Ford Thundenbind 1961, 1961 Thunderbind Shop Manual

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

1961 Ford Thunderbird Shop Manual

EAN: 978-1-60371-011-4

ISBN: 1-60371-011-6

Forel Publishing Company, LLC

3999 Peregrine Ridge Ct.

Woodbridge, VA 22192

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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.

NNoottee ffrroomm tthhee EEddiittoorr

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Disclaimer

INDEX

GROUP

SERVICE

DEPARTMENT

FORD

DIVISION

FORD

MOTOR

COMPANY

FIRST

PRINTING

1900

FORD

MOTOR

COMPANY,

DEARBORN.

MICHIGAN

Reprinted

with

Ford

Motor Company's

Permission

FOREWORD

This

manual

provides

information

for

the

proper

servicing

of

the

1961

Thunderbird.

The

descriptions

and

specifications

contained

in

this

manual

were

in

effect

at

the

time

the

manual

was

approved

for

printing.

The

Ford

Division

of

Ford

Motor

Company

reserves

the

right

to

discontinue

models

at

any

time,

or

change

specifications

or

design,

without notice

and

without

incurring

obligation.

SERVICE

DEPARTMENT

FORD

DIVISION

FORD

MOTOR

COMPANY

THUNDERBIRD

IDENTIFICATION

>EMBLY

PLANT

MODEL

ENGINE

CONSECUTIVE

UNIT

NUMBER

AXLE

RATIO

1Y71Z

100001

TP

MADE

IN

U.S.A.

BY

&&F<1'

*EG.

U.S.

'AT.

OFF.

BODY

COLOR

TRIM

DATE

TRANS.

A.

THIS

U/EHICLE

IS

CONSTRUCTED

UNDER

UNITED

STAT

CS

LETTER

PATENTS

2590719

2617681

2631694

2677572

26775ir4

2683578

'.698012

2726894

2782722

2784363

27896

1

2810447

OTHER

PATENTS

PENDING

MODEL

YEAR

FIG.

1

Thunderbird

Rating

Plate

TRANSMISSION

NIOOl-B

Figure

1

illustrates

a

Thunderbird

rating

plate

and

its

elements.

The

rating

plate

is

attached

to

the

left

door

front

pillar.

MODEL

YEAR

The

number

"1"

designates

1961.

ASSEMBLY

PLANT

The

letter

"Y"

designates

the

Lincoln

plant

at

Wixom,

Mich.

MODEL

71

Tudor

Hardtop

73

Convertible

ENGINE

1

390

cubic

inch

V-8

CONSECUTIVE

UNIT

NUMBER

The

assembly

plant,

with

each

model

year,

begins

with

consecutive

unit

number

100001

and

continues

on

for

each

unit

built.

BODY

53A

Tudor

Hardtop

70A

Convertible

COLOR

SOLID

COLOR

A

Black

C

Light

Aqua

D

Light

Blue

E

Green

Metallic

F

Gold

H

Dark

Blue

Metallic

J

Red

M

White

P

Q

R

Dark

Gray

Metallic

Light

Gray

Metallic

Medium

Blue

Metallic

S

T

V

Light

Green

Beige

Rose

W

Turquoise

Metallic

X

Y

z

Burgundy

Metallic

Mahogany

Metallic

Tan

Metallic

TWO-TONE

COLOR

Lower

Color

AM

Black

MA

White

JM

Red

MJ

White

PM

Dark

Gray

Metallic

QA

Light

Gray

Metallic

QM

Light

Gray

Metallic

HM

Dark

Blue

Metallic

RM

Medium

Blue

Metallic

MR

White

DM

Light

Blue

EM

Green

Metallic

ME

White

SM

Light

Green

Upper

Color

White

Black

White

Red

White

Black

White

White

White

Medium

Blue

Metallic

White

White

Green

Metallic

White

TWO-TONE

COLOR-Continued

Lower

Color

Upper

Color

WM

Turquoise

Metallic

White

MW

White

Turquoise

Metallic

CM

Light

Aqua

White

TZ

Beige

Tan

ZM

Tan

White

MZ

White

Tan

YM

Mahogany

Metallic

White

FM

Gold

White

VA

Rose

Black

VM

Rose

White

XM

Burgundy

Metallic

White

DATE

The

date

code

shows

the

day

and

month

when

the

Thunderbird

was

com

pleted.

The

months

are

designated

as

follows:

A

January

G

July

B

February

H

August

C

March

J

September

D

April

K

October

E

May

L

November

F

June

M

December

TRANSMISSION

4

AXLE

6

3..

H.

Cruise-O-Matic

3.00

to

1

3.10

to

1

2.91

to

1

GROUP

I

ENGINE

AND

EXHAUST

SYSTEM

PAGE

PART

1-1

ENGINE

1.

P

A

RT

1-2

EXHAUST

SYSTEM

1-45

PART

1-3

SPECIFICATIONS

1-47

12

Section

Page

1

Description

1-2

2

Engine

Trouble

Diagnosis.

.

1-6

3

Tune-Up

1-12

Engine

Compression

Test

.

1-13

Camshaft

Lobe

Lift

1-16

Valve

Clearance

1-16

Manifold

Vacuum

Test.

.

1-17

4

Engine

Removal

and

Installation

1-17

5

In-Chassis

Repair

Operations

1-19

Engine

Supports

1-19

Section

Page

Valve

Rocker

Aim

Shaft

Assembly

1-19

Intake

Manifold

1-21

Exhaust

Manifold

1-22

Regulator

Valve

Positive

Crankcase

Ventilation

System

1-23

Cylinder

Heads

and

Valves

1-23

Valve

Stem

Seal

Replacement

1-26

Cylinder

Front

Cover

and

Timing

Chain

1-27

Section

Page

Camshaft

1-29

Camshaft

Rear

Bearing

Bore

Plug

Replacement.

.

1-30

Hydraulic

Valve

Lifter

Replacement

1-30

Crankshaft

Lower

Rear

Oil

Seal

Replacement

1-31

Main

and

Connecting

Rod

Bearing

Replacement

1-32

Piston

and

Connecting

Rod

Assembly

1-32

Flywheel

1-36

Oil

Pan

and

Oil

Pump

..

.

1-36

Oil

Filter

Replacement.

.

.

1-36

6

Work

Stand

Repair

Operations

1-38

Crankshaft

1-38

Camshaft

Bearing

Replacement

1-40

Engine

Disassembly

1-40

Cylinder

Block

Cleaning

and

Inspection

1-42

Engine

Assembly

1-42

7

Crankcase

Ventilation

System

Maintenance

1-44

DESCRIPTION

A1240-B

FIG.

1

Thunderbird

390

Special

V-8

Engine

The

Thunderbird

390

Special

V-8

engine

(Figs.

1

and

2)

has

a

4.05-inch

bore

and

a

3.78-inch

stroke

and

a

total

piston

displacement

of

390

cubic

inches.

It

has

a

compression

ratio

of

9.6:1.

The

patent

plate

symbol

for

the

engine

is

"Z."

MANIFOLDS

The

intake

manifold

has

a

passage

through

the

center

section

and

under

the

carburetor,

through

which

hot

exhaust

gases

are

directed

to

assist

in

vaporizing

the

incoming

fuel

charge

(Fig.

3).

The

exhaust

gases

are

directed

into

the

intake

manifold

by

a

thermostatically

con

trolled

exhaust

valve

(Fig.

4).

The

A1241-B

FIG.

2

-Sectional

View

390

Special

V-8

Engine

PART

1-1

-ENGINE

1-3

AIR

INLET

A1242-A

FIG.

3

Intake

Manifold

Exhaust

Gas

Passages

valve

is

located

at

the

outlet

of

the

right

exhaust

manifold.

When

the

valve

is

in

the

closed

or

heat

on

posi

tion,

part

of

the

exhaust

gases

are

di

rected

from

the

right

exhaust

mani

fold,

through

the

heat

riser

passage,

to

the

left

exhaust

manifold.

When

the

valve

is

open

or

in

the

heat

off

position,

more

of

the

exhaust

gases

from

the

right

manifold

are

permitted

OPEN

(HEAT

OFF)

CLOSED

(HEAT

ON)

A1073-A

FIG.

4

Exhaust

Gas

Control

Valve

4

1243-A

FIG.

5-lntake

Manifold

Fuel

Passages

AIR HEAT

CHAMBER

A

1206-

A

FIG.

6

Automatic

Choke

Heat

Chamber

to

flow

directly

out

of

the

exhaust

system

in

the

normal

manner.

The

intake

manifold

has

two

sets

of

fuel

passages,

each

with

its

own

separate

inlet

connection

to

the

car

buretor

(Fig.

5).

The

right

barrels

of

the

carburetor

feed Nos.

1,

4,

6,

and

7

cylinders

and

the

left

barrels

feed

Nos.

2,

3,

5,

and

8

cylinders.

The

distributor

is

mounted

at

the

left front

of

the

intake

manifold.

Warm

air

for

the

automatic

choke

is

drawn

from

the

heat

chamber

of

the

right

exhaust

manifold

(Fig.

6).

CYLINDER

HEADS

The

cylinder

head

assemblies

con

tain

the

valves

and

the

valve

rocker

arm

shaft

assembly.

The

combus

tion

chambers are

machined

in

the

head.

Valve

guides

are

an

integral

VALVE

OPEN

LIFTER

BODY

A1244-A

FIG.

7

-Valve

Port

Arrangement

part

of

the

head.

The

valves

are

ar

ranged

from

front

to

rear

on

both

banks

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

(Fig.

7).

CYLINDER

BLOCK

The

cylinders

are

numbered

from

front

to

rear,

on

the

right

bank

1,

2,

3

and

4

and

on

the

left

bank

5,

6,

7

and

8.

The

firing

order

is

1-5-4-2-6-3-

7-8.

The

oil

pump,

mounted

inside

the

oil

pan

at

the

front,

is

driven

by

the

distributor

through

an

intermediate

drive

shaft.

The

crankshaft

is

supported

by

five

main

bearings.

Crankshaft

end

thrust

is

controlled

by

the

flanges

of

the

No.

3

main

bearing.

The

pistons

have

two

compression

rings

and

one

oil

control

ring.

The

top

compression

ring

is

chrome-

plated

and

the

lower

compression

ring

is

phosphate-coated.

The

oil

con

trol

ring

assembly

consists

of

a

ser

rated

spring

and

two

chrome-plated

steel

rails.

VALVE

TRAIN

The

intake

and

exhaust

valve

as

semblies

are

the

rotating-type

which

VALVE

CLOSED

DISC

VALVE

BASE

CIRCLE

A1245-A

FIG.

8

Typical

Hydraulic

Valve

Lifter

Operation

14

GROUP

1-

ENGINE

AND

EXHAUST

SYSTEM

rotate

each

time

the

valve

opens

and

closes.

The

push

rods

are

solid

steel

with

oil

cushioned

sockets.

The

camshaft

is

supported

by

five

bearings

pressed

into

the

block.

It

is

driven

by

a

sprocket

and

timing

chain

in

mesh

with

a

sprocket

on

the

crank

shaft.

Camshaft

end

play

is

controlled

by

a

thrust

button

and

spring

located

between

the

camshaft

sprocket

bolt

and

the

cylinder

front

cover.

An

ec

centric,

bolted

to

the

front

end

of

the

camshaft,

operates

the

fuel

pump.

Hydraulic

valve

lifters

are

used

which

provide

zero

valve

lash.

The

operation

and

parts

identification

of

the

hydraulic

valve

lifters

are

shown

in

Fig.

8.

When

the

valve

is

closed,

the

lifter

assembly

is

on

the

base

circle

of

the

camshaft

lobe

and

the

valve

push

rod

is

in

its

lowest

position.

With

the

lifter

assembly

in

this

position,

the

plunger

spring

expands

forcing

the

plunger

upward.

This

action

is

trans

mitted

to

the

valve

rocker

arm

via

the

valve

push

rod

until

there

is

solid

contact

between

the

valve

and

the

valve

end

of

the

valve

rocker

arm

(zero

valve

lash).

In

this

position,

the

oil

hole

in

the

lifter

and

plunger

is

indexed

with

the

lifter

oil

gallery

and

oil

is

forced

under

pressure

into

the

plunger.

This

creates

a

pressure

dif

ferential

above

and

below

the

valve

disc.

The

high

pressure

above

the

valve

disc

forces

the

valve

disc

open

and

the

oil

fills

the

area

below

the

plunger,

equalizing

the

pressure

on

each

side

of

the

valve

disc.

Whenever

clearance

between

the

valve

and

the

valve

rocker

arm

tends

to

be

present,

the

plunger

spring

expands

pushing

the

plunger

until

there

is

solid

contact

between

all

parts

of

the

valve

train

mech

anism.

As

the

camshaft

rotates

(valve

opening),

the

valve

lifter

is

raised

and

the

sudden

increase

in

oil

pres

sure

below

the

plunger

forces

the

valve

disc

closed

and

the

lifter

be

comes

a

hydraulic

ram.

During

this

period,

a

slight

leakage

of

oil

from

below

the

plunger

occurs.

As

the

high

point

on

the

camshaft

lobe

ro

tates

past

the

lifter,

the

push

rod

forces

the

valve

lifter

down

and

re

seats

the

valve.

The

pressure

on

the

oil

below

the

plunger

is

relieved

and

the

valve

disc

opens

so

that

the

chamber

can

again

be

filled.

This

cycle

is

repeated

for

each

revolution

of

the

camshaft.

Kd

if

-L

If

FIG.

9

Lubrication

System

LUBRICATION

SYSTEM

Oil

from

the

oil

pan

sump,

located

in

the

front

of

the

oil

pan,

is

forced

through

the

pressure-type

lubrication

system

(Fig.

9)

by

a rotor

oil

pump.

A

spring-loaded

relief

valve

in

the

pump

limits

the

maximum

pressure

of

the

system.

Oil

relieved

by

the

valve

is

directed

back

to

the

intake

side

of

the

pump.

All

the

oil

discharged

by

the

pump

passes

through

a

full

flow-type

filter

before

it

enters

the

engine.

The

filter

is

mounted

in

a

vertical position

at

the

lower

left

front

of

the

engine.

A

relief

valve

in

the

filter

permits

oil

to

by

pass

the

filter

if

it

becomes

clogged.

From

the

filter,

the

oil

flows

into

the

main

oil

gallery

which

is

located

in

the

center

of

the

valve

push

rod

chamber

floor.

The

oil

gallery

sup

plies

oil

to

each

individual

camshaft

bearing,

through

drilled

passages

in

the

block.

Passages

are

drilled

from

each

camshaft

bearing

to

each

main

bearing.

Number

1

camshaft

bearing

feeds

No.

1

main

bearing,

and

No.

2

camshaft

bearing

feeds

No.

2

main

bearing,

etc.

The

oil

then

flows

through

notches

or

grooves

in

the

main

bearings

to

lubricate

the

crank-

A1246-A

shaft

journals.

A

jiggle

pin

in

the

main

oil

gallery

front

plug

allows

any

air

that

may

be

trapped

in

the

oil

to

escape.

The

timing

chain

and sprock

ets

are

splash

lubricated

by

oil

from

the

jiggle

pin.

The

crankshaft

is

drilled from

the

main

bearings

to

the

connecting

rod

bearings.

A

small groove

is

located

in

the

connecting

rod

at

the

mating

face

where

the

cap

contacts

the

connect

ing

rod.

This

groove

is

used

as

an

oil

squirt

hole

for

cylinder

wall

lu

brication.

Oil

from

the

connecting

rod

squirt

hole

lubricates

the

oppo

site

cylinder

wall.

For

example,

the

No.

1

connecting

rod

oils

No.

5

cyl

inder,

etc.

As

the

crankshaft

turns,

the

hole

in

the

connecting

rod

bear

ing

aligns

with

the

hole

in

the

jour

nal

causing

a

direct

squirt

of

oil

onto

the

cylinder

wall.

Oil

passages

are

drilled

from

the

main

oil

gallery

to

each

valve

lifter

oil

gallery.

Oil

from

here

feeds

the

valve

lifter

assemblies.

A

reservoir

at

each

valve

lifter

bore

boss

traps

oil

so

that

oil

is

available

for

valve

lifter

lubrication

as

soon

as

the

en

gine

starts.

PART

1-1

-ENGINE

1-5

NO.

2

SUPPORT,

LEFT

HEAD

NO.

4

SUPPORT,

RIGHT

HEAD

FROM

NO.

2

CAMSHAFT

BEARING

TO

LEFT

CYLINDER

HEAD,

AND

FROM

NO.

4

CAMSHAFT

BEARING

TO

RIGHT

CYLINDER

HEAD,

A

1247-A

FIG.

10-Valve

Rocker

Arm

Shaft

Lubrication

An

oil

passage

is

drilled

from

No.

2

camshaft

bearing

web

to

the

left

cylinder

head

between

Nos.

5

and

6

cylinders

to

lubricate

the

valve

rocker

arm

shaft

assembly

(Fig.

10).

The

oil

passage

in

the

cyl

inder

head

is

drilled

from

the

cylin

der

head

bolt

bore

to

the

No.

2

valve

rocker

arm

shaft

support.

The

oil

flows

through

the

valve

rocker

arm

shaft

through

drilled

holes

in

each

valve

rocker

arm

to

lubricate

the

bushing

and

both

ends

of

the

valve

rocker

arm.

The

excess

oil

spi

rals

down

the

rotating

push

rods

and

lubricates

the

push

rod

seats.

The

right

valve

rocker

arm

shaft

assem

bly

is

similarly

lubricated

from

No.

4

camshaft

bearing

via

the

No.

4

valve

rocker

arm

shaft

support.

A

baffle

located

under

the

valve

rocker

arm

shaft

assembly

shields

the

valve

stems

from

oil

splash.

Excess

oil

is

returned

to

the

oil

pan

through

drain-back

holes

located

at

each

end

LOW

INTAKE

MANIFOLD

VACUUM

HIGH

SPEED

OPERATIONS

HIGH

INTAKE

MANIFOLD

VACUUM

LOW

SPEED

OPERATIONS

A1458-B

FIG.

12

Positive

Crankcase

Ventilation

Regulator

Valve

of

the

cylinder

head

and

in

the

push

rod

chamber

floor.

POSITIVE

CRANKCASE

VENTILATION

SYSTEM

Ventilating

air

is

drawn

into

the

engine

through

the

breather

cap

by

a

regulator

valve

located

in

the

intake

manifold.

The

valve

regulates

the

amount

of

air

to

meet

changing

oper

ating

conditions.

The

airisreturned

to

the

intake

manifold

through

an

exhaust

tube

which

extends

from

the

crankcase ventilation

outlet

at

the

rear

of

the

intake

manifold

to

a

spring-loaded

regulator

valve

in

stalled

in

the

intake

manifold

(Fig.

11).

When

the

engine

is

shut

off,

the

tt^^ft*

spring

forces

the

valve

off

its

seat.

This

closes

off

the

inlet

to

the

valve

housing.

During

idle,

intake

manifold

vac

uum

is

high.

The

high

vacuum

over

comes

the

tension

of

the

spring

pres

sure

and

seats

the

valve

(Fig.

12).

With

the

valve

in

this

position,

all

the

ventilating

air

passes

through

a

calibrated

orifice

in

the

valve.

With

the

valve

seated

there

is

minimum

ventilation.

As

engine

speed

increases

and

manifold

vacuum

decreases,

the

spring

forces

the

valve

off

its

seat

and

to

the

full

open

position.

This

increases

the

flow

of

ventilating

air.

From

the

breather

cap,

the

air

flows

into

the

front

section

of

the

valve

push

rod

chamber

where

there

are

few

contaminating

vapors.

Here,

&&%*

A1490-A

FIG.

11

Positive

Crankcase

Ventilation

System

16

GROUP

1-

ENGINE

AND

EXHAUST

SYSTEM

the

incoming

air

has

a

chance

to

warm

up

before

contacting

contam

inating

vapors

originating

in

the

crankcase.

Warm

ventilating

air

mini

mizes

the

formation

of

crankcase

sludge.

The

ventilating

air

is

directed

by

a

baffle,

located

on

the

underside

of

the

intake

manifold,

upward

into

the

front

of

both

valve

rocker

arm

chambers.

The

baffle

also

directs

air

to

the

front

of

the

lower

crankcase

and

into

the

timing

chain

chamber.

Air

from

the

valve

rocker

arm

chamber

and

from

the

crankcase

flows

into

the

rear

of

the

valve

push

rod

chamber.

All

air

is

then

drawn

through

the

regulator

valve

and

is

discharged

into

the

intake

manifold.

COOUNO

SYSTEM

The

coolant

is

drawn

from

the

bottom

of

the

radiator

by

the

water

pump

which

delivers

the

coolant

to

the

cylinder

block

(Fig.

13).

The

coolant

travels

through

cored

passages

to

cool

the

entire

length

of

each

cylinder

wall.

Upon

reaching

the

rear

of

the

cylinder

block,

the

coolant

is

directed

upward

into

the

cylinder

heads

where

it

cools

the

combustion

chambers,

valves,

and

valve

seats

on

its

return

to

the

front

of

the

engine.

TO

RADIATOR

SUPPLY

TANK

FIG.

13

Cooling

System

The

coolant

from

each

cylinder

head

flows

through

the

water

pas

sages

in

the

intake

manifold

and

past

the

water

thermostat,

if

it

is

open,

into

the

radiator

supply

tank.

A1249-B

If

the

thermostat

is

closed,

a

small

portion

of

the

coolant

is

returned

to

the

water

pump

for

recirculation.

The

entire

system

is

pressurized

to

13-15

psi.

ENGINE

TROUBLE

DIAGNOSIS

Engine

performance

complaints

usually

fall

under

one

of

the

basic

headings

listed

in

the

"Engine

Trouble

Diagnosis

Guide."

When

a

particular

trouble

can

not

be

traced

to

a

definite

cause

by

a

simple

check,

the

possible

items

that

could

be

at

fault

are

listed

in

the

order

of

their

probable occurrence.

Check

the

items

in

the

order

listed.

For

example,

under

Poor

Acceleration,

the

ignition

system

is

listed

as

a

probable

cause

of

the

trouble.

All

the

ignition

system

items

that

affect

acceleration

are

listed.

Check

all

these

items

before

proceeding

to

the

next

probable

cause.

ENGINE

TROUBLE

DIAGNOSIS

GUIDE

ENGINE

WILL

NOT

CRANK

The

cause

of

this

trouble

is

usually

starter.

If

the

engine

cranks,

it

indi-

in

the

starting

system

(Part

10-2).

cates

that

water

is

leaking

into

the

If

the

starting

system

is

not

at

fault,

cylinders.

Remove

the

cylinder

check

for

a

hydrostatic

lock

or

a

head(s)

and

inspect

the

gaskets(s)

seized

engine

as

follows:

and/

or

head(s)

for

cracks.

Examine

Remove

the

spark

plugs,

then

at-

the

cylinder

block

for

cracks.

tempt

to

crank

the

engine

with

the

ENGINE

CRANKS

NORMALLY,

BUT

WILL

NOT

START

-

Check

the

fuel

supply.

If

there

is

fault

perform

the

following

test:

sufficient

fuel

in

the

tank,

the

cause

Disconnect

a

spark

plug

wire.

of

the

trouble

probably

lies

in

either

Check

the

spark

intensity

at

the

end

the

ignition

or

the

fuel

system.

of

the

wire

by

installing

a

terminal

To

determine

which

system

is

at

adapter

in

the

terminal

of

the

wire

CONTINUED

ON

NEXT

PAGE

PART

1-1

-ENGINE

1-7

ENGINE

TROUBLE

DIAGNOSIS

GUIDE

(Continued)

ENGINE

CRANKS

NORMALLY,

BUT

WILL

NOT

START

(Continued)

to

be

checked.

Hold

the

adapter

ap

proximately

%e

inch

from

the

exhaust

manifold

and

crank

the

engine.

IF

THERE

IS

NO

SPARK

OR

A

WEAK

SPARK

AT

THE

SPARK

PLUGS

The

cause

of

the

trouble

is

in

the

ignition

system.

To

determine

if

the

cause

of

the

trouble

is

in

the

primary

or

the

secondary

circuit,

remove

the

coil

high

tension

lead

from

the

top

of

the

distributor

and

hold

it

approximately

Vie

inch

from

the

cylinder

head.

With

the

ignition

on,

crank

the

engine

and

check

for

a

spark.

If

the

spark

at

the

coil

high

ten

sion

lead

is

good,

the

cause

of

the

trouble

is

probably

in

the

distributor

cap

or

rotor.

If

there

is

no

spark

or

a

weak

spark

at

the

coil

high

tension

lead,

the

cause

of

the

trouble

is

probably

in

the

primary

circuit,

coil

to

dis

tributor

high

tension

lead,

or

the

coil.

IF

THERE

IS

A

GOOD

SPARK

AT

THE

SPARK

PLUGS

Check

the

spark

plugs.

If

the

spark

plugs

are

not

at

fault,

check

the

fol

lowing

items:

AUTOMATIC

CHOKE

Check

the

position

of

the

choke

plate.

If

the

engine

is

hot,

the

plate

should

be

open.

If

the

plate

is

not

open,

the

engine

will

load

up

due

to

the

excessively

rich mixture

and

will

not

start.

If

the

engine

is

cold,

the

plate

should

be

closed.

If

the

plate

is

not

operating

properly,

check

the

fol

lowing

items:

The

choke

linkage

for

binding.

The

fast

idle

cam

for

binding.

Thermostatic

spring

housing

ad

justment.

FUEL

SUPPLY

AT

THE

CARBURETOR

Work

the

throttle

by

hand

several

times.

Each

time

the

throttle

is

ac

tuated,

fuel

should

spurt

from

the

accelerating

pump

discharge

nozzles.

If

fuel

is

discharged

by

the

ac

celerating

pump,

the

engine

is

prob

ably

flooded,

or

there

is

water

in

the

fuel

system,

or

an

engine

me

chanical

item

is

at

fault.

If

fuel

is

not

discharged

by

the

accelerating

pump,

disconnect

the

carburetor

fuel

inlet

line

at

the

carburetor.

Use

a

suitable

container

to

catch

the

fuel.

Crank

the

en

gine

to

see

if

fuel

is

reaching

the

carburetor.

If

fuel

is

not

reaching

the

carbu

retor,

check:

The

fuel

filter.

The

fuel

pump.

The

carburetor

fuel

inlet

line

for

obstructions.

The

fuel

pump

flexible

inlet

line

for

a

collapsed

condition.

The

fuel

tank

line

for

obstruc

tions.

The

fuel

tank

vent.

If

fuel

is

reaching

the

carburetor,

check:

The

fuel

inlet

system

including

the

fuel

inlet

needle

and

seat

as

sembly,

and

the

float

assembly.

ENGINE

STARTS,

BUT

FAILS

TO

KEEP

RUNNING

FUEL

SYSTEM

Idle

fuel

mixture

needles

not

prop

erly

adjusted.

Engine

idle

speed

set

too

low.

The

choke

not

operating

properly.

Float

setting

incorrect.

Fuel

inlet

system

not

operating

properly.

Dirt

or

water

in

fuel

lines

or

in

the

fuel

filter.

Carburetor

icing.

Fuel

pump

defective.

Dirt

in

the

carburetor,

not

allowing

fuel

to

enter

or

be

discharged

from

the

idle

system.

IGNITION

SYSTEM

Leakage

in

the

high

tension

wiring.

ENGINE

RUNS,

BUT

MISSES

Determine

if

the

miss

is

steady

or

erratic

and

at

what

speed

the

miss

occurs

by

operating

the

engine

at

various

speeds

under

load.

MISSES

STEADILY

AT

ALL

SPEEDS

Isolate

the

miss

by

operating

the

engine

with

one

cylinder

not

firing.

CONTINUED

ON

NEXT

PAGE

1-8

GROUP

1-

ENGINE

AND

EXHAUST

SYSTEM

ENGINE

TROUBLE

DIAGNOSIS

GUIDE

(Continued)

This

is

done

by

operating

the

engine

FUEL

SYSTEM

with

the

ignition

wire

removed

from

Float

setting

incorrect.

ENGINE

RUNS,

BUT

one

spark

plug

at

a

time,

until

all

Fuel

inlet

system

not

operating

MISSES

(Continued)

cylinders

have

been

checked.

Ground

properly.

the

spark

plug

wire

removed.

Dirt

or

water

in

fuel

lines

or

car

buretor.

Restricted

fuel

filter.

If

the

engine

speed

changes

when

a

particular

cylinder

is

shorted

out,

that

cylinder

was

delivering

power

COOLING

SYSTEM

before

being

shorted

out.

If

no

change

Check

the

cooling

system

for

in

in

the

engine

operation

is

evident,

the

ternal

leakage

and/

or

for

a

condi

miss

was

caused

by

that

cylinder

not

tion

that

prevents

the

engine

from

delivering

power

before

being

shorted

reaching

normal

operating

tempera

out.

In

this

case,

check

the:

ture.

ENGINE

IGNITION

SYSTEM

If

the

miss

is

isolated

in

a

particu

Perform

a

compression

test

to

de

termine

which

mechanical

compo

lar

cylinder,

perform

a

spark

test

on

nent

of

the

engine

is

at

fault

(page

the

ignition lead

of

that

cylinder.

1-13).

If

a

good

spark

does

not

occur,

the

trouble

is

in

the

secondary

cir

MISSES

AT

IDLE

ONLY

cuit

of

the

system.

Check

the

spark

FUEL

SYSTEM

plug

wire

and

the

distributor

cap.

Idle fuel

mixture

needles

not

prop

If

a

good

spark

occurs,

check

the

erly

adjusted.

spark

plug.

If

the

spark

plug

is

not

at

IGNITION

SYSTEM

fault,

a

mechanical

component

of

the

engine

is

probably

at

fault.

Excessive

play

in

the

distributor

shaft.

ENGINE

Worn

distributor

cam.

Perform

a

compression

test

to

de

ENGINE

termine

which

mechanical

compo

Perform

a

compression

test

to

de

nent

of

the

engine

is

at

fault

(page

termine

which

mechanical

compo

1-13).

nent

of

the

engine

isatfault

(page

1-13).

MISSES

ERRATICALLY

AT

ALL

SPEEDS

MISSES

AT

HIGH

SPEED

ONLY

EXHAUST

SYSTEM

Exhaust

system

restricted.

FUEL

SYSTEM

Power

valve

clogged

or

damaged.

IGNITION

SYSTEM

Low

or

erratic

fuel

pump

pressure.

Defective breaker

points,

con

Fuel

inlet

system

not

operating

denser,

secondary

wiring,

coil,

or

properly.

spark

plugs.

Restricted

fuel

filter.

High

tension

leakage

across

the

COOLING

SYSTEM

coil,

rotor,

or

distributor

cap.

Engine

overheating.

FUEL

SYSTEM

Power

valve

leaking

fuel.

ROUGH

ENGINE

IDLE

Engine

idle

speed

set

too

low.

Idle

fuel

system

air

bleeds

or

fuel

Idle

fuel

mixture

needles

not

prop

passages

restricted.

erly

adjusted.

Fuel

bleeding

from

the

accelerat

Float

setting

incorrect.

ing

pump

discharge

nozzles.

Air

leaks

between

the

carburetor

Secondary

throttle

plates

not

clos

and

the

manifold

and/or

fittings.

ing.

CONTINUED

ON

NEXT

PAGE

PART

1-1

-ENGINE

1-9

ENGINE

TROUBLE

DIAGNOSIS

GUIDE

(Continued)

ROUGH

ENGINE

IDLE

(Continued)

Improper

secondary

throttle

plate

EXHAUST

SYSTEM

stop

adjustment.

Exhaust

gas

control

valve

inopera

tive

or

sticking.

IGNITION

SYSTEM

ENGINE

Improperly

adjusted

or

defective

Loose

engine

mounting

bolts

or

breaker

points.

worn

insulator.

Fouled

or

improperly

adjusted

Cylinder

head

bolts

not

properly

spark

plugs.

tightened.

r

r

Crankcase

ventilation

regulator

Incorrect

ignition

timing.

vajve

defective

or

a

restricted

exhaust

Spark

plug

misfiring.

tube.

POOR

ACCELERATION

IGNITION

SYSTEM

Leaky

power

valve,

gaskets,

or

ac

celerating

pump

diaphragm.

Incorrect

ignition

timing.

_.

i*:-

_

,

,

6

.

.

f

..

..

Dirt

or

corrosion

in

accelerating

Fouled

or

improperly

adjusted

spark

plugs.

^

Improperly

adjusted

or

defective

Distributor

vacuum

passages

in

breaker

points.

the

carburetor

blocked.

Distributor

not

advancing

prop-

Restricted

fuel

filter.

erly.

...

everru

EXHAUST

SYSTEM

FUEL

SYSTEM

Exhaust

gas

control

valve

stuck

Inoperative

accelerating

pump

in-

closed

let

ball

check.

Inoperative

accelerating

pump

dis

charge

ball

check.

BRAKES

PUmP

diaphragm

dC"

Improper

adjustment.

Float

setting

incorrect.

Throttle

linkage

not

properly

ad-

TRANSMISSION

^Accelerating

pump

stroke

not

Improper

band

adjustment.

properly

adjusted.

Converter

One-Way

Clutch.

ENGINE

DOES

NOT

DEVELOP

FULL

POWER,

OR

HAS

POOR

HIGH

SPEED

PERFORMANCE

FUEL

SYSTEM

Excessive

play

in

the

distributor

shaft.

Restricted

air

cleaner.

Distributor

cam

worn.

Restricted

fuel

filter.

Fou,ed

Qr

^^i

adjusted

Clogged

or

undersize

main

jets

k

.

and/

or

low

float

setting.

T

'.

,.

,

.

.

Clogged

or

undersize

secondary

.

ImProPerly

adJust^

or

defective

.

t

breaker

points.

Power

valve

clogged

or

damaged.

Secondary

throttle

plates

not

COOLING

SYSTEM

opening.

Fuel

pump

pressure

incorrect.

Thermostat

inoperative

or

incor-

Distributor

vacuum

passage

in

rect

heat

ran8e-

the

carburetor

blocked.

Check

the

cooling

system

for

in

ternal

leakage

and/or

for

a

condition

IGNITION

SYSTEM

that

Prevents

tne

en8'ne

from

reach

ing

normal

operating

temperature.

Ignition

timing

not

properly

ad

justed.

EXHAUST

SYSTEM

Defective

coil,

condenser,

or

rotor.

Exhaust

gas

control

valve

inopera-

Distributor

not

advancing

prop-

tive

or

sticking.

erly.

Restriction

in

system.

CONTINUED

ON

NEXT

PAGE

1-10

GROUP

1-

ENGINE

AND

EXHAUST

SYSTEM

ENGINE

TROUBLE

DIAGNOSIS

GUIDE

(Continued)

ENGINE

DOES

NOT

ENGINE

One

or

more

camshaft

lobes

worn

DEVELOP

FULL

POWER,

beyond

wear

limit.

OR

HAS

POOR

HIGH

Perform

an

engine

compression

TRANSMISSION

SPEED

PERFORMANCE

test

to

determine

which

mechanical

(Continued)

component

is

at

fault

(page

1-13).

Improper

band

adjustment.

Determine

the

actual

fuel

con

FINAL

CHECKS

sumption

with

test

equipment

in

EXCESSIVE

FUEL

stalled

in

the

car.

FUEL

SYSTEM

CONSUMPTION

Check:

If

the

test

indicates

that

the

fuel

Fuel

pump

pressure.

consumption

is

not

excessive,

dem

Engine

idle

speed.

onstrate

to

the

owner

how

improper

Idle

fuel

mixture

needles

for

driving

habits

will

affect

fuel

con

proper

adjustment.

sumption.

Automatic

choke

for

proper

oper

ation.

If

the

test

indicates

that

the

fuel

Fast

idle

speed

screw

for

proper

consumption

is

excessive,

make

a

adjustment.

preliminary

check

of

the

following

Accelerating

pump

stroke

ad

justment.

items

before

proceeding

to

the

fuel

Anti-stall

dashpot

for

proper

ad

and

ignition

systems.

justment.

Air

cleaner

for

restrictions.

PRELIMINARY

CHECKS

Float

setting

or

fuel

level.

Jets for

wear

and/or

damage.

CHASSIS

ITEMS

Power

valve

operation.

Check:

Air

bleeds

for

obstructions.

Accelerating

pump

discharge

noz

Tires

for

proper

pressure.

zles

for

siphoning.

Front

wheel

alignment.

IGNITION

SYSTEM

Brake

adjustment.

Check:

Spark

plug

condition

and

adjust

EXHAUST

SYSTEM

ment.

Check

the

exhaust

gas

control

Distributor

spark

advance

opera

valve

operation.

tion.

ENGINE

ODOMETER

Perform

an

engine

compression

Check

calibration.

test

to

determine

which

mechanical

IGNITION

SYSTEM

Check

ignition

timing.

component

of

the

engine

is

at

fault

(page

1-13).

COOLING

SYSTEM

ENGINE

Check

thermostat

operation

and

Crankcase

ventilation

regulator

heat

range.

valve

defective

or

restricted

exhaust

TRANSMISSION

tube.

Check

band

adjustment.

TEMPERATURE

SENDING

Low

oil

level

or

incorrect

viscos

UNIT

AND

GAUGE

ity

oil

used.

ENGINE

OVERHEATS

Unit

or

gauge

defective

(not

in

dicating

correct

temperature),

or

con

COOLING

SYSTEM

stant

voltage

regulator

defective.

Insufficient

coolant.

ENGINE

Cooling

system

leaks.

Cylinder

head

bolts

not

properly

Drive

belt

tension

incorrect.

torqued.

Radiator

fins

obstructed.

CONTINUED

ON

NEXT

PAGE

PART

1-1

-ENGINE

1-11

ENGINE

TROUBLE

DIAGNOSIS

GUIDE

(Continued)

ENGINE

OVERHEATS

(Continued)

Thermostat

defective.

Thermostat

improperly

installed.

Cooling

system

passages

blocked.

Water

pump

inoperative.

IGNITION

SYSTEM

Incorrect

ignition

timing.

LOSS

OF

COOLANT

COOLING

SYSTEM

Leaking

radiator.

Loose

or

damaged

hose

connec

tions.

Water

pump

leaking.

Radiator

cap

defective.

Overheating.

ENGINE

Cylinder

head

gasket

defective.

Intake

manifold

to

cylinder

head

gasket

defective.

Cylinder

head

or

intake

manifold

bolts

not

properly

torqued.

Cylinder

block

core

plugs

leak

ing.

Temperature

sending

unit

leak

ing.

Cracked

cylinder

head

or

block,

or

warped

cylinder

head

or

block

gasket

surface.

ENGINE

FAILS

TO

REACH

NORMAL

OPERATING

TEMPERATURE

TEMPERATURE

SENDING

UNIT

AND

GAUGE

Unit

or

gauge

defective (not

in

dicating

correct

temperature)

or

con

stant

voltage

regulator

defective.

COOLING

SYSTEM

Thermostats

inoperative

or

of

in

correct

heat

range.

NOISY

HYDRAULIC

VALVE

LIFTER

A

noisy

valve

lifter

can

be

located

by

operating

the

engine

at

idle

speed

and

placing

a

finger

on

the

face

of

the

valve

spring

retainer.

If

the

lifter

is

not

functioning

prop

erly,

a

shock

will

be

felt

when

the

valve

seats.

Another

method

of

identifying

a

noisy

lifter

is

by

the

use

ofapiece

of

hose.

With

the

engine

operating

at

idle

speed,

place

one

end

of

the

hose

near

the

end

of

the

valve stem

and

the

other

end

to the

ear

and

listen

for

a

metallic

noise.

Repeat

this

procedure

on

each

intake

and

exhaust

valve

until

the

noisy

lift-

er(s)

has

been

located.

The

most

common

causes

of

hy

draulic

valve

lifter

troubles

are

dirt,

gum,

varnish,

carbon

deposits,

and

air

bubbles.

Dirt

in

the

lifter

assembly

can

prevent

the

disc

valve

from

seating,

or

it

may

become

lodged

between

the

plunger

and

body

surfaces.

In

either

case,

the

lifter

becomes

inop

erative

due

to

failure

to

"pump-up,"

or

because

the

internal

parts

are

no

longer

free

to

function

properly.

When

dirt

is

found

to

be

respon

sible

for

lifter

malfunction,

remove

the

lifter

assembly

and

thoroughly

clean

it.

Recommended

engine

oil

and

filter

change

intervals

should

be

followed

to

minimize

lifter

prob

lems

caused

by

dirt.

Deposits

of

gum

and

varnish

cause

similar

conditions

to

exist

which

may

result

in

lifter

malfunc

tion.

If

these

conditions

are

found

to

be

present,

the

lifter

should

be

disassembled

and

cleaned

in

solvent

to

remove

all

traces

of

deposits.

Air

bubbles

in

the

lubricating

oil,

caused

by

an

excessively

high

or

low

oil

level,

may

likewise

cause

lifter

malfunction.

A

damaged

oil

pick

up

tube

may

allow

air

to

be

drawn

into

the

lubricating

system.

To

check

for

the

presence

of

air,

remove

a

valve

rocker

arm

cover

and

note

the

condition

of

the

oil

as

it

flows

from

the

valve

rocker

arm

shaft

as

sembly.

Perform

corrective

action

as

required

to

remove

air

from

the

lubri

cating

oil.

M2

GROUP

1-

ENGINE

AND

EXHAUST

SYSTEM

TUNE-UP

The

Tune-Up

Schedule

(Table

1)

is

for

either

an

A.

B,

or

C

tune-up.

Perform

all

operations

in

the

se

quence

listed.

The

recommended

mileage

interval

for

an

A

tune-up

is

4000

miles,

for

a

B

tune-up

it

is

8000

miles,

and

for

a

C

tune-up

it

is

12,000

miles.

For

a

detailed

descrip

tion

of

an

operation

procedure,

refer

to

the

operation

number

under

"Tune-Up

Procedure."

TUNE-UP

PROCEDURE

The

tune-up

is

divided

into

3

ma

jor

parts.

TABLE

1-Tune-Up

Schedule

The

first

part

is

performed

with

the

engine

not

operating.

The

first

step

consists

of

visual

and

mechani

cal

checks

and

adjustments.

The

sec

ond

step

consists

of

an

instrument

check.

Always

follow

the

instructions

of

the

manufacturer

of

the

test

equip

ment

used.

The

second

part

of

the

tune-up

covers

items

that

can

be

done

while

the

engine

is

warming

up

for

carbu

retor and

valve

adjustments.

The

third

part

of

the

tune-up

should

be

performed

with

the

engine

operating

at

normal

operating

tem

perature.

For

the

engine

to

reach

normal

operating

temperature,

it

should

be

operated

for

30

minutes

at

fast

idle

(1200

rpm).

For

more

detailed

information

on

corrective

action

to

be

taken

when

a

particular

defect

is

encountered,

re

fer

to

the

appropriate

part

of

the

manual.

At

the

end

of

the

"Tune-Up

Pro

cedure,"

additional

engine

checks

and

adjustments

are

described

for

use

as

necessary.

Operation

No.

Operation

ABC

ENGINE

NOT

OPERATING

MECHANICAL

CHECKS,

TESTS,

AND

ADJUSTMENTS

1

Clean,

adjust,

and

test

spark

plugs.

X

2

Take

a

compression

reading

of

each

cylinder.

X

3

Replace

spark

plugs.

X

4

Check

and

tighten

intake

manifold

bolts.

X

5

Check

and

adjust

the

deflection

of

the

drive

belts.

X

6

Replace

fuel

filter.

X

7

Check

and

adjust

carburetor

fuel

level.

X

8

Clean

the

distributor

cap

and

rotor.

X

X

9

Lubricate

the

distributor

cam,

lubricating

wick,

and

the

distributor

bushing.

X

10

Clean

battery

cables

and

terminals.

X

11

Clean

positive

crankcase

ventilation

system.

X

INSTRUMENT

CHECKS

12

'

Check

battery

state

of

charge.

x

Operation

No.

Operation

A

B

C

13

Check

and

adjust

breaker

point

dwell.

X

14

Check

and

adjust

spark

advance.

X

15

Perform

a

spark

intensity

test

of

each

spark

plug

wire.

X

16

Check

fuel

pump

pressure

and

capacity

X

WHILE

ENGINE

IS

WARMING-UP

17

Clean

carburetor

air

cleaner.

X

18

Inspect

the

radiator,

hoses,

and

engine

for

coolant

leaks.

X

19

Check

and

adjust

ignition

timing.

X

ENGINE

OPERATING

AT

NORMAL

TEMPERATURE

20

Adjust

accelerator

pump

link

to

seasonal

position.

X

21

Check

and

adjust

engine

idle

speed.

X

22

Check

and adjust

idle

fuel

mixture.

X

23

Check

and

adjust

anti-stall

dashpot

clearance.

X

PART

1-1

-ENGINE

1-13

B1390-A

FIG.

14

Cleaning

Plug

Electrode

ENGINE

NOT

OPERATING

Perform

the

following

tests

with

the

engine

off

and

at

room

tempera

ture.

MECHANICAL

CHECKS,

TESTS,

AND

ADJUSTMENTS

1.

Clean,

Adjust,

And

Test

Spark

Plugs.

Remove

the

wire

from

each

spark

plug

by

grasping

the

moulded

cap

only.

Clean

the

area

around

each

spark

plug

with

compressed

air,

then

re

move

the

spark

plugs.

Clean

the

spark

plugs

onasand

blast

cleaner

following

the

equip

ment

manufacturer's

instructions.

Remove

carbon

and

other

deposits

from

the

threads

with

a

stiff

wire

brush.

Clean

the

electrode

surfaces

with

a

small

file

(Fig.

14).

Dress

the

electrode

to

secure

flat

parallel

sur

faces

on

both

the

center

and

side

electrode.

After

cleaning,

inspect

the

plug

for

a

cracked

or

broken

insulator,

badly

B1391-A

FIG.

15

Gapping

Spark

Plug

pitted

electrodes,

or

other

signs

of

failure.

Replace

as

required.

Set

the

gap

of

all

serviceable

or

new

plugs

to

0.032-0.036

inch

by

bending

the

ground

electrode

(Fig.

15).

After

the

gap

has

been

adjusted,

check

the

plugs

on

a

testing

machine.

Compare

the

sparking

efficiency

of

the

cleaned

and

gapped

plug

with

a

new

plug.

Replace

the

plug

if

it

fails

to

meet

requirements.

Apply

a

coat

ing

of

oil

to

the

shoulder

of

the

plug

where

the

insulator

projects

through

the

shell,

and

to

the

top

of

the

plug,

where

the

center

electrode

and

termi

nal

project

from

the

insulator.

Place

the

spark

plug

under

pressure.

Leak

age

is

indicated

by

air

bubbling

through

the

oil.

If

the

test

indicates

compression

leakage,

replace

the

plug.

If

the

plug

is

satisfactory,

wipe

it

clean.

Install

the

spark

plugs

and

torque

them

to

15-20

ft-lbs.

2.

Take

A

Compression

Reading

Of

Each

Cylinder.

Remove

the

spark

plugs.

Remove

the

coil

high

tension

lead

at

the

distributor

cap.

Set

the

primary

throttle

plates

and

choke

plate

in

the

wide

open

position.

Install

a

compression

gauge

in

No.

1

cylinder.

Using

a

remote

starter

switch,

crank

the

engine

several

times

and

record

the

highest

reading

recorded.

Note

the

number

of

compression

strokes

required

to

obtain

the

highest

reading.

Repeat

the

test

on

each

cylinder,

cranking

the

engine

the

same

num

ber

of

times

for

each

cylinder

as

was

required

to

obtain

the

highest

reading

on

the

No.

1

cylinder.

A

variation

of

20

pounds

from

specified

pressure

of

180

psiissatis

factory.

However,

the

compression

of

all

cylinders

should

be

uniform

within

10

pounds.

A

reading

of

more

than

the

allow

able

tolerance

above

normal

indi

cates

excessive

deposits

in

the

cyl

inder.

A

reading

of

more

than

the

allow

able

tolerance

below

normal

indi

cates

leakage

at

the

cylinder

head

gasket,

piston

rings,

or

valves.

A

low

even

compression

in

two

adjacent

cylinders

indicates

a

cylin

der

head

gasket

leak.

This

should

be

checked

before

condemning

the

rings

or

valves.

To determine

whether

the

rings

or

the

valves

are

at

fault,

squirt

the

equi

valent

of

a

tablespoon

of

heavy

oil

into

the

combustion

chamber.

Crank

the

engine

to

distribute

the

oil

and

repeat

the

compression

test.

The

oil

will

temporarily

seal

leakage

past

the

rings.

If

approximately

the

same

reading

is

obtained,

the

rings

are

satisfactory,

but

the

valves

are

leak

ing.

If

the

compression

has

increased

10

pounds

or

more

over

the

original

reading,

there

is

leakage

past

the

rings.

During

a

compression

test,

if

the

pressure

fails

to

climb

steadily

and

remains

the

same

during

the

first

two

successive

strokes,

but

climbs

higher

on

the

succeeding

strokes,

or

fails

to

climb

during

the

entire

test,

it

indi

cates

a

sticking

valve.

3.

Replace

Spark

Plugs.

Install

new

spark

plugs

of

the

correct

heat

range

(Part

2-3).

Torque

the

plugs

to

15-20

ft-lbs.

4.

Check

And

Tighten

Intake

Manifold

Bolts.

Check

all

intake

manifold

bolts

for

the

recommended

torque

of

32-35

ft-lbs.

Torque

the

bolts,

as

necessary,

starting

at

the

center

bolts

and

working

outward.

5.

Check

And

Adjust

The

Deflec

tion

Of

The

Drive

Belts.

Check

the

deflection

of

the

drive

belts

using

tool

33-73F.

Follow

the

instructions

of

the

gauge

manufacturer.

Adjust

the

tension

as

follows:

Loosen

the

generator

mounting

bolts

and

the

adjusting

bracket

bolt.

Move

the

generator

toward

or

away

from

the

engine

until

the

proper

de

flection

is

obtained

between

the

water

pump

pulley

and

the

generator

pulley.

Tighten

the

generator

adjust

ing

bracket

bolt

and

the

mounting

bolts.

6.

Replace

Fuel

Filter.

Slide

the

clamps

closest

to

the

filter

away

from

the

filter

(Fig.

16).

Slide

the

new

filter

into

the

rubber

connections

and

slide

the

clamps

into

H410-A

FIG.

16

Fuel

Filter

Installation

1-14

GROUP

1-

ENGINE

AND

EXHAUST

SYSTEM

place.

Be

sure

the

fuel-flow

arrow

on

the

filter

are

pointed

toward

the

outlet

of

the

filter

(toward

the

carburetor).

7.

Check

And

Adjust

Carburetor

Fuel

Level.

Check

and

set

the

floats.

Refer

to

"Bench

Adjustments"

(Part

3-2).

8.

Clean

The

Distributor

Cap

And

Rotor.

Disconnect

the

coil

high

ten

sion

lead

and

the

spark

plug

wires

at

the

distributor

cap.

Remove

the

dis

tributor

cap

and

rotor.

Clean

the

inside

of

the

distributor

cap

and

clean

the

rotor

using

a

mild

cleaning

solvent

or

mineral

spirits

and

a

soft

bristle

brush.

Remove

dirt

or

corrosion

from

the

sockets

of

the

distributor

cap.

Inspect

the

cap

for

cracks,

burned

contacts,

or

perma

nent

carbon

tracks.

Inspect

the

rotor

for

cracks

or

a

burned

tip.

Replace

the

cap

and

/or

rotor

if

they

are

de

fective.

9.

Lubricate

The

Distributor

Cam,

Lubricating

Wick,

And

The

Distribu

tor

Bushing.

Apply

a

light

film

of

high-temperature,

non-fiber

grease

to

the

distributor

cam.

Do

not

use

en

gine

oil.

Saturate

the

lubricating

wick

with

SAE

10W

engine

oil.

Squirt

a

few

drops

of

SAE

10W

engine

oil

into

the

distributor

oil

cup.

10.

Clean

Battery

Cables

And

Terminals.

Disconnect

the

battery

cables.

Wash

the

battery

including

the

terminals

and

battery

carrier

in

cold

water

using

a

stiff

bristle

brush.

If

the

battery

is

extremely

dirty,

use

a

baking

soda

solution.

Inspect

the

bat

tery

cables

for

corrosion,

fraying,

or

breaks.

Apply

grease

to

the

battery

terminals

after

cleaning.

Connect

and

properly

tighten

the

cable

clamps.

11.

Clean

Positive

Crankcase

Ven

tilation

System.

Remove

the

crank

case

ventilation

regulator

valve,

ex

haust

tube,

and

connections.

Disas

semble

the

valve.

Clean

the

valve

and

exhaust

tube

in

clean

carburetor

solvent

and

dry

them

with

com

pressed

air.

Clean

the

rubber

hose

connections

with

a

low

volatility

petroleum

base

solvent

and

dry

them

with

compressed

air.

INSTRUMENT

CHECKS

Always

follow

the

instructions

of

the

test

unit

manufacturer

when

per

forming

instrument

checks.

All

the

tests

except

checking

distributor

spark

advance

can

be

made

in-

chassis.

Perform

the

tests

in

the

se

quence

listed.

12.

Check

Battery

State

of

Charge.

The

battery

state

of

charge

can

be

checked

by

measuring

the

battery

electrolyte

solution

specific

gravity

(hydrometer)

or

by

measur

ing

the

voltage

of

the

battery

cells

on

open

circuit

(no

current

flow)

with

a

battery

charge

tester.

If

a

hydrometer

is

used,

a

specific

gravity

of

1.275-1.285

indicates

a

fully

charged

battery.

1.230-1.240

indicates

approximately

60%

charge.

If

the

specific

gravity

varies

more

than

0.025

between

cells,

the

battery

should

be

replaced.

Refer

to

Part

10-1

which

de

scribes

in

detail

the

procedure

to

be

followed.

13.

Check

And

Adjust

Breaker

Point

Dwell.

If

the

contacts

are

ex

cessively

out of

alignment,

replace

the

breaker

point

assembly.

Do

not

attempt

to

align

used

breaker

points.

Install

a

new

breaker

point

assembly

if

necessary

(Part

2-2).

Use

a

dwell

meter

only

to

check

the

gap

of

used

breaker

points.

The

roughness

of

used

breaker

points

makes

an

accurate

gap

reading

or

setting

with

a

feeler

gauge

impos

sible.

Check

and

set

the

contact

dwell

to

specification

(Part

2-3)

by

follow

ing

the

instructions

of

the

meter

manufacturer.

Always

clean

used

points

before

adjusting.

14.

Check

And

Adjust

Spark

Ad

vance.

Refer

to

the

procedure

in

Part

2-1.

After

the

spark

advance

has

been

checked

and

adjusted,

install

the

rotor

and

position

the

distributor

in

the

block

so

that

the

rotor

is

aligned

with

the

mark

previously

scribed

on

the

distributor

body,

and

the

marks

on

the

body

and

engine

block

are

in

alignment.

Install

the

distributor

re

taining

screw(s).

Install

the

distribu

tor

cap.

Insert

each

distributor

wire

in

the

proper

distributor

cap

socket.

Be

sure

the

wires

are

forced

all

the

way

down

into

their

sockets.

The

No.

1

socket

is

identified

on

the

cap.

Starting

at

the

No.

1

socket,

install

the

wires

in

the

direction

of

distribu

tor

rotation

(counterclockwise)

in

the

firing

order

(1-5-4-8-6-3-7-2).

Push

all

weather

seals

into

position.

15.

Perform

A

Spark

Intensity

Test

Of

Each

Spark

Plug

Wire.

Check

the

spark

intensity

of

one

wire

at

a

time.

Install

a

terminal

adapter

in

the

terminal

of

the

wire

to

be

checked.

Hold

the

adapter

approxi

mately

%6

inch

from

the

exhaust

manifold

and

crank

the

engine

with

a

remote

starter

switch.

The

spark

should

jump

the

gap

regularly.

16.

Check

Fuel

Pump

Pressure

And

Capacity.

Disconnect

the

fuel

line

at

the

carburetor.

Install

a

pres

sure

gauge

(0-15

psi)

and

a

petcock

on

the

carburetor

fuel

inlet

line

(Fig.

17).

Vent

the

system,

by

opening

the

petcock

momentarily,

prior

to

taking

a

pressure

reading.

Operate

the

en-

FIG.

17

Fuel

Pump

Pressure

and

Capacity

Test

PART

1-1

-ENGINE

1-15

gine

at

500

rpm.

After

the

pressure

has

stabilized,

it

should

be

4.0-6.0

psi.

Operate

the

engine

at

500

rpm.

Open

the

petcock

and

expel

the

fuel

into

a

suitable

container.

Observe

the

time

required

to

expel

one

pint.

It

should

be

within

20

seconds.

If

the

capacity

is

not

to

specifica

tions,

remove

the

fuel

filter

from

the

system

and

make

another

capacity

check.

If

the

capacity

is

within

specifica

tions

with

the

fuel

filter

removed,

the

fuel

filter

was

restricted

and

a

new

one

should

be

installed.

If

the

capacity

is

not

within

speci

fications

with

the

fuel

filter

removed,

the

fuel

pump

is

defective.

WHILE

ENGINE

IS

WARMING-UP

Place

the

transmission

selector

lever

in

neutral

position

and

set

the

parking

brake.

Start

the

engine

and

operate

it

at

1200

rpm

for

30

min

utes

to

stabilize

engine

temperatures.

While

the

engine

is

warming

up,

per

form

the

following

operations:

17.

Clean

Carburetor

Air

Cleaner.

Direct

clean

compressed

air

against

the

element

in

the

opposite

direction

of

normal

air

flow,

that

is,

from

the

inside

of

the

filter

out.

Clean

the

air

cleaner

body

and

cover

in

cleaning

solvent,

then

wipe

them

dry.

Do

not

install

the

air

cleaner

at

this

time.

18.

Inspect

the

Radiator,

Hoses,

and

Engine

For

Coolant

Leaks.

In

spect

the

radiator

hoses

for

cracks,

leaks,

and

a

collapsed

condition.

In

spect

the

radiator

and

engine

for

ex

ternal

leaks.

Check

for

internal

leakage

by

op

erating

the

engine

at

fast

idle

and

looking

for

the

formation

of

bubbles

in

the

radiator

supply

tank.

Oil

in

the

supply

tank

may

indicate

leakage

in

the

engine

block

or

a

leak

in

the

auto

matic

transmission

oil

cooler.

Water

formation

on

the

oil

level

dipstick

could

be

an

indication

of

internal

leakage.

19.

Check

And

Adjust

Ignition

Timing.

Disconnect

the

distributor

vacuum

line.

Connect

the

timing

light

high

tension

lead

to

the

No.

1

spark

plug

and

the

other

two

leads

of

the

timing

light

to

the

battery

terminals.

PUT

ROD

IN

OUTSIDE

HOLE

ACCELERATING

PUMP

STROKE

SUMMER

SETTING

WINTER

SETTING

ENGINE

IDLE

SPEED

SCREW

LOCK

NUT

ANTI-STALL

DASHPOT

CLEARANCE

B1424-A

FIG.

18

Carburetor

Idle

Adjustments

Do

not

puncture

the

spark

plug

wire

or

moulded

cap.

Clean

the

dirt

from

the

timing

marks

pin

on

the

crankshaft

damper.

If

necessary,

chalk

the

proper

mark

to

improve

legibility.

Operate

the

engine

at

idle

speed.

Be

sure

the

engine

is

idling

below

550

rpm

so

that

there

will

be

no

cen

trifugal

advance.

The

timing

light

should

flash

just

as

the

proper

mark

lines

up

with

the

pin

indicating

cor

rect

timing.

The

operator's

eye

should

be

in

line

with

the

center

of

the

damper

and

the

timing

pointer.

Refer

to

Part

2-3

for

the

correct

specifications.

ENGINE

OPERATING

AT

NORMAL

TEMPERATURE

20.

Adjust

Accelerator

Pump

Link

to

Seasonal

Position.

The

over-travel

lever

has

four

holes

and

the

acceler

ating

pump

link

has

two

holes

to

con

trol

the

accelerating

pump

stroke

for

different

engine

applications

(Fig.

1

8).

Install

the

accelerating

pump

op

erating

rod

in

the

No.

4

(top)

hole

for

winter

operation

or

in

the

No.

2

hole

for

summer

operation

in

the

over-

travel

lever.

Install

the

accelerating

pump

operating

rod

in

the

outside

hole

in

the

accelerating

pump

link

for

all

climatic

conditions.

On

cars

operating

constantly

in

areas

of

75

ambient

temperature

or

over,

install

the

accelerating

pump

operating

rod

in

the

No.

1

hole

in

the

over-travel

lever.

21.

Check

And

Adjust

Engine

Idle

Speed.

Final

engine

idle

speed

may

be

varied

to

suit

the

conditions

under

which

the

car

is

to

be

oper

ated.

On

a

car

with

an

air

conditioner,

operate

the

air

conditioner

for

20

minutes

before

setting

the

engine

idle

speed.

Adjust

the

engine

idle

speed

with

the

air

conditioner

operating.

Be

sure

the

parking

brake

is

on.

Place

the

transmission

selector

lever

in

drive

range

position.

Check

the

engine

idle

speed

and

adjust

it

to

drive

range

specifications

(450-475

rpm).

Place

the

selector

lever

in

neu

tral,

accelerate

the

engine

and

let

it

return

to

idle.

Place

the

selector

lever

in

drive

range

and

check

the

engine

idle

speed.

After

the

hot

engine

idle

speed

has

been

adjusted,

adjust

the

fast

idle

speed

by

aligning

the

step

of

the

fast

idle

cam

with

the

fast

idle

screw

(Fig.

19).

With

the

fast

idle

screw

resting

on

the

step,

turn

the

screw

in

to

obtain

1

700

rpm.

FAST

IDLE

ADJUSTING

SCREW

FAST

IDLE

CAM

B1425-A

FIG.

19

Carburetor

Fast

Engine

Idle

Speed

Adjustment

1-16

GROUP

1-

ENGINE

AND

EXHAUST

SYSTEM

SOLID

TAPPET-TYPE

ADJUSTING

NEEDLES

B1426-A

FIG.

20

-Carburetor

Idle

Fuel

Mixture

Adjustment

22.

Check

And

Adjust

Idle

Fuel

Mixture

(Refer

to

Fig.

20).

Make

the

initial

mixture

adjustment

by

turning

the

needles

in

until

they

lightly

touch

the

seat,

then

back

them

off

1-1

Vi

turns.

Do

not

turn

a

needle

against

the

seat

tight

enough

to

groove

the

point.

If

a

needle

is

damaged,

it

must

be

replaced

before

a

proper

mixture

adjustment

can

be

obtained.

Turn

the

mixture

needles

in

until

the

engine

begins

to

run rough

from

the

lean

mixture.

Turn

the

needles

out

until

the

engine

begins

to

"roll"

from

the

rich

mixture.

Then

turn

the

needles

in

until

the

engine

runs

smoothly.

Always

favor

a

slightly

rich

mixture

rather

than

a

lean

mix

ture.

Check

the

engine

idle

speed.

23.

Check

And

Adjust

Anti-Stall

Dashpot

Clearance.

Loosen

the

anti-

stall

dashpot

lock

nut

(Fig.

18).

Hold

the

throttle

in

the

closed

position

and

depress

the

plunger

with

a

screw

driver

blade.

Turn

the

dashpot

in

its

bracket

inadirection

to

provide

a

clearance

of

0.060-0.090

inch

between

the

plunger

and

the

throttle

lever.

Tighten

the

lock

nut

after

the

adjustment

is

made.

ADDITIONAL

TESTS

AND

ADJUSTMENTS

CAMSHAFT

LOBE

LIFT

1.

Remove

the

air

cleaner

and

the

valve

rocker

arm

cover.

Remove

the

valve

rocker

arm

shaft

assembly

and

install

a

solid

tappet-type

push

rod

in

the

push

rod

bore

of

the

camshaft

lobe

to

be

checked.

2.

Make

sure

the

push

rod

is

in

the

lifter

push

rod

cup.

Install

a

dial

indicator

in

such

a

manner

as

to

have

the

actuating

point

of

the

indi

cator

in

the

push

rod

socket

and

in

the

same

plane

as

the

push

rod

move

ment

(Fig.

21).

Detail

1

Dial

Indicator

BE

SURE

TO

PLACE

Indicator

TIP

IN

CENTER

OF

PUSH ROD

SOCKET

A1202-A

FIG.

21

-Camshaft

Lobe

Lift

3.

Turn

the

crankshaft

damper

slowly

in

the

direction

of

rotation

until

the

lifter

is

on

the

base

circle

of

the

camshaft

lobe.

At

this

point,

the

push

rod

will

be

in

its

lowest

position.

4.

Zero

the

dial

indicator.

5.

Continue

to

rotate

the

damper

slowly

until

the

push

rod

is

in

the

fully

raised

position.

6.

Compare

the

total

lift

recorded

on

the

indicator

with

specifications.

7.

To

check

on

the

accuracy

of

the

original

indicator

reading,

continue

to

rotate

the

crankshaft

until

the

in

dicator

reads

zero.

8.

Remove

the

dial

indicator.

9.

Install

the

valve

rocker

arm

shaft.

Install

the

rocker

arm

cover

and

the

air

cleaner.

VALVE

CLEARANCE

A

0.060-inch

shorter

push rod

(color

coded

white)

or

a

0.060-inch

longer

push

rod

(color

coded

yel

low)

are

available

for

service

to

pro

vide

a

means

of

compensating

for

dimensional

changes

in

the

valve

mechanism.

Valve

stem

to

valve

rocker

arm

clearance

should

be

0.078-0.218

inch

with

the

hydraulic

lifter

completely

collapsed.

Repeated

valve

reconditioning

operations

(valve

and/or

valve

seat

refacing)

will

de

crease

this

clearance

to

the

point

that

if

not

compensated

for,

the

hydraulic

valve

lifter

will

cease

to

function.

To

determine

whether

a

shorter

or

a

longer

push

rod

is

necessary,

make

the

following

check:

1.

Position

the

crankshaft

as

out

lined

in

steps

5

and

6.

2.

Position

the

hydraulic

lifter

compressor

tool

on

the

rocker

arm

and

slowly

apply

pressure

to

bleed

down

the

hydraulic

lifter

until

the

plunger

is

completely

bottomed (Fig.

FIG.

22

Valve

Clearance

22).

Hold

the

lifter

in

the

fully

col

lapsed

position.

3.

Insert

the

correct

end

of

the

clearance

gauge

between

the

valve

stem

and

the

rocker

arm

of

the

valve

being

checked.

4.

If

the

first

step

of

the

gauge

en

ters,

a

standard

length

push rod

may

be

used.

If

the

first

step

of

the

gauge

does

not

enter,

replace

the

standard

push

rod

with

a

0.060-inch

shorter

service

push rod.

If

the

second

step

of

the

gauge

enters,

the

operating

range

of

the

lifter

is

excessive.

This

indicates

that

the

incorrect

push

rod

has

been

in

stalled

or

severe

wear

has

occurred

at

the

push

rod

ends,

rocker

arm,

or

valve

stem.

In

this

case,

it

will

be

nec

essary

to

determine

the

area

of

dis

crepancy

and

the

incorrect

or

defec

tive

part(s)

should

be

replaced.

If

all

the

valve

train

components

except

the

push

rod

are

within

limits,

install

a

0.060-inch

longer

push

rod.

5.

Rotate

the

crankshaft

until

No.

1

piston

is

on

TDC

at

the

end

of

the

compression

stroke.

With

No.

1

piston

on

TDC,

check

the

follow

ing

valves:

No.

1

Intake

No.

1

Exhaust

No.

3

Intake

No.

4

Exhaust

No.

7

Intake

No.

5

Exhaust

No.8Intake

No.

8

Exhaust

6.

Position

No.

6

piston

on

TDC

and

check

the

following

valves:

No.

2

Intake

No.

2

Exhaust

No.4Intake

No.

3

Exhaust

No.

5

Intake

No.

6

Exhaust

No.6Intake

No.

7

Exhaust

When

compressing

the

valve

spring

to

remove

push

rods,

be

sure

the

pis

ton

in

the

individual

cylinder

is

below

PART

1-1

-ENGINE

1-17

TDC

to

avoid

contact

between

the

valve

and

the

piston.

To

replace

a

push

rod,

it

will

be

necessary

to

remove

the

valve

rocker

arm

shaft

assembly.

Upon

replacement

of

a

valve

push

rod

and/

or

valve

rocker

arm

shaft

assembly,

the

engine

should

not

be

cranked

or

rotated

until

the

hydraulic

lifters

have

had

an

opportunity

to

leak

down

to

their

normal

operating

position.

The

leak-down

rate

can

be

accelerated

by

using

the

tool

shown

in

Fig.

22

on

the

valve

rocker

arm

and

applying

pressure

in

a

direction

to

collapse

the

lifter.

MANIFOLD

VACUUM

TEST

A

manifold

vacuum

test

aids

in

determining

the

condition

of

an

en

gine

and

also

in

helping

to

locate

the

cause

of

poor

engine

performance.

To

test

manifold

vacuum:

1.

Operate

the

engine

for

a

mini

mum

of

30

minutes

at

1200

rpm.

2.

Install

an

accurate,

sensitive

vacuum

gauge

in

the

fitting

in

the

in

take

manifold.

3.

Operate

the

engine

at

recom

mended

idle

rpm,

with

the

transmis

sion

selector

lever

in

neutral.

4.

Check

the

vacuum

reading

on

the

gauge.

TEST

CONCLUSIONS

Manifold

vacuum

is

affected

by

carburetor

adjustment,

valve

timing,

TABLE

2

Manifold

Vacuum

Gauge

Readings

Gauge

Reading

Engine

Condition

18

inches

Normal.

Low

and

steady.

Loss

of

power

in

all

cylinders

caused

possibly

by

late

ignition

or

valve

timing,

or

loss

of

compression

due

to

leakage

around

the

piston

rings.

Very

low.

Manifold,

carburetor,

or

cylinder

head

gasket

leak.

Needle

fluctuates

steadily

as

speed

increases.

A

partial

or

complete

loss

of

power

in

one

or

more

cylinders

caused

by

a

leaking

valve,

cyl

inder

head

or

intake

manifold

gasket

leak,

a

defect

in

the

ignition

system,

or

a

weak

valve

spring.

Gradual

drop

in

reading

at

engine

idle.

Excessive

back

pressure

in

the

exhaust

system.

Intermittent

fluctuation.

An

occasional

loss

of

power

possibly

caused

by

a

defect

in

the

ignition

system

or

a

sticking

valve.

Slow

fluctuation

or

drifting

of

the

needle.

Improper

idle

mixture

adjustment,

carburetor

or

intake

manifold

gasket

leak,

or

possibly

late

valve

timing.

the

condition

of

the

valves,

cylinder

compression,

and

leakage

of

the

man

ifold,

carburetor,

or

cylinder

head

gaskets.

Because

abnormal

gauge

readings

may

indicate

that

more

than

one

of

the

above

factors

is

at

fault,

exercise

caution

in

analyzing

an

abnormal

reading.

For

example,

if

the

vacuum

is

low,

the

correction

of

one

item

may

increase

the

vacuum

enough

to

indi

cate

that

the

trouble

has

been

cor

rected.

It

is

important,

therefore,

that

each

cause

of

an

abnormal

read

ing

be

investigated

and

further

tests

conducted

where

necessary

in

order

to

arrive

at

the

correct

diagnosis

of

the

trouble.

Table

2

lists

various

types

of

read

ings

and

their

possible

causes.

Allowance

should

be

made

for

the

effect

of

altitude

on

the

gauge

read

ing.

The

engine

vacuum

will

decrease

with

an

increase

in

altitude.

ENGINE

REMOVAL

AND

INSTALLATION

The

procedures

given

are

for

the

engine

without

the

transmission

attached.

If

the

engine

and

transmis

sion

are

removed

as

an

assembly,

in

stall

standard

eye

bolts

with

Vi-IA

threads

in

the

bosses

at

the

top

rear

of

the

exhaust

manifolds.

Then

at

tach

the

engine

lifting

bracket

and

sling

to

the

eye

bolts.

The

engine

in

stallation

is

shown

in

Fig.

23.

REMOVAL

1.

Drain

the

cooling

system

and

the

crankcase.

Remove

the

hood

and

the

air

cleaner.

2.

Disconnect

the

radiator

upper

hose

at

the

radiator

supply

tank

and

the

radiator

lower

hose

at

the

water

pump.

3.

Disconnect

the

transmission

oil

cooler

lines

at

the

radiator.

Remove

the

radiator

and

support

as

an

assem

bly.

4.

Disconnect

the

battery

ground

cable

at

the

generator

mounting

bracket. Remove

the

oil

level

dipstick

and

the

ignition

coil.

5.

Disconnect

the

oil

pressure

sending

unit

wire

at

the

sending

unit

and

the

flexible

fuel

line

at

the

fuel

tank

line.

6.

Remove

the

wire

loom

from

the

clips

on

the

left

valve

rocker

arm

cover

and

position

the

wires

out

of

the

way.

7.

Disconnect

the

three

windshield

washer

lines

at

the

washer

pump

and

position

them

out

of

the

way.

8.

Disconnect

the

accelerator

rod

at

the

carburetor.

Remove

the

accel

erator

retracting

spring.

Remove

the

accelerator

cross

shaft

bracket

from

the

intake

manifold

and

position

it

out

of

the

way.

9.

Disconnect

the

power

steering

pump

bracket

from

the

water

pump,

then

wire

the

power

steering

pump

to

the

hood

left

hinge

in

a

position

that

will

prevent

the

oil

from

draining

out.

10.

Disconnect

the

power

brake

line

at

the

intake

manifold

and

at

the

flexible

line.

Release

the

line

from

the

1-18

GROUP

1-

ENGINE

AND

EXHAUST

SYSTEM

FIG.

23

Engine

Installation

brackets

on

the

left

valve

rocker

arm

cover

and

remove

the

line.

On

a

car

with

an

air

conditioner,

disconnect

the

magnetic

clutch

wire.

Isolate

the

compressor.

11.

Disconnect

the

heater

hose

at

the

water

pump

and

at

the

intake

manifold.

12.

Disconnect

the

generator

wires

at

the

generator.

13.

Disconnect

the

water

tem

perature

sending

unit

wire

at

the

sending

unit.

14.

Remove

the

engine

ground

strap

and

the

starter

cable

retaining

bracket

from

the

generator

mounting

bracket.

15.

Raise

the

front

of

the

car.

16.

Remove

the

starter

and

dust

seal

and

the

transmission

fluid

filler

tube

bracket.

17.

Disconnect

the

muffler

inlet

pipes

from

the

exhaust

manifolds,

and

the

engine

right

and

left

support

insulators

at

the

engine.

18.

Remove

the

converter

hous

ing

lower

access

cover

and

the

cover

assembly.

Remove

the

flywheel

to

converter

nuts.

Secure

the

con

verter

assembly

in

the

housing.

Re

move

the

converter

housing

to

en

gine

lower

bolts,

and

remove

the

oil

A1479-A

cooler

lines

retaining

clamp

from

the

engine

block.

19.

Lower

the

car,

then

support

the

transmission.

Remove

the

con

verter

housing

upper

retaining

bolts.

20.

Install

the

engine

left

lifting

bracket

on

the

front

of

the

left

cyl

inder

head

where

the

coil

mounts.

Install

the

engine

right

lifting

brack

et

at

the

rear

of

the

right

cylinder

head.

Attach

the

engine

lifting

sling

(Fig.

24).

21.

Raise

the

engine

slightly

and

carefully

pull

it

from

the

transmis

sion.

22.

Lift

the

engine out

of

the

en

gine

compartment

and

install

it

on

a

work

stand

(Fig.

25).

INSTALLATION

1.

Position

the

exhaust

gas

control

valve,

with

a

new

gasket

on

each

side,

on

the

right

exhaust

manifold

studs.

Temporarily

tie

the

valve

to

the

manifold.

Place

a

new

gasket

over

the

studs

of

the

left

exhaust

manifold.

2.

Attach

the

engine

lifting

brack

ets

and

sling

(Fig.

24).

Remove

the

engine

from

the

work

stand.

3.

Lower

the

engine

carefully

into

the

engine

compartment.

Make

sure

the

exhaust

manifolds

are

properly

A1251-B

FIG.

24

Engine

Lifting

Brackets

and

Sling

aligned

with

the

muffler

inlet

pipes

and

the

dowels

in

the

block

engage

the

holes

in

the

converter

housing.

Start

the

converter

pilot

into

the

crankshaft.

4.

Install

the

converter

housing

upper

bolts.

Torque

the

bolts

to

specifications.

5.

Start

the

engine

right

and

left

support

insulator

to

engine

bolts.

Disconnect

the

engine

lifting

sling

and

remove

the

lifting

brackets.

6.

Raise

the

front

of

the

car.

In

stall

the

converter

housing

lower

re

taining

bolts.

Torque

the

bolts

to

specifications.

7.

Remove

the

retainer

securing

the

converter

in

the

housing. Install

the

flywheel

to

converter

lockwashers

and

nuts.

Torque

the

nuts

to

speci

fications.

Install

the

converter

lower

access

plate

and

the

housing

cover

assembly.

Install

the

oil

cooler

lines

retaining

clamp.

8.

Torque

the

engine

front

support

insulator

bolts

to

45-50

ft-lbs

torque.

9.

Remove

the

retainer

securing

the

exhaust

gas

control

valve.

Con

nect

both

exhaust

manifolds

to

the

muffler

inlet

pipes.

Torque

the

nuts

to

specifications.

10.

Position

the

dust

seal

and

in-

A1252-A

FIG.

25-Engine

Work

Stand

PART

1-1

-ENGINE

1-19

stall

the

starter

and

the

transmission

fluid

filler

tube

bracket.

11.

Remove

the

support

from

the

transmission

and

lower

the

car.

12.

Connect

the

generator

wires.

13.

Connect

the

water

tempera

ture

sending

unit

wire.

Connect

the

heater

hose

at

the

intake

manifold.

14.

Connect

the

engine

ground

strap

and

install

the

starter

cable

re

taining

clamp.

15.

Connect

the

flexible

fuel

line,

the

oil

pressure

sending

unit

wire,

and

the

windshield

wiper

vacuum

line.

16.

Install

the

ignition

coil

and

connect

the

coil

primary

and

high

tension

wires.

17.

Install

the

oil

level

dipstick.

18.

Position

the

wire

loom

in

the

retaining

clips

on

the

left

valve

rocker

arm

cover.

19.

Connect

the

windshield

wash

er

pump

lines.

20.

Install

the

accelerator

cross

shaft

bracket

and

the

accelerator

re

tracting

spring.

Connect

the

accelera

tor

rod.

21.

Connect

the

power

steering

pump

bracket

to

the

water

pump.

22.

Connect

the

power

brake

line

to

the

intake

manifold

and

to

the

flex

ible

line.

Install

the

line

in

the

retain

ing

clips

on

the

left

valve

rocker

arm

cover.

On

a

car

with an

air

conditioner,

connect

the

magnetic

clutch

wire

and

the

compressor

lines.

23.

Install

the

radiator

and

sup

port

as

an

assembly.

Connect

the

radiator

upper

and

lower

hoses.

Con

nect

the

transmission

oil

cooler

lines.

24.

Fill

and

bleed

the

cooling

sys

tem.

Connect

the

heater

hose

at

the

water

pump.

25.

Fill

the

crankcase

with

the

proper

grade and

quantity

of

engine

oil.

26.

Operate

the

engine

at

fast

idle

and

check

all

gaskets

and

hose

con

nections

for

leaks.

27.

Adjust

the

transmission

con

trol

linkage.

Install

the

air

cleaner.

28.

Install

and

adjust

the

hood.

IN-CHASSIS

REPAIR

OPERATIONS

ENGINE

SUPPORTS

The

front

supports

are

located

on

each

side

of

the

crankcase

and

the

rear

support

is

located

at

the

trans

mission

extension

housing.

ENGINE

FRONT

SUPPORT

The

engine

front

support

is

shown

in

Fig.

26.

The

procedures

given

ap

ply

to

either

a

right

or

left

installa

tion.

Removal

1.

Remove

the

insulator

assembly

to

engine

retaining

bolts,

and

insula

tor

to

underbody

retaining

nut.

If

only

one

support

is

being

re

moved,

loosen

the

other

support.

2.

Raise

the

engine

about

1

inch

with

a

jack

and

a

block

of

wood

SUPPORT

BRACKET

INSULATOR

ASSEMBLY

A1480-A

FIG.

26

Engine

Front

Support

placed

under

the

oil

pan,

then

re

move

the

insulator

assembly.

Installation

1.

Position

the

insulator

assembly.

Install,

but

do

not

tighten,

the

insula

tor

to

engine

lockwashers

and

bolts.

If

both

supports

have

been

removed,

install

the

bolts

on

the

opposite

side

before

proceeding

with

step

2.

2.

Lower

the

engine,

then

install

the

underbody

to

insulator

nut.

Torque

the

nut

to

45-50

ft-lbs.

Torque

the

insulator

to

engine

bolts

to

45-50

ft-lbs.

ENGINE

REAR

SUPPORT

The

engine

rear

support

is

shown

in

Fig.

27.

Removal

1.

Remove

the

support

retainer

bolts

and

washers

and

remove

the

re

tainer.

2.

Raise

the

extension

housing

slightly

to

relieve

the

pressure

on

the

support

assembly.

Remove

the

sup

port

assembly.

Installation.

Raise

the

extension

housing

enough

to

position

the

sup

port

assembly

and

retainer.

Install

the

support

retainer

to

extension

housing

washers

and

bolts.

Torque

the

support

retainer

bolts

to

45-50

ft-

lbs.

VALVE

ROCKER

ARM

SHAFT

ASSEMBLY

REMOVAL

1.

Operate

the

engine

until

normal

operating

temperature

has

been

reached.

Remove

the

air

cleaner.

2.

Disconnect

the

spark

plug

wires

at

the

spark

plugs.

Remove

the

wires

from

the

bracket

on

the

valve

rocker

arm

cover(s)

and position

the

wires

out

of

the

way.

To

remove

the

right

valve

rocker

arm

cover,

remove

the

carburetor

choke

heat

tube.

A1481-A

FIG.

27

Engine

Rear

Support

1-20

GROUP

1-

ENGINE

AND

EXHAUST

SYSTEM

To

remove

the

left

valve

rocker

arm

cover,

disconnect

the

brake

booster

line

and

position

the

line

out

of

the

way.

3.

Remove

the

valve

rocker

arm

cover(s).

If

the

left

cover

is

removed,

posi

tion

the

wire

loom

out

of

the

way.

4.

Crank

the

engine

until

the

No.

1

piston

is

at

TDC,

at

the

end

of

the

compression

stroke.

Rotate

the

crank

shaft

damper

an

additional

45

(iden

tified

by

"XX"

on

the

damper).

5.

Starting

at

the

No.

4

cylinder,

loosen

the

right

valve

rocker

arm

shaft

support

bolts

in

sequence,

two

turns

at

a

time.

After

the

bolts

are

all

loosened,

remove

the

valve

rocker

arm

shaft

assembly

and

the

oil

baffle

plate.

Starting

at

the

No.

5

cyl

inder,

follow

the

same

procedure

on

the

left

valve

rocker

arm shaft

sup

port

bolts.

This

procedure

must

be

followed

to

avoid

damage

to

the

valve

mechanism.

INSTALLATION

1.

Apply

Lubriplate

to

the

pad

end

of

the

rocker

arms,

to

the

tip

of

the

valve

stems,

and

to

both

ends

of

the

push

rods.

2.

Crank

the

engine

until

the

No.

1

piston

is

on

TDC

at

the

end

of

the

compression

stroke.

3.

Rotate

the

crankshaft

damper

an

additional

45

(identified

by

"XX"

on

the

damper).

4.

Position

the

baffle

plate

and

the

valve

rocker

arm

shaft

assembly

on

the

cylinder

heads

with

the

valve

push

rods

in

place

and

the

rocker

shaft

support

bolts

finger-tight.

Be

sure

the

shaft

is

turned

so

that

the

oil

holes

are

to

the

bottom.

5.

Starting

at

the

No.

4

cylinder,

tighten

the

bolts

in

sequence,

two

turns

at

a

time,

until

the

supports

fully

contact

the

cylinder

head.

Torque

the

bolts

in

sequence

to

40-45

ft-lbs.

6.

Starting

at

the

No.

5

cylinder,

follow

the

same

procedure

for

the

left

valve

rocker

arm

shaft

support

bolts.

The

additional

time

consumed

in

this

procedure

will

permit

the

hydraulic

lifters

to

leak

down.

This

will

minimize

the

possibility

of

bend

ing

the

push

rods,

valves,

or

the

rocker

arms.

Be

sure

that

the

hy

draulic

lifters

have

leak

down

to

their

normal

operating

position

be

fore

cranking

the

engine.

This

is

nec

essary

in

order

to

avoid

possible

damage

to

the

valves,

push

rods,

or

valve

rocker

arms.

7.

Clean

the

valve

rocker

arm

cover(s).

Apply

oil

resistant

sealer

to

one

side

of

new

cover

gasket(s).

Lay

the

cemented

side

of

the

gasket(s)

in

place

in

the

cover(s).

8.

Position

the

cover(s)

on

the

cylinder

head(s).

Make

sure

the

gas

ket

seats

evenly

all

around

the

head.

Install

the

bolts

(and

the

wire

loom

clamps

on

the

left

cover).

The

cover

is

tightened

in

two

steps.

First,

torque

the

bolts

to

4-7

ft-lbs.

Two

minutes

later,

torque

the

bolts

to

the

same

specifications.

If

the

left

cover

was

removed,

con

nect

the

brake

booster

vacuum

line.

If

the

right

cover

was

removed,

install

the

carburetor

choke

heat

tube.

9.

Connect

the

spark

plug

wires.

Install

the

air

cleaner.

DISASSEMBLY

1.

Remove

the

cotter

pins

from

each

end

of

the

valve

rocker

arm

shaft.

Remove

the

flat

washer

and

spring

washer

from

each

end

of

the

shaft.

2.

Slide

the

rocker

arms,

springs,

and

the

supports

off

the

shaft.

Be

sure

to

identify

all

the

parts.

3.

If

it

is

necessary

to

remove

the

plugs

from

each

end

of

the

shaft,

drill

or

pierce

one

plug.

Insert

a

steel

rod

through

the

plug

and

knock

out

the

plug

on

the

opposite

end.

Work

ing

from

the

open

end,

knock

out

the

remaining

plug.

ASSEMBLY

1.

Oil

all

the

moving

parts

with

engine

oil.

Apply

Lubriplate

to

the

pad

of

the

valve

rocker

arms.

2.

If

the

plugs

were removed

from

the

ends

of

the

shaft,

use

a

blunt

tool

or

large

diameter

pin

punch

and

in

stall

a

plug,

cup

side

out,

in

each

end

of

the

rocker

arm

shaft.

3.

Install

the

rocker

arms,

sup

ports,

and

springs

in

the

order

shown

BOLT

ROCKER

ARM

SUPPORT

COTTER

PIN

SPRING

WASHER

^B

OIL

BAFFLE

SUPPORT

BOLT

HOLES

PLUG

ROCKER

SHAFT

A1261-B

FIG.

28

Valve

Rocker

Arm

Shaft

Assembly

PART

1-1

-ENGINE

1-21

in

Fig.

28.

Be

sure

the

oil

holes

in

the

shaft

are

facing

downward.

Com

plete

the

assembly

by

installing

the

remaining

flat

washer

and

the

spring

washer

and

install

the

cotter

pin.

CLEANING

AND

INSPECTION

Clean

all

the

parts

thoroughly.

Make

sure

that

all

oil

passages

are

open.

Check

the

clearance

between

each

rocker

arm

and

the

shaft

by

checking

the

ID

of

the

rocker

arm

bore

and

the

OD

of

the

shaft.

If

the

clear

ance

between

any

rocker

arm

and

the

shaft

exceeds

the

wear

limit,

replace

the

shaft

and/or

the

rocker

arm.

In

spect

the

shaft

and

the

rocker

arm

bore

for

nicks,

scratches,

scores,

or

scuffs.

Dress

up

minor

surface

defects

with

a

hone.

Inspect

the

pad

at

the

valve

end

of

the

rocker

arms

for

a

grooved

radius.

If

the

pad

is

grooved,

replace

the

rocker arm.

Do

not

attempt

to

true

this

surface

by

grinding.

Check

for

broken

locating

springs.

INTAKE

MANIFOLD

REMOVAL

1.

Operate

the

engine

until

normal

operating

temperature

has

been

reached.

Drain

the

cooling

system.

Remove

the

air

cleaner.

2.

Disconnect

the

accelerator

rod

at

the

carburetor.

Remove

the

ac

celerator

cross

shaft

bracket

from

the

intake

manifold

and

position

it

out

of

the

way.

3.

Remove

the

carburetor

fuel

in

let

line

and

the

automatic

choke

heat

tube.

Disconnect

the

brake

vacuum

booster

line

at

the

intake

manifold

and

at

the

flexible

hose.

Remove

the

vacuum

line.

4.

Disconnect

the

coil

high

ten

sion

lead,

and

the

coil wires

at

the

coil.

Disconnect

the

oil

pressure

send

ing

unit wire

at

the

sending

unit.

Re

move

the

wire

loom

from

the

retain

ing

clips

on

the

left

valve

rocker

arm

cover

and

position

it

out

of

the

way.

5.

Disconnect

the

spark

plug

wires

at

the

spark

plugs

and

remove

the

wires

from

the

ignition

harness

brackets

on

the

valve

rocker

arm

covers.

6.

Remove

the

distributor

cap

and

spark

plug

wire

assembly.

Discon

nect

the

distributor

vacuum

line

at

the

distributor.

7.

Remove

the

distributor

hold-

down

bolt

and

clamp.

Remove

the

distributor.

8.

Disconnect

the

radiator

upper

hose

at

the

radiator

supply

tank,

then

remove

the

supply

tank.

Remove

the

heater

hose

at

the

intake

mani

fold,

and

the

water

temperature

send

ing

unit

wire

at

the

sending

unit.

9.

Slide

the

clamp

on

the

water

pump

by-pass

hose

toward

the

water

pump.

10.

Clean

the

outside

of

the

valve

rocker

arm

covers

and

remove

the

covers.

11.

Refer

to

"Valve

Rocker

Arm

Shaft

Assembly

Removal"

(page

1-

19)

and

remove

the

valve

rocker

arm

-T53L-300-A

Standard

Eye-Bolt

THREAD

A1253-B

FIG.

29-lntake

Manifold

Removal

or

Installation

THERMOSTAT

WATER

TEMPERATURE

SENDING

UNIT

GASKET

'

shaft

assembly

by

following

steps

4

and

5.

12.

Remove

the

valve

push

rods

in

sequence.

13.

Remove

the

intake

manifold

retaining

bolts.

14.

Install

standard

eye

bolts

with

%e-18

threads

in

the

left

front

and

right

rear

rocker

arm

cover

screw

holes.

Attach

the

engine

lifting

sling

(Fig.

29).

15.

Raise

the

manifold

and

care

fully

remove

the

intake

manifold

and

radiator

supply

tank

as

an

assembly.

Remove

the

intake

manifold

gaskets

and

seals.

16.

If

the

manifold

istobe

dis

assembled,

remove

the

radiator

sup

ply

tank,

thermostat,

and

gasket.

Remove

the

carburetor,

spacer,

and

gasket.

Remove

the

crankcase

venti

lation

regulator

valve

and

exhaust

tube.

INSTALLATION

The

intake

manifold

assembly

is

shown

in

Fig.

30.

1.

If

the

intake

manifold

was

dis

assembled,

install

the

carburetor,

spacer,

and

gasket.

Coat

the

thermo

stat

gasket

with

water

resistant

sealer

and

place

it

in

position

on

the

intake

CRANKCASE

BREATHER

CAP

OIL

FILLER

TUBE

MANIFOLD-TO-BLOCK

FRONT

SEAL

VACUUM

PUMP

EXHAUST

TUBE

CONNECTION

EXHAUST

TUBE

MANIFOLD-TO-HEAD

GASKET

REGULATOR

VALVE

VACUUM

PUMP

CONNECTION

INTAKE

MANIFOLD

CRANKCASE

j

0.

VENTILATION

OUTLET

MANIFOLD-TO-BLOCK

REAR

SEAL

FIG.

30

Intake

Manifold

Assembly

A1294-B

1-22

GROUP

1-

ENGINE

AND

EXHAUST

SYSTEM

manifold.

Install

the

thermostat

and

radiator

supply

tank.

2.

Clean

the

mating

surfaces

of

the

intake

manifold,

cylinder

heads,

and

cylinder

block.

3.

Coat

the

intake

manifold

and

cylinder

block

seal

surfaces

with

oil

resistant

sealer.

4.

Position

new

seals

on

the

cyl

inder

block

and

new

gaskets

on

the

cylinder

heads

with

the

gasket

rest

ing

on

the

cylinder

head

gasket

tabs.

Be

sure

the

holes

in

the

gaskets

are

aligned

with

the

holes

in

the

cylinder

heads.

The

correct

installation

of

the

gaskets

and

seals

is

shown

in

Fig.

31.

5.

Install

the

eye

bolts

in

the

in

take

manifold

and

attach

the

engine

lifting

sling

and

carefully

lower

the

intake

manifold

on

the

engine

(Fig.

29).

6.

Position

the

intake

manifold

by

inserting

the

distributor

in

place.

After

the

intake

manifold

is

in

place,

run

a

finger

around

the

seal

area

to

make

sure

the

seals

are

in

place.

If

the

seals

are

not

in

place,

remove

the

intake

manifold

and

reposition

the

seals.

7.

Start

the

water

pump

by-pass

hose

on

the

intake

manifold.

8.

Be

sure

the

holes

in

the

mani

fold

gaskets

and

manifold

are

in

alignment.

Install

the

manifold

re

taining

bolts

and

torque

them

to

32-35

ft-lbs,

working

from

the

center

to

the

ends.

9.

Remove

the

distributor

and

the

engine

lifting

sling

and

eye

bolts.

10.

Slide

the

water

pump

by-pass

hose

clamp

into

position.

Connect

the

water

temperature

sending

unit,

the

heater

hose,

and

the

radiator

upper

hose.

11.

Install

the

crankcase

ventila

tion

valve

and exhaust

tube.

295-A

FIG.

31

Intake

Manifold

Gaskets

and

Seals

Installation

12.

Apply

Lubriplate

to

both

ends

of

the

push

rods.

Install

the

push

rods

in

their

original

bores,

positioning

the

lower

ends

of

the

rods

in

the

lifter

cups.

Refer

to

"Valve

Rocker

Arm

Shaft

Assembly

Installation"

(Page

1-20)

and

install

the

valve

rocker

arm

shaft

assembly

by

following

steps

1

thru

6.

13.

Rotate

the

crankshaft

damper

until

the

No.

1

piston

is

on

TDC

at

the

end

of

the

compression

stroke.

Position

the

distributor

in

the

block

with

the

rotor

at

the

No.

1

firing

posi

tion

and

the

points

open.

Install

the

hold

down

clamp.

14.

Clean

the

valve

rocker

arm

covers.

Apply

oil

resistant

sealer

to

one side

of

new

cover

gaskets.

Lay

the

cemented

side

of

the

gaskets

in

place

in

the

covers.

Install

the

valve

rocker

arm

covers.

15.

Connect

the

brake

vacuum

booster

line

and

connect

the

flexible

hose.

16.

Install

the

carburetor

fuel

in

let

line

and

connect

the

distributor

vacuum

line.

Install

the

automatic

choke

heat

tube.

17.

Install

the

distributor

cap.

Connect

the

spark

plug

wires.

Install

the

wire

loom

in

the

retaining

clips

on

the

left

valve

rocker

arm

cover.

18.

Connect

the

oil

pressure

send

ing

unit

wire,

the

coil

high

tension

lead,

and

the

coil

primary

wire.

19.

Install

the

accelerator

cross

shaft

bracket.

Connect

the

acceler

ator

rod.

20.

Fill

and

bleed

the

cooling

system.

21.

Start

the

engine

and

check

and

adjust

the

ignition

timing.

Op

erate

the

engine

until

engine

tem

peratures

have

stabilized

and

adjust

the

engine

idle

speed

and

idle

fuel

mixture.

22.

Adjust

the

transmission

con

trol

linkage.

Install

the

air

cleaner.

CLEANING

AND

INSPECTION

Clean

the

manifold

in

a

suitable

solvent,

then

dry

it

with

compressed

air.

Inspect

the

manifold

for

cracks,

leaks,

or

other

defects

that

would

make

it

unfit

for

further

service.

Re

place

all

studs

that

are

stripped

or

otherwise

damaged.

Remove

all

fil

ings

and

foreign

matter

that

may

have

entered

the

manifold

asaresult

of

repairs.

Check

the

baffle

plate

on

the

under

side

of

the

manifold

for

looseness

and

be

sure

the

maze

screen

is

in

place.

Clean

off

any

varnish

accumulation.

EXHAUST

MANIFOLD

REMOVAL

1.

Remove

the

air

cleaner.

Discon

nect

the

exhaust

manifold

at

the

muf

fler

inlet

pipe.

2.

Remove

the

automatic

choke

heat

tube

from

the

right

exhaust

manifold.

3.

Disconnect

the

power

steering

pump

bracket

from

the

cylinder

block

and

move

it

out

of

the

way.

Position

the

pump

so

that

the

oil

will

not

drain

out.

Disconnect

the

power

steering

hose

bracket

and

position

the

hoses

out

of

the

way.

4.

Remove

the

dipstick

and

tube

assembly.

5.

Remove

the

retaining

bolts

and

tab

washers

and

remove

the

exhaust

manifolds

(and

the

exhaust

gas

con

trol

valve

with

the

right

exhaust

mani

fold).

INSTALLATION

1.

Clean

the

mating

surfaces

of

the

exhaust

manifold

and

cylinder

head.

Scrape

the

gasket

material

from

the

mounting

flange

of

the

ex

haust

manifold

and

muffler

inlet

pipe.

2.

Apply

graphite

grease

to

the

mating

surface

of

the

exhaust

mani

fold.

3.

Slide

the

exhaust

gas

control

valve

over

the

studs

of

the

right

ex

haust

manifold

with

a

new

gasket

on

each

side

of

the

control

valve.

4.

Position

the

exhaust

manifold

on

the

cylinder

head

and

install

the

retaining

bolts

and

tab

washers.

Torque

the

retaining

bolts

to

23-28

ft-lbs,

working

from

the

center

to

the

ends.

Lock

the

bolts

by

bending

one

tab

of

the

washer

over

a

flat

on

the

bolt.

5.

Install

the

dipstick

and

tube

assembly.

6.

Position

the

power

steering

pump

bracket

on

the

cylinder

block

and

install

the

retaining

bolts.

Adjust

the

belt

tension.

Position

the

hoses

and

install

the

power

steering

hose

bracket.

7.

Install

the

automatic

choke

heat

tube

on

the

right

exhaust

manifold.

PART

1-1

-ENGINE

1-23

CRANKCASE

VENTILATION

OUTLET

REGULATOR

VALVE

EXHAUST

TUBE

A1482-A

FIG.

32

Regulator

Valve

and

Exhaust

Tube

8.

Connect

the

exhaust

manifold

at

the

muffler

inlet

pipe.

Install

the

air

cleaner.

CLEANING

AND

INSPECTION

Inspect

the

manifolds

for

cracks,

leaks,

or

other

defects

that

would

make

them

unfit

for

further

service.

On

the

right exhaust

manifold,

clean

out

the

automatic

choke

air

heat

chamber

(Fig.

6).

Make

sure

the

air

inlet

and

outlet

holes

are

com

pletely

open

and

the

cover

does

not

leak.

Blow

out

the

automatic

choke

air

heat

tube

with

compresed

air.

REGULATOR

VALVEPOSITIVE

CRANKCASE

VENTILATION

SYSTEM

REMOVAL

1.

Disconnect

the

exhaust

tube

clamp

from

the

intake

manifold.

Dis

connect

the

exhaust

tube

from

the

crankcase

ventilation

outlet

and

from

the

intake

manifold

(Fig.

32).

2.

Remove

the

regulator

valve

as

sembly

from

the

exhaust

tube.

INSTALLATION

1.

Install

the

regulator

valve

on

the

exhaust

tube.

2.

Connect

the

rubber

connection

to

the

regulator

valve.

3.

Install

the

assembly

on

the

en

gine.

Connect

the

clamp

to

the

intake

manifold.

REGULATOR

VALVE

DISASSEMBLY

Place

the

hex

on

the

regulator

valve

body

in

a

vise.

Remove

the

con

nector,

valve,

and

spring

(Fig.

33).

CLEANING

Clean

the

valve

parts

and

exhaust

tube

in

clean

carburetor

solvent

and

dry

them

with

compressed

air.

Clean

the

rubber

hose

connections

with

a

low

volatility

petroleum

base

solvent

and

dry

with

compressed

air.

REGULATOR

VALVE

ASSEMBLY

Position

the

spring

and

valve

in

side

the

regulator

valve

body.

Install

the

regulator

valve

connector.

CYLINDER

HEADS

AND

VALVES

CYLINDER

HEAD

REMOVAL

1.

Remove

the

intake

manifold,

carburetor,

and

radiator

supply

tank

as

an

assembly

following

the

proce

dure

under

"Intake

Manifold

Re

moval"

(page

1-21).

2.

Disconnect

the

exhaust

mani

folds

at

the

muffler

inlet

pipes.

If

the

left

cylinder

head

istobe

re

moved,

remove

the

ignition

coil.

3.

Remove

the

cylinder

head

bolts.

Install

the

cylinder

head

holding

fix

tures

(Fig.

34).

4.

Lift

the

cylinder

heads

off

the

block.

Do

not

pry

between

the

head

and

the

block.

Remove

and

discard

the

cylinder

head

gasket.

CYLINDER

HEAD

INSTALLATION

1.

Clean

the

cylinder

head

and

cyl

inder

block

gasket

surfaces.

2.

If

the

cylinder

head

was

re

moved

for

a

cylinder

head

gasket

re

placement,

check

the

flatness

of

the

cylinder

head

and

block

gasket

sur

faces.

3.

Apply

cylinder

head

gasket

sealer

to

both

sides

ofanew

gasket.

Guided

by

the

word

"FRONT"

on

the

gasket,

install

the

gasket

over

the

cylinder

head

dowels.

4.

Place

the

cylinder

head

on

the

engine,

then

remove

the

holding

fix

ture.

SPRING

CONNECTOR

-

BODY

VALVE

A1469-A

FIG.

33

-Regulator

Valve

Assembly

Tool

T58P-6085-A

FIG.

34

Cylinder

Head

Holding

Fixtures

1-24

GROUP

1-

ENGINE

AND

EXHAUST

SYSTEM

l*Pf

USE

Tool-S-8683

A1292-A

FIG.

35

Cylinder

Head

Bolt

Tightening

Sequence

5.

Install

the

cylinder

head

bolts.

The

cylinder

head

bolts

are

tightened

in

three

progressive

steps.

Torque

all

the

bolts

in

sequence

(Fig.

35)

to

70

ft-lbs,

then

torque

them

to

80

ft-lbs.

Finally,

torque

them

to

90

ft-lbs.

After

the

cylinder

head

bolts

have

been

torqued

to

specifications,

the

bolts

should

not

be

disturbed.

6.

Connect

the

exhaust

manifolds

to

the

muffler

inlet

pipes.

7.

Install

the

intake

manifold

and

related parts

following

the

procedure

under

"Intake

Manifold

Installation"

(page

1-21).

CYLINDER

HEAD

DISASSEMBLY

1.

Install

the

cylinder

head

hold

ing

fixtures

(Fig.

34).

Remove

the

de

posits

from

the

cylinder

head

com

bustion

chambers

and

valve

heads

with

a

scraper

and

a

wire

brush

be

fore

removing

the

valves.

Be

careful

not

to

scratch

the

cylinder

head

gas

ket

surface.

2.

Compress

the

valve

spring

(Fig.

36).

Remove

the

valve

retainer

locks

and

release

the

spring.

Tool

6513-EE

A1262-A

3.

Remove

the

sleeve,

spring

re

tainer,

spring,

damper

spring,

stem

seal,

and

valve.

Discard

the

valve

stem

seals.

Identify

all

valve

parts.

CYLINDER

HEAD

CLEANING

After

the

valves

are

removed,

clean

the

valve

guide

bores

with

a

valve

guide

cleaning

tool.

Use

cleaning

solvent

to

remove

dirt,

grease,

and

other

deposits.

CYLINDER

HEAD

INSPECTION

Check

the

cylinder

head

for

cracks,

and

the

gasket

surface

for

burrs

and

nicks.

Replace

the

head

if

it

is

cracked.

Do

not

plane

or

grind

more

than

0.010

inch

from

the

cylinder

head

gasket

surface.

Remove

all

burrs

or

scratches

with

an

oil

stone.

Cylinder

Head

Flatness.

Check

the

flatness

of

the

cylinder

head

gasket

surface

(Fig.

37).

Seat

Width

Scale

CHECK

ACROSS

CENTER

A1207-A

FIG.

37

Cylinder

Head

Flatness

Valve

Seat

Runout.

Check

the

valve

seat

runout

with

an

accurate

gauge

(Fig.

38).

Follow

the

instructions

of

the

gauge

manufacturer.

If

the

run

out

exceeds

the

wear

limit,

reface

the

valve

and

valve

seat.

Valve

Seat

Width.

Measure

the

valve

seat

width

(Fig.

39).

Reaming

Valve

Guides.

If

it

be-

Runout

Gauge

FIG.

36

Compressing

Valve

Spring

A1209-A

FIG.

39-Valve

Seat Width

comes

necessary

to

ream

a

valve

guide

(Fig.

40)

to

install

a

valve

with

an

oversize

stem,

a

reaming

kit

is

available

which

contains

the

fol

lowing

reamer

and

pilot

combina

tions:

a

0.003-inch

OS

reamer

with

a

standard

diameter

pilot,

a

0.015-

inch

OS

reamer

with

a

0.003-inch

OS

pilot,

and

a

0.030-inch

reamer

with

a

0.015-inch

OS

pilot.

When

going

from

a

standard

size

valve

to

an

oversize

valve,

always

use

the

reamers

in

sequence.

Always

reface

the

valve

seat

after

the

valve

guide

has

been

reamed.

Refacing

Valve

Seats.

Refacing

of

the

valve

seats

should

be

closely

co

ordinated

with

the

refacing

of

the

valve

face

so

that

the

finished

seat

will

match

the

valve

face

and

be

centered.

This

is

important

so

that

the

valve

and

seat

will

have

a

good

compres-

A1208-A

A1237-A

FIG.

38-Valve

Seat

Runout

FIG.

40

Reaming

Valve

Guides

PART

1-1

-ENGINE

1-25

TO

REMOVE

STOCK

FROM

BOTTOM

\

OF

SEAT,

,

USE

60

WHEEL

TO

REMOVE

STOCK

FROM

TOP

OF

SEAT.

USE

30

WHEEL

*a

VALVE

SEAT

WIDTH:

0.060-0.080

A1211-B

FIG.

41-lntake

Valve

Seat

Refacing

sion

tight

fit.

Be

sure

that

the

refacer

grinding

wheels

are

properly

dressed.

Grind

the

exhaust

valve

seats

to

a

true

45

angle

(Fig.

41).

Remove

only

enough

stock

to

clean

up

pits,

grooves,

or

to

correct

the

valve

seat

runout.

After

the

seat

has

been

re

faced,

measure

the

seat

width

(Fig.

39).

Narrow

the

seat,

if

necessary,

to

bring

it

within

limits.

If

the

valve

seat

width

exceeds

the

maximum

limit,

remove

enough

stock

from

the

top

edge

and

/or

bottom

edge

of

the

seat

to

reduce

the

width

to

specifications

(Fig.

41).

Use

a

60

angle

grinding

wheel

to

remove

stock

from

the

bottom

of

the

seat

(raise

the

seat)

and

use

a

30

angle

wheel

to

remove

stock

from

the

top

of

the

seat

(lower

the

seat).

The

finished

valve

seat

should

contact

the

approximate

center

of

the

valve

face.

It

is

good

practice

to

determine

where

the

valve

seat

con

tacts

the

face. To

do

this,

coat

the

seat

with

Prussian

blue,

then

set

the

valve

in

place.

Rotate

the

valve

with

light

pressure.

If

the

blue

is

trans

ferred

to

the

center

of

the

valve

face,

the

contact

is

satisfactory.

If

the

blue

is

transferred

to

the

top

edge

of

the

valve

face,

lower

the

valve

seat.

If

the

blue

is

transferred

to

the

bottom

edge

of

the

valve

face,

raise

the

valve

seat.

VALVES

Cleaning.

Remove

all

deposits

from

the

valve

with

a

fine

wire

brush

or

buffing

wheel.

INSPECTION

The

critical

inspection

points

and

tolerances

of

the

valves

are

illustrated

in

Fig.

42.

Inspect

the

valve

face

and

the

edge

of

the

valve

head

for

pits,

grooves,

scores,

or

other

defects.

Inspect

the

stem

for

a

bent

condition

and

the

end

of

the

stem

for

grooves

DO

NOT

REMOVE

MORE

THAN

0.010

INCH

Va"

MINIMUM

CHECK

FOR

BENT

STEM

DIAMETER

FOR

DIMENSIONS

REFER

TO

SPECIFICATIONS

A1010-A

FIG.

42

Critical

Valve

Tolerances

or

scores.

Check

the

valve

head

for

signs

of

burning,

erosion,

warpage,

and

cracking.

Defects,

such

as

minor

pits,

grooves,

etc.,

may

be

removed.

Discard

valves

that

are

severely

damaged.

Inspect

the

valve

springs,

valve

spring

retainers,

locks,

and

sleeves

for

defects.

Discard

any

visually

de

fective

parts.

Valve

Face

Runout.

Check

the

valve

face

runout

(Fig.

43).

It

should

not

exceed

the

wear

limit.

Model

TV-2

'

??

AlOll-A

FIG.

43-Valve

Face

Runout

Valve

Stem

Clearance.

Check

the

valve

stem

to

valve

guide

clearance

of

each

valve

in

its

respective

valve

guide

with

the

tool

shown

in

Fig.

44

or

its

equivalent.

Use

a

flat-end

in

dicator

point.

Valve

Spring

Pressure.

Check

the

spring

for

proper

pressure

(Fig.

45).

Do

not

remove

the

damper

spring

when

checking

the

pressure.

Weak

valve

springs

cause

poor

engine

per

formance;

therefore,

if

the

pressure

of

any

spring

exceeds

the

wear

limit,

replace

the

spring.

Valve

Spring

Squareness.

Check

each

spring

for

squareness,

using

a

All

99-

A

FI6.

44

Valve

Stem

Clearance

Valve

Spring

Teste

A1013-A

FIG.

45

Valve

Spring

Pressure

steel

square

and

a

surface

plate

(Fig.

46).

Stand

the

spring

and

square

on

end

on

the

surface

plate.

Slide

the

spring

up

to

the

square.

Revolve

the

spring

slowly

and

observe

the

space

between

the

top

coil

of

the

spring

and

the

square.

If

the

spring

is

out

of

square

more

than

1/16

inch,

replace

it.

NOT

MORE

THAN

V\b

A1014-A

FIG.

46-Valve

Spring

Squareness

1-26

GROUP

1-

ENGINE

AND

EXHAUST

SYSTEM

Valve

Push

Rods.

Check

the

ends

of

the

push

rods

for

nicks,

grooves,

roughness,

or

excessive

wear.

The

push

rods

can

be

visually

checked

for

straightness

while

they

are

installed

in

the

engine

by

rotating

them

with

the

valve

closed.

They

also

can

be

checked

with

a

dial

indicator

(Fig.

47).

If

the

runout

exceeds

the

maximum

limit

at

any

point,

discard

the

rod.

Do

not

attempt

to

straighten

push

rods.

Refacing

Valves.

The

valve

refac

ing

operation

should

be

closely

co

ordinated

with

the

valve

seat

refacing

operation

so

that

the

finished

angle

of

the

valve

face

will

match

the

valve

seat.

This

is

important

so

that

the

valve

and

seat

will

have

a

good

com

pression

tight

fit.

Be

sure

that

the

re

facer

grinding

wheels

are

properly

dressed.

Dial

Indicator

Holding

Fixture

PUSH

ROD

A1003-A

FIG.

47-Push

Rod

Runout

If

the

valve

face

runout

is

exces

sive

and/

or

to

remove

pits

and

grooves,

reface

the

valves

to

a

true

44

angle.

Remove

only

enough

stock

to

correct

the

runout or

to

clean

up

the

pits

and

grooves.

If

the

edge

of

the

valve

headisless

than

1/32

inch

after

grinding,

replace

the

valve

as

the

valve

will

run

too

hot

in

the

engine.

Remove

all

grooves

or

score

marks

from

the

end

of

the

valve

stem,

then

chamfer

as

necessary.

Do

not

remove

more

than

0.010

inch

from

the

stem.

After

refacing

the

valves,

it

is

good

practice

to

lightly

lap

in

the

valves

with

a

medium

grade

lapping

compound

to

match

the

seats.

Be

sure

to

remove

all

the

compound

from

the

valve

and

seat

after

the

lapping

operation.

Select

Fitting

Valves.

If

the

valve

stem

to

valve

guide

clearance

ex

ceeds

the

wear

limit,

ream

the

valve

guide

for

the

next

oversize

valve

stem.

Valves

with

oversize

stem

diameters

of

0.003,

0.015,

and

0.030

inch

are

available

for

service.

Always

reface

the

valve

seat

after

the

valve

guide

has

been

reamed.

CYLINDER

HEAD

ASSEMBLY

1.

Install

each

valve

(Fig.

48)

in

the

port

from

which

it

was

removed

or

to

which

it

was

fitted.

Install

a

new

stem

seal

on

the

valve.

2.

Install

the

valve

springs

over

the

valve,

and

then

install

the

spring

re

tainer

and

sleeve.

Make

sure

the

valve

damper

spring

is

installed

in

the

valve

spring

so

that

the

coil

end

of

the

damper

spring

is

135

counterclock

wise

from

the

coil

end of

the

valve

spring.

3.

Compress

the

spring

and

in

stall

the

retainer

locks

(Fig.

36).

SPRING

RETAINER

SLEEVE

VALVE

SPRING

INTAKE

VALVE

A1263-B

FIG.

48-Valve

Assembly

4.

Measure

the

assembled

height

of

the

valve

spring

from

the

surface

of

the

cylinder

head

spring

pad

to

the

underside

of

the

spring

retainer

with

dividers (Fig.

49).

Check

the

dividers

against

a

scale.

If

the

assem-

UNDERSIDE

OF

SPRING

RETAINER

bled

height

is

greater

than

l1-^

inches,

install

the

necessary

0.030-

inch

thick

spacer(s)

between

the

cyl

inder

head

spring

Dad

and

the

valve

spring

to

bring

the

assembled

height

to

the

recommended

height

of

12%4-

\lVie

inches.

Do

not

install

spacers

unless

necessary.

Use

of

spacers

in

excess

of

recommendations

will

result

in

overstressing

the

valve

springs

and

overloading

the

camshaft

lobes

which

could

lead

to

spring

breakage

and

worn

camshaft

lobes.

VALVE

STEM

SEAL

REPLACEMENT

1.

Remove

the

air

cleaner

and

the

valve

rocker

arm

cover.

Remove

the

applicable

spark

plug.

2.

Crank

the

engine

until

the

ap

plicable

piston

is

on

TDC

after

the

compression

stroke.

Be

sure

that

both

valves

are

closed.

Be

sure

that

the

piston

is

on

TDC

to

prevent

the

crankshaft

from

turning

when

the

air

is

appUed.

3.

Install

an

air

line

with

an

adapter

in

the

spark

plug

hole

and

turn

on

the

air

supply.

4.

Position

the

hydraulic

lifter

compressor

tool

on

the

applicable

rocker

arm

and

slowly

apply

pressure

to

bleed

down

the

hydraulic

lifter

until

the

plunger

is

completely

bot

tomed

(Fig.

50).

Remove

the

push

rod.

5.

Push

the

rocker

arm

to

one

side

and

secure

it

in

this

position

Tool-T58P-6565-A-l

SURFACE

OF

SPRING

PAD

A1267-A

FIG.

49

Valve

Spring

Assembled

Height

FIG.

50

Bleeding

Down

Hydraulic

Valve

Lifter

PART

1-1

-ENGINE

1-27

SECURE

ROCKER

ARM

Tool-K-D915

Air

Line

Adapter

A1451-A

FIG.

51

Compressing

Valve

Spring

(Fig.

51).

Using

the

valve

spring

com

pression

tool

shown

in

Fig.

51,

com

press

the

valve

spring.

Remove

the

valve

spring

retainer

locks,

the

sleeve,

spring

retainer,

and

the

valve

spring.

If

an

end

rocker

arm

is

to

be

worked

on,

it

will

be

necessary

to

remove

the

rocker

arm

from

the

shaft.

6.

Remove

the

valve

stem

seal

(Fig.

52).

7.

Install

a

new

valve

stem

seal.

Place

the

spring

in

position

over

the

valve.

Install

the

spring

retainer

and

sleeve.

Compress

the

valve

spring

and

install

the

valve

spring

retainer

locks.

Be

sure

the

damper

spring

is

in-

IA1452-A

FIG.

52

-Valve

Stem

Seal

Removal

stalled

in

the

valve

spring

so

that

the

coil

end

of

the

damper

spring

is

135

counterclockwise

from

the

coil

end

of

the

valve

spring.

8.

Apply

Lubriplate

to

both

ends

of

the

push

rod.

Install

the

push

rod

making

sure

the

lower

end

of

the

rod

is

positioned

in

the

lifter

push

rod

cup.

9.

Remove

the

wire

securing

the

valve

rocker

arm

and

slide

the

rocker

arm

into

position.

Turn

off

the

air

and

remove

the

air

line

and

adapter.

Install

the

spark

plug.

10.

Install

the

valve

rocker

arm

cover

and

connect

the

spark

plug

wires.

Install

the

air

cleaner.

CYLINDER

FRONT

COVER

AND

TIMING

CHAIN

REMOVAL

1.

Drain

the

cooling

system

and

the

crankcase.

Remove

the

air

clean

er.

Disconnect

the

battery

ground

cable.

2.

Disconnect

the

radiator

upper

hose

at

the

radiator

supply

tank.

Dis

connect

the

radiator

lower

hose

at

the

water

pump.

3.

Disconnect

the

transmission

oil

cooler

lines

at

the

radiator.

Remove

the

radiator

and

support

asanassem

bly.

4.

Disconnect

the

heater

hose

at

the

water

pump.

Slide

the

water

pump

by-pass

hose

clamp

toward

the

engine.

5.

Disconnect

the

power

steering

pump

bracket

from

the

water

pump

and

remove

the

drive

belt.

Wire

the

power

steering

pump

assembly

to

the

left

side

of

the

car

in

a

position

that

will

prevent

the

oil

from

draining

out.

On

a

car

with

an

air

conditioner,

remove

the

compressor

drive

belt.

6.

Loosen

the

generator

mounting

bolts

at

the

generator.

Remove

the

drive

belt.

Remove

the

generator

sup

port

bolt

at

the

water

pump.

Remove

the

water

pump,

drive

belt

adjusting

arm,

pulley,

and

fan

as

an

assembly.

Remove

the

power

steering

pulley

from

the

crankshaft

damper.

7.

Remove

the

cap

screw

and

washer

from

the

end

of

the

crank

shaft.

Install

the

puller

on

the

crank

shaft

damper

(Fig.

53)

and

remove

the

damper.

8.

Disconnect

the

carburetor

fuel

inlet

line

at

the

fuel

pump.

ToolT58P-6316-A

A1257-B

FIG.

53

Crankshaft

Damper

Removal

9.

Remove

the

fuel

pump

retain

ing

bolts

and

lay

the

pump

to

one

side

with

the

flexible

fuel

line

still

attached.

10.

If

the

crankshaft

sleeve

is

not

stepped

down

(the

same

OD

on

both

ends),

remove

it

as

shown

in

Fig.

54.

If

the

sleeve

is

stepped

down,

remove

it

with

a

three

jawed

puller

(tool

7675-N).

11.

Remove

the

screws

fastening

the

cylinder

front

cover

to

the

block.

Remove

the

cylinder

front

cover.

On

a

car

with

an

air

conditioner,

the

compressor

brackets

are

retained

by

cylinder

front

cover

screws.

12.

Discard

the

cylinder

front

cover

gasket.

Remove

the

oil

slinger.

13.

Rotate

the

crankshaft

in

a

clockwise

direction

(as

viewed

from

the

front)

to

take

up

the

slack

on

the

left

side

of

the

chain.

14.

Establish

a

reference

point on

the

block

and

measure

from

this

point

to

the

chain

(Fig.

55).

15.

Rotate

the

crankshaft

in

the

opposite

direction

to

take

up

the

slack

on

the

right

side

of

the

chain.

Force

the

left

side

of

the

chain

Tool

T56P-6362-A

A1258-B

FIG.

54-Crankshaft

Sleeve

Removal

1-28

GROUP

1-

ENGINE

AND

EXHAUST

SYSTEM

REFERENCE

POINT

RIGHT

SIDE

OF

CHAIN

TAKE

UP

SLACK

ON

LEFT

SIDE,

ESTABLISH

REFERENCE

POINT.

MEASURE

DISTANCE

A.

TAKE

UP

SLACK

ON

RIGHT

SIDE.

FORCE

LEFT

SIDE

OUT.

MEASURE

DISTANCEB.DEFLECTION

IS

A

MINUS

B.

A1284-A

FIG.

55

Timing

Chain

Deflection

out

with

the

fingers

and

measure

the

distance

between

the

reference

point

and

the

chain.

The

deflection

is

the

difference

between

the

two

measure

ments.

If

the

deflection

exceeds

Vi

inch,

replace

the

timing

chain

and/or

sprockets.

16.

Crank

the

engine

until

the

timing

marks

on

the

sprockets

are

positioned

as

shown

in

Fig.

56.

17.

Remove

the

camshaft

thrust

FIG.

57

Timing

Chain

Removal

or

Installation

button

and

spring,

the

sprocket

cap

screw,

the

thrust

button

spring

re

tainer,

and

the

fuel

pump

eccentric.

18.

Slide

both

sprockets

and

the

timing

chain

forward,

and

remove

the

sprockets

and

timing

chain

as

an

as

sembly

(Fig.

57).

19.

Remove

the

oil

pan

and

oil

pump

screen,

following

the

proce

dure

under

"Oil

Pan

Removal"

(page

1-36).

INSTALLATION

1.

Position

the

sprockets

and

tim

ing

chain

on

the

camshaft

and

crank

shaft

(Fig.

57).

Be

sure

the

timing

marks

on

the

sprockets

are

posi

tioned

as

shown

in

Fig.

56.

2.

Install

the

fuel

pump

eccentric,

the

camshaft

sprocket

cap

screw,

and

FUEL

PUMP

ECCENTRIC

DOWEL

CRANKSHAFT

FRONT

OIL

SLINGER

A128S-A

the

thrust

button

spring

retainer.

Torque

the

sprocket

cap

screw

to

35-

45

ft-lbs.

Install

the

camshaft

thrust

button

spring

and

thrust

button

(Fig.

58).

Install

the

crankshaft

front

oil

slinger.

3.

Clean

the

cylinder

front

cover,

oil

pan,

and

the

block

gasket

sur

faces.

4.

Coat

the

gasket

surface

of

the

block

and

cover

and

the

cover

bolt

threads

with

sealer.

Position

a

new

gasket

on

the

block.

5.

Install

the

alignment

pilot

tool

on

the

cylinder

front

cover

so

that

the

keyways

in

the

pilot

aligns

with

the

keyway

in

the

pilot

aligns

with

the

cover

and

pilot

over

the

end

of

the

crankshaft

and

against

the

block

(Fig.

59).

Install

the

retaining

screws.

roo/-T67P-6079-B

A1287-B

TIMING

MARKS

A1283-A

FIG.

56

Aligning

Timing

Marks

FIG.

58

Fuel

Pump

Eccentric

and

Front

Oil

Slinger

Installed

FIG.

59

Cylinder

Front

Cover

Alignment

On

a

car

with

an

air

conditioner,

position

the

compressor

bracket

in

place

on

the

cylinder

front

cover

and

install

the

retaining

screws

finger

tight.

While

pushing

in

on

the

pilot,

torque

the

screws

to

12-15

ft-lbs.

Re

move

the

pilot.

6.

Install

the

crankshaft

sleeve.

7.

Line

up

the

damper

keyway

with

the

key

on

the

crankshaft.

In

stall

the

damper

on

the

crankshaft

(Fig.

60).

8.

Install

the

damper

cap

screw

and

washer,

and

torque

the

screw

to

70-90

ft-lbs.

9.

Install

the

power

steering

pump

pulley

on

the

damper.

Torque

the

screws

to

20-25

ft-lbs.

PART

1-1

-ENGINE

1-29

Tool-T52L-6306-AEE

A1289-B

FIG.

60

Crankshaft

Damper

Installation

10.

Clean

the

oil

pan

and

the

oil

pump

screen.

Install

the

oil

pump

screen

and

oil

pan

(Page

1-36).

11.

Clean

the

water

pump

gasket

surfaces.

Coat

new

gaskets

with

sealer

and

position

the

gaskets

on

the

block.

Install

the

water

pump,

pul

ley,

fan,

and

generator

adjusting

arm

as

an

assembly.

12.

Install

and

adjust

the

gener

ator

drive

belt(s).

On

a

car

with

an

air

conditioner,

install

and

adjust

the

drive

belt.

13.

Install

the

power

steering

pump

drive

belt

and

attach

the

pump

bracket

to

the

water

pump.

Adjust

the

drive

belt

tension.

14.

Install

the

fuel

pump

using

a

new

gasket.

15.

Connect

the

carburetor

fuel

inlet

line.

Connect

the

heater

hoses.

Slide

the

water

pump

by-pass

tube

clamp

forward

on

the

tube.

16.

Install

the

radiator

and

support

as

an

assembly.

Connect

the

radiator

lower

hose

at

the

water

pump

and

the

radiator

upper

hose

at

the

radiator

supply

tank.

Connect

the

battery

ground

cable.

Connect

the

transmis

sion

oil

cooler

lines.

17.

Fill

and

bleed

the

cooling

system.

Fill

the

crankcase

with

the

proper

grade

and

quantity

of

engine

oil.

Connect

the

heater

hose

to

the

intake

manifold.

18.

Operate

the

engine

at

fast

idle

and

check

for

coolant

and

oil

leaks.

Adjust

the

ignition

timing.

Install

the

air

cleaner.

CLEANING

AND

INSPECTION

Clean

all

parts

in

solvent

and

dry

them

with

compressed

air.

Inspect

the

chain

for

broken

links

and

the

sprockets

for

cracks,

and

worn

or

damaged

teeth.

Replace

all

the

com

ponents

of

the

timing

chain

and

sprocket

assembly

if

any

one

item

needs

replacement.

FRONT

OIL

SEAL

REPLACEMENT

It

is

good

practice

to

replace

the

oil seal

each

time

the

cylinder

front

cover

is

removed.

1.

Drive

out

the

old

seal

with

a

pin

punch.

Clean

out

the

recess

in

the

cover.

2.

Coat

a

new

seal

with

grease,

then

install

the

seal

(Fig.

61).

Drive

the

seal

in

until

it

is

fully

seated

in

the

recess.

Check

the

seal

after

in

stallation

to

be

sure

the

spring

is

properly

positioned

in

the

seal.

CAMSHAFT

The

camshaft

and

related

parts

are

shown

in

Fig.

62.

REMOVAL

1.

Operate

the

engine

until

normal

operating

temperature

has

been

-T58P-6700-B

A1286-B

FIG.

61

-Oil

Seal

Installation

reached.

Remove

the

cylinder

front

cover and

the

timing

chain

and

sprockets

following

steps

1

thru

18

under

"Cylinder

Front

Cover

and

Timing

Chain

Removal"

on

page

1-27.

2.

Disconnect

the

spark

plug

wires

at

the

spark

plugs

and

remove

the

wires

from

the

ignition

harness

brackets

on

the

valve

rocker

arm

covers.

Disconnect

the

coil

high

ten

sion

lead

at

the

coil.

Remove

the

distributor

cap

and

spark

plug

wire

assembly.

Disconnect

the

distributor

vacuum

line

at

the

distributor.

Re

move

the

distributor

hold

down

bolt

and

clamp

and

remove

the

distrib

utor.

3.

Remove

the

valve

rocker

arm

covers.

Refer

to

"Valve

Rocker

Arm

Shaft

Assembly

Removal"

(page

1-

19)

and

remove

the

valve

rocker

arm

shaft

assemblies

by

following

steps

4

and

5.

4.

Remove

the

valve

push

rods

in

sequence

and

place

them

in

a

rack

so

that

they

can

be

installed

in

their

original

positions.

5.

Position

an

inspection

light

through

a

push

rod

opening

and

into

the

valve

push

rod

valley

(Fig.

63).

Remove

the

valve

lifters

with

a

mag

net

through

the

push

rod

openings.

In

some

cases,

it

will

be

necessary

to

transfer

the

lifter

over

to

an

adjoin

ing

push

rod

opening

in

order

to

re

move

it.

Place

the

lifters

in

a

rack

so

that

they

can

be

installed

in

their

or

iginal

positions.

6.

Remove

the

oil

pan

and

oil

pump

screen

by

following

the

pro-

BEARINGS

CAMSHAFT

REAR

BEARING

BORE

PLUG

FUEL

PUMP

ECCENTRIC

BOLT

AND

WASHER

Cfy

A1275-A

FIG.

62-Camshoft

and

Related

Parts

1-30

GROUP

1-

ENGINE

AND

EXHAUST

SYSTEM

Magnetic

Lifter

Light

FILTER

FIG.

63

Valve

Lifter

Replacement

Intake

Manifold

Installed

A1488-A

cedure

under

"Oil

Pan

Removal"

on

page

1-36.

7.

Carefully

remove

the

camshaft

by

pulling

it

toward

the

front

of

the

engine.

Use

caution

to

avoid

damag

ing

the

camshaft

bearings.

INSTALLATION

1.

Oil

the

camshaft

and

apply

Lubriplate

to

the

lobes.

Carefully

slide

the

camshaft

through

the

bear

ings.

2.

Position

the

sprockets

and

tim

ing

chain

on

the

camshaft and

crank

shaft

(Fig.

57)

with

the

timing

marks

on

the

sprockets

aligned

as

shown

in

Fig.

56.

3.

Install

the

fuel

pump

eccentric,

the

camshaft

sprocket

cap

screw,

and

thrust

button

spring

retainer.

Torque

the

sprocket

cap

screw

to

35-45

ft-lbs.

Install

the

camshaft

thrust

button

(Fig.

58).

Install

the

front

oil

slinger.

4.

Replace

the

crankshaft

front

oil

seal

(page

1-29).

Install

the

cylinder

front

cover,

the

crankshaft

damper,

and

related

parts

following

steps

3

thru

16

under

"Cylinder

Front

Cover

and

Timing

Chain

Installation"

on

page

1-28.

5.

With

No.

1

piston

on

TDC

at

the

end

of

the

compression

stroke,

position

the

distributor

in

the

block

with

the

rotor

at

the

No.

1

firing

position

and

the

points

open.

Install

the

hold

down

clamp.

6.

Connect

the

distributor

vacuum

line.

Install

the

distributor

cap.

Con

nect

the

coil

high

tension

lead.

7.

Install

the

valve

lifters

in

the

bores

from

which

they

were

removed.

8.

Refer

to

"Valve

Rocker

Arm

Shaft

Assembly

Installation"

on

page

1-20

and

install

the

valve

rocker

arm

shaft

assembly

following

steps

1

thru

9.

9.

Fill

and

bleed

the

cooling

sys

tem.

Fill

the

crankcase

with

the

proper

grade

and

quantity

of

engine

oil.

10.

Start

the

engine

and

check

and adjust

the

ignition

timing.

Oper

ate

the

engine

at

fast

idle

and

check

all

hose

connections

and

gaskets

for

leaks.

CLEANING

AND

INSPECTION

Clean

the

camshaft

in

solvent

and

wipe

it

dry.

Inspect

the

camshaft

lobes

for

scoring,

and

signs

of

abnor

mal

wear.

Lobe

wear

characteristics

may

result

in

pitting

in

the

general

area

of

the

nose

portion

of

the

lobe.

This

pitting

is

not

detrimental to

the

operation

of

the

camshaft,

therefore,

the

camshaft

should

not

be

replaced

until

the

lobe

lift

loss

has

exceeded

0.005

inch.

The

lift

of

camshaft

lobes

can

only

be

accurately

checked

with

the

cam

shaft

installed

in

the

engine.

Refer

to

"Camshaft

Lobe

Lift"

on

page

1-16.

Check

the

distributor

drive

gear

for

broken

or

chipped

teeth.

Remove

light

scuffs,

scores,

or

nicks

from

the

camshaft

machined

surfaces

with

a

smooth

oilstone.

CAMSHAFT

REAR

BEARING

BORE

PLUG

REPLACEMENT

1.

Remove

the

transmission

and

converter

housing

by

following

the

procedure

in

Part

5-4.

2.

Remove

the

flywheel

retaining

bolts

and

remove

the

flywheel.

3.

Drill

a

'/2-inch

hole

in

the

cam

shaft

rear

bearing

bore

plug

and

use

tool

T-7600-E

to

remove

the

plug.

4.

Clean

out

the

plug

bore

recess

thoroughly.

5.

Coat

the

flange

of

a

new

plug

with

water

resistant

sealer

and

install

it

with

the

flange

facing

out

(Fig.

91).

6.

Install

the

flywheel.

7.

Install

the

transmission

and

converter

housing

by

following

the

procedure

in

Part

5-4.

HYDRAULIC

VALVE

LIFTER

REPLACEMENT

The

following

procedure

is

appli

cable

for

removing

one

or

all

of

the

valve

lifters.

This

procedure

can

not

be

used

if

the

valve

lifters

are

stuck

in

their

bores

by

excessive

varnish,

etc.

In

this

case

it

will

be

necessary

to

remove

the

intake

manifold

following

the

procedure

on

page

1-21.

After

the

intake

manifold

has

been

removed,

remove

the

valve

lifters.

1.

Refer

to

"Valve

Rocker

Arm

Shaft

Assembly

Removal"

(page

1-

19)

and

remove

the

valve

rocker

arm

covers

and

the

valve

rocker

arm

shaft

assemblies

by

following

steps

1

thru

5.

2.

Position

an

inspection

light

through

a

push

rod

opening

and

into

the

valve

push

rod

valley

(Fig.

63).

Remove

the

valve

lifters

with

a

mag

net

through

the

push

rod

openings.

In

some

cases,

it

will

be

necessary

to

transfer

the

lifter

over

to

an

adjoin

ing

push

rod

opening

in

order

to

re-

PART

1-1

-ENGINE

1-31

move

it.

Place

the

lifters

in

a

rack

so

that

they

can

be

installed

in

their

original

positions.

The

internal

parts

of

each

hy

draulic

valve

lifter

assembly

are

matched

sets.

Do

not

intermix

the

parts.

Keep

the

assemblies

intact

until

they

are

to

be

cleaned.

3.

Install

the

new

(or

cleaned)

hy

draulic

valve

lifters

through

the

push

rod

openings

with

a

magnet

(Fig.

63).

4.

Refer

to

"Valve

Rocker

Arm

Shaft

Assembly

Installation"

(page

1-20)

and

install

the

valve

rocker

arm

shaft

assemblies

and

the

covers

by

following

steps

1

thru

9.

CLEANING

AND

INSPECTION

The

lifter

assemblies

should

be

kept

in

proper

sequence

so

that

they

can

be

installed

in

their

original

position.

Inspect

and

test

each

lifter

separately

so

as

not

to

intermix

the

internal

parts.

If

any

part

of

the

lifter

assembly

needs

replacing,

re

place

the

entire

assembly.

Thoroughly

clean

all

the

parts

in

clean

solvent

and

wipe

them

with

a

clean,

lint-free

cloth.

Inspect

the

parts

and

discard

the

entire

lifter

assembly

if

any

part

shows

signs

of

pitting,

scoring,

gall

ing,

or

evidence

of

non-rotation.

Replace

the

entire

assembly

if

the

plunger

is

not

free

in

the

body.

The

plunger

should

drop

to

the

bottom

of

the

body

by

its

own

weight.

Assemble

the

lifter

assembly

and

check

the

assembly

for

freeness

of

operation

by

pressing

down

on

the

push

rod

cup.

The

lifter

can

also

be

checked

with

a

hydraulic

valve

lifter

tester

to test

the

leak-down

rate.

The

leak-down

rate

specification

is

10-80

seconds.

Follow

the

instructions

of

the

test

unit

manufacturer.

DISASSEMBLY

Each

valve

lifter

is

a

matched

as

sembly.

If

the

parts

of

one

lifter

are

inter-mixed

with

those

of

another,

improper

valve

operation

may

re

sult.

Disassemble

and

assemble

each

lifter

separately.

Keep

the

lifter

as

semblies

in

proper

sequence

so

that

they

can

be

installed

in

their

original

bores.

1.

Grasp

the

lock

ring

with

needle-

nose

pliers

to

release

it

from

the

groove.

If

necessary,

depress

the

plunger

to

fully

release

the

lock

ring.

2.

Remove

the

push

rod

cup,

plunger,

and

spring.

3.

Invert

the

plunger

assembly

and

remove

the

disc

valve

retainer

by

PUSH

ROD

CUP

DISC

VALVE

PLUNGER

SPRING

BODY

A1268-A

FIG.

64

Typical

Hydraulic Valve

Lifter

Assembly

carefully

prying

up

on

it

with

a

screw

driver.

Remove

the

disc

valve

and

spring.

ASSEMBLY

A

typical

hydraulic

valve

lifter

is

shown

in

Fig.

64.

1.

Place

the

plunger

upside

down

on

a

clean

work

bench.

2.

Place

the

disc

valve

in

position

over

the

oil

hole

on

the

bottom

of

the

plunger.

Set

the

disc

valve

spring

on

top

of

the

disc.

3.

Position

the

disc

valve

retainer

over

the

disc

and

spring

and

push

the

retainer

down

into

place

on

the

plunger.

4.

Place

the

plunger

spring,

and

then

the

plunger

(open

end

up)

into

the

lifter

body.

5.

Place

the

push

rod

seat

in

the

plunger.

6.

Depress

the

plunger,

and

posi

tion

the

closed

end

of

the

lock

ring

in

the

groove

of

the

lifter

body.

With

the

plunger

still

depressed,

position

the

open

ends

of

the

lock

ring

in

the

groove.

Release

the

plunger,

then

de

press

it

again

to

fully

seat

the

lock

ring.

CRANKSHAFT

LOWER

REAR

OIL

SEAL

REPLACEMENT

The

upper

oil

seal

in

the

block

cannot

be

replaced

with

the

crank

shaft

installed.

To

replace

the

lower

rear

oil

seal

in

the

rear

main

bearing

cap

and

the

side

seals:

1.

Remove

the

oil

pan

and

related

parts

(page

1-36).

2.

Remove

the

rear

main

bearing

cap.

Remove

and

discard

the

rear

seal

and

side

seals.

3.

Clean

the

rear

journal

oil

seal

groove.

4.

Install

a

new

rear

journal

oil

seal

in

the

rear

main

bearing

cap

(Fig.

65).

After

installation,

cut

the

ends

of

the

seals

flush.

5.

Apply

a

thin

coating

of

oil

re

sistant

sealer

to

the

rear

main

bearing

cap

at

the

rear

of

the

top

mating

sur

face

(Fig.

65).

Do

not

apply

sealer

to

the

area

forward

of

the

side

seal

groove.

Install

the

rear

main

bearing

cap.

Torque

the

cap

bolts

to

95-105

ft-lbs.

6.

Dip

the

side

seals

in

light

engine

oil,

then

immediately

install

them

in

the

grooves.

Do

not

use

sealer

on

the

side

seals.

The

seals

are

designed

to

expand

when

dipped

in

oil.

Using

sealer

may

retard

this

expansion.

It

may

be

necessary

to

tap

the

seals

into

place

for

the

last

Vi

inch

of

travel.

Do

not

cut

the

seal

projecting

ends.

7.

Check

the

retainer

side

seals

for

leaks

by

squirting

a

few

drops

of

oil

into

the

parting

lines

between

the

rear

main

bearing

cap

and

the

cylin

der

block

from

the

outside.

Blow

compressed

air

against

the

seals

from

the

inside

of

the

block.

If

air

bubbles

appear

in

the

oil,

it

indicates

possible

oil

leakage.

This

test

should

not

be

performed

on

newly

installed

seals

until

sufficient

time

has

been

allowed

for

the

seals

to

expand

into

the

seal

grooves.

8.

Install

the

oil

pan and

related

parts

(page

1-36).

9.

Fill

the

crankcase.

Start

the

en

gine

and check

for

oil

pressure.

Op

erate

the

engine

at

fast

idle

and

check

for

oil

leaks.

Tool-

T58P-6701-A

A1278-B

FIG.

65

-Seal

To

Rear

Bearing

Cap

Installation

1-32

GROUP

1-

ENGINE

AND

EXHAUST

SYSTEM

MAIN

AND

CONNECTING

ROD

BEARING

REPLACEMENT

The

main

connecting

rod

bearing

inserts

are

selective

fit.

Do

not

file

or

lap

bearing

caps

or

use

shims

to

obtain

the

proper

bearing

clearance.

Selective

fit

bearings

are

available

for

service

in

standard

sizes

only.

Standard

bearings

are

divided

into

two

sizes

and

are

identified

by

a

daub

of

red

or

blue

paint.

Refer

to

the

Parts

Catalog

for

the

available

sizes.

Red

marked

bearings

increase

the

clearance;

blue

marked

bearings

de

crease

the

clearance.

Undersized

bearings,

which

are

not

selective

fit,

are

available

for

use

on

journals

that

have

been

refinished.

MAIN

BEARING

REPLACEMENT

1.

Drain

the

crankcase.

Remove

the

oil

level

dipstick.

Remove

the

oil

pan

and

oil

pump

by

following

the

procedures

on

page

1-36.

Remove

the

spark

plugs

to

allow

easy

rotation

of

the

crankshaft.

2.

Replace

one

bearing

at

a

time

leaving

the

other

bearing

securely

fastened.

Remove

the

main

bearing

cap

to

which

new

bearings

are

to

be

installed.

3.

Insert

the

upper

bearing

re

moval

tool

(tool

6331)

in

the

oil

hole

in

the

crankshaft.

4.

Rotate

the

crankshaft

in

the

direction

of

engine

rotation

to

force

the

bearing

out

of

the

block.

5.

Clean

the

crankshaft

journal

and

bearing

inserts.

When

replacing

standard

bearings

with

new

bearings,

it

is

good

practice

to

first

try

to

ob

tain

the

proper

clearance

with

two

blue

bearing

halves.

6.

To

install

the

upper

main

bear

ing,

place

the

plain

end

of

the

bear

ing

over

the

shaft

on

the

locking

tang

side

of

the

block.

Using

tool

6331

in

the

oil

hole

in

the

crank

shaft,

rotate

the

crankshaft

in

the

opposite

direction

of

engine

rotation

until

the

bearing

seats

itself.

Remove

the

tool.

7.

Replace

the

cap

bearing.

8.

Support

the

crankshaft

so

its

weight

will

not

compress

the

Plasti

gage

and

provide

an

erroneous

read

ing.

Position

a

small

jack

so

it

will

bear

against

the

counterweight

ad

joining

the

bearing

which

is

being

checked.

9.

Place

a

piece

of

Plastigage

on

the

bearing

surface

the

full

width

of

the

bearing

cap

and

about

Va

inch

off

center

(Fig.

66).

PLACE

Plastigage

FULL

WIDTH

OF

JOURNAL

ABOUT

'/<

INCH

OFF

CENTER

CHECK

WIDTH

OF

Plastigage

INSTALLING

Plastigage

MEASURING

Plastigage

A1022-A

FIG.

66

Installing

and

Measuring

Plastigage

Engine

In

Chassis

10.

Install

the

cap

and

torque

the

bolts

to

95-105

ft-lbs.

Do

not

turn

the

crankshaft

while

the

Plastigage

is

in

place.

When

checking

the

width

of

the

Plastigage,

check

at

the

widest

point

in

order

to

get

the

minimum

clearance.

Check

at

the

narrowest

point

in

order

to

get

the

maximum

clearance.

The difference

between

the

two

readings

is

the

taper.

If

the

clearance

is

less

than

the

specified

limits,

try

two

red

bearing

halves

or

a

combination

of

red

and

blue

depending

upon

the

condition.

If

the

standard

bearings

do

not

bring

the

clearance

within

the

desired

limits,

refinish

the

crankshaft

journal,

then

install

undersize

bearings.

11.

After

the

bearing

has

been

checked

and

found

to

be

satisfactory,

apply

a

light

coat

of

engine

oil

to

the

journal

and

bearings,

then

install

the

bearing

cap.

Torque

the

cap

bolts

to

95-105

ft-lbs.

12.

Repeat

the

procedure

for

the

remaining

bearings

that

require

re

placement.

13.

If

the

rear

main

bearing

is

re

placed,

replace

the

lower

oil

seal

in

the

rear

main

bearing

cap

and

the

side

seals

and

check

the

side

seals

for

leaks

by

following

steps

3

thru

7

under

"Crankshaft

Lower

Rear

Oil

Seal

Replacement"

on

page

1-31.

14.

Disassemble,

clean,

and

as

semble

the

oil

pump

(page

1-37).

15.

Install

the

oil

pump

and

oil

pan

(page

1-36).

Install

the

oil

level

dipstick.

Fill

the

crankcase

with

the

proper

amount

and

viscosity

oil.

In

stall

the

spark

plugs.

16.

Operate

the

engine

and

check

for

oil

leaks.

CONNECTING

ROD

BEARING

REPLACEMENT

1.

Follow

step

1

under

"Main

Bearing

Replacement."

2.

Turn

the

crankshaft

until

the

connecting

rod

to

which

new

bear

ings

are

to

be

fitted

is

down.

3.

Remove

the

connecting

rod

cap.

Push

the

connecting

rod

up

into

the

cylinder

and

remove

the

bearing

in

sert

from

the

rod

and

cap.

4.

Follow

step

5

under

"Main

Bearing

Replacement."

5.

Install

the

new

bearings

in

the

connecting

rod

and

cap.

Pull

the

connecting

rod

assembly

down

firmly

on

the

crankshaft

journal.

6.

Place

a

piece

of

Plastigage

on

the

lower

bearing

surface,

the

full

width

of

the

cap

and

about

Va

inch

off

center.

7.

Install

the

cap

and

torque

the

connecting

rod

nuts

to

40-45

ft-lbs.

Do

not

turn

the

crankshaft

while

the

Plastigage

is

in

place.

8.

Remove

the

cap.

Using

the

Plastigage

scale,

check

the

width

of

the

Plastigage

by

following

step

1

1

under

"Main

Bearing

Replacement."

9.

After

the

bearing

clearance

has

been

checked

and

found

to

be

satis

factory,

apply

a

light

coat

of

engine

oil

to

the

journal

and

bearings.

In

stall

the

connecting

rod

cap.

10.

Repeat

the

procedure

for

the

remaining

connecting

rods

that

re

quire

new

bearings.

11.

Follow

steps

14,

15,

and

16

under

"Main

Bearing

Replacement."

CLEANING

AND

INSPECTION

Clean

the

bearing

inserts

and

caps

thoroughly.

Inspect

each

bearing

carefully.

Bearings

that

have

a

scored,

chipped,

or

worn

surface

should

be

replaced.

Typical

exam

ples

of

bearing

failure

and

their

causes

are

shown

in

Fig.

67.

Check

the

clearance

of

bearings

that

ap

pear

to

be

satisfactory

with

Plasti

gage.

Fit

new

bearings

following

the

recommended

procedure.

The

cop

per

lead

bearing

base

may

be

visible

through

the

bearing

overlay.

This

does

not

mean

that

the

bearing

is

worn.

Do

not

replace

the

bearing

if

the

bearing

clearance

is

within

rec

ommended

limits.

PISTON

AND

CONNECTING

ROD

ASSEMBLY

REMOVAL

1.

Drain

the

cooling

system

and

the

crankcase.

Remove

the

intake

PART

1-1

-ENGINE

1-33

SCRATCHES

SCRATCHED

BY

DIRT

^P^^VERLAY

GON^^B

w

FROM

ENTIRE

SURFACE

TAPERED

JOURNAL

LACK

OF

OIL

BRIGHT

(POLISHED)

SECTIONS

IMPROPER

SEATING

RADIUS

RIDE

RADIUS

RIDE

FIG.

67

Typical

Bearing

Failures

manifold,

cylinder

heads,

oil

pan

and

oil

pump

following

the

procedures

in

this

section.

2.

Remove

any

ridge

and/or

de

posits

from

the

upper

end

of

the

cyl

inder

bores

as

follows:

Turn

the

crankshaft

until

the

pis

ton

to

be

removed

is

at

the

bottom

of

its

travel

and

place

a

cloth

on

the

piston

head

to

collect

the

cuttings.

Remove

any

ridge

and/or

deposits

from

the

upper

end

of

the

cylinder

bores.

Remove

the

cylinder

ridge

with

a

ridge

cutter.

Follow

the

in

structions

furnished

by

the

tool

man

ufacturer.

Never

cut

into

the

ring

travel

area

in

excess

of

1/32

inch

when

removing

ridges.

3.

Make

sure

all

connecting

rod

caps

are

marked

so

that

they

can

be

installed

in

their

original

locations.

4.

Turn

the

crankshaft

until

the

connecting

rod

being

removed

is

down.

5.

Remove

the

connecting

rod

cap.

6.

Push

the

connecting

rod

and

piston

assembly

out

the

top

of

the

cylinder

with

the

handle

end

of

a

hammer.

Avoid

damage

to

the

crank

shaft

journal

or

the

cylinder

wall

when

removing

the

piston

and

rod.

7.

Remove

the

bearing

inserts

from

the

connecting

rod

and

cap.

8.

Install

the

cap

on

the

connect

ing

rod

from

which

it

was

removed.

INSTALLATION

1.

If

new

piston

rings

are

to

be

installed,

remove

the

cylinder

wall

glaze.

Follow

the

instructions

of

the

tool

manufacturer.

2. Oil

the

piston

rings,

pistons,

and

cylinder

walls

with

light

engine

oil.

Be

sure

to

install

the

pistons

in

the

same

cylinders

from

which

they

were

removed,

or

to

which

they

were

.^CRATERS

OR

POCKETS^

FATIGUE FAILURE

A1021-A

fitted.

The

connected

rods

and

bear

ing

caps

are

numbered

from

1

to

4

in

the

right

bank

and

from

5

to

8

in

the

left

bank

beginning

at

the

front

of

the

engine.

The

numbers

on

the

connect

ing

rod

and

bearing

cap

must

be

on

the

same

side

when

installed

in

the

cylinder

bore.

If

a

connecting

rod

is

ever

transposed

from

one

block

or

cylinder

to

another,

new

bearings

should

be

fitted

and

the

connecting

rod

should

be

numbered

to

cor

respond

with

the

new

cylinder

number.

3.

Make

sure

the

ring

gaps

are

properly

spaced

around

the

circum

ference

of

the

piston.

4.

Install

a

piston

ring

compressor

on

the

piston

and

push

the

piston

in

with

a

hammer

handle

until

it

is

slightly

below

the

top

of

the

cylinder

(Fig.

68).

Be

sure

to

guide

the

con

necting

rods

to

avoid

damaging

the

crankshaft

journals.

Install

the

piston

with

the

indentation

in

the

piston

head

toward

the

front

of

the

engine.

5.

Check

the

clearance

of

each

bearing

by

following

the

procedure

61

49-

A

FRONT

/

INDENTATION

TO

FRONT

OF

ENGINE

A1281-B

under

"Connecting

Rod

Bearing

Re

placement."

6.

After

the

bearings

have

been

fitted,

apply

a

light

coat

of

engine

oil

to

the

journals

and

bearings.

7.

Turn

the

crankshaft

throw

to

the

bottom

of

its

stroke.

Push

the

piston

all

the

way

down

until

the

connecting

rod

bearing

seats

on

the

crankshaft

journal.

8.

Install

the

connecting

rod

cap.

Torque

the

nuts

to

40-45

ft-lbs.

9.

After

the

piston

and

connecting

rod

assemblies

have

been

installed,

check

the

side

clearance

between

the

connecting

rods

on

each

crankshaft

journal.

(Fig.

69).

10.

Disassemble,

clean,

and

assem

ble

the

oil

pump

(page

1-37).

Clean

the

oil

pump

inlet

tube

screen,

and

the

oil

pan

and

block

gasket

surfaces.

11.

Install

the

oil

pump

and

the

oil

pan

(page

1-36).

12.

Install

the

cylinder

heads

by

following

steps

1

thru

5

under

"Cyl

inder

Head

Installation"

on

page

1-23.

13.

Refer

to

"Intake

Manifold

In

stallation"

on

page

1-21

and

install

the

intake

manifold

by

following

steps

2

thru

19.

14.

Fill

and

bleed

the

cooling

sys

tem.

Fill

the

crankcase

with

the

proper

grade

and

quantity

of

engine

oil.

15.

Operate

the

engine

and

check

for

oil

and

coolant

leaks.

Check

and

FIG.

68

Piston

Installation

A1282-B

FIG.

69

Connecting

Rod

Side

Clearance

1-34

GROUP

1-

ENGINE

AND

EXHAUST

SYSTEM

adjust

the

ignition

timing.

Adjust

the

engine

idle

speed

and

fuel

mixture.

16.

Install

the

air

cleaner.

DISASSEMBLY

1.

Mark

the

pistons

and

pins

to

assure

assembly

with

the

same

rod

and

installation

in

the

same

cylinder

from

which

they

were

removed.

2.

Remove

the

piston

rings.

Re

move

the

piston

pin

retainers.

Drive

the

pin

out

of

the

piston

and

connect

ing

rod

(Fig.

70).

Discard

the

re

tainers.

LEFT

BANK

RIGHT

BANK

FIG.

70

Piston

Pin

Removal

UPPER

v-

COMPRESSION

RING

LOWER

COMPRESSION

RING

PISTON

RETAINER

CONNECTING

ROD

RETAINER

BEARING

INSERTS

A1472-A

BEARING

LOCK

SLOTS

TO

OUTSIDE

OF

ENGINE

"V"

t

FRONT

I

INDENTATION

TO

FRONT

OF

ENGINE

A1271-B

FIG.

71

-Piston,

Connecting

Rod,

and

Related

Parts

FIG.

72

Connecting

Rod

and

Piston

Assembly

ASSEMBLY

The

piston,

connecting

rod,

and

related

parts

are

shown

in

Fig. 71.

1.

Lubricate

all

parts

with

light

engine

oil.

Position

the

connecting

rod

in

the

piston and

push

the

pin

into

place.

Assemble

the

piston and

con

necting

rod

with

the

oil

squirt

hole

positioned

as

shown

in

Fig.

72.

2.

Insert

new

piston

pin

retainers

by

spiraling

them

into

the

piston with

the

fingers.

Do

not

use

pliers.

Follow

the

instructions

contained

on

the

pis

ton

ring

package

and

install

the

piston

rings.

3.

Check

the

ring

side

clearance

of

the

compression

rings with

a

feeler

gauge

inserted

between

the

ring

and

its

lower

land

(step

6

under

"Fit

ting

Piston

Rings"

on

page

1-36).

4.

Be

sure

the

bearing

inserts

and

the

bearing

bore

in

the

connecting

rod

and

cap

are

clean.

Foreign

ma

terial

under

the

inserts

may

distort

the

bearing

and

cause

a

failure.

In

stall

the

bearing

inserts

in

the

con

necting

rod

and

cap

with

the

tangs

fitting

in

the

slots

provided.

CONNECTING

ROD

CLEANING

AND

INSPECTION

The

connecting

rods

and

related

parts

should

be

carefully

inspected

and

checked

for

conformance

to

specifications.

Various

forms

of

en

gine

wear

caused

by

these

parts

can

be

readily

identified.

A

shiny

surface

on

the

pin

boss

side

of

the

piston

usually

indicates

that

a

connecting

rod

is

bent

or

the

piston

pin

hole

is

not

in

proper

re

lation

to

the

piston

skirt

and

ring

grooves.

Abnormal

connecting

rod

bearing

wear

can

be

caused

by

either

a

bent

connecting

rod,

an

improp

erly

machined

crankshaft

journal,

or

a

tapered

connecting

rod

bore.

Twisted

connecting

rods

will

not

create

an

easily

identifiable

wear

pattern,

but

badly

twisted

rods

will

disturb

the

action

of

the

entire

pis

ton,

rings,

and

connecting

rod

as

sembly

and

may

be

the

cause

of

excessive

oil

consumption.

Clean

the

connecting

rod

in

sol

vent,

including

the

rod

bore

and

the

back

of

the

inserts.

Do

not

use

a

caustic

cleaning

solution.

Blow

out

all

passages

with

compressed

air.

Inspect

the

connecting

rods

for

signs

of

fractures

and

the

bearing

bores

for

out-of-round

and

taper.

If

the

bore

exceeds

the

recom

mended

limits

and/or

if

the

con

necting

rod

is

fractured,

it

should

be

replaced.

Check

the

piston

pin

to

connecting

rod

bushing

clearance.

Replace

the

connecting

rod

if

the

bushing

is

so

worn

that

it

cannot

be

reamed

or

honed

for

an

oversize

pin.

Replace

defective

connecting

rod

nuts

and

bolts.

After

the

connecting

rods

are

as

sembled

to

the

piston,

check

the

con

necting

rods

for

bend

or

twist

on

a

suitable

alignment

fixture.

Follow

the

instructions

of

the

fixture

manufac

turer.

If

the

bend

and/

or

twist

is

ex

cessive,

the

connecting

rod

should

be

straightened

or

replaced.

PISTONS,

PINS,

AND

RINGS

CLEANING

AND

INSPECTION

Remove

deposits

from

the

piston

surfaces.

Clean

gum

or

varnish

from

the

piston

skirt,

piston

pins,

and

rings

with

solvent.

Do

not

use

a

caustic

cleaning

solution or

a

wire

brush

to

clean

pistons.

Clean

the

ring

grooves

with

a

ring

groove

cleaner

(Fig.

73).

Make

sure

the

oil

ring

slots

(or

holes)

are

clean.

Carefully

inspect

the

pistons

for

fractures

at

the

ring

lands,

skirts,

and

pin

bosses,

and

for

scuffed,

rough,

or

scored

skirts.

If

the

lower

inner

portion

of

the

ring

grooves

have

high

steps,

replace

the

piston.

The

step

will

interfere

with

ring

operation

and

cause

excessive

ring

side

clearance.

A1016-A

FIG.

73

Cleaning

Ring

Grooves

PART

1-1

-ENGINE

1-35

AVa

5

POUNDS

(EXAMPLE)

-

\

\

\

\

\

\

\

\

\

^

.0045

RIBBON

\

\

\

\

\

\

\

y.O

U4

KIBBUN

-

035

RIBBON

03

RIBBON

025

RIBBON.

02

RIBBON

\

\

\

\

\

\

\

y-0

>

n

\

\

\

\

\

Y

\

\

N

\

4r

.Ouio

KIBBUIN

"

\

\

\

s,

i

'

\

\

\

\

\

\

s,

\

\

\

\

k

.

.

\

-V

\

\

\

\

\.

\

\

\

f

\

\

K

\

\

\

"

\

\

"\

\

\

\

\

\

\

\

\

\l

\

\

\

k

\

\

\

\

1

\

\

\

\

\

\

\

\

\

.0

02

.c

01

<

CLE

)+

ARA

.0(

NCE

)i

IN

.0(

INCI

)2

HES

.0(

)3

004

.005

4

POUNDS

(EXAMPLE)

(EXAMPLE)

(EXAMPLE)

A1017-A

FIG.

74

Piston

Clearance

Chart

Spongy,

eroded

areas

near

the

edge

of

the

top

of

the

piston are

usually

caused

by

detonation,

or

pre-ignition.

A

shiny

surface

on

the

thrust

surface

of

the

piston,

offset

from

the

centerline

between

the

pis

ton

pin

holes,

can

be

caused

by

a

bent

connecting

rod.

Replace

pis

tons

that

show

signs

of

excessive

wear,

wavy

ring

lands,

fractures,

and/or

damage

from

detonation

or

pre-ignition.

Check

the

piston

to

cylinder

bore

clearance

with

a

tension

scale

and

ribbon

by

following

the

procedure

under

"Fitting

Pistons."

Check

the

ring

side

clearance

by

following

the

procedure

under

"Fitting

Piston

Rings."

Replace

piston

pins

showing

signs

of

fracture

or

etching

and/or

wear.

Check

the

piston

pin

fit

in

the

piston

and

rod.

Replace

all

rings

that

are

scored,

chipped,

or

cracked.

It

is

good

prac

tice

to

always

install

new

rings

when

overhauling

the

engine.

Rings

should

not

be

transferred

from

one

piston

to

another

regardless

of

mileage.

FITTING

PISTONS

Pistons

are

available

for

service

in

standard

sizes

and

0.020,

0.030,

0.040,

and

0.060-inch

oversize.

The

piston

to

cylinder

bore

clear

ance

should

be

from

0.0017-0.0035

inch.

The

wear

limit

is

0.006

inch.

If

the

clearance

is

greater

than

the

maximum

limit,

recheck

calculations

to

be

sure

that

the

proper

size

piston

has

been

selected,

check

for

a

dam

aged

piston,

then

try

a

new

piston.

If

the

clearance

is

less

than

the

minimum

limit,

recheck

calculations

before

trying

another

piston.

If

none

can

be

fitted,

refinish

the

cylinder

for

the

next

size

piston.

When

a

piston

has

been

fitted,

mark

it

for

assembly

in

the

cylinder

to

which

it

was

fitted.

If

the

taper

and

out-of-round

con

ditions

of

the

cylinder

bore

are

with

in

limits,

new

piston

rings

will

give

satisfactory

service

provided

the

pis

ton

clearance

in

the

cylinder

bore

is

within

limits.

If

the

new

rings

are

to

be

installed

in

a

used

cylinder

that

has

not

been

refinished,

remove

the

cylinder

wall

"glaze."

To

fit

a

piston:

1.

Calculate

the

size

piston

to

be

used

by

taking

a

cylinder

bore

check

(Fig.

94).

2.

Select

the

proper

size

piston

to

provide

the

desired

clearance.

3.

Make

sure

the

piston

and

cyl

inder

bore

are

at

room

temperature

(70F).

After

any

refinishing

opera

tion,

allow

die

cylinder

bore

to

cool

and

make

sure

the

piston

and

bore

are

clean

and

dry

before

the

piston

fit

is

checked.

4.

Attach

a

tension

scale

to

the

end

of

a

feeler

gauge

ribbon

that

is

free

of

dents

or

burrs.

The feeler

ribbon

should

be

V^-inch

wide

and

of

one

of

the

thicknesses

shown

in

Fig. 74.

5.

Position

the

ribbon

in

the

cyl

inder

bore

so

that

it

extends

the

en

tire

length

of

the

piston

at

90

from

the

piston

pin

location.

Invert

the

pis

ton

and

install

it

in

the

bore

so

that

the

end

of

the

piston

is

about

lVi

inches

below

the

top

of

the

cylinder

block

and

the

piston

pin

is

parallel

to

the

crankshaft

axis.

Hold

the

piston

and

slowly

pull

the

scale

in

a

straight

line

with

the

ribbon,

noting

the

pull

required

to

remove

the

feeler

ribbon

(Fig.

75).

In

Fig.

74

the

diagonal

lines

rep

resent

feeler

ribbons

of

various

thick

nesses,

the

horizontal

lines

represent

the

pounds

pull,

and

the

vertical

fines

represent

the

clearances.

To

deter

mine

the

clearance,

locate

the

line

representing

the

pounds

pull

required

to

remove

the

feeler

ribbon

from

the

cylinder

bore.

Follow

the

horizontal

fine

to

the

right

until

it

intersects

the

diagonal

line

representing

the

feeler

ribbon.

Read

down

the

vertical

line

for

the

clearance.

Example

1.

If

a

0.0015-inch

feeler

ribbon

is

used

and

it

takes

approxi

mately

AVa

pounds

pull

to

remove

the

feeler

ribbon,

the

clearance

is

ap

proximately

0.0008

inch.

This

is

de

termined

by

locating

the

pounds

pull

{AVa

)

in

Fig.

74

and

following

the

line

to

the

right

until

it

intersects

with

the

diagonal

line

representing

the

0.0015-inch

feeler

ribbon.

Read

down

the

vertical

line

for

the

clear-

-L>

IA1201-B

FIG.

75-Chedring

Piston

Fit

1-36

GROUP

1-

ENGINE

AND

EXHAUST

SYSTEM

*A1238-A

FIG.

76

Piston

Ring

Gap

ance

(approximately

0.0008

inch).

Example

2.

If

a

0.003-inch

feeler

ribbon

is

used

and

it

takes

approxi

mately

9

pounds

pull

to

remove

the

ribbon,

the

resultant

clearance

is

ap

proximately

0.0015

inch.

FITTING

PISTON

RINGS

1.

Select

the

proper

ring

set

for

the

size

piston

to

be

used.

2.

Position

the

ring

in

the

cylinder

bore

in

which

it

is

going

to

be

used.

3.

Push

the

ring

down

into

the

cylinder

bore

area

where

normal

ring

wear

is

not

encountered.

4.

Use

the

head

of

a

piston

to

position

the

ring

so

that

the

ring

is

square

with

the

cylinder

wall.

Use

caution

to

avoid

damage

to

the

ring

or

cylinder

bore.

5.

Measure

the

gap

between

the

ends

of

the

ring

with

a

feeler

gauge

(Fig.

76).

If

the

gap

is

less

than

the

recommended

lower

limit,

try

another

ring

set.

6.

Check

the

ring

side

clearance

of

the

compression

rings

with

a

feeler

gauge

inserted

between

the

ring

and

its

lower

land

(Fig.

77).

The

gauge

020-A

FIG.

77

Ring

Side

Clearance

should

slide

freely

around

the

entire

ring

circumference

without

binding.

Any

wear

that

occurs

will

form

a

step

at

the

inner

portion

of

the

lower

land.

If

the

lower

lands

have

high

steps,

the

piston

should

be

replaced.

FITTING

PISTON

PINS

The

piston

pin

fit

should

be

a

light

thumb

press

fit

at

normal

tempera

ture

(70F).

Standard

piston

pins

are

coded

green.

Pins

of

0.001-inch

oversize

(color

coded

blue)

and

0.002-inch

oversize

(color

coded

yellow)

are

available.

If

the

pin

hole

in

the

piston

must

be

reamed,

use

an

expansion-type

piloted

reamer.

Place

the

reamer

in

a

vise

and

revolve

the

piston

around

the

reamer.

Set

the

reamer

to

the

size

of

the

pin

bore,

then

expand

the

reamer

slightly

and

trial

ream

the

pin

bore.

Take

a

light

cut.

Use

a

pilot

sleeve

of

the

nearest

size

to

maintain

alignment

of

the

bores.

Check

the

hole

size,

using

the

new

piston

pin.

If

the

bore

is

small,

ex

pand

the

reamer

slightly

and

make

another

cut.

Repeat

the

procedure

until

the

proper

fit

is

obtained.

Check

the

piston

pin

for

fit

in

the

respec

tive

rod

bushing.

If

necessary,

ream

or

hone

the

bushing

to

fit

the

pin.

FLYWHEEL

REMOVAL

1.

Disconnect

the

transmission

from

the

engine

and

slide

it

to

the

rear

as

outlined

in

Part

5-4.

2.

Remove

the

flywheel

retaining

bolts

and

remove

the

flywheel.

INSTALLATION

1.

Install

the

flywheel

on

the

crankshaft

flange

and

install

the

re

taining

bolts.

Torque

the

bolts

in

sequence

across

from

each

other

to

75-85

ft-lbs.

2.

Connect

the

transmission

to

the

engine

as

outlined

in

Part

5-4.

OIL

FILTER

REPLACEMENT

1.

Place

a

drip

pan

under

the

filter.

Unscrew

the

filter

from

the

adapter

fitting.

Clean

the

adapter

fil

ter

recess.

2.

Coat

the

gasket

on

the

new

fil

ter

with

oil,

and

place

the

filter

in

position

on

the

adapter

(Fig.

78).

Hand

tighten

the

filter

until

the

gas

ket

contacts

the

adapter

face,

then

advance

it

Vi

turn.

COAT

GASKET

WITH

ENGINE

OIL

FIG.

78

Oil

Filter

Replacement

3.

Operate

the

engine

at

fast

idle

and

check

for

leaks.

If

oil

leaks

are

evident,

perform

the

necessary

re

pairs

to

correct

the

leakage.

Check

the

oil

level

and

fill

the

crankcase

if

necessary.

OIL

PAN

AND

OIL

PUMP

REMOVAL

1.

Drain

the

cooling

system

and

the

crankcase.

Disconnect

the

radia

tor

upper

hose

at

the

radiator

supply

tank.

2.

Remove

the

oil

pan

retaining

screws

and

lower

the

oil

pan

to

the

underbody

cross

member.

Position

the

crankshaft

so

that

the

counter

weight

will

clear

the

oil

pan

and

move

the

pan

forward.

3.

Install

the

engine

lifting

brack

ets

and

sling.

Raise

the

engine

high

enough

to

place

tension

on

the

engine

mounts.

4.

Remove

the

engine

front

in

sulator

to

engine

retaining

bolts.

Raise

the

engine

high

enough

to

per

mit

removal

of

the

oil

pump

retaining

bolts,

then

remove

the

bolts.

Remove

the

oil

pan

and

the

oil

pump.

INSTALLATION

1.

Clean

the

oil

pan

and

block

gasket

surfaces.

Clean

the

oil

pump

and

inlet

tube

screen.

Position

a

new

PART

1-1

-ENGINE

1-37

DISTRIBUTOR

INTERMEDIATE

DRIVE

SHAFT.

INLET

TUBE

ASSEMBLY

GASKET

A1290-A

FIG.

79

Oil

Pump

and

Inlet

Tube

Installed

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.

2.

Raise

the

engine

high

enough

to

allow

installation

of

the

oil

pump

and

the

oil

pan.

Place

the

oil

pump

in

the

oil

pan

and

position

the

oil

pan

on

the

underbody

cross

member.

Insert

the

oil

pump

drive

shaft

into

the

oil

pump

housing

and

install

the

oil

pump

and

shaft

as

an

assembly.

Do

not

attempt

to

force

the

pump

into

position

if it

will

not

seat

readily.

The

drive

shaft

hex

may

be

misaligned

with

the

dis

tributor

shaft.

To

align,

rotate

the

intermediate

shaft

into

a

new

posi

tion.

Tighten

the

oil

pump

retaining

screws

to

specifications

(Fig.

79).

3.

Hold

the

oil

pan

in

place

against

the

cylinder

block

and

install

a

retaining

screw

on

each

side

of

the

oil

pan.

Install

the

remaining

screws

and

tighten

them,

from

the

center

outward,

to

specifications.

4.

Lower

the

engine,

then

install

the

engine

right

and

left

front

support

retaining

bolts.

Tighten

the

bolts

to

specifications.

Remove

the

engine

lifting

bracket

and

sling.

Connect

the

radiator

upper

hose.

Fill

the

cooling

system.

Fill

the

crankcase

with

the

proper

grade

and

quantity

of

engine

oil.

Operate

the

engine

and

check

for

leaks.

OIL

PUMP

DISASSEMBLY

1.

Remove

the

oil

inlet

tube

from

the

oil

pump

and

remove

the

gasket.

2.

Remove

the

cover

retaining

PLATE

-**1

A

1272-

A

FIG.

80

Oil

Pump

Assembly

screws,

then

remove

the

cover.

Re

move

the

inner

rotor

and

shaft

as

sembly,

then

remove

the

outer

race.

3.

Insert

a

self-threading

sheet

metal

screw

of

the

proper

diameter

into

the

oil

pressure

relief

valve

chamber

cap

and

pull

the

cap

out

of

the

chamber.

Remove

the

spring

and

plunger.

OIL

PUMP

ASSEMBLY

The

oil

pump

assembly

is

shown

in

Fig.

80.

1.

Oil

all

parts

thoroughly.

2.

Install

the

oil

pressure

relief

valve

plunger,

spring,

and

a

new

cap.

3.

Install

the

outer

race,

and

the

inner

rotor

and

shaft

assembly.

The

inner

rotor

and

shaft,

and

the

outer

race

are

serviced

as

an

assembly.

One

part

should

not

be

replaced

without

replacing

the

other.

Install

the

cover.

Torque

the

cover

retaining

screws

to

6-9

ft-lbs.

4.

Position

a

new

gasket

and

the

oil

inlet

tube

on

the

oil

pump

and

install

the

retaining

bolts.

OIL

PAN

CLEANING

AND

INSPECTION

Scrape

any

dirt

or

metal

particles

from

the

inside

of

the

pan.

Scrape

all

old

gasket

material

from

the

gas

ket

surface.

Wash

the

pan

in

a

sol

vent

and

dry

it

thoroughly.

Be

sure

all

foreign

matter

is

removed

from

below

the

baffle

plate.

Check

the

pan

for

cracks,

holes,

damaged

drain

plug

threads,

a

loose

baffle,

and

a

nicked

or

warped

gas

ket

surface.

FIG.

81

Outer

Race

To

Housing

Clearance

Repair

any

damage,

or

replace

the

pan

if

repairs

can

not

be

made.

OIL

PUMP

CLEANING

AND

INSPECTION

Wash

all

parts

in

a

solvent

and

dry

them

thoroughly.

Use

a

brush

to

clean

the

inside

of

the

pump

housing

and

the

pressure

relief

valve

chamber.

Be

sure

all

dirt

and

chips

are

re

moved.

Check

the

inside

of

the

pump

hous

ing

and

the

outer

race

and

rotor

for

damage

or

excessive

wear.

Check

the

mating

surface

of

the

pump

cover

for

wear.

If

the

cover

mating

surface

is

worn,

scored,

or

grooved,

replace

the

cover.

Measure

the

outer

race

to

hous

ing

clearance

(Fig.

81).

With

the

rotor

assembly

installed

in

the

housing,

place

a

straight

edge

over

the

rotor

assembly

and

the

hous

ing.

Measure

the

rotor

end

play

clear

ance

between

the

straight

edge

and

the

rotor

and

outer

race

(Fig.

82).

The

outer

race,

shaft

and

rotor

are

replaceable

only

as

an

assembly.

Straight

Edge

Feeler

Gouge

FIG.

82-Rotor

End

Play

A1027-A

1-38

GROUP

1-

ENGINE

AND

EXHAUST

SYSTEM

Check

the

drive

shaft

to

housing

bearing

clearance

by

measuring

the

OD

of

the

shaft

and

the

ID

of

the

housing

bearing.

Inspect

the

relief

valve

spring

for

a

collapsed

or

worn

condition.

Check

the

relief

valve

spring

ten

sion.

If

the

spring

tension

is

not

with

in

specifications

and/or

the

spring

is

defective,

replace

the

spring.

Check

the

relief

valve

piston

for

scores

and

free

operation

in

the

bore.

WORK

STAND

REPAIR

OPERATIONS

To

perform

the

operations

in

this

section,

it

will

be

necessary

to

remove

the

engine

from

the

car

and

install

it

on

a

work

stand

(Page

1-17).

CRANKSHAFT

REMOVAL

The

crankshaft

and

related

parts

are

shown

in

Fig.

83.

1.

Remove

the

generator

adjusting

arm

bracket

bolt

from

the

generator

and

the

upper

support

bracket

bolt

at

the

water

pump.

Remove

the

spark

plugs

to

allow

easy

rotation

of

the

crankshaft.

2.

Remove

the

fuel

pump.

Slide

the

water

pump

by-pass

hose

clamp

toward

the

rear

of

the

engine.

Re

move

the

water

pump

and

fan

as

an

assembly.

3.

Remove

the

crankshaft

damper,

cap

screw

and

washer.

Install

the

pul

ler

on

the

damper

(Fig.

53)

and re

move

the

damper.

4.

If

the

crankshaft

sleeve

is

not

stepped

down

(the

same

OD

on

both

ends),

remove

it

as

shown

in

Fig.

54.

If

the

sleeve

is

stepped

down,

remove

it

with

a

three-jawed

puller

(tool

7675-N).

5.

Remove

the

cylinder

front

cover.

6.

Remove

the

oil

slinger.

Check

the

timing

chain

deflection,

then

re

move

the

timing

chain

and

sprockets

by

following

steps

13

thru

18

under

"Cylinder

Front

Cover

Removal"

on

page

1-27.

7.

Invert

the

engine

on

the

work

stand.

Remove

the

flywheel.

Remove

the

oil

pan and

gasket.

Remove

the

oil

pump.

8.

Make

sure

all

bearing

caps

(main

and

connecting

rod)

are

marked

so

that

they

can

be

installed

in

their

original

locations.

Remove

the

connecting

rod

bearing

caps.

Turn

the

crankshaft

until

the

con

necting

rod

from

which

the

cap

is

being

removed

is

down

and

remove

the

cap.

Push

the

connecting

rod

and

piston

assembly

up

into

the

cylinder.

9.

Remove

the

main

bearing

caps.

10.

Carefully

lift

the

crankshaft

out

of

the

block

so

that

the

thrust

bearing

surfaces

are

not

damaged.

Handle

the

crankshaft

with

care

to

avoid

possible

fracture

or

damage

to

the

finished

surfaces.

INSTALLATION

1.

Remove

the

rear

journal

oil

seal

from

the

block

and

rear

main

bearing

cap.

Remove

the

rear

main

bearing

cap

to

block

side

seals.

2.

Remove

the

main

bearing

in

serts

from

the

block

and

bearing

caps.

3.

Remove

the

connecting

rod

bearing

inserts

from

the

connecting

rods

and

caps.

4.

If

the

crankshaft

main

bearing

journals

have

been

refinished

to

a

definite

undersize,

install

the

correct

undersize

bearings.

Be

sure

the

bear

ing

inserts

and

bearing

bores

are

clean.

Foreign

material

under

the

in-

CYLINDER

BLOCK

JOURNAL

SEAL

MAIN

BEARING

INSERTS

BOLT

RING

GEAR

BOLT

DAMPER

POWER

STEERING

PUMP

PULLEY

MAIN

BEARING

CAPS

WASHER

FIG.

83

-Crankshaft

and

Related

Parts

A1276-B

PART

1-1

-ENGINE

1-39

PLACE

Plastigage

FULL

WIDTH

OF

JOURNAL

ABOUT

y4

INCH

OFF

CENTER

CHECK

WIDTH

OF

Plastigage

-670

A1277-A

FIG.

84-Seal

To

Block

Installation

serfs

may

distort

the

bearing

and

cause

a

failure.

5.

Place

the

upper

main

bearing

inserts

in

position

in

the

bores

with

the

tang

fitting

in

the

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.

84).

After

in

stallation,

cut

the

ends of

the

seals

flush.

8.

Carefully

lower

the

crankshaft

into

place.

Be

careful

not

to

damage

the

bearing

surfaces.

9.

Check

the

clearance

of

each

main

bearing

as

follows:

Place

a

piece

of

Plastigage

on

the

crankshaft

journal

the

full

width

of

the

journal

and

about

Va

inch

off

center

(Fig.

85).

Follow

steps

10

thru

12

under

"Main

Bearing

Re

placement"

(page

1-32).

10.

After

the

bearings

have

been

fitted,

apply

a

light

coat

of

engine

INSTALLING

MEASURING

PLASTIGAGE

PLASTIGAGE

A1023-A

FIG.

85

Installing

&

Measuring

Plastigage

Engine

Removed

oil

to

the

journals

and

bearings.

In

stall

a

new

seal

in

the

rear

main

bearing

cap

and

install

the

rear

main

bearing

cap

by

following

steps

3

thru

7

under

"Crankshaft

Lower

Rear

Oil Seal

Replacement"

(page

1-31).

Install

all

the

bearing

caps,

except

the

thrust

bearing

cap

(No.

3

bear

ing).

Be

sure

that

the

main

bearing

caps

are

installed in

their

original

lo

cations.

Torque

the

bearing

cap

bolts

to

95-105

ft-lbs.

11.

Install

the

thrust

bearing

cap

with

the

bolts

finger-tight.

12.

Pry

the

crankshaft

forward

against

the

thrust

surface of

the

upper

half

of

the

bearing

(Fig.

86).

13.

Hold

the

crankshaft

forward

and

pry

the

thrust

bearing

cap

to

the

rear

(Fig.

86).

This

will

align

the

thrust

surfaces

of

both

halves

of

the

bearing.

14.

Retain

the

forward

pressure

on

the

crankshaft.

Tighten

the

cap

bolts

to

95-105

ft-lbs

(Fig.

86).

15.

Force

the

crankshaft

toward

the

rear

of

the

engine.

16.

Install

a

dial

indicator

so

that

the

contact

point

rests

against

the

crankshaft

flange

and

the

indicator

A1280-A

FIG.

87-Crankshaft

End

Play

axis

is

parallel

to

the

crankshaft

axis

(Fig.

87).

17.

Zero

the

dial

indicator.

Push

the

crankshaft

forward

and

note

the

reading

on

the

dial.

If

the

end

play

exceeds

the

wear

limit,

replace

the

thrust

bearing.

If

the

end

play

is

less

than

the

mini

mum

limit,

inspect

the

thrust

bearing

faces

for

scratches,

burrs,

nicks,

or

dirt.

If

the

thrust

faces

are

not

de

fective

or

dirty,

they

probably

were

not

aligned

properly.

Install

the

thrust

bearing

and

align

the

faces

fol

lowing

the

recommended

procedure

(steps

11,

12,

13,

and

14),

then

check

the

end

play.

18.

Install

new

bearing

inserts

in

the

connecting

rods

and

caps.

Check

the

clearance

of

each

bearing

by

fol

lowing

the

procedure

on

page

1-32.

19.

After

the

connecting

rod

bearings

have

been

fitted,

apply

a

light

coat

of

engine

oil

to

the

journals

and

bearings.

20.

Turn

the

crankshaft

throw

to

the

bottom

of

its

stroke.

Push

the

piston

all

the

way

down

until

the

rod

HOLD

CRANKSHAFT

FORWARD

PRY

CRANKSHAFT

FORWARD

FIG.

86

Thrust

Bearing

Alignment

PRY

CAP

BACKWARD

TIGHTEN

CAP

A1279-A

1-40

GROUP

1-

ENGINE

AND

EXHAUST

SYSTEM

bearing

seats

on

the

crankshaft

jour

nal.

21.

Install

the

connecting

rod

cap.

Torque

the

nuts

to

40-45

ft-lbs.

22.

After

the

piston

and

connect

ing

rod

assemblies

have

been

in

stalled,

check

the

side

clearance

be

tween

the

connecting

rods

on

each

connecting

rod

crankshaft

journal

(Fig.

69).

23.

Clean

the

oil

pan,

oil

pump,

and

oil

pump

screen.

Install

the

oil

pump,

oil

pan,

and

oil

filter.

24.

Position

the

flywheel

on

the

crankshaft.

Install

the

retaining

bolts.

Torque

the

bolts

to

75-85

ft-lbs.

25.

Install

the

timing

chain

and

sprockets,

cylinder

front

cover

and

crankshaft

damper,

following

steps

1

thru

8

under

"Cylinder

Front

Cover

Installation"

on

page

1-28.

26.

Install

the

oil

filter,

fuel

pump,

and

carburetor

fuel

inlet

line.

Install

the

generator.

Install

the

spark

plugs.

27.

Remove

the

engine

from

the

work

stand

and

install

in

the

car

(page

1-18).

CLEANING

AND

INSPECTION

Handle

the

crankshaft

with

care

to

avoid

possible

fractures

or

dam

age

to

the

finished

surfaces.

Clean

the

crankshaft

with

solvent,

then

blow

out

all

oil

passages

with

com

pressed

air.

Inspect

main

and

connecting

rod

journals

for

cracks,

scratches,

grooves,

or

scores.

Dress

minor

im

perfections

with

an

oilstone.

Refin

ish

severely

marred

journals.

Measure

the

diameter

of

each

journal

inatleast

four

places

to

de

termine

out-of-round,

taper,

or

un

dersize

condition

(Fig.

88).

If

the

journals

exceed

the

wear

limit,

they

should

be

refinished

to

size

for

the

next

undersize

bearing.

A

VS

B

=

VERTICAL

TAPER

C

VS

D

=

HORIZONTAL

TAPER

A

VS

C

AND

BVSD

=

OUT-OF-ROUND

CHECK

FOR

OUT-OF-ROUND

AT

EACH

END

OF

JOURNAL

Tool

T52L-6261-CEE

Tool-

T54L-6250-B

INSTALL

FRONT

BEARING

0.005-0.020

INCH

BELOW

FRONT

FACE

OF

BLOCK

A1015-A

FIG.

88-Crankshoft

Journal

Measurements

I

A1260-A

FIG.

89

Camshaft

Bearing

Replacement

Refinishing

Journals.

Refinish

the

journal

to

give

the

proper

clearance

with

the

next

undersize

bearing.

If

the

journal

will

not

"clean

up"

to

give

the

proper

clearance

with

the

maximum

undersize

bearing

avail

able,

replace

the

crankshaft.

Always

reproduce

the

same

jour

nal

shoulder

radius

that

existed

originally.

Too

small

a

radius

will

result

in

fatigue

failure

of

the

crank

shaft.

Too

large

a

radius

will

result

in

bearing

failure

due

to

radius

ride

of

the

bearing.

After

refinishing

the

journals,

chamfer

the

oil

holes,

then

polish

the

journal

with

a

No.

320

grit

polishing

cloth

and

engine

oil.

Crocus

cloth

may

be

used

also

as

a

polishing

agent.

CAMSHAFT

BEARING

REPLACEMENT

The

bearings

are

available

pre-

finished

to

size

for

standard and

0.015-inch

undersize

journal

diam

eters.

The

bearings

are

not

inter

changeable

from

one

bore

to

another.

1.

Remove

the

camshaft,

the

fly

wheel

and

the

crankshaft.

Push

the

pistons

to

the

top

of

the

cylinders.

2.

Remove

the

camshaft

rear

bear

ing

bore

plug

(page

1-30).

Remove

the

camshaft

bearings

(Fig.

89).

3.

Position

the

new

bearings

at

the

bearing

bores,

and

press

them

in

place

with

the

tool

shown

in

Fig.

89.

11273-A

FIG.

90

Camshaft

Front

Bearing

Measurement

Align

the

oil

holes

in

the

bearings

with

the

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.

90).

4.

Clean

out

the

camshaft

rear

bearing

bore

plug

recess

thoroughly.

Coat

the

flange

of

a

new

plug

with

water

resistant

sealer

and

install

the

plug

(Fig.

91).

5.

Install

the

camshaft,

crank

shaft,

flywheel,

and

related

parts.

In

stall

the

engine

in

the

car.

ENGINE

DISASSEMBLY

1.

Install

the

engine

on

the

work

stand

(Fig.

25).

2.

Remove

the

distributor

cap

and

spark

plug

wire

assembly.

3.

Disconnect

the

distributor

vac

uum

line

at

the

distributor.

Remove

the

carburetor

fuel

inlet

line.

Remove

the

fuel

pump

and

discard

the

gasket.

4.

Slide

the

clamp

on

the

water

Too/-T58P-6266-A

A1274-B

FIG.

91

Camshaft

Rear

Bearing

Bore

Plug

Installation

PART

1-1

-ENGINE

1-41

pump

by-pass

hose

toward

the

water

pump.

Remove

the

automatic

choke

heat

tube.

Remove

the

valve

rocker

arm

covers.

5.

Crank

the

engine

until

the

No.

1

piston

is

at

TDC

at

the

end

of

the

compression

stroke.

Rotate

the

crank

shaft

damper

an

additional

45

(iden

tified

on

the

damper

by

"XX").

Starting

at

the

No.

4

cylinder,

loosen

the

right

rocker

arm

shaft

support

bolts

in

sequence,

two

turns

at

a

time.

After

the

bolts

are

all

loosened,

re

move

the

valve

rocker

arm

shaft

as

sembly

and

the

oil

baffle

plate.

Start

ing

at

the

No.

5

cylinder,

follow

the

same

procedure

on

the

left

valve

rocker

arm

shaft

support

bolts.

This

procedure

must

be

followed

to

avoid

damage

to

the

valve

mechanism.

6.

Remove

the

valve

push

rods

in

sequence

and

put

them

in

a

rack

so

that

they

can

be

installed

in

their

original

bore.

7.

Remove

the

distributor

hold

down

bolt

and

clamp

and

remove

the

distributor.

8.

Remove

the

intake

manifold

retaining

bolts.

9.

Install

standard

eye

bolts

with

%6-18

threads

in

the

left

front

and

right

rear

rocker

arm

cover

screw

holes

and

attach

the

engine

lifting

sling

(Fig.

24).

10.

Raise

the

manifold

and

care

fully

remove

it

from

the

engine.

Dis

card

the

intake

manifold

gaskets

and

seals.

11.

Remove

the

baffle

plate

from

the

valve

push

rod

chamber

floor

by

prying

up

on

the

baffle

with

a

screw

driver

(Fig.

92).

12.

Lift

the

valve

lifters

from

the

cylinder

block

and

place

them

in

a

rack

so

that

they

can

be

installed

in

Magnetic

Lifter

A1254-A

FIG.

92

-Baffle

Plate

Removal

A1255-A

FIG.

93-Hydraulic

Valve

Lifter

Removal

their

original

bore (Fig.

93).

The

in

ternal

parts of

each

hydraulic

valve

lifter

assembly

are

matched

sets.

Do

not

intermix

the

parts.

Keep

the

as

semblies

intact

until

they

are

to

be

cleaned.

13.

Remove

the

exhaust

mani

folds

and

the

spark

plugs.

14.

Remove

the

cylinder

head

bolts,

and

then

install

the

cylinder

head

holding

fixtures

(Fig.

34).

15.

Lift

the

cylinder

heads

off

the

block.

Do

not

pry

between

the

head

and

the

block.

Discard

the

cylinder

head

gaskets.

16.

Remove

the

oil

filter.

Remove

the

oil

filter

adapter

assembly

and

oil

pressure

sending

unit

as

an

assem

bly.

Discard

the

gasket.

17.

Remove

the

generator,

brack

ets,

and

drive

belts.

18.

Remove

the

water

pump,

pul

ley,

and

fan

as

an

assembly.

19.

Remove

the

power

steering

pulley.

Remove

the

crankshaft

damp

er

(Fig.

53).

20.

If

the

crankshaft

sleeve

is

not

stepped

down

(the

same

OD

on

both

ends),

remove

it

as

shown

in

Fig.

54.

If

the

crankshaft

sleeve

is

stepped

down

(different

OD

on

each

end),

re

move

it

with a

three-jawed

puller

(tool

7675-N).

21.

Remove

the

cylinder

front

cover.

Discard

the

gasket.

Remove

the

crankshaft

front

oil

slinger.

22.

Check

the

timing

chain

deflec

tion

by

following

steps

13,

14,

and

15

under

"Cylinder

Front

Cover

and

Timing

Chain

Removal"

on

page

1-27.

23.

Remove

the

camshaft

thrust

button

and

spring,

the

sprocket

cap

screw,

and

thrust

button

spring

re

tainer,

and

the

fuel

pump

eccentric.

Remove

the

crankshaft

sprocket

key.

Remove

the

sprockets

and

timing

chain

as

an

assembly

(Fig.

57).

24.

Remove

any

ridge

and/or

car

bon

deposits

from

the

upper

end

of

the

cylinder

bores.

Move

the

piston

to

the

bottom

of

its

travel

and

place

a

cloth

on

the

piston

head

to

collect

the

cuttings.

Remove

the

cylinder

ridge

with

a

ridge

cutter.

Follow

the

instructions

furnished

by

the

tool

manufacturer.

Never

cut

into

the

ring

travel

area

in

excess

of

1/32

inch

when

removing

ridges.

After

the

ridge

has

been

removed,

remove

the

cutter

from

the

cylinder

bore.

25.

Remove

the

flywheel.

26.

Invert

the

engine.

Remove

the

oil

pan.

Discard

the

gasket.

27.

Remove

the

oil

pump

and

in

let

tube

as

an

assembly.

Remove

the

oil

pump

drive

shaft.

Discard

the

oil

pump

gasket.

28.

Make

sure

all

connecting

rods

and

caps

are

marked

so

that

they

can

be

installed

in

their

original

locations.

Turn

the

crankshaft

until

the

con

necting

rod

being

removed

is

down.

Remove

the

rod

cap.

29.

Push

the

connecting

rod

and

piston

assembly

out

the

top

of

the

cylinder

with

the

handle

end

of

a

hammer.

Avoid

damage

to

the

crankpin

or

the

cylinder

wall

when

removing

the

piston

and

rod.

30.

Remove

the

bearing

inserts

from

the

connecting

rods

and

caps.

Install

the

rod

caps

on

the

connect

ing

rods

from

which

they

were

re

moved.

31.

Remove

the

main

bearing

caps.

32.

Carefully

lift

the

crankshaft

out

of

the

cylinder

block

so

that

the

thrust

bearing

surfaces

are

not

dam

aged.

Handle

the

crankshaft

with

care

to

avoid

possible

fracture

or

damage

to

the

finished

surfaces.

33.

Remove

the

rear

journal

oil

seal

from

the

block

and

rear

bearing

cap,

and

remove

the

cap

to

block

side

seals.

34.

Remove

the

main

bearing

in

serts

from

block

and

bearing

caps.

Install

the

main

bearing

caps

in

their

original

positions.

35.

Carefully

remove

the

cam

shaft

by

pulling

it

toward

the

front

of

the

engine.

Use

caution

to

avoid

damaging

the

journals

and

lobes.

36.

Remove

the

camshaft

rear

bearing

bore

plug.

Remove

the

cam

shaft

bearings

(Fig.

89).

1-42

GROUP

1-

ENGINE

AND

EXHAUST

SYSTEM

CYLINDER

BLOCK

CLEANING

AND

INSPECTION

Thoroughly

clean

the

block

in

solvent.

Remove

old

gasket

material

from

all

machined

surfaces.

Remove

all

pipe

plugs

which

seal

oil

pas

sages,

then

clean

out

all

the

pas

sages.

Blow

out

all

passages,

bolt

holes,

etc.

with

compressed

air.

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

block

has

been

thor

oughly

cleaned,

make

a

check

for

cracks.

Minute

cracks

not

visible

to

the

naked

eye

may

be

detected

by

coating

the

suspected

area

with

a

mixture

of

25%

kerosene

and

75%

light

motor

oil.

Wipe

the

part

dry

and

immediately

apply

a

coating

of

zinc

oxide

dissolved

in

wood

alcohol.

If

cracks

are

present,

the

coating

will

become

discolored

at

the

defective

area.

Replace

the

block

if

it

is

cracked.

Check

all

machined

gasket

sur

faces

for

burrs,

nicks,

scratches,

and

scores.

Remove

minor

imper

fections

with

an

oil

stone.

Check

the

flatness

of

the

cylinder

block

gasket

surface

following

the

procedure

and

specifications

recommended

for

the

cylinder

head.

Replace

all

expansion-type

plugs

that

show

evidence

of

leakage.

Inspect

the

cylinder

walls

for

scor

ing,

roughness,

or

other

signs

of

wear.

Check

the

cylinder

bore

for

out

-

of

-

round

and

taper.

Measure

the

bore

with

an

accurate

gauge

CENTER

LINE

OF

ENGINE

A

A

--W

AT

i

|

^^.

'

i

RIGHT

ANGLE

TO

CENTER

LINE

OF

ENGINE

B

PARALLEL

TO

CENTER

LINE

OF

ENGINE

k

A

m*mm.

i

1.

OUT-OF-ROUND

=

DIFFERENCE

BETWEEN

A

AND

B

2.

TAPER

=

DIFFERENCE

BETWEEN

THE

A

MEASUREMENT

AT

TOP

OF

CYLINDER BORE

AND

THE

A

MEASUREMENT

AT

BOTTOM

OF

CYLINDER

BORE

A1025-A

FIG.

94

-Cylinder

Bore

Out-of-

Round

and

Taper

following

the

instructions

of

the

manufacturer.

Measure

the

diam

eter

of

each

cylinder

bore

at

the

top,

middle,

and

bottom

with

the

gauge

placed

at

right

angles

and

parallel

to

the

centerline

of

the

engine

(Fig.

94).

Refinish

cylinders

that

are

deeply

scored

and/

or

when

out-of-round

and/or

taper

exceed

the

wear

limits.

If

the

cylinder

walls

have

minor

surface

imperfections,

but

the

out-

of-round

and

taper

are

within

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

operation.

REFINISHING

CYLINDER

WALLS

Honing

is

recommended

for

re

finishing

cylinder

walls

only

when

the

walls

have

minor

imperfections,

such

as

light

scuffs,

scratches,

etc.

The

grade

of

hone

to

be

used

is

determined

by

the

amount

of

metal

to

be

removed.

Follow

the

instruc

tions

of

the

hone

manufacturer.

If

coarse

stones

are

used

to

start

the

honing

operation,

leave

enough ma

terial

so

that

all

hone

marks

can

be

removed

with

the

finishing

hone

which

is

used

to

obtain

the

proper

piston

clearance.

Cylinder

walls

that

are

severely

marred

and/or

worn

beyond

the

specified

limits

should

be

refinished.

Before

any

cylinder

is

refinished,

all

main

bearing

caps

must

be

in

place

and

tightened

to

the

proper

torque

so

that

the

crankshaft

bearing

bores

will

not

become

distorted from

the

refinishing

operation.

Refinish

only

the

cylinder

or

cyl

inders

that

require

it.

All

pistons

are

the

same

weight,

both

standard

and

oversize;

therefore,

various

sized

pis

tons

can

be

intermixed

without

upset

ting

engine

balance.

Refinish

the

cylinder

with

the

most

wear

first

to

determine

the

maximum

oversize.

If

the

cylinder

will

not

clean

up

when

refinished

for

the

maximum

oversize

piston

recommended,

replace

the

block.

Refinish

the

cylinder

to

within

ap

proximately

0.0015

inch

of

the

re

quired

oversize

diameter.

This

will

allow

enough

stock

for

the

final

step

of

honing

so

that

the

correct

surface

finish

and

pattern

are

obtained.

Use

clear

sharp

hones

of

No.

220-280

grit

for

this

operation.

For

the

proper

use

of

the

re

finishing

equipment,

follow

the

in

structions

of

the

manufacturer.

Only

experienced

personnel

should

be

al

lowed

to

perform

this

work.

After

the

final

operation

in

either

of

the

two

refinishing

methods

de

scribed

and

prior

to

checking

the

piston

fit,

thoroughly

wash

the

cyl

inder

walls

with

solvent

to

remove

all

abrasive

particles,

then

thoroughly

dry

the

walls.

Check

the

piston

fit.

Mark

the

pistons

to

correspond

to

the

cylinders

in

which

they

are

to

be

installed.

When

the

refinishing

of

all

cylinders

that

require

it

has

been

completed

and

all

pistons

fitted,

thor

oughly

clean

the

entire

block

to

re

move

all

particles

from

the

bearing

bores,

oil

passages,

cylinder

head

bolt

holes,

etc.

Coat

the

cylinder

walls

with

oil.

ENGINE

ASSEMBLY

1.

Remove

the

glaze

from

the

cyl

inder

bores

by

following

the

instruc

tions

of

the

tool

manufacturer.

2.

Invert

the

engine

on

the

work

stand.

3.

Position

the

new

bearings

at

the

bearing

bores,

and

press

them

in

place

with

the

tool

shown

in

Fig.

89.

Align

the

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.

90).

4.

Check

the

oil

passage

that

feeds

the

rocker

arm

shafts

for

obstruc

tions

by

squirting

oil

into

the

open

ing

on

each

cylinder

bank

and

ob

serving

the

flow

through

the

oil

holes

at

Nos.

2

and

4

bearings.

5.

Clean

out

the

camshaft

rear

bearing

bore

plug

recess

thoroughly.

6.

Coat

the

flange

ofanew

plug

with

water

resistant

sealer

and

in

stall

it

with

the

flange

facing

out

(Fig.

91).

Drive

the

plug

in

until

it

is

flush

or

slightly

below

the

casting

surface.

7.

Oil

the

camshaft

and

apply

Lubriplate

to

all

lobes,

then

carefully

slide

it

through

the

bearings.

8.

Be

sure

that

the

rear

oil

seal

grooves

are

clean.

Install

a

new

rear

journal

oil

seal

in

the

block

(Fig.

84).

After

installation,

cut

the

ends

of

the

seals

flush.

9.

If

the

crankshaft

main

bearing

journals

have

been

refinished

to

a

definite

undersize,

install

the

correct

undersize

bearings.

Be

sure

the

bear

ing

inserts

and

bearing

bores

are

PART

1-1

-ENGINE

1-43

clean.

Foreign

material

under

the

in

serts

may

distort

the

bearing

and

cause

a

failure.

Place

the

upper

main

bearing

in

serts

in

position

in

the

bore

with

the

tang

fitting

in

the

slot

provided.

10.

Install

the

lower

main

bearing

inserts

in

the

bearing

caps.

11.

Carefully

lower

the

crank

shaft

into

place.

Be

careful

not

to

damage

the

bearing

surfaces.

12.

Check

the

clearance

of

each

main

bearing

by

following

the

proce

dure

under

"Main

Bearing

Replace

ment"

(page

1-32).

13.

After

the

bearings

have

been

fitted,

apply

a

light

coat

of

engine

oil

to

the

journals

and

bearings.

14.

Be

sure

that

the

oil

seal

grooves

in

the

rear

main

bearing

cap

are

clean.

Install

a

new

journal

seal

in

the

cap

(Fig.

65).

After

installa

tion,

cut

the

ends

of

the

seal

flush.

Apply

a

thin

coating

of

oil

resistant

sealer

to

the

rear

main

bearing

cap

at

the

rear

of

the

top

mating

surface.

(Fig.

67).

Do

not

apply

sealer

to

the

area

forward

of

the

side

seal

groove.

Install

the

rear

main

bearing

cap

and

the

remainder

of

the

caps,

except

the

thrust

bearing

cap

(No.

3

bearing).

Be

sure

that

the

main

bearing

caps

are

installed

in

their

original

loca

tions.

Torque

the

bearing

cap

bolts

to

95-105

ft-lbs.

15.

Install

the

thrust

bearing

cap

and check

crankshaft

end

play

by

following

steps

11

thru

17

under

"Crankshaft

Installation"

on

page

1-38.

16.

Turn

the

engine

on

the

work

stand

so

that

the

front

end

is

up.

17.

Install

the

pistons

and

con

necting

rods

by

following

steps

1

thru

9

under

"Piston

and

Connect

ing

Rod

Installation"

on

page

1-33.

18.

Position

the

sprockets

and

tim

ing

chain

on

the

camshaft and

crank

shaft

(Fig.

57).

Be

sure

the

timing

marks

on

the

sprockets

are

positioned

as

shown

in

Fig.

56.

19.

Lubricate

the

timing

chain

and

sprockets

with

engine

oil.

20.

Install

the

fuel

pump

eccen

tric

(Fig.

58),

the

camshaft

sprocket

cap

screw,

and

thrust

button

spring

retainer.

Torque

the

sprocket

cap

screw

to

35-45

ft-lbs.

Install

the

cam

shaft

thrust

button

spring

and

thrust

button

(Fig.

58).

Install

the

crank

shaft

front

oil

slinger.

21.

Clean

the

cylinder

front

cover

and

the

cylinder

block

gasket

sur

faces.

Install

a

new

crankshaft

front

oil

seal

(Fig.

61).

22.

Coat

the

gasket

surface

of

the

block

and

cover

and

the

cover

bolt

threads

with

sealer.

Position

a

new

gasket

on

the

block.

23.

Install

the

alignment

pilot

tool

on

the

cylinder

front

cover

so

that

the

keyway

in

the

pilot

aligns

with

the

key

in

the

crankshaft.

Position

the

cover

and

pilot

over

the

end

of

the

crankshaft

and

against

the

block

(Fig.

60).

24.

Install

the

cylinder

front

cov

er

bolts

finger-tight.

Position

the

gen

erator

support

bracket

and

the

gen

erator

adjusting

arm

bracket,

then

install

the

bolts

(on

a

car

equipped

with

an

air

conditioner,

connect

the

compressor

and

brackets

to

the

cyl

inder

front

cover).

While

pushing

in

on

the

pilot,

torque

the

cover

bolts

to

12-15

ft-lbs.

Remove

the

pilot.

25.

Lubricate

the

crankshaft

with

a

white

lead

and

oil

mixture

and

lubricate

the

oil

seal

rubbing

surface

with

grease.

26.

Install

the

crankshaft

sleeve

with

the

smallest

OD

end

into

the

cylinder

front

cover

bore

if

the

sleeve

is

stepped

down

(different

OD

on

each end).

27.

Line

up

the

damper

keyway

with

the

key

on

the

crankshaft,

then

install

the

damper

on

the

crankshaft

(Fig.

60).

Install

the

damper

cap

screw

and

washer,

and

torque

the

screw

to

70-90

ft-lbs.

28.

Install

the

power

steering

pump

pulley

on

the

crankshaft

damper.

29.

Clean

the

water

pump

gasket

surfaces

and

apply

sealer.

Position

new

gaskets

on

the

pump

and

install

the

water

pump,

pulley,

and

fan

as

an

assembly.

30.

Using

a

new

gasket,

install

the

fuel

pump.

Install

the

generator,

brackets,

and

drive

belts.

31.

Turn

the

engine

on

the

work

stand

so

that

the

top

of

the

engine

is

up.

32.

Clean

the

cylinder

head

and

block

gasket

surfaces.

Apply

sealer

to

both

sides

of

a

new

gasket.

Guided

by

the

word

"FRONT"

on

the

gasket,

install

the

head

gasket

over

the

cylinder

head

dowels.

33.

Place

the

cylinder

head

on

the

engine,

then

remove

the

holding

fix

tures.

Coat

the

head

bolt

threads

with

water

resistant

sealer,

and

then

install

the

bolts.

34.

The

cylinder

head

bolt

tight

ening

procedure

is

performed

in

three

progressive

steps.

Torque

the

bolts

in

sequence

(Fig.

35)

to

70

ft-lbs,

then

to

80

ft-lbs,

and

finally

to

90

ft-lbs.

After

the

cylinder

head

bolts

have

been

torqued

to

specifica

tions,

the

bolts

should

not

be

dis

turbed.

35.

Coat

the

mating

surfaces

of

the

exhaust

manifold

with

a

light

film

of

graphite

grease.

36.

Using

a

new

gasket,

install

the

automatic

choke

air

chamber

cover on

the

right

exhaust

manifold.

Be

sure

the

cover

is

securely

fastened.

Position

the

exhaust

gas

control

valve

over

the

muffler

inlet

pipe

studs

of

the

right

exhaust

manifold,

using

a

new

gasket

on

each

side

of

the

valve.

Temporarily

tie

the

valve

to

the

ex

haust

manifold.

37.

Position

a

new

gasket

over

the

muffler

inlet

pipe

studs

of

the

left

ex

haust

manifold.

38.

Position

the

exhaust

manifolds

on

the

cylinder

heads

and

install

the

retaining

bolts

and

tab

washers.

Torque

the

retaining

bolts

to

23-28

ft-lbs,

working

from

the

center

to

the

ends.

Lock

the

bolts

by

bending

one

tab

of

the

washer

over

a

flat

on

the

bolt.

39.

Install

the

spark

plugs.

40.

Position

the

baffle

plate

in

the

valve

push

rod

chamber.

Press

it

into

place

(Fig.

95).

41.

Coat

the

outside

of

each

valve

lifter

with

engine

oil

to

provide

ini

tial

lubrication.

Do

not

fill

the

lifters

with

oil.

The

lifters

will

fill

much

faster

after

the

engine

is

started,

if

FIG.

95-Baffle

Plate

Installation

1-44

GROUP

1-

ENGINE

AND

EXHAUST

SYSTEM

they

are

free

of

any

oil

film

which

may

cause

an

oil

seal

between

the

plunger

and

the

lifter

body.

Place

each

lifter

in

the

bore

from

which

it

was

removed.

42.

Clean

the

mating

surfaces

of

the

intake

manifold,

cylinder

heads,

and

cylinder

block.

43.

Coat

the

intake

manifold

and

cylinder

block

seal

surfaces

with

oil

resistant

sealer.

44.

Position

new

seals

on

the

cyl

inder

block

and

new

gaskets

on

the

cylinder

heads

with

the

gasket

rest

ing

on

the

cylinder

head

gasket

tabs.

Be

sure

the

holes

in

the

gaskets

are

aligned

with

the

holes

in

the

cylinder

heads.

The

correct

installation

of

the

gaskets

and

seals

are

shown

in

Fig.

31).

45.

Install

the

eye

bolts

in

the

in

take

manifold

and

attach

the

engine

lifting

sling

and

carefully

lower

the

intake

manifold

on

the

engine

(Fig.

29).

46.

Position

the

intake

manifold

by

inserting

the

distributor

in

place.

After

the

intake

manifold

is

in

place,

run

a

finger

around

the

seal

area

to

make

sure

the

seals

are

in

place.

If

the

seals

are

not

in

place,

remove

the

intake

manifold

and

position

the

seals.

47.

Start

the

water

pump

by-pass

hose

on

the

intake

manifold.

48.

Be

sure

the

holes in

the

mani

fold

gaskets

and

manifold

are

in

alignment.

Install

the

manifold

re

taining

bolts

and

torque them

to

32-

35

ft-lbs,

working

from

the

center

to

the

ends.

49.

Remove

the

distributor

and

the

engine

lifting

sling

and

eye

bolts.

50.

Refer

to

"Valve

Rocker

Arm

Shaft

Assembly

Installation"

(page

1

-20)

and

install

the

valve

rocker

arm

shaft

assembly

by

following

steps

1

thru

6.

51.

Install

the

automatic

choke

heat

tube.

52.

Rotate

the

crankshaft

damper

until

the

No.

1

piston

is

on

TDC

then

position

the

distributor

in

the

block

with

the

rotor

at

the

No.

1

fir

ing

position

and

the

points

open.

In

stall

the

hold down

clamp.

53.

Connect

the

distributor

vac

uum

line.

Install

the

distributor

cap.

Install

the

valve

rocker

arm

covers.

54.

Connect

the

spark

plug

wires.

Install

the

carburetor

fuel

inlet

line.

55.

Invert

the

engine

on

the

work

stand.

Position

the

oil

pump

drive

shaft

into

the

distributor

socket.

With

the

shaft

firmly

seated

in

the

distributor

socket,

the

stop

on

the

shaft

should

touch

the

roof of

the

crankcase.

Remove

the

shaft

and

position

the

stop

as

necessary.

56.

With

the

stop

properly

posi

tioned,

insert

the

oil

pump

drive

shaft

into

the

oil

pump.

57.

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.

58.

Position

a

new

gasket

on

the

pump

housing

and

install

the

pump

and

shaft

as

an

assembly.

Do

not

at

tempt

to

force

the

pump

into

posi

tion

if

it

will

not

seat

readily.

The

drive

shaft

hex

may

be

misaligned

with

the

distributor

shaft.

To

align,

rotate

the

intermediate

shaft

into

a

new

position.

59.

Position

a

new

gasket

on

the

oil

pan

and

place

the

oil

pan

assem

bly

on

the

block.

Install

the

retain

ing

screws

and

torque

them

from

the

center

outward

to

9-13

ft-lbs.

60.

Position

the

flywheel

on

the

crankshaft

and

install

the

retaining

OIL

PRESSURE

SENDING

UNIT

ADAPTER

-

FILTER

ELEMENT

A1291-B

FIG.

96

Oil

Filter

Assembly

bolts.

Torque

the

bolts

to

75-85 ft-lbs.

61.

The

oil

filter

assembly

is

shown

in

Fig.

80.

Clean

the

oil

filter

adapter

gasket

surfaces.

62.

Apply

sealer

to

a

new

adapter

gasket,

and

install

the

adapter

assem

bly

and

gasket.

63.

Clean

the

adapter

filter

re

cess.

Coat

the

gasket

on

a

new

filter

with

oil.

Place

the

filter

in

position

on

the

adapter.

Hand

tighten

the

fil

ter

until

the

gasket

contacts

the

adapter

face,

and

then

advance

it

Vi-tum.

64.

Install

the

engine

in

the

car

(page

1-18).

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

dashpot.

65.

Adjust

the

transmission

con

trol

linkage.

CRANKCASE

VENTILATION

SYSTEM

MAINTENANCE

Refer

to

Group

16

for

the

correct

mileage

interval

for

maintenance.

BREATHER

CAP

The

breather

cap

located

on

the

oil

filter

tube

should

be

cleaned

with

a

solvent

at

the

proper

mileage

in

terval.

POSITIVE

CRANKCASE

VENTILATION

SYSTEM

At

the

recommended

interval,

re

move

the

crankcase

ventilation

regu

lator

valve,

exhaust

tube,

and

con

nections.

Clean

the

valve

and

exhaust

tube

in

clean

carburetor

solvent

and

dry

them

with

compressed

air.

Clean

the

rubber

hose

connection

with

a

low

volatility

petroleum

base

solvent

and

dry

them

with

compressed

air.

FORM

7750-61

LITHO

\H

U.S

A