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 ...
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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:
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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
