Hudson Hornet 1955, 1955 Wasp, 1955 Rambler Technical & Service Manual
2
ENGINE SECTION
(6 Cylinder)
ENGINE IDENTIFICATION
The engine number is located on the upper left
hand forward portion of the cylinder block on
the "Hornet" and "Wasp" Series.
The engine number on the "Rambler" Series is
located on a machined surface on the right side
of the engine block just above the exhaust pipe.
Letter Identification, Size of Bore, Main Bearings and
Connecting Rod Bearings
In the machining of cylinder .blocks and
crankshafts, it is sometimes necessary to
machine the cylinder bores to .010" oversize,
and the crankshaft main bearing journals or
crank pins to 0.10" undersize.
These engines are marked with a three letter
code. The code is stamped adjacent to the
engine number. The letters are decoded as
follows:
First Letter Size of Bore
Second Letter Size of Main Bearings
Third Letter Size of Connecting Rod
Bearings
Letter "A" Standard
Letter "B" .010" Undersize
Letter "C" .010" Oversize
Engines (after Number F-2814 or M-3616) that
are not marked are standard in all respects.
CYLINDER HEAD AND GASKET
Whenever a cylinder head is removed, inspect
the mating surfaces on the cylinder head and
block for cleanliness and squareness with a
straight edge.
Coat the gasket with a non-hardening gasket
paste and locate the gasket on the cylinder
block. A pair of guide pins, size 3" x 1/2"-13
"Hornet" and 3" x 7/16"-14 "Wasp" Series, will
aid in the installation of the cylinder head
(Fig. 1).
Series, and the studs on "Rambler" Series, as
they connect to water passages in the cylinder
head.
Tighten the cap screws or stud nuts with a
torque wrench in a uniform manner, following
the sequence shown in Figures 2 and 3.
The "Hornet" Series, with aluminum cylinder
head, cap screws should be drawn up to 75-80
foot pounds of torque with engine at room
temperature.
The "Wasp" Series, with cast iron cylinder
head, cap screws are drawn up to 60-65 foot
pounds of torque with engine at normal operating temperature. With aluminum cylinder head,
tighten to 60-65 foot pounds of torque with
engine at room temperature.
Tighten the "Rambler" Series stud nuts to
57-60 foot pounds torque with engine at normal
operating temperature.
FIGURE 2—"Hornet" and "Wasp" Series
Cylinder Head Tightening Sequence
FIGURE 3—Cylinder Head Tightening
Sequence "Rambler" Series
VALVES
Valve Springs
Whenever valve springs are removed, they should
be tested according to the specifications
listed below, using a valve spring tester (Fig.
4). Any spring not within the specifications
should be replaced.
FIGURE 1—Guide Pin Installation to Install
Cylinder Head
Be sure that a sealing compound is used on all
cylinder head cap screws, "Hornet" and "Wasp"
Valve Spring Specifications
Series "Hornet" "Wasp" "Rambler"
Valve Spring
Approximate
Free Height 2-1/2" 2-3/16" 2-5/32"
Valve Spring
Pressure
Valve Closed 73-81 Lbs. 40-48 Lbs. 37-41 Lbs.
@ 2-1/2" @ 1-61/64" @ 1-3/4"
Valve Open 153-165 Lbs. 16-124 Lbs. 75-82 Lbs.
@ 1-27/32" @ 1-19/32" @ 1-7/16"
1. Torque Wrench
2. Valve Spring Tester
3. Valve Spring
ENGINE 6 CYLINDER
engine supports and loosening the rear supports. The engine may then be moved slightly
upward and to the left.
To assist in the installation of valve
locks, Tool J-1953 can be used on the "Hornet"
and "Wasp" Series (Fig. 6).
FIGURE 6—Valve Lock Installation "Hornet"
3
and "Wasp" Series
FIGURE 4—Valve Spring Tester
Valve Spring Position
The valve springs are installed with the closed
coils toward the head of the valve as shown in
Figure 5.
1. Correct Position, Closed Coils Up
2. Arrow Points to the Valve Seat
3. Incorrect Position, Closed Coils Down
FIGURE 5—Correct Position of the
Valve Spring
Valve Spring and Valve Removal
The valve springs and valves can be removed
after the manifolds (where necessary), cylinder
heads, and valve covers are removed.
"Hornet" 6 and "Wasp" Twin-H-Power
To remove the intake and exhaust manifolds as
an assembly with the carburetors, required
additional clearance can be obtained by removing the 5/8" nut from the top of the front
"Wasp" Hi-Torque 6
Clearance permits removal of the manifolds
without movement of the engine.
"Rambler" Series
Exhaust pipe mounted to side of engine need
not be removed.
Valve Spring Compressor J-4487 ("C" Type) will
facilitate valve spring removal and replacement on the "Rambler" Series.
Valve Adjustment
After removing the intake and exhaust manifold
assembly and valve covers, the valves on the
"Hornet" and "Wasp" can be adjusted to a cold
setting clearance of .010" "go"-.011" "no-go"
on the intake valves and .014" "go"-.015"
"no-go" on the exhaust valves.
The "Rambler" valves are adjusted without
removal of the exhaust pipe to a cold setting
clearance of .016" intake valves and .018"
exhaust valves.
Valve Refacing
It is important when refacing valves that just
enough material be ground off to clean up the
face.
The valve should be replaced if there is less
than approximately 1/16" material, "Hornet"
and "Wasp" Series and 1/3
2" "Rambler" Series, left on outer diameter of
the valve head known as the valve head margin.
A heavy margin aids in the dissipation of heat
and helps avoid valve warpage (Fig. 7).
The "Hornet" Series intake and exhaust valve
seat and face angle is ground to 45°.
6
TECHNICAL SERVICE MANUAL
1. Correct Valve Refacing
2. Incorrect Valve Refacing
FIGURE 7—Correct Valve Refacing
1. Valve Guide Removing Tool J-2814
The "Wasp" Series intake valve seat and
face angle is 45°. The exhaust valve seat and
face angle is 46°.
The "Rambler" Series intake and exhaust
valve face angle is 44°. The valve seat angle
is 45°.
Valve Guides
"Hornet" Series valve stem to guide clearance
is .0015"-.003" Intake, .002"-.004" Exhaust;
"Wasp" Series .001"-.003" Intake, .002".004" Exhaust; "Rambler" Series .0018".0033" Intake and Exhaust.
Replace the guides when these clearances are
exceeded. Check valve stem diameters to
determine whether or not proper stem to guide
clearance exists.
Stem diameters are:
Intake
Exhaust
“Hornet”
.3412”-.3422”
.3402”-.3412”
The valve guides can be removed through
the valve seat opening with a puller.
"Rambler" Series Tool J-2814, illustrated in
Figure 8, can also be adapted to the "Hornet"
and "Wasp" Series by using the spacers from
their respective guide installing tools.
The "Hornet" Series valve guides are
installed with Tool J-883-A (Pilot J-883-8
or 9) to insure that the guides are driven
to the correct depth of 1-3/32 for the
exhaust guides, 1-7/16" intake guides, from
the top of the guide to the top face of the
block (Fig. 9).
“Wasp”
.3412”-.3422”
3402”-.3412”
“Rambler”
.3407”-.3412
.3407”-.3412
FIGURE 8—Removing Valve Guides
"Rambler" Series
FIGURE 9—Installing Valve Guides
The "Wasp" Series valve guides are installed with Tool J-883-A (Pilot J-883-101.
The guides are inserted to a depth of 1%9"
from the top of the guide to the top face of
block.
Use Tool J-1429-A to install the "Rambler"
ENGINE 6 CYLINDER
Series valve guides. Drive the guides flush
with the opening of the guide bore in the
block.
Valve Timing
Valve timing is determined by the relation
between the sprocket on the camshaft and the
sprocket on the crankshaft.
"Hornet" and "Wasp" Series
When installing timing assembly, line up the
marked teeth on the sprockets with the marked
links on the chain. Correct installation will
result in locating 7 links or 14 pins between
marks on sprockets as illustrated in Figure 10.
5
mark on the inner timing mark radius (5.06"
flywheel radius).
This distance should be 21/4" plus or minus 1/s"
for valve lash errors. One tooth off timing on
crankshaft sprocket will affect this dimension
by plus or minus 1-31/64". One tooth off on
camshaft sprocket will affect this dimension by
plus or minus 13/16".
1. Marked Tooth on Camshaft Sprocket
2. Marked Tooth on Crankshaft Sprocket
3. 7 Links or 14 Pins
FIGURE 10—Correct Timing Chain Installation
"Hornet" and "Wasp" Series
"Hornet" Series
Valve timing can be checked without dismantling the engine.
With the engine at room temperature,
locate No. 1 piston at U.D.C. exhaust stroke.
Install a dial indicator on No. 1 cylinder
exhaust valve head through spark plug opening. Crank engine slowly until dial indicator
indicates valve has seated.
Place a chalk mark on the flywheel,
through the ignition timing mark opening in
line with the lower ledge of opening.
Crank engine backwards to expose both the
chalk mark and U.D.C. mark on flywheel. (This
is only possible if timing is correct or
early.) With a pair of dividers, measure the
distance between the U.D.C. mark and chalk
FIGURE 11—Valve Timing Diagram
"Hornet" Series
"Wasp" Series
To check valve timing on the "Wasp" Series,
crank engine until No. 1 piston is at T.D.C.
exhaust stroke.
Install a dial indicator on No. 1 cylinder
exhaust valve head through spark plug opening.
Crank engine slowly until dial indicator indicates valve has seated.
Place a chalk mark on outer edge of vibration
damper below pointer.
Measure distance from chalk mark back to U.D.C.
No. 1 mark with steel scale located around
circumference of damper. This distance should be
approximately 13/4" (with cold valve lash .015")
plus or minus 1/8" for valve lash errors. If the
camshaft sprocket is off one tooth, it will
affect the dimension by plus or minus 1%2". If
the crankshaft sprocket is off one tooth, the
dimension will be affected by plus or minus
13/16".
"Rambler" Series
When installing timing assembly, line up the
marked teeth adjacent to each other on a center
line drawn through the center of the camshaft
and the center of the crankshaft (Fig. 13).
Before installing the timing chain cover, check
the correct installation of the timing chain;
locate the marked tooth of the camshaft sprocket
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TECHNICAL SERVICE MANUAL
1. Marked Tooth on the Camshaft Sprocket
2. Marked Tooth on the Crankshaft Sprocket
3. 91/2 Links or 19 Pins
FIGURE 12—Valve Timing Diagram
"Wasp" Series
FIGURE 14—Correct Timing Chain Installation
"Rambler" Series
FIGURE 13—Place Marked Teeth on Center
Line When Installing Sprockets and Chain
"Rambler" Series
at approximately the one o'clock position.
This should place the marked tooth of the
crankshaft sprocket where it begins to mesh
with the chain (Fig. 14). Count the number
of links between the marked teeth of both
sprockets. There should be 91/2 links or 19
pins.
Valve timing may be inspected by locating
the No. 6 piston on T.D.C. in firing
position. Then set valves on the No. 1
cylinder to .003" clearance. Slowly rock the
crankshaft back and forth.
If the timing is set properly, the
exhaust valve should open before the D.C.
mark on the vibration damper lines up with
the pointer. Note this distance. The intake
valve should open an equal distance after the
D.C. mark passes the pointer.
FIGURE 15—Valve Timing Diagram
"Rambler" Series
TIMING CHAIN COVER
"Hornet" and "Wasp" Series
The timing chain cover oil seal is a leather
chevron design, spring loaded, to contact the
seal surface of the vibration damper under
ENGINE 6 CYLINDER
7
pressure.
Tool J-2776 is used to remove and install
the timing chain cover oil seal (Figs. 16 and
17):
lip of leather is in good condition and
not curled over.
FIGURE 16—Removing Timing Chain Cover
Oil Seal—"Hornet" and "Wasp" Series
Insert the collar so that slot in collar
engages depression in cover. Support the
cover when driving out the seal with the
straight side of the driver.
NOTE: The tool head is reversible on the
handle. The side with the tapered pilot
is used for installing the seal and the
large size for removal. Before installing
a new oil seal, apply a coating of white
or red lead in the well of the timing
cover. Install the oil seal in cover
using tapered pilot side of tool (Fig.
17). With J-872-5, handle screw in
opposite end of tool, and with an arbor
press or soft hammer, press the seal
tightly into place. After seal is installed, recheck to make certain that the
FIGURE 17— Installing Timing Chain Cover Oil
Seal—"Hornet" and "Wasp" Series
"Rambler" Series
The timing chain cover is provided with a
felt seal to prevent the leakage of oil
around the front crankshaft pulley hub. To
prevent damage to this seal, it is important
that the cover be properly aligned when
installing the vibration damper. This is
accomplished by leaving the cover to block
screws loose until the vibration damper has
been partially installed. Then tighten the
cover screws.
At time of installation of a new seal,
the rubber section of the seal must be
installed to the rear of the cover.
The oil seal installed in the timing
chain cover is replaced by driving the old
one out from the rear and installing a new
seal and retainer from the front.
An oil slinger is used inside the timing
chain cover.
8
The slinger is held in place by the crankshaft
sprocket and vibration damper.
TECHNICAL SERVICE MANUAL
CAMSHAFT AND BEARINGS
The camshaft is supported by four steel
shelled, babbitt lined bearings which have
been pressed into the block and line reamed.
The camshaft bearings are step bored being
larger at the front bearing than at the rear
to permit easy removal and installation of the
camshaft. All camshaft bearings are lubricated under pressure through drilled passages
in the cylinder block.
To simplify camshaft removal on the "Hornet"
and "Wasp" Series, remove the radiator core
and grille assemblies and intake exhaust
manifold. Then raise the front of the engine
slightly.
On cars equipped with air conditioning and all
"Rambler" Series, the engine should be
removed for camshaft removal.
The engines should also be removed from the
car if camshaft bearing replacement and/or
line reaming is contemplated.
Camshaft Bearing Oil Clearances
"Hornet" .0015"-.002"
"Wasp" .0005"-.0015"
"Rambler" .001"-.002"
FIGURE 19—Removing Vibration Damper
Assembly "Wasp" Series
Locate engine with timing assembly lined
up as shown in Figure 10.
Remove timing chain cover and cut safety
wire from camshaft sprocket mounting bolts.
Remove camshaft sprocket and chain assembly.
Use Puller 1-471 to remove crankshaft
sprocket (Fig. 20) if a gear change is to be
made.
Camshaft Removal
"Hornet" and "Wasp" Series
Remove the radiator, radiator grille, fan
assembly, and intake and exhaust manifolds.
Pull the vibration damper pulley assembly
after removing retaining cap screw. Use
Puller J-676-C for the "Hornet" Series (Fig.
18) and J-5371 "Wasp" Series (Fig. 19).
FIGURE 20—Removing Crankshaft Sprocket
Remove valve side covers and raise valves
and springs sufficiently to install tools
1-1612-3-A tappet holders (Fig. 21). Remove
oil spout on the "Wasp" Series and spout and
chain silencer on the "Hornet" Series.
Remove camshaft thrust plate.
Remove camshaft.
To reinstall the crankshaft sprocket, if
removed, use Driver J-5369 (Fig. 22):
FIGURE 18—Removing Vibration Damper
Assembly "Hornet" Series
"Rambler" Series
Remove engine from the car. Remove fan
assembly and cylinder head. Remove valve
tappet covers and vibration damper. Remove
valves and valve springs;
ENGINE 6 CYLINDER
End Play: .003"-.005" "Hornet" and "Wasp"
Series .004"-.006" "Rambler" Series
The camshaft end play can be checked with a
feeler gauge between the rear of the camshaft
sprocket and the front surface of the
camshaft thrust plate. A dial indicator can
also be used for checking the end play of the
camshaft.
PISTONS
"Hornet" and "Wasp" Series
The pistons are aluminum alloy cam ground
with taper ground skirt.
Ring grooves are provided for four piston
rings, two compression and two oil control
rings. One oil control ring is installed
below the piston pin while two compression
rings and one oil control ring are above the
pin. The rings are positioned and retained
in a limited working area by pins installed
in the piston ring grooves.
"Rambler" Series
9
FIGURE 21—Tool J-1612-3A Tappet Holders
FIGURE 22—Installing Crankshaft Sprocket
"Hornet" and "Wasp" Series
retain tappets with wire.
Remove timing chain cover and oil slinger.
Position engine with timing marks on a
center line (Fig. 12). Remove camshaft
sprocket retaining screw. Remove timing
chain and sprockets. The sprockets can be
pryed off of the shafts.
Remove camshaft thrust plate and camshaft.
Camshaft End Play
The camshaft end play is obtained between
the front surface on the camshaft bearing
and the camshaft thrust plate. When excessive end play occurs, a change in thrust
plate will restore the correct end play.
The pistons are aluminum alloy cam ground
having a larger diameter measured at right
angles to the piston pin hole and taper
ground skirt. A steel strut for structural
strength and to control expansion is located
in the pin boss structure.
Ring grooves are provided for four rings
above the piston pin, two compression and two
oil control rings. The piston pin is off-set
from the center axis toward the thrust side
of the cylinder.
To insure proper installation of off-set pin,
a notch is cast in top of piston. Piston must
be installed in the engine with the notch
toward the front.
Piston Removal
Piston removal is accomplished from the top
of the engine. However, before removing the
pistons, the ring ridges in the cylinder
bores must be removed. Failure to remove the
ridge at the top of the cylinder bore will
very often result in piston ring breakage and
damage to the piston groove land. If cylinder
taper exceeds .009", bore must be trued up
and oversize pistons and rings used.
Fitting Pistons
"Hornet" and "Wasp" Series
The pistons are fitted by the use of a spring
scale and feeler tape for a clearance of
.002" under a three to four pound pull.
(Parts must be clean, dry, and at room
temperature.)
"Rambler" Series
The piston is fitted so that each piston will
support its own weight in any portion of the
cylinder with all parts clean and dry. Piston
10
TECHNICAL SERVICE MANUAL
to bore clearance is .0006" to .0012".
PISTON RINGS
The pistons are fitted with four piston
rings, two compression and two oil control
rings.
A chrome plated upper ring is used to resist
corrosion.
Before assembling the rings to the piston,
carbon must be cleaned from all ring grooves.
The oil drain holes in the oil ring grooves
must be cleared. Care must be exercised not
to remove metal from the grooves, since that
will change their depth, nor from the lands,
since that will change the ring groove
clearance and destroy ring to land seating.
Checking Ring Groove Clearance
Side groove clearance is measured with a
feeler gauge. Roll the rings around the
piston in the grooves in which they operate.
Check for freedom all the way around.
The groove clearances are listed below by
ring number with the top ring as number one.
Ring Number 1 2 3 4
"Hornet" .002"-.004" .002"-.004" ,001"-.003" ..001"-.003"
"Wasp" .002"-.004" .002"-.004" .001"-.003" .001"-.003"
"Rambler" .002"-.004" .002"-.004" .002"-.004" .002"-.004"
Rings must be installed on pistons with a
ring installation tool to prevent distortion
and ring breakage.
Detailed instructions in service ring packages must be followed.
"Hornet" and "Wasp" Series
Four piston rings are used; three rings are
located above the piston pin and one below
the pin. The rings are pinned in place to
prevent movement (Figs. 23 and 24).
Checking Ring Gap Clearance
Piston ring gap clearance is measured in the
bottom of the cylinder near the end of the
ring travel area. To square the ring in the
bore for checking gap clearance, place the
ring in the bore. Then, with an inverted
piston, push the ring down near the lower end
of the ring travel area. When other than
standard ring sizes are used, rings should
be individually fitted to their respective
bores.
The ring gaps for fitting rings are listed below:
"Hornet" .006"-.014"
"Wasp" .004"-.009"
"Rambler" .010"-.020"
Piston Ring Installation
Removal of glaze from the cylinder wall for
quicker ring seating can be accomplished by
various methods. If the expanding flexible
type hone is used, do not use more than 10
strokes (each stroke down and return) to
recondition a cylinder wall.
Successful ring installation depends upon
cleanliness in handling parts and while
honing the cylinder walls. The engine bearings and lubrication system must be protected
from abrasives.
Rigid type hones are not to be used to
remove cylinder glaze as there is always a
slight amount of taper in cylinder walls
after the engine has been in service.
FIGURE 23—Ring Arrangement
"Hornet" Series
The rings are notched on the inner diameter
at the gap slot. The width of the notch is
.125". Approximately .075" is at one end of
the ring and .050" at the other end. This
off-setting of the notch enables a single pin
pressed in from the top of the piston to
locate the three top rings without having the
gaps on adjacent rings aligned (Fig. 25).
ENGINE 6 CYLINDER
CAUTION: Because of the backlash clearance requirement, it is suggested that
no ring be filed to fit a bore size
smaller than the ring size.
"Rambler" Series
The two compression and two oil control rings
are located above the piston pin. The
compression rings are of the "twist" design
with an inner groove installed to the top of
piston. A conventional oil control ring is
used in the third ring groove.
11
FIGURE 24—Ring Arrangement
"Wasp" Series
FIGURE 25—Pinning of Piston Rings "Hornet"
and "Wasp" Series
The end gap is equal to the backlash of the
ring notch on pin. Therefore, if the ends of
a ring are filed to obtain the correct ring
end gap, the notch has to be filed enough to
provide the backlash in equal amount.
1. Inner Groove Up
2. Oil Control Ring
3. Oil Control Ring "U" Flex
FIGURE 26—Ring Installation
"Rambler" Series
The "U" flex oil control ring used in the
lower oil control ring groove, as original
equipment, differs from all other rings. The
normal free diameter of this ring is 1/8" to
3/1_6" larger than the bore diameter in which
it is installed. Installation is outlined in
Figures 27, 28, 29, and 30.
Before installing piston in engine,
arrange ring gaps 180° apart, being sure no
gap is over the piston pin.
Service Ring Sets
For service ring replacement, follow detailed instructions enclosed in the ring
package.
12
TECHNICAL SERVICE MANUAL
FIGURE 27—Step 1—Place "U" Flex Ring in
Bottom of Oil Ring Groove. Lubricate all
Rings and Piston Skirt with a Light
Grade Engine Oil. Butt Ends of
"U" Flex Ring Together
FIGURE 28—Step 2—Keep Ends of "U" Flex
Ring Butted Together and Place Compressor
Over Piston, Either a Constricting Band
or Split Sleeve Type Compressor
can be Used
FIGURE 30—Step 4—Make Sure Compressor
Rests Squarely on Top of Block, and
Push or Tap Piston into Cylinder
CAUTION: If Piston Does not Enter
Cylinder without Excessive Force, Remove Piston Assembly and Examine Rings
for Ring Interference.
PISTON PINS
"Hornet" and "Wasp" Series
Full floating type piston pins are used. They
are retained in the piston by two circular
lock rings, one at each end of the pin. The
piston pin fit in the connecting rod bushing
is a hand push fit at room temperature (70°).
The piston pin fit in the piston is a
hand push fit in a heated piston. Heat piston
in water or electric furnace to 200°F.
The piston pin bushings are steel back
bronze. To remove and replace, press out old
bushing, using burnisher block tool J-2950
and remover J-2948 for the "Hornet" Series,
and J-2951 and J-2948 "Wasp" Series. Install
new bushing with same tools making sure oil
holes in bushing and rod are in alignment.
Burnish bushing with block J-2950 and burnisher J-2791 "Hornet" Series, and J-2951 and
J-2949 "Wasp" Series (Fig. 31).
The bushing should be reamed .0003"
larger than its matching pin diameter. Check
the fit by holding the piston with the
connecting rod in a horizontal position. The
rod should just turn on the pin under its own
weight.
FIGURE 29—Step 3—Tighten Ring Compressor
if Band Type is Used. If Sleeve Type is Used,
BE SURE THAT IT IS NOT PULLED
HIGHER THAN THE TOP OF THE
PISTON. However, it Should be
Drawn up High Enough to
Cover all of the Rings
The standard piston pin dimensions are:
“Hornet”
“Wasp”
Length
2.942" — 2.932"
2.4375" + or
—.005"
Diameter
.9687" — .96845"
.7499" + .000"
—.00025"
"Rambler" Series
The piston pin is locked in place in the
connecting rod by means of a locking bolt
(Fig. 32).
To fit the piston pin, hone the connecting rod to fit the pin. Then hone the piston
to allow a thumb press
ENGINE 6 CYLINDER
Tighten piston pin clamp screw to 18-22
foot pounds torque.
CONNECTING RODS
"Hornet" and "Wasp" Series
The connecting rods have oil squirt holes to
provide cylinder wall lubrication, at low and
idle speed, to the thrust side of the
cylinders. An oil hole on the top of the rod
supplies lubrication to the piston pins.
When installing connecting rods, the
squirt hole is toward the camshaft side
(thrust side) of the engine.
The cylinder location numbers are stamped
on the connecting rod and caps during initial
assembly.
"Rambler" Series
Two oil squirt holes are provided in the
upper rod cap section for cylinder wall
lubrication at low and idle speeds.
The notch on the top perimeter of the
piston and the identification boss on the
connecting rod (Fig. 33) must be installed
to the front of the engine.
13
FIGURE 31—Burnishing Connecting Rod
Bushing "Hornet" and "Wasp" Series
1. Locking Bolt and Notch
2. Piston Pin
FIGURE 32— Piston Pin "Rambler" Series
fit or .0002" maximum loose fit in piston at
room temperature (70°F.).
The standard piston pin dimensions are:
Length 2.755", Diameter .8598"-.8595".
1. Identification Boss
FIGURE 33—Connecting Rod Identification
Boss "Rambler" Series
The connecting rods are stamped by cylinder number location during initial assembly.
Always assemble the rods and caps with the
cylinder location numbers on the same side.
Connecting Rod Alignment
Whenever new rings are installed or new
piston pins are replaced, it is necessary to
align the connecting rods and pistons, as
assemblies, to insure true operation in the
cylinder bore.
Misaligned rods will cause uneven piston
and ring wear which will result in oil
consumption and noise. The connecting rod
should be inspected for a twisted or bent
condition (Figs. 34 and 35).
Always bend beyond the true alignment
position and then bend back to straighten so
the stresses and strains in the rod material
are relieved. If the stresses are not
relieved, the rod will not hold its alignment
after installation in the engine.
14
TECHNICAL SERVICE MANUAL
FIGURE 34—Checking Connecting Rod
Alignment for Twist
Connecting Rod Bearings
The connecting rod bearings are the steel
backed babbitt lined precision type. They are
installed as pairs in connecting rod and cap.
CAUTION: Never file a connecting rod or
cap to adjust bearing clearance.
If the bearing clearance is excessive,
the correct connecting rod undersize bearing
set must be installed. The correct connecting
rod bearing clearance is .0005" to .0015"
"Hornet" and "Wasp" Series and .001" to
.0015" on "Rambler" Series.
To determine the amount of bearing
clearance, use a piece of Plastigage in the
bearing cap as shown in Figure 36. Then
tighten the cap to the torque specification
to compress the gauge.
Remove the bearing cap and calibrate the
width of the Plastigage with the scale
furnished as shown in Figure 37.
Connecting Rod Bearing Caps
FIGURE 35—Checking Connecting Rod
Alignment for Bend
It is important that the connecting rod cap
bolt nuts be drawn up to the correct tension.
Tighten to:
"Hornet" 40-45 Ft. Lbs.
"Wasp" 40-50 Ft. Lbs.
"Rambler" 27-30 Ft. Lbs.
FIGURE 36—Plastigage in Place in the
Bearing Cap
ENGINE 6 CYLINDER
FIGURE 37—Measure the Width of the
Plastigage Scale
Reduce torque 15 per cent if threads are
oily
The notches on the lower and upper rod
caps should be to the same side of engine
with the squirt hole on upper cap to camshaft
side of engine on the "Hornet" and "Wasp"
Series.
The cylinder numbers are to the camshaft
side of the engine and the identification
mark (Fig. 33) to the front of engine on the
"Rambler" Series.
Connecting rod side clearance:
"Hornet" and "Wasp" .007" — .013"
"Rambler" .005" — .015"
CRANKSHAFT
"Hornet" and "Wasp" Series
The crankshaft is supported by four main
bearings with the end thrust taken at the No.
3 bearing position.
The crankshaft, flywheel, and vibration
damper are balanced as individual units.
Complete engine assemblies are then balanced
with all reciprocating parts in motion.
Replacement of vibration damper or flywheel
can be accomplished without rebalancing the
complete assembly.
15
caps should never be filed.
When either half of a bearing requires
replacement, a complete set should be installed. To replace the upper half of a
bearing, remove the bearing cap of the
bearing to be replaced. Then loosen all of
the other bearing caps and insert a small pin
in the crankshaft oil hole. The head of the
pin should be large enough so that it will
not fall into the oil hole, yet thinner than
the thickness of the bearing (Fig. 38).
FIGURE 38—Removing Main Bearing Insert
With the pin in place, rotate the shaft so
that the upper half of the bearing will
rotate in the direction of the locating
tongue on the bearing.
Tool J-2955 will greatly facilitate front and
rear bearing cap removal on the "Hornet" and
"Wasp" Series (Fig. 39).
CAUTION: Care must be exercised on
removal of the front main bearing cap
because if the front engine end plate
gasket is damaged, a replacement requires the removal and replacement of
timing assembly and front engine end
plate.
"Rambler" Series
The crankshaft is supported by four main
bearings with the end thrust taken at the
front main bearing location.
The component parts of the crankshaft
assembly are individually balanced; then
rebalanced as an assembly.
Replacement of vibration damper or flywheel can be accomplished without rebalancing
the complete assembly.
Crankshaft. Main Bearings
Main bearings are of the precision type
having a steel back with a babbitt lining.
The bearings are not adjustable. Shims should
never be used and the bearing
FIGURE 39— Removing Front Min Bearing
Cap with Tool J-2955 "Hornet" and
"Wasp" Series
Crankshaft Main Bearing Clearance
The standard clearance of .0005" to .0015"
on the "Hornet" and "Wasp' Series and .001"
to .0015" "Rambler" Series can be accurately
checked by the use of Plastigage.
NOTE: When checking bearing clearance
with the engine in such a position
that the bearing caps support the
weight of the crankshaft and flywheel, keep all main bearing caps
tight except the one being checked.
Support the weight o f the crankshaft
with a jack.
Remove the bearing cap and wipe the oil
from the bearing insert.
Place a piece of Plastigage across the
full width of the bearing insert (Fig. 36).
Reinstall the bearing cap and tighten
75-80 foot pounds torque (dry) on the
"Hornet" and "Wasp" Series and 66-70 foot
pounds torque (dry) on the "Rambler" Series.
Then remove the bearing cap and with the
graduated scale, which is printed on the
plastigage envelope, measure the width of the
flattened plastigage at its widest point
(Fig. 37). The number within the graduation
indicates the clearance in thousandths of an
inch. Install the proper size bearing liners
(inserts) to bring the clearance to standard.
Before installing crankshaft or main bearing
inserts, the journals must be inspected for
condition and dimensions.
Main Bearing Journals
Main journals can be measured without removing the crankshaft from the engine block.
There are various gauges for this use, one
of which is shown in Figure 40.
Then release the plunger so that it is up
against the journal and lock the adjusting
screw in position. Remove the gauge carefully
and double the micrometer reading across the
pin and anvil in the center of the
"V". This reading is the diameter of the
journal.
Always check the journal at both ends for
taper. Then rotate the shaft 90° and measure
for out-of round. The out-of-round and taper
limit is to be held to .001".
Main Journal
Series Diameter
"Hornet" 2.4988"-2.4998"
"Wasp" 2.4988"-2.4998"
"Rambler" 2.4791"-2.4798"
Connecting Rod Bearing or
Series Crankpin Diameter
"Hornet" 2.1244"-2.1254"
"Wasp" 1.937" -1.938"
"Rambler" 2.0948"-2.0955"
Main bearing caps are recessed into the
engine block and line reamed. Therefore, it
is not practical to replace them in the field.
Crankshaft End Play
The "Hornet" and "Wasp" Series end thrust of
.003" to .009" is taken at the No. 3 main
bearing. The "Rambler" Series end thrust of
.003" to .008" is taken at the flanged front
main bearing.
MAIN BEARING OIL SEALS
"Hornet" and "Wasp" Series
The rear main bearing oil seal is a metal
backed neoprene lined seal made in two
identical halves. The upper half can be
removed without removing the crankshaft by
removing the rear main bearing cap and
applying pressure against the metal part of
the seal with a 1/4" brass rod. At the same
time, rotate the flywheel to assist in
removing the seal.
At time of installation of the seals, coat
the groove of the seal with non-hardening
sealer.
FIGURE 40—Measuring Main Bearing Journal
To operate this gauge, remove the main
bearing cap and place the gauge against the
crankshaft journal
1. Packing Groove
2. Oil Seal
FIGURE 41—Rear Main Bearing Oil Seal
"Hornet" and "Wasp" Series
ENGINE 6 CYLINDER
After the rear main bearing cap is replaced,
cotton waste must be driven into the vertical
packing holes to seal the side of the cap. A
punch smaller in diameter than the vertical
holes and at least 4" long will facilitate
the packing of the cotton waste. Enough
packing must protrude to seal between the pan
gasket and bearing cap.
The front main bearing cap has both a
horizontal and a vertical seal to prevent
external oil leakage. This packing seals from
leakage between the engine front end plate
gasket and the bearing cap. The vertical
grooves are packed before the horizontal
grooves (Fig. 42).
17
FIGURE 42— Front Bearing Cap Oil Seal
Groove Locations "Hornet" and
"Wasp" Series
"Rambler" Series
A hemp packing and "L" shaped neoprene rubber
type rear main bearing oil seals are used. A
special tool J-1610 is required to install
the hemp packing (Fig. 43) . To properly
replace upper hemp packing, the crankshaft
must be removed.
VIBRATION DAMPER
"Hornet" Series
The vibration damper (Fig. 45) on the "Hornet"
Series has two punch marks for alignment to
maintain proper balance when the damper is
disassembled for replacement of rubber discs.
2. Point at which Packing is Cut Flush
1. Oil Seal Installing Tool J-1610
FIGURE 43—Installing Hemp Packing Oil Seal
in Rear Main Bearing Cap "Rambler"
Series
1. Hemp Packing
2. Cap Side Seal
3. Cap Side Seal
4. Main Bearing Cap
FIGURE 44— Rear Main Bearing Cap and Seals
"Rambler" Series
Pulley Remover J-676-C and Replacer J-483
will facilitate removal and replacement
operations (Fig. 18).
18
TECHNICAL SERVICE MANUAL
1. Outer Member 5. Spacer
2. Rubber Discs 6. Oil Seal
3. Inner Member 7. Retainer Plate
4. Damper Cap Screw
FIGURE 45—Vibration Damper "Hornet"
Series
Tighten damper cap screw to 100-120 foot
pounds torque.
"Wasp" Series
The vibration damper has an off-set screw
location to insure proper reassembly for
balance in the event disassembly was made to
replace rubber cushions.
Pulley Remover J-5371 and Replacer J-5369
will facilitate removal and replacement
operations (Fig. 19)
Tighten damper cap screw to 80-90 foot
pounds torque.
"Rambler" Series
The vibration damper is not adjustable. The
screws that retain the rubber are drawn up
to a point where the shoulders will limit the
tension of the rubber blocks (Fig. 47).
1. Damper Cap Screw 8. Damper Cover Plate
2. Cap Screw Lock 9. Rear Damper Cushion
3. Nut 10. Pulley to Damper
4. Lockwasher Screw
5. Front Damper Cushion 11. Hub
6. Damper Pulley 12. Key
7. Damper
FIGURE 46— Vibration Damper "Wasp" Series
FIGURE 47—Vibration Damper "Rambler"
Series
Tighten damper cap screw to 100-110 foot
pounds torque
ENGINE 6 CYLINDER
19
STARTER RING GEAR
With the exception of the flywheel, as used
with the automatic transmission, which is a
steel stamping, the starter ring gear can be
replaced by placing the flywheel in an arbor
press with steel blocks equally spaced around
the gear and pressing the flywheel through,
or the ring gear can be broken with a chisel.
To install the new starter ring gear, first
heat it to expand the inside diameter so that
it can be pressed over the flywheel.
SHAFT PILOT BEARING
The pilot bearing for the shaft is located
at the center of the rear end of the
crankshaft. This is an oil impregnated bronze
bearing. It is pressed into the end of the
crankshaft. This bearing does not require any
lubrication after assembly. When assembled
in service, it is advisable to place a small
amount of high melting point grease on the
end of the shaft as it is installed into the
bearing. Bearings being installed must be of
the correct size for the series and type of
transmission.
LUBRICATION SYSTEM
The lubrication system is of the full
pressure type with all vital moving parts
receiving lubrication under pressure except
the piston pins.
"Hornet" and "Wasp" Series
The pressure is supplied by a positive
displacement rotor type oil pump mounted on
the right lower side of cylinder block and
driven from a gear cut on the camshaft.
The oil is drawn through the floating oil
intake screen (Fig. 48) to the intake side
of the oil pump.
Oil under pressure passes the plunger of
the oil relief valve assembly and fills the
main horizontal oil gallery from which it is
directed through drilled passages to lubricate the camshaft bearings, tappet assembly,
main and connecting rod bearings, cylinder
walls, and timing assembly.
Piston pins are lubricated by oil "throwoff" from rotating parts and wiping action
of piston rings.
Before removing the oil pump, position the
engine crankshaft so that No. 1 cylinder
piston is at T.D.C. exhaust stroke and No. 6
cylinder piston is at T.D.C. on compression
stroke.
Upon disassembly of the oil pump, remove
the oil pump cover and use a brass drift to
mark an indexing point of one lobe and notch
on rotor and internal gear or outer rotor to
insure relationship for reassembly.
Measure the clearance between a lobe and
notch opposite the reference mark. This
clearance should be .010" or less. If more
than .010", replace both rotors and shaft.
Place a straight edge across the pump body
between the screw holes. Use a feeler gauge
to measure the clearance between the top of
the rotors and the straight edge. This
clearance should be .004" or less. If the
clearance is greater than this limit, the
pump body must be replaced.
With the outer rotor pressed against one
side of the pump body, measure the clearance
between this rotor and the body on the
opposite side. If this clearance is more than
.008", replace the pump body.
The pump cover plate must be smooth and
not worn from the rotors. Place a straight
edge across the cover. If a .002" feeler can
be inserted between the cover and the
straight edge, the cover is worn and must be
replaced.
1. Swivel Connectlon
2. Intake Screen
3. Drain Plug Outlet
FIGURE 48— Oil Intake Screen Assembly
"Hornet" and "Wasp" Series
1. Oil Pump Drive Gear Pin
2. Oil Pump Drive Gear
3. Oil Pump Body
4. Oil Pump Shaft
5. Oil Pump Inner Rotor
6. Inner Oil Pump Rotor Lobe
7. Outer Oil Pump Rotor
8. Oil Pump Cover Gasket
9. Oil Pump Cover
10. Oil Pump Cover Screws
FIGURE 49—Oil Pump Assembly "Hornet"
and "Wasp" Series.
20
TECHNICAL SERVICE MANUAL
In the event the engine crankshaft was not
moved, replacement of the oil pump presents
no problem. However, if the crankshaft was
moved, the following procedure can be used
to insure basic distributor timing location
inasmuch as the distributor is driven by the
oil pump shaft.
Crank the engine until the No. 1 cylinder
piston is on T.D.C. exhaust stroke and No. 6
is on T.D.C. in firing position.
Install Aligning Tool J-2794 so that the
guide pin indexes with the distributor
mounting screw hole (Fig. 50).
1. Screen and Retainer 9. Idle Gear
2. Bolt 10. Key
3. Inlet Tube Gasket 11. Oil Pump Drive Shaft
4. Bolts 12. Oil Pump Idle Shaft
5. Cap Screws 13. Oil Pump Body
6. Oil Pump Cover 14. Oil Pump Drive Gear Pin
7. Gasket 15. Thrust Washer
8. Drive Gear (In Pump) 16. Oil Pump Drive Gear
FIGURE 51— Oil Pump "Rambler" Series
FIGURE 50—Oil Pump Shaft Aligning Tool
Install the oil pump, indexing the slot
in the pump shaft with the tang on aligning
tool, and push out the tool.
Install distributor with rotor aligned
with terminal in distributor cap which leads
to No. 6 cylinder spark plug.
"Rambler" Series
The oil pump is mounted on the right hand
side of the cylinder block. It is of the
positive displacement gear type.
The oil pump is driven off of a gear cut
on the camshaft and in turn drives the
distributor by means of an off-set tang which
is part of the oil pump main shaft. Oil is
drawn from the oil pan reservoir through a
fixed inlet screen assembly to the intake
side of the oil pump. The oil is discharged
under pressure past a relief valve in the
main oil gallery and then through holes
drilled through the main bearing webs to the
crankshaft and camshaft main bearing locations. The crankshaft drillings provide
lubrication from the main bearings to the
connecting rod bearings. The front camshaft
bearing permits oil to flow onto the timing
gear and chain assembly.
The valve tappets and piston pins are
lubricated by crankshaft oil "throw-off" and
vapors.
CAUTION: Always maintain a tight
connection between the oil pump inlet
flange and oil inlet hole located on
the right side at the bottom of the
cylinder block
The position of the oil pump drive gear
keyway should be noted before removal of oil
pump. Installing in the same location will
prevent disturbance of distributor timing.
In the event the crankshaft has been moved,
crank the engine until No. 1 cylinder is at
T.D.C. in firing position. The keyway will
be located at approximately the three-thirty
o'clock position, viewed from the lower
section of the pump body.
Oil Pressure Relief Valve
The oil pressure relief valve consists of a
plunger, spring, and retainer.
The valve is located on the left side of
the cylinder block on the "Hornet" and "Wasp"
Series and the right side of the cylinder
block on the "Rambler" Serieas.
The oil pressure relief valve is not
adjustable. A setting of 40 P.S.I. for the
"Hornet" and "Wasp" Series and 50-58 P.S.I.
for the "Rambler" Series is built into the
tension of the spring.
1. Housing Plug 3. Spring
2. Gasket 4. Plunger
FIGURE 52— Oil Pressure Relief Valve
"Rambler" Series
ENGINE 6 CYLINDER
ENGINE SPECIFICATIONS
21
Series
Type
No. Cylinders
Bore
Stroke
Compression Ratio
(Standard)
(Optional)
Piston Displacement
Compression Pressure
at Cranking Speed
Horsepower
Twin Carburetor
Engine Lubrication
Series
Stem Diameter
Intake
Exhaust
"Hornet"
L-Head
6
3-13/16"
41/2"
7.5:1
308 Cu. In.
100 P.S.I. Min.
160 @
3800 R.P.M.
170 @
4000 R.P.M.
Pressure
VALVE SPECIFICATIONS
"Hornet"
.3412"-.3422"
.3402"-.3412"
"Wasp"
L-Head
6
3"
43/4"
7.5:1
8.0:1
202 Cu. In.
100 P.S.I. Min.
115 @
4000 R.P.M.
126 @
4000 R.P.M.
Pressure
"Wasp"
.3412"-.3422"
.3402"-.3412"
"Rambler"
L-Head
6
3W'
41/4"
7.32:1
195.6 Cu. In.
120 P.S.I.
90 @
3800 R.P.M.
Pressure
"Rambler"
.3407"-.3412"
.3407"-.3412"
Stem to Guide Clearance
Intake
Exhaust
Head Diameter
Intake
Exhaust
Seat Angle
Intake
Exhaust
Valve Face Angle
Intake
Exhaust
Valve Spring Free Height
Valve Spring Pressure
Valve Open
Valve Closed
Spring Retainer Lock
.0015"-.003"
.002"-.004"
1.831"
1.556"
45°
45°
45°
45°
2-1/2"
153-165 Lbs.
@ 1-27/32
73-81 Lbs.
@ 23/16"
Split Two Piece
.001"-.003"
.002"-.004"
1.495"-1.505"
1.390"-1.400"
45°
46°
45°
46°
2-1/2"
116-124 Lbs.
@ 1-13/32"
40-48 Lbs.
@ 1-61/64"
Split Two Piece
.0018"-.0033"
.0018"-.0033"
1.594"
1.343"
45°
45°
44º
44°
2-1/2"
75-82 Lbs.
@ 17/16"
37-41 Lbs.
@ 1-3/4"
Single Horseshoe
Tappet Clearance
Cold Setting
Intake
Exhaust
.010" "Go"
.011" "No-go"
.014" "Go"
.015" "No-go"
.010" "Go"
.011" "No-go"
.014" "Go"
.015" "No-go"
.016"
.018"
22
TECHNICAL SERVICE MANUAL
OIL SYSTEMS
Series
Oil Pump Type
Normal Oil Pressure
Oil Pressure Release
Engine Oil Refill
Capacity
Series
Bearing Type
No. of Main Bearings
Main Bearing Clearance
Diameter
Shaft End Play
End Thrust Taken By
Bearing Cap
Adjustment
"Hornet"
Rotor
40 P.S.I. @
30 M.P.H.
40 P.S.I.
7 Qts.
CRANKSHAFT AND BEARINGS
"Hornet"
Replaceable
4
.0005"-.0015"
24988"-2.4998"
.003"-.009"
No. 3 Main Bearing
75-80 Ft. Lbs.
(Dry)
"Wasp"
Rotor
40 P.S.I. @
30 M.P.H.
40 P.S.I.
5 Qts.
7
"Wasp"
Replaceable
4
.0005"-.0015"
2.4988"-2.4998"
.003"-.009"
No. 3 Main Bearing
75-80 Ft. Lbs.
(Dry
"Rambler"
Gear
30 P.S.I. @
20 M.P.H.
12 P.S.I. Min.
@ 600 Engine R.P.M.
50-58 P.S.I.
4 Qts.
"Rambler"
Replaceable
4
.001"-.0015"
2.4791"-2.4798"
.003"-.008"
Front Main Bearing
66-70 Ft. Lbs.
(Dry)
Series
No. Rings Per
Piston
End Gap
(Except "U"
Flex Ring)
Compression Ring Side
Clearance in Ring
Groove
Oil Ring Side Clearance
in Ring Groove
Series
Bearing Type
Bearing Clearance
Crankpin Diameter
Bearing End Play
Bearing
PRODUCTION PISTON RINGS
"Hornet"
4
.006"-.014"
.002"-.004"
.001"-.003"
"Wasp"
.004"-.009"
.002"-.004"
.001"-.003"
CONNECTING ROD AND BEARING
"Hornet"
Replaceable
.0005"-.0015"
2.1244"-2.1254"
.007"-.013"
40-45 Ft. Lbs.
(Dry)
"Wasp"
Replaceable
.0005"-.0015"
1.937"-1.938"
.007"-.013"
40-50 Ft. Lbs.
4
(Dry)
"Rambler"
4
.010"-.020"
.002"-.004"
.002"-.004"
"Rambler"
Replaceable
.001"-.0015"
2.0948"-2.0955"
.005"-.015"
27-30 Ft. Lbs.
(Dry)
ENGINE 6 CYLINDER
TUNE-UP DATA
23
Series
"Hornet"
"Wasp"
"Rambler"
Engine Idle Speed—Transmission in Neutral, Air
Conditioning on.
"Hornet" and "Wasp" 540-560 R.P.M. (Standard
Transmission)
575 R.P.M. (Overdrive
Transmission)
490-510 R.P.M. (Hydra Matic)
"Rambler" 500-550 R.P.M. (Standard
and Overdrive)
475 R.P.M. (Hydra Matic)
500 R.P.M. (With
Air Conditioning on)
Compression Pressure at Cranking Speed —
"Hornet" and "Wasp" 100 P.S.I. Minimum
"Rambler" 120 P.S.I.
Spark Advance (See Electrical Section—Distributor)
Firing Order-1, 5, 3, 6, 2, 4
Plug
Gap
.032"
.032"
.030"
Int. Exh.
.10" "Go"
.11" "No-go"
.010 "Go"
.11" "No-go"
.016"
Tappet Clr. Cold
.14" "Go"
.15" "No-go"
.14" "Go"
.15" "No-go"
.018"
Distributor
Point Gap
.020"
.020"
.018"-.024"
Positive Battery Terminal Grounded
Coil—Secondary Terminal Tower, Negative Polarity
Breaker Point Spring Tension—
"Hornet" and "Wasp" 17-20 Ounces
"Rambler" 17-21 Ounces
Spark Plugs"Hornet"—Champion H-11 Torque 25 Ft. Lbs.
(Aluminum Head)
"Wasp"—Champion H-10 Torque 30 Ft. Lbs.
(Cast Iron)
25 Ft. Lbs. (Aluminum Head)
"Rambler"—Auto-Lite A-7 Torque 30 Ft. Lbs.
(Cast Iron)
Cylinder Head—Nut or Cap Screws Torque Specifications—
"Hornet"-75-80 (Cold)
"Wasp"-60-65 (Operating Temperatures) Cast
Iron (Cold) Aluminum
"Rambler"-57-60 (Operating Temperature)
Dwel
Angle
38º
38º
31º-37º
Igniton Timing
T.D.C.
at Idle Speed
T.D.C.
at Idle Speed
4° A.T.D.C.
at Idle Speed
Description
Cylinder Head
Exhaust Pipe Clamp Nut
Exhaust Manifold
Intake Manifold
Oil Pan Bolt
Timing Chain Cover
Piston Pin Clamp Screw
Connecting Rod Cap Nuts
Crankshaft Main Bearing
Cap Screws
Vibration Damper
Retaining Screw
Flywheel Retaining Cap
Screw or Nuts
Camshaft Sprocket Screw
*Aluminum cylinder heads are tightened at room temperature (70° F.).
ENGINE TORQUE TIGHTENING CHART
(Foot Pounds Dry)
"Hornet"
*75-80
20-35
12-15
15-20
15-20
40-45
75-80
100-120
40-45
20-30
"Wasp"
*60-65
20-30
12-15
15-20
15-20
40-50
75-80
80-90
40-45
20-30
"Rambler"
57-60
10-15
15-20
15-20
18-22
27-30
66-70
65-70
100-110
50-55
24
TECHNICAL SERVICE MANUAL
TECHNICAL SERVICE LETTER REFERENCE
Date Letter No. Subject Changes of informatin on Page. No.
2
ENGINE SECTION
V-8
FIGURE 1—V-8 Engine Assembly
ENGINE IDENTIFICATION
The engine number is located at the right
rear upper corner of the cylinder block below
the rear exhaust manifold port (Fig. 2)
FIGURE 2—Engine Number Location
CYLINDER HEAD AND GASKET
After thoroughly cleaning the top surface of
the block and the bottom surface of the
cylinder head, inspect each for smooth and
flat surfaces with a straight edge.
The cylinder block surface has two sleeve
locating dowels to assist in lining up and
holding position of cylinder head and gasket
during installation or removal.
Coat the gasket with a non-hardening
gasket paste. For convenience in removing and
installing the cylinder head, use Tool J-4159
(Fig. 3).
FIGURE 3—Removing or Installing Cylinder
Heads with Tool I-4159
After installing the push rods, rocker arm
assembly, and cylinder head cap screws, tighten
them evenly.
ENGINE V-8
Then retighten to 55 to 60 foot pounds with
torque wrench following the sequence outlined
in Figure 4.
3
FIGURE 4—Torque Tightening Sequence
55-60 Ft. Lbs.
ROCKER ARM AND SHAFT ASSEMBLY
The rocker arm shaft assembly is secured to
the cylinder head with four long cylinder
head and rocker arm shaft retaining cap
screws. The rocker arm shafts axe hollow,
plugged at each end, serving as oil galleries
for rocker arm, push rod end, and valve stem
lubrication.
The oil pressure supply for the left hand
bank rocker arm assembly is taken from the
left main oil gallery at the front camshaft
bearing. The oil under pressure through
connecting passages in cylinder block and
cylinder head enters around the undercut stem
area of. the front rocker arm shaft mounting
cap screw upward into the rocker arm shaft.
The right bank rocker arm assembly lubrication pressure is taken from the vertical
oil gallery passages at the rear camshaft
bearing oil passage through the cylinder head
and block to the rear rocker arm shaft
retaining cap screw.
Two different rocker arms are used to
accommodate the angle from the rocker arm
shaft support to the valve stems. However,
the rocker arm shaft assemblies are interchangeable from cylinder bank to cylinder
bank.
1. Exhaust Valves
2. Intake Valves
FIGURE 6—Valve Arrangement
Intake or Exhaust Valve Spring:
Valve Closed 78-86 Lbs. @ 1-3/4"
Valve Open 158-172 Lbs. @ 1-3/8"
Valve springs are installed with the
inactive (closed) coils against the cylinder
head.
The valve spring retainer serves the dual
purpose of holding the valve and spring
together and providing a valve stem oil seal.
The seal is moulded onto the retainer. At
valve service periods, the valve spring
retainers should be replaced to insure good
oil control at this point.
Tool J-5988 will facilitate removal of the
valves from the cylinder head (Fig. 7). The
half conical shaped valve locks can be
removed after compressing the spring.
FIGURE 5—Valve Rocker Arm Assembly
VALVES
Figure 6 illustrates the valve arrangement.
Valve Springs
Whenever valve springs are removed, they
should be tested according to the specifications listed below. Use valve spring tester
and replace all springs not within specifications.
FIGURE 7—Removing Valves from
Cylinder Head
Valve Stem to Guide Clearance
Valve guides are cast integrally with the
cylinder head. The valves are replaced with
oversize stem valves when excessive stem to
guide clearance develops (Fig. 8). For
service, valves with oversize stems are
supplied in .003", .010", .020', and .030".
A special set of valve guide reamers
(J-6042) are available to fit the various
size valves to their guide.
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