten the nuts to 25-28 foot-pounds torque. Install the converter lower access plate and the washers and nuts.

housing

work stand.

up"

or

the

the left exhaust manifold.

studs of

housing

Disconnect

bracket

rod and remove

to

flywheel

the

tie

Place

manifold.

(transmission

slowly

gear) until the shaft splines the clutch disc splines.

stall

bracket). Remove the crankcase ventilation tube. Disconnect the muf fler inlet pipes from the exhaust tube

crankshaft

and remove

cylinder

right

Work Stand

Disconnect the

(Fig. 14).

INSTALLATION

4. Raise the front move

bolts. Install the engine left lifting bracket on the front of the left cyl inder head where the coil mounts. Install the engine right lifting brack et

at

FIG. 14 Engine

Sling

cover

oil cooler

Install the

assembly.

lines retaining

clamp.

On a manual-shift transmission, install the clutch bracket. Connect

install the retracting spring. Install the flywheel housing lower cover. 6. Tighten all the engine front sup port insulator bolts and nuts to 45-50

the clutch release rod and clutch

foot-pounds torque. Remove the

re

tainer securing the exhaust gas con trol valve, then connect both exhaust manifolds and

pounds and

to the muffler

inlet

tighten the nuts to 23-28

foot

torque. Position the dust seal

install the

matic

pipes

(and the auto fluid filler tube

starter

transmission

bracket). Remove the mission and

support

lower the

from the trans

car.

1-30


7. Connect the

generator

On

wires,

the engine temperature sending unit wire, and connect the heater hose at

intake

On

Connect the en gine ground strap and install the starter cable retaining clamp to the rear of the right cylinder head. 8. Connect the flexible fuel line,

the

the coil

and

and

accelerator rod

the transmission rod.

install

tracting

the

re

accelerator

Connect

spring.

the accelera

tor rod.

On

nect the power

On

cover.

On

air conditioner,

a car with an

the compressor lines.

9. Install bleed

the

the

cooling

heater hose steering, con

a car with power

steering pump bracket

a car with power

brakes,

con

nect

the power brake line to the in

take

manifold and

to the

flexible line

at

Fill

radiator.

and

Connect the

system.

the water

pump.

Fill

the crankcase with the proper grade and

to the water pump.

and

install the line in the retaining on the left valve rocker arm

and clips

connect the magnetic clutch wire and

a car with manual-shift trans

mission,

the coil

connect

washer,

pump lines.

washer

a car with an automatic trans

On

high tension wires. In stall the oil level dipstick. Position the wire loom in the retaining clips on the left valve rocker arm cover. primary

the three

mission, connect the

manifold.

the oil pressure sending unit wire, and the windshield wiper vacuum line. In stall

a car with a windshield

connect

quantity

of engine

the engine at

fast idle

gaskets

hose

and

leaks. Install the

Operate

oil.

and check all

connections

for

air cleaner.

ENGINE DISASSEMBLY (ENGINE REMOVED) 1

INTAKE MANIFOLD AND DISTRIBUTOR 1. Disconnect spark

plugs

the

and

wires

remove

the

45.

wires

plug wire assembly. 3. Disconnect the distributor

the

line

at

and all

fuel

inlet

vac

plate.

of

additional

valve

rocker

arm

line,

4. Slide the clamp on the pump bypass hose toward the pump. Remove the automatic valve

the

avoid

at

and the oil

baffle

the No. 5 cylinder,

same procedure on the

damage to the

ism. Remove the

valve mechan

valve push rods

in

water

sequence.

water

6. Remove the distributor hold down bolt and clamp and remove the distributor. 7. Remove the 10 intake manifold retaining bolts.

choke rocker

arm covers. engine until

remove the valve rocker

left valve rocker arm shaft support bolts. This procedure must be followed to

pump lines, then remove the fuel pump and discard the gas ket. Remove the radiator supply tank.

5. Crank the

an

end

Rotate the

the No. 4 cylinder,

assembly

Starting

follow the

vacuum

heat tube. Remove the

right

loosened,

arm shaft

the distributor. Remove

carburetor

at

the

bolts in sequence, two time. After the bolts are

turns at a

spark

uum

at

shaft support

distributor cap

the

damper

Starting

loosen the

on

rocker arm covers.

2. Remove

T.D.C.

at

crankshaft

the

at

from the ignition harness brackets the valve

is

piston

the compression stroke.

the No.

8. Install standard eye bolts with 5/16-18 threads in the left front and right

rear

rocker

arm

holes

and

attach

the

cover

screw

engine

lifting

sling (Fig. 15).

9. Raise

fully move

and

the

and

manifold

care

it from the engine. Re the intake manifold gaskets

remove

seals.

10. Remove the baffle the valve

prying up

on the

baffle

from floor by

plate

push rod chamber

with a screw

driver (Fig. 16). 11. Lift the hydraulic valve lifters from the cylinder block and place them in a rack so that they can be installed in their original bore. The internal parts of each hydraulic lifter assembly are matched Do not intermix the parts. Keep

valve sets.

the assemblies

intact

until

they

are

to be cleaned. Tool T53L-300-A

Standard Eye

5^6-18

-Bolt

THREAD

1 730-A

FIG. 15-lntake

Manifold Removal

or

Installation

1863- A

FIG. 16 Baffle

Plate Removal

1-31

PART 1-2 -THUNDERBIRD 352 SPECIAL V-8 Tool S8690

Tool-T58P-6085-A

1524-A

FIG. 18 FIG. 17 Hydraulic Valve

-Cylinder

Head

Holding Fixtures

Lifter Removal

ToolT56P-6362-A

Crankshaft Sleeve

FIG. 20 Crankshaft Sleeve

T58P-6316-A

1S52-B

Removal

1551-B

FIG. 19 Crankshaft Damper

justing

Removal

If the hydraulic valve lifters be removed with the fingers, remove them with the tool shown in Fig. 17. 12.

can not

OIL PAN AND OIL PUMP 1. Invert the

engine on the

work

stand.

2.

2. Remove the screws and

CYLINDER HEADS

oil

remove

pan

the oil

retaining pan. Dis

card the gasket.

1. Remove the exhaust manifold lower retaining bolts and tab wash ers

and

the exhaust

remove

folds. Remove the

2.

Remove

bolts, head

the

3. Remove the oil pump attach bolts and remove the oil pump

ing

and

inlet tube

remove

head

the

Discard the

as

oil

oil

an

assembly, and

pump drive pump gasket.

shaft.

Lift the

head

the

1.

pry between the head

shift

the block. Remove and discard

sure

not

cylinder

off

the cylinder head gasket.

On

a

flywheel for

transmission, plate

replaced

cover

in the

so

mark

a

manual-

the

pres

that it can

same

be

position, and

remove the clutch pressure plate and

OIL FILTER AND ADAPTER filter from the Remove the oil filter adapter

Unscrew the adapter.

assembly unit

as

gasket.

and an

oil

oil

pressure

assembly.

sending Discard the

3.

at

the

generator.

Remove the water pump, fan as an assembly.

pul

and

On

a car with power

steering,

the two cap screws and lock washers securing the power steering

cover assembly.

2. Remove the flywheel retaining bolts and remove the flywheel.

Disconnect the drive belt

Remove the large cap screw from the end of the crankshaft. Install the puller on the crankshaft damper (Fig. 19) and re move the damper. 5.

washer

If the

stepped

is O.D.

crankshaft sleeve

down (the

same

not

on

both ends), remove it as shown in Fig. 20. If the crankshaft sleeve is stepped down (different O.D. on each end), remove it with a threejawed puller (tool 7675-N). Remove the screws fastening front cover to the block. Then remove the cylinder

the ad

damper.

4.

6.

CYLINDER FRONT COVER 1.

pulley to the crankshaft Then remove the pulley. and

FLYWHEEL

(Fig. 18).

ley,

arm

the generator support

remove

then install the cylinder

and

3.

mani

plugs.

cylinder

holding fixtures

block. Do and

spark

Re bolt at the water pump and the bracket bolt at the cylinder block. Remove the generator, brackets, and drive belts.

move

cylinder

1-32

1-

GROUP


place

cloth

a

the

on

inder

w

ridge with

head to

piston

Remove the

collect the cuttings.

low the instructions furnished tool

the ring travel

inch 3.

removing

Make

sure all

caps

and

in

area

when

are

the

into

excess of

1/32

ridges. rods

connecting to

marked

be installed in their

can

by

cut

Never

manufacturer.

cyl

Fol

cutter.

a ridge

that

they

original

lo

cations.

4.

Turn the

being

5. Remove the rod

necting

removed

from the

nuts

bolts,

cylinder

hammer.

a

crankpin

Chain Removal

the

end

to

wall

cylinder

the of

the

when

7. Remove the bearing inserts from the connecting rods and caps.

Installati on

or

Avoid

and

of

removing the piston and rod.

538-A

FIG. 21 Timing

or

con

rod

top

handle damage

the

with

the

out

assembly

is

and then pull the

cap off the rod. 6. Push the connecting piston

the

until

crankshaft

rod

connecting down.

CRANKSHAFT 1.

Tool T52L-6261-CEE Tool T54L-6250-B

Detail

REMOVAL BEARING REPLACER

6 BEARING

Detail 8

Remove

the

Carefully

lift

2.

out of the cylinder

thrust

bearing

aged.

Handle

crankshaft so that the

surfaces are not

the

dam

crankshaft

with

fracture

damage to the finished

surfaces.

3.

avoid

or

seal

Remove the rear journal oil from the block and rear bear

ing

cap,

block

and

side

from

serts

the

remove

cap

to

seals.

Remove the

4.

S56-A

the

block

possible

to

care

FIG.

bearing

main

caps.

main

block

the

bearing in bearing

and

caps.

22 Camshaft Bearing Removal

or

Installation

CAMSHAFT front

Discard

cover.

front

cover

the

cylinder

forward,

chain

timing

the sprockets and

gasket.

and

timing

remove

chain as an

assembly (Fig. 21).

TIMING

engine.

CHAIN

oil

the

crankshaft

the

camshaft

front

1. Turn the

button

and

thrust

thrust

DISASSEMBLY AND VALVE

stand

ROCKER

ARM SHAFT

carbon

the

of

1.

Remove the

pins

from

caution

to

and

of

avoid

by the

dam

lobes.

end

ridge

cylinder

bores.

bottom

of

is

work

and

/

CAMSHAFT Drill

up. or

BEARINGS

%-inch hole in

a

shaft rear

bearing

the cam

bore plug

and use

upper end

tool T-7600-E to remove the plug.

Move

Remove the 22).

its travel

the and

camshaft

bearings (Fig.

ASSEMBLY OF COMPONENT PARTS end

each

and cotter

any

the

on

deposits from the

piston to the

shaft, DISASSEMBLY

engine

the front

so that

2. Remove

spring, the sprocket cap

button spring re tainer, and the fuel pump eccentric. 3. Slide both sprockets and the the

screw,

Use

front

the

ASSEMBLIES

slinger.

2. Remove

remove the camshaft

aging the journals

ROD

CONNECTING

AND SPROCKETS 1. Remove

Carefully

pulling it toward

2.

then

spring

of

the

valve

remove

the

rocker

flat

arm

washers

washers.

Slide the rocker arms, springs,

and

the

sure to

supports

identify

off

the

3. If it is necessary to plugs

from

shaft.

Be

all the parts.

each

end

of

remove the

the

shaft,


1-33

BOLT SPRING WASHER

ROCKER ARM

SUPPORT

PLUG

ROCKER SHAFT

COTTER PIN

1327-C

FIG. 23 Valve Rocker Arm Shaft Assembly drill a

or pierce one plug.

steel

knock end.

rod

through

out the

Working

knock

out

plug

Then insert

the

plug

and

on the opposite

from the

open

engine

and

install end

plug, cup

CYLINDER HEADS

side

the rocker arm DISASSEMBLY

3.

1. Install the

rocker

arms,

sup

the moving parts with

oil.

the shaft are plete

2. If the plugs were removed from the ends of the shaft, use a blunt tool or large diameter pin

sure

the

oil

facing downward. Com by installing the

(Fig. 24). Then

the assembly

tainer

the cotter pin.

1S2S-A

FIG. 24-Valve Spring Retainer Locks-Removal Installation

carbon

locks,

out

of

the

combustion chambers

2. Compress

Too/-65J3-EE

or

head

before removing the

holes in

remaining two flat washers with the spring washer between them and in stall

Clean the

cylinder

ports, and springs in the order shown

in Fig. 23. Be all

a

of

shaft.

end,

the remaining plug.

ASSEMBLY

1. Oil

punch

out, in each

the

valves. valve

remove the

and

release

springs

spring

re

the spring.

1-34

GROUP 1 -ENGINES AND EXHAUST SYSTEM UNDERSIDE OF SPRING RETAINER

SLEEVE

VALVE SPRING

EXHAUST VALVE

SURFACE OF SPRING PAD

1530-B

FIG. 26 Valve Spring Assembled

Height

improper valve operation may re Disassemble and assemble each lifter separately. Keep the lifter as semblies in proper sequence so that they can be installed in their original bore.

INTAKE VALVE

sult.

1900- A

FIG. 25-Valve Assembly

DISASSEMBLY DISC VALVE RETAINER

LOCK RING

1.

Grasp

needle nose

PLUNGER

lock

the

DISC VALVE SPRING

3. Invert and

1716-A

27 Typical Hydraulic Valve Remove the sleeve, spring

re

tainer, spring, stem seal, and valve. Discard the valve stem seals. Identify all valve parts.

1. Install

each

it

which

(Fig.

valve

it

25) in

was removed

fitted. Install

was

a

the valve.

new stem seal on

height

is

inches, install

greater

the

than

necessary

valve

bring

the assembled height

height of lê12%2 inches. Do not install spacers unless necessary. Use of spacers in

excess of recommendations will result

the

retainer

of the

valve

the

the with

underside

dividers

dividers

and

assembled

spring from the

cylinder

plunger

disc

by carefully

prying up

screwdriver.

Then

and

assembly

valve

retainer

it

on

remove

A typical hydraulic

valve

springs

lead to excessive load loss spring breakage.

lifter is

in Fig. 27. 1. Place the plunger

shown

upside down bench. 2. Place the disc valve in position over the oil hole on the bottom of plunger. the Set the disc valve on a clean work

over

valve

a

ASSEMBLY

and

the

with

the disc

spring.

spring on top of the disc. 3. Position the disc valve

overstressing

in

the disc

and

spring

retainer

and

push

plunger.

locks (Fig. 24).

4. Measure the of

cup,

the retainer down into place on the

Compress the spring

3.

the the

which will

tainer and sleeve.

stall

rod

12%2 0.030-

inch thick spacer(s) between the cyl inder head spring pad and the valve

in

spring over the then install the spring re

2. Install the valve, and

bled

remove

valve

to the recommended

the guide from which

to

Assembly

spring to

ASSEMBLY

or

Lifter

push

plunger, and spring.

PLUNGER SPRING

DISC VALVE

3.

from

the groove. It may be necessary to depress the plunger to fully re

lease the lock ring. 2. Remove the

FIG.

with

ring

to release it

pliers

surface

head spring

of the

(Fig.

26).

pad

HYDRAULIC VALVE LIFTERS

5. Place the Each

Check the

sembly.

If the

assem

valve

If the

inter-mixed

lifter is

a matched as

parts of one

with

those

of

lifter

plunger

spring,

and

then the plunger (open end up) into the lifter body.

to

retainer

spring

against a scale.

4. Place the

height

are

another,

push

rod seat

in the

plunger.

6. Depress the plunger. Then posi lock ring

tion the closed end of the

1-35

PART 1-2 -THUNDERBIRD 352 SPECIAL V-8 installation in

and

the

cylin

same

der from which they were removed. 2. Remove the piston rings. Re

Tool T52P-6135-DAD

the piston

move

pin

piston

and

(Fig. 28). Discard the

rod

connecting

then

retainers,

drive the pin out of the retainers.

ASSEMBLY

The piston,

and

rod

connecting

are shown

related parts

in Fig. 29.

1. Lubricate all parts with light oil. Position the connecting rod in the piston and push the pin into place. Assemble the piston and

engine

connecting rod with the oil hole in the connecting rod tioned as shown in Fig. 30. 2. Insert

by

posi

piston pin retainers

into the

them

spiraling

piston

fingers. Do not use pliers. Follow the instructions contained on the piston ring package and install the

with

1119-B

FIG. 28 Piston

new

squirt

Pin Removal

the piston

OIL RING ASSEMBLY

rings.

3. Check the ring the

of

feeler

side

compression

clearance with

rings

a

inserted between the its lower land (Fig. 31).

gauge

ring

and

The

gauge

around

should

the

entire

freely

slide

circumfer

ring

binding. Any wear that form a step at the inner portion of the lower land. If the lower lands have high steps, the pis ton should be replaced.

ence without

occurs will

CONNECTING ROD

4. Be

sure the bearing inserts and bearing bore in the connecting

the

Foreign ma inserts may distort the bearing and cause a failure. In stall the bearing inserts in the con rod

and

are clean.

cap

terial under the NUT

RETAINER BEARING INSERTS

necting rod and cap with the tangs fitting in the slots provided.

OIL PUMP

1559-B

DISASSEMBLY

FIG. 29 Piston, Connecting Rod, and Related Parts

1. Remove the

inlet tube from

oil

the oil pump and remove the gasket.

RIGHT BANK

LEFT BANK

2. Remove

the

cover

retaining

screws, then remove the cover. Re move the inner rotor and shaft as BEARING LOCK SLOTS TO OUTSIDE OF ENGINE

sembly, then remove the outer race.

"V"

3. Insert

? I

INDENTATION TO FRONT OF ENGINE

into

11 20- A

in the groove of the lifter body. With the plunger still depressed, po sition the open ends of the lock ring

PISTONS AND

in the groove. Release the plunger, then depress it again to fully seat the

DISASSEMBLY

Jock

ring.

assembly

oil

cap

self

of

threading

sheet

the proper diameter

pressure and

the chamber.

and

pull

relief

the

valve

cap

out

Remove the spring

plunger.

ASSEMBLY

The oil pump assembly is in Fig. 32.

CONNECTING RODS

assure

the

chamber of

FIG. 30 Connecting Rod and Piston Assembly

1. Mark the

a

metal screw

FRONT

1. Oil pistons with

and

pins

to

the same rod

all

2. Install valve

parts

the

shown

thoroughly.

oil

plunger, spring,

pressure

relief

and a new cap.

1-36

1-

GROUP


DISTRIBUTOR INTERMEDIATE DRIVE SHAFT

GASKET

1564-B

Flu. 31 Ring

Side Clearance

PLATE

1531

3. Install the inner rotor and

shaft

inner

shaft,

rotor and

race

are

One

part

without

outer

serviced

race,

assembly.

the

and

as

should

and

an

not

replacing the

the

FIG. 32 Oil Pump Assembly

The

outer

replaced

taining

Install

torque.

other.

ENGINE ASSEMBLY CAMSHAFT BEARINGS bearings are available for standard and 0.015-inch undersize journal diame ters. The bearings are not inter changeable from one bore to an other. The bearings must be in Camshaft

6-9

to

screws

foot-pounds

oil

inlet

tube

a

new

on

the

gasket oil

1. the

in their

bearing bore,

place

with

the

22. Align the

ing

respective

Position the

with

block

new

and

tool

oil

bores.

bearing it

in

press

shown

when

the

in Fig.

holes in the bear bearings

are

Be sure the camshaft front bearing is installed 0.005-0.020 inch below the front face of the cylinder block (Fig. 33). 2. Clean out the camshaft rear

stalled. at

the oil holes in the cylinder

BELOW FRONT FACE OF BLOCK

bearing bore 3.

in-

with

plug recess thoroughly. Coat the flange of a new plug

water

resistant

it with (Fig. 34).

stall

the

sealer

flange

FIG. 34 Camshaft Front

Bearing

Measurement

Rear Installation

and

in

facing in

Tool-T58P-6266-A

FIG.

the and

install the retaining bolts.

INSTAU FRONT BEARING 0.005-0.020-INCH

33 Camshaft

and

pump

(ENGINE REMOVED) stalled

pre-finished to size

4. Position

the cover and tighten the cover re

assembly.

be

-A

Bearing Bore Plug

1S4S-A

PART 1-2 4. flush

Drive the plug in until it is slightly below the casting

-THUNDERBIRD

The are

CAMSHAFT camshaft

are shown

Oil the plate slide

related

parts

in Fig. 35.

camshaft and

apply Lubri

then

all

oil

Be

seal

stall

lobes, carefully it through the bearings. to

shown

1. and

a

and

crankshaft

surface.

The

2. If the

CRANKSHAFT

or

parts

that the rear journal

grooves new

related

are

rear

ing

clean, then in

journal

oil

seal

crankshaft main

bearing

journals have been refinished to a definite undersize, install the correct undersize bearings. Be sure the bear

in Fig. 36.

sure

1-37

352 SPECIAL V-8

inserts

clean.

in

and

Foreign

bearing material

inserts may distort the cause a failure.

block (Fig. 37) and rear main bearing cap (Fig. 38). After installa tion, cut the ends of the seals flush. the

Place the serts

in

upper main

position

bores

are

under

the

bearing

and

bearing

in the bore

with

in the

BEARINGS

CAMSHAFT REAR

BEARING BORE PLUG

TIMING CHAIN AND CAMSHAFT SPROCKET FUEL PUMP ECCENTRIC

FIG. 35 Camshaft

BOLT AND WASHER

and

1 536-B

Related Parts

CYLINDER BLOCK JOURNAL SEAL

MAIN BEARING INSERTS

DAMPER

POWER STEERING

PUMP PULLEY

MAIN BEARING CAPS WASHER

FIG. 36-Crankshaft and

1537-A

Related Parts

1-38

GROUP

1- ENGINES

AND EXHAUST SYSTEM

crankshaft

forward

the

against

thrust surface of the upper half of

bearing

the

crankshaft

to the

bearing cap

thrust

39). This faces

(Fig. 39). Hold the forward and pry the

will

align

both halves

of

Retain the forward

rear

(Fig.

the thrust sur of

the bearing. the

on

pressure

crankshaft, and tighten the cap bolts to specifications (Fig. 39).

8. the

Force the

indicator against

the

FIG. 37 Seal

so

the

Install

a

dial

the contact point

rests

flange

and

crankshaft

indicator

toward

crankshaft

rear of the engine.

axis

is

parallel

to the

to Block Installation

tang fitting in the

slot

3. Install the lower inserts in the bearing

provided.

bearing

main

caps. Tool-T 58P-6701

-A

4. Carefully lower the crankshaft into place. Be careful not to damage the

bearing

5. main

dure

surfaces.

Check the

clearance

bearing following "Main Bearing

of

the

under

each

proce

Replace

ment."

6.

If the

satisfactory,

bearing apply

engine oil to the

ings,

then

clearances

a

light

journals

install

(No. 3 bearing). Main numbered

and

are

of

bear

bearing bearing cap bearing caps the

all

caps, except the thrust are

coat

1 thru 5 starting at engine. The arrows

the front of the

on the cap should be pointed toward the front of the engine. Tighten the

bearing cap bolts 7. with

to

bearing finger tight. Pry

Install the thrust the bolts

14 59- A

specifications.

FIG. 38 Seal

cap

to Rear

Bearing Cap

Installation

the

fs~ ;,

PRY CRANKSHAFT FORWARD

-**t#m,mu.

,

.

;;

PRY CAP BACKWARD

TIGHTEN CAP

1810-A

FIG. 39-Thrust

Bearing

Alignment

1-39


Tool 6U9-A

505-A

FIG. 40-Crankshaft crankshaft

dial

on

forward

shaft

(Fig.

axis

zero, then

End

Play

40).

push

and note

INDENTATIONS TO FRONT OF ENGINE

Set the

1

the reading

FIG. 41 Piston

the dial.

on

9.

If the

limit,

wear

ing. If the minimum

end

play

replace

exceeds

the thrust

play is less than the limit, inspect the thrust scratches,

burrs,

nicks, or dirt. If the thrust faces are not

defective

were

not

or

dirty, they probably

aligned

properly.

Install

bearing and align the following the recommended procedure (step 7), then recheck the

the

thrust

faces end

seals

Dip

in light

engine oil, then im install them in the

rear

bearing

cap

side

few drops

of oil

bearing

the cylinder block

from the

inch

seals

of

travel. Do not cut the seal

projecting

ends.

Do

not

use

sealer

the side seals, the seals are de

on

signed

oil.

to

Using

expand sealer

when

may

dipped in retard

this

expansion.

cap

side seals

rear

main

for leaks

by

bearing

squirting

Blow If

air

compressed

bubbles

indicates above

Rod Side Clearance

air

from the inside appear

possible

oil

test should not

cap

against of

and

outside.

the

the block.

in the oil, it

leakage. The be performed

newly installed seals until suf ficient time has been allowed for the

on

seals

to

expand

into

the

seal

grooves.

TIMING MARKS

FIG. 42 Connecting

into the parting

mediately grooves. It may be necessary to tap the seals into place for the last Vi

11. Check the the

a

lines between the

play.

10.

Installation

the

bear

end

bearing faces for

566- A

the crank

lb. 43 Aligning Timing

1539-B

Mark:

1-40

1-

GROUP

REFERENCE POINT


RIGHT SIDE OF CHAIN

FUEL PUMP ECCENTRIC

DOWEL

k

TAKE UP SLACK ON LEFT SIDE. ESTABLISH A REFERENCE POINT AND TAKE UP SLACK ON RIGHT SIDE AND FORCE LEFT SIDE OUT WITH THE FINGERS AND MEASURE DISTANCE B. DEFLECTION IS A MINUS B. 151 l-B MEASURE DISTANCE A.

FIG. 44 Timing CONNECTING

stand

ROD

the

is

end

rings,

cylinder walls with

and

the work

on

front

piston

Eccentric Slinger Installed

the front of the engine. When installed, the bearing lock slots in the connecting rod should be toward the outside of the engine. 4. Check the clearance of each

toward

engine

so that the

2. Oil

FIG. 45 Fuel Pump

Chain Deflection

ASSEMBLIES 1. Turn the

CRANKSHAFT FRONT OIL SLINGER

up.

pistons,

light

engine

bearing under

oil.

following

the

procedure

"Connecting Rod Bearing Re

front)

the

4. Establish

to

which

they they rod

were

removed,

Each

fitted.

were

bearing

and

or

cap

which

connecting

are

numbered

from 1 to 4 in the right bank and from 5 to 8 in the left bank, begin ning at the front of the engine. The the connecting

on

numbers

rod

and

cap must be on the same when installed in the cylinder

bearing side

transposed

connecting rod is from one block or

inder

to

another,

should

be fitted

If

bore.

rod

a

and

be

should

respond with

cyl

bearings

new

the connecting

to

numbered

the

ever

5. If the

tion

the

tance

ings.

and

the

bottom

of

the

piston

all

the

compressor

ton

ring push

mer

handle

the

top

the

gaps

ring

7. After the

ing

rod

on

the

piston

in with a ham it is slightly below 41).

to guide the connecting

rods

Be

sure

to

avoid

the

cylinder

damaging

journals. Install the indentation

in

piston

assemblies

and

have

on

the

tighten

connect

been

in be

the connecting rods on each

journal (Fig. 42).

the

the

crankshaft

piston

with

piston

CHAIN

the

head

the

slot

chain

crankshaft

timing

in

key

position

in

sprockets and

the

on

(Fig.

marks

on

camshaft

21). the

Be

tim and

sure

the

sprockets

are

in Fig. 43. 3. Rotate the crankshaft in a clockwise direction (as viewed from positioned

as

dis

the

point

reference

The deflection is the

between

the

deflection

replace the

two

meas

exceeds

timing

chain

Vz

and/

sprockets.

6. Install the fuel pump cap

45), screw

retainer. screw

eccentric

and the camshaft sprocket

thrust

and

button spring

Tighten the

to

sprocket

cap

Install

the

specifications.

button spring and thrust button. Install the crankshaft front oil slinger.

camshaft

thrust

shown

FRONT OIL

SEAL

FRONT OIL SEAL REPLACEMENT

the crankshaft.

2. Position the

ing

measure

the

CYLINDER FRONT COVER AND

the

on

or

force

the chain out with

of

the

the

on

then

AND

SPROCKETS 1. Place

inch,

(Fig.

stalled, check the side clearance tween

5. If

until

are

(Fig.

of

urements.

Install

then

cap,

push

seats

point on

slack

chain,

and

the chain.

difference

the nuts to specifications.

crankshaft

piston

until

rod

cor

properly spaced around the circum ference of the piston. Install a pis

and

journal.

crankshaft

connecting

bearing

rod

reference

up the

between

to

throw

its stroke, then the way down

the connecting

TIMING the

sure

left side fingers

the

crankshaft

on

measure

the

of

side

clearances are to

6. Turn the

a

and

take

to

specifications, apply a light coat of engine oil to the journals and bear

new cylinder num

ber. Make

bearing

slack

from this point to the chain (Fig. 44). Rotate the crankshaft in the opposite direc block

the

right pistons

up the

to take

the left side of the chain.

placement."

3. Be sure to install the in the same cylinders from

Front Oil

and

It is

good

practice to replace the

oil seal each time

the cylinder

is removed. 1. Drive out the

front

cover

pin punch,

in the

old

seal

with

a

then clean out the recess

cover.

2. Coat

a

new

seal

with

grease,

1-41


Too-T58P-6700-B

1526-A Too/-T58P-60 ? 9-A

46 Oil

FIG.

1 5 5 5-B

Seal Installation

FIG. 47 Cylinder

Tool T52L-6306-AEE

FIG. 48 Crankshaft

Front Cover Alignment

1553-B

Sleeve Installation

(Fig. 46). Drive it is fully seated in the recess. Check the seal after in stallation to be sure the spring is then install the seal

the seal in until

positioned

properly

in the

Tool T52L-6306-AEE

Flu. 49 Crankshaft

seal.

1554-B

Damper Installation

CYLINDER FRONT COVER INSTALLATION

1. Clean the and

the

front

cylinder

cylinder

block

cover sur

gasket

gasket

with

sealer.

cover

Position

a

3. Install the

in the

new

face

keyway key in the cover and crankshaft

aligns

and

(Fig.

48)

so

the

into the

with

the

the

cover

crankshaft.

Position the

the

end

against

the

pilot over

with

of

the

block

oil

is

sleeve

key

then

While

pushing

in

on

the

pilot,

sleeve

bore if down (dif

cover

damper

keyway

the crankshaft, then

screw screw

to specifications. an

water

apply the

pump gasket Position

sealer.

pump

and

install fan as

an assembly.

On

ing

an engine with a power steer

pump, the pump is retained

by

the water pump retaining bolts.

10. Using a new gasket, install fuel pump. Install the generator,

the

brackets,

and

drive belts.

OIL PUMP AND OIL PAN

washer, and tighten the

power

and

on the crankshaft

8. Install the damper cap and

On

install the bolts.

new gaskets on

the

on

(Fig. 49).

bracket,

sur

stepped

4. Install the cylinder front cover bolts finger tight. Position the gen erator support bracket and the gen arm

rubbing

front

install the damper

adjusting

seal

crankshaft

(Fig. 47).

erator

surfaces

on each end).

7. Line up

9. Clean the

and

the smallest O.D. end

cylinder

the

with

mixture

the water pump, pulley, and

the

with

ferent O.D. with

crankshaft

pulley on the crankshaft damper. Tighten the screws to specifications.

oil

and

grease.

6. Install

front

pilot

lead

white

lubricate the

pilot tool

alignment

cylinder

a

bolt

the block.

on

the

and the

cover

and

threads

gasket surface of the

specifica

pilot.

5. Lubricate the

2. Coat the

on

Remove the

tions.

faces. block

bolts to

tighten the cover

shaft

engine

steering

1. Invert the stand.

with

pulley,

a

separate

install

the

engine on the work

Position the into the oil

pump drive pump socket. firmly seated in the

With the shaft distributor socket,

oil

position

the

oil

1-42

GROUP

1- ENGINES

AND EXHAUST SYSTEM

OIL PRESSURE

ADAPTER

SENDING UNIT

GASKET

FILTER ELEMENT

1568-A 1S28-A

FIG. 50 Oil

Pump

and

Inlet Tube Installed

FIG. 51

-Oil

Filter

Assembly

2. Place the

head

cylinder

engine, then remove the

Coat the

tures.

head

with water resistant

QO) 1532-A

pump into

pump

The stop

place.

should

touch

the

Remove the

crankcase.

and position the

roof

the

the

of

the

taining bolts

3. Position

housing

pump

as

shaft

4. Position

stop

as neces

sembly

on

an

new

a

on

gasket

the

the

on

the as

the block. Install the

re

place

screws

taining from the

gasket

install the pump assembly (Fig. 50).

and

pan

and

pan

new

a

oil

tighten

and

them,

outward, to specifi

center

cations.

the

flywheel

on

the

install

the retaining Tighten the bolts to specifica

crankshaft

and

tions.

shift

re

OIL FILTER AND ADAPTER The oil filter assembly is Fig. 51.

threads

then

and

1. Clean the

ket

oil

filter

shown

in

adapter gas

surfaces.

2.

Apply

gasket,

sembly

and

install the

adapter

as

and gasket.

filter recess. on a new filter with oil. Then place the filter in position on the adapter. Hand tighten the filter until the gasket contacts the

face,

a

flywheel

transmission,

locate the

clutch

for

use

a

manual-

tool 7563 to

disc. Then install

4. Coat

and

"Front"

head

then advance it Vi

-

gasket, install

on the

gasket

head dowels. Do

over not

the cylinder

apply

sealer to

the gasket or gasket surface of the

head

or

block.

the

surfaces

mating

the

exhaust

film

of graphite grease.

manifold

with

a

of

light

adapter

1. Clean the cylinder head and block gasket surfaces. Guided by the the

performed

tighten the bolts to 80-90 foot-pounds torque in the same sequence. After the cylinder head bolts have been tightened to speci fications, the bolts should not be disturbed.

5. On the right using

a new

matic

choke

exhaust manifold, gasket, install the auto air

chamber

the manifold.

Be

fold, using

new

cover on

cover is securely fastened. Position the ex haust gas control valve over the muffler inlet pipe studs of the mani

side

word

is

sealer to a new adapter

3. Clean the Coat the gasket

adapter

cylinder

procedure

Finally,

CYLINDER HEADS

1. Position

2. On

Tighten the

plate.

to specifications.

turn.

FLYWHEEL

bolts.

pressure

shaft and oil

2. With the stop properly posi tioned, insert the oil pump drive shaft into the oil pump.

oil

bolt

sealer,

head bolt tighten in three progressive steps. Tighten the bolts to 60-70 foot-pounds torque in the proper sequence (Fig. 52), then tighten them to 70-80 foot-pounds torque in the same sequence.

ing

on

sary.

and

3. The

52 Cylinder Head Bolt Tightening Sequence

shaft

the

install the bolts.

USE Tool-S-8683

Flu.

on

holding fix

of

a

the

valve.

sure

the

gasket

on

each

Temporarily

tie

the valve to the exhaust manifold.

6. Position muffler

inlet

a new gasket over

pipe

studs

of

the

the left

exhaust manifold.

7. Position the exhaust manifold head and install the

on the cylinder

1-43

PART 1-2 -THUNDERBIRD 352 SPECIAL V-8 retaining bolts and tab washers. Tighten the retaining bolts to 23-28 foot-pounds torque, working from the center to the ends. Lock the bolts by bending one tab of the washer over a

flat

on the

bolt.

cylinder

of

8. Install the spark plugs. 9. Position the baffle plate in the valve push rod chamber. Press it into place with the hands (Fig. 53).

VALVE LIFTERS Coat the outside of each valve lifter with engine oil to provide initial lubrication. Do not fill the lifters with oil. The lifters will fill much faster after the engine is started, if they are free of any oil film which may cause an oil seal between the plunger and the lifter body. Place each lifter in the bore from which it was removed.

heads

with

the gasket

in

rest

head gasket tabs. Be sure the holes in the gaskets are aligned with the holes in the cylin der heads. The correct installation

ing

on the cylinder

the gaskets and seals

are

6. Start the water pump by-pass hose on the intake manifold.

shown

7. Be fold

4. Install the

eye

take manifold and

lifting

sling

intake

manifold

and

bolts in the in

attach

If the seals are not in place, intake manifold and re

position the seals.

in Fig. 55.

intake manifold the distributor in place. by inserting After the intake manifold is in place, run a finger around the cork to

the

make sure

tighten

and

lifting sling

Install the

radiator

the

lower

the

and

bolts.

supply tank.

valve

ends of

to

them

and eye

their proper sequence,

the seals are

in re

from

distributor

the

the engine

9. Install the

mani

are

manifold

specifications, working center to the ends.

8. Remove

5. Position

manifold

and

Install the

taining bolts

the engine

carefully lower the on the engine (Fig.

holes in the

sure the

gaskets

alignment.

15).

seal area

place.

remove the

push

rods

making

the rods are

in

sure posi-

CRANKCASE BREATHER CAP

THERMOSTAT

OIL FILLER TUBE

INTAKE MANIFOLD AND

^>A

The intake manifold assembly is in Fig. 54.

shown

1. Clean the mating the

intake manifold,

surfaces

cylinder

SENDING

MANIFOLD-TO-HEAD GASKET

UNIT

of

heads,

block.

and cylinder

2. Coat the intake manifold cylinder block cork seal surfaces 3. Position

new

and

CRANKCASE VENTILATION TUBE

and

with

oil resistant sealer.

inder block

MANIFOLD-TO-BLOCK FRONT SEAL

WATER TEMPERATURE

DISTRIBUTOR

VACUUM PUMP seals on the

new gaskets on

cyl

CONNECTION

the INTAKE MANIFOLD

MANIFOLD-TO-HEAD GASKET

FIG.

54 Intake

Manifold

CYLINDER HEAD GASKET TABS

POSITION NOTCH OVER RIDGE ON SEAL

FIG.

53 Baffle

FIG. 55 Intake Plate Installation

MANIFOLD-TO-BLOCK REAR SEAL

1519-C

Assembly

INTAKE MANIFOLD LOCATING DOWEL

MANIFOLD GASKET TABS

Manifold Gaskets Installation

and

1520-C

Seal;

1-44 tioned in the lifter

push rod cup.

10. Crank the engine until the No. 1 piston is on T.D.C. at the end of the compression stroke.

11. Rotate the crankshaft damper 45. 12. Install the right valve rocker

an additional

arm

shaft

plate on valve

assembly

and

rods

shaft

in

place

support

tight. Be sure the shaft

that the

13.

holes

oil

Starting

tighten turns

baffle

at

time,

a

are

and

the

bolts finger is turned so

to the bottom.

the No. 4 cylinder,

bolts in sequence, two

the

at

fully

the

the cylinder head with the

push

rocker

contact

until

the

the supports

cylinder

head.

REPAIR OPERATIONS ENGINE SUPPORTS The front each rear

1-

GROUP

side

of the

located

crankcase

and

on

the

is located at the trans extension housing.

support

mission

ENGINE FRONT SUPPORT

either

a

right or

left installa

tion.

Removal 1. Remove the insulator assembly

washer. one

support

is

being

re

moved, loosen the other support.

2. Raise the engine about 1 inch with a jack and a block of wood

bending rocker

Be sure that the hydraulic lift have leaked down to their normal

arms. ers

operating

before cranking

position

the engine. This is necessary in order to avoid possible damage to the

valves,

push

or

rods,

valve

rocker

arms.

15. Install

the

automatic

choke

heat tube.

16. Rotate the crankshaft damper the No. 1 piston is on T.D.C, then position the distributor in the block with the rotor at the No. 1 until

breaker points Install the hold down clamp. 17. Connect the distributor vac uum line. Install the distributor cap. Install the valve rocker arm covers. Connect the spark plug wires. Be sure the spark plug wires for No. 7 and 8 cylinders are properly posi tioned. See Fig. 8Part 2-1. Install the vacuum booster pump line and the carburetor fuel inlet line.

firing

position and the

open.

(ENGINE INSTALLED) move

the

under

the

oil

insulator

then

pan,

re

assembly.

bolts

1. Position the insulator

Install, but do If both

tighten, lockwashers not

supports

install the bolts

assembly.

the

insula

and

bolts.

have been removed, on

the opposite side

before proceeding with step 2. 2. Lower the engine, then install underbody

washer

and

to 40-45 the

to

nut and

insulator

lock

tighten the

nut

foot-pounds torque. Tighten

insulator

to engine

bolts

to

35-40

The

REAR

and

2. Raise slightly to support port

the

support and

retainer

remove

Remove the sup

assembly.

assembly

housing

extension

and

retainer.

Installation 1. Raise enough

bly

the

housing

extension

to position the support assem

and

retainer.

to

retainer

washers,

Install the

extension

lockwashers,

support

housing flat and

bolts, the bolts,

assembly to underbody and nuts.

2. Remove the jack from the

engine rear support

is

shown

in Fig. 57.

the

the pressure on the

relieve

lockwashers

SUPPORT

the

washers,

assembly to underbody bolts.

support

support

foot-pounds torque. ENGINE

Removal 1. Remove

Installation

the

to engine retaining bolts, and insula tor to underbody retaining nut and

If only

the possibility of

minimize

the push rods, valves, or the

tor to engine

The engine front support is shown in Fig. 56. The procedures given ap ply to

Tighten the bolts in sequence to spec ifications. 14. Starting at the No. 5 cylinder, follow the same procedure for the left valve rocker arm shaft support bolts. The additional time consumed in this procedure will permit the hy draulic lifters to leak down. This will

placed

supports are


tension port

ex

housing,

retainer

then tighten the sup bolts to 25-30 foot-

SUPPORT ASSEMBLY

1745-A

FIG. 56 Engine

Front Support

1746- A

Mb. 57 Engine

Rear Support

1-45

PART 1-2 -THUNDERBIRD 352 SPECIAL V-8 pounds

torque,

sembly

nuts

the support as

and

40-45

to

3. Install the

foot-pounds

torque.

sending sion

REMOVAL

1. Drain the cooling 2. On

Re

system.

car with

a

a

at

acceler

Remove

the carburetor.

the accelerator retracting spring.

3. On

a

car

with

an

transmission, disconnect ator

rod

the

at

the acceler

accelerator

cross

shaft

from the intake manifold tion it out of the way. 4. Remove let line, the

line,

ing

fuel in

windshield wiper vacuum

the vacuum booster pump

and

lead,

coil.

posi

and

the

coil

coil

Disconnect the

high ten

wires

at

the

oil pressure send

sending unit. Re move the wire loom from the retain ing clips on the left valve rocker arm unit wire at the

it

cover and position

6. Disconnect the at

the

spark

plugs

out of the way. spark

and

high ten

a

accelerator

the

connect

a

plug

wires

remove

the

from the ignition harness brackets on the valve rocker arm covers. Remove the distributor cap

car

with

manual-shift

a

transmission, install the

accelerator

the

and connect

ac

plug wire assembly. Dis the distributor vacuum line

spark

connect at

the distributor.

7. Disconnect the radiator upper hose at the radiator supply tank, then remove the supply tank. Remove the heater hose at the intake mani

fold, and the water temperature send ing unit wire at the sending unit. 8. Remove the battery ground

6. Fill and bleed the cooling tem. Install the air cleaner.

sys

arm

covers

and

remove

the

covers.

dure under

by following "Intake

removal

steps

Manifold

tributor"

on page

5

proce

thru

and

9

Dis

1-30.

by

the word

ket,

"FRONT"

install the

to the

head

on the gas

gasket over

der head dowels. Do

not

the cylin

apply

sealer

gasket or gasket surface of

or

the

page

2. Place the

cylinder

head

on the

holding

engine, then remove the

fix

ture. Coat the head bolt threads with water resistant

sealer, then install the

3. Tighten the bolts to 60-70 foot torque in the sequence shown

in Fig. 52,

and then tighten

them to

70-80 foot-pounds torque in the sequence.

Finally,

same

tighten the bolts to

80-90 foot-pounds torque in the

same

sequence.

4. Install the

exhaust manifolds.

the

intake

valve rocker arm shaft

distributor under

following

battery

assembly, and

"Intake Manifold

1 thru 17

and

Distrib

1-43.

strap, the water temperature sending radiator unit, the heater hose, and the upper

hose.

and

the

and tighten

washer,

screw

screw

to

in

steering,

power

a car with

specifications.

3. Install the drive belts, the radi radiator supply tank, and hood.

ator,

Fill

bleed the cooling

and

system.

CYLINDER FRONT COVER AND TIMING CHAIN REMOVAL

1. Drain the cooling the

crankcase.

cleaner, radiator, and

and

system

hood,

Remove the

radiator

air

supply

tank.

2. Disconnect the

inlet line,

carburetor

manifold vacuum vacuum

wiper

fuel

line, line,

the and

3. Remove

fuel

the

and

pump

gasket.

4. On

with power

a car equipped

steering, disconnect the power

ing

pump bracket then

wire

from the

the

steer

water

pump to the

a position that will

from draining out. 5. Disconnect the heater hose at the water pump. Slide the water pump by-pass hose tube clamp to ward the engine. Disconnect the drive belt adjusting arm at the water pump.

prevent the oil

6. Loosen the

bolts

at

generator

the generator.

mounting Remove the

drive belt. Remove the generator sup bolt at the water pump. Remove

port

the water pump, drive

belt adjusting

as an assembly.

crankshaft

damper

Remove the screws fastening the cylinder front cover to the block and oil pan, then remove the cylinder front cover. On and

crankshaft

sleeve.

a car equipped with an air condition

er, the compressor brackets are re

CRANKSHAFT DAMPER

ground

Then

on the crankshaft

(Fig. 49).

7. Remove the

manifold,

steps

by cylinder front cover screws. 8. Discard the cylinder front cover gasket. Remove the oil pan. 9. Remove the crankshaft front

tained REMOVAL

1. Drain the cooling the

keyway

crankshaft.

arm, pulley, and fan

under

1-43.

2. Connect

the

hood left hinge in

INSTALLATION

on

on

install the damper

pump,

block.

on page

Distributor"

damper

the

up

key

with the

the flexible line at the fuel pump.

1. Clean the cylinder head and cyl inder block gasket surfaces. Guided

utor"

1. Follow steps 1 thru 17 "Intake Manifold and

INSTALLATION

windshield

INSTALLATION

5. Install

10. Complete the

and re

the power steering pump pulley on the damper. Tighten the screws to

1. Remove the intake manifold distributor following the proce dure in this section. 2. Remove the exhaust manifolds. If the left cylinder head is to be re moved, remove the ignition coil. 3. Remove the cylinder head bolts, and then install the cylinder head holding fixtures (Fig. 18). 4. Lift the cylinder heads off the block. Do not pry between the head and the block. Remove and discard the cylinder head gasket.

pounds

rocker

19)

stall

and

the water pump by-pass hose toward the water pump. Remove the auto

heat tube. Disconnect the crankcase ventilation tube from the intake manifold. 9. Clean the outside of the valve

the

on

puller

damper.

move the

On

bolts.

choke

Install the

damper (Fig.

crankshaft

specifications.

CYLINDER HEADS

strap retaining screw from the ther mostat housing. Slide the clamp on

matic

steering pump pulley

2. Install the damper cap

celerator rod.

wires

and

power

from the crankshaft damper. 3. Remove the large cap screw from the end of the washer and

1. Line

accelerator rod.

5. On

the

move

crankshaft.

automatic

an

with

car

REMOVAL

the carburetor

line. 5. Disconnect the sion

Remove bracket

and

oil pressure

coil

and the coil wires.

retracting spring

automatic

the carburetor.

the

re

valve rocker

transmission, install the cross shaft bracket. Then

manual-shift

transmission, disconnect the rod

leads,

loom in the

left

Connect the

unit wire,

4. On

move the air cleaner.

ator

taining

arm cover.

INTAKE MANIFOLD

wire

clips on the

move

the

hood,

radiator

system.

Re

supply tank,

and the radiator.

2. Remove the drive belts. On a car with power steering,

oil slinger.

timing re

Crank the

marks

on

engine until the

the

positioned as shown

sprockets

are

in Fig. 43.

Re-

1-46

GROUP 1

move the camshaft

thrust button and

spring, the sprocket cap screw, the thrust button spring retainer, and the

fuel pump eccentric. 10. Slide both sprockets

timing

chain

forward,

the sprockets and

and

timing

the

and

remove

key in

in the

position

slot on the crankshaft.

2. Position the

ing

chain

(Fig.

crankshaft

timing

marks

sprockets and tim

the

on

manifold vacuum

camshaft

heater hoses. Slide the water pump by-pass tube clamp forward on the tube.

the

CAMSHAFT

are

REMOVAL

in Fig. 43.

front cover,

cylinder

Working from

engine, position the engine

block.

tighten,

the oil pan

oil

pan

of

on

1. Drain the cooling

crankshaft

front

the

oil

alignment pilot tool

front

cylinder

cover and

cover

Position the

crankshaft.

crankshaft

the end of the

and

against

block

the

(Fig. 47).

9. Install the cylinder front cover bolts finger tight. Position the gen erator support bracket and the gen arm

erator

adjusting install the bolts. While

bracket,

then

2. Remove the

cover

oil pan

bolts,

bolts to

from the

oil

pan to cylinder

then tighten all the

specifications

center of

the pan

working

and

sprockets,

fold

crankshaft

install the damper

procedure

in this

sleeve,

following

the

following

water

and

fan

as

from

at the arm

plugs, and

cover(s)

wires

rocker

rocker

valve

arm

step 5 Dis and

by following

shaft

assembly under "Intake

Manifold

tributor"

1-30.

page

4. Remove the

lifters

valve

through

the procedures

mani

in this

new

block

cylinder

lifters

valve

place

and

valve

lifter(s)

through the push rod opening with a magnet.

6. Install the bores.

push

rods

in

their

original

7. Install

the

valve

rocker

arm

assembly by following steps 10 thru 14 under "Intake Manifold and shaft

Distributor"

on page

the

plug the

and gasket(s).

3. Remove the

on

spark

remove

8. Install

the

and

cover(s)

1-43.

valve

rocker

Install

gasket(s).

arm

the

engine.

heat tube if it was removed. Connect the spark plug wires and install the air cleaner. The preceding procedure can not be used if the hydraulic valve lifters are stuck in their bore by excessive varnish, etc. In this case it will be necessary to remove the intake mani fold following the procedure in this section. After the intake manifold has been removed, remove the hy draulic valve lifter with the tool shown in Fig. 17.

INSTALLATION

FLYWHEEL

them in

a

rack so

they may be bore. It is

that

their original

necessary to

not

plate

4.

Carefully

remove the camshaft

pulling it toward the front

by

1. Oil

the

camshaft

Lubriplate to the

of

the

lobes,

and

apply

then carefully

it through the bearings. 2. Install the hydraulic valve lift ers in the bores from which they were removed. Install the baffle plate if it was removed. 3. Install the intake manifold, tim slide

chain

and

front cover, per

and

following

sprockets,

cylinder

the crankshaft dam

in this

the procedures

bleed

choke

REMOVAL

1. Disconnect from the

engine

transmission

it to the

slide

Group 3 (manualtransmissions) or Group 4 (auto

rear as outlined shift

the and

matic

transmission).

2. On mark

in

a manual-shift

the

pressure

transmission,

plate

cover

the

cooling

system.

Fill

the

and

flywheel to facilitate assembly, then loosen the cover to flywheel bolts evenly to

release

the pressure plate

spring tension. Remove the

4. Install the radiator, the radiator supply tank, and the hood. Fill and

plate

pressure

and cover assembly.

3. Remove the flywheel retaining and remove the flywheel.

bolts

crankcase with the proper grade and

INSTALLATION

of engine oil.

5. Start the

engine and adjust

the

ignition timing. Operate the engine at fast idle and check all hose con nections and gaskets

HYDRAULIC

for leaks.

carburetor

fuel

VALVE LIFTER

the flywheel on the flange and install the re taining bolts. Tighten the bolts in sequence across from each other to

1. Install

crankshaft

2. On a manual-shift install the pressure

REPLACEMENT

To

an assembly.

the

remove the

specifications.

pump, drive

belt adjusting arm, pulley 14. Connect

chain

the intake

and

section.

13. Install the

is to be removed, heat tube.

section.

quantity a

gasket.

12. Install the then

damper,

outward.

11. Install the fuel pump using new

crankshaft

section.

tions. Remove the pilot.

10. Install the

the hood.

and

front cover, timing

cylinder

ing

in on the pilot, bolts to specifica

pushing

tighten the cover

front

supply tank,

radiator

the

so

the pilot aligns with the

pilot over

and

remove the baffle from the valve push rod cham ber floor to remove the valve lifters. The internal part of each hydraulic valve lifter assembly are matched sets. Do not intermix the parts. Keep the assemblies intact until they are to be cleaned.

7. Coat the gasket surface of the block and cover and the cover bolt threads with sealer. Position a new gasket on the block.

keyway in key in the

system

the crankcase. Remove the radiator,

the

do not to engine block

be removed, bank of the

the

on

5. Install the

installed in

seal.

8. Install the

radiator

the

but

Install,

retaining bolts. 6. Replace the

front

the

engine

choke

right

lifter

a

air cleaner.

are to

the push rod openings with a magnet.

3. Lift the hydraulic

pan, and the block gasket surfaces.

on

radiator,

and the hood. Fill and bleed the cooling system. Connect the heater hose to the water pump. Oper ate the engine at fast idle and check all hose connections and gaskets for leaks.

sure

Be

the

1. Remove the all the lifters

If or if

2. Disconnect the

15. Install the

slinger.

4. Clean the

the wind

and

3. Install the fuel pump eccentric, and the camshaft sprocket cap screw and thrust button spring retainer. Tighten the sprocket cap screw to specifications. Install the camshaft thrust button spring and thrust but ton. Install the crankshaft front oil

5.

and

line. Connect the

shield wiper vacuum

sprockets

21).

on

positioned as shown

oil

line,

supply tank,

INSTALLATION

1. Place the

AND EXHAUST SYSTEM

inlet line, the flexible fuel line, the

chain as an

assembly (Fig. 21).

-ENGINES

remove

draulic

valve

one or

lifters:

sion, all of

the

hy

cover start

assembly the cover

on

the

transmis plate

flywheel,

and

and

bolts. Use tool 7563

1-47

PART 1-2 -THUNDERBIRD 352 SPECIAL V-8 COAT GASKET WITH ENGINE OIL

Install the to

engine

tension

place

Remove the

sulator

to

Raise the

engine

engine

mit removal of

bolts,

then

remove

and

enough

the

engine

front in retaining bolts. engine

high

the

way.

high

on

mounts.

the

brackets

lifting

engine

Raise the

sling.

coil out of

the

and position

oil

enough

to per

pump retaining bolts. Remove

the

the oil pan and the oil

pump.

INSTALLATION

1. Raise the engine low installation of the the oil pan. Position a the

enough

oil

to al and

pump

new gasket on

pump housing and on the oil Place the oil pump in the oil pan

oil

pan.

and position the oil pan on the under

body

member.

cross

pump drive

housing

and

Insert the

shaft as an assembly.

Do

to force the pump into will no seat readily.

hex may be

1 529-A

not attempt

position

The drive

misaligned with

tributor shaft. To align,

FIG. 58 Oil

intermediate

Filter Replacement

oil

into the oil pump install the oil pump and

shaft

shaft

into

a

if it

shaft

the dis

rotate

new

the

posi

tion. Tighten the screws to

to

the

align

clutch

tighten

evenly

the

disc,

and

then

bolts

cover

to

3. Operate the engine at fast idle for leaks. If oil leaks are

and check

specifications.

evident,

3. Connect the transmission to the engine as outlined in Group 3 (man

pairs

ual-shift

transmissions)

or

Group

4

perform

necessary re leakage. Check fill the crankcase if

OIL FILTER REPLACEMENT filter.

with

position

the

gasket on

the

adapter

Hand tighten the filter

ket

contacts

advance

1. Drain the cooling

the

new

fil

58).

until the gas

the adapter

it Vi turn.

(Fig.

face,

then

system

the crankcase. Disconnect the tor upper hose

at

the

radiator

Remove the oil screws and lower the tank.

oil, then place the filter in on

OIL PUMP

oil

pan

in

place

retaining

pan

and

radia

supply

retaining

oil pan

screw on each side of

the

Install the remaining screws tighten them from the center out to 12-15 foot-pounds torque.

3. Lower the engine, then install the engine right and left front support

REMOVAL

the

under

recess.

2. Coat the ter

pan

filter from the fitting. Clean the adapter fil

Unscrew

adapter

ter

drip

the

the cylinder block and install

oil pan.

ward

OIL PAN AND

a

a

and

necessary.

(automatic transmission).

1. Place

2. Hold against

the

to correct the

the oil level and

oil pump retaining 23-28 foot-pounds torque.

to the

retaining bolts. Tighten the bolts to 40-45 foot-pounds torque. Remove the engine

Install the

lifting bracket

and

sling.

coil and connect the radia

the crankshaft so the counterweight

tor upper hose. Fill the cooling sys tem. Fill the crankcase with the

will clear the oil pan

proper grade and

underbody

pan

cross

member.

Position

and move the

forward.

2. Remove the

oil. coil

retaining bolts

Operate the

leaks.

quantity

of engine

engine and check

for

1-48

Pare

Section

PART THUNDERBIRD 430 SPECIAL

1-3

Assembly (Engine Removed)

5

Engine

6

Repair Operations (Engine

1-61

1-68

Installed)

V-8

Intake Manifold

1-68 1-68

Cylinder Heads

1-69

Engine Supports

1-70

Crankshaft Damper Cylinder Front Cover Section

Page

1

Description

2

Engine Removal Installation

3 4

Page

Timing Chain

1-70

Valve Rocker Arm Shaft.

1-56

Camshaft

1-70

Cylinder Heads

1-56

Hydraulic Valve Lifter

Section

1-48 and

1-52 Hydraulic Valve Lifters

Engine

Disassembly (Engine 1-54 Removed) Disassembly of

and

Component Parts

||

Pistons

Assembly 1-56

and

.

1-71

Flywheel

Connecting

and

1-71

Replacement

1-57

.

Oil Filter Replacement.

Rods

1-58

Oil- Vacuum

1-59

Pump

Oil Pan

.

1-71

.

and Oil- Vacuum

1-71

Pump

DESCRIPTION

The Thunderbird 430 Special V-8 (Fig. 1) has a 4.30-inch bore and a 3.70-inch stroke and a total piston displacement of 430 cubic inches. It has a compression ratio of 10.0:1. The patent plate symbol for engine

the engine is

"J."

The intake

(Fig.

has two

sets

fuel passages, each with its separate inlet connection to the

own

and are arranged so

car

haust

manifold

of

buretor (Fig. 2). The right side carburetor feeds Nos. 1, 4, 6 cylinders and the

2, 3, 5,

and

8

left

side

of

valve ports

the

and

The intake

CYLINDER

manifold

is

water

to assist in vaporizing the

fuel charge. The located beneath Refer to

"Cooling

water

the

incoming

passages

fuel

System"

tion for a description

heated

of

are

passages.

in this

sec

the water

circulation through the manifold.

The

The

valves

rear on

feeds Nos.

the on

right

The

head

valves and

integral

from front to

bank I-E-I-E-I-E-I-E, and the left bank E-I-E-I-E-I-E-I.

7

HEADS

arm shaft assembly. an

jacketed

that no two ex

cylinders.

cylinder

tain the

are water

valves are adjacent.

are arranged

BLOCK

CYLINDER MANIFOLDS

3)

part of

pump is

assemblies con

mounted to

cated at the

guides are

the head. The in

rotate

time the valve opens and closes.

and

vacuum

front. The distributor is lo front of the engine and drives the oil pump through an inter at

which

oil

the engine block

the

the valve rocker

Valve

take and exhaust valve assemblies

the rotating-type

combination

mediate

are

The

each

The

cated

drive

in

the

chambers

top

shaft.

combustion chambers

are

of each

cylinder

are

block.

formed by casting

bank

at a

10

lo

The the

angle with

"

t*MM

_

I A

Cr FRONT

1869-A

FIG. 1

-Thunderbird

430 Special V-8

'

\ '.J'* ^

%T-

*

Tg

\A J,*