DEMO - 1963 Ford Thunderbird Shop Manual

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Ford Thunderbird Shop Manual, provides the necessary in formation for ... ment were in effect at the time the manual was approved for printing. The Ford ...
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

1963 Ford Thunderbird Shop Manual EAN: 978-1-60371-013-8 ISBN: 1-60371-013-2 Forel Publishing Company, LLC 3999 Peregrine Ridge Ct. Woodbridge, VA 22192 Email address: [email protected] Website: http://www.ForelPublishing.com

This publication contains material that is reproduced and distributed under a license from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company.

Note from the Editor This product was created from the original Ford Motor Company’s publication. Every effort has been made to use the original scanned images, however, due to the condition of the material; some pages have been modified to remove imperfections.

Disclaimer Although every effort was made to ensure the accuracy of this book, no representations or warranties of any kind are made concerning the accuracy, completeness or suitability of the information, either expressed or implied. As a result, the information contained within this book should be used as general information only. The author and Forel Publishing Company, LLC shall have neither liability nor responsibility to any person or entity with respect to any loss or damage caused, or alleged to be caused, directly or indirectly by the information contained in this book. Further, the publisher and author are not engaged in rendering legal or other professional services. If legal, mechanical, electrical, or other expert assistance is required, the services of a competent professional should be sought.

GROUP INDEX THUNDERBIRD IDENTIFICATION

ENGINE AND EXHAUST SYSTEM

FORD THUNDERBIRD

IGNITION SYSTEM

FUEL SYSTEM

COOLING SYSTEM

CRUISE-O-MATIC TRANSMISSION

REAR AXLE AND DRIVE LINE

STEERING

SHOP MANUAL SUPPLEMENT

BRAKES AND SUSPENSION

GENERATING AND STARTING SYSTEMS

LIGHTS, INSTRUMENTS AND ACCESSORIES

BODY

MAINTENANCE, LUBRICATION AND SPECIAL TOOLS

SPECIFICATIONS SERVICE

FORD

DEPARTMENT

DIVISION

(^)MOTOR FIRST PRINTING

COMPANY

SEPTEMBER, 1962

1962 FORD MOTOR COMPANY. DEARBORN, MICHIGAN

Reprinted

with

Ford Motor Company's Permission

FOREWORD The information in this supplement, Ford Thunderbird

Shop Manual,

formation for servicing 1963

maintenance

The descriptions ment were

printing.

in

the

information

when used with the

1963

cations or

necessary in

Thunderbird.

and specifications are

and specifications contained

Complete included.

in this

supple

effect at the time the manual was approved

The Ford Division of Ford Motor

the right to

the

provides

1962

discontinue

design,

models at

any time,

Company

for

reserves

or change specifi

without notice and without

incurring

obliga

tion.

SERVICE

FORD

DEPARTMENT

DIVISION

FORD MOTOR

COMPANY

THUNDERBIRD IDENTIFICATION

BODY

COLOR

TRIM

DATE

J

85

9H

63A

TRANS

AXLE

DSO

VEHICLE WARRANTY NUMBER

5vrd

3Y83Z100001 NOT FOR

TITLE OR

REGISTRATION

PURPOSES

THIS VEHICLE IS MANUFACTURED UNDER ISSUED AND PENDING UNITED STATES AND FOREIGN PATENTS

( SvFCt

A PRODUCT OF

MOTOR COMPANY

M1087-A

1

FIG.

Figure 1 illustrates

Warranty The

is

plate

official

Thunderbird

a

attached

(Fig. 2). Do

on

the

body just

not use

plate

number

forward

the Vehicle

for title

Warranty

plate and

to the left door front

Vehicle Identification

stamped

Warranty

is

Warranty Plate

-Thunderbird

of

for title the

Warranty

its

The

elements.

BODY

pillar.

Tudor Hardtop Tudor Convertible

63A 7SA

and registration purposes

right-hand

number which

hood lock

plate

appears on

the

COLOR If

or registration purposes.

a special paint

is used, the

paint color space will not

be

stamped.

M30J/M32J

Code

O R S T U V W X Z

Ml 088- A

FIG. 2 -Vehicle Identification Number Location VEHICLE

.Silver

.1515.

.

.

.1452.

.

.

.1458.

.

.

.1238.

.

.

.

.

921. 1554

Red Lt. Turquoise Pink White Diamond Blue Med. Green Metallic Yellow Dk. Green Metallic

1456 1453 1543 1450 1470 1555 1444 1427

Lt. Beige Dark Turquoise Metallic Chestnut Metallic Lt. Pink Metallic Maroon Metallic Beige Metallic

Sandshell Beige

Deep Sea Blue Chestnut Rose Beige Heritage Burgundy Fieldstone Tan

TRIM

J

85

9H

11

1

4

Deviation trim

sets will use

a numerical suffix

is

existing trim

not

serviced,

codes plus a suffix.

while a

63A

Tudor Hardtop

j

Red

85

Red Leather

9H

Ninth

11

District Code

72 77

1

3.00:1 Axle Ratio

74

Lt. Blue D/L Lt. Turquoise D/L Pearl Beige

Cruise-0-

76

Black

4

Raven Black Patrician Green Acapulco Blue Silver Mink Caspian Blue Rangoon Red Chalfonte Blue Sahara Rose Corinthian White Diamond Blue Green Mist Tucson Yellow Cascade Green

DATA

Example (Fig. 1): 63A

Black Med. Turquoise Metallic Med. Blue Metallic Blue Metallic Dark Blue Metallic

1724 1070 1269 1446 1544

.

Sales Name

Color

Number

A D E G H

with

betical

day

of

August

Matic

suffix

Code

is

trim code

A trim

with

an

code

alpha

serviced.

Crinkle Vinyl

Pin Stripe B/C Dk. Blue Dk. Turquoise Med. Beige Black

THUNDERBIRD IDENTIFICATION Code

Crinkle Vinyl

Vachette Vinyl

52...

Med. Blue D/L

Lt. Blue D/L

57...

Med. Turquoise D/L

Lt. Turquoise D/L

59...

Med. Chestnut D/L

Med. Chestnut D/L

54...

Pearl Beige

Pearl Beige

AXLE

Code

Ratio

1

.3.00:1

A*

56...

Black

Black

55...

Red

Red

50...

Med. Silver Blue Met

Lt. Silver Blue D/L

58...

Lt. Gold D/L

Lt. Gold D/L

51...

Lt. Rose Beige D/L

LL Rose Beige D/L

Code

Crinkle Leather

.3.00:1

*Equa-Lock Type.

82...

Lt. Blue D/L

Lt. Blue D/L

84...

Pearl Beige

Pearl

86...

Black

Black

85...

Red

Red

of

code

the

letters

Code

Type

4

Cruise-O-Matic

VEHICLE WARRANTY NUMBER

DATE The

TRANSMISSION

Vachette Leather

letters for the

month when

are

to be

month are preceded

by

a numeral

to

show

the Thunderbird was completed. The second

used

if

12

model production exceeds

day

Second

Model Year

Example (Fig. 1): 3Y83Z1000O1

3

months.

First Month

the

year code

Model Year

January February

A

N

B

P

March

C

Q

April

D

R

May

E

S

June

F

T

July

G

U

August

H

V

September

J

W

October

K

X

November

L

Y

December

M

Z

1963 Model

Y

Wixom

83 Z

Tudor Hardtop 8-Cylinder 390 Cubic Inch Engine

1 00001

First Unit Built

Assembly Plant

MODEL YEAR The

"3"

number

designates 1963.

ASSEMBLY PLANT

Code

Location

DSO Thunderbirds built to a Domestic Special Order, Foreign Special Order, or Pre-Approved Order have the complete order number recorded in this space. Also appearing in this space is the two digit code number of the District which ordered the unit. If the unit is regular production, only the District code number will appear.

.Wixom

Assembly Plant

Pilot Plant

MODEL DISTRICT CODE

Code Code

District

Code

District

Type

11

Boston

45

Davenport

83

Tudor

12

Buffalo

51

Denver

85

Tudor Convertible

13

New York

52

Des Moines

87

Tudor Landau

14

Pittsburgh

53

Kansas

89

Tudor Roadster

15

Newark

54

Omaha

21

Atlanta

55

St. Louis

22

Charlotte

61

Dallas

23

Philadelphia

62

Houston

City

ENGINE

24

Jacksonville

63

Memphis

25

Richmond

64

New Orleans

26

Washington

65

31

Cincinnati

71

Oklahoma City Los Angeles

32

Cleveland

72

San Jose

33

Detroit

73

Salt Lake

34

Seattle

City

Indianapolis

74

35

Lansing

81

Ford

36

Louisville

83

Government

of

Hardtop

Code

Type

M

8- Cylinder

9

8-Cylinder 390 Cubic

Z

8-Cylinder 390 Cubic Inch (4-barrel)

390 Cubic Inch

(6-barrel

High Performance)

Inch (4-barrel Low Compression

Export 84 Octane)

Canada

41

Chicago

84

Home Office Reserve

42

Fargo

85

American Red Cross

43

Rockford

89

Transportation Services

44

Twin Cities

90-99

Export

CONSECUTIVE UNIT NUMBER The assembly plant, with each model year, begins number 100001 and continues on for each unit built.

with consecutive unit

1

GROUP

GROUP 1 -ENGINE AND EXHAUST SYSTEM The 1963 maintenance recommen dations are in Group 12 and the 1963 specifications are in Group 13 this

of

All

manual.

the

lined in

I

Group

out

procedures

1962

of the

Performance

follow

engine with the

390 4-V ENGINE (Part 1-1) CAMSHAFT The

an

adjoining

can

so

be installed in their

5. Install indicator sprocket

dial indicator

a

that

camshaft

the

on

1. Oil so

the

camshaft

Push

screw.

retaining

the

toward the rear of the en

dial indicator

the

set

gine

and

zero.

Pull the

forward and the indicator

Compare

it.

reading

with the specifications.

If the

play is excessive, check the spacer for correct installation before it is

having Removal

be

1. Refer to "Valve Rocker Arm (page Shaft Assembly

The

a

chamfer

the

against

nal.

side

If the

the

of on

spacer

1-15, 1962 Shop Manual) valve

arm

rocker

re

and

shaft

the ID

2. Remove the steps

cylinder

1 thru 16

inder Front Cover Removal"

(page

and

front

cover

"Cyl

under

Timing

Chain

1962

Shop

1-23,

Manual).

3. Remove the and

sequence

that

so

they

valve push

them

place

can

rods

in

a

in

rack

be installed in their

original positions.

front jour is installed cor

camshaft

spacer

4. Position valve

page

inspection

an

move

some

push

light

the valve the

valley (Fig. 55, Shop Manual). Re

lifters

push

cases, it

into

rod

1-26, 1962

through

rectly, replace the thrust plate.

6. Remove the dial indicator. Re the

move

camshaft

sprocket

fuel pump eccentric. 7. Slide both sprockets

timing

with a magnet

rod

openings.

In

be necessary to

will

chain

forward,

and

and

cap

the

remove

chain as an

timing assembly (Fig. 49, 1962 Shop Man ual).

thrust

the

ID

be above the it must face towards

and

(against

the

camshaft

under

"Camshaft

8. Remove pump

the

pan

oil

by following "Oil Pan

and

the

Oil

moval"

(page

1-32,

9. Remove and

avoid

the

spacer.

the camshaft

front

of the

2. Follow step 5 Removal"

and

3. Position the

ing

by

thrust

the

with

shaft

the

as

camshaft bear-

48,

1-24, 1962 Shop Manual.

page

shown

4. Install the fuel pump eccentric, flat washer, lock washer, and sprocket Torque the

screw.

cap

to

front

sprocket

cap

Install

the

specifications.

oil slinger.

5. Replace the

Install the

front

crankshaft

cylinder

front

damper,

crankshaft

following

parts

steps

3

"Cylinder Front Cover Installation"

Chain

and

related under

Timing

and

(page 1-24, 1962

Shop Manual). 6. With No. the end

of

position

the

the

with

1

the

piston

TDC

on

compression

distributor in the block at the No. 1 firing

Install

the points open.

and

the hold

down

clamp.

vacuum

Con

cap.

the coil high tension lead.

8. Install the from

bores

9. Refer to Shaft

they

the

were

re

push rods.

"Valve Rocker Arm

Assembly

the valve

Installation"

in

and

rocker

following

sembly

lifters in

valve

which

Install the

moved.

stall

at

stroke,

rotor

position

nect

BEARING

oil

cover,

16

thru

line. Install the distributor

arm

shaft

1

thru

steps

as

9,

1-16, 1962 Shop Manual.

page

PLUG

the

on

in Fig.

aligned

engine.

damaging

marks

timing

sprockets

remove

pulling it toward the Use caution to

tim

and

sprockets

chain on the camshaft and crank

oil

Pump Re 1962 Shop

Carefully

camshaft

play.

end

the

camshaft

the

check

procedure

Manual). plate

sprocket).

7. Connect the distributor

BORE

in the

oil groove

must

plate

camshaft, the front

having

side

against the camshaft

front journal. The thrust

Install

plate.

the thrust plate with the

seal.

BEARINGS

CAMSHAFT REAR

apply

Carefully

the camshaft through the bear

ings. Install

screw

the sprockets and

under

through a push rod opening and the

lobes.

the

must

screw, lock washer, flat washer, and

assemblies.

following

and

camshaft

to

and

Removal"

the

the

Lubriplate

a chamfered

on

camshaft

release

removed.

in Fig. 3.

move

Installation

origi

slide

is

point

ings.

remove

end

camshaft and related parts are

shown

to

over

nal positions.

Shop

exceptions.

lifter

opening in order to it. Place the lifters in a rack

push rod

they

service

Manual apply for both the 1963 390 4-V engine and the 390 6-V High

ing

transfer the

10. Fill

and

Fill

the

tem.

proper grade

bleed the cooling crankcase

and

quantity

sys

with

the

of eneine

oil.

11. Start the adjust

the

the engine TIMING CHAIN AND CAMSHAFT SPROCKET

hose

engine and check and

ignition at

timing.

fast idle

connections

and

Operate

and check

all

gaskets

for

leaks. FLAT WASHER

-

A1275-B

Cleaning to the

FIG. 3-Camshaft

and

Related Parts

ing

1962

and

and

Inspection. Refer

Shop Manual

inspection

for

clean

procedures.

I

GROUP 390 6-V HIGH PERFORMANCE ENGINE (Part 1-1) The warranty plate identification symbol for the engine is "M". This engine is the same as the 390 4-V engine except for specifications

(Group 13)

and

the

spacer

is

on

exhaust

mounted

with

control

valve

The dual

the counterweight

consists of:

gas

the outboard side of the engine.

1. A cast aluminum intake mani fold replaces the cast iron intake manifold used on the 390 4-V engine. 2. The coolant-heated carburetor

A

single

exhaust

system

birds.

dual

A

available

as

stand

system

is

equipment

on

exhaust

optional

is

Thunder-

1963

ard equipment on all

and

right

and

integral

ing

front

section

joined together

cross-over

right

(Fig. 3 A)

a one-piece muffler

that are

welded

DESCRIPTION

exhaust system

pipe with separate pipes

EXHAUST SYSTEM (Part 1-2)

dif

following

ferences:

models.

all

eliminated.

3. The

is

1

pipe;

inlet inlet

by

a

separate

left inlet extension pipes; left mufflers that contain

muffler

clamps,

outlet

brackets,

pipes;

retain

nuts and

bolts;

two exhaust manifolds to inlet pipe gaskets.

A1730-A

FIG. 3A-Dual Exhaust System The

single

exhaust

3B)

consists of:

inlet

pipe with

"Y"

that are

joined

muffler

taining

inlet

clamps,

inlet

type

and welded

a muffler with an a

system

(Fig.

a one-piece muffler

integral

re

pipe;

brackets, bolts

nuts; two exhaust manifolds to

and

inlet

sealing gasket, located the flange of the inlet pipe and the

pipe gaskets; a at

inlet

extension

INLET

pipe

rear

PIPE REPLACEMENT

flange.

PIPE, INLET EXTENSION

Muffler

haust. serviced

Inlet

The

in

one

1. Loosen the

inlet

Pipe

Ex

-Dual

inlet

muffler

pipe

is

piece.

forward

on

Disconnect the inlet haust manifolds.

bracket re Disconnect the inlet extension pipe from the inlet pipe and remove the inlet pipe. 3. Clean the mounting surfaces of muffler rear

the exhaust manifolds and the

muffler

inlet

pipe

to

extension pipe clamps and slide

the clamps

Remove the

taining bolts.

pipes

together;

outlet pipe;

extension

PIPE, MUFFLER AND OUTLET

the

inlet

pipe at

pipe.

the ex

2. Disconnect the hanger bracket clamp from the inlet extension pipe.

inlet

pipes.

4. and

Install the gaskets, inlet pipes, the

retaining

nuts.

Torque the

nuts to specifications.

5. Position the front clamp on the inlet extension pipe. Connect the inlet pipe

and

the

inlet

extension

pipe;

1

GROUP

A1731-A

FIG. 3 B- Single Exhaust System then install the muffler, muffler rear

let

bracket retaining bolts, and the inlet extension bracket clamp.

muffler

6. Align the exhaust system; then, the front clamp, inlet ex

torque

tension muffler

to

bracket

pipe rear

bracket retaining bolts

specifications.

7. Check the Muffler

system

Exhaust. The

procedure

left

a right or

either

for leaks.

Outlet Pipe

and

applies

to

assembly.

pipe

tension ward until sion

and

assembly.

the

new

assembly

pipe.

and

muffler

on the

Slide the

into the inlet the slots in the are

Remove the

and outlet pipe assembly.

3. Position

inlet

muffler

extension

muffler

ex

for pipe

exten

blocked.

4. Align

the

pipe assembly.

Inlet Pipe Extension procedure applies

to

left

assembly.

muffler

and

outlet

2. Loosen the

muffler

inlet extension

muffler

Install the

and

outlet

muffler

in

Remove the inlet

exhaust pipe

haust

extension

front clamp on the Connect the

pipe.

of

the

inlet

inlet extension pipe to the inlet pipe. Install the inlet extension pipe front clamp and the hanger bracket clamp. 4. Install the muffler and outlet pipe assembly.

5. Torque the inlet

front

extension

and rear clamps and the

pipe

hanger

bracket clamp to specifications. 6. Check the system for leaks. Muffler

Inlet

Pipe

Single

ex

the pipe

the

manifold.

and

manifolds.

Clean the mounting

3.

and

end

extension

surfaces of

the exhaust manifolds and the

extension pipe

pipe.

Remove

and

inlet pipes at Remove the gaskets from the ex

2. Disconnect the

pipes.

3. Position the inlet

flange.

pipe

clamp from the inlet hanger bracket.

inlet

front clamp and remove the inlet extension pipe hanger bracket clamp.

is

pipe

1. Remove the retaining bolts from the inlet pipe to inlet

tension

Dual Exhaust. The either a right or

inlet

muffler

serviced as one piece.

pipe

bracket securing the muffler rear

outlet

Muffler

Exhaust. The

nuts

-Dual

it forward on the 2. Remove the retaining bolts

muffler

nuts.

bolts to specifications. 5. Check the system for leaks.

1. Remove the

extension pipe.

to the hanger

rear

pipe assembly.

1. Loosen the muffler to muffler inlet extension pipe clamp and slide

nuts

and

and

clamp,

and the pipe clamp bracket retaining bolts Torque the clamp and

extension

inlet

Install the gaskets, inlet pipes,

retaining

nuts.

Torque the

nuts

to specifications.

4. Install

inlet

a new gasket

pipe and

the

inlet

between the

pipe extension

flange. Install the flange retaining bolts and nuts; then, torque them to specifications.

5. Install the inlet extension pipe hanger bracket clamp and torque the

retaining

nuts

6. Check the

Muffler

-

to

specifications.

system

Single

for leaks.

Exhaust. The is serviced as

muffler and outlet pipe

8

GROUPS

one

piece.

the

outlet

front

pipe

hanger bracket clamps. 2. Remove the inlet extension pipe to muffler flange retaining bolts. Remove the flange gasket and the

and

system; then, clamp bolts and muffler flange bolts to specifications. 5. Check the system for leaks. and

1. Remove rear

1-2-3

the

align

exhaust

Pipe

Extension

Inlet

Muffler

3. Clean the

muffler and inlet pipe flanges. Position the muffler flange and a new gasket on the inlet extension pipe flange. Install the re taining bolts and nuts. 4. Install the outlet pipe clamps extension

3. Clean

1. Remove

2.

Pry

the

the

the

inlet

pipe

inlet

the

on

of

position

flanges.

Insert a new gasket between the front and the rear flanges. Install the mounting bolts and nuts. 4. Install the inlet extension pipe and

muffler

hanger bracket bolt to

the inlet

remove

mating

extension

gaskets.

surfaces

mounting flanges; then,

flange bolts

toward the right

muffler

the car and

side of

extension

clamp from hanger bracket. the

pipe

extension

inlet

the

of

Remove

pipe.

flange bolts from

the

both flanges

the

the

pipe

Single Exhaust

muffler and outlet pipe assembly.

the flange

extension pipe and

torque the

Torque the

clamp.

hanger clamp

the

and

specifications.

5. Check the

for leaks.

system

GROUP 2-IGNITION SYSTEM The

1963

maintenance

in

mendations are

1963 specifications

in

are

and the

13

Group

ignition

The

recom

12

Group

system

in

outlined

cedures

service

pro

1962

Shop

the

Manual apply to the 1963 Thunder

bird. Refer to

ice

2

Group

for the

manual

1962

of the

serv

recommended

procedures.

this 'manual.

of

GROUP 3-FUEL SYSTEM The

1963

maintenance

mendations are

1963

3

390 4-V

the

Service

1962

Man

Shop

for the

series

except

1963 as

de

(Ford 4-V carburet

for the 1963 390 6-V engine

procedures

Performance (three

series

13

same

engine

herein

scribed

High

Group

dual

Holley

carburet

ors) are included in this supplement.

FORD 4-BARREL CARBURETOR

4. Standpipe

level

This

differential for

horn

air

in

plate

the

to

the

entrap

closed

position

holding

during

choke plate closed

the

cold engine

2. A lower torque rate choke hous ing spring has been incorporated to reduce

the forces

choke

plate

bowl the

by the

tending the

after

the

of

carburetor

external

added cover

highly

to to

the ten

provide

system

over-

opening has secondary fuel an escape

for

fuel vapors, there

reducing the possibility

intake

to

"loading".

vent

the

volatile

has

engine

the engine and cause

3. An been

to close the

thereby minimizing

started,

choke

evacuation of

hot

internal fuel

thrown

soak period.

and

secondary control

each

forces

balance

in

passage

within

these

since

of

added

proper

metering forces out

the ex

equalizer

between the primary fuel bowls to permit the

pressure

by

secondary fuel bowl

during

section of

to

the carburetor was revised

for the

compensate

the

the secondary

calibration of

forces.

metering

for

specifications

of a

flooding

hot

soak

4. Loosen the attaching screws the magnet and bracket

reduction

Refer

the proper

choke

plate.

screws

and

Set the

ing

other

to

in the

metering

derbird

procedure

and

bracket

housing

the

adjust

magnet

assembly:

1. Rotate coil

to

the 90

thermostat "rich"

direc

tion (counterclockwise).

2. Adjust necessary, tween cam

the

and

rear of

the to

bellcrank

obtain

top

edge

the cast

the choke

attaching hous All

mark.

for adjusting the the same as out

1962 Thun

of the

Manual.

Shop

Fuel Level Float Adjustment. On Viton-

with

equipped

inlet needles, the float fuel level settings should be fuel

tipped

as

a

guide

be

made as

1. Operate at

minutes

the

1200

follows:

flat

a

carburetor

Stop air

to

30

normalize

and

place

as near

surface

2. Remove the

for

engine rpm

temperatures,

on

check

the wet fuel level

and adjustment of should

final

a

and

only,

dry used

ve

level

the engine. air cleaner

horn

assembly,

assembly,

and

gasket.

choke

in the

the

index

proper

procedures

as possible.

Automatic Choke. Use the follow

as

the

contacts

thermostat coil

choke

lined in Part 3-1

hicle

IN-CHASSIS ADJUSTMENT

and

the feeler gauge.

automatic choke are

engine

ing

Tighten

remove

the

to

it just

that

so

sembly

carburetors ex

horn

air

addi

ternal vent.

6. The

the

and

plate

adjust

were

the

choke

gauge

rear straight edge of

casting.

openings

5. Two baffles have been the

the

the

openings.

through

a

bowl

jets.

starting.

dency

vent vent

proper

during

between the top

raise

necessary

vapors

tion of the

bracket assembly to the front wall of the

increase the force

and

provides the

ternal vent

to

0.010-inch feeler

a

were

magnet and

carburetor

choke

the

internal

the gaseous

fuel

secondary

external

changes:

added

was

incorporates

carburetor

1. A

the

tubes

pitot

openings

the

of

above

the

vent

fuel bowl,

OPERATION

following

to

added

of

The

3. Place

period.

internal

of the

remain

or).

the

service procedures outlined

Group

ual

in

and

manual.

All the

in

recom

12

Group

specifications are

this

of

in

main

lever, if

0.050 inch be of the fast idle

stop boss

housing.

3.

on

the

Temporarily

gasket

in

place

body

and

the engine. Let

start

the engine idle for

several

then remove the air

4. While the standard

vertical

depth

the air horn

the carburetor

position on

horn

engine scale

minutes;

gasket.

is idling,

use a

to measure the

distance from the top

ma-

GROUP 3 ating rod may be placed in the No. 1 hole position of the over-travel

PUT ROD IN INSIDE HOLE

lever

(hole to

shaft)

throttle

the

to

closest

individual operating

suit

conditions.

The

correct position

the

rod at

operating

lever, for

for the pump

accelerator

pump

operating con ditions, is in the inboard hole (hole plunger

all

to the pump

closest

plunger).

HOLLEY DUAL CARBURETORS IN-CHASSIS ADJUSTMENTS

Idle Fuel Mixture Adjustment 1. Operate

the

until

engine

it

operating tempera is equipped with an air conditioner, the engine must be All operated at least 20 minutes. normal

reaches

ture. If the car

ACCELERATING PUMP LINK

ACCELERATING

PUMP OPERATING ROD

B1424-C

idle fuel

engine speed and

FIG. 4 -Accelerating

Pump Stroke

Adjustment

adjustments

the chined surface of the carburetor main

to the level of the fuel in the

body

fuel bowl. The at least

made

vertical surface

measurement must

inch

1/4 to

be

from any

assure an accurate

reading because the surface of the fuel is concave (higher at the edges than in the center). Care must be to

exercised

the

measure

fuel level (wet)

correct

5. If any the

stop

the fuel.

for the

specifications

adjustment

to

engine

setting.

throttle

shaft).

from the at

the

contacting in relation

original

position,

level

and

time

an

alter

be

engine must

to idle for

(below

the

40F),

rod

fuel

to the

made

suit

operation

ambient

(Fig.

individual

5) inward

15F

(

and

be

operating

condi

high

ambient

temperature

(above 80F

and/or above

are

they

until

both idle

carburetor

each

seated.

Then turn the idle

screws

on

tor (Fig.

3. Install

lightly

mixture

secondary carbure 3/4 turns, and

each

6)

outward

idle mix full turn.

carburetor

ture screws outward one

an engine speed

tachom

Start the engine; move the trans mission selector lever to the DRIVE

eter.

and

position,

575-600 speed

rpm

adjusting

set

engine

the parking idle rpm to

by turning screw

(Fig.

primary carburetor only. 4. Turn the primary

idle

operation

screws

brake. Adjust the

tem

tions.

For

on

(Dl)

shaft).

the pump operating rod may be placed in the No. 4 hole position

to

by turning

mixture

mixture

engine

lean

5000 feet altitude), the pump

oper

SECONDARY THROTTLE LEVER

DLE MIXTURE SCREW

screws

begins to

mixture.

screws

run rough

Turn

idle

on the

carburetor

inward

outward until

the

5)

the

until

the

from the mixture

the engine be-

the fuel level the

started and permitted

WIDE-OPEN THROTTLE STOP

least three (3) minutes the fuel level. Check the

after each adjustment until

specified

6. Install and

is

ambient temperature oper

place the pump No. 3 hole posi in the operating tion of the over-travel lever (third ation

an

ture adjustment

at

stabilize

fuel level

the

raise

the

downward to lower it. Each adjustment

float tab to

the

to

the

inlet

to

upward,

valve

to

fuel

it is dis

cleaner

air

2. Establish

turn the primary

For low

For extremely low

the

rod

the tab

press

until

hole from the throttle

level, bend

fuel

the

engaged.

perature

tab

clip,

away from the clip

low),

adjust

over-

the clip toward the rod, and the same time press the rod

when

float

retainer

release

the

of fire due to fuel spray the float setting is disturbed.

the

end of

hazard To

To

is required,

minimize

of

position

lever (second hole from the

travel

fuel level

at the point of contact with

Refer to the

the No. 2 hole

mixture

be made with installed. initial idle fuel mix

must

level is a

new

achieved.

air

carburetor air

horn

horn

gasket

assembly.

7. Check the engine idle speed idle fuel mixture and adjust as

and re

quired.

8. Install the

air cleaner assembly.

Accelerating Pump Stroke. The over-travel

lever has 4 holes

and

the

accelerating pump link has 2 holes the accelerating pump to control stroke for different engine applica tions (Fig. 4).

For

average (40

operation accelerator

ambient

to

temperature

80F),

place

pump operating

rod

SECONDARY THROTTLE ROD

PRIMARY

PRIMARY

THROTTLE LEVER

THROTTLE ROD

IDLE SPEED ADJUSTING SCREW

the

in

FIG. 5-390 6-V Carburetor Throttle Linkage Installation

B1718-A

I I

10

GROUP 3

PRIMARY CARBURETOR

SECONDARY CARBURETORS

AUTOMATIC CHOKE

IDLE ADJUSTING

CHOKE THERMOSTAT HOUSING

SCREW

B1730-A

FIG. 7 -Fast Idle Speed Adjustment increase

to

ward

decrease the idle specified

to

outward

or

speed

to

the

obtain

rpm.

Throttle Lever Synchronization. If the throttle linkage is disassembled

it is improperly synchronized, the following procedure is recommended

or

for synchronizing the throttle levers the three carburetors.

on

1. Insert TRUNNION

BELLCRANK LEVER

PRIMARY THROTTLE ROD

ACCELERATOR-TO-BELLCRANK ROD CONNECTION

B1719-A

1/8-inch diameter

a

rod

through the gauging holes (Fig. 8) provided in the bellcrank lever and

mounting bracket on the left side of bellcrank assembly. This locks the

FIG* 6-390 6-V Carburetor Installation

the

to roll from the rich mixture.

gins

Turn

the

engine

screws

runs

Always favor

fuel

the

cleaner

evenly.

normal

until

and

"rich"

a

slightly

idle

mixture.

to adjust the

procedure

idle

mixture screws on

front secondary

6.

Following

adjust rhe rear

secondary

left

and

any

idle idle

carburetor.

the same procedure, mixture screws on the carburetor. mixture

The

right

screws

on

be open 1/8 turn,

one carburetor should

an equal

after

amount, within the final adjustment.

7. With

idle

(step 4)

and

the

1. Back

range, check the engine tachometer should

speed.

The

indicate 575-600

(Fig.

screw

the stop

at

2. Disconnect the secondary throttle

5)

adjust

speed

on each

secondary the

allow

3/4

turns.

an

A

throttle

do

plates.

stick

not

at

the

second

The only re is that the in the bores.

1200

speed

for

engine

30

to normalize

rpm

temperatures.

engine

the

necessary

2. Operate minutes

throttle

minimum on

then

1/2 to

additional

opening is desired ary

lever;

the throttle

on

it inward

8. If the engine still does not idle properly, due to a too rich mixture, i.e., idle mixture screws are seated,

Install

tachometer.

an

Start

Move the transmission

each secondary carburetor lever (Fig. 5). Disconnect the primary throttle rod at the bell crank lever. at

throttle

the

selec

lever to the DRIVE (Dl) posi tion, and set the parking brake. Ad just the engine idle rpm to 575-600

by turning

rpm

ing

screw on

the

idle

speed adjust

the primary carburetor

only.

3. Set the fast idle with

speed

(cold)

the engine at normal

the fast screw

idle

operating Align the high step on

cam

with

the

(Fig. 7). Turn the

adjusting screw

3. Loosen the lock

length

nut and adjust

front secondary carburetor throttle rod so that, when installed, the throttle lever of the front secondary carburetor will be the

of

the

completely closed when the primary lever is closed against the idle speed adjusting screw stop throttle

(normal idle

position).

4. Adjust the length secondary

of

the rear

carburetor throttle rod

in

the same manner.

en

tor

temperature.

Idle Speed Adjustment. All engine and idle fuel mixture adjust

idle

sufficiently to

turn

engine.

speed

engine

in the throttle bores. Turn the idle speed screws in ward until the screw end just touches

gine

levers are not synchronized, it will be difficult to obtain a satisfactory idle adjustment.

lever in the gauging (closed throttle) position.

throttle plates to seat

engine rpm.

it may be caused by improper initial idle speed setting of the secondary carburetors. Also, if the throttle

air

temperature.

the

off

carburetor

plates

operating at the transmission in Drive

the

with

the

and

operating

quirement

engine

made

rods

ing

5. Repeat this the

inward

smoothly

be installed

must

ments

in-

5. Install rods on with

the

secondary

throttle

the secondary throttle

levers

the spacer washers and retainers.

Tighten the lock

nuts

to

secure

the

adjustment.

6. With the primary throttle lever idle stop, adjust the length of the primary throttle rod (Fig. 6), against the

so that the trunnion will just engage in the hole in the bellcrank lever. Install the rod retainer clip.

7. Adjust clearance.

the

anti-stall

dashpot

n

GROUP 3

BELLCRANK LEVER

adjusting screw into the head to increase the clearance and outward to decrease the clearance.

screw

the

ANTI-STALL DASHPOT

One-half turn

the

of

After the fuel level has stop the

To

equals

screw

two

either of

top hole

of

be

can

cam

placed

lever

is

which

gives

in

the

Aligning

positions.

top hole

the cam with the

the throttle

of

stroke

climates, the accel

various

erating pump

Float Adjustment require

acceleration

satisfy

in

the shortest

for

recommended

warm weather or average conditions.

Aligning LOCK NUT

B1720-A

longest for

FIG. 8 Anti-Stall Dashpot Adjustment

1. If the fuel level is too high, it should first be lowered below speci fications and then raised until it is just

hole

bottom

is

stroke which

the

gives

recommended

cold weather operation.

idle

engine

to the

3

idle fuel mixture, and synchro the carburetor linkage. Operate

the

engine

it

until

reaches

position

Q

gauging inch diameter

the lock bowl just

holes

ing

lever left

and side

rod

1/8-

3. Loosen the lock

in,

screw

blade,

screwdriver

clearance

between

bellcrank

lever

the

Tighten the locknut 1/8-inch

ment to control

temperature. screws stat

to

its

Turning

mixture, mixture

is

housing in a indicated by

housing.

for the

the three

By loosening

counterclockwise

as

to engine

be turned

can

the

housing in

direction and

a

a

by turning

clockwise

level floor.

a

on

the

specifications

proper setting.

pressure

is

tions.

Operate

the

minutes

at

operating reached.

the

collect

any

rotation

at

the

the fuel level

adjust

running because

engine

in the line

will

spray

fire hazard.

out and present a

within

a

specifica

for

engine until

level

sight

edge

been

container

plug to fuel.

of

the

level

fuel

lock

Start

screw.

should

has

below

be

limits. If it is not,

3, turning

step

repeat

the adjusting nut an sufficient to lower

additional amount

the

fuel below the

specified

5. Loosen the lock the

level.

of

fuel level is

justment, the

screw and

turn

adjusting nut out in increments 1/6 turn or less until the correct

then

lower

plug opening 3/64 inch).

30

sight

spill-over of

(1/6 turn

the engine. After the fuel level

normal

has

suitable

fuel level

car

fuel

the

sure

rpm

specifications

adjusting nut, depending on the direction of rotation, will raise or lower the float assembly at the fuel the

start

achieved.

After

each ad

tighten the lock screw, and the

engine

and

stabilize

fuel level. Check the fuel level

sight

plug opening 1/16 inch. If the fuel level is satisfactory, in the sight plug. Do not install the

stall

air cleaner at

this time.

If the fuel level is too high, drain fuel bowl and refill it and check

the

it

before altering the float set This will eliminate the pos sibility of foreign material causing a again

drain

the wide-open-throttle position and

and the

the

pressure

The

With the engine stopped, remove the fuel level sight plug and gasket and check the fuel level (Fig. 10). The fuel level within the bowl should

in

the accelerating pump arm fully de pressed (manually), there should be

head

1200

Place

temporary

screw

fuel

the

allow

ting.

Accelerating Pump Adjustment. 9) held

clearance

Pump

temperature

With the throttle lever (Fig.

0.015-inch

Be

pump

be

of

top

stabilized, stop the engine and check the level at the sight plug opening.

Fuel Level Check. Position the on

to

or attempt

specified

direction

arrows

Refer to the

FIG. 9 -Accelerating Adjustment

provides a

conversely,

obtained

the

ad

stopped, loosen

to

enough

4. Tighten the B1731-A

adjust

the thermostatic spring

justment.

the

an

CAM WINTER SETTING

/ /

ACCELERATING PUMP CAM

below

reaction

housing (Fig.7), it

leaner

the

holes.

that retain the choke thermo

alter

richer

remove

gauge

has

choke

automatic

inch.

Adjustment.

Choke

Automatic

The

and

from the

rod

and

plunger

1/8-3/16

to

the

adjust

and

/ /

or

away from the bellcrank lever. Fully depress the dashpot plunger with a

on

adjusting nut underneath (Fig. 10). Do not loosen the lock screw

of

turn

and

nut

dashpot

anti-stall

/

/

ACCELERATING PUMP LEVER

in the bellcrank

mounting bracket on the of the bellcrank assembly

(Fig. 8).

the

ACCELERATING PUMP ARM

through the gaug

provided

engine

screw

level below

*%

BODY ASSEMBLY

ROTOR AND SHAFT ASSEMBLY

/I

,

f

^jI

FIG.

I

73 Outer Race To Housing

Clearance PLATE

Repair

A1290-A

damage,

any

or

the pan if repairs can not

FIG. 71

Pump

Oil

Installed a new oil pump inlet tube gasket on the oil pump and install the tube. Prime the oil pump by filling either the inlet or outlet port with engine oil. Rotate the pump shaft to distribute the oil within the pump body.

3. Raise the engine high enough to allow installation of the oil pump and the oil pan. Place the oil pump in the the oil

oil pan and position

pan on

the

underbody cross member. Insert the oil pump drive shaft into the oil pump housing and install the oil pump and

not

seat readily.

sembly, then remove the

3. Insert

the intermediate

rotate

position.

screws

retaining

4. Hold against

shaft

Torque the

oil

into

to specifications.

the

oil

the cylinder

in

pan

block

and

place

install

screw on each side of

a

retaining Install the remaining and torque them, from the oil pan.

outward, to

a

pump

the

screws

center

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

the

retaining bolts. Torque the bolts to

Remove

lifting

bracket

radiator

upper

the cooling

and sling.

the

into

system.

and

Fill the

bleed

crankcase

the proper grade and quantity of engine oil. Operate the engine and with

check

the

oil

self -threading

for leaks.

PUMP

cap

pressure and

1. Remove the 2. Remove

oil

inlet tube from

and remove

the

cover

relief

valve

pull

and plunger.

OIL

2. Install valve

the

shown

a

solvent

the gasket.

retaining

and

clean

the inside of the pump

and

the pressure

Be

sure

dirt

all

housing

relief valve chamber. and

chips

are

re

moved.

Check the inside

ing

the

and

damage

the pump hous

of

outer race and rotor

for

or excessive wear.

oil

plunger, spring,

grooved,

replace

the cover.

Measure the outer race to hous ing clearance (Fig. 73).

thoroughly.

all parts

in

parts

Check the mating surface of the cover for wear. If the cover mating surface is worn, scored, or

PUMP ASSEMBLY

1. Oil

all

them thoroughly. Use a brush to

pump

The oil pump assembly is in Fig. 72.

relief

pressure

and a new cap.

With the

rotor

in the housing,

assembly installed

place a straight edge

assembly and the hous ing. Measure the rotor end play clear ance between the straight edge and the rotor and outer race (Fig. 74). over the rotor

3. Install the outer race, and the inner rotor and shaft assembly. The inner rotor and shaft, and the outer race

are

One

part

without

serviced should

an

as not

replacing the

be

assembly. replaced

other.

Install

The

outer

race,

are replaceable

only

shaft

and

as an

the cover. Torque the cover retaining screws to specifications.

OIL PAN

CLEANING AND INSPECTION

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

from the

ket

pan

Wash the

surface.

vent and

dry

foreign

in

it thoroughly. Be

matter

is

gas

a

removed

sol sure

from

plate.

Feeler Gouge

Check the pan for cracks, holes, damaged drain plug threads, a loose

baffle, ket

and

surface.

a

nicked or warped

rotor

assembly,

Straight Edge

4. Position a new gasket and the inlet tube on the oil pump and install the retaining bolts.

all

DISASSEMBLY

the oil pump

sheet

the proper diameter

the cap out of the chamber. Remove the spring chamber

below the baffle OIL

outer race.

dry

engine

Connect the

hose. Fill

PUMP

CLEANING AND INSPECTION

oil

specifications.

specifications.

a

metal screw of

The

shaft hex may be misaligned the distributor shaft. To align,

drive with

new

will

Pump Assembly

Wash

assembly (Fig. 71). Do not to force the pump into posi

tion if it

Oil

screws, then remove the cover. Re move the inner rotor and shaft as

shaft as an attempt

OIL

FIG. 72

tube screen. Position

made.

A1272-A

Inlet Tube

and

replace

be

gas

FIG. 74-Rotor

End

Play

1-34 Check the drive

bearing OD

1-

GROUP

shaft

by

clearance

the shaft and

of

housing

to

measuring the the ID of the

bearing.

housing

ENGINE AND EXHAUST SYSTEM

Inspect the

spring for

relief valve

Check the sion.

in

relief valve spring ten If the spring tension is not with

the spring is

specifications and/ or

defective,

a collapsed or worn condition.

replace

Check the scores and

the

relief

free

spring.

valve

operation

piston for in the bore.

WORK STAND REPAIR OPERATIONS To

perform

the operations in this

4. If the

ends), remove

on a work

If the

stand.

stepped

sleeve

it with a 7675-N).

CRANKSHAFT

it

is

The

related

and

crankshaft

the upper

support

at the water pump.

to

allow

adjusting generator

bracket bolt

Remove the

easy

rotation

spark

the

of

crankshaft.

three-

on

in Fig. 46.

down,

jawed

remove

(tool

puller

2. Remove the fuel

pump.

Slide

the

water

pump

and

fan

by following

front

cylinder

damper,

Install the

cap ler on the damper (Fig. 45) move the damper.

pul

and

re

Check

slinger.

oil

steps

13 thru 18

7. Invert the

under

out

Carefully

bearing

main

lift the

caps.

crankshaft

the block so that the thrust

of

surfaces

Handle the the finished

are

damaged.

not

crankshaft with

fracture

or

care

to

damage to

surfaces.

INSTALLATION

on

engine

the

work

Remove the flywheel. Remove

stand. oil

pan

gasket.

and

Remove the

oil pump.

8. Make (main

sure

and

all

that

they

original

the

being

rod

from

removed

rod)

caps

are

be installed

can

locations. Remove

connecting rod Turn the crankshaft necting

bearing

connecting

bearing until

which

is down

the

caps. con

the cap is

and

1. Remove

the rear journal oil from the block and rear main bearing cap. Remove the rear main bearing cap to block side seals. seal

Removal."

"Cylinder Front Cover

marked so

crankshaft

screw and washer.

10.

bearing the

timing chain deflection, then re timing chain and sprockets

in their

3. Remove the

9. Remove the

avoid possible

as an

assembly.

the cap. Push the connecting rod and piston assembly up into the cylinder.

move the

the

the water pump by-pass hose clamp toward the rear of the engine. Re move

as shown

6. Remove the the

generator

bracket bolt from the

plugs

parts

in Fig. 75.

1. Remove the and

OD

cover.

are shown

arm

same

stepped

5. Remove REMOVAL

is not both

crankshaft sleeve

down (the

section, it will be necessary to remove the engine from the car and install it

remove

2. Remove the serts

bearing in bearing caps.

main

from the block

and

3. Remove the connecting rod inserts from the connecting

bearing

rods and caps.

4. If the crankshaft main bearing journals have been refinished to a definite undersize, install the correct undersize

bearings. Be

ing inserts clean.

and

Foreign

the bear bores are

sure

bearing

material under

the in-

CYLINDER BLOCK JOURNAL SEAL MAIN BEARING INSERTS

REAR

BEARING CAP JOURNAL SEAL

DAMPER

POWER STEERING

REAR BEARING CAP

PUMP PULLEY

SIDE SEALS

BOLT

jjgS

MAIN BEARING CAPS WASHER

FIG. 75

-Crankshaft

A1276-C and

Related Parts

PART 1-1

CHECK WIDTH OF Plastigage

PLACE Plastigage FULL

WIDTH OF JOURNAL ABOUT

0.002'

INCH

Va

1-35

-ENGINE

CLEARANCE

OFF CENTER

INSTALLING

MEASURING

PLASTIGAGE

PLASTIGAGE

A1023-A

FIG.

77 Installing & Measuring

Plastigage Engine

Removed A1280-A

to the journals

oil

stall

Tool-T58P-6701

A1277-A

-A

FIG. 76-Seal

To Block

thru 7

Installation

bearing

and

cause a

5. Place the

inserts in

upper

bearing

in the bores

position

tang fitting in

the

main

the

with

slot provided.

6. Install the lower main bearing inserts in the bearing caps. 7. Install a new rear journal oil seal in the block (Fig. 76). After in stallation, cut the

ends

of

the

8. the

bearing

Be

main

crankshaft

to damage

Place

as

of

thru

(Fig. 12

follows: on

77).

under

the

Pry half

the

of

forward

crankshaft

thrust

the

against

rear

Plastigage

on

Follow

"Main

steps

the

of

surface

bearing

the

(Fig. 78).

78).

(Fig.

forward

crankshaft

pry the thrust

bearing

This

surfaces of

will

cap to the align

both halves

of

the

the

14. Retain the forward pressure the crankshaft. Tighten the cap

bolts to

(Fig. 78).

specifications

10

Bearing Re

15. Force the the

rear

the

of

16. Install

a

crankshaft

toward

dial indicator

so that

placement."

the

10. After the bearings have been fitted, apply a light coat of engine

j

contact

crankshaft

axis

is

flange

parallel

If the

limit, the

rests and

to the

against

on

the

the indicator

crankshaft axis

forward

and note

end

play

exceeds

the

wear

the thrust bearing. If

play is less than the

limit,

the

the dial.

replace

end

inspect the thrust

mini

bearing

faces for scratches, burrs, nicks, or dirt. If the thrust faces are not de fective or dirty, they probably were Install

properly.

aligned

not

the

bearing and align the faces fol lowing the recommended procedure thrust

(steps the

11, 12, 13,

and

14),

then check

end play.

18. Install

new

bearing

inserts in

the connecting rods and caps. Check the clearance of each bearing by fol

lowing the Bearing

procedure

under

"Main

Replacement."

the

bearings have been

light

engine.

point

crankshaft

reading

19. After

of off

17. Zero the dial indicator. Push the

mum

11. Install the thrust bearing cap with the bolts finger-tight.

upper

Play

(Fig. 79).

specifications.

each

crankshaft journal the full width the journal and about Va inch

center

3

bearing.

clearance

a piece of

steps

locations. Torque the

cap bolts to

bearing

12.

End

Replacement."

original

thrust

surfaces.

bearing

their

FIG. 79-Crankshaft

main

"Crankshaft Lower Rear Install all the

under

13. Hold the

lower the

9. Check the

by following

cap

main

bearing caps, except the thrust bear ing cap (No. 3 bearing). Be sure that the main bearing caps are installed in

and

careful not

Carefully place.

in the rear install the rear

seals

flush. into

and

cap

Oil Seal

may distort the failure.

serts

bearing bearing

bearings. In

seal

new

a

and

and

connecting

fitted,

coat of engine oil

rod

apply

a

to the journals

bearings.

20. Turn the crankshaft throw to the bottom of its stroke. Push the piston all the way down until the rod

>***

HOLD CRANKSHAFT PRY FORWARD

PRY CRANKSHAFT FORWARD

FIG. 78

-Thrust

Bearing

Alignment

FORWARD

PRY

CAP BACKWARD

TIGHTEN CAP A1279-A

1-36

1-

GROUP

bearing

ToolT52L-6261-CEE

the crankshaft jour

seats on

ENGINE AND EXHAUST SYSTEM INSTALL FRONT BEARING 0.005-0.020 INCH BELOW FRONT FACE OF BLOCK

nal.

21. Install the connecting rod cap. Torque the nuts to specifications. 22. After the

ing

rod

piston and connect

stalled, check the side tween the connecting rod

connecting (Fig. 61).

oil

pump

rods

each

on

journal

oil

pan,

pump,

Install the

screen.

Tool-

T54T-6250-B

oil

pan.

and oil

pump

oil

be

clearance

crankshaft

23. Clean the and

in

have been

assemblies

24. Position the flywheel on the Install the retaining bolts. Torque the bolts to specifications. crankshaft.

25. Install the timing sprockets, cylinder front

chain

and

cover

and

damper, following

crankshaft

steps

Measurement

1

Align the

thru 8 under "Cylinder Front Cover A1260-B

26. Install the oil filter, fuel pump, and carburetor fuel inlet line. Install

FIG. 81 Camshaft Bearing

the generator. Install the spark

Replacement

engine

in the

plugs.

car.

Refinishing CLEANING AND

journal to

INSPECTION

to avoid

care

with

fractures

possible

or

dam

the finished surfaces. Clean

age

to

the

crankshaft

blow

crankshaft

oil

all

out

with

then

solvent,

passages

with

the

journal the

give

or

an

with

rod

connecting

ish severely

marred

Measure

journal in

the at

oilstone.

Refin

journals.

diameter

least four

each

of

places

to de

termine out-of-round, taper, or

dersize

condition

size

for the

exceed

should

next

un

(Fig. 80).

If the journals

limit, they

be

the

wear

refinished

undersize

bearing

undersize

Always

scratches, cracks, scores. Dress minor im

perfections

up"

to

the

with

avail

to

shoulder

shaft.

that

radius

Too

originally. result

jour

reproduce the same

small

a

bearing failure due

of

the bearing.

will

to radius ride

the

journal

holes,

oil

journals,

then

No.

FOR OUT-OF ROUND AT

EACH

END OF JOURNAL

rear

water resistant sealer and

install the

plug (Fig. 83).

5. Install stall

the

flywheel,

the engine

ENGINE

camshaft,

crank

and related parts.

in the

In

car.

DISASSEMBLY

1. Install the stand

(Fig.

polish

and spark

engine on

the work

17).

plug

the

distributor

cap

wire assembly.

3. Disconnect the distributor

vac

grit

cloth and engine polishing Crocus cloth may be used also

oil.

the carburetor fuel inlet line. Remove

as a

the fuel pump and discard the gasket.

polishing

with

a

agent.

uum

line

at

the distributor. Remove

4. Slide the clamp

on

the water

Too/-T58P-6266-A

CAMSHAFT BEARING

CHECK

camshaft

320

the

bearing.

A VS B = VERTICAL TAPER C VS D = HORIZONTAL TAPER A VS C AND B VS D = OUT-OF-ROUND

the

out

bore plug recess thoroughly. Coat the flange of a new plug with

2. Remove

After refinishing the chamfer

4. Clean

existed

radius

in fatigue failure of the crank Too large a radius will result

in

oil

bearing

shaft,

com

for

journals grooves,

and

"clean

not

clearance

able, replace the crankshaft.

nal main

will

proper

maximum

pressed air.

Inspect

Journals. Refinish the

give the proper clearance

the next undersize bearing. If

with

Handle the

holes in the bearings holes in the cylinder block when the bearings are installed. Be sure the camshaft front bearing is installed 0.005-0.020 inch below the front face of the cylinder block (Fig. 82). oil

the

with

Installation."

27. Install the

82 Camshaft Front Bearing

FIG.

REPLACEMENT Camshaft

bearings

are

available

prefinished

to size for standard and

0.015-inch

journal diam bearings are not inter from one bore to another.

eters.

undersize

The

changeable

1. Remove the camshaft, the fly and the crankshaft. Push the

wheel,

pistons

to the

top

of

the cylinders.

2. Remove the camshaft rear bear ing bore plug. Remove the camshaft A1015-A

FIG.

80 Crankshaft Journal

Measurements

bearings (Fig. 81).

3. Position the

bearing bores, place with

new

and

bearings

press

at

the

them

in

the tool shown in Fig. 81.

FIG. 83Camshaft Bore

Plug

Rear Installation

Bearing

PART 1-1 pump by-pass hose toward the water pump. Remove the automatic choke heat tube. Remove the valve rocker

1-37

-ENGINE

Magnetic Lifter

Remove

5. Crank the engine until the No. is at TDC at the end of the

piston

compression stroke. shaft

damper

tified

on

Starting

at

Rotate the

the right rocker

arm

the

support

ring A1255-A

at

same

the

and

oil

baffle

bolts. This be followed to avoid

FIG. 85-Hydraulic

Valve Lifter

damage to the

valve mechanism.

6. Remove the

valve push rods

in a rack so be installed in their

sequence and put them

that

they

original

can

bore.

8. Remove the retaining bolts.

intake

manifold

standard

right

rear

rocker

holes

and

attach

semblies

eye

cover

screw

the engine

lifting

arm

intact

until

the intake

manifold gaskets and

14. Remove

bolts,

they

are

valve push rod chamber

prying up on the baffle driver (Fig. 84).

from floor by

plate

and

the

gasket.

then install the cylinder

holding

filter. Remove

sending unit bly. Discard the gasket.

Turn the

rod

necting

and

as an assem

17. Remove the generator, brack and drive belts.

ets,

connecting rods that they can

original

being

locations. the

until

crankshaft

Remove the

fixtures (Fig. 26).

oil

sure all

be installed in their head

rod cap.

29. Push the connecting piston

Avoid

crankpin

or

the

removing the

rod

top

the handle

with

hammer.

the

out

assembly

cylinder

con

is down.

removed

end

damage

and

the

of

of

to

a

the

cylinder wall when

piston and rod.

30. Remove the bearing inserts from the connecting rods and caps. Install the rod caps on the connect

ing

from

rods

which

they

the

main

were

re

moved.

18. Remove the water pump, and fan as an assembly.

pul

31. Remove

19. Remove

the

Remove the (Fig. 45).

pulley. er

it with (tool 7675-N).

move

power

steering

crankshaft

a

damp

Carefully

puller

bearing

aged.

Handle to

care

cylinder

gasket.

front

Remove

crankshaft

surfaces are not

avoid

the

possible

damage to the finished 33. Remove the from the block

seal

and

remove

dam

crankshaft

or

surfaces.

rear

journal

and rear

the

with

fracture

oil

bearing

cap to block

side seals.

34. Remove the main bearing in from block and bearing caps.

serts

oil slinger.

deflec tion by following steps 13, 14, and 15 under "Cylinder Front Cover and Timing Chain

Install the

main

chain

Removal."

23. Remove the camshaft thrust button and spring, the sprocket cap screw, and thrust button spring re tainer, and the fuel pump eccentric. crankshaft sprocket

lift the

the cylinder block so that the

thrust

cap,

22. Check the timing

Remove the

32. out of

three-jawed

21. Remove the Discard the the crankshaft front cover.

bearing

caps.

20. If the crankshaft sleeve is not stepped down (the same OD on both ends), remove it as shown in Fig. 46. If the crankshaft sleeve is stepped down (different OD on each end), re

Plate Removal

27. Remove the oil pump and in let tube as an assembly. Remove the oil pump drive shaft. Discard the oil

and caps are marked so

cylinder

oil pressure

valve

FIG. 84-Baffle

26. Invert the engine. Remove the Discard the gasket.

mani

ley,

A1254-A

the

oil pan.

pump

the oil filter adapter assembly

with a screw

lifters from the cylinder block and place them in a rack so that they can be installed in

After

25. Remove the flywheel.

to be

15. Lift the cylinder heads off the block. Do not pry between the head and the block. Discard the cylinder head gaskets.

seals.

11. Remove the baffle

the

has been removed, remove the cutter from the cylinder bore.

28. Make

16. Remove the

10. Raise the manifold and care fully remove it from the engine. Dis

12. Lift the

valve

13. Remove the exhaust folds and the spark plugs.

sling (Fig. 16).

the

hydraulic

of each

lifter assembly are matched sets. Do not intermix the parts. Keep the as

head

bolts with %6-18 threads in the left front and

card

parts

cleaned.

7. Remove the distributor hold down bolt and clamp and remove the distributor.

9. Install

bore (Fig. 85). The in

their original

ternal

in

tool

1/32 inch

excess of

ridges.

removing

the

into

Removal

rocker arm shaft support procedure must

in

cut

ridge

Start

plate.

the No. 5 cylinder, follow the procedure on the left valve

when

area

collect

cylinder

Follow the

by

Never

manufacturer.

travel

and place

the

furnished

instructions

move the valve rocker arm shaft as

ing

Remove

cuttings.

ridge with a ridge cutter.

bolts in sequence, two turns at a time. After the bolts are all loosened, re sembly

its travel

of

the piston head to

a cloth on

45

shaft

assembly (Fig. 49).

to the bottom

crank

(iden the damper by "XX"). the No. 4 cylinder, loosen an additional

timing

and

sprockets

24. Remove any ridge and/ or car bon deposits from the upper end of the cylinder bores. Move the piston

arm covers.

1

the

chain as an

key.

bearing

caps

in their

original positions.

35. shaft

the

Carefully remove the cam by pulling it toward the front of

engine.

damaging

the

Use caution to avoid journals and lobes.

36. Remove shaft

the

camshaft

bore plug. Remove the bearings (Fig. 81).

bearing

rear cam

1-38

CYLINDER BLOCK

Thoroughly from

old gasket material

Remove

all machined surfaces.

pipe

which

plugs

in

block

the

clean

Remove

solvent.

sages,

then

sages.

Blow

out

holes,

etc.

with

clean

seal

oil

pas

all

the

pas

out

passages,

bolt

compressed

air.

all

Make sure 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 remove any deposits. After the

been thor check for

block has

Minute

a

make

oughly cleaned, cracks.

cracks

not visible

to

the naked eye may be detected by coating the suspected area with a

25% kerosene light motor oil. Wipe the

immediately

zinc oxide

If

a

apply

dissolved in

75%

and

mixture of

and

dry

part

coating

of

wood alcohol.

present, the coating will discolored at the defective

cracks are

become area. Replace

the

ENGINE AND EXHAUST SYSTEM

following

CLEANING AND INSPECTION

all

1-

GROUP

it

if

block

is

burrs,

nicks, scratches, Remove minor imper

scores.

and

fections flatness

the

cylinder

following

surface

cylinder

block

middle, and placed

at

right

angles

86).

scored

and/or

show

cylinder

out-

surface

of-round and taper are within

out

evidence

operation.

REFINISHING

CYLINDER

the walls have

The

by

the amount

tions

of

or

Check the of

round

bore

the

with

other

honing

operation, leave

used

to

ma

enough

which

is

piston

clearance.

to obtain the

used

proper

:

for

scor

signs

of

limits

Before any

OF ENGINE

'

"W

A AT RIGHT

"'W

Jms

Pi

B

\l

ANGLE

TO

CENTER LINE OF ENGINE

tightened to the

not

B PARALLEL

TO

\^^

=

A AND B DIFFERENCE BETWEEN THE A MEASUREMENT AT TOP OF CYLINDER BORE AND THE A MEASUREMENT AT BOTTOM OF CYLINDER BORE A1025-A

and

Taper

bearing

bores

become distorted from the

oversize; therefore, tons can be intermixed

without upset

passages,

cylinder

Coat the

etc.

If the

cylinder will not clean

when refinished

for the

maximum

oversize piston recommended, replace

block.

oversize

clear

so

of

and pattern are of

operation.

ap

the re will

for the final step

that the

sharp hones

for this

within

diameter. This

allow enough stock

finish Out-of-

been thor re

bearing

the

head bolt walls

cylinder

oil.

ASSEMBLY

ENGINE

from the cyl following the instruc

1. Remove the inder bores

by

glaze

tions of the tool manufacturer.

2. Invert the

engine

the work

on

stand.

3. Position the

bearing bores,

bearings

new

and

the tool

shown

at

the

in in Fig. 81. them

press

oil holes in the cylinder block when the bearings are installed. Be sure the camshaft front bearing is installed 0.005-0.020 inch below the front face of the cylinder block (Fig. 82).

Align the

4. Check the the

rocker

oil passage

arm

that feeds

for

shafts

obstruc

into the open by squirting ing on each cylinder bank and ob serving the flow through the oil holes at Nos. 2 and 4 bearings. tions

oil

out

bearing bore

the

plug

camshaft

recess

6. Coat the flange with stall

water

it

with

of

a new

resistant

sealer

the flange

facing until

the

Lubriplate to slide

camshaft all

lobes,

plug

in (Fig.

and out

it is flush

slightly below the casting

7. Oil

rear

thoroughly.

surface.

and

apply

then carefully

it through the bearings.

8. Be

sure

that the rear oil seal

Install a new rear in the block (Fig. 76).

grooves are clean.

Refinish the cylinder to proximately 0.0015 inch

honing

of all

block to

oil

83). Drive the plug in

Refinish the cylinder with the most wear first to determine the maximum

of

are

fitted,

bores, holes,

and

ting engine balance.

quired

be

from

5. Clean

various sized pis

up

to

to

they

operation.

the same weight, both standard

oversize.

correspond

which

particles

i

DIFFERENCE BETWEEN

86 Cylinder Bore

torque

proper

thoroughly piston fit.

all

refinished.

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

the mmOOO,

the

to

remove all

move

or

CENTER LINE OF ENGINE

=

caps

so that the crankshaft will

be

is refinished, all must be in place

and

gauge

severely

beyond

cylinder

bearing

main

should

Measure

accurate

are

worn

bore for

1

A . 1. OUT-OF-ROUND

that

walls

and/or

in

clean the entire

oughly

place with

hone

finishing

the

with

to

the walls. Check the pistons

de the

the cyl

wash

then

particles,

al

either

checking

completed and all pistons

If the

start

terial so that all hone marks can be

taper.

an

i

Round

are

cylinder

and

tk

FIG.

manufacturer.

stones

refinishing LIN

-CENTER

2. TAPER

hone

the

coarse

to

walls with solvent

cylinders

in

methods

installed. When the refinishing cylinders that require it has

metal

of

Follow the instruc

Only

be

work.

operation

prior

and

Mark the

imperfections,

minor

light scuffs, scratches, etc. grade of hone to be used is as

such

this

perform

abrasive

dry the

should

personnel

fit, thoroughly

piston

inder

in

two refinishing

scribed

with

WALLS

Honing is recommended for re finishing cylinder walls only when

marred

leakage.

cylinder walls

roughness,

-

limits,

it may be possible to remove the imperfections by honing the cylin der walls and installing new serv ice piston rings providing the piston clearance is within limits. Use the finest grade of honing stone for this

Cylinder of

the

re

of

the manufacturer.

After the final

walls

plugs

expansion-type

all

Inspect the wear.

the wear limits.

have minor imperfections, but the

specified

ing,

deeply

out-of-round

when

and/or taper exceed

If the

that are

cylinders

head.

Replace

lowed to

of

Refinish

equipment,

experienced

to the centerline of the engine (Fig.

removed

for the

parallel

and

the

follow the

use

proper

eter of each

gasket

the procedure and

recommended

specifications

that

Check the

with an oil stone. of

sur

gasket

machined

all

the

structions of

to be removed.

Check faces for

For

finishing

determined

cracked.

instructions of the Measure the diam cylinder bore at the top, bottom with the gauge

the

manufacturer.

correct surface

obtained.

No. 220-280

Use grit

journal

oil seal

After installation, seals flush.

cut

the ends of the

9. If the crankshaft main bearing journals have been refinished to a definite undersize, install the correct

bearings. Be sure the bear inserts and bearing bores are

undersize

ing

PART 1-1

21. Clean the

Foreign material under the in may distort the bearing and a failure.

clean. serts

cause

oil

block

lower

the

crank

into place. Be careful damage the bearing surfaces. shaft

12. Check the

each

of

clearance

to

not

cover

sur

gasket

front

with

the

and

Position

sealer.

a

progressive

bolts

in

the pilot aligns with the

Position the

crankshaft.

the

cover and pilot over and

a light coat of engine journals and bearings.

oil

apply

cov

bolts finger-tight. Position the erator support bracket and the

gen

cylinder

er

install the bolts (on 14. Be

the

that

sure

seal

oil

in the rear main bearing cap are clean. Install a new journal seal in the cap (Fig. 57). After installa tion, cut the ends of the seal flush. grooves

Apply

a

thin coating

to the

sealer

rear of

the not

the

forward

area

Install the the

are

top mating

rear main

bearing

bearing

the caps,

installed in their

tions. Torque the

conditioner,

compressor

and

surface

except

the

caps

loca

original

bearing

a

following

lubricate the

11

cap

play by 17 under

thru

the

with

the

on

engine

is

end

is

sleeve

OD

sleeve

into the bore if the down (different

OD

stepped

end

on each end).

key

the

and

keyway

torque

and

washer,

the

to specifications.

28. Install pump

the

exhaust

film

of graphite grease.

36. the

the

head

Using

cover on

Be

new

a

the

the

sure

inlet

haust

a

of

light

install

gasket,

chamber

air

choke

right exhaust manifold.

cover

37. Position muffler

surfaces

with

manifold

automatic

is securely fastened.

a new gasket over

pipe

the

of

studs

the ex

manifolds.

38. Position the the

cylinder

retaining

exhaust manifolds

heads

bolts

and

and

install the

tab

washers.

Torque the retaining bolts to specifi cations, working from the center to ends.

Lock the bolts

by bending

one

tab of the washer over a

the

bolt.

39. Install the

place

on

plate

in the

Press it into

(Fig. 87).

41. Coat the lifter

flat

spark plugs.

40. Position the baffle

outside of each valve

with engine oil

to provide

ini

tial lubrication. Do not fill the lifters with

faster

power

on

pulley

cylinder

valve push rod chamber.

install the damper on the crankshaft (Fig. 52). Install the damper cap screw

to

finally

35. Coat the mating

the crankshaft, then

on

27) and

the

cover

27. Line up the damper

work

up.

surface

crankshaft

smallest

front

cylinder

screw

that the front

rubbing

70

(Fig.

ft-lbs,

turbed.

the

26. Install the

Installation."

16. Turn the stand so

bearing

oil seal

and

mixture

with grease.

cap bolts to

end

crankshaft steps

cyl

crankshaft with

oil

and

sequence

in

Torque the

bolts have been torqued to specifica tions, the bolts should not be dis

the

cover).

lead

white

with

"Crankshaft

brackets to the

25. Lubricate the

performed

steps.

to 90 ft-lbs. After the

on

and

cap

bearing

15. Install the thrust check

connect

While pushing in on the pilot, torque the cover bolts to specifications. Remove the pilot.

inder front

specifications.

and

equipped

car

with an air

cap

cap (No. 3 bearing).

that the main

sure

bearing

apply sealer to the the side seal groove.

remainder of

thrust

Be

of

a

then

of oil resistant

rear main

(Fig. 57). Do

at

gen

bracket,

arm

adjusting

is

then to 80

ft-lbs,

block

the

front

erator

with

then install

the

end of

against

24. Install the

to the

and

head bolt tight

cylinder

procedure

three

ment."

fitted,

34. The ening

(Fig. 51).

13. After the bearings have been

sealer,

new

23. Install the alignment pilot tool on the cylinder front cover so that the

keyway in key in the

water resistant

bolt

cover

the block.

gasket on

holding fix

the

remove

tures. Coat the head bolt threads

gasket surface of the

cover

and

threads

engine, then

the bolts.

(Fig. 53).

crankshaft

bearing by following the proce dure under "Main Bearing Replace

main

block

a new crankshaft

22. Coat the

10. Install the lower main bearing inserts in the bearing caps.

Carefully

seal

front

cylinder

cylinder

faces. Install

Place the upper main bearing in serts in position in the bore with the tang fitting in the slot provided.

11.

the

and

1-39

-ENGINE

oil.

The lifters

after

the

will

engine

fill

much

is started, if

steering

crankshaft

damper. 17. Install the under

Rod

ing

by following

rods

necting thru 9

"Piston

and

steps

29. Clean the

1

Connect

Installation."

surfaces

and

new gaskets on

pump gasket Position

water

sealer.

apply

the pump

the water pump, pulley,

18. Position the

ing

chain on

shaft

the

(Fig. 49).

marks on as

con

and

pistons

the

sprockets and

tim

Be

sure

the

timing

sprockets are positioned

19. Lubricate

the

timing

20. Install the fuel pump

50),

the

thrust

camshaft

thrust

button

button (Fig.

crankshaft

front

oil

30.

fuel

Using

stand

is eccen

sprocket

50).

spring

slinger.

so

gasket, install the the generator,

Install

and

drive belts. engine on the work

that the

top

the

of

engine

up.

32. Clean the

cylinder

block gasket surfaces. to both sides of a

Guided the

and

Install the

a new

pump.

31. Turn the

chain

button spring cap screw, and thrust Torque the sprocket cap retainer. screw to specifications. Install the camshaft

as

an assembly.

brackets,

and sprockets with engine oil.

tric (Fig.

install fan

camshaft and crank

in Fig. 48.

shown

and and

over

by

gasket,

the

head

Apply new

and

sealer

gasket.

"FRONT"

on

word

install

the

head

gasket

the cylinder head dowels.

33. Place the

cylinder

head

on

t

the

(

A1293-A

-X*--

FIG. 87 Baffle

Plate Installation

1-40

free

they

are

may

cause

of

an

film

oil

any

oil

which

between the

seal

and the lifter body. Place lifter in the bore from which

plunger each

it

1-

GROUP

51. Install

block.

block

cylinder

manifold and

seal surfaces with oil

resistant sealer.

the

new seals on

cyl

inder block and new gaskets on the heads. Position the gasket slots in the end tabs over the ribs

cylinder

the

on

the

Be

seals.

gaskets

holes in the

heads. The

cylinder

installation

rect

the No.

45. Install the

lifting

sling

intake

manifold

engine

by inserting

the distributor in place.

After the intake finger

run a

is in place,

manifold

around

the

in place,

seals are not

If

place.

the

remove

the

position

and

manifold

to

seal area

the seals are in

make sure

intake

manifold

seals.

the holes in the

sure

and

gaskets

manifold

Install the

alignment.

taining bolts to the

mani

in

are

re

manifold

and torque

them to

cifications, working from

the

In

open.

distributor

vac

line. Install the distributor

Install the

valve rocker

54. Connect the

Install the

plug wires. fuel inlet line.

engine on

Position the

into

shaft

the

work

pump drive distributor socket.

the

oil

firmly

shaft

stop

Remove

the

the

on

the

shaft

and

the stop as necessary.

position

A1291-B

56. With the stop properly posi tioned, insert the oil pump drive

into the

distribute the body.

oil

by filling

pump

the

within

pump

new

a

housing

gasket on

the

install the pump Do not at

and

tempt to force the pump into posi tion if it will not seat readily. The

engine

distributor

the

lifting

sling

valve

rocker

and eye

arm

and

bolts.

Refer to mileage

Group

12 for the

interval for

BREATHER

as

shaft

CRANKCASE

correct

maintenance.

terval.

new

gasket on

the

bly ing

on

the block. Install the

the

center outward

screws

61. The shown

oil filter assembly is in Fig. 88. Clean the oil filter

adapter

bly

gasket surfaces.

Apply and

gasket,

sealer

to

install the

a new adapter

adapter assem

and gasket.

63. Clean

the adapter filter re Coat the gasket on a new filter with oil. Place the filter in position on the adapter. Hand tighten the fil cess.

ter

until

the

face,

adapter

gasket and

the

contacts

then

it

advance

-turn.

from

specifications.

64. Install the engine in the car. Operate the engine and check for oil and coolant leaks. Check the ignition timing, adjust the engine idle speed, idle fuel mixture, and anti-stall dash-

the

pot.

install the retaining bolts. Torque the bolts to

trol

crankshaft

on

and

specifica-

65. Adjust the transmission

lator valve,

exhaust

outlet

and

valve

exhaust

adapter

solvent

and

pressed

air.

connection

in

dry

tube,

base

clean

them

a

and

quires

cleaning

mileage

with

rubber

low

com

hose

if there is

excessive

necessary.

evidence of crankcase pres

dry

screen

sludge

move the crankcase ventilation regu

The

road

draft tube

seldom

remove re

In

and

deposits.

be

cleaned

addition,

in the intake

air.

VENT TUBE-TYPE CRANKCASE VENTILATION SYSTEM

during a high However,

overhaul.

sure, the tube should be checked

volatility them

except

engine

carburetor

solvent and

compressed

con

Clean

tube, fittings,

Clean the with

and

adapter.

plate should

re

con

linkage.

SYSTEM MAINTENANCE

nections,

with

SYSTEM

interval,

to

retain

them

torque

and

60. Position the flywheel

petroleum

CRANKCASE

recommended

a

and place the oil pan assem

the

The breather cap located on the oil filter tube should be cleaned with a solvent at the proper mileage in

At the

Assembly

tions.

Vi

oil pan

VENTILATION

CAP

VENTILATION

To align, into a

shaft

position.

outlet

POSITIVE

misaligned

shaft.

the intermediate

59. Position

Installation"

the

rotate new

hex may be

shaft

the distributor

with

88 Oil Filter

62.

58. Position

pump

oil

inlet or outlet port with Rotate the pump shaft to

the

engine oil.

FIG.

oil pump.

57. Prime the either

FILTER ELEMENT

in the

seated

the

touch the roof of

should

crankcase.

cap.

covers.

spark

carburetor

55. Invert the stand.

arm

spe

50. Refer to "Valve Rocker Arm and in Shaft Assembly stall

the points

center

ends.

49. Remove the

the No. 1 fir

rotor at

53. Connect the

drive 48. Be

fold

TDC

on

and shaft as an assembly.

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

ADAPTER

damper

the hold down clamp.

stall

shaft

46. Position the intake

the

with

position and

distributor socket,

carefully lower the on the engine (Fig.

and

is

piston

With the

21).

the

block

shaft

the

attach

1

and

bolts in the in

eye

and

crankshaft

cor

gaskets

in Fig. 23.

seals are shown

take manifold

the

of

the

with

aligned

are

holes in

the

sure

OIL PRESSURE SENDING UNIT

choke

then position the distributor in the

uum

44. Position

1 thru 6.

steps

automatic

52. Rotate the

ing

43. Coat the intake

the

heat tube.

until

and cylinder

by following

sembly

was removed.

42. Clean the mating surfaces of the intake manifold, cylinder heads,

ENGINE AND EXHAUST SYSTEM

the

manifold

cleaned

in

any accumulation

for

out

if

maze

baffle

solvent to of

sludge

1-41

Section

Page

1

Description

2

Inlet Pipe, Muffler, and Outlet Pipe Replacement.

1-41

.

1-42

EXHAUST SYSTEM

489-B

FIG.

1 Exhaust System

DESCRIPTION A dual used

on

exhaust system

all

(Fig. 1) is

Thunderbirds. The

sys

tem consists of a separate muffler,

muffler

inlet

pipe

muffler outlet pipe manifold.

The

rear

for

section,

and

each exhaust

right and

left

muffler

inlet piece such.

pipe

front

assembly

sections are a and

are

one-

serviced

as

1-42

1-

GROUP

ENGINE AND EXHAUST SYSTEM

INLET PIPE, MUFFLER, AND OUTLET PIPE REPLACEMENT MUFFLER The front

INLET

right and

sections

PIPE

left are

muffler

inlet

serviced

pipe

as

one

the front and rear sections. Place new gasket on

piece.

1. Loosen the muffler inlet pipe front bracket clamp bolt and slide the clamp from the bracket. Disconnect the inlet pipes at the exhaust mani

the exhaust

6. Position the inlet

bly

the

on

exhaust

it

off

spread

the

pipe

the clamp

muffler.

2. Remove the lower half assem

pipe

the

7. Connect the inlet

clamp,

and slide

inlet

muffler

then

manifolds.

manifold

and on the extension of

a

1. Loosen the rear

studs

muffler rear clamp.

of

Remove the

fler from the inlet

pipe.

3. Position the

new

the

muf

mufflers.

pipe

to the

muffler

and

assembly on the inlet pipe. Slide the muffler forward into the outlet pipe

folds.

exhaust

2. Remove

the

retaining clamp from the rear section of the inlet pipe. Disconnect the rear bracket from the rear section of the

inlet

3. Remove the

inlet

5. Position the clamp on the rear the new inlet pipe. Connect

section of

section.

manifolds

torque

the

inlet 8. Align the inlet and connect

rear section of

pipe

assembly

the brackets.

inlet

pipe

front

pipe until

extension must not

The

AND

procedure

right or

left

OUTLET applies

assembly.

to

PIPE either

assembly. a

the slots

in the

muffler

blocked. The overlap be greater than IVa inches. are

4. Align the

the

MUFFLER the

and

to specifications.

pipe.

pipe.

4. Remove

nuts

muffler and outlet pipe

Position the

muffler

inlet

clamp and install the retaining bolts. Install the muffler rear clamp. pipe

1-43

SPECIFICATIONS

NOTE: All Specifications

are given

GENERAL

in inches

unless otherwise noted.

CYLINDER

ENGINE MODELS AND PISTON

DISPLACEMENT Cubic

Inches

Thunderbird Special V-8

390

GASKET SURFACE FLATNESS

0.003 inch in any 6 inches

9.6:1

390

@

0.006 inch

overall

Intake

and

Exhaust 0.3728-0.3735

390

Specified RPM VALVE SEAT WIDTH

390

300 @ 4600

@

TORQUEFOOT-POUNDS

Intake

and

Exhaust

390

Specified RPM

390

@ 2800

.427

.0.070-0.090

VALVE SEAT ANGLE

Intake BORE AND

or

VALVE GUIDE BORE STANDARD DIAMETER

COMPRESSION RATIO

BRAKE HORSEPOWER

HEAD

STROKE Inches

and

Exhaust

390

390

.4.05

x

3.78 VALVE SEAT RUNOUT

COMPRESSION

PRESSURE Sea

Level

@

CRANKING SPEED

180

390

Wear Limit 0.0025

390 20 COMBUSTION CHAMBER

TAXABLE HORSEPOWER

390

,73.1-76.1

52.49

390

VALVE

FIRING ORDER

MECHANISM

1-5-4-2-6-3-7-8

390

VALVE VALVE

VOLUME CC

ARRANGEMENT

0.078-0.218

390

Front to Rear

E-I-E-I-I-E-I-E

390

?Hydraulic at

ENGINE IDLE

CLEARANCE*

valve

the valve

lifters

stem

tip

Clearance

with

specified

is

obtained

the lifter collapsed.

RPM*

Cruise-O-Matic (Drive

VALVE STEM DIAMETER

Range)

390 *If equipped with air conditioner, it should be at least 20 minutes before setting idle speed.

475-500

Standard

for

Intake

run

390

0.3711-0.3718

Exhaust ENGINE IDLE MANIFOLD

@

VACUUM Minimum

Specified Engine Neutral Idle

rpm

Inches

of

Mercury

SEA LEVEL

18

390

390

0.3693-0.3700

0.003 Oversize Intake

INITIAL IGNITION

TIMING

390

B.T.D.C.

390 Cruise-O-Matic

390 CRANKCASE OIL

CAPACITY*

5

390 ?Add

one quart extra when

changing

oil

quarts

OIL

390

Psi hot

@

2000

0.3723-0.3730

0.015 Oversize Intake

filter.

390 PRESSURE

0.3741-0.3748

Exhaust

0.3861-0 3868

Exhaust

rpm

,35-55

390

0 18