1963 Ford Thunderbird Shop Manual EAN: 978-1-60371-013-8 ISBN: 1-60371-013-2

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GROUP INDEX

THUNDERBIRD IDENTIFICATION

ENGINE AND EXHAUST SYSTEM

FORD IGNITION SYSTEM

FUEL SYSTEM

THUNDERBIRD COOLING SYSTEM

CRUISE-O-MATIC TRANSMISSION

REAR AXLE AND DRIVE LINE

STEERING

SHOP BRAKES AND SUSPENSION

GENERATING AND STARTING MANUAL SYSTEMS LIGHTS, INSTRUMENTS AND ACCESSORIES

SUPPLEMENT BODY

MAINTENANCE, LUBRICATION AND SPECIAL TOOLS

SPECIFICATIONS SERVICE DEPARTMENT FORD DIVISION

(^)MOTOR COMPANY

FIRST PRINTING SEPTEMBER, 1962

1962 FORD MOTOR COMPANY. DEARBORN, MICHIGAN

Reprinted with Ford Motor Company's Permission FOREWORD

The information in this supplement, when used with the 1962

Ford Thunderbird Shop Manual, provides the necessary in formation for servicing the 1963 Thunderbird. Complete

1963 maintenance information and specifications are included.

The descriptions and specifications contained in this supple ment 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 specifi cations or design, without notice and without incurring obliga tion.

SERVICE DEPARTMENT FORD DIVISION FORD MOTOR COMPANY THUNDERBIRD IDENTIFICATION

BODY COLOR TRIM DATE DSO AXLE TRANS 63A J 85 9H

VEHICLE WARRANTY NUMBER 3Y83Z100001 5vrd NOT FOR TITLE OR REGISTRATION PURPOSES

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

A PRODUCT OF ( SvFCt MOTOR COMPANY

M1087-A

FIG. 1 -Thunderbird Warranty Plate

Figure 1 illustrates a Thunderbird Warranty plate and its elements. The BODY Warranty plate is attached to the left door front pillar. 63A Tudor Hardtop 7SA Tudor Convertible The official Vehicle Identification number for title and registration purposes is stamped on the just forward of the right-hand hood lock plate body COLOR (Fig. 2). Do not use the Vehicle Warranty number which appears on the If a special paint is used, the paint color space will not be stamped. Warranty plate for title or registration purposes.

M30J/M32J Code Number Color Sales Name A 1724 Black Raven Black D 1070 Med. Turquoise Metallic Patrician Green E 1269 Med. Blue Metallic Acapulco Blue

G 1446 .Silver Blue Metallic Silver Mink H 1544 Dark Blue Metallic Caspian Blue

.1515. .. Red Rangoon Red

.1452. .. Lt. Turquoise Chalfonte Blue

.1458. . . Pink Sahara Rose

.1238. . . White Corinthian White

. 921. . . Diamond Blue Diamond Blue O 1554 Med. Green Metallic Green Mist R 1456 Yellow Tucson Yellow S 1453 Dk. Green Metallic Cascade Green T 1543 Lt. Beige Sandshell Beige Ml 088-A U 1450 Dark Turquoise Metallic Deep Sea Blue V 1470 Chestnut Metallic Chestnut FIG. 2 -Vehicle Identification W 1555 Lt. Pink Metallic Rose Beige Number Location X 1444 Maroon Metallic Heritage Burgundy Z 1427 Beige Metallic Fieldstone Tan VEHICLE DATA

Example (Fig. 1): TRIM 63A J 85 9H 11 1 4 Deviation trim sets will use existing trim codes plus a suffix. A trim code with a numerical suffix is not while a trim code with an 63A Tudor Hardtop serviced, alpha betical suffix is serviced. j Red 85 Red Leather Code Crinkle Vinyl Pin Stripe B/C 9H Ninth day of August 72 Lt. Blue D/L Dk. Blue District Code 11 77 Lt. Turquoise D/L Dk. Turquoise 1 3.00:1 Axle Ratio 74 Pearl Beige Med. Beige Cruise-0- 4 Matic 76 Black Black THUNDERBIRD IDENTIFICATION

Code Crinkle Vinyl Vachette Vinyl AXLE 52... Med. Blue D/L Lt. Blue D/L 57... Med. Turquoise D/L Lt. Turquoise D/L Code Ratio 59... Med. Chestnut D/L Med. Chestnut D/L

1 .3.00:1 54... Pearl Beige Pearl Beige A* 56... Black Black .3.00:1 55... Red Red *Equa-Lock Type. 50... Med. Silver Blue Met Lt. Silver Blue D/L 58... Lt. Gold D/L Lt. Gold D/L 51... Lt. Rose Beige D/L LL Rose Beige D/L TRANSMISSION Code Crinkle Leather Vachette Leather 82... Lt. Blue D/L Lt. Blue D/L Code Type 84... Pearl Beige Pearl 4 Cruise-O-Matic 86... Black Black 85... Red Red

DATE VEHICLE WARRANTY NUMBER

The code letters for the month are preceded by a numeral to show the day Example (Fig. 1): 3Y83Z1000O1 of the month when the Thunderbird was completed. The second year code letters are to be used if model production exceeds 12 months. 3 1963 Model Y Wixom Plant First Second Assembly 83 Tudor Month Model Year Model Year Hardtop Z 8-Cylinder 390 Cubic Inch Engine January A N 1 00001 February B P First Unit Built March C Q April D R May E S MODEL YEAR June F T

July G U "3" The number designates 1963. August H V September J W October K X November L Y ASSEMBLY PLANT December M Z Code Location DSO

.Wixom Plant Thunderbirds built to a Domestic Special Order, Foreign Special Order, or Assembly Pre-Approved Order have the complete order number recorded in this Pilot Plant space. Also appearing in this space is the two digit code number of the District which ordered the unit. If the unit is regular production, only the District code number will appear. MODEL DISTRICT CODE Code Type Code District Code District 11 Boston 45 Davenport 83 Tudor Hardtop 12 Buffalo 51 Denver 85 Tudor Convertible 13 New York 52 Des Moines 87 Tudor Landau 14 Pittsburgh 53 Kansas City 89 Tudor Roadster 15 Newark 54 Omaha 21 Atlanta 55 St. Louis 22 Charlotte 61 Dallas ENGINE 23 Philadelphia 62 Houston 24 Jacksonville 63 Memphis 25 Richmond 64 New Orleans Code Type

26 Washington 65 Oklahoma City 8- M Cylinder 390 Cubic Inch (6-barrel High Performance) 31 Cincinnati 71 Los Angeles 9 8-Cylinder 390 Cubic Inch (4-barrel Low Compression Cleveland 72 San Jose 32 Export 84 Octane) 33 Detroit 73 Salt Lake City Z 8-Cylinder 390 Cubic Inch (4-barrel) 34 Indianapolis 74 Seattle 35 Lansing 81 Ford of Canada 36 Louisville 83 Government 41 Chicago 84 Home Office Reserve CONSECUTIVE UNIT NUMBER 42 Fargo 85 American Red Cross

43 Rockford 89 Transportation Services The assembly plant, with each model year, begins with consecutive unit 44 Twin Cities 90-99 Export number 100001 and continues on for each unit built. GROUP 1

GROUP 1 -ENGINE AND EXHAUST SYSTEM

The 1963 maintenance recommen transfer the lifter over to an adjoining ings. dations are in Group 12 and the push rod opening in order to remove Installation 1963 specifications are in Group 13 it. Place the lifters in a rack so that of this manual. they can be installed in their origi 1. Oil the camshaft and apply All the service procedures out nal positions. Lubriplate to the lobes. Carefully lined in Group I of the 1962 Shop 5. Install a dial indicator so the slide the camshaft through the bear Manual apply for both the 1963 390 indicator point is on the camshaft ings. Install the thrust plate. Install 4-V engine and the 390 6-V High sprocket retaining screw. Push the I the thrust plate with the side having Performance engine with the follow camshaft toward the rear of the en a chamfered ID against the camshaft ing exceptions. gine and set the dial indicator on front journal. The oil groove in the zero. Pull the camshaft forward and thrust plate must be above the 390 4-V ENGINE (Part release it. Compare the indicator 1-1) camshaft, and it must face towards reading with the specifications. If the CAMSHAFT the front (against the camshaft end play is excessive, check the spacer sprocket). The camshaft and related parts are for correct installation before it is 2. Follow step 5 under "Camshaft removed. The side of the spacer shown in Fig. 3. Removal" and check the camshaft having a chamfer on the ID must end play. Removal be against the camshaft front jour 3. Position the sprockets and tim 1. Refer to "Valve Rocker Arm nal. If the spacer is installed cor Removal" ing chain on the camshaft and crank Shaft Assembly (page rectly, replace the thrust plate. shaft with the timing marks on the 1-15, 1962 Shop Manual) and re 6. Remove the dial indicator. Re sprockets aligned as shown in Fig. move the valve rocker arm shaft move the camshaft sprocket cap 48, page 1-24, 1962 Shop Manual. assemblies. screw, lock washer, flat washer, and 4. Install the fuel pump eccentric, 2. Remove the cylinder front cover fuel pump eccentric. flat washer, lock washer, and sprocket following steps 1 thru 16 under "Cyl 7. Slide both sprockets and the cap screw. Torque the sprocket cap inder Front Cover and Timing Chain timing chain forward, and remove Removal" screw to specifications. Install the (page 1-23, 1962 Shop the sprockets and timing chain as an front oil slinger. Manual). assembly (Fig. 49, 1962 Shop Man 5. Replace the crankshaft front oil 3. Remove the valve push rods in ual). seal. Install the cylinder front cover, sequence and place them in a rack 8. Remove the oil pan and oil the crankshaft damper, and related so that they can be installed in their pump by following the procedure parts following steps 3 thru 16 under original positions. under "Oil Pan and Oil Pump Re moval" "Cylinder Front Cover and 4. Position an inspection light (page 1962 Timing 1-32, Shop Installation" Chain (page 1-24, 1962 through a push rod opening and into Manual). Shop Manual). the valve push rod valley (Fig. 55, 9. Remove the camshaft thrust 6. With No. 1 piston on TDC at page 1-26, 1962 Shop Manual). Re plate and spacer. Carefully remove the end of the compression stroke, move the valve lifters with a magnet the camshaft by pulling it toward the position the distributor in the block through the push rod openings. In front of the engine. Use caution to with the rotor at the No. 1 some cases, it will be necessary to avoid damaging the camshaft bear- firing position and the points open. Install the hold down clamp.

7. Connect the distributor vacuum BEARINGS line. Install the distributor cap. Con nect the coil high tension lead. 8. Install the valve lifters in the bores from which they were re moved. Install the push rods. 9. Refer to "Valve Rocker Arm Installation" Shaft Assembly and in stall the valve rocker arm shaft as

CAMSHAFT REAR BEARING sembly following steps 1 thru 9, BORE PLUG page 1-16, 1962 Shop Manual. 10. Fill and bleed the cooling sys tem. Fill the crankcase with the proper grade and quantity of eneine oil.

11. Start the engine and check and adjust the ignition timing. Operate

the engine at fast idle and check all TIMING CHAIN AND CAMSHAFT SPROCKET hose connections and gaskets for leaks.

FLAT WASHER - A1275-B Cleaning and Inspection. Refer to the 1962 Shop Manual for clean 3-Camshaft and Related Parts FIG. ing and inspection procedures. GROUP 1

390 6-V HIGH PERFORMANCE spacer is eliminated. all models. ENGINE (Part control valve 1-1) 3. The exhaust gas The dual exhaust system (Fig. 3 A) The warranty plate identification is mounted with the counterweight consists of: a one-piece muffler inlet symbol for the engine is "M". This on the outboard side of the engine. pipe with separate front section inlet engine is the same as the 390 4-V pipes that are joined together by a engine except for specifications EXHAUST SYSTEM (Part 1-2) welded cross-over pipe; separate (Group 13) and the following dif right and left inlet extension pipes; DESCRIPTION ferences: right and left mufflers that contain 1. A cast aluminum intake mani A single exhaust system is stand integral muffler outlet pipes; retain fold replaces the cast iron intake ard equipment on all 1963 Thunder- ing clamps, brackets, nuts and bolts; manifold used on the 390 4-V engine. birds. A dual exhaust system is two exhaust manifolds to inlet pipe

2. The coolant-heated carburetor available as optional equipment on gaskets.

A1730-A

FIG. 3A-Dual Exhaust System

The single exhaust system (Fig. PIPE, MUFFLER AND OUTLET Remove the muffler rear bracket re 3B) consists of: a one-piece muffler PIPE REPLACEMENT taining bolts. Disconnect the inlet "Y" inlet pipe with type inlet pipes extension pipe from the inlet pipe Muffler Inlet Pipe -Dual Ex that are joined and welded together; and remove the inlet pipe. haust. The muffler inlet pipe is a muffler with an integral outlet pipe; 3. Clean the mounting surfaces of serviced in one piece. a muffler inlet extension pipe; re the exhaust manifolds and the inlet 1. Loosen the muffler inlet pipe to taining clamps, brackets, bolts and pipes. inlet extension pipe clamps and slide nuts; two exhaust manifolds to inlet 4. Install the gaskets, inlet pipes, the clamps forward on the inlet pipe. pipe gaskets; a sealing gasket, located and the retaining nuts. Torque the Disconnect the inlet pipe at the ex at the flange of the inlet pipe and the nuts to specifications. haust manifolds. inlet extension pipe rear flange. 5. Position the front clamp on the 2. Disconnect the hanger bracket inlet extension pipe. Connect the inlet INLET PIPE, INLET EXTENSION clamp from the inlet extension pipe. pipe and the inlet extension pipe; GROUP 1

A1731-A

FIG. 3 B- Single Exhaust System

then install the muffler, muffler rear let extension pipe clamp and the Exhaust. The muffler inlet pipe is muffler rear bolts serviced as one piece. bracket retaining bolts, and the inlet bracket retaining the and extension bracket clamp. and nuts. Torque the clamp and 1. Remove retaining bolts 6. Align the exhaust system; then, bolts to specifications. nuts from the inlet pipe to inlet ex torque the front clamp, inlet ex 5. Check the system for leaks. tension pipe flange. Remove the and from the inlet extension pipe tension pipe bracket clamp, Muffler Inlet Pipe Extension clamp rear bracket bolts hanger bracket. muffler retaining Dual Exhaust. The procedure applies specifications. 2. Disconnect the inlet pipes at to to either a right or left assembly. Check the system for leaks. the exhaust manifold. Remove the 7. 1. Remove the muffler and outlet inlet pipe and gaskets from the ex pipe assembly. Muffler and Outlet Pipe -Dual haust manifolds. 2. Loosen the muffler inlet extension procedure applies to Exhaust. The 3. Clean the mounting surfaces of pipe front clamp and remove the inlet either a right or left assembly. the exhaust manifolds and the inlet extension pipe hanger bracket clamp. muffler to muffler 1. Loosen the pipes. Install the gaskets, inlet pipes, Remove the inlet extension pipe. slide inlet extension pipe clamp and and retaining nuts. Torque the nuts 3. Position the inlet extension pipe it forward on the extension pipe. to specifications. front clamp on the end of the inlet 2. Remove the retaining bolts and 4. Install a new gasket between the pipe. Connect the inlet extension rear bracket nuts securing the muffler inlet pipe and the inlet pipe extension pipe to the inlet pipe. Install the inlet to the hanger assembly. Remove the flange. Install the flange extension pipe front clamp and the retaining muffler and outlet pipe assembly. bolts and nuts; then, torque them to hanger bracket clamp. 3. Position the new muffler and specifications. 4. Install the muffler and outlet on the inlet ex outlet pipe assembly 5. Install the inlet extension pipe pipe assembly. muffler for tension pipe. Slide the hanger bracket and torque 5. Torque the inlet extension pipe clamp extension pipe ward into the inlet the nuts to specifications. front and rear clamps and the hanger retaining until the slots in the muffler exten 6. Check the system for leaks. bracket clamp to specifications. sion are blocked. 6. Check the system for leaks. 4. Align the muffler and outlet Muffler - Single Exhaust. The

pipe assembly. Install the muffler in Muffler Inlet Pipe Single muffler and outlet pipe is serviced as 8 GROUPS 1-2-3

one piece. and align the exhaust system; then, extension pipe and the flange gaskets. 1. Remove the outlet pipe front torque the clamp bolts and muffler 3. Clean the mating surfaces of and rear hanger bracket clamps. flange bolts to specifications. the mounting flanges; then, position 2. Remove the inlet extension pipe 5. Check the system for leaks. the inlet extension pipe on the inlet to muffler flange retaining bolts. pipe and muffler flanges. Insert a Extension Remove the flange gasket and the Muffler Inlet Pipe new gasket between the front and Single Exhaust muffler and outlet pipe assembly. the rear flanges. Install the mounting 3. Clean the muffler and inlet pipe 1. Remove the flange bolts from bolts and nuts. extension flanges. Position the muffler both flanges of the inlet extension 4. Install the inlet extension pipe flange and a new gasket on the inlet pipe. Remove the clamp from the hanger bracket clamp. Torque the extension pipe flange. Install the re extension pipe hanger bracket. flange bolts and the hanger clamp taining bolts and nuts. 2. Pry the muffler toward the right bolt to specifications. 4. Install the outlet pipe clamps side of the car and remove the inlet 5. Check the system for leaks.

GROUP 2-IGNITION SYSTEM

The 1963 maintenance recom The ignition system service pro bird. Refer to Group 2 of the 1962 mendations are in Group 12 and the cedures outlined in the 1962 Shop manual for the recommended serv 1963 specifications are in Group 13 Manual apply to the 1963 Thunder ice procedures. of this 'manual.

GROUP 3-FUEL SYSTEM

The 1963 maintenance recom period. 3. Place a 0.010-inch feeler gauge mendations are in Group 12 and the 4. Standpipe pitot tubes were between the top rear straight edge of 1963 specifications are in Group 13 added to the secondary fuel bowl the choke plate and the air horn of this manual. internal vent openings to raise the casting. All the service procedures outlined level of the internal vent openings 4. Loosen the attaching screws and in Group 3 of the 1962 Shop Man above the external vent openings. adjust the magnet and bracket as ual remain the same for the 1963 This provides the necessary pressure sembly so that it just contacts the 390 4-V engine series except as de differential for proper evacuation of choke plate. Tighten the attaching scribed herein (Ford 4-V carburet the gaseous vapors through the ex screws and remove the feeler gauge. or). Service procedures for the 1963 ternal vent during a hot soak period. Set the choke thermostat coil hous High Performance 390 6-V engine 5. Two baffles have been added in ing to the proper index mark. All series (three Holley dual carburet the internal fuel equalizer passage other procedures for adjusting the are included in this supplement. automatic choke are the same as out ors) between the primary and secondary fuel bowls to permit proper control lined in Part 3-1 of the 1962 Thun FORD 4-BARREL CARBURETOR of the metering forces within each derbird Shop Manual. OPERATION fuel bowl, since these forces were Fuel Level Float Adjustment. On thrown out of balance by the addi The carburetor incorporates the carburetors equipped with Viton- tion of the secondary fuel bowl ex following changes: tipped fuel inlet needles, the dry ternal vent. 1. A magnet and bracket assembly float fuel level settings should be used 6. The calibration of the secondary was added to the front wall of the as a guide only, and a final check section of the carburetor was revised carburetor air horn to entrap the and adjustment of the wet fuel level to compensate for the reduction in choke plate in the closed position should be made as follows: the metering forces. Refer to the and increase the force holding the 1. Operate the engine for 30 specifications for the proper metering choke plate closed during cold engine minutes at 1200 rpm to normalize jets. starting. engine temperatures, and place ve 2. A lower torque rate choke hous hicle on a flat surface as near level IN-CHASSIS ADJUSTMENT ing spring has been incorporated to as possible. Stop the engine. Automatic Choke. Use the follow reduce the forces tending to close the 2. Remove the air cleaner assembly, procedure to adjust the magnet choke plate after the engine has ing carburetor air horn assembly, and and bracket assembly: started, thereby minimizing the ten gasket. dency of the carburetor to over- 1. Rotate the choke thermostat 3. Temporarily place the air horn 90 "rich" choke the engine and cause "loading". coil housing in the direc gasket in position on the carburetor 3. An external vent opening has tion (counterclockwise). main body and start the engine. Let been added to the secondary fuel 2. Adjust the bellcrank lever, if the engine idle for several minutes; bowl cover to provide an escape for necessary, to obtain 0.050 inch be then remove the air horn gasket. the highly volatile fuel vapors, there tween the top edge of the fast idle 4. While the engine is idling, use a by reducing the possibility of flooding cam and the cast stop boss on the standard depth scale to measure the the intake system during a hot soak rear of the choke housing. vertical distance from the top ma- GROUP 3

ating rod may be placed in the No. PUT ROD IN over-travel INSIDE HOLE 1 hole position of the lever (hole closest to the throttle shaft) to suit individual operating conditions. The correct position for the pump operating rod at the accelerator pump plunger lever, for all operating con ditions, is in the inboard hole (hole closest to the pump plunger).

HOLLEY DUAL CARBURETORS

IN-CHASSIS ADJUSTMENTS Idle Fuel Mixture Adjustment I 1. Operate the engine until it reaches normal operating tempera ture. If the car is equipped with an air conditioner, the engine must be operated at least 20 minutes. All I ACCELERATING PUMP LINK ACCELERATING PUMP OPERATING ROD B1424-C engine speed and idle fuel mixture FIG. 4-Accelerating Pump Stroke Adjustment adjustments must be made with the air cleaner installed.

over- chined surface of the carburetor main the No. 2 hole position of the 2. Establish an initial idle fuel mix body to the level of the fuel in the travel lever (second hole from the ture adjustment by turning both idle fuel bowl. The measurement must be throttle shaft). To release the rod mixture screws on each carburetor made at least 1/4 inch from any from the retainer clip, press the tab (Fig. 5) inward until they are lightly vertical surface to assure an accurate end of the clip toward the rod, and seated. Then turn the idle mixture the rod on each carbure reading because the surface of the at the same time press screws secondary fuel is concave (higher at the edges away from the clip until it is dis tor (Fig. 6) outward 3/4 turns, and than in the center). Care must be engaged. turn the primary carburetor idle mix

exercised to measure the fuel level For low ambient temperature oper ture screws outward one full turn.

at the point of contact with the fuel. ation (below 40F), place the pump 3. Install an engine speed tachom Refer to the specifications for the operating rod in the No. 3 hole posi eter. Start the engine; move the trans correct fuel level (wet) setting. tion of the over-travel lever (third mission selector lever to the DRIVE 5. If any adjustment is required, hole from the throttle shaft). (Dl) position, and set the parking stop the engine to minimize the For extremely low ambient tem brake. Adjust the engine idle rpm to hazard of fire due to fuel spray perature operation ( 15F and be 575-600 rpm by turning the idle when the float setting is disturbed. low), the pump operating rod may speed adjusting screw (Fig. 5) on the To adjust the fuel level, bend the be placed in the No. 4 hole position primary carburetor only. float tab contacting the fuel inlet to suit individual operating condi 4. Turn the primary carburetor valve upward, in relation to the tions. idle mixture screws inward until the original position, to raise the fuel For high ambient temperature engine begins to run rough from the level and downward to lower it. Each operation (above 80F and/or above lean mixture. Turn the mixture be- time an adjustment is made to the 5000 feet altitude), the pump oper screws outward until the engine float tab to alter the fuel level the

engine must be started and permitted SECONDARY THROTTLE LEVER DLE MIXTURE SCREW WIDE-OPEN THROTTLE STOP to idle for at least three (3) minutes to stabilize the fuel level. Check the fuel level after each adjustment until

the specified level is achieved. 6. Install a new air horn gasket and the carburetor air horn assembly. 7. Check the engine idle speed and idle fuel mixture and adjust as re quired.

8. Install the air cleaner assembly.

Accelerating Pump Stroke. The over-travel lever has 4 holes and the accelerating pump link has 2 holes to control the accelerating pump stroke for different engine applica tions (Fig. 4). SECONDARY PRIMARY PRIMARY IDLE SPEED For average ambient temperature THROTTLE ROD THROTTLE LEVER THROTTLE ROD ADJUSTING SCREW (40 B1718-A operation to 80F), place the accelerator pump operating rod in FIG. 5-390 6-V Carburetor Throttle Linkage Installation 10 GROUP 3

IDLE CHOKE THERMOSTAT PRIMARY CARBURETOR SECONDARY AUTOMATIC CHOKE CARBURETORS ADJUSTING HOUSING SCREW

B1730-A

FIG. 7-Fast Idle Speed Adjustment

ward to increase or outward to decrease the idle speed to obtain the

specified rpm.

Throttle Lever Synchronization. If the throttle linkage is disassembled or it is improperly synchronized, the following procedure is recommended for synchronizing the throttle levers on the three carburetors.

1. Insert a 1/8-inch diameter rod BELLCRANK LEVER TRUNNION PRIMARY ACCELERATOR-TO-BELLCRANK through the gauging holes (Fig. 8) THROTTLE ROD ROD CONNECTION B1719-A provided in the bellcrank lever and FIG* 6-390 6-V Carburetor Installation mounting bracket on the left side of the bellcrank assembly. This locks the lever in the gauging (closed throttle) gins to roll from the rich mixture. ments must be made with the air position. Turn the screws inward until the cleaner installed and the engine at 2. Disconnect the engine runs smoothly and evenly. normal operating temperature. secondary throttle "rich" Always favor a slightly idle rods at each secondary carburetor 1. Back off the idle speed adjust fuel mixture. throttle lever (Fig. 5). Disconnect screw (Fig. 5) on each secondary ing the primary throttle rod at the bell 5. Repeat this procedure (step 4) carburetor to allow the sufficiently crank lever. to adjust the idle mixture screws on throttle plates to seat in the throttle 3. Loosen the lock nut and adjust the front secondary carburetor. bores. Turn the idle speed screws in the length of the front secondary 6. Following the same procedure, ward until the screw end just touches carburetor throttle rod so that, when adjust rhe idle mixture screws on the the stop on the throttle lever; then the throttle lever of the turn it an installed, rear secondary carburetor. The right inward additional 1/2 to front secondary carburetor will be and left idle mixture screws on 3/4 turns. A minimum throttle completely closed when the primary any one carburetor should be open opening is desired on the second throttle lever is closed against the an equal amount, within 1/8 turn, ary throttle plates. The only re idle speed screw after the final adjustment. quirement necessary is that the adjusting stop (normal idle position). plates do not stick in the bores. 7. With the engine operating at 4. Adjust the length of the rear idle and the transmission in Drive 2. Operate the engine for 30 secondary carburetor throttle rod in range, check the engine speed. The minutes at 1200 rpm to normalize the same manner. tachometer should indicate 575-600 engine temperatures. Install an en engine rpm. gine speed tachometer. Start the 5. Install the secondary throttle rods on engine. Move the transmission selec the secondary throttle levers 8. If the engine still does not idle with tor lever to the DRIVE posi the spacer washers and retainers. properly, due to a too rich mixture, (Dl) Tighten tion, and set the brake. Ad the lock nuts to secure the i.e., idle mixture screws are seated, parking just the engine idle rpm to 575-600 adjustment. it may be caused by improper initial rpm the idle speed adjust 6. With the idle speed setting of the secondary by turning primary throttle lever screw on the carburetor against the carburetors. Also, if the throttle ing primary idle stop, adjust the length only. of the levers are not synchronized, it will primary throttle rod (Fig. 6), so that the trunnion will be difficult to obtain a satisfactory 3. Set the fast idle speed (cold) just engage in the hole in the idle adjustment. with the engine at normal operating bellcrank lever. Install the rod temperature. Align the high step on retainer clip. Adjustment. All engine cam Idle Speed the fast idle with the adjusting 7. Adjust the anti-stall dashpot speed and idle fuel mixture adjust screw (Fig. 7). Turn the screw in- clearance. GROUP 3 n

the screw into the screw After the fuel level has stabilized, BELLCRANK LEVER ANTI-STALL DASHPOT adjusting fuel head to increase the clearance and stop the engine and check the outward to decrease the clearance. level. One-half turn of the screw equals approximately 0.015 inch. Float Adjustment

To satisfy acceleration require 1. If the fuel level is too high, it ments in various climates, the accel should first be lowered below speci erating pump cam can be placed in fications and then raised until it is either of two positions. Aligning the just at the lower edge of the sight with the hole top hole of the cam top plug opening. If the fuel level is too of the throttle lever gives the shortest low, it is only necessary to raise it stroke which is recommended for to the specified level; thus omit steps warm weather or average conditions. 3 and 4 of this procedure. Aligning the cam bottom hole with 2. With the engine stopped, loosen LOCK the lever bottom hole gives the screw on of the fuel NUT B1720-A the lock top longest stroke which is recommended bowl just enough to allow rotation for cold weather operation. underneath (Fig. FIG. 8 Anti-Stall Dashpot of the adjusting nut SCREW ADJUSTING THROTTLE CAM SUMMER 10). Do not loosen the lock screw Adjustment HEAD SCREW LEVER SETTING or attempt to adjust the fuel level with the engine running because Anti-Stall Dashpot Adjustment the pressure in the line will spray hazard. 1. Adjust the engine idle speed fuel out and present a fire Q and idle fuel and synchro mixture, 3. Turn the adjusting nut approxi nize the carburetor linkage. Operate mately Vi turn in to lower the fuel reaches normal the engine until it level below specifications (1/6 turn temperature. operating <& of the adjusting nut, depending on ACCELERATING the throttle linkage in the / / the direction of rotation, will raise or 2. Lock PUMP ARM / / CAM a 1/8- lower the float assembly at the fuel gauging position by inserting ACCELERATING / WINTER level sight 3/64 inch). inch diameter rod through the gaug PUMP LEVER / SETTING plug opening

ing holes provided in the bellcrank ACCELERATING 4. Tighten the lock screw. Start on the PUMP CAM B1731-A lever and mounting bracket the engine. After the fuel level has left side of the bellcrank assembly stabilized, stop the engine and check FIG. 9-Accelerating Pump (Fig. 8). the level at the sight opening. Adjustment plug 3. Loosen the lock nut and turn The fuel level should be below specified limits. repeat the anti-stall dashpot screw in, or If it is not, Fuel Level Check. Position the car the nut an away from the bellcrank lever. Fully step 3, turning adjusting on a level floor. Be sure the fuel depress the dashpot plunger with a additional amount sufficient to lower pressure is within specifica pump below specified screwdriver blade, and adjust the the fuel the level. tions. Operate the engine for 30 clearance between the plunger and 5. Loosen the lock screw and turn minutes at 1200 rpm until normal bellcrank to 1/8-3/16 inch. lever the nut out in temperature has been adjusting increments Tighten the locknut and remove the operating of 1/6 turn or less until the correct reached. Place a suitable container 1/8-inch rod from the gauge holes. fuel level is achieved. After each ad below the fuel level sight plug to Automatic Choke Adjustment. justment, tighten the lock screw, and collect any spill-over of fuel. The automatic choke has an adjust then start the engine and stabilize With the engine stopped, remove ment to control its reaction to engine the fuel level. Check the fuel level the fuel level sight plug and gasket temperature. By loosening the three and check the fuel level (Fig. 10). screws that retain the choke thermo The fuel level within the bowl should stat housing (Fig.7), it can be turned be at the lower edge of the sight to alter the thermostatic spring ad plug opening 1/16 inch. justment. Turning the housing in a counterclockwise direction provides a If the fuel level is satisfactory, in

richer mixture, and conversely, a stall the sight plug. Do not install the leaner mixture is obtained by turning air cleaner at this time. the in a clockwise direction housing If the fuel level is too high, drain as indicated the arrows on the by the fuel bowl and refill it and check housing. Refer to the specifications it again before altering the float set for the proper setting. ting. This will eliminate the pos

Adjustment. of foreign material a Accelerating Pump sibility causing FUEL LEVEL (Fig. held condition. To With the throttle lever 9) temporary flooding SIGHT PLUG in the wide-open-throttle position and drain the fuel bowl, remove one OPENING the accelerating pump arm fully de lower retaining bolt from the fuel pressed (manually), there should be bowl and drain the fuel into a suit B1167-A 0.015-inch clearance between the able container. Install the bolt and 10- screw head and the pump arm. Turn start the engine to fill the fuel bowl. FIG. Fuel Level Adjustment 12 GROUPS 3-4

pump except for incorporation of a place COVER horizontal cross vent system in of the vertical passage, increased di ameter internal fuel passages, and

pressure leak-down bleeds in the pump valves. In addition, the pump will incorporate the long-life, dispos able fuel filter element (Fig. 12).

ROCKER ARM PIN. ROCKER ARM FUEL PUMP-*. PIN PLUG BODY REMOVABLE ELEMENT

B1745-A ROCKER ARM SPRING FIG. 1 1 -Air Cleaner Assembly

DIAPHRAGM AND VALVE at the sight opening. the SPRING ASSEMBLY plug Install mended maintenance mileage inter HOUSING W I sight and gasket. plug val for cleaning and replacement of 6. Install the air cleaner. Check air cleaner elements.

and adjust the idle fuel mixture and PULSATOR idle speed as necessary. REMOVAL DIAPHRAGM

1. Remove the air cleaner wing AIR CLEANER (Part 3-1) nut. Disconnect the choke clean air VALVE- tube, and lift the air cleaner off the ai The engine is equipped with a dry- HOUSING V*rW carburetor. COVER P type air cleaner that has a replace able cellulose fiber filtering element 2. Remove the cover and lift the element out of the air cleaner body. (Fig. 11). The air from the engine O- FILTER HOUSING compartment enters the air cleaner GASKET INSTALLATION through the opening on the side and passes through the filter element. The 1. Place the air cleaner on body FILTER- filtered air is deflected down into the the carburetor so that the word carburetor. Dust particles are trapped "FRONT" faces the front of the car. in the filter element as the air rushes Connect the choke clean air tube to through it. A tube attached to the the air cleaner. filtered air chamber is connected to 2. Place the element in the air the automatic choke heat chamber in FILTER HOUSING cleaner body. Install the cover. the right exhaust manifold to supply clean air to the automatic choke. FUEL PUMP (Part 3-3) B1733-A MAINTENANCE FIG. 12 -Fuel The 1963 Carter design fuel pump Pump Asssembly Refer to Group 12 for the recom- is basically the same as the 1962

GROUP 4-COOLING SYSTEM

The 1963 maintenance recom THERMOSTAT TEST locations on the perimeter of the

mendations are in 12 and the valve be detected. This should Group Remove the thermostat and im may 1963 specifications are in 13 be considered normal. Group merse it in boiling water. Replace the of this manual. thermostat if it does not open more All the service procedures outlined than 1/4 inch. If the problem being FAN BELTS in Group 4 of the 1962 Shop Manual investigated is insufficient heat, the REMOVAL remain the same with the following thermostat should be checked for exceptions. leakage. This may be done by holding 1. Loosen the power steering pump the thermostat to a lighted back up bracket at the water THERMOSTAT pump and re ground. Light leakage around the move the drive belt. Only one type of thermostat thermostat valve (thermostat at room On a car with an air (poppet-type) is being used in the temperature) is unacceptable and the conditioner, remove the compressor drive belt. 1963 Thunderbirds. For replacement thermostat should be replaced. It is

"Thermostat," instructions, refer to possible, on some thermostats, that 2. Loosen the alternator mounting Manual. a slight leakage of light at one or two and page 4-4, 1962 Shop bolts the alternator adjusting arm GROUPS 4-5 13

pressor drive belt to specifications. bolt. Move the alternator toward the sert the belts in the water pump engine. Remove the the crankshaft pulley, and alter belts from pulley, 3. Install the power steering pump alternator and crankshaft nator grooves. Adjust the belt pulleys, pulley drive belt and tighten the pump tension to specifications. and lift them over the fan. bracket to the water pump. Adjust

tension to specifica INSTALLATION 2. On a car with an air condi the drive belt

1. Place the belts over the fan. In tioner, install and adjust the com tions.

GROUP 5-CRUISE-O-MATIC TRANSMISSION

GOVERNOR VALVE BODY TRANSMISSION MODEL DETAIL CHANGES

,OIL DISTRIBUTOR SLEEVE

SPEEDOMETER DRIVE GEAR

OUTPUT SHAFT

PRY BETWEEN J \ GOVERNOR COUNTERWEIGHT AND { -j OIL DISTRIBUTOR SLEEVE I """^^GOVERNOR COUNTERWEIGHT D1284-A

TRANSMISSION SERIAL NUMBER D1252-C FIG. 1 5-Pressure Apply Point for Drive Gear Removal I FIG. 1 3-Cruise-O-Matk Identification Tag

5. Slide the oil delivery sleeve to The 1963 maintenance recom new seal is 1/8-inch narrower than ward the front of the transmission. used. seal is mendations are in Group 12 and the the seal previously The 6. a hammer and a small 1963 specifications are in Group 13 removed and installed in the same Using the gear and of this manual. manner as the old type except for brass drift, tap evenly (T59L- cock the tool. The existing tool alternately (Fig. 16) to prevent All of the procedures outlined in 77837-A) can be reworked as ing it on the shaft. Tap the gear Group 5 of the 1962 Shop Manual shown in Fig. 14 to install the nar gently to prevent damaging it. remain the same with the following (T63L- rower seal or a new tool the it in exceptions. 7. To install gear, dip available. 77837-A) is transmission fluid and place it on an illuminated 100-watt light bulb. IDENTIFICATION TAG (Part 5-1) Allow the gear to remain on the The transmission identification tag NYLON-TYPE SPEEDOMETER 8. bulb for five turn it (Fig. 13) is attached to the left side DRIVE GEAR (Part 5-5) minutes, then, over and heat the other side for of the case. The first line on the tag A nylon speedometer drive gear minutes. will the gear indicates the model. The second line five This heat replaces the steel drive gear pre 180F. indicates the Serial No. and starts to approximately viously used. If gear replacement is with 100001. 9. Make sure the lock ball is in necessary, the old type steel gear may be used. FRONT OIL PUMP SEAL (Part 5-5) The nylon drive gear is a 0.004- 0.010-inch shrink fit on the output A new improved pump seal is shaft and can be removed or installed being used in the 1963 models. The in the following manner.

1. Remove the output shaft from CHAMFER TO REMOVE BURRS the transmission in the usual manner.

2. Remove the oil distributor tubes from the sleeve.

3. Remove the speedometer drive gear snap ring from the shaft. FRONT PUMP OIL SEAL

INSTALLATION 4. Pry the oil delivery sleeve to iF OFF M I' T0ol-TS9L-77837-A MACHINE ward the rear of shaft with a ham D1283-A mer handle. Make certain to apply D1285-A pressure on the governor counter 6 FIG. 14-ToolT59L-77837-A weight, and not against the gov FIG. 1 Speedometer Drive Rework Dimensions ernor valve body (Fig. 15). Gear Removal 14 GROUP 5

place on the shaft, then quickly slide the gear into place.

10. Install the speedometer drive ACCUMULATOR TUBE gear snap ring on the output shaft.

11. Install the output shaft in the usual manner.

OUTPUT SHAFT THRUST WASHER (Part 5-5) A new type needle bearing thrust washer is used in the 1963 Thunder bird transmission. A counterbore is provided in the rear pump to accom modate the thrust bearing race. Fig ure 17 shows the relative position of

the thrust washer and race.

TORQUE CONVERTER (Part 5-6) PISTON SEALS SPRING The 1963 converter has been

modified to replace the sprag-type -Front Servo clutch with a roller-type clutch. Also, FIG. 1 8 the bronze and aluminum thrust parts have been re washers have been replaced with an 0.075-inch thick engine rear cover The following

aluminum coated stamped thrust plate mounted between the trans vised to accommodate the new type washers and flat steel retainers. mission and engine, a new converter linkage; manual shaft and lever, con The design of the new thrust housing and converter assembly is trol valve detent lever, toggle lift a new used. The new converter will washers is such that longer housing lever, torsion rod and the lift lever rod (Tool have the starter pilot eliminated. locking T63P-7902-A) shaft. will be required for use with the Piloting of the starter will be accom existing converter clutch checking plished by the engine rear cover PLANETARY CLUTCH (Part 5-5) tool. plate. The checking procedure is the The new converter assembly will A new roller-type planetary clutch same as for previous model con have longer flywheel mounting stud has replaced the sprag-type clutch verters. pads and a longer crankshaft pilot, previously used. The new roller-type adequate pilot in order to provide clutch requires a new planet carrier FRONT SERVO (Part 5-5) in the crankshaft and maintain ing with a cam-type clutch race (Fig. 20) . piston and related the same converter to front pump The accumulator In conjunction with the clutch and parts have been eliminated on the relationship. the planet carrier, a new type center 1963 models. Servicing of the servo PARKING LINKAGE (Part 5-5) support is used. remains the same as in the 1962 The roller clutch is installed in the manual with the exception of the Figure 19 illustrates the new type same location, and functions in the eliminated parts shown in Figure 18. parking pawl linkage in the trans same manner as the sprag-type clutch mission. The control rod incorpo CONVERTER HOUSING used. The original center rates a compression spring to drive previously (Part 5-4) the toggle lift lever into the apply support is chamfered at the rear of To accommodate the addition of position.

TOGGLE TORSION LIFT ROD LEVER REAR PUMP-

OUTPUT SHAFT

THRUST WASHER

D1290-

D1289-A FIG. 19-Parking Linkage FIG. 1 7-0utput Shaft Thrust Washer and Race Installed GROUP 5 15

2. Install the primary sun gear rear

TYPE" and the CENTER SUPPORT CAM CLUTCH RACE thrust bearing race bearing in the planet carrier using petroleum PLANETARY CLUTCH jelly to retain them in place.

3. Lubricate the bearing surface on the center support, the rollers of the planetary clutch and the cam race in the carrier with petroleum jelly.

4. Install the planetary clutch on the center support with the "saw

teeth" the clutch cage in CHAMFER ON PRODUCTION of pointing clockwise direction as viewed PART, ONLY-SERVICE PART NOT CHAMFERED PLANET CARRIER D1288-A the from the rear (Fig. 22). Make sure Support cage. FIG. 20-Planetary Clutch, Planet Carrier and Center that all rollers are in the

5. Position the planet carrier on the clutch race to accommodate the will ride up the chamfer on the the support so that the cams in the new type roller clutch only. The new planetary support and onto the inner "saw-teeth" carrier engage the on the service planetary support is not pro race. clutch cage. vided with a chamfer and can be 7. Push the planet carrier all the used with the sprag-type clutch as forward. 6. Push the planet carrier forward well as the new roller clutch. The way until the rollers are felt to contact new chamfered support planetary 8. Check the operation of the the surface of cam race. cannot be used with the sprag-type planetary clutch by rotating the car clutch because the chamfer could re counterclockwise. It should ro rier 7. While applying forward pres contact area on the inner duce sprag while tate with a slight drag rotating sure on the carrier, rotate it counter in loss of and race, resulting capacity it counterclockwise (viewed from the clockwise as viewed from the rear. cause premature clutch wear. The rear) and it should lock up when This will cause the rollers to roll to method of the roller-type installing attempting to rotate it in a clockwise ward the large opening end of the clutch on the center support with a direction. cams in the race, compressing the chamfered edge is different from a springs slightly, so that the roller will support with a square edge as de INSTALLATION-Center Support enter the cams. tailed in the following procedure. with Square Edge 8. Some rollers may become cocked their into INSTALLATION-Center Support 1. Install the center support and preventing entry the rear band in the case. the outer race. These rollers must be with Chamfered Edge

1. Install the center support and

the rear band in the case.

2. Install the primary sun gear rear thrust bearing race and the bear ing in the planet carrier using petro leum jelly to retain them in place. 3. Lubricate the bearing surface on the center support, the rollers of the planetary clutch and the cam race in the carrier with petroleum jelly.

4. Install the planetary clutch in the carrier (Fig. 21).

5. Carefully position the planet car rier on the center support. Move the

carrier forward until the clutch

rollers are felt to contact the bearing

surface of the center support.

6. While applying forward pres ROTATE CARRIER COUNTER CLOCKWISE sure on the planet carrier, rotate it

counterclockwise as viewed from the

rear. This will cause the clutch rollers to roll toward the large opening end D1292-A of the cams in the race, compressing the springs slightly, so that the rollers FIG. 2 1 -Planetary Clutch Installed in Carrier 16 GROUPS 5-6

positioned individually with a small screwdriver by pushing the rear of ROTATE the rollers toward the center of the CENTER CARRIER transmission and into the cam race SUPPORT COUNTER CLOCKWISE (Fig. 22). Keep pressure applied to the carrier at all times.

9. After all of the rollers have been started into the cam race, ro tate the carrier counterclockwise while pushing it forward. Again, straighten any rollers or springs which still may be in a cocked posi tion and prevent the carrier from sliding onto the support.

Make sure that all springs are entered into the cam race before pushing the carrier onto the roller clutch.

10. Push the carrier all the way forward and check the operation of MOVE ROLLER TOWARD CENTER the clutch by rotating it in a counter clockwise direction. The carrier

should rotate counterclockwise with a slight drag and should lock up D1291-A when attempting to rotate it in a FIG. 22-Planetary Clutch Installed on Center Support clockwise direction.

GROUP 6-REAR AXLE AND DRIVE LINE

The 1963 maintenance recom 4. Remove the two short pinion to align the shaft retainer holes mendations are in Group 12 and the shafts. Using a drift, drive each shaft as each shaft is being driven into 1963 specifications are in Group 13 from the center outward. place. of this manual. 5. Lift out the center block, then 5. Drive the long pinion shaft into All the service remove the gears and thrust washers. procedures outlined place from the retainer hole end of in 6 of the 1962 Manual Group Shop 6. To disassemble the remaining the case being sure to align the re to the 1963 Thunderbird with apply carrier parts, follow steps 7 through tainer hole in the shaft with that in the exceptions. following 13 on page 6-9 of the 1962 manual. the case.

6. Place the second side gear and REAR AXLE OVERHAUL ASSEMBLY OF 4-PINION (Part 6-2) DIFFERENTIAL CASE LONG PINION SHAFT RETAINER SHAFT DISASSEMBLY OF 4-PINION HOLES Lubricate all parts thoroughly DIFFERENTIAL CASE with axle lubricant during assem bly. 1. Remove the differential case

1. Place a thrust washer and side DIFFERENTAL from the carrier and remove the SHAFT CASE bearings and drive gear from the case gear in the differential case bore. RETAINER HOLES as outlined in steps 1 through 4 un 2. Install the four thrust washers, der of Conventional "Disassembly and place the pinion gears on the Carrier," Differential page 6-8 of the side gear. Align the washers and 1962 manual. pinion gears with the pinion shaft

the case 2. Drive out the three differential holes in (Fig. 23).

pinion shaft retainers with a drift, 3. Install the center block so that

and separate the 2-piece differential its four small diameter holes are

case. aligned with the holes in the pinion

gears and in the case. 3. With a brass drift, drive out the long pinion shaft. Drive from the 4. With a brass drift, drive in the SHORT PINION SHAFTS E1248-A end opposite the retainer hole (Fig. two short pinion shafts from the out 23). side of the case (Fig. 23). Be sure FIG. 23-Four-Pinion Differential GROUPS 6-7 17

thrust washer on top of the four 9. Insert two 7/16 (N.F.) bolts Press Ram pinion gears, then install the differ 2-inches long through the differential

and or 4 turns ential case cover so that the three flange, thread them 3 into the drive gear as a guide in shaft retainer holes in the cover are aligning the drive gear bolt holes. aligned with their corresponding Press or tap the drive gear into posi holes in the case. tion.

7. Install the three shaft retainer 10. Install and tighten the drive pins with a drift. A pinion or axle gear bolts and washers evenly, and shaft spline can be inserted in the torque them alternately across the side gear spline to check for free ro gear to specifications.

tation of the differential gears. E1024-A 11. If the differential bearings have 8. Fill differential case with axle been removed, press them on as FIG. 24- Differential Bearing lubricant. shown in Fig. 24. Installation

GROUP 7-STEERING

The 1963 maintenance recom the return line from the steering gear mendations are in Group 12 and the housing. Plug the openings and cap SECTOR SHAFT ARM 1963 specifications are in Group 13 the lines. of this manual. 2. Remove the bolt that locks the

All the service procedures outlined flex joint clamp to the steering gear in Group 7 of the 1962 Shop Manual worm shaft (Fig. 25). apply to the 1963 Thunderbird with 3. Raise the car and disconnect the the following exceptions. sector shaft (pitman) arm from the sector shaft, using the tool shown in REPAIR (Part 7-2) Fig. 26. 4. Remove the steering gear mount. STEERING GEAR REMOVAL ng bolts (Fig. 27), and pull the AND INSTALLATION steering gear assembly out of the flex 1. Disconnect the pressure line and joint.

Tool-3590-FC G 1090-A

FIG. 26-Sector Shaft Arm Removal

GEAR ASSEMBLY

'FLEX JOINT

'CLAMP BOLT (2)

WORM SHAFT

SECTOR SHAFT BODY (PITMAN ARM) MEMBER G1166-A

G1165-A FIG. 27-Steering Gear FIG. 2 5 -Steering Column and Shaft-to-Steering Gear Connections Mountings 1962 FORD

SHOP MAN

1962 Ford Thunderbird Shop Manual EAN: 978-1-60371-012-1 ISBN: 1-60371-012-4

Forel Publishing Company, LLC 3999 Peregrine Ridge Ct. Woodbridge, VA 22192 Email address: [email protected] Website: http://www.ForelPublishing.com

Note from the Editor

Disclaimer

INDEX GROUP

THUNDERBIRD IDENTIFICATION

ENGINE AND EXHAUST SYSTEM

CRUISE-O-MATIC TRANSMISSION

REAR AXIE AND DRIVE LINE

ENERATING AND STARTING SYSTEMS

IGHTS, INSTRUMENTS, AND ACCESSORIES

BODY

ENANCE, LUBRICATION, AHB SPECIAL TOOLS

SERVICE DEPARTMENT FORD DIVISION FICATIONS AT THE END OF EACH GROUP (J^3)motor company

PRINTING FIRST SEPTEMBER. 1961

COMPANY, DEARBORN, MICHIGAN 1961 FORD MOTOR

Motor 2006 Reproduced under License #5008 from Ford Company January FOREWORD

This manual provides information for the proper servicing of

the 1962 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

BODY COLOR TRIM DATE D.S.O. AXLE TRANS.

MADE IN REG. U.S. U.S.A. BY PAT. OFF. SERIAL NUMBER EHHEEESi ggy&et,

THIS VEHICLE IS CONSTRUCTED UNDER UNITED STATES LETTER PATENTS

2590719 2617681 2631694 2677572 2677574 2683578

2698012 2726894 2782722 2784363 2789621 2810447

OTHER PATENTS PENDING

M1072-A

FIG. 1Thunderbird Patent Plate

Fig. 1 illustrates a Thunderbird patent plate and its elements. The patent TRIM plate is attached to the left door front pillar. Deviation trim sets will use existing trim codes plus a suffix. A trim code with a numerical suffix is not serviced, while a trim code with an alphabetical VEHICLE DATA suffix is serviced.

Example (Fig. 1): Code Color and Material 63A J 85 9H 1 4 50 Lt. Silver Blue Met. Vinyl 63A Tudor Hardtop J Red 52 Light Blue Metallic Vinyl 85 Red Leather 9H Ninth day of August 54 Lt. Pearl Beige Vinyl 1 3.00:1 Axle Ratio 4 Cruise-O-Matic 55 Red Vinyl

56 Black Vinyl BODY 57 Light Turquoise Vinyl 63A Tudor Hardtop Metallic 76A Tudor Convertible 59 Med. Chestnut Vinyl

70 Lt. Silver Blue Met. Vinyl & Med. Silver COLOR Blue Bedford Cloth

If a special paint is used, the paint color space will not be stamped. 72 Lt. Blue Met. Vinyl & Med. Blue Bedford Cloth

M30J 74 Lt. Pearl Beige Vinyl & Med. Beige Bedford Cloth Code Number Color Sales Name A 1 724 Black Raven Black 76 Black Vinyl & Med. Gray Bedford Cloth D 1070 Med. Turquoise Metallic Patrician Green E 1269 Med. Blue Metallic Acapulco Blue 77 Lt. Turquoise Met. Vinyl & Med. Turquoise Bedford Cloth F 1226 Lt. Blue Skymist Blue G 1446 Silver Blue Metallic Silver Mink 80 Lt. Silver Blue Met. Leather H 1544 Dark Blue Metallic Caspian Blue J 1515 Red Rangoon Red 82 Med. Blue Leather K 1452 Lt. Turquoise Chalfonte Blue L 1458 Pink Sahara Rose 84 Lt. Pearlescent Beige Leather M 1238 White Corinthian White N 921 Diamond Blue Diamond Blue 85 Red Leather R 1456 Yellow Tucsoi Yellow T 1543 Lt. Beige Sandshell Beige 86 Black Leather U 1450 Dark Turquoise Metallic Deep Sea Blue V 1470 Chestnut Metallic Chestnut 87 Lt. Turquoise Metallic Leather X 1444 Maroon Metallic Heritage Burgundy Z 1427 Beige Metallic Fieldstone Tan 89 Med. Chestnut Metallic Leather DATE SERIAL NUMBER

The code letters for the month are preceded a numeral to show the by day Example (Fig. 1): 2Y83Z100001 of the month when the Thunderbird was completed. The second year code 2 1962 Model letters are to be used if 1962 model production exceeds 12 months. Y Wixom Assembly Plant Month First Model Year Second Model Year 83 Tudor Hardtop January A N Z 8-Cylinder 390 Cubic Inch Engine February B P 100001 First Unit Built March C Q April D R MODEL YEAR May E S "2" June F T The number designates 1962. July G U August H V ASSEMBLY PLANT September J W October K X Code Location November L Y Y Wixom Assembly Plant December M Z S Pilot Plant

DSO MODEL

Code Type Thunderbirds built to a Domestic Special Order, Foreign Special Order, or Pre-Approved Order have the complete order number recorded in this 83 Tudor Hardtop Tudor Convertible space. If the unit is regular production, this space will remain blank. 85

AXLE ENGINE

Code Ratio Code Type 1 3.00:1 R 8-Cylinder 390 Cubic Inch (4-barrel Low Compression A* 84 .3.00:1 Export, Octane) 8-Cylinder 390 Cubic Inch *Equa-Lock type. (4-barrel)

TRANSMISSION CONSECUTIVE UNIT NUMBER

Code Type The assembly plant, with each model year, begins with consecutive unit 4 Cruise-O-Matic number 100001 and continues on for each unit built. GROUP I

ENGINE AND EXHAUST SYSTEM

PAGE

PART 1-1 ENGINE 1-2

PART 1-2 EXHAUST SYSTEM 1-41

PART 1-3 SPECIFICATIONS 1-43 1-2

=^- -^ ^gr Section Page ^=s 5 In-Chassis Repair sill Operations (Continued) Camshaft Rear Bearing Bore Plug Replacement. . 1-26 Hydraulic Valve Lifter IBB ENGINE Replacement 1-26 Crankshaft Lower Rear Oil Seal Replacement 1-27 Main and Connecting Rod Bearing Replacement 1-28 Piston and Connecting Section Page Section Page Rod Assembly 1-28 Flywheel 1-32 1 Description 1-2 5 In-Chassis Repair Operations (Continued) Oil Filter Replacement. . . 1-32 2 Engine Trouble Diagnosis . . 1-6 Oil Pan and Oil .. 1-32 Intake Manifold , 1-17 Pump. 3 Engine Tests and Exhaust Manifold 1-18 6 Work Stand Repair Adjustments 1-12 Positive Crankcase Operations 1-34 Ventilation System 1-19 4 Engine Removal and Crankshaft 1-34 Installation 1-13 Cylinder Heads and Camshaft Bearing Valves 1-19 Replacement 1-36 5 In-Chassis Repair Valve Stem Seal Engine Disassembly 1-36 Operations 1-15 Replacement 1-22 Cylinder Block 1-38 Engine Supports 1-15 Cylinder Front Cover Engine Assembly. 1-38 Valve Rocker Arm Shaft and Timing Chain 1-23 7 Crankcase Ventilation Assembly 1-15 Camshaft 1-25 System Maintenance 1-40

DESCRIPTION

A1240-C

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 "Z." the engine is

MANIFOLDS

An engine coolant heated spacer is located between the carburetor and the intake manifold (Fig. 3). The coolant flows from the front of

the engine through the spacer inlet

hose and into the carburetor coolant A1241-C

spacer. The coolant circulates through

the spacer and flows into the heater Ex- inlet hose and into the heater. FIG. 2-Sectional View 390 Special V-8 Engine PART 1-1 -ENGINE 13

AIR INLET AIR OUTLET TO CHOKE A

A1244-A

FIG. 6Valve Port Arrangement

VALVE TRAIN

The intake and exhaust valve as

semblies are the rotating-type which A1561-A AIR HEAT CHAMBER rotate each time the valve opens and A 1206-A FIG. 3-Intake Manifold Coolant closes. i. 5Automatic Choke Heat Passages The push rods are solid steel with Chamber oil cushioned sockets.

haust gases provide the initial heat The camshaft is supported by five 3 and 4 and on the left bank 7 necessary to assist in vaporizing the 5, 6, bearings pressed into the block. It is fuel and 8. The order is 1-5-4-2-6-3- incoming mixture. firing driven by a sprocket and timing chain The intake manifold has two sets 7-8. in mesh with a sprocket on the crank of fuel passages, each with its own shaft. Camshaft end is controlled The oil pump, mounted inside the play separate inlet connection to the car by a thrust button and spring located oil pan at the front, is driven by the buretor (Fig. 4). The right barrels of between the camshaft sprocket bolt distributor through an intermediate the carburetor feed Nos. 1,4, 6, and and the cylinder front cover. An ec 7 and drive shaft. cylinders the left barrels feed centric, bolted to the front end of the Nos. 2, 3, 5, and 8 cylinders. pump. The crankshaft is supported by camshaft, operates the fuel The distributor is mounted at the five main bearings. Crankshaft end Hydraulic valve lifters are used left front of the intake manifold. thrust is controlled by the flanges of which provide zero valve lash. The Warm air for the automatic choke the No. 3 main bearing. operation and parts identification of is drawn from the heat chamber of the hydraulic valve lifters are shown the right exhaust manifold (Fig. 5). The pistons have two compression in Fig. 7. rings and one oil control ring. The When the valve is the lifter CYLINDER HEADS chrome- closed, top compression ring is assembly is on the base circle of the plated and the lower compression The cylinder head assemblies con camshaft lobe and the valve push rod is phosphate-coated. The oil con tain the valves and the valve rocker ring is in its lowest position. With the trol consists of a ser arm shaft assembly. The combus ring assembly lifter assembly in this position, the tion chambers are machined in the rated spring and two chrome-plated plunger spring expands forcing the head. Valve guides are an integral steel rails. plunger upward. This action is trans- part of the head. The valves are ar

ranged from front to rear on both VALVE OPEN banks E-I-E-I-I-E-I-E (Fig. 6). LIFTER BODY VALVE CLOSED

CYLINDER BLOCK

The cylinders are numbered from front to rear, on the right bank 1, 2,

DISC VALVE

CAMSHAFT CAMSHAFT

A1243-A BASE CIRCLE FIG. 4-lntcke Manifold Fuel A1245-A Passages FIG. 7Typical Hydraulic Valve Lifter Operation 1-4 GROUP 1- ENGINE AND EXHAUST SYSTEM

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 A1246-A tates past the lifter, the push rod forces the valve lifter down and re FIG. 8Lubrication System seats the valve. The pressure on the oil below the plunger is relieved and the valve disc opens so that the bearing. No. 1 camshaft bearing oil gallery. Oil from here feeds the feeds 1 main and chamber can again be filled. This No. bearing, No. 2 valve lifter assemblies. A reservoir camshaft No. 2 main cycle is repeated for each revolution bearing feeds at each valve lifter bore boss traps etc. oil then of the camshaft. bearing, The flows oil so that oil is available for valve through notches or grooves in the lifter lubrication as soon as the en main bearings to lubricate the crank gine starts. LUBRICATION SYSTEM shaft journals. A jiggle pin in the An oil passage is drilled from Oil from the oil pan sump, located main oil gallery front plug allows any No. 2 camshaft bearing web to the in the front of the oil pan, is forced air that may be trapped in the oil to left cylinder head between Nos. 5 through the pressure-type lubrication escape. The timing chain and sprock and 6 cylinders to lubricate the ets are splash lubricated oil from system (Fig. 8) by a rotor oil pump. by valve rocker arm shaft assembly the pin. A spring-loaded relief valve in the jiggle (Fig. 9). The oil passage in the cyl pump limits the maximum pressure The crankshaft is drilled from the inder head is drilled from the cylin of the system. Oil relieved by the main bearings to the connecting rod der head bolt bore to the No. 2 valve valve is directed back to the intake bearings. rocker arm shaft support. side of the pump. A small groove is located in the The oil flows through the valve All the oil discharged by the pump connecting rod at the mating face rocker arm shaft through drilled holes passes through a full flow-type filter where the cap contacts the connect in each valve rocker arm to lubricate rod. This groove is used as an before it enters the engine. The filter ing the bushing and both ends of the is mounted in a vertical position at the oil squirt hole for cylinder wall lu valve rocker arm. The excess oil spi brication. Oil from the lower left front of the engine. A relief connecting rals down the rotating push rods and rod squirt the oppo valve in the filter permits oil to by hole lubricates lubricates the push rod seats. The site cylinder wall. pass the filter if it becomes clogged. For example, the right valve rocker arm shaft assem No. 1 rod oils No. 5 cyl is From the filter, the oil flows into connecting bly similarly lubricated from No. inder, etc. As the crankshaft turns, 4 camshaft the main oil gallery which is located bearing via the No. 4 the hole in the rod bear in the center of the valve push rod connecting valve rocker arm shaft support. aligns with the hole in the jour chamber floor. The oil gallery sup ing A baffle located under the valve nal causing a direct squirt of oil onto plies oil to each individual camshaft rocker arm shaft assembly shields the cylinder wall. bearing, through drilled passages in the valve stems from oil splash. Excess the block. Passages are drilled from Oil passages are drilled from the oil is returned to the oil pan through each camshaft bearing to each main main oil gallery to each valve lifter drain-back holes located at each end PART 1-1 -ENGINE 15

NO. 2 SUPPORT, LEFT HEAD CYLINDER NO. 4 SUPPORT, HEAD BOLT RIGHT HEAD BORE FROM CRANKCASE OUTLET

FROM NO. 2 CAMSHAFT V\/\A/s BEARING TO LEFT CYLINDER LOW INTAKE HEAD, AND MANIFOLD VACUUM HIGH SPEED OPERATIONS FROM NO. 4 CAMSHAFT BEARING TO RIGHT CYLINDER HEAD, FROM A1247-A TO INTAKE CRANKCASE MANIFOLD OUTLET FIG. 9-Valve Rocker Arm Shaft Lubrication

HIGH INTAKE of the cylinder head and in the push MANIFOLD VACUUM LOW SPEED OPERATIONS A1458-B rod chamber floor.

CRANKCASE VENTILATION FIG. 11 Positive Crankcase Ventilation Regulator Valve

tube- The engine has either a vent push rod chamber where there are POSITIVE CRANKCASE VENTILATION type ventilation system crankcase or few contaminating vapors. Here, the SYSTEM a positive crankcase ventilation sys incoming air has a chance to warm Ventilating air enters the engine in tem. before up contacting contaminating the normal manner through the vapors originating in the crankcase. breather cap and is distributed VENT TUBE-TYPE CRANKCASE Warm air minimizes the ventilating through the engine in the same man VENTILATION SYSTEM formation of crankcase sludge. ner as in the vent tube-type system. A crankcase ventilation tube is lo The ventilating air is directed by However, instead of the ventilating cated at the rear of the engine. The a baffle, located on the underside of air being discharged to the atmos forward motion of the car causes a the intake manifold, upward into phere, it is directed into the intake manifold thru partial vacuum to be formed at the the front of both valve rocker arm the carburetor spacer. tube outlet. vacuum action The air is directed into the intake This chambers. The baffle also directs air causes air to be drawn through the manifold through an exhaust tube to the front of the lower crankcase engine from the oil filler cap located which extends from the crankcase and into the timing chain chamber. at the front of the intake manifold ventilation outlet to a spring-loaded Air from the valve arm (Fig. 10). The filler cap contains a rocker regulator valve and then into the car filtering element which filters the in chamber and from the crankcase buretor spacer (Fig. 10). The valve coming air. flows into the rear of the valve push regulates the amount of air to meet conditions. From the filler cap, the air flows rod chamber. All air is then directed changing operating into the front section of the valve out the crankcase ventilation tube. During idle, intake manifold vac-

VENT-TUBE VENTILATION POSITIVE VENTILATION

A1454-B

FIG. 10-Crankcase Ventilating Systems 1-6 GROUP 1- ENGINE AND EXHAUST SYSTEM

uum is high. The high vacuum over comes the tension of the spring pres sure and seats the valve (Fig. 11). With the valve in this position, all TO RADIATOR SUPPLY TANK 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.

COOLING SYSTEM

The coolant is drawn from the bottom of the radiator by the water pump which delivers the coolant to the cylinder block (Fig. 12). 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. A1249-B The coolant from each cylinder head flows through the water pas 12 System sages in the intake manifold and FIG. Cooling past the water thermostat, if it is open, into the radiator supply tank. portion of the coolant is returned to The entire system is pressurized to If the thermostat is closed, a small the water pump for recirculation. 12-15 psi.

ENGINE TROUBLE DIAGNOSIS

Engine performance complaints the possible items that could be at cause of the trouble. All the ignition usually fall under one of the basic fault are listed in the order of their system items that affect acceleration headings listed in the "Engine probable occurrence. Check the items are listed. Check all these items Guide." Trouble Diagnosis When a in the order listed. For example, before proceeding to the next proba Acceleration," particular trouble can not be traced under "Poor the igni ble cause. to a definite cause by a simple check, tion system is listed as a probable

ENGINE TROUBLE DIAGNOSIS GUIDE

The cause of this trouble is usually starter. If the engine cranks, it indi- in the starting system (Part 9-2). cates that water is leaking into the If the starting system is not at fault, cylinders. Remove the cylinder ENGINE WILL check for a hydrostatic lock or a head(s) and inspect the gaskets(s) CRANK NOT 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

Check the fuel supply. If there is to be checked. Hold the adapter ap- sufficient fuel in the tank, the cause proximately 3/ie inch from the exhaust ENGINE CRANKS of the trouble probably lies in either manifold and crank the engine. the ignition or fuel system. NORMALLY, BUT WILL the To determine which system is at NOT START if THERE IS NO SPARK OR perform the test: fault, following A WEAK SPARK AT THE Disconnect a spark wire. plug SPARK PLUGS Check the spark intensity at the end of the wire by installing a terminal The cause of the trouble is in the adapter in the terminal of the wire ignition system.

CONTINUED ON NEXT PAGE PART 1-1 -ENGINE 1-7

ENGINE TROUBLE DIAGNOSIS GUIDE (Continued)

To determine if the cause of the The fast idle cam for binding. trouble is in the primary or the Thermostatic spring housing ad ENGINE CRANKS secondary circuit, remove the coil justment. NORMALLY, BUT WILL high tension lead from the top of the FUEL SUPPLY AT THE CARBURETOR distributor and hold it NOT START (Continued) approximately 3/io inch from the cylinder head. With Work the throttle by hand several the ignition on, crank the engine and times. Each time the throttle is ac check for a spark. tuated, fuel should spurt from the If the spark at the coil high ten accelerating pump discharge nozzles. sion lead is good, the cause of the If fuel is discharged by the ac trouble is probably in the distributor celerating pump, the engine is prob cap or rotor. ably flooded, or there is water in If there is no spark or a weak the fuel system, or an engine me spark at the coil high tension lead, chanical item is at fault. the cause of the trouble is probably If fuel is not discharged by the in the primary circuit, coil to dis accelerating pump, disconnect the tributor high tension lead, or the carburetor fuel inlet line at the coil. carburetor. Use a suitable container to catch the fuel. Crank the en IF THERE IS A GOOD SPARK gine to see if fuel is reaching the carburetor. AT THE SPARK PLUGS If fuel is not reaching the carbu Check the spark plugs. If the spark retor, check: plugs are not at fault, check the fol The fuel filter. lowing items: The fuel pump. The carburetor fuel inlet line for AUTOMATIC CHOKE obstructions. Check the position of choke the The fuel pump flexible inlet line plate. If the engine is hot, the plate for a collapsed condition. should be open. If the plate is not The fuel tank line for obstruc open, the engine will load up due to tions. the excessively rich mixture and will The fuel tank vent. not start. If the engine is the cold, If fuel is reaching the carburetor, plate should be closed. If the plate is check: not check the fol operating properly, The fuel inlet system including lowing items: the fuel inlet needle and seat as The choke linkage for binding. sembly, and the float assembly.

FUEL SYSTEM Carburetor icing.

Fuel pump defective. ENGINE STARTS, BUT Idle fuel mixture needles not prop FAILS TO KEEP RUNNING erly adjusted. Dirt in the carburetor, not allowing Engine idle speed set too low. fuel to enter or be discharged from The choke not operating properly. the idle system. Float setting incorrect. Fuel inlet system not operating IGNITION SYSTEM properly. Dirt or water in fuel lines or in the Leakage in the high tension fuel filter. wiring.

Determine if the miss is steady or cylinders have been checked. Ground erratic and at what speed the miss the spark plug wire removed. ENGINE RUNS, BUT occurs by operating the engine at If the engine speed changes when MISSES various speeds under load. a particular cylinder is shorted out, that cylinder was delivering power MISSES STEADILY AT before being shorted out. If no change in the engine operation is evident, ALL SPEEDS the miss was caused by that cylinder not Isolate the miss by operating the delivering power before being shorted engine with one cylinder not firing. out. In this case, check the: This is done by operating the engine IGNITION SYSTEM with the ignition wire removed from

one spark plug at a time, until all If the miss is isolated in a particu-

CONTINUED ON NEXT PAGE 1-8 GROUP 1- ENGINE AND EXHAUST SYSTEM

ENGINE TROUBLE DIAGNOSIS GUIDE (Continued)

lar cylinder, perform a spark test on ternal leakage and/or for a condi the ignition lead of that cylinder. tion that prevents the engine from ENGINE RUNS, BUT If a good spark does not occur, reaching normal operating tempera MISSES (Continued) the trouble is in the secondary cir ture. cuit of the system. Check the spark ENGINE plug wire and the distributor cap. If a good spark occurs, check the Perform a compression test to de spark plug. If the spark plug is not at termine which mechanical compo fault, a mechanical component of the nent of the engine is at fault. engine is probably at fault. MISSES AT IDLE ONLY ENGINE

Perform a compression test to de FUEL SYSTEM termine which mechanical compo Idle fuel mixture needles not prop nent of the engine is at fault. erly adjusted.

MISSES ERRATICALLY IGNITION SYSTEM AT ALL SPEEDS Excessive play in the distributor shaft. EXHAUST SYSTEM Worn distributor cam. Exhaust system restricted. ENGINE IGNITION SYSTEM Perform a compression test to de Defective breaker points, con termine which mechanical compo denser, secondary wiring, coil, or nent of the engine is at fault. spark plugs. High tension leakage across the MISSES AT HIGH SPEED coil, rotor, or distributor cap. ONLY FUEL SYSTEM FUEL SYSTEM Float setting incorrect. Power valve clogged or Fuel inlet system not operating damaged. properly. Low or erratic fuel pump pressure. Dirt or water in fuel lines or car Fuel inlet system not operating buretor. properly. Restricted fuel filter. Restricted fuel filter.

COOLING SYSTEM COOLING SYSTEM

Check the cooling system for in- Engine overheating.

FUEL SYSTEM IGNITION SYSTEM

ROUGH ENGINE IDLE Engine idle speed set too low. Improperly adjusted or defective Idle fuel mixture needles not prop breaker points. erly adjusted. Fouled or adjusted Idle compensator malfunction. improperly spark plugs. Float setting incorrect. Air leaks between the carburetor, Incorrect ignition timing. spacer, and the manifold and/ or fit tings. Spark plug misfiring. Power valve leaking fuel. Idle fuel system air bleeds or fuel ENGINE passages restricted. Loose engine bolts or Fuel bleeding from the accelerat mounting worn insulator. ing pump discharge nozzles. Secondary throttle plates not clos Cylinder head bolts not properly ing. torqued. Improper secondary throttle plate stop adjustment. Crankcase ventilation regulator Leaking fuel pump, lines, or fit valve defective or a restricted exhaust tings. tube.

CONTINUED ON NEXT PAGE PART 1-1 -ENGINE 1-9

ENGINE TROUBLE DIAGNOSIS GUIDE (Continued)

IGNITION SYSTEM Accelerating pump stroke not properly adjusted. POOR ACCELERATION Incorrect ignition timing. Leaky power valve, gaskets, or ac Fouled or improperly adjusted celerating pump diaphragm. spark plugs. Improperly adjusted or defective Dirt or corrosion in accelerating breaker points. system.

Distributor not advancing prop Distributor vacuum passages in erly. the carburetor blocked.

Restricted fuel filter. FUEL SYSTEM

Inoperative accelerating pump in BRAKES let ball check. dis Inoperative accelerating pump Improper adjustment. charge ball check.

Accelerating pump diaphragm de fective. TRANSMISSION Float setting incorrect. Improper band adjustment. Throttle linkage not properly ad justed. Converter One-Way Clutch.

FUEL SYSTEM Improperly adjusted or defective breaker points. ENGINE DOES NOT Restricted air cleaner. | DEVELOP FULL POWER, Restricted fuel filter. OR HAS POOR HIGH Clogged or undersize main jets COOLING SYSTEM SPEED PERFORMANCE and/or low float setting. Thermostat inoperative or incor Clogged or undersize secondary rect heat range. jets.

Check the system for in Power valve clogged or damaged. cooling ternal leakage and/or for a condition Secondary throttle plates not prevents engine reach opening. that the from ing normal operating temperature. Fuel pump pressure incorrect.

Distributor vacuum passage in

the carburetor blocked. EXHAUST SYSTEM

Restriction in system. IGNITION SYSTEM

Ignition timing not properly ad ENGINE justed.

Defective coil, condenser, or Perform an engine compression

rotor. test to determine which mechanical

Distributor not advancing prop component is at fault.

erly. One or more camshaft lobes worn

Excessive play in the distributor beyond wear limit. shaft.

Distributor cam worn. TRANSMISSION Fouled or improperly adjusted

spark plugs. Improper band adjustment.

CONTINUED ON NEXT PAGE 1-10 GROUP 1- ENGINE AND EXHAUST SYSTEM

ENGINE TROUBLE DIAGNOSIS GUIDE (Continued)

Determine the actual fuel con FINAL CHECKS

sumption with test equipment in EXCESSIVE FUEL FUEL SYSTEM stalled in the car. 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 items before proceeding to the fuel justment.

and ignition systems. Anti-stall dashpot for proper ad justment.

Air cleaner for restrictions.

PRELIMINARY CHECKS Float setting.

Jets for wear and/or damage. CHASSIS ITEMS Power valve operation.

Check: Air bleeds for obstructions.

discharge noz Tires for proper pressure. Accelerating pump zles for siphoning. Front wheel alignment. Accelerator linkage for binds.

Brake adjustment. Choke adjustment.

IGNITION SYSTEM EXHAUST SYSTEM Check: System restricted. Spark plug condition and adjust ment. ODOMETER Distributor spark advance opera

Check calibration. tion.

ENGINE IGNITION SYSTEM Perform an engine compression

Check: test to determine which mechanical

Distributor breaker points. component of the engine is at fault.

Ignition timing. COOLING SYSTEM

Check thermostat operation and ENGINE heat range. Crankcase ventilation regulator

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.

Drive belt tension Cylinder head bolts not properly incorrect.

torqued. Radiator fins obstructed.

CONTINUED ON NEXT PAGE PART 1-1 -ENGINE 1-11

ENGINE TROUBLE DIAGNOSIS GUIDE (Continued)

Thermostat defective. Faulty fan drive. ENGINE OVERHEATS Thermostat improperly installed. IGNITION SYSTEM (Continued) Cooling system passages blocked. Water pump inoperative. Incorrect ignition timing.

COOLING SYSTEM Intake manifold to cylinder head gasket defective. Leaking radiator. LOSS OF COOLANT Cylinder head or intake manifold Loose or damaged hose connec bolts not properly torqued. tions. Cylinder block core plugs leak Water leaking. pump ing. Radiator cap defective. Temperature sending unit leak Overheating. ing.

Cracked cylinder head or ENGINE block, or warped cylinder head or block Cylinder head gasket defective. gasket surface.

TEMPERATURE SENDING ENGINE FAILS TO REACH UNIT AND GAUGE COOLING SYSTEM NORMAL OPERATING Unit or gauge defective (not in Thermostat inoperative or of in TEMPERATURE dicating correct temperature) or con correct heat range. stant voltage regulator defective.

A noisy valve lifter can be located longer free to function properly.

by operating the engine at idle When dirt is found to be respon NOISY HYDRAULIC speed and placing a finger on the sible for lifter malfunction, remove VALVE LIFTER face of the valve spring retainer. If the lifter assembly and thoroughly the lifter is not functioning prop clean it. Recommended engine oil

erly, a shock will be felt when the and filter change intervals should be

valve seats. followed to minimize lifter prob Another method of identifying a lems caused by dirt. noisy lifter is by the use of a piece Deposits of gum and varnish of hose. With the engine operating cause similar conditions to exist at idle speed, place one end of the which may result in lifter malfunc

hose near the end of the valve stem tion. If these conditions are found

and the other end to the ear and to be present, the lifter should be

listen for a metallic noise. Repeat disassembled and cleaned in solvent

this procedure on each intake and to remove all traces of deposits. lift- exhaust valve until the noisy Air bubbles in the lubricating oil, er(s) has been located. caused by an excessively high or The most common causes of hy low oil level, may likewise cause

draulic valve lifter troubles are dirt, lifter malfunction. A damaged oil

gum, varnish, carbon deposits, and pick-up tube may allow air to be air bubbles. drawn into the lubricating system. Dirt in the lifter assembly can To check for the presence of air,

prevent the disc valve from seating, remove a valve rocker arm cover and

or it may become lodged between note the condition of the oil as it flows

the plunger and body surfaces. In from the valve rocker arm shaft as either the case, lifter becomes inop sembly. Perform corrective action as "pump-up," erative due to failure to required to remove air from the lubri or because the internal parts are no cating oil. 1-12 GROUP 1- ENGINE AND EXHAUST SYSTEM

ENGINE TESTS AND ADJUSTMENTS

CAMSHAFT LOBE LIFT mechanism. Valve stem to valve If all the valve train components rocker arm clearance should be except the push rod are within limits, 1. Remove the air cleaner and the 0.078-0.218 inch with the hydraulic install a 0.060-inch longer push rod. valve rocker arm cover. Remove the lifter collapsed. Repeated completely 5. Rotate the crankshaft until valve rocker arm shaft and assembly valve operations (valve reconditioning No. 1 piston is on TDC at the end install a solid tappet-type push rod and/or valve seat will de refacing) of the compression stroke. With No. in the push rod bore of the camshaft crease this clearance to the point that 1 piston on check the follow lobe to be checked. TDC, if not compensated for, the hydraulic ing valves: 2. Make sure the push rod in is valve lifter will cease to function. the lifter push rod cup. Install a No. 1 Intake No. 1 Exhaust To determine whether a shorter or dial indicator in such a manner as to No. 3 Intake No. 4 Exhaust a longer push rod is necessary, make have the actuating point of the indi No. 7 Intake No. 5 Exhaust the following check: cator in the push rod socket and in No. 8 Intake No. 8 Exhaust 1. Position the crankshaft as out the same plane as the push rod move 6 piston on TDC lined in steps 5 and 6. 6. Position No. ment (Fig. 13). and check the valves: 2. Position the hydraulic lifter following No. No. Exhaust SOLID TAPPET-TYPE compressor tool on the rocker arm 2 Intake 2 PUSH ROD 4 No. 3 Exhaust and slowly apply pressure to bleed No. Intake down the hydraulic lifter until the No. 5 Intake No. 6 Exhaust plunger is completely bottomed (Fig. No. 6 Intake No. 7 Exhaust 14). Hold the lifter in the fully col When compressing the valve spring lapsed position. to remove push rods, be sure the pis correct end of the 3. Insert the ton in the individual cylinder is below clearance gauge the valve between TDC to avoid contact between the stem the rocker arm of valve and the valve and the piston. being checked. BE SURE TO To replace a push rod, it will be PLACE Indicator If the first of the gauge en 4. step necessary to remove the valve rocker TIP IN CENTER ters, a standard length push rod may arm shaft assembly. OF PUSH ROD be used. SOCKET Upon replacement of a valve push A1202-A If the first step of the gauge does rod and/ or valve rocker arm shaft not enter, replace the standard push the engine should not be FIG. 13-Camshaft Lobe Lift assembly, rod with a 0.060-inch shorter service cranked or rotated until the hydraulic push rod. lifters have had an opportunity to 3. Turn the crankshaft damper If the second step of the gauge leak down to their normal operating slowly in the direction of rotation enters, the operating range of the position. The leak-down rate can be until the lifter is on the base circle lifter is excessive. This indicates that accelerated by using the tool shown of the camshaft lobe. At this point, the incorrect push rod has been in in Fig. 14 on the valve rocker arm the push rod will be in its lowest stalled or severe wear has occurred and applying pressure in a direction position. at the push rod ends, rocker arm, or to collapse the lifter. 4. Zero the dial indicator. valve stem. In this case, it will be nec to determine the area of dis 5. Continue to rotate the damper essary and the incorrect or defec MANIFOLD VACUUM TEST slowly until the push rod is in the crepancy tive should replaced. raised part(s) be fully position. A manifold vacuum test aids in 6. Compare the total lift recorded determining the condition of an en on the indicator with specifications. gine and also in helping to locate the cause of poor engine performance. 7. To check on the accuracy of the Detail 1 To test manifold vacuum: original indicator reading, continue

to rotate the crankshaft until the in 1. Operate the engine for a mini

dicator reads zero. mum of 30 minutes at 1200 rpm.

8. Remove the dial indicator. 2. Install an accurate, sensitive vacuum gauge in the in the in 9. Install the valve rocker arm fitting take manifold. shaft. Install the rocker arm cover

and the air cleaner. 3. Operate the engine at recom mended idle rpm, with the transmis sion selector lever in neutral. VALVE CLEARANCE 4. Check the vacuum reading on push rod A 0.060-inch shorter the gauge. (color coded white) or a 0.060-inch TEST longer push rod (color coded yel CONCLUSIONS

available for service to pro low) are A1204-A Manifold vacuum is affected by vide a means of compensating for carburetor adjustment, valve timing, 14 dimensional changes in the valve FIG. Valve Clearance the condition of the valves, cylinder PART 1-1 -ENGINE 1-13

compression, and leakage of the man TABLE 2Manifold Vacuum Gauge Readings ifold, carburetor, carburetor spacer, or cylinder head gaskets. Gauge Reading Engine Condition Because abnormal gauge readings may indicate that more than one of 18 inches Normal. the above factors is at fault, exercise caution in analyzing an abnormal Low and steady. Loss of power in all cylinders caused possibly or loss of reading. For example, if the vacuum by late ignition or valve timing, is compression due to leakage around the piston low, the correction of one item may rings. increase the vacuum enough to indi cate that the trouble has been cor Very low. Manifold, carburetor, spacer, or cylinder rected. It is important, therefore, head gasket leak. that each cause of an abnormal read ing be investigated and further tests Needle fluctuates steadily as A partial or complete loss of power in one or speed increases. more cylinders caused a valve, cyl conducted where necessary in order by leaking inder head or intake manifold gasket a to arrive at the correct diagnosis of leak, defect in the ignition or a weak valve the trouble. system, spring. Table 2 lists various types of read

ings and their possible causes. Gradual drop in reading at Excessive back pressure in the exhaust system. Allowance should be made for the engine idle. effect of altitude on the gauge read caused ing. The engine vacuum will decrease Intermittent fluctuation. An occasional loss of power possibly a defect in the ignition system or a with an increase in altitude. by sticking valve.

COMPRESSION TEST Slow fluctuation or drifting Improper idle mixture adjustment, carbu of the needle. retor, spacer, or intake manifold gasket leak, 1. Be sure the is properly battery or possibly late valve timing. charged. Operate the engine for a minimum of 30 minutes at 1200 rpm. Turn the ignition switch off, TEST CONCLUSIONS the valves are at squirt the then remove all the spark plugs. Re fault, equivalent of a tablespoon of move the coil high tension lead at A variation of 20 pounds from heavy the distributor cap. specified pressure is satisfactory. oil into the combustion chamber. However, the compression of all Crank the engine to distribute the 2. Set the primary throttle plates cylinders should be uniform within oil and repeat the compression test. and choke plate in the wide open 10 pounds. The oil will temporarily seal leakage position. A reading of more than the allow past the rings. If approximately the 3. Install a compression gauge in able tolerance above normal indi same reading is obtained, the rings No. 1 cylinder. cates excessive deposits in the cyl are satisfactory, but the valves are 4. Using a remote starter switch, inder. leaking. If the compression has in crank the engine several times and A reading of more than the allow creased 10 pounds or more over the record the highest reading recorded. able tolerance below normal indi original reading, there is leakage Note the number of compression cates leakage at the cylinder head past the rings. strokes required to obtain the highest gasket, piston rings, or valves. During a compression test, if the reading. A low even compression in two pressure fails to climb steadily and 5. Repeat the test on each cylin adjacent cylinders indicates a cylin remains the same during the first two der head gasket leak. This should be successive der, cranking the engine the same strokes, but climbs higher number of times for each cylinder as checked before condemning the rings on the succeeding strokes, or fails to was required to obtain the highest or valves. climb during the entire test, it indi To determine whether the rings or cates a valve. reading on the No. 1 cylinder. sticking

ENGINE REMOVAL AND INSTALLATION

The procedures given are for the REMOVAL cooler lines at the radiator. Remove

engine without the transmission the radiator and support as an assem 1. Drain the cooling system and attached. If the engine and transmis bly. the crankcase. Remove the hood and are removed as an assembly, in sion 4. Disconnect the ground the air cleaner. battery standard eye bolts with Vi-IA stall cable at the generator 2. Disconnect the radiator upper mounting threads in the bosses at the top rear bracket. Remove the oil level dipstick hose at the radiator tank and of the exhaust manifolds. Then at supply and the ignition coil. the radiator lower hose at the water tach the engine lifting bracket and bolts. engine in pump. 5. Disconnect the oil pressure sling to the eye The 3. oil stallation is shown in Fig. 15. Disconnect the transmission sending unit wire at the sending unit 1-14 GROUP 1- ENGINE AND EXHAUST SYSTEM

Tool- Tool-T58P-6000-A T53L-300-A

A1251-C

FIG. 16Engine Lifting Brackets and Sling

Install the engine right lifting brack et at the rear of the right cylinder head. Attach the engine lifting sling (Fig. 16).

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. 17).

A1479-B

FIG. 1 5Engine Installation INSTALLATION

1. Place a new gasket over the and the flexible fuel line at the fuel 12. Disconnect the generator wires studs of the exhaust manifolds. tank line. at the generator. 2. Attach the engine lifting brack 6. Remove the wire loom from the 13. Disconnect the water tem ets and sling (Fig. 16). Remove the clips on the left valve rocker arm perature sending unit wire at the engine from the work stand. cover and position the wires out of sending unit. the way. 3. Lower the engine into 14. Remove the engine ground carefully the engine compartment. Make sure 7. Disconnect the three windshield strap. Remove the starter cable re washer lines at the washer and the exhaust manifolds are pump taining bracket from the generator properly position them out of the way. mounting bracket. aligned with the muffler inlet pipes 8. Disconnect the accelerator rod and the dowels in the block engage 15. Raise the front of the car. at the carburetor. Remove the accel the holes in the converter housing. 16. Remove the starter and dust erator spring. Remove the Start the converter pilot into the retracting seal and the transmission fluid filler accelerator cross shaft bracket from crankshaft. tube bracket.

the intake manifold and position it 4. Install the converter 17. Disconnect the muffler inlet housing out of the way. upper bolts. Torque the pipes from the exhaust manifolds, bolts to 9. the power Disconnect steering and the engine right and left support specifications. pump bracket from the water pump, insulators at the engine. 5. Start the engine right and left then wire the power steering pump 18. Remove the converter hous support insulator to engine bolts. to the hood left hinge in a position ing lower access cover and the cover that will prevent the oil from assembly. Remove the flywheel to draining Tool- 1 009 out. converter nuts. Secure the con 10. Disconnect the power brake verter assembly in the housing. Re line at the intake manifold and at the move the converter housing to en flexible line. Release the line from the gine lower bolts, and remove the oil brackets on the left valve rocker arm cooler lines retaining clamp from the

cover and remove the line. engine block.

On a car with an air conditioner, 19. Lower the car, then support disconnect the magnetic clutch wire. the transmission. Remove the con Isolate the compressor. verter housing upper retaining bolts. 11. Disconnect the heater hose at 20. Install the engine left lifting A1252-B the water pump and at the intake bracket on the front of the left cyl manifold. inder head where the coil mounts. FIG. 17-Engine Work Stand PART 1-1 -ENGINE 1-15

Disconnect the engine lifting sling 13. Connect the water tempera 22. Connect the power brake line and remove the lifting brackets. ture sending unit wire. Connect the to the intake manifold and to the flex manifold. Install the line in the retain 6. Raise the front of the car. In heater hose at the intake ible line. clips on the left valve rocker arm stall the converter housing lower re 14. Connect the engine ground ing cover. taining bolts. Torque the bolts to strap. Install the starter cable retain specifications. ing clamp. On a car with an air conditioner, and 7. Remove the retainer securing 15. Connect the flexible fuel line, connect the magnetic clutch wire the converter in the housing. Install the oil pressure sending unit wire, and the compressor lines. the flywheel to converter lock wash the windshield wiper vacuum line. 23. Install the radiator and sup ers and nuts. Torque the nuts to speci 16. Install the ignition coil and port as an assembly. Connect the fications. Install the converter lower radiator upper and lower hoses. Con connect the coil primary and high access plate and the cover housing tension wires. nect the transmission oil cooler lines. assembly. Install the oil cooler lines 17. Install the oil level dipstick. 24. Fill and bleed the cooling sys retaining clamp. tem. Connect the heater hose at the 18. Position the wire loom in the 8. Torque the engine front support water pump. clips on the left valve rocker insulator bolts to specifications. retaining arm cover. 25. Fill the crankcase with the 9. Connect both exhaust mani proper grade and quantity of engine 19. Connect the windshield wash folds to the muffler inlet pipes. oil. er Torque the nuts to specifications. pump lines. 26. Operate the engine at fast idle 10. Position the dust seal and in 20. Install the accelerator cross and check all gaskets and hose con stall the starter and the transmission shaft bracket and the accelerator re nections for leaks. fluid filler tube bracket. tracting spring. Connect the accelera tor rod. 27. Adjust the transmission con 11. Remove the support from the trol linkage. Install the air cleaner. transmission and lower the car. 21. Connect the power steering 12. Connect the generator wires. pump bracket to the water pump. 28. Install and adjust the hood.

IN-CHASSIS REPAIR OPERATIONS

ENGINE SUPPORTS enough to position the support as sembly and retainer. Install the sup The engine rear support is shown The front supports are located on port retainer to extension housing each side of the crankcase and the in Fig. 19. washers and bolts. Torque the sup rear support is located at the trans port retainer bolts to specifications. mission extension housing. 1. Remove the support retainer

bolts and washers and remove the re ENGINE FRONT SUPPORT VALVE ROCKER ARM tainer. The engine front support is shown SHAFT ASSEMBLY 2 Raise the extension in Fig. 18. The procedures given ap housing to relieve the pressure on the REMOVAL ply to either a right or left installa slightly tion. support assembly. Remove the sup 1. Remove the air cleaner. port assembly. Removal 2. Disconnect the spark plug wires at the spark plugs. Remove the wires 1. Remove the insulator assembly 1, Raise the extension housing from the bracket on the valve rocker to engine retaining bolts, and insula arm cover(s) and position the wires tor to underbody retaining nut. out of the way. If only one support is being re loosen the other support. To remove the right valve rocker moved, SUPPORT BRACKET arm cover, remove the carburetor 2. Raise the engine about 1 inch choke heat tube. with a jack and a block of wood

placed under the oil pan, then re To remove the left valve rocker

move the insulator assembly. arm cover, disconnect the brake booster line and position the line out Installation of the way. 1. Position the insulator assembly. INSULATOR 3. Remove the valve rocker arm but do not tighten, the insula Install, ASSEMBLY cover(s). tor to engine lock washers and bolts. the left cover is posi If both supports have been removed, If removed, tion wire out of install the bolts on the opposite side the loom the way. with before proceeding step 2. 4. Crank the engine until the No.

2. Lower the engine, then install 1 piston is at TDC, at the end of the A1480-A compression the underbody to insulator nut. stroke. Rotate the crank 45 Torque the nut and bolts to speci shaft damper an additional (iden "XX" fications. FIG. 18Engine Front Support tified by on the damper). 1-16 GROUP 1- ENGINE AND EXHAUST SYSTEM

SUPPORT the push rods. cylinder head(s). Make sure the gas ASSEMBLY 2. Crank the engine until the No. ket seats evenly all around the head. 1 piston is on TDC at the end of the Install the bolts (and the wire loom cover compression stroke. clamps on the left cover). The is tightened in two steps. First, 3. Rotate the crankshaft damper 45 "XX" torque the bolts to specifications. an additional (identified by Two minutes torque the bolts on the damper). later, to the same specifications. 4. Position the baffle plate and the If the left cover was removed, con valve rocker arm shaft assembly on nect the brake booster vacuum line. the cylinder heads with the valve If the right cover was removed, push rods in place and the rocker install the carburetor choke heat tube. shaft support bolts finger-tight. Be 9. Connect the spark plug wires. sure the shaft is turned so that the Install the air cleaner. oil holes are to the bottom. DISASSEMBLY 5. Starting at the No. 4 cylinder, tighten the bolts in sequence, two 1. Remove the cotter pins from turns at a time, until the supports each end of the valve rocker arm fully contact the cylinder head. shaft. Remove the flat washer and Torque the bolts in sequence to spring washer from each end of the SUPPORT specifications. shaft. BRACKET 2. Slide the rocker 6. Starting at the No. 5 cylinder, arms, springs, A1481-A and the supports off the shaft. Be follow the same procedure for the sure to all the parts. FIG. 19Engine Rear Support left valve rocker arm shaft support identify 3. If it is to remove the bolts. The additional time consumed necessary plugs from each end of the in this procedure will permit the shaft, 5. Starting at the No. 4 cylinder, drill or pierce one plug. Insert a steel loosen the right valve rocker arm hydraulic lifters to leak down. This rod through the and knock out will minimize the of bend plug shaft support bolts in sequence, two possibility the plug on the opposite end. Work turns at a time. After the bolts are ing the push rods, valves, or the from the open knock out the rocker arms. Be sure that the ing end, all loosened, remove the valve rocker hy draulic lifters have leaked down to remaining plug. arm shaft assembly and the oil their normal position be baffle plate. Starting at the No. 5 cyl operating ASSEMBLY follow the same procedure on fore cranking the engine. This is nec inder, 1. Oil all the moving parts with the left valve rocker arm shaft essary in order to avoid possible sup engine oil. Apply Lubriplate to the port bolts. This procedure must be damage to the valves, push rods, or pad of the valve rocker arms. followed to avoid damage to the valve valve rocker arms. 2. If the plugs were removed from mechanism. 7. Clean the valve rocker arm the ends of the shaft, use a blunt tool cover(s). oil resistant sealer to Apply or large diameter pin punch and in INSTALLATION one side of new cover gasket(s). Lay stall a plug, cup side out, in each end the cemented side of the in 1. Apply Lubriplate to the pad gasket(s) of the rocker arm shaft. place in the cover(s). end of the rocker arms, to the tip of 3. Install the rocker arms, sup the valve stems, and to both ends of 8. Position the cover(s) on the ports, and springs in the order shown

SPRING WASHER

ROCKER ARM

SUPPORT

SUPPORT BOLT HOLES

ROCKER SHAFT A1261-B

FIG. 20Valve Rocker Arm Shaft Assembly PART 1-1 -ENGINE 1-17

steps 4 and 5. in Fig. 20. Be sure the oil holes in 8. Disconnect the radiator upper assembly by following the shaft are facing downward. Com hose at the radiator supply tank, 12. Remove the valve push rods in Remove plete the assembly by installing the then remove the supply tank. sequence. flat washer and the the heater hose at the intake mani remaining spring 13. Remove the intake manifold washer and install the cotter pin. fold, and the water temperature send retaining bolts. ing unit wire at the sending unit. 14. Install standard eye bolts with CLEANING AND INSPECTION the on the water 9. Slide clamp 5/ie-18 threads in the left front and toward the water pump by-pass hose cover screw Clean all the parts thoroughly. right rear rocker arm pump. Make sure that all oil passages are holes. Attach the engine lifting sling open. 10. Clean the outside of the valve (Fig. 21). rocker arm covers and remove the Check the clearance between each 15. Raise the manifold and care covers. rocker arm and the shaft by checking fully remove the intake manifold and "Valve Rocker Arm assembly. the ID of the rocker arm bore and 11. Refer to radiator supply tank as an Removal" and re the OD of the shaft. If the clear Shaft Assembly Remove the intake manifold gaskets move the valve rocker arm shaft ance between any rocker arm and the and seals. shaft exceeds the wear replace limit, 16. If the manifold is to be dis Too-T53L-300-A the shaft and/or the rocker arm. In assembled, remove the radiator sup spect the shaft and the rocker arm ply tank, thermostat, and gasket. bore for nicks, scratches, scores, or Remove the carburetor, spacer, and scuffs. Dress minor surface defects up gasket. with a hone. On an engine with positive crank Inspect the pad at the valve end case ventilation, remove the crank of the rocker arms for a grooved case ventilation regulator valve and

radius. If the pad is grooved, replace exhaust tube. the rocker arm. Do not attempt to true this surface by grinding. INSTALLATION Check for broken locating springs. The intake manifold assembly is shown in Fig. 22. INTAKE MANIFOLD 1. If the intake manifold was dis REMOVAL A1253-C assembled, install the carburetor, spacer, and gasket. Coat the thermo 1. Drain the cooling system. Re FIG. 21 -Intake Manifold stat gasket with water resistant sealer move the air cleaner. Removal or Installation and place it in position on the intake 2. Disconnect the accelerator rod THERMOSTAT at the carburetor. Remove the ac WATER TEMPERATURE CRANKCASE BREATHER CAP celerator cross shaft bracket from the \ SENDING UNIT intake manifold and position it out OIL FILLER TUBE of the way. GASKET 3. Remove the carburetor fuel in EXHAUST and the automatic choke heat TUBE let line MANIFOLD-TO-BLOCK tube. Disconnect the brake vacuum FRONT SEAL MANIFOLD-TO-HEAD manifold booster line at the intake GASKET and at the flexible hose. Remove the

vacuum line. REGULATOR VALVE 4. Disconnect the coil high ten N^Jv^/ 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 SPACER \fe brackets on the valve rocker arm

covers.

6. Remove the distributor cap and Discon INTAKE spark plug wire assembly. CRANKCASE MANIFOLD &r \\^^^ nect the distributor vacuum line at if \ VENTILATION OUTLET the distributor. MANIFOLD-TO-BLOCK REAR SEAL 7. Remove the distributor hold- A1294-C down bolt and clamp. Remove the distributor. FIG. 22Typical Intake Manifold Assembly 1-18 GROUP 1- ENGINE AND EXHAUST SYSTEM

manifold. Install the thermostat and case ventilation, install the crankcase ings and foreign matter that may have radiator supply tank. ventilation regulator valve and ex entered the manifold as a result of tube. 2. Clean the mating surfaces of haust repairs. the intake cylinder Check the baffle plate on the under manifold, heads, 11. Apply Lubriplate to both ends and cylinder block. manifold for looseness and of the push rods. Install the push rods side of the the maze screen is in place. 3. Coat the intake manifold and in their original bores, positioning be sure varnish accumulation. cylinder block seal surfaces with oil the lower ends of the rods in the lifter Clean off any resistant sealer. cups. Refer to "Valve Rocker Arm

Installation" 4. Position new seals Shaft and in on the cyl Assembly EXHAUST MANIFOLD inder block and new gaskets on the stall the valve rocker arm shaft as cylinder heads. Position the gasket sembly by following steps 1 thru 6. REMOVAL slots in the end tabs over Discon the ribs on 12. Rotate the crankshaft damper 1. Remove the air cleaner. the seals. Be sure the the manifold at the muf holes in until the No. 1 piston is on TDC at nect the exhaust gaskets are aligned with the holes in the end of the compression stroke. fler inlet pipe. the cylinder heads. The correct in Position the distributor in the block 2. Remove the automatic choke stallation of the gaskets and seals is with the rotor at the No. 1 firing posi heat tube from the right exhaust shown in Fig. 23. tion and the points open. Install the manifold. 5. Install the eye bolts in the in hold down clamp. 3. Disconnect the power steering take manifold and attach the engine 13. valve rocker arm Clean the pump bracket from the cylinder block lifting sling and carefully lower the covers. Apply oil resistant sealer to and move it out of the way. Position intake manifold on the engine (Fig. one side of new cover gaskets. Lay the so that the oil will not 21). pump the cemented side of the gaskets in drain out. Disconnect the power 6. Position the intake manifold place the covers. Install the valve in steering hose bracket and position the the in place. by inserting distributor rocker arm covers. hoses out of the way. After the intake manifold is in place, 14. Connect the brake vacuum 4. Remove the dipstick and tube run a finger around the seal area to booster line and connect the flexible assembly. make sure the seals are in place. If hose. the seals are not in place, remove the 5. Remove the retaining bolts and intake manifold and reposition the 15. Install the carburetor fuel in tab washers and remove the exhaust seals. let line and connect the distributor manifolds.

vacuum line. Install the automatic 7. Start the water pump by-pass choke heat tube. INSTALLATION hose on the intake manifold. 1. Clean the surfaces of 8. Be sure the holes in the mani 16. Install the distributor cap. mating the exhaust manifold and cylinder fold gaskets and manifold are in Connect the spark plug wires. Install head. Scrape the gasket material alignment. Install the manifold re the wire loom in the retaining clips from the flange of the ex taining bolts and torque them to on the left valve rocker arm cover. mounting haust manifold and muffler inlet pipe. specifications, working from the cen 17. Connect the oil pressure send ter to the ends. 2. Apply graphite grease to the ing unit wire, the coil high tension surface of the exhaust mani 9. distributor and mating Remove the the lead, and the coil wire. primary fold. engine lifting sling and eye bolts. 18. Install the accelerator cross 3. Install a new gasket on the 10. Slide the water pump by-pass shaft bracket. Connect the acceler studs of hose into position. Connect the exhaust manifold. clamp ator rod. the water temperature sending unit, 4. Position the exhaust manifold 19. Fill and bleed the the heater hose, and the radiator cooling on the cylinder head and install the upper hose. system. retaining bolts and tab washers.

- from the center to On an engine with positive crank 20. Start the engine and check Working the ends torque the bolts to and adjust the ignition timing. Op retaining specifications. Lock the erate the engine until engine tem bolts by one tab over peratures have stabilized and adjust bending of the washer a on the the engine idle speed and idle fuel flat bolt. mixture. 5. Install the dipstick and tube

assembly. 21. Adjust the transmission con

trol linkage. Install the air cleaner. 6. Position the power steering pump bracket on the cylinder block CLEANING AND INSPECTION and install the retaining bolts. Adjust the belt tension. Position the hoses Clean the manifold in a suitable and install the power hose solvent, then dry it with compressed steering bracket. air.

7. Install the automatic choke heat Inspect the manifold for cracks, tube on the right exhaust manifold. leaks, or other defects that would

make it unfit for further service. Re 8. Connect the exhaust manifold 23Intake Manifold Gaskets FIG. place all studs that are stripped or at the muffler inlet pipe. Install the and Seals Installation otherwise damaged. Remove all fil air cleaner. PART 1-1 -ENGINE 1-19

CRANKCASE VENTILATION OUTLET If the left cylinder head is to be re moved, remove the ignition coil.

3. Remove the cylinder head bolts. Install the cylinder head holding fix tures (Fig. 26).

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 (Fig. 29).

3. Apply cylinder head gasket sealer to both sides of a new gasket. "FRONT" Guided by the word on the gasket, install the gasket over the cylinder head dowels.

4. Place the cylinder head on the engine, then remove the holding fix tures. EXHAUST TUBE REGULATOR VALVE A1482-B

24 . Regulator Valve and Exhaust Tube

CLEANING AND INSPECTION 2. Install the regulator valve in the Tee-fitting. BODY Inspect the manifolds for cracks, leaks, or other defects that would 3. Install the exhaust tubes. make them unfit for further service. REGULATOR VALVE DISASSEMBLY On the right exhaust manifold, Place the hex on the regulator clean out the automatic choke air valve body in a vise. Remove the con heat chamber (Fig. 5). Make sure the nector, valve, and spring (Fig. 25). air inlet and outlet holes are com

pletely open and the cover does not CLEANING leak. Blow out the automatic choke Clean the valve parts and exhaust air with compressed air. heat tube tube in clean carburetor solvent and CONNECTOR dry them with compressed air. Clean the rubber hose connections with a POSITIVE CRANKCASE low volatility petroleum base solvent VENTILATION SYSTEM and dry with compressed air. A1469-B

REMOVAL REGULATOR VALVE ASSEMBLY 25 1. Disconnect the exhaust tube at FIG. Regulator Valve Position the and the crankcase ventilation outlet and spring valve in Assembly side the regulator valve body. Install regulator valve and remove the tube.

the regulator valve connector. Tool Remove the exhaust tube that con T58P-6085-A nects to the spacer (Fig. 24). USE INTAKE \ CYLINDER HEADS MANIFOLD \j 2. Remove the regulator valve as MOUNTING BOLTS AND VALVES sembly from the Tee-fitting. 3. Remove the outlet adapter from CYLINDER HEAD REMOVAL the intake manifold. 1. Remove the intake manifold, carburetor, and radiator supply tank INSTALLATION as an assembly following the proce 1. Install the outlet adapter. If dure under "Intake Manifold Re

moval." A1256-A the adapter enters the intake mani 26 fold more than Vi inch, replace the 2. Disconnect the exhaust mani FIG. Cylinder Head Holding adapter. folds at the muffler inlet pipes. Fixtures 1-20 GROUP 1- ENGINE AND EXHAUST SYSTEM

tainer, spring, damper spring, stem Seat Width Scale seal, and valve. Discard the valve stem seals. Identify all valve parts.

' CYLINDER HEAD CLEANING w ST USE Tool-S-8683 A1292-A After the valves are removed, clean the valve guide bores with a valve FIG. 27Cylinder Head Bolt guide cleaning tool. Use cleaning solvent to remove and Tightening Sequence dirt, grease, other deposits.

5. Install the cylinder head bolts. CYLINDER HEAD INSPECTION The cylinder head bolts are tightened A 1209-A in three progressive steps. Torque all Check the cylinder head for cracks, the bolts in sequence (Fig. 27) to 70 and the gasket surface for burrs and 31-Valve Seat Width ft-lbs, then torque them to 80 ft-lbs, nicks. Replace the head if it is FIG. and finally to 90 ft-lbs. After the cracked. Do not plane or grind more cylinder head bolts have been than 0.010 inch from the cylinder comes necessary to ream a valve torqued to specifications, the bolts head gasket surface. Remove all burrs guide (Fig. 32) to install a valve should not be disturbed. or scratches with an oil stone. with an oversize stem, a reaming kit is available which contains the fol 6. Connect the exhaust manifolds Cylinder Head Flatness. Check the reamer and pilot combina to the muffler inlet pipes. flatness of the cylinder head gasket lowing

surface (Fig. 29). tions: a 0.003-inch OS reamer with 7. Install the intake manifold and a standard diameter pilot, a 0.015- related parts following the procedure Installation." inch OS reamer with a 0.003-inch under "Intake Manifold "N-^ OS pilot, and a 0.030-inch reamer

CYLINDER HEAD DISASSEMBLY with a 0.015-inch OS pilot.

When from a standard size 1. Install the cylinder head hold going valve to an oversize always ing fixtures (Fig. 26). Remove the de valve, use the reamers in sequence. Always posits from the cylinder head com CHECK DIAGONALLLY f\l)\mz) reface the valve seat after the valve bustion chambers and valve heads CHECK ACROSS CENTER (J) guide has been reamed. with a scraper and a wire brush be A1207-A fore removing the valves. Be careful Refacing Valve Seats. Refacing of scratch cylinder head gas not to the FIG. 29Cylinder Head Flatness the valve seats should be closely co ket surface. ordinated with the refacing of the 2. Compress the valve spring (Fig. valve face so that the finished seat will Valve Seat Runout. Check the valve 28). Remove the valve retainer locks match the valve face and be centered. seat runout with an accurate gauge and release the spring. This is important so that the valve (Fig. 30). Follow the instructions of compres- re- and seat will have a good 3. Remove the sleeve, spring 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. 31). Reaming Valve Guides. If it be-

Runout Gauge

A1262-A

FIG. 28Compressing Valve A1208-A A1237-A Spring FIG. 30-Valve Seat Runout FIG. 32Reaming Valve Guides PART 1-1 -ENGINE 1-21

TO REMOVE STOCK TO FROM BOTTOM \ REMOVE STOCK OF SEAT, \ FROM TOP OF SEAT, 30 USE 60 WHEEL USE WHEEL DO NOT REMOVE MORE THAN 0.010 INCH DIAMETER

FOR DIMENSIONS REFER TO SPECIFICATIONS

VALVE SEAT WIDTH: 0.060-0.080

A1211-B

Y32" FIG. 33-lntake Valve Seat MINIMUM Refacing i_ A1010-A

sion tight fit. Be sure that the refacer FIG. 34Critical Valve Tolerances grinding wheels are properly dressed. 45 All 99 A Grind the valve seats to a true or scores. Check the valve head for angle (Fig. 33). Remove enough only signs of burning, erosion, warpage, 36 stock to clean FIG. Valve Stem Clearance up pits, grooves, or to and cracking. Defects, such as minor correct the valve seat runout. After pits, grooves, etc., may be removed. the seat has been measure refaced, Discard valves that are severely the seat width (Fig. 31). Narrow the damaged. seat, if necessary, to it within bring Inspect the valve springs, valve limits. spring retainers, locks, and sleeves If the valve seat width exceeds for defects. Discard any visually de the maximum limit, remove enough fective parts. stock from the top edge and/or Valve Face Runout. Check the bottom edge of the seat to reduce valve face runout (Fig. 35). It should LENGTH SCALE the width to specifications (Fig. 33). not exceed the wear limit.

60 Use a angle grinding wheel to Model TV-2 remove stock from the bottom of the 30 seat (raise the seat) and use a angle wheel to remove stock from the top of the seat (lower the seat). A1013-B The finished valve seat should 37 contact the approximate center of FIG. Valve Spring Pressure the valve face. It is good practice to determine where the valve seat con steel square and a surface plate (Fig. tacts the face. To do this, coat the 38). Stand the spring and square on seat with Prussian blue, then set the end on the surface plate. Slide the valve in place. Rotate the valve with spring up to the square. Revolve the light pressure. If the blue is trans spring slowly and observe the space ferred to the center of the valve face, between the coil of the and A1011-A top spring the contact is satisfactory. If the blue the square. If the spring is out of is transferred to the top edge of the 35Valve Face Runout square more than 1/16 inch, replace valve face, lower the valve seat. If the FIG. it. blue is transferred to the bottom edge of the valve face, raise the valve seat. Valve Stem Clearance. Check the valve stem to valve guide clearance of

VALVES each valve in its respective valve NOT MORE guide with the tool shown 36

Valve Push Rods. Check the ends CYLINDER HEAD ASSEMBLY dividers against a scale. If the assem of the push rods for nicks, grooves, bled height is greater than specifica 1. Install each valve (Fig. in 40) 0.030- roughness, or excessive wear. tions, install the necessary the port from which it was removed inch thick spacer(s) between the cyl The push rods can be visually or to which it was fitted. Install a inder head spring pad and the valve checked for straightness while they new stem seal on the valve. spring to bring the assembled height are installed in the engine by rotating 2. Install the valve springs over the to the recommended height. Do not them with the valve closed. They also valve, and then install the re install spacers unless necessary. Use can be checked with a dial indicator spring tainer and sleeve. Make sure the valve of spacers in excess of recommenda (Fig. 39). If the runout exceeds the damper spring is installed in the valve tions will result in overstressing the maximum limit at any point, discard so that the coil end of the valve springs and overloading the the rod. Do not attempt to straighten spring 135 damper is counterclock= camshaft lobes which could lead to push rods. spring wise from the coil end of the valve spring breakage and worn camshaft Refacing Valves. The valve refac spring. lobes. ing operation should be closely co 3. Compress the spring and in ordinated with the valve seat refacing VALVE STEM SEAL stall the retainer locks (Fig. 28). operation so that the finished angle of REPLACEMENT the valve face will match the valve LOCKS seat. This is important so that the SPRING RETAINER 1. Remove the air cleaner and the

valve and seat will have a good com valve rocker arm cover. Remove the

pression tight fit. Be sure that the re DAMPER applicable spark plug. SPRING facer grinding wheels are properly 2. Crank the engine until the ap dressed. plicable piston is on TDC after the compression stroke. Be sure that both

valves are closed. Be sure that the

Dial Indicator piston is on TDC to prevent the crankshaft from turning when the air is applied.

3. Install an air line with an adapter in the spark plug hole and

PUSH ROD turn on the air supply. Holding Fixture A 1003-A 4. Position the hydraulic lifter FIG. 39-Push Rod Runout compressor tool on the applicable

INTAKE VALVE rocker arm and slowly apply pressure to bleed down the hydraulic lifter If the valve face runout is exces until the plunger is completely bot sive and/ or to remove pits and Al 263=1 tomed (Fig. 42). Remove the push grooves, reface the valves to a true 44 40 rod. angle. Remove only enough stock FIG. Valve Assembly 5. Push the rocker arm to one to correct the runout or to clean up side and secure it in this position the pits and grooves. If the edge of 4. Measure the assembled height the valve head is less than 1/32 inch of the valve spring from the surface Tool-T58P-6565-A-l after replace the valve as grinding, of the cylinder head spring pad to the valve v/ill run too hot in the the underside of the spring retainer engine. with dividers (Fig. 41). Check the

Remove all grooves or score

marks from the end of the valve UNDERSIDE OF SPRING RETAINER 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 v/ear 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 SURFACE OF SPRING PAD A1267-A A1450-A available for service. Always reface 41Valve Assembled 42 Down the valve seat after the valve guide FIG. Spring FIG. Bleeding Hydraulic has been reamed. Height Valve Lifter PART 1-1 -ENGINE 1-23

SECURE ROCKER ARM Too/-K-D9J5 stalled in the valve spring so that the 135 coil end of the damper spring is 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 Tool T58P-6316-A and remove the air line and adapter. A1257-B Install the spark plug. FIG. 45-Cronkshaft Damper 10. Install the valve rocker arm Removal cover and connect the spark plug wires. Install the air cleaner. 9. Remove the fuel pump retain ing bolts and lay the pump to one CYLINDER FRONT COVER side with the flexible fuel line still AND TIMING CHAIN attached.

10. If the crankshaft sleeve is not Air Line Adapter A1451-A REMOVAL stepped down (the same OD on both

43 system and remove it as shown in Fig. 46. FIG. Compressing Valve 1. Drain the cooling ends), Spring the crankcase. Remove the air clean If the sleeve is stepped down, remove er. Disconnect the battery ground it with a three jawed puller (tool cable. 7675-N). (Fig. 43). the valve com Using spring 11. Remove the screws 2. Disconnect the radiator upper fastening pression tool shown in Fig. 43, com the cylinder front cover to the block. hose at the radiator tank. Dis press the valve spring. Remove the supply Remove the cylinder front cover. On connect the radiator lower hose at valve retainer locks, the sleeve, spring a car with an air the the water pump. conditioner, spring retainer, and the valve spring. compressor brackets are retained by If an end rocker arm is to be worked 3. transmission oil Disconnect the cylinder front cover screws. on, it will be necessary to remove the cooler lines at the radiator. Remove 12. Discard the cylinder front rocker arm from the shaft. the radiator and support as an assem cover gasket. Remove the oil slinger. 6. Remove the valve stem seal bly. (Fig. 44). 13. Rotate the crankshaft in a 4. Disconnect the heater hose at 7. Install a new valve stem seal. clockwise direction (as viewed from the water pump. Slide the water the to take slack on Place the spring in position over the front) up the the by-pass hose toward the pump clamp left side of the chain. valve. Install the spring retainer and engine. sleeve. Compress the valve spring and 14. Establish a reference point on install the valve spring retainer locks. 5. Disconnect the power steering the block and measure from this in- Be sure the damper spring is pump bracket from the water pump point to the chain (Fig. 47). and remove the drive belt. Wire the 15. Rotate the crankshaft in the power steering pump assembly to the opposite direction to take up the left side of the car in a position that slack on the right side of the chain. will prevent the oil from draining out. Force the left side of the chain 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. 45) and remove ToolT56P-6362-A the damper. A1258-B 1452-A 46 8. Disconnect the carburetor fuel FIG. Crankshaft Sleeve PIG. 44-Valve Stem Seal Removal inlet line at the fuel pump. Removal 1-24 GROUP 1- ENGINE AND EXHAUST SYSTEM

REFERENCE POINT RIGHT SIDE OF CHAIN the thrust button spring retainer. Torque the sprocket cap screw to specifications. Install the camshaft thrust button spring and thrust but ton (Fig. 50). 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 keyway in the pilot aligns with A1259-A the key in the crankshaft. Position the cover and pilot over the end of FIG. 49Timing Chain Removal the crankshaft and against the block or Installation (Fig. 51). Install the screws. TAKE UP SLACK ON LEFT SIDE, ESTABLISH retaining REFERENCE POINT. MEASURE DISTANCE A. button and the sprocket TAKE UP SLACK ON RIGHT SIDE. FORCE LEFT spring, cap SIDE OUT. MEASURE DISTANCE B. DEFLECTION screw, the thrust button spring re IS A MINUS B. A1284-A tainer, and the fuel pump eccentric.

18. Slide both sprockets and the FIG. 47Timing Chain Deflection timing chain forward, and remove the sprockets and timing chain as an as out with the fingers and measure the sembly (Fig. 49). distance between the reference point 19. Remove the oil pan and oil and the chain. The deflection is the the proce difference between the two measure pump screen, following Removal." under ments. dure "Oil Pan

If the deflection exceeds Vi inch, replace the timing chain and/ or INSTALLATION sprockets. 1. Position the sprockets and tim 16. Crank the engine until the ing chain on the camshaft and crank timing marks on the sprockets are shaft (Fig. 49). Be sure the timing positioned as shown in Fig. 48. marks on the sprockets are posi

17. Remove the camshaft thrust tioned as shown in Fig. 48.

ToolT6IP-6019-B 2. Install the fuel pump eccentric, A1287-B the camshaft sprocket cap screw, and FIG. 51Cylinder Front Cover FUEL PUMP ECCENTRIC DOWEL 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 specifications. Remove 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. 52).

8. Install the damper cap screw CRANKSHAFT FRONT and washer, and torque the screw to OIL SLINGER specifications.

TIMING MARKS A1283-A 9. Install the power steering pump FIG. 50Fuel Eccentric and Pump pulley on the damper. Torque the FIG. 48Aligning Timing Marks Front Oil Slinger Installed screws to specifications. PART 1-1 -ENGINE 1-25

damaged teeth. Replace all the com er and the timing chain and sprock ponents of the timing chain and ets following steps 1 thru 18 under sprocket assembly if any one item "Cylinder Front Cover and Timing Removal." needs replacement. Chain

FRONT OIL SEAL REPLACEMENT 2. Disconnect the spark plug wires at the spark plugs and remove the It is good practice to replace the wires from the ignition harness oil seal each time the cylinder front brackets on the valve rocker arm cover is removed. covers. Disconnect the coil high ten 1. Drive out the old seal with a sion lead at the coil. Remove the pin punch. Clean out the recess in the distributor cap and spark plug wire cover. assembly. Disconnect the distributor 2. Coat a new seal with grease, Tool-T52L-6306-AEE A1289-B vacuum line at the distributor. Re then install the seal (Fig. 53). Drive move the distributor hold down bolt the seal in until it is seated in FIG. 52Crankshaft Damper fully and clamp and remove the distrib the recess. Check the seal after in Installation utor. stallation to be sure the spring is properly positioned in the seal. 3. Remove the valve rocker arm 10. Clean the oil pan and the oil covers. Refer to "Valve Rocker Arm Removal" pump screen. Install the oil pump CAMSHAFT Shaft Assembly and re screen and oil pan. move the valve rocker arm shaft as

The camshaft and related parts semblies steps 4 and 5. 11. Clean the water gasket by following pump are shown in Fig. 54. surfaces. Coat new gaskets with 4. Remove the valve push rods in REMOVAL sealer and position the gaskets on the sequence and place them in a rack block. Install the water pul cov- pump, 1. Remove the cylinder front so that they can be installed in their and generator arm ley, fan, adjusting original positions. as an assembly. Tool-T58P-6700-B 5. Position an inspection light 12. Install and adjust the gener through a push rod and ator drive belt(s). opening into the valve push rod valley (Fig. 55). On a car with an air conditioner, Remove the valve lifters with a mag install and adjust the drive belt. net through the push rod openings. 13. Install power the steering In some cases, it will be necessary to pump drive belt and attach the pump transfer the lifter over to an adjoin bracket to the water pump. the Adjust ing push rod opening in order to re drive belt tension. move it. Place the lifters in a rack so

that can be their or 14. Install the fuel pump using a they installed in new gasket. iginal positions.

15. carburetor Connect the fuel 6. Remove the oil pan and oil

inlet line. Connect the heater hoses. pro- FIG. 53 Oil Seal Installation pump screen by following the Slide the water pump by-pass tube clamp forward on the tube. BEARINGS

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 THRUST BUTTON , supply tank. Connect the battery ground cable. Connect the transmis

sion oil cooler lines. SPRING 17. Fill and bleed the cooling system. Fill the crankcase with the CAMSHAFT REAR BEARING BORE of engine proper grade and quantity PLUG 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

FUEL PUMP ECCENTRIC BOLT AND WASHER Clean all parts in solvent and dry them with compressed air. Inspect A1275-A the chain for broken links and the sprockets for cracks, and worn or FIG. 54-Camshaft and Related Parts 1-26 GROUP 1- ENGINE rSTEM

Magnetic Lifter 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."

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.

iHE PLUG HEPlAeiMIWT

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 Vi -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. Light A1488-B 5. Coat the flange of a new plug 55 Replacement FIG. Valve Lifter Intake Manifold Installed with water resistant sealer and install it with the flange facing out (Fig. 83). Removal." cedure under "Oil Pan 5. With No. 1 piston on TDC at 6. Install the flywheel. the end of the compression stroke, 7. remove the camshaft 7. Install and Carefully position the distributor in the block the transmission by pulling it toward the front of the converter the with the rotor at the No. 1 firing housing by following engine. Use caution to avoid procedure damag position and the points open. Install in Part 5-4. the camshaft bearings. ing the hold down clamp. HYDRAULIC VALVE INSTALLATION 6. Connect the distributor vacuum LIFTER line. Install the distributor cap. Con 1. Oil the camshaft and apply nect the coil high tension lead. Lubriplate to the lobes. Carefully The following procedure is appli 7. Install the valve lifters in the slide the camshaft through the bear cable for removing one or all of the bores from which were removed. ings. they valve lifters. This procedure can not 8. Refer to "Valve Rocker Arm be used if the valve lifters are stuck 2. Position the sprockets and tim Installation" Shaft Assembly and in in their bores by excessive varnish, ing chain on the camshaft and crank stall the valve rocker arm shaft as etc. In this case it will be necessary to shaft (Fig. 49) with the timing marks sembly following steps 1 thru 9. remove the intake manifold. After on the sprockets aligned as shown in the intake manifold has re 9. and sys been Fig. 48. Fill bleed the cooling remove the valve lifters. tem. Fill the crankcase with the moved, 3. Install the fuel pump eccentric, proper grade and quantity of engine 1. Refer to "Valve Rocker Arm the camshaft sprocket and Removal" cap screw, oil. Shaft Assembly and re retainer. Torque thrust button spring move the valve rocker arm 10. Start the engine and check covers sprocket screw to specifica the cap and the valve rocker arm and adjust the ignition timing. Oper shaft as Install the camshaft thrust tions. but semblies steps ate the engine at fast idle and check by following 1 thru 5. ton (Fig. 50). Install the front oil all hose connections and gaskets for 2. Position an inspection light slinger. leaks. through a push rod opening and into 4. Replace the crankshaft front oil the valve push rod valley (Fig. 55). CLEANING AND INSPECTION seal. Install the cylinder front cover, Remove the valve lifters with a mag the crankshaft damper, and related Clean the camshaft in solvent and net through the push rod openings. In parts following steps 3 thru 16 under wipe it dry. Inspect the camshaft some cases, it will be necessary to "Cylinder Front Cover and Timing lobes for scoring, and signs of abnor transfer the lifter over to an adjoin Installation." Chain mal wear. Lobe wear characteristics ing push rod opening in order to re- PART 1-1 E 1-27

ROD CUP move it. Place the lifters in a rack so PUSH 5. Apply a thin coating of oil re that can be installed in their they (DISC VALVE sistant sealer to the rear main bearing original positions. PLUNGER cap at the rear of the top mating sur The internal parts of each by- SPRING face (Fig. 57). Do not apply sealer to draulic valve lifter assembly are the area forward of the side seal BODY matched sets. Do not intermix the groove. Install the rear main bearing parts. Keep the assemblies intact until cap. Torque the cap bolts to specifi they are to be cleaned. cations.

3. Install the new (or cleaned) hy 6. Dip the side seals in light engine draulic valve lifters through the push oil, then immediately install them in rod openings with a magnet (Fig. 55). the grooves. Do not use sealer on the

4. Refer to "Valve Rocker Arm side seals. The seals are designed to Shaft Installation" Assembly and in expand when dipped in oil. Using stall the valve rocker arm shaft as sealer may retard this expansion. It semblies and the covers the seals into by following carefully prying up on it with a screw may be necessary to tap steps 1 thru 9. driver. Remove the disc valve and place for the last Vi inch of travel. spring. Do not cut the seal projecting ends. CLEANING AND INSPECTION 7. Check the retainer side seals for The lifter assemblies should be leaks squirting a few drops of oil A typical hydraulic valve lifter is by kept in proper sequence so that they into the parting lines between the shown in Fig. 56. can be installed in their original rear main bearing cap and the cylin 1. Place the plunger upside down position. Inspect and test each lifter der block from the outside. Blow on a clean work bench. separately so as not to intermix the compressed air against the seals from 2. Place the disc valve in position internal parts. If any part of the the inside of the block. If air bubbles over the oil hole on the bottom of lifter assembly needs replacing, re appear in the oil, it indicates possible the plunger. Set the disc valve place the entire assembly. spring oil leakage. This test should not be on of the disc. top performed on installed seals Thoroughly clean all the parts in newly the valve retainer clean solvent and wipe them with a 3e Position disc until sufficient time has been allowed over the disc and and push clean, lint-free cloth. spring for the seals to expand into the seal the retainer down into place on the grooves. Inspect the parts and discard the plunger. entire lifter assembly if any part 8. Install the oil pan and related 4. Place the plunger spring, and shows signs of pitting, scoring, gall parts. then the plunger (open end into ing, or evidence of non-rotation. up) the lifter body. 9. Fill the crankcase. Start the en Replace the entire assembly if the gine and check for oil pressure. plunger is not free in the body. The 5. Place the push rod seat in the Op erate the engine at fast idle and plunger should drop to the bottom of plunger. check for oil leaks. the body by its own weight. 6. Depress the plunger, and posi Assemble the lifter assembly and tion the closed end of the lock ring check the assembly for freeness of in the groove of the lifter body. With operation by pressing down on the the plunger still depressed, position push rod cup. The lifter can also be the open ends of the lock ring in the checked with a hydraulic valve lifter groove. Release the plunger, then de

rate. press it again to seat the lock tester to test the leak-down fully Tool- Follow the instructions of the test ring. T58P-6701-A

unit manufacturer.

DISASSEMBLY

Each valve lifter is a matched as The upper oil seal in the block sembly. If the parts of one lifter are cannot be replaced with the crank inter-mixed with those of another, shaft installed. To replace the lower improper valve operation may re rear oil seal in the rear main sult. Disassemble and assemble each bearing and the side seals: lifter separately. Keep the lifter as cap semblies in proper sequence so that 1. Remove the oil pan and related they can be installed in their original parts. bores. 2. Remove the rear main bearing 1. Grasp the lock ring with needle- cap. Remove and discard the rear SEALER nose pliers to release it from the seal and side seals.

groove. If necessary, depress the 3. Clean the rear journal oil seal lock ring. plunger to fully release the groove. 2. Remove the push rod cup, 4. Install a new rear journal oil A1278-B plunger, and spring. seal in the rear main bearing cap 57Seal To Rear 3. Invert the plunger assembly and (Fig. 57). After installation, cut the FIG. Bearing remove the disc valve retainer by ends of the seals flush. Cap Installation 1-28 GROUP 1- ENGINE AND EXHAUST SYSTEM

MAIN AND CONNECTING PLACE Plastigage FULL CONNECTING ROD BEARING WIDTH OF JOURNAL ROD BEARING REPLACEMENT CHECK WIDTH REPLACEMENT ABOUT y4 INCH OF Plastigage OFF CENTER 1. Follow 1 under "Main The main and rod step connecting Replacement." Bearing bearing inserts are selective fit. Do until the not file or lap bearing caps or use 2. Turn the crankshaft new bear shims to obtain the proper bearing connecting rod to which clearance. ings are to be fitted is down.

Selective fit bearings are available 3. Remove the connecting rod cap. for service in standard sizes only. Push the connecting rod up into the Standard bearings are divided into cylinder and remove the bearing in two sizes and are identified by a daub sert from the rod and cap. of red or blue paint. Refer to the 4. Follow step 5 under "Main Parts for the available sizes. Replacement." Catalog MEASURING Bearing Red marked bearings increase the Plastigage "*~ INSTALLING 5. Install the new bearings in the blue marked de clearance; bearings Plastigage A1022-A connecting rod and cap. Pull the crease the clearance. Undersized 58 connecting rod assembly down firmly bearings, which are not selective fit, FIG. and Installing Measuring on the crankshaft journal. are available for use on journals that PlastigageEngine In Chassis 6. Place a piece of Plastigage on have been refinished. the lower bearing surface, the full 10. Install the and torque the MAIN BEARING REPLACEMENT cap width of the cap and about Va inch bolts to specifications. Do not turn off center. 1. Drain the crankcase. Remove the crankshaft while the Plastigage 7. Install the and torque the the oil level dipstick. Remove the oil cap is in place. When the width checking rod nuts to specifications. pan and oil pump. Remove the spark connecting of the check at the widest Plastigage, Do not turn the crankshaft while the plugs to allow easy rotation of the point in order to get the minimum Plastigage in place. crankshaft. is clearance. Check at the narrowest 8. Remove the cap. the 2. Replace one at a time Using bearing point in order to get the maximum Plastigage check the width of the other scale, leaving bearing securely clearance. The difference between the Plastigage 11 fastened. Remove the main by following step bearing the two readings is the taper. Replacement." under "Main cap to which new bearings are to be Bearing If the clearance is less than the installed. 9. After the bearing clearance has specified limits, try two red bearing been checked and found to be satis 3. Insert the upper bearing re halves or a combination of red and a light coat of engine moval tool (tool in the oil hole factory, apply 6331) upon condition. blue depending the If oil to the journal and bearings. In in the crankshaft. the standard bearings do not the bring stall the connecting rod cap. 4. Rotate the crankshaft in the clearance within the desired limits, 10. Repeat the procedure for the direction of engine rotation to force refinish the crankshaft journal, then remaining connecting rods that re the bearing out of the block. install undersize bearings. quire new bearings. 5. Clean the crankshaft journal 11. After the has been bearing 11. Follow steps and 16 and inserts. When 14, 15, bearing replacing checked and found to be Replacement." satisfactory, under "Main standard bearings with new bearings, Bearing apply a light coat of engine oil to the it is good practice to first try to ob CLEANING AND INSPECTION journal and bearings, then install the tain the proper clearance with two Clean the inserts and caps bearing cap. Torque the cap bolts to bearing blue halves. thoroughly. Inspect each bearing specifications. bearing 6. To install the upper main bear carefully. Bearings that have a 12. Repeat the procedure for the ing, place the plain end of the bear scored, chipped, or worn surface re remaining bearings that require should be replaced. Typical exam ing over the shaft on the locking placement. ples of failures and their tang side of the block. Using tool bearing causes are shown in Fig. 59. Check 6331 in the oil hole in the crank 13. If the rear main bearing is re the clearance of bearings that shaft, rotate the crankshaft in the placed, replace the lower oil seal in ap pear to be with Plasti opposite direction of engine rotation the rear main bearing cap and the satisfactory gage. Fit new bearings the until the bearing seats itself. Remove side seals and check the side seals following recommended procedure. The the tool. for leaks by following steps 3 thru 7 cop per lead bearing base may be visible 7. Replace the cap bearing. under "Crankshaft Lower Rear Oil Seal Replacement." through the bearing overlay. This 8. Support the crankshaft so its does not mean that the bearing is compress the Plasti weight will not 14. and as Disassemble, clean, worn. Do not replace the bearing if read gage and provide an erroneous semble the oil pump. the bearing clearance is within rec ing. Position a small jack so it will 15. Install the oil and oil ommended limits. bear against the counterweight ad pump pan. Install the oil level dipstick. Fill the which is joining bearing being PISTON AND CONNECTING the crankcase with the proper amount checked. ROD ASSEMBLY and viscosity oil. Install the spark 9. Place a piece of Plastigage on plugs. REMOVAL the bearing surface the full width of the bearing cap and about Va inch 16. Operate the engine and check 1. Drain the cooling system and off center (Fig. 58). for oil leaks. the crankcase. Remove the intake PART 1-1 -ENGINE 1-29

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 OVERLAY GONE crankshaft journal. RADIUS RIDE FROM ENTIRE SURFACE CRATERS OR POCKETS 8. Install the rod cap. TAPERED JOURNAL RADIUS RIDE FATIGUE FAILURE connecting Torque the nuts to specifications. A1021-A

9. After the piston and connecting FIG. 59Typical Bearing Failures rod assemblies have been installed, check the side clearance between the connecting rods on each crankshaft manifold, cylinder heads, oil pan and fitted. The connecting rods and bear journal (Fig. 61). oil pump following the procedures ing caps are numbered from 1 to 4 in in this section. the right bank and from 5 to 8 in the 10. Disassemble, clean, and assem left bank at the front of the ble the oil pump. Clean the oil pump 2. Remove any ridge and/or de beginning engine. The numbers on the connect inlet tube screen, and the oil pan and posits from the upper end of the cyl rod and must be on block gasket surfaces. inder bores as follows: ing bearing cap the same side when installed in the 11. Install the oil and the Turn the crankshaft until the pis pump cylinder bore. If a connecting rod is ton oil pan. to be removed is at the bottom ever transposed from one block or of its travel and place a cloth on the cylinder to another, new bearings 12. Install the cylinder heads by piston head to collect the cuttings. should be fitted and the connecting following steps 1 thru 5 under "Cyl Installation." Remove any ridge and/or deposits rod should be numbered to cor inder Head from the upper end of the cylinder respond with the new cylinder 13. Refer to "Intake Manifold In

bores. Remove the cylinder ridge number. stallation" and install the intake man with a ridge cutter. Follow the in 3. Make sure the gaps are ring ifold by following steps 2 through 19. structions furnished the tool man by properly spaced around the circum ufacturer. Never cut into the 14. Fill and bleed the sys ring ference of the piston. cooling travel area in excess of 1/32 inch tem. Fill the crankcase with the 4. Install a piston ring compressor when ridges. proper grade and quantity of engine removing on the piston and push the piston in oil. 3. Make sure all connecting rod with a hammer handle until it is caps are marked so that they can be slightly below the top of the cylinder 15. Operate the engine and check installed in their original locations. (Fig. 60). Be sure to guide the con for oil and coolant leaks. Check and 4. Turn the crankshaft until the necting rods to avoid damaging the crankshaft journals. Install the piston connecting rod being removed is down. with the indentation in the piston head toward the front of the engine. 5. Remove the connecting rod 5. Check the clearance of each cap. bearing by following the procedure 6. Push the connecting rod and piston assembly out the top of the Tool cylinder with the handle end of a 49-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, INDENTATION TO FRONT OF ENGINE A1282-B and cylinder walls with light engine A1281-B oil. Be sure to install the pistons in Rod the same cylinders from which they FIG. 61 Connecting Side were removed, or to which they were FIG. 60-Piston Installation Clearance 1-30 GROUP 1- ENGINE AND EXHAUST SYSTEM

adjust the ignition timing. Adjust the LEFT BANK RIGHT BANK pattern, but badly twisted rods will engine idle speed and fuel mixture. disturb the action of the entire pis ton, rings, and connecting rod as 16. Install the air cleaner. sembly and may be the cause of DISASSEMBLY excessive oil consumption. BEARING LOCK SLOTS TO "V" rod sol OUTSIDE OF ENGINE Clean the connecting in 1. Mark the pistons and pins to vent, including the rod bore and the assure with the same rod assembly FRONT back of the inserts. Do not use a and installation in the same cylinder I INDENTATION TO caustic cleaning solution. Blow out from which were removed. FRONT OF ENGINE they A1271-B all passages with compressed air. 2. Remove the piston rings. Re Inspect the connecting rods for 64 Rod and move the piston pin retainers. Drive FIG. Connecting signs of fractures and the bearing the pin out of the piston and connect Piston Assembly bores for out-of-round and taper. ing rod (Fig. 62). Discard the re If the bore exceeds the recom tainers. mended limits and/ or if the con ASSEMBLY necting rod is fractured, it should be replaced. The piston, connecting rod, and related parts are shown in Fig. 63. Check the piston pin to connecting rod bushing clearance. Replace the 1. Lubricate all parts with light connecting rod if the bushing is so engine oil. Position the connecting worn that it cannot be reamed or rod in the piston and push the pin into honed for an oversize pin. place. Assemble the piston and con Replace defective connecting rod necting rod as shown in Fig. 64. nuts and bolts. 2. Insert new piston pin retainers After the connecting rods are as them into the piston with by spiraling sembled to the piston, check the con the fingers. Do not use pliers. Follow necting rods for bend or twist on a the instructions contained on the pis suitable alignment fixture. Follow the ton package and install the piston ring instructions of the fixture manufac rings. turer. If the bend and/or twist is ex 3. Check the ring side clearance cessive, the connecting rod should be of the compression rings with a straightened or replaced. feeler gauge inserted between the ring and its lower land (step 6 under "Fit PISTONS, PINS, AND RINGS ting Piston Rings"). CLEANING AND INSPECTION FIG. 62Piston Pin Removal 4. Be sure the bearing inserts and Remove deposits from the piston UPPER the bearing bore in the connecting surfaces. Clean gum or varnish from COMPRESSION rod and cap are clean. Foreign ma the piston skirt, piston pins, and rings RING terial under the inserts may distort with solvent. Do not use a caustic the bearing and cause a failure. In cleaning solution or a wire brush to LOWER stall the inserts in the con clean pistons. Clean the grooves COMPRESSION bearing ring RING necting rod and cap with the tangs with a ring groove cleaner (Fig. 65). fitting in the slots provided. Make sure the oil ring slots (or holes) PISTON are clean.

inspect the pistons for CONNECTING ROD CLEANING AND Carefully fractures at the INSPECTION ring lands, skirts, RETAINER and pin bosses, and for scuffed, or scored skirts. If lower The connecting rods and related rough, the inner portion of the grooves parts should be carefully inspected ring and checked for conformance to have high steps, replace the piston. specifications. Various forms of en The step will interfere with ring gine wear caused by these parts can operation and cause excessive ring be readily identified. side clearance.

A shiny surface on the pin boss RETAINER 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 BEARING INSERTS grooves. Abnormal connecting rod bearing wear can be caused by either a bent connecting rod, an improp erly machined crankshaft journal, or A1472-A a tapered connecting rod bore. A1562-A FIG. 63-Piston, Connecting Rod, Twisted connecting rods will not 65 and Related Parts create an easily identifiable wear FIG. Cleaning Ring Grooves PART 1-1 -El 1-31

of one of the thicknesses shown in Fig. 66.

5. Position the ribbon in the cyl

inder bore so that it extends the en 90 tire length of the piston at 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 AVa s required to remove the feeler ribbon POUNDS (Fig. 67). (EXAMPLE) - In Fig. 66 the diagonal lines rep resent feeler ribbons of various thick nesses, the horizontal lines represent the pounds pull, and the vertical lines represent the clearances. To deter mine the clearance, locate the line the pounds pull required .00) 0+ .001 .002 representing CLEARANCE IN INCHES to remove the feeler ribbon from the cylinder bore. Follow the horizontal (EXAMPLE) (EXAMPLE) A1017-A line to the right until it intersects the diagonal line representing the feeler FIG. 66Piston Clearance Chart ribbon. Read down the vertical line for the clearance. Spongy, eroded areas near the er size piston has been selected, check Example 1. If a 0.0015-inch feeler edge of the top of the piston are for a damaged piston, then try a new ribbon is used and it takes approxi usually caused by detonation, or piston. mately AVa -pounds pull to remove pre-ignition. A surface on the shiny If the clearance is less than the the feeler ribbon, the clearance is ap thrust surface of the piston, offset minimum limit, recheck calculations proximately 0.0008 inch. This is de from the centerline between the pis before another piston. If none trying termined by locating the pounds pull ton pin can be caused a holes, by can be refinish the cylinder for fitted, {AVa) in Fig. 66 and following the bent rod. Replace pis connecting the next size piston. When a piston line to the right until it intersects tons that show signs of excessive has been mark it for fitted, assembly with the diagonal line representing wear, wavy ring lands, fractures, in the cylinder to which it was fitted. the 0.0015-inch feeler ribbon. Read and/or damage from detonation or If the taper and out-of-round con down the vertical line for the clear- pre-ignition. ditions of the cylinder bore are with Check the piston to cylinder bore in limits, new piston rings will give with a tension scale and clearance satisfactory service provided the pis ribbon by following the procedure ton clearance in the cylinder bore is Pistons." under "Fitting Check the within limits. If the new rings are to ring side clearance by following the be installed in a used cylinder that procedure under Piston "Fitting has not been refinished, remove the Rings." "glaze." cylinder wall

Replace piston pins showing signs To fit a piston: of fracture or etching and/or wear. 1. Calculate the size piston to be Check the piston pin fit in the piston used a cylinder bore check and rod. by taking (Fig. 86). Replace all rings that are scored, 2. Select the proper size piston to chipped, or cracked. It is good prac provide the desired clearance. tice to always install new rings when

overhauling the engine. Rings should 3. Make sure the piston and cyl not be transferred from one piston to inder bore are at room temperature another regardless of mileage. (70F). After any refinishing opera tion, allow the cylinder bore to cool FITTING PISTONS and make sure the piston and bore Pistons are available for service are clean and dry before the piston fit in standard sizes and 0.020, 0.030, is checked.

and 0.060-inch oversize. 0.040, 4. Attach a tension scale to the If the clearance is greater than the end of a feeler gauge ribbon that is maximum specified limit, recheck free of dents or burrs. The feeler 67 calculations to be sure that the prop ribbon should be ^-inch wide and FIG. Checking Piston Fit 1-32 GROUP 1- ENGINE AND EXHAUST SYSTEM

COAT GASKET WITH ENGINE OIL 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 A1238-A piloted reamer. Place the reamer in a 68 FIG. Piston Ring Gap vise and revolve the piston around the reamer. Set the reamer to the size ance (approximately 0.0008 inch). of the pin bore, then expand the Example 2. If a 0.003-inch feeler reamer slightly and trial ream the pin

ribbon is used and it takes approxi bore. Take a light cut. Use a pilot mately 9-pounds pull to remove the sleeve of the nearest size to maintain alignment of the bores. ribbon, the resultant clearance is ap FIG. 70 Oil Filter Replacement proximately 0.0015 inch. Check the hole size, using the new piston pin. If the bore is small, ex FITTING PISTON RINGS pand the reamer slightly and make 3. Operate the engine at fast idle another cut. Repeat the procedure and check for leaks. If oil leaks are 1. Select the proper ring set for the until the proper fit is obtained. Check evident, perform the re size piston to be used. necessary the piston pin for fit in the respec pairs to correct the leakage. Check 2. Position the ring in the cylinder tive rod bushing. If necessary, ream the oil level and fill the crankcase if bore in which it is going to be used. or hone the bushing to fit the pin. necessary. 3. Push the ring down into the cylinder bore area where normal ring OIL PAN AND OIL PUMP wear is not encountered. FLYWHEEL

the of a piston to 4. Use head REMOVAL REMOVAL position the ring so that the ring is 1. 1. Drain the cooling system and square with the cylinder wall. Use Disconnect the transmission the crankcase. radia from the engine and slide it to the Disconnect the caution to avoid damage to the ring rear as outlined tor upper hose at the radiator or cylinder bore. in Part 5-4. supply 2. tank. 5. Measure the gap between the Remove the flywheel retaining bolts and remove oil pan ends of the ring with a feeler gauge the flywheel. 2. Remove the retaining (Fig. 68). If the gap is less than the screws and lower the oil pan to the INSTALLATION recommended lower limit, try another underbody cross member. Position ring set. 1. Install the flywheel on the the crankshaft so that the counter crankshaft flange and re weight will clear the oil pan and move 6. Check the ring side clearance of install the the compression rings with a feeler taining bolts. Torque the bolts in the pan forward. gauge inserted between the and sequence across from each other to ring 3. Install the engine lifting brack its lower land (Fig. 69). The gauge specifications. ets and sling. Raise the engine high 2. Connect the transmission to the enough to place tension on the engine engine as outlined in Part 5-4. mounts.

4. Remove the engine front in OIL FILTER REPLACEMENT sulator to engine retaining bolts. Raise the engine high enough to per 1. Place a drip pan under the filter. Unscrew the filter from the mit removal of the oil pump retaining then remove adapter fitting. Clean the filter adap bolts, the bolts. Remove ter recess. the oil pan and the oil pump.

2. Coat the gasket on the new fil INSTALLATION ter with oil, and place the filter in 1. Clean the oil pan and block position on the adapter (Fig. 70). 'A1020-A gasket surfaces. Position a new gas Hand tighten the filter until the gas ket on the oil pan. ket contacts the adapter face, then 69 FIG. Ring Side Clearance advance it Vi turn. 2. Clean the oil pump and inlet PART 1-1 -ENGINE 1-33

DISTRIBUTOR INTERMEDIATE Feeler Gauge DRIVE SHAFT

GASKET OIL RELIEF VALVE ASSEMBLY

GASKET >*%

BODY ASSEMBLY / , I f

ROTOR AND SHAFT ^j 73 ASSEMBLY I I FIG. Outer Race To Housing Clearance

PLATE A1290-A Repair any damage, or replace the pan if repairs can not be made. A1272-A FIG. 71 Oil Pump and Inlet Tube Installed OIL PUMP FIG. 72 Oil Pump Assembly CLEANING AND INSPECTION

Wash all parts in a solvent and tube screen. Position a new oil pump then remove the cover. Re screws, them thoroughly. Use a brush to inlet tube gasket on the oil pump and dry move the inner rotor and shaft as clean the inside of the install the tube. Prime the oil pump pump housing then remove the outer race. sembly, and the pressure relief valve chamber. by filling either the inlet or outlet 3. Insert a self sheet Be sure all dirt and chips are re port with engine oil. Rotate the pump -threading moved. shaft to distribute the oil within the metal screw of the proper diameter into the oil valve pump body. pressure relief Check the inside of the pump hous chamber cap and pull the cap out and the outer race and rotor for 3. Raise the engine high enough to ing of the chamber. Remove the spring damage or excessive wear. allow installation of the oil pump and and plunger. Check surface of the oil pan. Place the oil pump in the the mating the oil pan and position the oil pan on the cover for wear. If the cover OIL PUMP ASSEMBLY pump underbody cross member. Insert the mating surface is worn, scored, or The oil is shown replace oil pump drive shaft into the oil pump pump assembly grooved, the cover. in Fig. 72. housing and install the oil pump and Measure the outer race to hous shaft as an assembly (Fig. 71). Do not 1. Oil all parts thoroughly. ing clearance (Fig. 73). attempt to force the into posi pump With the rotor installed 2. Install the oil pressure relief assembly tion if it will not seat readily. The in the place a straight edge valve plunger, spring, and a new cap. housing, drive shaft hex be misaligned may over the rotor assembly and the hous with the distributor shaft. To 3. Install the outer race, and the align, ing. Measure the rotor end play clear rotate the intermediate shaft into a inner rotor and shaft assembly. The ance between the straight edge and position. oil inner rotor and and the outer new Torque the pump shaft, the rotor and outer race (Fig. 74). retaining screws to specifications. race are serviced as an assembly. The outer race, shaft and rotor One part should not be replaced 4. Hold the oil pan in place are replaceable only as an assembly, without the other. Install against the cylinder block and install replacing the cover. Torque the cover retaining a retaining screw on each side of the Straight Edge screws to specifications. oil pan. Install the remaining screws and torque them, from the center 4. Position a new gasket and the outward, to specifications. oil inlet tube on the oil pump and install the bolts. 5. Lower the engine, then install retaining the engine right and left front support OIL PAN bolts. Torque the bolts to retaining CLEANING AND INSPECTION specifications. Remove the engine lifting bracket and sling. Connect the Scrape any dirt or metal particles radiator upper hose. Fill and bleed from the inside of the pan. Scrape the cooling system. Fill the crankcase all old gasket material from the gas with the proper grade and quantity ket surface. Wash the pan in a sol of engine oil. Operate the engine and vent and dry it thoroughly. Be sure check for leaks. all foreign matter is removed from below the baffle plate. Feeler Gouge OIL PUMP DISASSEMBLY Check the pan for cracks, holes, tube from 1. Remove the oil inlet damaged drain plug threads, a loose remove the gasket. the oil pump and baffle, and a nicked or warped gas 2. Remove the cover retaining ket surface. FIG. 74-Rotor End Play 1-34 GROUP 1- ENGINE AND EXHAUST SYSTEM

Check the drive shaft to housing Inspect the relief valve spring for in specifications and/or the spring is bearing clearance by measuring the a collapsed or worn condition. defective, replace the spring. OD of the shaft and the ID of the Check the relief valve spring ten Check the relief valve piston for housing bearing. sion. If the spring tension is not with scores and free operation in the bore.

WORK STAND REPAIR OPERATIONS

To perform the operations in this 4. If the crankshaft sleeve is not the cap. Push the connecting rod and section, it will be necessary to remove stepped down (the same OD on both piston assembly up into the cylinder. the engine from the car and install it remove it as shown in Fig. 46. ends), 9. Remove the main bearing caps. on a work stand. If the sleeve is stepped down, remove 10. Carefully lift the crankshaft it with a three-jawed puller (tool out of the block so that the thrust 7675-N). CRANKSHAFT bearing surfaces are not damaged. 5. Remove the cylinder front Handle the crankshaft with care to REMOVAL cover. avoid possible fracture or damage to

The crankshaft and related parts the finished surfaces. 6. Remove the oil slinger. Check are shown in Fig. 75. the chain then re timing deflection, INSTALLATION move the chain and sprockets 1. Remove the generator timing adjusting 1. Remove the rear journal oil steps 13 thru 18 under arm bracket bolt from the generator by following Removal." seal from block and rear main "Cylinder Front Cover the and the upper support bracket bolt bearing cap. Remove the rear main at the water pump. Remove the spark 7. Invert the engine on the work bearing cap to block side seals. plugs to allow easy rotation of the stand. Remove the flywheel. Remove 2. Remove the main in crankshaft. bearing the oil pan and gasket. Remove the serts from the block and bearing caps. 2. Remove the fuel pump. Slide oil pump. 3. Remove the connecting rod water hose the pump by-pass clamp inserts from the 8. Make sure all bearing caps bearing connecting toward rear of the engine. Re the rods and (main and connecting rod) are caps. move the water pump and fan as an marked so that they can be installed 4. If the crankshaft main bearing assembly. in their original locations. Remove journals have been refinished to a 3. Remove the crankshaft damper, the connecting rod bearing caps. definite undersize, install the correct cap screw and washer. Install the pul Turn the crankshaft until the con undersize bearings. Be sure the bear ler on the damper (Fig. 45) and re necting rod from which the cap is ing inserts and bearing bores are move the damper. being removed is down and remove clean. Foreign material under the in-

CYLINDER BLOCK JOURNAL SEAL

MAIN BEARING INSERTS

REAR BEARING CAP JOURNAL SEAL

DAMPER

POWER STEERING REAR PUMP PULLEY BEARING CAP SIDE SEALS

BOLT jjgS

MAIN BEARING CAPS WASHER A1276-C

FIG. 75 -Crankshaft and Related Parts 1-35 PART 1-1 -ENGINE

CHECK WIDTH PLACE Plastigage FULL OF Plastigage WIDTH OF JOURNAL ABOUT Va INCH 0.002' OFF CENTER CLEARANCE

INSTALLING MEASURING PLASTIGAGE PLASTIGAGE A1023-A

FIG. 77Installing & Measuring PlastigageEngine Removed

A1280-A

oil to the journals and bearings. In 79-Crankshaft End stall a new seal in the rear main FIG. Play Tool-T58P-6701 -A A1277-A bearing cap and install the rear main bearing cap by following steps 3 (Fig. 79). 76-Seal To Block FIG. thru 7 under "Crankshaft Lower Rear 17. Zero the dial indicator. Push Replacement." Installation Oil Seal Install all the the crankshaft forward and note the thrust bear bearing caps, except the reading on the dial. serts distort the bearing and cap (No. 3 bearing). Be sure that may ing If the end play exceeds the wear cause a failure. the main bearing caps are installed in limit, replace the thrust bearing. If their original locations. Torque the 5. Place the upper main bearing the end play is less than the mini to specifications. position the bores with bearing cap bolts inserts in in mum limit, inspect the thrust bearing provided. the tang fitting in the slot 11. Install the thrust bearing cap faces for scratches, burrs, nicks, or 6. Install the lower main bearing with the bolts finger-tight. dirt. If the thrust faces are not de inserts in the bearing caps. fective or dirty, they probably were 12. Pry the crankshaft forward properly. Install the rear journal oil not aligned 7. Install a new against the thrust surface of the block (Fig. 76). After in thrust bearing and align the faces fol seal in the upper half of the bearing (Fig. 78). the recommended procedure stallation, cut the ends of the seals lowing 13. Hold the crankshaft forward then check flush. (steps 11, 12, 13, and 14), and pry the thrust bearing cap to the the end play. 8. lower the crankshaft Carefully rear (Fig. 78). This will align the new inserts in into place. Be careful not to damage 18. Install bearing thrust surfaces of both halves of the the surfaces. the connecting rods and caps. Check bearing bearing. the clearance of each bearing by fol 9. Check the clearance of each 14. Retain the forward pressure lowing the procedure under "Main as follows: main bearing Replacement." on the crankshaft. Tighten the cap Bearing Place a piece of Plastigage on the bolts to specifications (Fig. 78). 19. After the rod crankshaft journal the full width of connecting 15. Force the crankshaft toward bearings have been fitted, apply a the journal and about Va inch off the rear of the engine. light coat of engine oil to the journals center (Fig. 77). Follow steps 10 and bearings. thru 12 under "Main Bearing Re 16. Install a dial indicator so that

placement." the contact point rests against the 20. Turn the crankshaft throw to the bottom of its stroke. Push the 10. After the bearings have been crankshaft flange and the indicator engine axis is parallel to the crankshaft axis piston all the way down until the rod fitted, apply a light coat of

j >***

HOLD CRANKSHAFT PRY FORWARD FORWARD

PRY BACKWARD TIGHTEN CAP CRANKSHAFT FORWARD CAP PRY A1279-A

Alignment FIG. 78 -Thrust Bearing 1-36 GROUP 1- ENGINE AND EXHAUST SYSTEM

ToolT52L-6261-CEE INSTALL FRONT BEARING 0.005-0.020 INCH bearing seats on the crankshaft jour BELOW FRONT FACE OF BLOCK nal.

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

22. After the piston and connect rod ing assemblies have been in Tool- stalled, check the side clearance be T54T-6250-B tween the connecting rods on each connecting rod crankshaft journal (Fig. 61).

23. Clean the oil pan, oil pump, and oil pump screen. Install the oil pump and oil pan.

24. Position the flywheel on the crankshaft. Install the retaining bolts. Torque the bolts to specifications. FIG. 82Camshaft Front Bearing 25. Install the timing chain and Measurement sprockets, cylinder front cover and crankshaft steps 1 damper, following Align the oil holes in the bearings thru 8 under "Cylinder Front Cover with the oil holes in the cylinder Installation." A1260-B block when the bearings are installed. 26. Install the oil filter, fuel pump, Be sure the camshaft front bearing is FIG. 81Camshaft and carburetor fuel inlet line. Install Bearing installed 0.005-0.020 inch below the

the generator. Install the spark plugs. Replacement front face of the cylinder block (Fig. 82). 27. Install the engine in the car. Refinishing Journals. Refinish the 4. Clean out the camshaft rear CLEANING AND INSPECTION journal to give the proper clearance bearing bore plug recess thoroughly. with the next undersize bearing. If Coat the flange of a new plug with Handle the crankshaft with care up" the journal will not "clean to water resistant sealer and install the to avoid possible fractures or dam give the proper clearance with the plug (Fig. 83). age to finished Clean the surfaces. maximum undersize avail bearing 5. Install the camshaft, crank the crankshaft with then solvent, able, replace the crankshaft. shaft, flywheel, and related parts. In blow out all oil passages with com Always reproduce the same jour stall the engine in the car. pressed air. nal shoulder radius that existed Inspect main and rod connecting originally. Too small a radius will ENGINE DISASSEMBLY journals for cracks, scratches, result in fatigue failure of the crank minor grooves, or scores. Dress im shaft. Too large a radius will result 1. Install the engine on the work perfections with an oilstone. Refin in bearing failure due to radius ride stand (Fig. 17). ish severely marred journals. of the bearing. 2. Remove the distributor cap Measure the diameter of each After refinishing the journals, and spark plug wire assembly. journal in at least four places to de chamfer the oil then polish holes, 3. Disconnect the distributor vac termine or un the journal with a No. 320 grit out-of-round, taper, uum line at the distributor. Remove dersize condition (Fig. 80). cloth and engine oil. polishing the carburetor fuel inlet line. Remove Crocus cloth may be used also as a If the journals exceed the wear the fuel pump and discard the gasket. polishing agent. should be refinished to limit, they 4. Slide the clamp on the water size for the next undersize bearing. CAMSHAFT BEARING Too/-T58P-6266-A

A VS B = VERTICAL TAPER REPLACEMENT C VS D = HORIZONTAL TAPER A VS C AND B VS D = OUT-OF-ROUND Camshaft bearings are available CHECK FOR OUT-OF ROUND AT prefinished to size EACH END OF JOURNAL 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. Remove the camshaft A1015-A bearings (Fig. 81).

3. Position the new bearings at the FIG. 80Crankshaft Journal 83 bearing bores, and press them in FIG. Camshaft Rear Bearing Measurements place with the tool shown in Fig. 81. Bore Plug Installation PART 1-1 -ENGINE 1-37

pump by-pass hose toward the water Magnetic Lifter Remove the sprockets and timing pump. Remove the automatic choke chain as an assembly (Fig. 49). heat tube. Remove the valve rocker 24. Remove any ridge and/or car arm covers. bon deposits from the upper end of

5. Crank the engine until the No. the cylinder bores. Move the piston 1 piston is at TDC at the end of the to the bottom of its travel and place

compression stroke. Rotate the crank a cloth on the piston head to collect 45 shaft damper an additional (iden the cuttings. Remove the cylinder tified on the damper by "XX"). ridge with a ridge cutter. Follow the Starting at the No. 4 cylinder, loosen instructions furnished by the tool the right rocker arm shaft support manufacturer. Never cut into the bolts in sequence, two turns at a time. ring travel area in excess of 1/32 inch After the bolts are all loosened, re when ridges. After the A1255-A removing move the valve rocker arm shaft as ridge has been removed, remove the sembly and the oil baffle plate. Start cutter from the cylinder bore. at the No. 5 follow the FIG. 85-Hydraulic Valve Lifter ing cylinder, 25. Remove the flywheel. same procedure on the left valve Removal rocker arm shaft support bolts. This 26. Invert the engine. Remove the procedure must be followed to avoid oil pan. Discard the gasket. their original bore (Fig. 85). The in damage to the valve mechanism. ternal parts of each hydraulic valve 27. Remove the oil pump and in 6. Remove the valve push rods in lifter assembly are matched sets. Do let tube as an assembly. Remove the sequence and put them in a rack so not intermix the parts. Keep the as oil pump drive shaft. Discard the oil that they can be installed in their semblies intact until they are to be pump gasket. original bore. cleaned. 28. Make sure all connecting rods 7. Remove the distributor hold 13. Remove the exhaust mani and caps are marked so that they can and down bolt clamp and remove the folds and the spark plugs. be installed in their original locations. distributor. Turn the crankshaft until the con 14. Remove the cylinder head 8. Remove the intake manifold rod removed is down. bolts, and then install the cylinder necting being bolts. the rod cap. retaining head holding fixtures (Fig. 26). Remove 9. Install standard eye bolts with 29. rod and 15. Lift the cylinder heads off the Push the connecting %6-18 threads in the left front and piston out the of the block. Do not pry between the head assembly top right rear rocker arm cover screw and the block. Discard the cylinder cylinder with the handle end of a holes and attach the engine lifting head gaskets. hammer. Avoid damage to the sling (Fig. 16). crankpin or the cylinder wall when 16. Remove the oil filter. Remove 10. Raise the manifold and care removing the piston and rod. the oil filter adapter assembly and remove it from the engine. Dis fully oil pressure sending unit as an assem 30. Remove the bearing inserts card the intake manifold gaskets and bly. Discard the gasket. from the connecting rods and caps. seals. Install the rod caps on the connect 17. Remove the generator, brack 11. Remove the baffle plate from rods from which were re ets, and drive belts. ing they the valve push rod chamber floor by moved. 18. Remove the water pump, pul on the baffle with a screw prying up 31. the main and fan as an assembly. Remove bearing driver (Fig. 84). ley, caps. 19. Remove the power 12. Lift the valve lifters from the steering pulley. Remove the crankshaft 32. Carefully lift the crankshaft cylinder block and place them in a damp er (Fig. 45). out of the cylinder block so that the rack so that they can be installed in thrust bearing surfaces are not dam 20. If the crankshaft sleeve is not aged. Handle the crankshaft with stepped down (the same OD on both care to avoid possible fracture or ends), remove it as shown in Fig. 46. damage to the finished surfaces. If the crankshaft sleeve is stepped down (different OD on each end), re 33. Remove the rear journal oil move it with a three-jawed puller seal from the block and rear bearing (tool 7675-N). cap, and remove the cap to block side seals. 21. Remove the cylinder front cover. Discard the gasket. Remove 34. Remove the main bearing in the crankshaft front oil slinger. serts from block and bearing caps. Install the main bearing caps in their 22. Check the timing chain deflec original positions. tion by following steps 13, 14, and 15 under "Cylinder Front Cover and 35. Carefully remove the cam Removal." Timing Chain shaft by pulling it toward the front of the engine. Use caution to avoid 23. Remove the camshaft thrust the journals and lobes. button and spring, the sprocket damaging A1254-A cap screw, and thrust button spring re 36. Remove the camshaft rear tainer, and the fuel pump eccentric. bearing bore plug. Remove the cam FIG. 84-Baffle Plate Removal Remove the crankshaft sprocket key. shaft bearings (Fig. 81). 1-38 GROUP 1- ENGINE AND EXHAUST SYSTEM

CYLINDER BLOCK following the instructions of the For the proper use of the re manufacturer. Measure the diam finishing equipment, follow the in CLEANING AND INSPECTION eter of each cylinder bore at the top, structions of the manufacturer. Only personnel should be al Thoroughly clean the block in middle, and bottom with the gauge experienced perform this work. solvent. Remove old gasket material placed at right angles and parallel lowed to from all machined surfaces. Remove to the centerline of the engine (Fig. After the final operation in either all pipe plugs which seal oil pas 86). of the two refinishing methods de prior to the sages, then clean out all the pas Refinish cylinders that are deeply scribed and checking wash the cyl sages. Blow out all passages, bolt scored and/or when out-of-round piston fit, thoroughly remove all holes, etc. with compressed air. and/or taper exceed the wear limits. inder walls with solvent to Make sure the threads in the cyl abrasive particles, then thoroughly If the cylinder walls have minor inder head bolt holes are clean. Dirt the walls. Check the piston fit. out- dry surface imperfections, but the in the threads may cause binding Mark the pistons to correspond to of-round and taper are within limits, and result in a false torque reading. the cylinders in which they are to be it may be possible to remove the Use a tap to true-up threads and to installed. When the refinishing of all imperfections by honing the cylin remove any deposits. cylinders that require it has been der walls and installing new serv After the block has been thor completed and all pistons fitted, thor ice piston rings providing the piston re make a check for oughly clean the entire block to oughly cleaned, clearance is within limits. Use the particles the cracks. Minute cracks not visible to move all from bearing finest grade of honing stone for this the naked eye detected bores, oil passages, cylinder head bolt may be by operation. etc. Coat the cylinder walls coating the suspected area with a holes, with oil. mixture of 25% kerosene and 75% REFINISHING CYLINDER WALLS light motor oil. Wipe the part dry Honing is recommended for re and immediately apply a coating of ENGINE ASSEMBLY cylinder walls when zinc oxide dissolved in wood alcohol. finishing only the walls have minor imperfections, 1. Remove the glaze from the cyl If cracks are present, the coating will such as light scuffs, scratches, etc. inder bores the instruc become discolored at the defective by following The grade of hone to be used is tions of the tool manufacturer. area. Replace the block if it is determined the amount of metal cracked. by 2. Invert the engine on the work to be removed. Follow the instruc stand. Check all machined gasket sur tions of the hone manufacturer. If 3. Position the new bearings at the faces for nicks, scratches, burrs, coarse stones are used to start the and press and scores. Remove minor imper bearing bores, them in honing operation, leave enough ma fections with an oil stone. Check the place with the tool shown in Fig. 81. terial so that all hone marks can be flatness of the cylinder block gasket Align the oil holes in the cylinder removed with the finishing hone surface the procedure and block when the bearings are installed. following which is used to obtain the proper sure the camshaft specifications recommended for the Be front bearing is piston clearance. cylinder head. installed 0.005-0.020 inch below the Cylinder walls that are severely front face of the cylinder block (Fig. Replace all expansion-type plugs marred and/or worn beyond the 82). that show evidence of leakage. specified limits should be refinished. 4. Check the oil passage that feeds scor Inspect the cylinder walls for Before cylinder is all any refinished, the rocker arm shafts for obstruc other signs of ing, roughness, or main caps must be in place bearing tions squirting oil into the open cylinder for by wear. Check the bore and tightened to the proper torque on each cylinder bank and ob - ing out of round and taper. Measure so that the crankshaft bores bearing the flow through the oil holes gauge serving the bore with an accurate will not become distorted from the at Nos. 2 and 4 bearings. refinishing operation. 5. Clean out the camshaft rear -CENTER LIN : OF ENGINE ' A Refinish the cylinder or cyl only recess tk AT bearing bore plug thoroughly. "W inders that require it. All pistons are i "'W RIGHT 6. Coat the flange of a new ANGLE the same weight, both standard and plug TO with water resistant sealer and in oversize; therefore, various sized pis 1 CENTER stall it with the flange out (Fig. LINE OF tons can be intermixed without upset facing 83). Drive the in until it is flush Jms ENGINE ting engine balance. plug or below the B slightly casting surface. Pi B Refinish the cylinder with the most \l 7. Oil the camshaft and PARALLEL wear first to determine the maximum apply TO Lubriplate to all lobes, then carefully CENTER oversize. If the cylinder will not clean slide it through the bearings. LINE OF up when refinished for the maximum ENGINE oversize piston recommended, replace 8. Be sure that the rear oil seal \^^ the block. grooves are clean. Install a new rear . A mmOOO, i journal oil seal in the block (Fig. 76). 1. OUT-OF-ROUND = DIFFERENCE BETWEEN Refinish the cylinder to within ap A AND B After cut the ends of 0.0015 inch of the re installation, the 2. TAPER = DIFFERENCE BETWEEN THE A proximately seals flush. MEASUREMENT AT TOP OF quired oversize diameter. This will CYLINDER AND THE BORE A allow enough stock for the final step 9. If the crankshaft main MEASUREMENT AT BOTTOM OF bearing of so that the correct surface journals have been refinished a CYLINDER BORE A1025-A honing to finish and pattern are obtained. Use definite undersize, install the correct 86Cylinder Out-of- FIG. Bore clear sharp hones of No. 220-280 grit undersize bearings. Be sure the bear Round and Taper for this operation. ing inserts and bearing bores are PART 1-1 -ENGINE 1-39

fix clean. Foreign material under the in 21. Clean the cylinder front cover engine, then remove the holding tures. Coat the head bolt threads with serts may distort the bearing and and the cylinder block gasket sur and then install cause a failure. faces. Install a new crankshaft front water resistant sealer, oil seal (Fig. 53). the bolts. Place the upper main bearing in 34. The cylinder head bolt tight serts in position in the bore with the 22. Coat the gasket surface of the procedure is performed in tang fitting in the slot provided. block and cover and the cover bolt ening steps. Torque the threads with sealer. Position a new three progressive 10. main Install the lower bearing sequence to 70 gasket on the block. bolts in (Fig. 27) inserts in the caps. bearing ft-lbs, then to 80 ft-lbs, and finally 23. Install the alignment pilot tool After the cylinder head 11. lower the crank to 90 ft-lbs. Carefully on the cylinder front cover so that the have been torqued to specifica shaft into place. Be careful not to bolts in the pilot aligns with the keyway bolts should not be dis damage the surfaces. tions, the bearing in the crankshaft. Position the key turbed. 12. Check the clearance of each cover and pilot over the end of the block 35. Coat the mating surfaces of main bearing by following the proce crankshaft and against the the exhaust manifold with a light dure under "Main Bearing Replace (Fig. 51). ment." film of graphite grease. 24. Install the cylinder front cov 36. a new gasket, install er Position the gen Using 13. After the bearings have been bolts finger-tight. the automatic choke air chamber erator support bracket and the gen a light coat of engine oil fitted, apply cover on the right exhaust manifold. erator arm then to the journals and bearings. adjusting bracket, Be sure the cover is fastened. install the bolts (on a car equipped securely 14. Be sure that the oil seal with an air conditioner, connect the 37. Position a new gasket over the main grooves in the rear bearing cap compressor and brackets to the cyl muffler inlet pipe studs of the ex are clean. a new journal seal Install inder front cover). While pushing in haust manifolds. installa in the cap (Fig. 57). After on the pilot, torque the cover bolts 38. Position the exhaust manifolds tion, cut the ends of the seal flush. to specifications. Remove the pilot. on the cylinder heads and install the Apply a thin coating of oil resistant 25. Lubricate the crankshaft with retaining bolts and tab washers. sealer to the rear main bearing cap a white lead and oil mixture and Torque the retaining bolts to specifi at the rear of the top mating surface lubricate the oil seal rubbing surface cations, working from the center to (Fig. 57). Do not apply sealer to the with grease. the ends. Lock the bolts area forward of the side seal groove. by bending one tab of the washer over a flat on Install the rear main bearing cap and 26. Install the crankshaft sleeve the bolt. the remainder of the caps, except the with the smallest OD end into the thrust bearing cap (No. 3 bearing). cylinder front cover bore if the 39. Install the spark plugs. Be sure that the main bearing caps sleeve is stepped down (different 40. Position the baffle plate in the are installed in their original loca OD on each end). valve push rod chamber. Press it into tions. Torque the bearing cap bolts to 27. Line the damper place (Fig. 87). specifications. up keyway with the on the then key crankshaft, 41. Coat the outside of each valve 15. Install the thrust install the damper on the crankshaft bearing cap lifter with engine oil to provide ini check crankshaft end (Fig. 52). Install the damper and play by cap tial lubrication. Do not fill the lifters steps 11 thru 17 under screw and and torque the following washer, with oil. The lifters will fill much Installation." "Crankshaft screw to specifications. faster after the engine is started, if

16. Turn the engine on the work 28. Install the power steering stand so that the front end is up. pump pulley on the crankshaft damper. 17. Install the pistons and con 29. Clean the water gasket necting rods by following steps 1 pump surfaces and sealer. Position thru 9 under "Piston and Connect apply Installation." new gaskets on and install ing Rod the pump the water pump, pulley, and fan as and 18. Position the sprockets tim an assembly. ing chain on the camshaft and crank 30. a new gasket, install the shaft (Fig. 49). Be sure the timing Using fuel pump. Install the generator, marks on the sprockets are positioned and drive belts. as shown in Fig. 48. brackets,

31. Turn the engine on the work 19. Lubricate the timing chain stand so that the top of the engine and sprockets with engine oil. is up. 20. Install the fuel pump eccen 32. Clean the cylinder head and tric (Fig. 50), the camshaft sprocket block gasket surfaces. Apply sealer screw, and thrust button spring cap to both sides of a new gasket. retainer. Torque the sprocket cap "FRONT" Guided by the word on screw to specifications. Install the the gasket, install the head gasket thrust button and camshaft spring A1293-A over the cylinder head dowels. t ( -X*---^^^+ thrust button (Fig. 50). Install the cylinder on 87 crankshaft front oil slinger. 33. Place the head the FIG. Baffle Plate Installation 1-40 GROUP 1- ENGINE AND EXHAUST SYSTEM

they are free of oil film which steps 1 thru 6. any sembly by following OIL PRESSURE cause an oil seal may between the 51. Install the automatic choke SENDING UNIT plunger and the lifter body. Place heat tube. each lifter in the bore from which ADAPTER 52. Rotate the crankshaft damper it was removed. until the No. 1 piston is on TDC 42. Clean the mating surfaces of then position the distributor in the the intake manifold, cylinder heads, block with the rotor at the No. 1 fir and cylinder block. ing position and the points open. In 43. Coat the intake manifold and stall the hold down clamp.

cylinder block seal surfaces with oil 53. Connect the distributor vac resistant sealer. uum line. Install the distributor cap.

Install the valve rocker arm covers. 44. Position new seals on the cyl inder block and new gaskets on the 54. Connect the spark plug wires. cylinder heads. Position the gasket Install the carburetor fuel inlet line.

slots in the end tabs over the ribs 55. Invert the engine on the work

on the seals. Be sure the holes in stand. Position the oil drive pump FILTER the gaskets are aligned with the shaft into the distributor socket. ELEMENT holes in the cylinder heads. The cor With the shaft firmly seated in the rect installation of the gaskets and distributor socket, the stop on the seals are shown in Fig. 23. shaft should touch the roof of the

crankcase. 45. Install the eye bolts in the in Remove the shaft and position the as necessary. take manifold and attach the engine stop A1291-B lifting sling and carefully lower the 56. With the stop properly posi 88Oil Filter intake manifold on the engine (Fig. tioned, insert the oil pump drive FIG. Assembly 21). shaft into the oil pump. tions. 46. Position the intake manifold 57. Prime the oil pump by filling 61. by inserting the distributor in place. either the inlet or outlet port with The oil filter assembly is shown in Fig. After the intake manifold is in place, engine oil. Rotate the pump shaft to 88. Clean the oil filter run a finger around the seal area to distribute the oil within the pump adapter gasket surfaces. make sure the seals are in place. If body. 62. Apply sealer to a new adapter the seals are not in place, remove the 58. Position a new gasket on the gasket, and install the adapter assem position the intake manifold and pump housing and install the pump bly and gasket. seals. and shaft as an assembly. Do not at 63. Clean the adapter filter re tempt to force the into posi cess. Coat the 47. Start the water pump by-pass pump gasket on a new filter tion if it will not seat readily. The with oil. hose on the intake manifold. Place the filter in position drive shaft hex may be misaligned on the adapter. Hand tighten the fil 48. Be sure the holes in the mani with the distributor shaft. To align, ter until the gasket contacts the fold gaskets and manifold are in rotate the intermediate shaft into a adapter face, and then advance it alignment. Install the manifold re new position. Vi -turn. taining bolts and torque them to spe 59. Position a new gasket on the 64. Install the engine in the car. cifications, working from the center oil pan and place the oil pan assem Operate the engine and check for oil to the ends. bly on the block. Install the retain and coolant leaks. Check the ignition 49. Remove the distributor and screws and torque them from ing timing, adjust the engine idle speed, and eye bolts. the engine lifting sling the center outward to specifications. idle fuel mixture, and anti-stall dash- 50. Refer to "Valve Rocker Arm 60. Position the flywheel on the pot.

Installation" and crankshaft and install the Shaft Assembly in retaining 65. Adjust the transmission con specifica- stall the valve rocker arm shaft as bolts. Torque the bolts to trol linkage.

CRANKCASE VENTILATION SYSTEM MAINTENANCE

lator exhaust and con Refer to Group 12 for the correct valve, tube, quires cleaning except during a high interval for maintenance. nections, and outlet adapter. Clean mileage mileage engine overhaul. However, the valve exhaust tube, fittings, and BREATHER CAP if there is evidence of crankcase pres outlet adapter in clean carburetor The breather located on the sure, the tube should be checked for cap solvent and dry them with com oil filter tube should be cleaned with pressed air. Clean the rubber hose excessive sludge and cleaned out if a solvent at the proper mileage in connection with a low volatility necessary. In addition, the maze terval. petroleum base solvent and them dry screen in the intake manifold baffle POSITIVE CRANKCASE with compressed air. plate should be cleaned in solvent to VENTILATION SYSTEM VENT TUBE-TYPE CRANKCASE remove any accumulation of sludge At the recommended interval, re VENTILATION SYSTEM move the crankcase ventilation regu The road draft tube seldom re deposits. 1-41

Section Page

1 Description 1-41

2 Inlet Pipe, Muffler, and

Outlet Pipe Replacement. . 1-42 EXHAUST SYSTEM

489-B FIG. 1Exhaust System

DESCRIPTION

system is muffler A dual exhaust (Fig. 1) inlet pipe rear section, and inlet pipe front sections are a one- all Thunderbirds. The sys muffler outlet pipe used on for each exhaust piece assembly and are serviced as tem consists of a separate muffler, manifold. The right and left muffler such. 1-42 GROUP 1- ENGINE AND EXHAUST SYSTEM

INLET PIPE, MUFFLER, AND OUTLET PIPE REPLACEMENT

MUFFLER INLET PIPE 5. Position the clamp on the rear 1. Loosen the muffler inlet pipe section of the new inlet pipe. Connect rear then spread the The right and left muffler inlet pipe clamp, clamp the front and rear sections. Place a front sections are serviced as one and slide it off the muffler. new gasket on the exhaust manifolds. piece. 2. Remove the lower half of the 6. Position the inlet pipe assem 1. Loosen the muffler inlet pipe muffler rear clamp. Remove the muf front on the exhaust manifold studs bracket clamp bolt and slide the bly fler from the inlet pipe. clamp from the bracket. Disconnect and on the extension of the mufflers. 3. Position the new muffler and the inlet pipes at exhaust mani the 7. Connect the inlet pipe to the folds. outlet pipe assembly on the inlet pipe. exhaust manifolds and torque the Slide the muffler forward into the 2. Remove the retaining clamp nuts to specifications. inlet pipe until the slots in the muffler from the rear section of the inlet pipe. 8. Align the inlet pipe assembly extension are The Disconnect the rear bracket from the blocked. overlap and connect the brackets. rear section of the inlet pipe. must not be greater than IVa inches.

3. Remove the rear section of the 4. Align the muffler and outlet pipe MUFFLER AND OUTLET PIPE inlet pipe. assembly. Position the muffler inlet

4. Remove the inlet pipe front The procedure applies to either a pipe clamp and install the retaining section. right or left assembly. bolts. Install the muffler rear clamp. 1-43

SPECIFICATIONS

NOTE: All Specifications are given in inches unless otherwise noted.

GENERAL CYLINDER HEAD

ENGINE MODELS AND PISTON DISPLACEMENTCubic Inches GASKET SURFACE FLATNESS Thunderbird Special V-8 390 0.003 inch in any 6 inches or 0.006 inch overall

COMPRESSION RATIO VALVE GUIDE BORE STANDARD DIAMETER Intake and Exhaust 390 9.6:1 390 0.3728-0.3735

BRAKE HORSEPOWER @ Specified RPM VALVE SEAT WIDTH 390 300 @ 4600 Intake and Exhaust

390 .0.070-0.090 TORQUEFOOT-POUNDS @ Specified RPM

390 .427 @ 2800 VALVE SEAT ANGLE

Intake and Exhaust BORE AND STROKEInches 390

390 .4.05 x 3.78

VALVE SEAT RUNOUT COMPRESSION PRESSURESea Level CRANKING SPEED @ 390 Wear Limit 0.0025 390 180 20

COMBUSTION CHAMBER VOLUMECC TAXABLE HORSEPOWER 390 ,73.1-76.1 390 52.49

FIRING ORDER VALVE MECHANISM 390 1-5-4-2-6-3-7-8 VALVE CLEARANCE*

VALVE ARRANGEMENT Front to Rear 390 0.078-0.218

390 E-I-E-I-I-E-I-E ?Hydraulic valve lifters Clearance specified is obtained at the valve stem tip with the lifter collapsed. ENGINE IDLE RPM* Cruise-O-Matic (Drive Range) VALVE STEM DIAMETER 390 475-500 Standard

*If equipped with air conditioner, it should be run for Intake at least 20 minutes before setting idle speed. 390 0.3711-0.3718 Exhaust ENGINE IDLE MANIFOLD VACUUMMinimum Inches of Mercury 390 0.3693-0.3700 @ Specified Engine Neutral Idle rpmSEA LEVEL 390 18 0.003 Oversize Intake INITIAL IGNITION TIMING B.T.D.C. 390 0.3741-0.3748 390Cruise-O-Matic Exhaust 390 0.3723-0.3730 CAPACITY* CRANKCASE OIL 0.015 Oversize 390 5 quarts Intake ?Add one quart extra when changing oil filter. 390 0.3861-0 3868

OIL PRESSURE Psi hot @ 2000 rpm Exhaust

390 ,35-55 390 0 18

VALVE MECHANISM (Continued) CAMSHAFT AND TIMING CHAIN

0.030 Oversize CAMSHAFT JOURNAL STANDARD DIAMETER 2.1238-2.1248 Intake 390 390 0.4011-0.4018 CAMSHAFT JOURNAL RUNOUT Exhaust 390 0.005 390 0.3993-0.4000 CAMSHAFT JOURNAL TO BEARING CLEARANCE 0.001-0.003 VALVE STEM TO VALVE GUIDE CLEARANCE 390 Wear Limit 0.006 Intake TIMING CHAIN DEFLECTION-INCHES 390 0.0010-0.0024Wear Limit 0.0045 390 .0.5 Exhaust 390 0.0028-0.0042Wear Limit 0.0055 INTAKE AND EXHAUST CAMSHAFT LOBE LIFT 390 0.2316Wear Limit 0.2266

VALVE HEAD DIAMETER MAXIMUM ALLOWABLE LOBE LIFT LOSS Intake 390Intake and Exhaust 0.005 390 2.022-2.037 Exhaust 390 1.551-1.566 CAMSHAFT BEARINGS

VALVE FACE ANGLE INSIDE DIAMETER 390 390 2.1258-2.1268

INTAKE AND EXHAUST VALVE FACE RUNOUT LOCATION IN RELATION TO FRONT FACE OF BLOCK CAM 390 0.002Wear Limit 0.0025 BEARING BORE-NO. 1 BEARING ONLY-BELOW 390 0.005-0.020

VALVE SPRING APPROXIMATE FREE LENGTH

390 ,2.15 CRANKSHAFT VALVE SPRING MAXIMUM OUT-OF-SQUARE 390 Vie MAIN BEARING JOURNAL STANDARD DIAMETER 390 (Coded Red) 2.7488-2.7492 VALVE SPRING PRESSURE (LBS.) @ SPECIFIED LENGTH (Coded Blue) 2.7484-2.7488 390 74-84 @ 1.820 MAIN BEARING JOURNAL MAXIMUM RUNOUT Wear Limit 67 @ 1.820 390 0.002Wear Limit 0.003 190-208 (5 1.420

Wear Limit 171 @ 1.420 CONNECTING ROD AND MAIN BEARING JOURNALS MAXIMUM OUT-OF-ROUND VALVE SPRING ASSEMBLED HEIGHT 390 0.0004Wear Limit 0.0006 390 l13/l6-l27/32 CONNECTING ROD AND MAIN BEARING JOURNALS TAPER 0.0003 VALVE PUSH ROD RUNOUT 390 Wear Limit 0.001

390 .0.025 THRUST BEARING JOURNAL LENGTH 390 1.124-1.126 VALVE TAPPET STANDARD DIAMETER

390 .0.8740-0.8745 MAIN BEARING JOURNAL THRUST FACE RUNOUT 390 0.001 VALVE TAPPET TO TAPPET BORE CLEARANCE 390 0.0005-0.0020 CONNECTING ROD JOURNAL DIAMETER 390 (Coded Red) 2.4384-2.4388 (Coded 2.4380-2.4384 HYDRAULIC VALVE LIFTER LEAK DOWN RATE Blue) 10-80 390 Seconds CRANKSHAFT FREE END PLAY 390 0.004-0.008Wear Limit 0.012 ROCKER ARM TO ROCKER SHAFT CLEARANCE 390 0.003-0.005Wear Limit 0.006 ASSEMBLED FLYWHEEL CLUTCH FACE RUNOUT

390 .0.010

ROCKER ARM SHAFT OUTSIDE DIAMETER ASSEMBLED FLYWHEEL RUNOUT

390 .0.839-0.840 390 .0.007

ROCKER SHAFT BORE DIAMETER ASSEMBLED SPROCKET OR GEAR FACE RUNOUT 390 0.843-0.844 390 0.006 PART 1-3 -SPECIFICATIONS 1 45

MAIN BEARINGS PISTON PIN

JOURNAL CLEARANCE PISTON PIN DIAMETER

390 0.0006-0.0031Wear Limit 0.0039 Standard 390 0.9750-0.9753 0.001 Oversize 390 0.9760-0.9763 CONNECTING ROD 0.002 Oversize (Color Coded Yellow) 390 0.9770-0.9773

PISTON PIN BORE OR BUSHINGINSIDE DIAMETER Standard PISTON PIN LENGTH 390 0.9752-0.9755 390 3.156-3.170

PISTON PIN BUSHING MAXIMUM OUT-OF-ROUND PISTON PIN TO PISTON CLEARANCE 0.0001-0.0003 390 0.0004 390 Wear Limit 0.0008

PISTON PIN TO CONNECTING ROD BUSHING PISTON PIN BUSHING MAXIMUM TAPER CLEARANCE

390 .0.0003 390 0.0001-0.0005Wear Limit 0.001

BEARING BORE DIAMETER 390 (Coded Red) 2.5907-2.5911 (Coded Blue) 2.5911-2.5915 PISTON RINGS BEARING BORE MAXIMUM OUT-OF-ROUND AND

TAPER RING WIDTH

390 .0.0004 Upper Compression Ring 390 0.0774-0.0781 CONNECTING ROD CENTER-TO-CENTER LENGTH Lower Compression Ring 390 6.486-6.490 390 0.0930-0.0940

CONNECTING ROD SIDE CLEARANCE Maximum Twist Total Difference Upper Compression Ring 390 0.012 390 0.0024-0.0041Wear Limit 0.006 Bend Total Difference Maximum Lower Compression Ring 390 0.004 390 0.002-0.004Wear Limit 0.006 Oil Ring CONNECTING ROD ASSEMBLYAssembled to crankshaft 390 Snug Side Clearance 390 0.006-0.016Wear Limit 0.019 RING GAP WIDTH Compression Ring (Standard Bore Upper and Lower) 390 0.015-0.025 Oil Ring (Standard Bore)* CONNECTING ROD BEARINGS 390 0.015-0.055

TO CRANKSHAFT CLEARANCE BEARING ?Steel rail 390 0.0007-0.0028Wear Limit 0.0038

CYLINDER BLOCK

PISTON CYLINDER BORE DIAMETER (Standard, spread for 8 grades) 390 4.0500-4.0524 PISTON DIAMETER Red Color Code CYLINDER BORE MAXIMUM OUT-OF-ROUND 390 4.0477-4.0483 390 0.001Wear Limit 0.003 Blue Color Code 390 4.0489-4.0495 CYLINDER BORE TAPER Oversize 0.003 390 0.001Wear Limit 0.005 390 4.0501-4.0507

HEAD GASKET SURFACE FLATNESS CLEARANCE INCH FROM BOTTOM OF SKIRT PISTON TO BORE Va 390 0.003 inch in any 6 inches or 0.0017-0.0035 390 Wear Limit 0.006 0.006 inch overall 1-46 GROUP 1- ENGINE AND EXHAUST SYSTEM

OIL PUMP TORQUE LIMITS (ft-lbs) (Continued)

RELIEF VALVE SPRING TENSION-LBS. @ SPECIFIED LENGTH CYLINDER FRONT COVER 12-15 390 9.0-9.6 . . 1.53 inches 390

RELIEF VALVE CLEARANCE WATER OUTLET HOUSING

390 .0.0015-0.0029 390 12-15

DRIVE SHAFT TO HOUSING BEARING CLEARANCE WATER PUMP TO CYLINDER BLOCK OR FRONT COVER 390 0.0015-0.0029 390 23-28

ROTOR ASSEMBLY END CLEARANCE PUMP ASSEMBLED

390 0.0011-0.0041 CAMSHAFT SPROCKET TO CAMSHAFT

390 ,35-45 OUTER RACE TO HOUSINGRADIAL CLEARANCE 390 0.006-0.012 DAMPER OR PULLEY TO CRANKSHAFT

390 ,70-90 DRIVE SHAFT LENGTHROTOR ASSEMBLY FACE TO SHAFT END 390 2.24-2.26 CONNECTING ROD NUTS

390 .40-45

TORQUE LIMITS (ft-lbs) VALVE ROCKER ARM COVER

MAIN BEARING CAP BOLTS OILED THREADS 390 .4-7

390 ,95-105

VALVE ROCKER SHAFT SUPPORT TO CYLINDER HEAD CYLINDER HEAD BOLTS OILED THREADS 390 40-45

390 .80-90

OIL PICK-UP TUBE TO OIL PUMP OIL PAN TO CYLINDER BLOCK 390 12-15 390 .9-13

MANIFOLDS TO CYLINDER HEAD FUEL PUMP TO CYLINDER BLOCK OR CYLINDER FRONT Intake COVER

390 .32-35 390 23-28 Exhaust

390 .12-18 ENGINE SUPPORT

FLYWHEEL TO CRANKSHAFT Front Insulator to Engine

390 .75-85 390 35-40 Front Insulator to Intermediate Bracket OIL PUMP TO CYLINDER BLOCK 390 ...30-42

390 . 23-28 Intermediate Bracket to Cross Member 390 30-42 OIL PUMP COVER PLATE Support Retainer to Extension Housing 390 .6-9 390 25-30

OIL FILTER ANGLE ADAPTER TO CYLINDER BLOCK Support to End Bracket 390 12-15 390 30-42

STANDARD TORQUE LIMITS FOR VARIOUS SIZE BOLTS

CAUTION : Special torque limits listed in the preceding tables should be used in preference to these standard limits wherever they apply. Size (Inches) Ya-20 1/4-28 5^6-18 5^-24 H-16 %-24

Torque (Foot-Pounds) 6-9 6-9 12-15 15-18 23-28 30-35

Size (Inches) ^6-14 7^6-20 &-13 Vt-20 %-l% 54-18

Torque (Foot-Pounds) 45-50 50-60 60-70 70-80 85-95 130-145 GROUP 2

IGNITION SYSTEM

PAGE

PART 2-1 IGNITION SYSTEM MAINTENANCE 2-2

PART 2-2 DISTRIBUTOR 2-1

PA RT 2-3 SPECIFICATIONS 2- 16 FORM 7750-62 LITHO IN U.S.A.