1955 Ford Car Shop Manual

''.

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SHOP MANUAL

FORD DIVISION

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Copyright © 2009, Forel Publishing Company, LLC, Woodbridge, Virginia All Rights Reserved. No part of this book may be used or reproduced in any manner whatsoever without written permission of Forel Publishing Company, LLC. For information write to Forel Publishing Company, LLC, 3999 Peregrine Ridge Ct., Woodbridge, VA 22192

1955 Ford Car Shop Manual EAN: 978-1-60371-004-6 ISBN: 1-60371-004-3 Forel Publishing Company, LLC 3999 Peregrine Ridge Ct. Woodbridge, VA 22192 Email address: [email protected] Website: http://www.ForelPublishing.com

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

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

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

FOREWORD This

manual

contains

information for Cars

the

and

cleaning

and

for

inspecting,

various

these

Step-

Ford Thunderbird.

new

procedures

systems on

service

Ford Passenger

1955

all

by-step

placing the

complete

trouble

shooting, and

repairing,

alignment

and

In addition, given in this

re

window glass adjustments are part.

FOUR CHASSIS contains

Part

the

on

mation

here.

manual also contains maintenance and

lubrication data

as well

the

of

many

the

disassembly

cases,

a glance at

all

you

views

of

or

(frames,

In

Service

in this

arranged

in five

tell

will

Table

of

Contents

Under

each

on

chapter

in

major subjects

The section headings indicate the

the

manual

following

tenance

pages.

each part are given.

under each chapter

in the

proper

do

with

ONE POWER

the 6

and

title

chapter.

that

various systems operation.

and

PLANT has

8-cylinder are

engines and

to the

left-hand, name

of

name of

Thus, you

at

ELECTRICAL

TWO

systems and units

and all of

Overdrive

and

on

the

of

necessary for

Ford Cars.

the

and

odd-numbered

the

wherever

you

the

of

top

open

top on

the

the two

the

of each

the

gives

page

involved

section

of each

gives

page

even-numbered

the chapter,

and

the

page.

manual,

pages will

what subject matter

a

tell

is discussed

point.

This

accessories

BODIES

manual

has been

prepared

to

help

in

doing a good servicing job on Ford Keep your manual where it will be

readily

available

for

reference at all

times.

electrical

(except

sys

the

FORD

Fordomatic).

Part THREE formation

the

AND

(except the ignition

the

information,

specifications

servicing

exactly

that

you

systems.

ACCESSORIES covers all of

tem)

the

right-hand,

Cars. Part

a separate manual.

necessary to their

These include the fuel, ignition,

cooling

in

Throughout this manual, the top

glance at

Part

for the Fordomatic trans

lubrication

and

is

headings covering

subjects covered

brakes, wheels, linkages, etc.).

SPECIFICATIONS gives complete main

listed in the

main parts as

gear

MAINTENANCE AND

Part FIVE

the

the

procedures

contains all

material presented

part,

springs, suspension,

tires, steering gear, steering

many

how the

about

the running

and

axles, etc.)

mission are published

parts go together.

The

rear

(clutch,

order of

illustrations

to know

lines,

principal

assembly.

these

need

the

in the

various parts

their

you

of

service operations are given

here. Disassembled units show

tabulation

Detailed illustrations

service specifications. of

as a

train

power

entire

infor

transmissions, Overdrive, drive

conventional

This

including adjustment of doors, hoods, and fenders.

components,

and

parts, assemblies,

vehicles are presented

body

all

contains

in

maintenance and repair of

DIVISION

FORD MOTOR SERVICE

COMPANY

DEPARTMENT

TABLE OF CONTENTS Page

2

Foreword

Part

ONE POWER PLANT

CHAPTER

I GENERAL

ENGINE REPAIR Page

Page

Section 1 2 3 4 5 6

Trouble Shooting Engine Tune-Up Engine Removal and Installation Intake and Exhaust Manifolds Rocker Mechanism, Cylinder Head, Valves, Valve Lash Adjustment, and Valve Timing Camshaft Sprocket, Camshaft and Camshaft Bearings

CHAPTER Section 1 2

Engine Front

.

.

5 8 10 13

Section 7

14

9

Steady Rest

Manifolds Valves

30

4

Oil Pan and Oil Pump and Pressure Relief Valve

32

.

.

.

CHAPTER

(ECJ Manifolds Cylinder Heads and Valves Oil Pan and Oil Pump and Pressure R.elief Valve Crankshaft Damper, Pulley Cylinder Front Cover

5 6

III 8-CYLINDER

and

Section 1

2

IV

57

2 3

27

ENGINES

(EBP)

Crankshaft Damper, Cylinder Front Cover, and Oil Seal Camshaft Sprocket, Camshaft and Bearings Flywheel, Crankshaft, and Bearings Connecting Rods, Pistons, Pins, and Rings Exhaust System

...

33 34 36 37 39

Timing Chain, Sprockets, Camshaft, and

48

Bearings

Flywheel, Crankshaft

7

Connecting Rods, PistogjF, Pins,

8

Exhaust System

aftcl

51

Bearings^. and

Rings t

53 55

70 75 78

TWO ELECTRICAL I GENERATING

101

105

81

8

Fuel Pumps

92

9

Fuel Tanks

120 123

and

and

10

Fans

11

Water Pumps

12

Radiator, Hoses,

and

Vacuum Booster

Lines

94

Belts

95 .

and

Thermostats

96 98

AND ACCESSORIES SYSTEM AND BATTERY Section 3 4

II STARTING

Trouble Shooting Starter and Circuit

III LIGHTING

Carburetor Operation, Adjustment and Overhaul Four-Barrel

Section 7

64

Trouble Shooting

Generator Regulator

Battery

m H6

SYSTEM

Section 3

Starter Drive

128

SYSTEM, HORNS AND INSTRUMENTS

Trouble Shooting. Lighting System

Shooting

Exhaust System

6

61

....

Generator

Trouble Radio Heater

24

IGNITION, FUEL, AND COOLING SYSTEMS

130

133

CHAPTER Section 1

23

Cylinder Block, Pistons, Piston Rings, and Connecting Rods

Tappets

47

,

CHAPTER

Section 5

and

CHAPTER

2

and Oil Pump Pressure Relief Valve

Pan, Oil Filter,

272 (ECG and ECH) AND 292 INCH ENGINES

46

CHAPTER

Section 1

6 7 8 9

19

Connecting Rod Bearings

INTERCEPTOR) CUBIC

Ignition System Distributor Minor Repair and Adjustments Distributor Overhaul Carburetor Operation and Adjustments Single and Two-Barrel Carburetors Carburetor Overhaul 6-Cylinder Engine Carburetor Overhaul and Adjustment Two-Barrel Carburetors

Part

Section 1 2

Section 5

42 44

CHAPTER Section 1 2 3 4

10

29 and

Oil

and

28

Cylinder Heads

4

8

223 CUBIC INCH

3

Section 1 2 3

and

18

II 6-CYLINDER

Flywheel, Crankshaft, Main Bearings,

Section 3 4

Horns Instruments

133 139

IV ACCESSORIES

143 146 151

Section 4 5

Windshield Wiper Miscellaneous Accessories

154 155

Part THREE-BODIES CHAPTER I-BODY CONSTRUCTION AND MAINTENANCE Page

Page

Section 1

Construction Details

2

Undercoating

3

Body Alignment

the

and

Sealer Application.

CHAPTER

Section 1 2 3 4

Door

and

II

2

3

176 178 III REMOVABLE

Door Replacement and Alignment Door Locking Mechanism Luggage Compartment Door Replacement and Alignment Luggage Compartment Door Locking Mechanism

2

Power Windows Power Seats

3

Convertible

Quarter Panel Repair General Body Maintenance

167 169

AND WINDOW GLASS

Section 5 6 7

171 1 74

Assembly

Door Glass Quarter Glass Windshield and Rear Window

179

183 188

SHEET METAL ASSEMBLIES

Section 5

193 196 199

Grille

and

203

Hood

6

Hood Alignment

7

Thunderbird Grille

8

Front Fenders

and

Lock Adjustment

and

Hood

205 207 208

201

IV POWER

CHAPTER

Section 1

TRIM, UPHOLSTERY,

Headlining Replacement Window Regulators Door Ventilator

Section 4 5

157 163 166

.

Quarter Trim Panels

CHAPTER

Section 1

.

Body

INSTALLATIONS AND SPECIAL ITEMS Section 4 5

211

215 219

Top

Care of Country Squire Paneling Crown Victoria Transparent Top

224 225

Part FOUR-CHASSIS CHAPTER

Section 1 2

Trouble Clutch

I

3-SPEED STANDARD TRANSMISSION, AND GEAR SHIFT LINKAGE

CLUTCH,

CHAPTER

Section 1 2

Overdrive Overdrive

Operating Operating

Principles Principles

II OVERDRIVE

Mechanical. Electrical

CHAPTER Section 1 2

.

III REAR

Trouble Shooting Banjo Housing Hypoid Rear Axle

IV RUNNING

267 269 271 273 277

CHAPTER Section 1 2

Construction Inspection

Operation Trouble Shooting

Power Brakes

3 4 5 6 7

Steering

Engines Clutch and Transmission

Integral Housing Hypoid Rear Axle Drive Lines

260 265

GEAR Shock Absorbers Steering Gear Steering Linkage Wheels and Tires Hubs and Bearings

278 279 284 286 289

Overhaul

302

Section 5 6

7

Brake Assemblies

325

Brake Drums

326

,

.

Parking Brakes

.

326

AND SPECIFICATIONS

I MAINTENANCE

329

Preventive Maintenance

Wheels and Tires Brakes Wheel Alignment and Rear Axle Frame and Springs

243 245

VI BRAKES

FIVE MAINTENANCE

CHAPTER Section 1 2

Overhaul

STEERING

Section 3

316 317 319 322

CHAPTER Section 1

Trouble Shooting

299

Trouble Shooting Adjustments Hydraulic System

Part

10

292

CHAPTER Section 1 2 3 4

Section 6 7 8 9

V POWER

and

and

Section 3 4

252

Rear Springs

233 238

AXLES AND DRIVE LINES

252

Trouble Shooting Wheel Alignment Frames Front Suspension

3 -Speed Standard Transmission Gear Shift Linkage

TRANSMISSION

Section 3 4

240 242

.

CHAPTER Section 1 2 3 4 5

Section 3 4

229 230

Shooting

Section 2

Lubrication

331

II SPECIFICATIONS

334 334 335 335 336 336 338

Section 8 9 10 11 12

13 14

Cooling Fuel System Generating System Starting System

Ignition Lights and Horns Tools and Equipment

338 339 339 339 340 340

340

Part ONE

POWER PLANT Chapter

i

General Engine Repair Section

Page

1. 2.

Trouble Shooting Engine Tune Up

3.

Engine Removal

4.

Intake

5.

Rocker

and

5 8 10

Installation

and

13

Exhaust Manifolds

Mechanism, Cylinder Head, Valves, Valve Lash Adjustment, Camshaft Sprocket, Camshaft, and Camshaft Bearings Flywheel, Crankshaft, Main Bearings, and Connecting Rod Bearings Oil Pan, Oil Filter, and Oil Pump and Pressure Relief Valve Cylinder Block, Pistons, Piston Rings, and Connecting Rods

6. 7. 8. 9. 10.

to

cedures,

applicable

For the

removal and

refer to the chapter

Inasmuch

all

are given

engines,

installation

Trouble shooting is the cedure, in

in

be borne in mind,

a wet or cold

when

ment of one

part,

of en

definite

pro

and eliminate

such as : an

or

in this

It

the

should

empty gas tank,

disconnected wiring,

or

any

to forces

on

vehicle

be attributed to the

that tend to retard

retarding force is

example of a

cause the engine

to

work

harder

its

motion.

dragging brakes and results

in

engine

which

poor en

gine performance.

Engine

Perform the

depends

Check

(a)

they do

it,

(b)

corroded

the

on proper

fuel distribu

with

instructions

conditions

and

discussed

on what

regain

of exhaust gases.

good

under

to do to

engine

or

turns it

over

correct

the

performance.

ENGINE WILL NOT CRANK. If the

turn the engine over,

the head

starter

does

too slowly to

further,

horn

the

as necessary.

at

the starter, relay,

or replace

them

Check

and make

ing

can

the

remove

(2) The

be

or

are not at

engaging the

starter

However,

engine.

Starter Drive. If the

fault,

the trouble is prob

drive. If the

flywheel,

by loosening

drive. If the

and make

ENGINE

starter

remove

most probable cause of

with

does

is

run

the starter

the

the starter

starter

the necessary

CRANKS,

(Refer

necessary.

drive may lock up

corrected

starter

it

as necessary.

the necessary repairs to the starter

cases, the

This

Starter

the

starter or starter

not

and

Relay Circuit. The relay contact become so badly burned that they will

from cranking the other wiring may be at fault. Repair as to Electrical System Section. )

ably in the

battery,

or

the

prevent the starter

(d)

lights. If

or

Battery Cables. Check for loose

Clean, tighten,

Check

Try

properly, test the battery. Recharge

connections

rare

symptoms are

shoot

actual repair work.

Battery.

or check

Check

to the cylinders, and unobstructed flow

not

it,

replace

ning, but

ings below

the

not operate

tion, correctly timed ignition, normal and uniform com pression, properly regulated flow of the fuel-air mixture Engine trouble

parts; therefore,

of

the trouble is determined:

cause of

above components

performance

combination

likely to be in the battery or the starter. following checks in the order listed, until the

surfaces seldom

the

a

start, the fault is

(c)

engine performance can

or

section, and precedes the

ground.

section.

Engine. Poor

attributed

TROUBLE SHOOTING

item that may cause a temporary defect. The various factors affecting power plant operation

are outlined

ing

be

Many defects in engine directly to a maladjust

first.

presented

tune-up logically follows the trouble

general engine

trouble shooting, to first look for

engine, loose

is

components,

engine.

application of a

trouble

section

shooting

can

other such

(1)

24

performance

a particular system or unit.

obvious causes of

above

23

work, the trouble

repair

logical sequence, to locate

a

cause of trouble

An

19

chapter.

the basic cause

of

any

in this

of engine

covering the specific

determination

as a

and repair pro

1.

or

18

27

gine trouble should precede

a.

14

Timing

Exhaust System

Trouble shooting, tune-up, inspection,

the

Valve

and

drive. In flywheel.

and releas

not

operate,

repairs.

BUT WILL NOT START. this trouble is a

defect in the

I General

Chapter ignition tion

The

system.

the fuel

of

plug,

insert

and

fault. Remove

obtained,

the

turning

steps

the fuel

check

hold the

engine over,

ignition

No Spark. If

(a)

from

one wire

If

good

a

it

the

spark spark

follow the

no spark was obtained, cause and make

necessary

(1)

Pull the

from the top

coil wire

and with

the ignition

if there is

a spark at

the

on and

this

turning

engine

If there is

point.

If there

and

distributor

the

points

are

If there

tor cap and

if the

necessary.

If there is

the

the

for

the

spark at

"jumper"

a

circuit of

the

points.

points.

If

a spark

exists,

if

replace

"jumper"

between

distributor, a

spark,

then

replace

no

spark,

terminals

coil

spark now exists

between the

the coil, then

the

check

at

battery

spark at

switch or

is defective

and must

wiring

be

a

showed

(

line

order

1)

weak

spark,

perform

test at the

the

spark

following

plug

checks

in

listed:

Battery

may be

weak.

Test,

at

of

spurt

accelerator

this point, the

pump engine

If fuel line

throat, loosen the fuel pump to fuel tank the fuel pump. Remove the fuel tank filler cap.

at

freely,

runs out

by

out

the

air pressure

Check

NOTE:

the

line is

If not, blow the

clean.

from the fuel pump

flexible

end.

line for

gas

collapsed

a

condition.

If the fault has

(4)

pump pressure, then

not

been found,

repair or replace

check

the fuel

the fuel pump

or

carburetor.

RUNNING. The is the fuel

most probable cause of

system.

recharge, or

replace,

The ignition

this

system

malfunction

sometimes

can

trouble, but it is usually after the engine has run for some time and is at operating temperature. In either cause

case,

check

the fuel system first.

(a) Check

(b) Try constant

(c) to the

fuel supply

the

to

start

the

foot throttle,

the choke

at

vehicle.

adjust

the

gas

If it

the idle

tank. operate with

will

speed

and

check

adjustment.

If it the

foot throttle,

will not operate with constant

air

cleaner,

carburetor.

and check

This is done

by

if fuel is getting looking down the car

to

see

buretor while operating the throttle. If gasoline is observed spurting from the accelerator pump discharge nozzle, the

(d) spark

from the

emitted

a

carburetor

engine was either

Weak Spark. If the

working the throttle

while

If there is fuel

nozzle.

re

paired or replaced.

(b)

be

if it is

cleaner, and look

air

Each time the throttle is worked,

should

see

this.

is probably flooded or there is water in the fuel system. (3) If no accelerator pump discharge is observed in

remove

"jumper"

a

coil

as

they break is defective. If

If there is

a

an

and

coil

the

wire.

coil

distribu

exists, the ignition

to the

switch

the

or

between the two primary

post of

coil

there is

and

Adjust

If there is

points.

If not, install

battery

from the

the

gasoline

Remove the

throat

carburetor

hand.'

by

carburetor.

doing

not

(3) ENGINE STARTS BUT FAILS TO KEEP

remove the

coil and

Replace the

recheck.

(2),

the points,

to distributor primary

coil

and the

the

post of

tower

necessary.

the points; install a

no spark at

the distributor

a weak spark

"breaking"

points.

spark at

properly, the secondary there is

in

points are

to

coil

between the

wire

if

replace

was no spark

see

the

Test the condenser, the points. If a weak spark

and adjust

charge

and

plug

arcing.

probably

electrical

install

reaching the

the

defective.

not

clean

If

and check again.

persists, test the coil and

(3)

(1)

the high tension

if necessary

replace

in

was no spark

socket or replace

the

spark

the fuel tank. Do

at

any other fuel system checks before If there is fuel in the tank, check to

or replace as necessary.

(2)

check

or

see

over,

spark, the

a good

trouble lies in the distributor cap, rotor, wires. See that they are clean, dry, and

Repair

distributor,

the

of

observed, check

a good spark was

Check the fuel supply

discharge

repairs or replacements.

necessary.

attempt

(2)

be

should

coil

follows:

system as

down the

system.

below to determine the

(1)

is is

if

Good Spark. If

the fuel

persists, the

spark

weak

and replaced

(c)

on and

end of

the block. If no

system.

tested

a spark

a piece of proper sized metal rod so

check the

obtained,

determine

If the

(4)

a malfunc

simple check will

approximately %G-inch from

rod

is

cause

from the insulator. With the ignition

will protrude

the starter

A

system.

which system is at

likely

next most

Engine Repair

If

the fuel system has

pump discharge is

water

in it.

observed

in

throat, loosen the fuel pump to fuel tank pump. Remove the fuel tank filler cap.

at

the fuel

If fuel

runs out

line

or

no accelerator

the carburetor

line

flooded

freely,

the line is

out with air pressure

clear.

If not, blow the

from the fuel pump

end.

the battery.

Remove the distributor cap,

(2) tion

the

of

necessary.

that the

points.

Severly

voltage

Adjust,

clean,

pitted points are

regulator

is

and check or

the

them

replace

usually

improperly

an

condi

the

and

Check the

plug

fully

wires.

seated

which

condition of

The

wires must

con

the rotor, distributor cap,

be clean, dry,

in the terminals. Always

is damaged

or

has

corroded

and must

replace

terminals.

any

the

flexible

gas

line for

a

collapsed

condition.

denser is faulty.

(3)

Check

as

indication

set or

NOTE:

be

wire

(e) check

If the

cause of

the trouble has not been

the fuel pump pressure, and repair

found,

or replace

the

fuel pump or carburetor. (f) If the fuel system is operating correctly and the engine still stalls, it may be due to the coil or condenser

breaking

down

under

replace as necessary.

operating temperature. Check

and

1Trouble

Section

(4) ENGINE CONTINUALLY MISSES When the

AT IDLE.

engine

continually misses on the same cylinders, the fault generally lies in the ignition system.

Isolate

(a)

the miss

time from the

at a

inspect,

by

one spark

pulling

cable

plug

Remove the plugs, then clean, them. Replace those that are badly

plugs.

and adjust

fouled. Check the

spark

wires

plug

Replace

and corrosion.

for

signs of

the

If

then

clean

made.

and

Make

to determine if

check

intake

compression and

manifold passages are satisfactory.

(5)

by

caused

in

the

ture setting,

After preliminary checks are made, check the com pression. This should quickly indicate whether the in ternal

components are

choke operation,

idle

mix

(b) The

ignition system, starting with the spark plugs, if the carburetor adjustment does not eliminate the

The

(c)

is

miss

Valve

(d)

lines

at all

fittings

and

Make any necessary

still present.

limits,

initial timing

including

(c)

If the

the

check

distributor

and

check

and

fuel pump

If the

(d)

the ignition

and

compression

are

system

including

the fuel system,

carburetion

pressure.

timing. Repair

be

check of mechanical

exists, a

problem still

Check the

made.

valve

lash, lift,

and

or replace as necessary.

The fuel

connecting lines. Dirt

and

carburetor,

is usually

However,

sumption. should

be

foreign

problems, and

system

as clean as possible.

responsible

for

following

the

and other

CONSUMPTION.

FUEL

EXCESSIVE

(1)

carburetion

test if

be kept

all components should

repairs.

operation and make a compression

fuel

material are a major source of

tank, fuel pump,

the fuel

system consists of

repairs.

lines for leaks

vacuum

properly.

operating

compression checks within

ignition system,

float level.

trouble. Make necessary

remains open.

b. Fuel System.

sequence :

and

the way

opens all

things. Check

a combination of

following (a) Carburetor, including

checks should

(a)

components must

ENGINE MISSES ERRATICALLY AT IDLE.

This may be

that the throttle

certain

that the choke

satisfactory,

the above corrects the condition,

none of

compression

if the

be

preliminary

some

operation.

Remove the distributor cap and rotor, inspect them. Replace if necessary.

(d)

deteriora

as necessary.

(c) and

However,

compression.

(b) If the

(b) tion

Shooting

excessive

Faulty

fuel

preliminary

checks

Check for fuel leaks in the system,

made.

con

check

miss persists.

ENGINE MISFIRES OR HESITATES ON AC

(6)

be

of

faults in the ignition

caused

checks

(a) (b) valve.

(c)

in the

following

dragging. Then

(a) Verify in the tion

Check the

operation

adjust

the

the

and make certain

the

if the brakes

are

see

carburetor.

test

complaint with

Show the

vehicle.

Check the If the

equipment

installed

how improper

customer

opera

is

the

of

of

the

(b)

the exhaust thermostat

the intake

carburetor

heat

riser

passage

may

manifold

burned off, the

not

fuel

vehicle will affect

consumption.

accelerator pump.

or replace as necessary.

paint on

paint

the

remove

If sticking, free up

may

not

be vaporizing

If test the

is usually usually the

shows

consumption

carburetor and rebuild. of

combination

a

not advisable

Time

carburetor.

buretor

fuel

to

be

will

Since poor

carburetion

internal malfunctions, it is to

try

to be excessive,

repair

saved

only

by

one system

in

car

a complete

overhaul.

gasoline properly.

(d ) Remove the Replace any

plugs

(e) Remove gap, distributor and

Perform the

system.

operation of

obstructed and

the

and

adjustment,

sequence given:

Check the

passage.

be

the exhaust

by

is usually a combina fuel system, but also can

malfunction

and

linkage is free. Check to

accelerator

CELERATION. This tion

choke operation

spark

that

plugs,

are

defective

shaft

clearance,

(f)

if

Make

check

the

repairs

point

lobes,

replacements.

or

signs of

Replace

faulty

Check fuel pump

and

problem check

the

still

persists, take

valve

rates and assembled

action.

compression

Check the

held

height. Repair

Lack

DOES

of

power

NOT

or replace as

DEVELOP

is usually

caused

FULL

by

by

open

steps

float. Check the

be

gaskets or

foreign

in

visual

casting

flooding

material.

stops,

If the

below:

air cleaner and check choke operation.

and

the

condition

the

of

the needle and

condition of

necessary.

Check fuel pump

and should

leaking

bowl. If the

Check the float level

Replace if

(c)

carburetor

Remove the

was

pressure.

forcing

fuel

If the past

pressure

is

ex

the float needle

rebuilt or replaced.

c.

Cooling The cooling

ENGINE

POWER.

was

for

a

valve

necessary.

(7)

the

persists, follow the

carburetor

pressure and adjust carburetor

carburetor

cessive, the pump

If the

readings

spring

flooding

(a ) (b)

the

Tap

needle

seat.

float level.

(h)

the

deterioration,

units.

(g)

defects.

necessary.

a coil and condenser check.

CARBURETOR FLOODS. Make

spection of

lead fouled.

condition of cam

Check the high tension wiring for and replace

or

(2)

clean and re-gap.

the distributor cap and

Make necessary

points.

inspect,

poor

regulate engine

short engine

System. system

is thermostatically controlled to

operating temperature

warm-up

period.

and provide

for

a

8

Chapter

(1) ENGINE OVERHEATS. Usually,

heating

is the

insufficient

result of

coolant supply.

If the supply is low,

system,

cause

of

water

heat

for leaks in the cooling

Check the

(g)

dirt,

the

etc.) Clean if

(d) Using gauge

fins for

radiator

proper

tension

and

(bugs,

obstructions

a

NOTE: Inaccurate

check

the

by

between the head casting and unit element. Repair or re~

2.

tune-up

Any make

the

the life

type

the wiring,

hoses,

services.

satisfactory performance,

an engine

and

performed periodically.

test

outlined

are

hose,

make

inspection

of

hose, heater

system

cooling

the defective

A reading

tune-up

the

following

operations:

(1) INSPECT IGNITION WIRES, BATTERY CABLES, AND CHECK CONDITION OF THE BAT TERY. Inspect

ignition

all

cables

for

sure

that the

spark

damaged

worn or

plug

wires are

firmly

in the distributor cap and that the terminals terminal sockets are free from corrosion. seated

head

or

clean, file the gap.

the

water

nections

battery

for

case

level in the battery. Inspect

for corrosion,

and clean

cable connectors with grease

then tighten the

(2) the

TEST

and

to

CYLINDER

Turn the ignition the throttle to

Using

inder.

further corrosion,

reached.

leave it

open

to

compression pounds.

cylinders should

be tested the

operate

timing light

plugs

sive

all

cylinders

Record the

metal

cannot

(5)

be

should

compression

be

the

and make

transfer,

the

porcelain

wipe

or

adjust spark

approved

an

that do

the

spark

plug tester.

or chipped

porcelain,

not check satisfac

tighten

plugs and

spark

idle fuel

the necessary

line

vacuum

idle

idle

IDLE.

engine

with

adjustments.

after

points

Con

for pits,

exces which

points

application of a point

VACUUM Check

the

a

completing the

burns. Replace

by light

up

Start the

Check the timing

speed.

and

line be

vacuum

file.

AND

ADJUST

engine

manifold

speed.

is lower than specified, check for leakage lines and intake manifold. Check the

adjustment.

is

still

below

normal or

is erratic, it is

an

bad rings, sticky valves, weak valve springs, gaskets. If this condition exists, it should be

leaky

reported

carburetor.

ENGINE

vacuum

indication

at

the rings,

SPARK

and

Inspect the distributor

vacuum

of

to the

Set the

of each cyl

flat,

tips

and

idle

at

vacuum

If the

or

at

INSTALL

plugs,

that have broken

cleaned

for

uniform

it

CHECK

If the at

indi

cylinder.

AND

spark

electrodes,

CARBURETOR

assure accurate readings.

of

in

the distributor

carburetor

same

plugs

distributor

tween the

Set

tester, test the compression Crank the engine for at least four com

All

Re

accuracy.

above normal

BREAKER POINTS. Disconnect the

Operate

all spark plugs.

and

sending

CHECK AND ADJUST TIMING AND INSPECT

vacuum at

operating temperature is

Remove

gauge and

not

gasket.

the tester. Install the

on

(4)

Brush the

COMPRESSION.

switch off.

number of strokes

10

necessary.

cable con

a compression

pression strokes.

within

leaks. Check

battery

retard

wide open position

of each cylinder.

The

to

if

and

does

specifications.

nect

connectors securely.

engine until normal

the test.

cracks

by

caused

still

indicates leakage

normal

electrode

Test the

adjustments.

Inspect the

the

than 10 pounds

PLUGS. Sandblast the

and

insulation. Make

engine

check

(3) CLEAN, ADJUST,

torily

consists of

being

lead deposits in the

A reading below

Replace any

etc.

minor

or replace

unit.

of more

cates carbon or

to

As

procedures.

visual

a

used

Minor Tune-Up. A

defective

a

the wrong heat range.

of

thermometer in radiator, for

with a

valves,

may be

in the checking

performed,

vacuum

equipment

or

operating temperature,

reach

badly burned a.

for

Repair

or water passage obstruction.

Check the thermostat first. If the

should

inspection

engine

of

and check

ENGINE TUNE-UP

vehicle, it

automotive

maintenance

be

the tests

checks

an

of

maintain

should

pump

ATING TEMPERATURE. Generally, this is

place

to

flow. Flush if

proper

ENGINE FAILS TO REACH NORMAL OPER

(2)

place as necessary.

However,

water

the thermostat sticking

readings are sometimes caused

clearance

regular

necessary.

as necessary.

unit,

receive

if

and adjust

for

radiator

Remove the

(h)

the temperature sending

During

the wrong heat range, replace

clogged.

thermometer in the radiator, reading for accuracy.

insufficient

or of

necessary.

pump belt for

impeller

(c) Inspect

If defective

range.

and

operation

proper

the thermostat.

if loose.

adjust

Check the thermostat for

(f ) Check the ignition timing

make repairs as necessary.

Check the

(b)

check

Check

Engine Repair

(e)

over

engine

the coolant level first. Make certain that the trouble is not anti-freeze evaporation.

(a)

I General

customer.

carburetor

idle

speed

adjustment to obtain

the highest manifold

Reset the idle

speed

if

to

the

vacuum

required.

specifications.

Set the

smoothest engine

and/or

engine

idle

r.p.m.

2 Engine

Section

(6) CLEAN

AIR

BOWL. Clean the

(dry-type). If the

CLEANER AND FUEL PUMP

air

and

cleaner,

is the

air cleaner

to the indicated level

with

engine

the

re-oil oil

oil

element

bath-type, the

of

refill

specified

Remove

and clean

filter. Install the

the fuel pump bowl. Install

sediment

bowl

a new

major

tune-up

and

Remove the terminals

checking the

cylinder com engine

valves.

from the battery. Clean the

cables

battery battery case

Inspect the

and cable connectors.

leaks. Fill to the

level. Re

proper water

deteriorated connectors, and cables that are shorted have worn insulation. Brush the cable connectors with to retard

Connect the

corrosion.

to the

cables

battery.

it, if

and

output,

generator.

the

regulator.

Repair

or replace

the

Adjust

or

procedure given under,

regulator

"a. Minor

generator

replace

if

faulty

a

and exhaust manifold

Follow the

Tune-Up."

bolts

and nuts

to 23-28

foot-pounds torque.

PLUGS. Sandblast the clean, file the gap.

Test the

electrode

in

plugs

spark

INSTALL

SPARK

the

porcelain

plugs,

flat,

tips

and

approved

an

wipe

the

adjust

spark

spark

plug tester.

Replace any plugs that have broken or chipped porcelain, badly burned electrodes, or that do not check satisfac

torily

the tester. Install the

on

them to the

(6)

specified

TEST

Set the distributor or

point

check

correct at or

necessary with

the

the

parts.

distributor

(7)

for

wires

the

the

engine).

engine).

dwell. The

If the dwell

point and

Lubricate the distributor

and

dwell

angle

is

not

cam

is

corrosion.

housing

sockets

cap is

or

in the

at

machine.

should

idle speed, the

Visually

amps.

be

inspect

and poor connections.

plug

wire will

rotor or

external

jump cap,

primary at

housing

inch

gap.

plugs, trouble

internally in

the

circuit.

some

plug wires, the trouble is in the

in the

%6"

a

at all spark

is unsatisfactory

not seated

socket,

or

but

not all

wire

itself,

of

the

the distributor

shorted.

CHECK AND ADJUST VALVE LASH. Check

(11)

the

and adjust

valve

lash

after

the

engine

is thoroughly

warmed up.

TEST FUEL PUMP PRESSURE. Check the

(12)

fuel pump pressure. The p.s.i. at 900 r.p.m.

cam

lightly

cracks

or

other

be free from

be

pressure should

within

(13) TEST FUEL PUMP VACUUM. Check pump

vacuum.

If the

if the

or

is stopped,

vacuum

vacuum

drops rapidly

repair or replace

Remove

and

filter. Install the

when

sediment

bowl

level,

the

of

engine

THE FUEL PUMP.

Install

a

new

and a new gasket.

(15) CLEAN CARBURETOR. fuel bowl. Set the float

the fuel

the pump.

the fuel pump bowl.

clean

4.0-5.0

is below 10.5 inches

(14) INSPECT AND CLEAN

Clean the

and check

carburetor

the accelerator

operation.

(16) CLEAN AIR CLEANER. Clean the air cleaner, oil the element (dry-type), and install. If the air cleaner is the oil bath-type, fill to the indicated level with engine oil.

TEST ENGINE VACUUM. Check the

(17)

idle

manifold vacuum at

If the at

the

buretor idle If the an

be

intake

manifold.

for leakage

Check the

car

is

below

normal or is erratic, it is bad rings, sticky valves, weak valve leaking gaskets. If this condition exists, it

vacuum

or

and

check

adjustment.

indication

should

lines

engine

speed.

is lower than specified,

vacuum

vacuum

springs,

should

be 2.75-3.0

test

stopped

operating

is unsatisfactory

spark

spark

is

engine

insulation

faulty

spark

If the

Replace the

lubricant.

CAP. Inspect the distributor cap for

should

each spark

distributor, the

engine

in the coil, condenser,

exists

After

CLEAN AND INSPECT THE DISTRIBUTOR

damage. Terminal

from

If the

26-28 Vi

gap, the distributor

assembly is damaged.

cam

distributor

0.014-0.016 inch (8-cylin

point

completing

advance.

TEST SPARK INTENSITY. Determine if the

(10) spark

the

with

tighten

replacements as required.

at

specified point

point

and

distributor test stand,

or

gap

Test

be 35-38 degrees (6-cylinder engine),

degrees (8-cylinder

worn

plugs,

0.024-0.026 inch (6-cylinder

setting the gap, should

the

pump

DISTRIBUTOR.

adjustments, repairs,

der engine)

spark

torque.

vacuum advance on a suitable

make

draw

mercury,

AND

(5) CLEAN, ADJUST,

after

amperage with a suitable

With the

amps.

amperage

CHECK MANIFOLD BOLT TORQUE. Tighten

the intake

line

for ignition

and check

adjustments.

necessary

vacuum

with

necessary.

(3) TEST CYLINDER COMPRESSION.

(4)

5-5.5

necessary, to insure dependa

Check the charging circuit, the

service.

the

the

start

carburetor,

Check the timing

speed.

make

and

draw

amperage

wire

TEST CHARGING SYSTEM. Test the battery,

and recharge or replace

ble

idle

at

and

vacuum

(9 ) CHECK IGNITION PRIMARY CIRCUIT. Check

place

(2)

timing light

the adjustment,

AND INSPECT BATTERY CABLES.

cracks and

grease

a

The

consists of

adjusting the

(1) CLEAN

or

it

engine and operate

the primary circuit

pression, the ignition system, the fuel system, the

for

IGNITION. Before connecting the

line between the distributor

and a new gasket.

b. Major Tune-Up.

vacuum,

(8) TIME

Connect the distributor

viscosity.

A

Tune-Up

still

of

reported

to the

customer.

(18) ADJUST CARBURETOR IDLE. Connect vacuum

with

a

gauge,

and

set

a

the idle speed to specifications

tachometer installed

on

the engine.

Set the idle

10

Chapter

I General

fuel adjustment to obtain the smoothest engine idle at the highest manifold vacuum and/or engine r.p.m. Reset the idle

if

speed

required.

(19) ROAD TEST.

procedures

a.

final

vehicle as a

are

for the

given

conventional

following

passenger cars. vehicles

noted when

The

Differences in the

they

with

with

8

an

all

remove or

install the

If the

is

vehicle

equipped

the

bushing. Disconnect the

jack,

a

bar

equalizer

and

upper

housing

spring.

support

support

linkage

accelerator

bolts. Remove the flywheel flywheel

(a)

release

then remove the

fold bellcrank. Remove the two

with

at

the

flywheel

and

mani

housing the

support

cover,

then remove the remaining

Steps Peculiar To Fordomatic. Disconnect the

(b)

transmission throttle linkage at the

the linkage to the dash

remove

the two

cross

shaft,

and

Remove the idler

panel.

bracket. Fold back the floor mat, plugs, then

the two

remove

top

converter

tie

arm

rubber

housing

to

bolts. Jack up the front of the vehicle and position safety stands. Support the transmission with a jack, then engine

remove the

converter

remaining

Remove the

converter

remove

the

six

Remove

the

dip

stick

to

tube

cylinder

block,

to

engine

access

bolts.

cover, then

flywheel assembly bolts.

linkage

control

then

remove

the

splash shield

oil

system

cooling

and

the

Remove the heater

crankcase.

vehicles

remove

On remove

an

8-cylinder

engine,

the heater inlet duct. vehicles

Disconnect the Attach the

Remove the

the

upper

radiator.

a

6-cylinder

engine,

motor.

and

Remove

air

starter.

the

engine.

horn

closed.

rear of

the carburetor.

inlet

muffler

pipes

lift bracket

engine

right and

Loosen the two

Disconnect

the

at

exhaust

left front

engine

lower

Disconnect the

battery

hoses,

then

ground cable

2).

or

splash aprons.

front steady

vehicle and position

the

engine support at

safety

to frame bolts.

rest

stands.

engine.

On 6-cylinder engines, remove the left-hand mounting bolts at the insulator, and the right-hand mounting nuts at

the

engine.

Raise the

slightly, then carefully pull the engine

engine

from the transmission.

the

against

Do

engine on

a

lifting bracket or sling. (2) INSTALLATION. and

(d). If the

matic, follow steps

let the

engine

lift bracket

work

of

swing

If

the

stand.

or

vehicle

is

is

engine

equipped

and

steps

Fordo

equipped with

(d).

sling, then remove the

Lower the

appro

transmission, follow

vehicle

(a), (c),

using the

Engine Installation. Install the

(a)

out

engine

4). Remove the

or

standard or overdrive

(a), (b),

engine

not

work stand

(fig. 3

engine mount

with a

lift the

grille.

Install the priate

Carefully

compartment.

engine

appropriate engine

from

carefully into the

engine

engine compartment.

pump to

oil pan

line

clears

Start the transmission

left-hand

the

main

drive

start

the

engine until

gear

oil

engine support.

into the

the converter

clutch

pilot

into

the crankshaft.

On

necessary to with

radiator

sling (fig. 1

or

On 8-cylinder engines, remove the left-hand engine support. Remove the cap screws from the right-hand

NOTE:

with

equipped

the heater blower

Remove the remove

with

equipped

coil.

linkage.

disc. On Fordomatic units,

hoses.

On

the

cleaner, then tape the

On 8-cylinder engines, lower the

filter.

Engine Removal. Remove the hood. Drain the

(c)

from the

choke cable at

accelerator

at

then remove the

starter

ground cable

air

tem

hose,

wire, and the oil pressure sending

the

starter cable at

the

assembly.

Remove the transmission

from the

housing

housing lower

converter

the fuel

at

vacuum

Disconnect the primary wire

Disconnect the the

the flex fuel line

windshield wiper

unit

sending

Disconnect the

the

bolts.

housing

the

and

Remove the fan.

unit wire.

a

Overdrive

or

clutch

retaining the

housing,

block,

cylinder

Raise the

screws

to the flywheel

transmission

steps

with

(c).

Transmission. Disconnect Remove the

the

at

Fordomatic, follow

Steps Peculiar To Standard

(a)

required

manifold.

equipped with

is

when

engine

attached.

(c). If the

and

are

toler

compartment

transmission, follow

(b)

engine

only, without

engine

standard or overdrive

steps

conventional

6-cylinder

or

Engine

it impractical to

vehicle

Recommend any additional service the vehicle is delivered to the owner.

perature

procedures peculiar to

for the

attached.

(1) REMOVAL.

perform optional

Remove the

procedures given are

the transmission

the

any

Disconnect the

exist.

the transmission ances make

apply to

procedures

equipped

the transmission, axle,

ance of

pump.

Conventional Passenger Car. The

Also, notice brakes, and

work performed.

ENGINE REMOVAL AND INSTALLATION

Thunderbird.

passenger car and the

the

check on

accessories.

Road test the

3. Separate

Engine Repair

shaft

relation will

"hangs

standard adjust

or

the

overdrive

position

to the engine

not

enter

the

if

units, it may

of the transmission

the transmission

clutch

be

disc.

If

the

input

engine

up"

after

the shaft enters, turn the

crank-

Section

3 Engine

Removal

11

Installation

and

Too/-T52L-6000-C

\ToolT54T6005-D (SPLINED SHAFT) I r00/ 7547 6Q05-E (KEYED SHAFT) 3 Engine Mounf 8-Cylinder

Fig.

mounting two 6286

nuts

bolts to

and

front steady

engine

shaft

the

Bracket 6-Cylinder

Engine

left

slowly (with the transmission in gear)

shaft

Make

splines

sure

8-cylinder

with

mesh

the studs

engines

on

are

the

clutch

the manifolds

aligned

with

of

the

disc

until

engage

the holes

on

with

block. Install the two cap

Tighten

bolts to

both the 6

and

holes in the

the

insulator

support

engine.

inlet pipes, and the dowels in the block engage the holes in the clutch housing (on Fordomatic units the must

frame bolts to

align

the holes in the

converter

housing).

the

screws on

right side of

the two engine front steady rest to

specifications.

Connect the

Install the

manifold

the starter, then matic).

right

and

the

frame

left front

connect

Connect the

to the the

muffler

inlet

starter cable

ground

cable

pipe.

Install

(except Fordo

to the

rear

of

the

engine, the temperature sending unit and oil pressure unit

to the

and

the ignition

Connect the ignition

switch wire

wires, the generator wires,

to the

switch wire

the

coil.

engine clips.

Connect the

accelerator

linkage

and

choke wire.

Connect vacuum

wiper line and the fuel pump line. Connect the fuel pump flexible line. Install

the windshield

the fan assembly, then

Tool-T53L-300-A

engine

splash aprons.

sending

On the 6-cylinder engine, install the right-hand mount ing nuts. Install the left-hand mounting bolts. Tighten all

speci

the mounting holes in the

splines.

muffler

block dowels

to

Tighten the

fications.

On the 8-cylinder engine, Fig.lLift

Engine

specifications.

rest

6288

Install the

Connect the

radiator

battery

adjust

and

the fan belt.

connect

ground cable

the

to the

radiator engine.

hoses.

Remove

Tool-T53L-6000-B

ToolT52T6005-CJD (Splined Shaft) ToolT52T-6005-KJD (Keyed Shaft) 6287

Fig.

2

Lifting

Sling 8-Cylinder

Engine

6289

Fig.

4 Engine

Mount Adapter 6-Cylinder Engine

12

I General

Chapter

the tape from the carburetor

horn

air

Install the heater blower

cleaner.

and

motor

install the

(6-cylinder

air en

the heater inlet duct (8-cylinder engine), then connect the heater hoses.

gine)

and

Install the hood. Fill

the

system

cooling

and

the

crankcase.

mission with a

Standard Or Overdrive Transmis Install the bushings in the equalizer bar support, then install the support on the flywheel housing. Install sion.

the transmission to flywheel them to 40-50

foot-pounds Connect

cover.

housing bolts,

and

tighten

torque. Install the flywheel

the clutch

release spring.

the clutch

free play (JLVfc-1% inch). Adjust the

pedal

free play if

Jack up the front

necessary.

bolts,

converter

pan

Align the flywheel verter, install the

foot-pounds

evenly to

and

to

engine upper en

and position

plugs,

and

drive

bolts,

six

the floor mats.

holes

plate

and

the

with

con

tighten them to 25-28

bracket. Tighten the idler

bracket

arm

nuts to

28-43 foot-pounds torque. Install the

housing

lower

converter

the throttle linkage and make the

and connect

necessary linkage

adjustments.

Remove the jack

support

Check Engine For Oil

Warm the

to

engine

normal

hose

all gaskets and

or

Coolant Leaks.

operating temperature, then connections

for leaks.

cooling

system and

remove

the

the

Disconnect the

Disconnect the

panel.

battery

the

may be

the fuel

at

starter

the trans

(1)

REMOVAL. To

remove

the

engine

only, from a

vehicle equipped with a standard or overdrive

sion, follow

only, from

(b)

steps

and

(c). To

and

equipped

vehicle

a

(c). To

as an assembly,

(a)

(a)

steps

follow

remove steps

Steps Peculiar

the

(c)

to

the

screws

the flywheel

ing.

retaining the

housing,

Remove

the

engine

Fordomatic, follow

engine and

and

the

remove

Fordomatic

(d).

Standard

Transmission. Disconnect the move

with

transmis

Overdrive

clutch release spring. equalizer

bar

support

then remove the support and

two

Remove the flywheel

upper

housing

flywheel cover,

Re to

bush

housing bolts.

support

the trans

starter

line,

pump

remove

and

the cable clamp

to

erator

wires.

Remove the

the temperature sending

unit and

sending

assembly.

Disconnect the

cable.

the

the dash

at

coil wire at

from the

wires

the

the fuel inlet

starter cable at

switch

the

the bat

cable at

relay

Disconnect the two heater hoses. Remove the

coil.

the

gen

pressure

oil

Remove

unit.

Disconnect the tachometer disconnect

rod, then

accelerator

the link bracket at the block (this bracket also

serves as

the ignition cable bracket).

Raise the

vehicle and position

exhaust pipes at

engine

front

mount

the

bolt

left insulator

right and

them

Remove the

exhaust manifold.

insulator. Remove the

and

bolts

support

one

Disconnect

stands.

safety

the engine, then

at

the

so

side

engine

engine

will

clear

upon removal.

Remove the safety the engine

lifting

Carefully lift

lower the

stands and

vehicle.

sling (fig. 2). Raise the

pull

the

engine

the engine

out

In

engine

from the transmis

of

the

engine

com

partment.

mount shown

engine on a work

Fordomatic in step

(c),

as an

the throttle

Removing

following

shift control

control rod.

lifting

the

sling.

Engine

vehicle

is

and

raised

additional operations:

linkage

at

the transmission

Disconnect the

speedometer

Remove the drive shaft, and plug the transmission

with an extension

duct

to

engine

Assembly. While the

perform the

Disconnect the

cable.

stand, using the engine

in fig. 3. Remove the

Steps Peculiar

(d)

and

or

Remove

ground cable at

Disconnect the

pump.

solenoid, then

Install the

mission attached.

to

Disconnect the ignition

panel.

sion.

removed with or without

control

engine ground wire at

battery

vacuum

slightly, then carefully

engine

remove

Remove the fan, then

crankcase.

radiator and shroud as an assembly.

air cleaner.

stall

b. Thunderbird.

then

splash shield.

turn the insulator to

the transmission.

jack,

safety

Engine Removal. Remove the hood. Drain the

(c)

the

access covers.

with a

position

Remove the transmission

assembly.

the heater blower

torque.

arm and

tube

linkage

line

housing

the vehicle, and

of

transmission

tery. Disconnect the

Install the starter, and tighten the bolts to 15-20 foot pounds torque. Install the dipstick tube assembly. Install

The

arm

housing to engine bolts. Remove the con verter housing lower access cover, then remove the six converter to flywheel assembly bolts. Remove the dip

avoid

tighten them to 40-45 foot-pounds torque.

and

Install the floor

check

Remove the idler

panel.

tie

and

the converter

engine and

NOTE: Tighten the bolts slowly binding on the dowel pins.

Install the two

Support the

stands.

dash

(d)

Fordomatic. Disconnect the

to

the linkage to the dash

them to 40-45 foot-pounds torque.

ing

the remaining flywheel

remove

transmission throttle linkage at the cross shaft,

the

Install

Steps Peculiar

(b)

(c) Connect Fordomatic Transmission. Install the two converter housing to engine lower bolts, and tighten

the idler

then

housing bolts.

stick

Remove the jack supporting the transmission. Check

gine

jack,

bracket.

(b) Connect

housing

Engine Repair

assembly.

Remove

housing

cap.

converter air

Remove the

engine rear mount

dip stick tube assembly. bolt, raise the transmission,

and remove the cross member rear mount.

Remove the

that

serves as

the engine

3 Engine

Section

Remove the transmission jack and lower the Install the engine lifting sling. Raise the engine then carefully pull the

Carefully

lift the

slightly,

solenoid cable.

transmission from the

engine

compartment.

install the

only in

engine

a vehicle equipped with a standard or overdrive

mission, follow only in

(a), (c),

steps

(a), (b),

steps

Fordomatic

a

assembly, follow

matic as an

sling, then remove the engine

carefully into the

Start the transmission

from the

drive

On

necessary to with

not enter

the

disc.

clutch

after

the

(with

the transmission

mesh

shaft

the

with

Make

sure

engage

the

converter

Raise the engine

exhaust

the

in gear)

disc

into

units, it may be

input

the

shaft

"hangs

crankshaft

until

the

will

wires.

safety

aligned with

stands.

bolt. Install the

on

Install the

left

right and

exhaust pipe stand

and

rod, then connect the

Install the heater blower

Connect the

assembly.

to the

lower

acceler

connect vacuum

starter

generator

the

cable

starter

pump line

clamp

cable

and

Install the

the temperature sending wires.

heater hoses. Connect the ignition Install the

on

to the

oil

unit

Connect the two

switch

to

coil wire.

the dash panel, starter.

and

Connect the

the fuel pump inlet line. Connect

4. The following inspection

Cleaning Remove the

the

outside

procedures are applicable

to

handle.

Inspection.

of

on

engine

bolts slowly the dowel pins. the

housing

converter

drive

and

bolts,

six

bolts,

tighten

and

and

evenly to

avoid

to

bolts,

engine

plate

holes

with

fly

the converter, install

tighten them to

and

and

25-28 foot-pounds

torque.

Install the starter, and tighten the bolts to 15-20 foot pounds torque. Install the dipstick tube assembly. Install the idler

arm and

bracket. Tighten the idler

arm

bracket

to 28-43 foot-pounds torque. Install the converter

housing

lower

Install

access covers.

and connect

necessary linkage

the throttle

linkage,

and make

the

Remove the jack sup

adjustments.

porting the transmission.

Install Engine

bly.

While the

following

vehicle

additional

and

is

Fordomatic

raised

as an

in step (a),

Assem

perform

the

operations:

Jack up the transmission. Install the engine rear mount. Lower the transmission, then install the engine rear mount

bolt. Install the

Install the

dip

stick

tube

converter

assembly.

air

duct

Remove the

assembly. extension

housing cap from the transmission, and install the drive shaft. Connect the speedometer cable. Connect the shift control

linkage

and

the throttle control

Inspect the mating flanges cracks, nicks,

rod.

round, bristle brush attached to a flexible

of power.

with compressed air.

burrs,

the intake manifold for

of

or scratches.

On the intake manifold, check the fuel-air passages and the heat riser for restrictions. Check the manifold open ings for

Dry

to

tighten them to 40-45 foot-pounds torque. Align the

Wash grease, oil, and dirt from the manifold. Clean the inside of the

manifolds.

manifold with a wire

and

housing

INTAKE AND EXHAUST MANIFOLDS

new and used manifolds.

a.

binding

the

Remove the safety

unit and

Tighten

NOTE:

(d)

sending

necessary.

converter

shaft splines

link bracket to the block. Connect the tachometer

pressure

clutch release spring.

them to 40-45 foot-pounds torque.

nuts

accelerator

tighten

and

Connect Fordomatic Transmission. Install the

(c)

wheel

bolts. Connect the

manifold.

housing bolts,

splines.

vehicle and position

support

the flywheel housing. Install

support on

Connect the

cover.

Install the

slowly

housing).

Connect the

cable.

then install the

bar support,

equalizer

up"

vehicle.

ator

Install the bushings in the

free play, if

inlet pipe, and the dowels in the the holes in the clutch housing (on Fordo

and

Overdrive Transmis

or

clutch

into the

converter pilot

the

Standard

Remove the jack supporting the transmission. Check the clutch pedal free play (lVs-1% inches). Adjust the

muffler

front insulator

insulator

oil.

(b) Connect sion.

grade

and

quantity

Lower

the block dowels must engage the holes

matic units

of engine

correct

work stand.

the engine

turn

enters,

clutch

If

the

crankcase with

system.

housing

the studs on the manifold are

the holes in the

block

if

shroud, then

and

radiator

lifting

overdrive

the engine,

to

relation

Install the

them to 40-50 foot-pounds torque. Install the flywheel

the position of the transmission

adjust

Install

install the fan. Install the hood. Fill the cooling

two lower

standard or

engine ground wire.

(e).

the crankshaft.

NOTE:

Connect the

and

engine

gear

the

start

starter

engine

the transmission to flywheel

engine compartment.

main

disc. On Fordomatic units,

and

the

to the

Fordo

engine and

(a), (d),

steps

engine

follow

equipped vehicle,

Engine Installation. Install the

(a) the

(e). To install the

and

(e). To install the

and

trans

ground cable

cleaner.

air

Fill the

(2) INSTALLATION. To

engine

battery

the

the

13

Installation

and

vehicle.

transmission forward.

engine and

engine and

Removal

head

proper alignment with

ports.

Improper

Inspect the

entire

their respective cylinder

alignment

intake

may

manifold

for

result

in

a

loss

cracks or visible

14

Chapter

casting defects

further

I General

which would make the manifold unfit

for

service.

deep

Remove passages.

Inspect the cracks,

Engine Repair

exhaust

nicks,

manifold

for burned

out

spots,

and scratches.

and

obstructions

all

Replace

from the intake

cracked or

those manifolds

severely

manifold

warped manifolds

which contain unremovable obstruc

tions. Replace defective

exhaust manifolds.

b. Repairs. Dress

nicked or warped

Minor nicks, burrs,

plate.

mating

surfaces on a surface

or scratches

may be

removed

file.

with a

Remove

CAUTION: that

may have

filings

all

entered

the

foreign

and

manifold

as

matter

result

a

of

repair work.

5.

ROCKER MECHANISM, CYLINDER HEAD, VALVES, VALVE LASH

ADJUSTMENT, AND VALVE TIMING Check the

centers with a and

socket

for bend between ball

and

cup

dial indicator (fig. 5). Check the ball

end

push

end

of

rods

the push

rods

for nicks, grooves,

or

roughness.

A

NOTE:

rough

for bent

check

push

they are installed in the engine (valve closed) and observing the

made while fixture'

Holding

Fig.

This dures

5 Push

6263

to the

and valves.

rocker

In addition, the

to

head,

and

rocker

and/or

are given.

Remove

REPAIRS. If the arms

the

rocker

arms.

to

by rotating runout. If

check

the

rod

above.

clearance

exceeds

check valve

.004

between the

shaft

replace

the

shaft

rocker

arms

inch,

Replace

all

that

have severely scored or scuffed bores and/or grooved pads. Replace all severely scored or scuffed rocker shafts.

Rocker Mechanism.

a.

(2) and

sure

runout

proce

cylinder

mechanism,

methods used

any

repair

and

them

is observed, be between centers as described

Rod Runout Check

tion covers the inspection

s

applicable

timing

PUSH ROD

be

can

rods

disassemble the

Dress up

rocker mechanism.

minor nicks or scratches.

Replace

all

damaged

lock nuts, adjusting screws, and springs. Replace the oil drain tube if it is cracked or has

rocker arm

CLEANING AND INSPECTION. Check the I. D.

(1) of

the rocker

shaft,

at

cations.

bore

arm

the location

Make

sure

nicks,

or scratches.

pads.

Check the

for

of

these

the

the O. D. rocker

for

or

rocker

free

the rocker

arm

against specifi of

scuffs, scores,

for

rocker arms

grooved

adjusting screws and lock

broken threads

nicks and scratches.

freely in the rocker the locating springs

screws turn

Inspect of

arms,

surfaces are

Inspect the

of

a

sharp bend.

If the total

runout of a push rod exceeds

any point, discard the

rod.

Do

not attempt

0.020 inch, to

at

straighten

push rods.

stripped

screw

and

and

nuts

the ball end of the

Make

sure

the adjusting

arms.

for

cracks or

other signs

failure.

b. Cylinder Head. Remove the

(1)

cylinder

head.

CLEANING AND INSPECTION. Remove

deposits from the

combustion chamber and valve

with a scraper and a wire

Inspect the

oil

drain tube for

cracks or

sharp bends.

the gasket

surface.

carbon

brush. Be

Clean the

to remove any gasket

careful not

to

heads

scratch

gasket surface with solvent

sealer.

\D,(3) check diagonally

(5) CHECK Fig.

6

ACROSS CENTER

Checking Flatness

of

6262

the Cylinder Head

Gasket Surface

6264

Fig.

7

Checking Flatness of the Mating Surfaces

Intake Port

Section

5 Rocker

Mechanism, Cylinder Head, Valves, Valve

Lash Adjustment,

Valve

and

15

Timing

6268 10

Fig.

Valve Fig.

8 Valve

Check the head for

Face Runout Check

for flatness (fig. 6). Check to are open.

block port

are

Make

sure

surfaces

Check the

see

that

gasket surfaces

head

cylinder

in fig. 7.

plug for

an oil stone.

head. Discard

brush

of

replace

burrs

all

Replace the head if it is

cylinder

head

core

plug

leaks,

with

or

scratches

cracked.

replace

with

Remove

varnish

with

warpage.

the

Check the

length,

replace

as

stem

and

valve stems.

of

for

evidence

valve

or

face

of

valve

stem

and/or

wire

the

valves.

Carefully

clean

brush.

imperfect seating,

erosion, or evidence

(fig;

runout

8),

of

and also

for

grooves or scores.

valve springs

valve

for

spring

cracks or other signs of pressure

(fig.

9), free

and squareness.

Check the

valve

spring

retainers

failure. Check the tapered

noted

heads.

the face for pits and grooves. Inspect the ends of

valve stem

in the

Scrape

valve seat with a wire

valve

failure. Check the

Spring

Tester

cylinder

umbrella-type

new seals.

from the

from the

Check the

check

it.

the

available

are

from the head

carbon

Inspect the Valve

stems

heavy discoloration, burning

REPAIRS. Remove

If the

and

all carbon

evidence

leakage.

(2)

oversized

cylinder

seals, and

Check the intake

as shown

core

with

integral

if it becomes necessary to ream the valve guides. Disassemble CLEANING AND INSPECTION.

(1) the

guides are made

all water passages

or scratches.

for flatness

Valves ments

the gasket surfaces of both head

free from burrs

mating

Check the

cracks.

the Valve Guide

of

Valve Mechanism.

c.

6266

D.

Measuring I.

retainer.

by

ridges

These locks

for

seat where are

split,

wear or signs of

the

valve

locks

may be the locks.

and wear

left between the halves

of

Micrometer

^*~

Fig.

9 Valve

Spring

Pressure Check

Fig. ?

?

Measuring

O. 0.

6269 of

Valve Stem

16

I General

Chapter

Engine Repair

Seat Width Scale

6271

Fig.

14

Measuring Valve Seat

Width

6209

However, do

ends.

12

Fig.

Check the I. D. O. D.

of

of

the intake

the diameter

of

the

valve guides

If the

the

clearance

valve stem

select a new valve with a stem

limit. If the

clearance

valve guide

(fig.

Check the

12)

is

10)

(fig.

11)

limits, lower limit,

the

on

diameter

on

the

limits,

upper

ream

the

next oversize valve stem.

the

valve seat width

14. or

re

tainers.

(2)

REFACING VALVES. Grind the

angle on

valve

a

face. If the wide after

If the

edge of

grinding,

valve

valve

face

the

valve

replace

clean

up

stock

the

width.

Use

the bottom stock

of

the seat

After refacing

off

only

mating

lead

of

the

bottom

17),

If the

the

enough

to

reduce

seat

remove stock

angle wheel

and a

Keep

the

valve seat

just

60

seat as near

to

from

remove

to the

center

possible.

valves and

the

to

enough stock

remove

edge of

angle wheel

a

the valve face as

to

(fig.

seat.

valve

seats, it is good

practice

valves with a medium grade

match

the seat

and

seat and valve with

the

valve.

to

lapping

Check the

Prussian Blue

or soft

pencil.

inch

valve.

specifications,

grind

runout still exceeds specifications

grinding, discard the

Grind

the

and

in the

30

from the top.

compound

%2

(fig. 16). Remove only

pits or grooves

from the top

at a

valve

stem.

width exceeds specifications

face

from the

head is less than

runout exceeds

face. If the

valve

(fig. 15). Grind

grinder

enough stock to remove pits and grooves

after

to

than 0.010 inch from

REFACING VALVE SEATS. Grind the

lightly lap in

45

the

the

not remove more

seat with a grinder

of

Discard any defective valves, springs, locks,

end of

(3)

the

and

not within

still not within

for the

and

is

is

valve seat runout and

in figs. 13

as shown

(fig.

the

and exhaust valve stems

against specifications. and

Reaming

Valve Guides

valve.

all grooves or score marks

from the

valve stem

Runout Gauge

for Removing and Installing Gauge

Pilot

Fig.

13 Valve

Seat Runout Check

6270

6341

Fig.

IS

Refacing Valves

Section

5 Rocker

Mechanism, Cylinder Head, Valves,

Valve Lash Adjustment,

and

Combination

Valve

17

Timing

Tool

Adjusting

30

ANGLE WHEEL FOR BOTTOM OF SEAT , ANGLE WHEEL I FOR TOP OF SEAT 60

*

Feeler Gauge

Fig.

18 Valve

6210

Lash Check

6272

Check the intake Fig.

16

Valve Seat

Refacing

cylinder with a

lock

nut

If the

located

cylinder

removed

lash

tune-up, the

on

the

head

the

or

adjustment

step

procedure

(a)

for the

clearance

means of

the

push rod end of

is

set screw and

the

rocker arm.

rocker mechanism

has been

be necessary to

will

before starting the

adjustment

omit

by

installed, it

and

preliminary valve

adjusted

for the

made

make

a

If the

engine.

purpose of engine

and proceed with

(b)

step

under

ing

turn

of

Preliminary Adjustment. Remove the Rotate the

arm

cover.

near

top dead

crankshaft until

(T.D.C.)

center

at

No. 1

the end

of

rocker

piston

the

is

Turn the

tion,

No. 1

timing

with

marks

on

operation

Vz

piston

is

near

mark on

the

T.D.C.

both

at

the

end

the

represents

of

the way

around

Vz

the damper

the

turn in the direction

Vz

valve

lash

No. 5

of

for No. 3, No. 6, No. 2,

for approximately 30

minutes

specifications

(fig.

19)

bring

valve

with

No. 4

fast idle

it to

lash for

the

Repeat

cylinders.

engine at

to

of rota

cylinder.

and

Final Adjustment. Run the

to

damper

crankshaft

mark

operating temperature. Check the ance

nut without mov

.

crankshaft

and check

this

(120

ADJUSTING SCREW

compression stroke when

the

chalk

)

not

screw.

crankshaft or

circumference

screw

until

normal

conform

engine

idling.

com

pression stroke.

NOTE:

the

lash for No. 1

(fig. 18). If the lash is

gauge

away from the timing

speed

(a)

valve

Tighten the lock

obtained.

Make two

(b)

ENGINE.

is

the adjusting

120

this

applicable engine.

(1) 6-CYLINDER

feeler

exhaust

to specifications, loosen the adjusting

d. Valve Lash Adjustment. Valve lash is

and

Valve

gapper

of the

valves are closed and

crankshaft

damper is in line

the pointer.

REFER TO SPECIFICATIONS

VALVE SEAT

6292

6273

Fig. 17-Valve Seat Width

Fig. 19-Valve Lash Check

18

I General

Chapter

Engine Repair

Repeat the Dial Indicator

V*

the crankshaft

firing

for

procedure

turn

checking the

while

in the

valves

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

order

Final Adjustment. Run the

(b)

turning

each set of valves,

fast idle

engine at

for approximately 30 minutes to bring it to normal operating temperature. With the engine idling, check the speed

BE SURE TO PLACE INDICATOR TIP IN CENTER OF PUSH ROD CUP

lash

valve

if

as

in figs. 18

shown

necessary.

Install the to the

gasket

valve rocker arm

cover

if

limit

the cover

or

necessary.

Tighten the

Valve timing performance is

20- Camshaft

Fig.

taken

this

Adjust the lash, if

a new gasket

cover, cementing

Do

tighten the cover

not

Install the

necessary.

the

to the to

nuts

valve rocker arm

if

cover

necessary.

than 2.0-2.5 foot

more

be distorted.

(2)

torque, 8-CYLINDER ENGINES.

(a)

Preliminary Adjustment. Remove the

pounds

or

arm cover.

top dead

Rotate the

cover will

(T.D.C.)

center

No. 1

the end

at

of

No. 1

is

piston

near

timing

is in line

the

mark on

the

with

T.D.C.

both

at

valves

crankshaft

piston

the

the

rocker

is

near

compres

end

of the

are closed and

pulley

equal

Remove the

the heel

Back

of off

the rocker

engine

To

with

the

lash for

to

conformance

lash, bend angle

type

the

proper

one

about

manifolds while

gauge

inch from

the No. 1 intake

to

stock

the end or use

Tighten the adjust

the

nut

nut

the

without

screw

valve

lash to

angle

an

to

specifica

moving the

screw.

specifications

and

in the

CAMSHAFT

ponents are contained

a.

Camshaft Sprocket Before the timing

ward

deflection

of

chain

the

right-hand

No. 1 intake tappet is

valve

the desired lift is on

the pulley

Valve

Timing

push

adjusting screw, a

dial indicator

in fig. 20. Zero the dial indicator, then until

on

obtained

the

with

rotate

the

(Table 1).

specifications.

Specifications

Intake Valve Opens Crankshaft Degrees at Cam Lift

Camshaft

EBP-6250-C

272

B5A-6250-A

292

B5A-6250-A

13

BTDC

@ BTDC @

12

12

BTDC

@

Cam Lift

.013

Cam Lift

.016

Cam Lift

.016

If the

valve

timing is

not within

bent timing pointer as follows: piston to T.D.C. and see if the timing the T.D.C.

If the shaft

pointer

mark on

is

sprocket,

not at

the

fault,

crankshaft

and crankshaft

pointer

crankshaft check

the

the No.

Bring

a

with

check

specifications,

pulley

is

1

aligned

damper.

or

timing chain,

cam

sprocket, camshaft, crankshaft

in the

order of accessibility.

SPROCKET, CAMSHAFT, AND CAMSHAFT BEARINGS

Procedures for the inspection

in the

the 6-cylinder the

remove

is ap

lift.

change-in cam

side, then install

one

223

pulley,

same manner.

6.

crankshaft

a

to 30-35 foot-pounds torque. Check

exhaust

the

60

for

and adjust

Tighten the lock

tions.

to

arm

Table 1

valve

feeler blade holder.

Loosen the lock nut,

the trouble.

lobe.

cam

speci

adjusting the

feeler

correct

rocker chamber cover on

No. 1 intake

slowly

damper

or

the possibility of interference

eliminate

exhaust

change of

to 0.0004 inch

Compare the degrees

fications (fig. 18). NOTE:

side

pointer.

valve

car

such as

for checking valve timing is of No. 1 intake cam lobe. At

engine over until

Engine

Check the intake

etc., fail to

On 8-cylinder engines,

engine.

checks,

procedure

degree

one

proximately

as shown

compression stroke when

the

point a

made when poor engine

noted and all other

the opening

on

be

rocker chamber cover.

sion stroke.

NOTE:

checks should

following

Turn the

crankshaft until

the torque

be distorted.

will

buretion, ignition timing, The

Lobe Lift Check

not exceed

cover nuts

Valve Timing.

e.

6274

a new

cover, cementing

to 2.0-2.5 foot-pounds torque. Do

FABRICATED CLIP

19. Adjust the lash,

or

these

and repair of

following and

slack side of

paragraphs.

Timing

is removed, the

com

chain

the

outward

chain.

Chain.

measure

the

out

(fig. 21). If

deflection

Replace the

sprockets

(1) INSPECTION. and

timing

aged

chain.

exceeds

V2 inch,

if

the

timing

necessary.

Remove the

Inspect the

replace

camshaft

sprocket

for

sprocket

worn or

teeth. Inspect the chain for broken links.

dam

Section

(2) REPAIRS. b. Camshaft to

Replace the

be

that the

an extent

The tappet

Check

fig. 20. It

will

cam

minimum

lift

ing iron. (1) INSPECTION. the

end

following

Push the

the

with a

lobe

or

ex

must also

dial indicator

camshaft

to

conformance

as shown

be in

is removed,

specifications

in

manner:

camshaft

toward the the

against

rear of

the

side

rear

flange. Set the dial to zero, then

the

of

the

push

engine.

Place

camshaft

camshaft

Compare the dial indicator reading

ward.

worn

tolerance.

allowable

worn

Before the

play for

dial indicator

a

for

speci

with

fications.

l/2"

Remove the for

abnormal wear.

Suspected

worn

lobe to be

sure

for

wear

and

camshaft

the lobes for pitting, scoring,

and signs

should

diagnosis is

or

scores

lobes nicks

scuffed

with

a

with crocus

7.

between the bear exceed

or

worn

wear.

that

all camshafts

on

the

Chain Deflection Check

Timing

If the front journal to it

can

be

that

assumed

bearing

clearance

bearings

all

are

is excessive,

worn

and need

replacement.

have

cracks

lobes. Remove light

elsewhere

21

same manner.

0.003 inch.

for broken for

Fig.

camshaft

scuffs

hard Arkansas stone, then polish the cloth. Remove raised metal from small

abrasions

and

gear

eccentric

or scored

CHAIN, THEN, TAKE UP SLACK ON DRIVING SIDE OF CHAIN AND MEASURE SLACK SIDE. 6366

OF

micrometer.

Measure the

the journal should not

(2 ) REPAIRS. Replace

a

TAKE UP SLACK ON THIS SIDE OF

CHAIN TO ESTABLISH STRAIGHT POSITION

MOVEMENT OF CHAIN

Measure the journal

amount of clearance

teeth. Check the fuel pump

severely

with

FIRST,

MAXIMUM LATERAL

compared with a good

correct.

Check the distributor drive

or

be

out-of-roundness.

surface and

check

Check the lobes

lobes

front bearing. The

ing

Thoroughly

the

camshaft.

Examine

cracks.

of

DRIVING SIDE OF CHAIN

SLACK SIDE OF CHAIN

be necessary to fabricate a clip to hold the The clip shown in fig. 20 is made from band

push rod.

the

lobe lift (intake

cam

which mates with

replaced.

check

timing

any lobe is

replaced when

is less than the

haust)

the

or

19

Camshaft Bearings

and

Camshaft Bearings.

and

camshaft must

such

sprocket

Sprocket, Camshaft,

deemed necessary by inspection.

chain as

The

6 Camshaft

camshaft

in the

If any of the teeth on the distributor drive gear are broken or worn, it will be necessary to replace the camshaft.

If the

play is excessive,

end

replace

the thrust plate

and/or spacer.

FLYWHEEL, CHANKSHAFT, MAIN BEARINGS, AND CONNECTING ROD BEARINGS

Procedures for the inspection ponents are contained

in the

and repair of

following

these

com

(2) REPAIRS. inch

paragraphs.

and

If the flywheel

the flange is not at

replaced or machined.

Flywheel.

a.

The flywheel

flywheel if it is and

ring

gear

are

shrink

a

fit

and

are

INSPECTION. Check the flywheel face

(1) with a

dial indicator (fig. 22 ). Be

full forward not

show

0.010 of

the

or rearward so

up

inch,

as

remove

crankshaft

remove

the

flywheel

sure

flywheel,

the

If the and

mounting flange. It

crankshaft

Inspect the ring

if the flange

gear

to hold the flywheel

that crankshaft

runout.

end

check

will

play

runout

the

will

exceeds

runout

be necessary to

should

If the ring worn,

gear as

the friction surface of the

If it is necessary to remove more stock from the original thickness, the

of

be

gear

if the

or

the flywheel should be

replaced.

teeth

are

broken, cracked, or 0.010 inch, replace the ring

chipped,

runout exceeds

follows:

Heat the defective ring

the gear, then knock

engine side of

CAUTION:

gear with a

Do

not

hit

the

it

blow torch off

flywheel

the

the or

cracked

indicated in fig. 23.

ring

on

the

flywheel.

when

requires machining.

for worn, chipped,

teeth. Check the ring gear runout as

runout

Machine

0.010

scored.

than 0.045 inch

flywheel

replaceable as separate parts.

fault,

runout exceeds

removing

gear.

Heat the

new

ring

gear

evenly

until

the

gear

expands

20

Chapter

I General

Engine Repair

When the

gear teeth.

form

new

is installed, per ring gear and flywheel.

the

a runout check on

gear

ring

b. Crankshaft. is removed, the

crankshaft

for

to

conformance

Push the

Place shaft

a

end

in the

specifications

toward the

crankshaft

dial indicator

against

flange. Set the dial

the

forward. Compare the reading

on

checked

following manner :

rear

the

of

rear side of

then

on zero

be

should

play

the

Before

INSPECTION.

AND

CLEANING

(1)

push

the

engine.

the

crank

crankshaft

the dial indicator

with

specifications.

After removing the crankshaft, wash it in and blow out the oil passages with compressed

ine the

Measure

cracks or other signs of

each crankpin and

formance to taper

for

shaft

specifications.

a

solvent,

air.

Exam

failure.

journal diameter for

Check the

shaft

con

journals for

and out-of-roundness at several places around

the

circumference.

(2) REPAIRS. tions, 6085

replace

Replace the Dress

Fig.

22 Flywheel

Runout Check

seated

to slip

properly

If the

the flywheel. Make sure the gear is

against the shoulder.

Do

not

exceeded, the temper

will

be

undersize

to be

heat any portion of the gear to 500 F. If this limit is temperature higher than

CAUTION: a

onto

removed

from

the ring

limits,

play is

three

journals

the

not within specifica

main

if it

bearing.

shows

signs

of

out-of-round

shaft should

//

the

be

ground

beyond the for the

correct undersize

undersize

bearing

main

before it is ground

CAUTION:

to

journal

will

23

Ring Gear Runout

Check

next

bearing

"clean

2.4990.010=2.489 inches

it to that

diameter,

and

install 0.010

bearings.

Never

grind

of 0.030 inch

journals

or

crankpins

in

undersize.

1158

6084

Fig.

failure.

follows:

used as

excess

are

bearing. Calculate the

diameter, finish inch

number

crankshaft

or

pins

EXAMPLE: up"

end

minor nicks or scratches.

specified enough

the

If the

Fig.

24

Bearing

Failure Lack of

Oil

Section

7

Flywheel, Crankshaft,

Main Bearings,

21

Rod Bearings

Connecting

and

OVERLAY GONE FROM ENTIRE SURFACE

1161

Fig. 27 Bearing pin or oil.

journal

Crocus

cloth

Main

c.

with

serts are used

No. 320

may

also

grit

be

polishing

used as a

copper-lead,

for both

Journal

cloth and engine

agent.

polishing

Rod Bearings.

Connecting

and

Steel-backed,

Failure Tapered

lead babbitt bearings in

or

main and

connecting

rod

bearings.

Check the bearings for scratches, improper seating, 1159

Fig.

25 Fatigue

Failure

and

Always pin or

may will

reproduce

journal that

result

result

the

same radii

existed originally.

in

crankshaft

in

bearing failure.

After grinding,

in the

failure,

chamfer

the

Too

while

corners of

the

small a radius

too large

a radius

holes,

then polish the

radius

failures

ride, are

29. Replace

all

(1) FITTING

and

worn

overlay.

Examples

of

illustrated in figs. 24, 25, 26, 27, 28, defective bearings.

MAIN

AND

CONNECTING

ROD

BEARINGS PLASTIGAGE procedure applies either

oil

of

bearing

Bearing

of

dence

evi

installed

If the

METHOD. The following to fitting main bearings with the engine

on a workstand or

bearing fits

are

to be

in the

vehicle.

checked with

the

engine

DIRT IMBEDDED IN BEARING MATERIAL FATIGUE FAILURE FROM EXCESSIVE LOAD

"7 RADII RIDE

SCRATCHES

1160

Fig.

26

Bearing Scratched by Dirt

Fig.

28

Bearing Showing Radius Ride

1162

22

Chapter IGeneral Engine Repair

BRIGHT

(POLISHED) SECTIONS

1163 29

Fig.

Bearing

in the vehicle, a

small

jack

against the

jack

should

The

pad

block half

the

of

which

shaft can also

are not

bolts just upper

being

be

being

and

checked.

counterweight

checked

for

to

the

prevent

pressing the

Journal Oil Seal to Cylinder Block Installation Typical

clear

Install the cap fications. center.

by

thin

a

the journal

of

rubber

two bear

Tighten the bearing cap

crankshaft

the

against

up

CAUTION:

Do

Plastigage is in

to

checking

weight

support

main

of the

the

weight

Plastigage, thereby

the

widest

If the

bearing

crankshaft

of the

point,

com

an

erro

providing

bolts to

tighten the

the

crankshaft

speci

while

the

place. check

with

is

clearance

clearances,

from

and

turn

not

Remove the cap,

It is necessary when

63 73

31 Rear

Fig.

inserts. The

bearing

supported

to hold the

enough

crankshaft

the width

the Plastigage

not within

of

the

scale

limits, try

Plastigage,

at

(fig. 30). another

selec-

reading.

Place cap

shaft

is

Tool T52L-6701- AGD

crankshaft upward

bearing inserts.

NOTE:

neous

main

Seating

crankshaft with

the crankshaft

against

bearing

the

of

to hold the

between the cap insert

ings that

ing

the weight

positioned

adjoining the ance.

support

bear

Spots Improper

Bright

a piece of

insert,

on

Plastigage,

the full

bearing

surface

the

journal if the

engine

is

inverted)

CLEARANCE

width of

(or

on

about

the bear

the

crank

Va inch

off

Too/-T52L-6707-AGD

Flattened Plastic

GRADUATED CONTAINER

6374

1282

Fig. Fig.

30

Measuring

Plastigage

32 Rear

Journal Oil Seal to Seal Retainer

Installation Typical

7

Section tive fit

bearing

limit. Red marked

tive fit

to

bring

Flywheel, Crankshaft, Main Bearings,

the clearance

the desired

within

bearings increase clearance; blue bearings decrease clearance. If the various selec marked

bearings do

cations, it

journals

the clearance

within specifi

be necessary to regrind the install undersize bearing inserts.

will

and

NOTE:

Normally,

and

not

are

bring

not

chankshaft

SEALS. Remove seal groove

for the

cap to block

being fitted to an out-of-round journal, be sure to fit the bearing to the maximum diameter of the journal. the If bearing is fitted to the minimum diameter with clearance, interference may result, causing early failure, lt is not recommended that bearings

in the

an

be fitted

to

journal

a crankshaft

0.001 inch

which

is

journal

a new

retainer

in the

be

Install

as shown

cap

bearing

main

to

THRUST except

tighten the cap bolts to

bearing

cap

crankshaft

half

of

forward

the bearing. While

pry the thrust the thrust

bearing

cap bolts to

cap to the

specifications.

(3) REPLACING

journal

cap to

The inspection

applicable

also

to

the outside

given,

BEARING

repeat

inasmuch

to the

below. In addition, the

as

these

of

the

procedures are

it,

faces

of

spring

dirty

Scrape any dirt or metal the pan. Scrape all old gasket

of

Wash the

pan

in

bearing bearing oil

not

be

caps

into the

block

block. Blow

place

for leaks.

seal

corners of

the

seals on

compressed

air

the block. If

air

remove the seal retainer.

Be

from the inside

in the oil,

into

seals

surfaces are clean.

of

Install

new seals and

test.

pan

valve

pressure and

will

is

behind the not

permit

the inner face

the

valve

to

open.

particles material

valve.

of

thereby maintaining

a

to overcome the

When the

sufficient

a

flow

the valve

difference between the

valve

element of

drops,

faces is

is

oil, the and

the

enough

to

Oil then by-passes the element,

supply

of oil

to the

engine

lubri

cation system.

(1) REMOVAL. holes, damaged drain

for cracks,

not great enough

outer

a solvent and

loose, or warped gasket surface. Repair any damage, or replace the pan if

threads,

the

pressure

gasket surface.

Check the

air

pressure on

it thoroughly.

dry

block

main

the pressure difference between the inner and

cause

from the

the

cylinder

cylinder

mating

oil pan.

from the inside

the

of

of oil

crankshaft end play.

all engines.

Remove the

few drops

sure all

Oil Pan.

a.

a

appear

assembly, and installation

disassembly,

filter is

Squirt

to

retainer

bubbles

and repair procedures applicable

above components are presented

oil

Check the

tighten the

MAIN

cylinder

then install the

friction,

It may be necessary to tap the for the last Vi inch of travel.

seal corners

OIL

oil seal

inserts. Lubricate

grooves.

into the

and

any

OIL PAN, OIL FILTER, AND OIL PUMP AND PRESSURE RELIEF VALVE

8.

removal,

align

will

without

seal inserts, then install the rear main retainer. Dip the retainer to cylinder block oil seals in light engine oil, then immediately install them in the

upper

forward,

the

block.

cylinder

the bearing. Retain

of

Check the

REAR

This

rear.

pry the

the

crankshaft

the crankshaft,

on

and

cap,

then

surface of

holding the

both halves

surfaces of

the forward pressure

finger-tight,

the thrust

the

Install the thrust

specifications.

against

Install

bearing

the thrust

bolts

the

with

BEARING.

as

in fig. 32. On 6-cyl

caps and

reduce

block

seal and

flush

cut

and

(2) ALIGNING main bearing caps,

procedure

cylinder

a new

new retainer

grease

with

in the

On 8-cylinder engines, install the

out-of-round.

the

clean

oil seal retainer

block journal

seal must

oil seal retainer

the seals

more than

Remove the

oil seal

edges overlapping.

Install the

seals.

block. Repeat this

cylinder

inder engines, install

minimum

and

cylinder

seals.

retaining cap journal

frayed

from the

oil seal

sealing material,

cylinder

in fig. 31. The

shown

main

out-of

in the

old

oil seal retainer cap.

Install

bearing journals wear evenly round. However, if a bearing is

the journal

block. Remove the

23

Rod Bearings

Connecting

and

plug

of

the

vehicle.

Place

Remove the filter from the bottom a pan on

the floor

directly

under

the

a

ENTER TUBE BOLT

repairs can

FILTER HOUSING

made.

SPRING

SPRING RETAINER

b. Oil Filter.

GASKET

The full flow-type the

entire output of

engine

lubrication

element

the hollow valve.

the pump before the

provides oil

becomes

center

When the

used on all

engines, filters oil enters

the

system.

A built in by-pass filter

filter,

oil

bolt

clogged.

and

element

is

to the

system

in

case

the

GASKET BY-PASS VALVE SPRING

BY-PASS VALVE

of a

spring loaded

clean and oil will

flow through

FILTER ELEMENT ANTI- DRAWBACK'

DIAPHRAGM

The by-pass is located in

consists

ADAPTER FITTING

Fig.

33 Oil Filter Disassembled

Element Shown

6080

Metal Type

24

I General

Chapter

Engine Repair

CYLINDER BLOCK

TOP

ASSEMBLY. Install

(4) center

bolt,

then place the

Install the spring Install

the

sure

making

and

seat

tangs

in the

engaged

are

the

on

assembly

filter

a new neoprene gasket and a new

over

the center bolt. The pressed paper type

does

not use

the

holes in the

Be

neoprene

block,

the

spring.

element

element

in the filter

gasket

elongated

the top,

when

in fig. 34. Install

a new

are

as shown

two

the

sure

filter diaphragm

oil

positioned on

bolt,

neoprene gasket.

INSTALLATION.

(5)

the

on

gasket

bolt through the filter housing.

spring

seat

fibre

new

a

at

housing

Place the

recess.

filter assembly in position, and thread the center bolt into the adapter finger-tight. Rotate the filter assembly slightly, in seated

direction,

each

evenly.

to

Tighten the

make

center

the gasket is

sure

bolt 3/4-l

complete

turn (20-25 foot-pounds torque).

With the operating

fast

at

idle,

gasket or around

Fig.

34 Oil

the

Filter Diaphragm Position

If

housing

oil

leaks

bolt for

filter. Remove the filter filter assembly

On

NOTE:

it

full

with

to turn the

power

front

facilitate

to

wheels

removal

neoprene gasket

seat, then

and

from the The

oil

(3)

(with

remove

cover.

filter is

center

metal

to the

of the

oil

the

shown

center

bolt

and

fibre

Make

sure

all

in

a solvent and

the

openings

dry

in the

ing, inspecting,

and

fitting

block; for clean fitting piston rings;

cylinder

pistons; for rod

alignment

are

If

housing for

bolt gasket,

the

housing

leaks

oil

past

proper seating.

the

check

center

the gasket.

or replace

dirt rial

and

Pressure Relief Valve.

and

Wash

thoroughly. Use

parts

all

brush to

a

and chips are removed.

from the pump

body

gear

the

of

compression

oil

pump

dry

the inside

clean

Remove

the pump

of

bore. Be

valve

them

sure

all

all old gasket mate

and cover.

teeth for

the

relief

in the

relief valve clearance

and pressure

a solvent and

housing for damage

Check the pump

driven

in

the pressure relief

Check the pump

or excessive wear.

damage

Check the

spring.

valve

relief valve

Check

or wear.

bore. Check the

shaft clearance. worn or

gauge.

mitted

Only

defective

parts.

Rebore the

b.

Make

a

thorough

to the

check

motor oil.

cracks are

of

cylinder

Wipe the

zinc

oxide

part

dry

Inspect the

and

immediately

dissolved in will

wood

apply

alcohol.

become discolored

If at

may be

present

and

ring

along

cylinder

bores for

out of

scores.

Check the

round, and wear,

cylin

with a cylinder

and/or

maximum allowable

and

with

bands, the

per

out-of-

tolerances.

Rings.

to

avoid

remove

any

damage to ridges

that

upper part of each cylinder

follows: Move the

a cloth on

piston

the

to the bottom

piston

head to

of

instructions furnished remover

being

used.

by

its travel,

and place

collect the cuttings.

the cylinder ridge as shown in fig.

area.

der bore for taper,

the taper

piston removal and

the piston rings

as

the

when

Pistons, Piston Pins,

To facilitate

cracks not

may be detected by coating the mixture of 25% kerosene and 75%

present, the coating

the defective

Minute

cracks.

naked eye

suspected area with a

coating

for

be

experienced personnel should

to take these measurements.

roundness exceed

Cylinder Block.

visible

bore

given

below.

a

gasket.

disassemble the

and

Replace any

for checking connecting

light

Pump

relief valve.

are clean.

Procedures for checking the

a.

Oil

Remove

gasket

element and all gaskets.

all parts

past

CYLINDER BLOCK, PISTONS, PISTON RINGS, AND CONNECTING RODS

9.

and

element,

disassembled in fig. 33.

CLEANING. Wash

bolt

filter

the

type element only), spring,

Discard the filter

thoroughly.

them

Remove

the

center

torque

proper

housing DISASSEMBLY.

check

the

past

bolt

center

leaks

oil

-

steering,

filter.

(2)

the

gasket,

for

check

and

then remove the c.

equipped

vehicles

position

right

bolt,

and gasket.

be necessary

will

center

operating temperature

engine at normal

Remove

35, according

the manufacturer

of

to the

the ridge

9Cylinder

Section Never

CAUTION:

of 1/32 inch

excess

Remove the Turn the

into the ring

cut

when

ridge

the

ridges.

from the is

piston

bore.

cylinder

at

the

top

carefully remove the cloth with the piston head. Remove the pistons.

stroke and

from the

its

of

cuttings

Groove Cleaning Tool T52L-6110-AAD

( 1 ) CLEANING AND INSPECTION. Clean the piston grooves with a

ring the

in

piston

tion. Make

Inspect

piston

solvent.

the

sure

pistons

bosses.

and pin

Check the

not use a caustic

ring

Spongy, on

by detonation,

Inspect the

(2)

Do

oil

for

slots

skirt

cleaning

holes)

are clean.

6097

lands,

the ring

at

solu

skirt,

edge of

the

the side opposite the valves,

are

the

or pre-ignition.

for

proper

signs of

fit in the

REPAIRS. Replace

cessive

(or

eroded areas near

piston pins

pin

(fig. 36). Clean

groove cleaner

for fractures

top, usually

caused

ring

clearance, wavy

fracture

or etching.

bushing.

ring lands, fractures

or

ing. Piston or

rod

piston pins pins

that

bushing

showing

show wear or

should

be

fit

fracture

loosely in

the

piston

Replace

all

piston

replaced.

attach

PISTONS. To fit a

a piston

in the

tension scale to the end

hole. Invert the piston, then

feeler into the bore

so

the end

proximately 1 Vz inches below the

the

piston pin

the piston

reading

If the able or

on

pull,

pull,

try

cylinder

the

parallel

pull

of a

slightly

is ap

piston

crankshaft axis.

Hold

greater

ribbon,

than the

in both the connecting

of

the

the size and

of

the

pin

the

bore,

trial ream the pin

Check the

to

Take

a

reamed

being

be reamed,

Place the

around

piston

nearest size

piston

must

piloted reamer.

CAUTION:

the

hole

use an expan

in

reamer

reamer.

then

bore,

Set the

reamer

the

reamer

expand

using

a pilot sleeve

maintain alignment of

very light

the bores.

cut.

hole size, using the

reamed.

a vise and

piston pin

If the bore is small,

expand

for the

noting the

maximum allow

damaged piston, try a new piston, bore to obtain the proper fit.

reading is less than the

another piston.

to the

the piston

Keep

of

piston pin should

a

cylinder

scale

the

clearance

it.

piston.

piston pin

sion-type,

feeler

the block.

top

to the

push

balance.

(fig. 37).

pull scale

for

of

the feeler

out

reading is

check

hone the If the

bore

and

scale

If the

to the

ribbon (Vi inch wide) of the proper thickness. 90 from the Position the feeler on the side of the piston

and

the

engine

upsetting

PISTON PINS. The

have 0.0001-0.0003 inch

cylin

gauge

piston pin

without

cylinder or cylinders which require

(4) FITTING

revolve

(3) FITTING

Cleaning Ring Grooves

or etch

pin retainers.

der bore,

be intermixed

rod and

signs of

36

Rebore only the

signs of ex

showing

damage from detonation.

Replace

Fig.

can

piston and rod

pistons

25

Rods

Connecting

and

in

travel area

removing

remover

crankshaft until

Block, Pistons, Piston Rings,

If

minimum allowable

be fitted,

none can

rebore

the

next oversize piston.

NOTE:

All

ard and

oversize;

pistons are

the

same

therefore,

weight, both

pistons

of

stand

various sizes

Piston

pull

scale

Thickness

scale

6215

Fig.

35 Cylinder

Ridge Removal

Fig. 37-Piston Fit Check

26

I General

Chapter

Engine Repair

bore PISTON

the back

and

holes

Check

fitting

the

Inspect the

the bore for

check

for

deep

threads,

signs of

or

(2 ) REPAIRS. If the

If the 6216

Fig. reamer

38

the

procedure until

(5) FITTING

proper

the ring

the

ring.

Be in

which

identify

to

they

Check the installed

on

oil rings

have

the

Whenever

the

feeler

the

top

piston and

bore

the

ring

(fig. 38). Side sealing type

full

solution.

they

are

Remove the to be

installed in

should

be

a used

the

bent

than specified, it

next oversize

or

more

fractures,

nicks, signs of

bolts.

or with

the

should

be

0.0004 inch

than

more

nuts and/or

rod

removed

Rod Bearings

a piece of

width of

Plastigage

bearing,

the

about

tighten the

and

on

the

surface, the

bearing

V* inch

off center.

Install

bolts to 45-50 foot-pounds

rod

Do

NOTE:

not

turn the crankshaft with

Plastigage

place.

to

aid

Remove the

in

measure

bearing

the

cap,

width of

widest point.

and use

the Plastigage scale

the flattened piece

Select fit bearings to

of plastic at

obtain

the

proper

clearance.

Never

use

a

caustic

thoroughly

If the crankpin is out-of-round, be sure bearing to the maximum diameter of the

all parts

NOTE:

cleaning

fit the

bearing inserts (identify

used again), then

them if

clean

the

rod

pin.

It is

adjust

recommended

not

to

or

the

file

or

bearing

lap

bearing shims of bearing caps in order

to use

the

clearance.

If the reading is within limits, 0.0004-0.0023 (6-cylin der engine) or 0.0008-0.0027 inch (8-cylinder engine),

Tool M-120-RA-72

the fit is

If the tive fit

Red

satisfactory.

clearance

bearing

marked

to

is

not within

bring

fit bearings do

tions, it journals

APPLY PRESSURE TO HOLD ROD DOWN

will

and

Rotate the Alignment Check

be

sure

the

the

limits, try

another selec

clearance within

the limit.

bearings increase the clearance, blue

bearings decrease the

Connecting Rod

to

crank'

any type, to

39

clear

cylinder,

ROTATE PISTON AND OBSERVE INDICATOR

Pig,

bushing

torque.

in

Rod.

solvent

to rod

Plastigage Method.

to

in

deep

out-of-round

the cap

CLEANING AND INSPECTION. Clean

passages

corners.

bushing for

Fitting Connecting

the

and

damaged

piston pin

the

for damaged

and nuts

straightened or replaced.

with

Place

seating.

(1)

and

square

gauge.

groove side clearance with

the bore

d.

to

used.

proper piston

Connecting

c.

with a

rings with

piston rings are

on

ring

to

and use

no side clearance.

"glaze"

the

the

to be

are

ring

ring in

down the bore to

halfway

fractures,

of

obtained.

PISTON RINGS. Install the

about

bore

fixture

replaced.

fit is

Measure the ring gap

sure

Rods

trial cut. Repeat the

the cylinder bore. Invert the piston, push

bolts

Replace defective connecting

Ring Clearance Check

and make another

slightly

be

should

ream

is twisted

rod

bushing.

the bushing.

or replace

pin,

rod

alignment on a

nicks, signs

rod

nicking,

is excessive,

should

pin

out-of-roundness.

Check the connecting

ance

squirt

(fig. 39).

piston pins

rods

in the

clearance

connecting rod for

each

fit The

bushing

to

piston pin

0.0001-0.0003 inch

a

after

the

sure

are clean.

Check the have

Make

the inserts.

of

not

clearance.

bring

the

If the

various selective

clearance within specifica

be necessary to regrind the install undersize bearing inserts. crankshaft after

bearing is

not

marked

the

chankshaft

bearing is installed

too tight.

to

Section 10

10. The

EXHAUST SYSTEM

following general inspection and repair procedures to the exhaust system

pertain

of all engines.

ing

surfaces.

system

for

exhaust

Check the

signs of

severly

various sections of

leaking

thermostat

or

valve

or

for

burning

mating

surfaces with

signs of

sections

showing

exhaust

thermostat

nicks and

control

oil stone.

an

leaking

or

valve

burrs from the

burning

Replace

through.

assembly does

all

The

not re

warped mat

the

exhaust

through. Check the

proper operation.

SERVICE Letter No.

REPAIRS. Remove the

(2)

manifold

(1) CLEANING AND INSPECTION. Clean the mat ing surfaces of the manifolds and cylinder heads. Inspect the manifold for cracked, nicked,

27

Exhaust System

quire replacement unless valve

is burned. Free up frozen heat

graphited

LETTER

Date

Subject

i

it becomes inoperative,

penetrating

or

the

control valves with

oil.

REFERENCE Changes Information on Page No.

Part ONE

POWER PLANT Chapter

n

(EBP)

6-Cylinder 223 Cubic Inch

Engines Page

Section

Engine Front

2

Manifolds

3

Cylinder Heads

and

4

Oil Pan

Pump

5

Crankshaft

6

Camshaft Sprocket, Camshaft,

7

Flywheel, Crankshaft,

8

Connecting Rods, Pistons, Pins,

9

Exhaust System

has

a

bore

of

Steady Rest

29

and

Oil

30

Valves and

and

engine

support

and

34

Bearings

36

and

37

Rings

cubic

inch

car engine

front steady weight

(figs. 1

and a stroke of

rest

and,

front

its

and

name

4) does not implies, acts

one

retains

bolt from the

remove

(2)

the steady

rest.

Remove the

the insulators in the steady

7.5 to 1.

3.6 inches.

REMOVAL. Remove the two clamp bolts of

a compression ratio of

ENGINE FRONT STEADY REST

(figs. 3 as

It has

and

as a stabilizer only.

(1)

33

Oil Seal

39

3.62 inches

any engine

and

Cover,

Bearings

1. The

32

Pressure Relief Valve

Cylinder Front

Damper,

The 6-cylinder 223

2)

28

1

rest

spacer

at

the

rest,

bolt that

the insulators. Remove two bolts from the left

rest

of

the

ngine

rest

Before

installing

bracket for

Check the insulators for damage

bracket

Replace defective on

the

block,

then

assembly.

the steady

pressibility.

side and

side

INSTALLATION.

check

welds.

bracket. Remove

the bracket

right

cylinder

parts.

the

steady

cracks or

broken

and

loss

of

corn-

Install the steady

block. Tighten the bolts to

T~

46 H'Z

"~~^

V^^l'll*fr^l^^ 33797-S

,

~^5265^

^*N^[ X

/ V 'W/*.^ J

'

\"''

^^^ :

^

^34846-S

..-'///

/

-t5^S^V

^

/ .

v*-*r^t7 ::

'**'/''''

ill ^V

SCREW

39935-S

SUPPORT5261

MUFFLER5230 BOLT23438-S ^^^ip!^C'''

*fg&.

MUFFLERINLET PIPE-.

CLAMP5260

34846-S 33797-S

Fig.

29 Exhaust System 6-Cylinder

SERVICE Letter No.

Date

LETTER Subject

1822

Engine

REFERENCE Changes Information on Page No.

Part ONE

POWER PLANT Chapter

m

8-Cylinder 272 (ECG

(ECJ

and

ECH)

and

292

Interceptor) Cubic Inch Engines

and

Section

Page

1

Manifolds

2

Cylinder Heads

and

3

Oil Pan

Pump

4

Crankshaft Damper, Pulley,

5

Timing Chain, Sprockets, Camshaft, Tappets,

6

Flywheel, Crankshaft,

7

Connecting Rods, Pistons, Pins,

8

Exhaust System

and

42

Oil

The 8-cylinder, 272 used

in the

a stroke of

44

Valves

and

Front Cover

Cylinder

and

and

51 53

Rings

and

inch

engine

a

bore

3.30 inches. It has

a

7.6:1

of

(fig. 1

and

3.62 inches

2)

models

is

interceptor

used

cubic

unit and

inch

the

ECJ

in the Thunderbird (figs. 3

is

used

version of

and

in the

engine

are

bore

police

Overdrive) Repair

the engine

4). Both

a

pression ratio.

compression ratio.

engine

have

inches. The

and

or

police

48

Bearings

Bearings

has

The 8-cylinder, 292

47

55

cubic

passenger car,

46

Pressure Relief Valve

and

The or

of

3.75 inches

interceptor

ECJ

8.5:1

and a stroke of

has

engine

engine

has

an

(Fordomatic)

a

7.6:1

3.30 com-

8.1:1 (Standard

compression ratio.

and maintenance procedures

for these

engines

same unless otherwise noted.

mmmmmmmmmm

6324

Fig. 1

9A Front

View 272

6325

Cubic Inch Engine

Fig. 2% Rear

41

View 272

Cubic inch Engine

42

Chapter

III 8-Cylinder

272 (ECG

and

ECH)

and

292 (ECJ

Interceptor) Cubic Inch Engines

and

6326

6327

Fig. 3-% Fronf View-292 Cubic Inch (ECJ) Engine

Fig. 4-% Rear View-292 Cubic Inch (ECJ) Engine

1. MANIFOLDS The following replacement procedures may be used for all 272 and 292 cubic inch engines. Follow the proce dures carefully

as

some

differences

exist

sage,

than from left to right as in the single exhaust

system.

between the

various engines.

rather

(1) REMOVAL.

Drain the

Remove the

radiator.

(on the two-barrel carburetor, tape the

cleaner

air

air

horn

closed).

Intake Manifold.

a.

The intake the

straddles

manifold,

manifold

is bolted to the

center portion

the cylinder

of

automatic

carburetor,

heads

cylinder

choke

on

and

block. The engines

so

8-cylinder intake

through the through

center

hot

which

manifolds

section

contain

under

and

exhaust gases are

a

passage

the carburetor,

directed to

assist

in

incoming fuel charge, thus, stalling and icing is minimized during cold engine opera

vaporizing the carburetor

tion. The

fold

by

exhaust gases are

an exhaust

exhaust gases

diverted into the intake

thermostat

control valve.

flow from the left-hand

Part

exhaust

manifold,

until

opens, allowing manifold

in the

On

more of

the

exhaust

directly out the

vehicles equipped with a

thermostat

the right-hand

gases

thermostatically

of

the

exhaust

controlled

valve

from the left-hand

exhaust system

assembly

flow from

dual

control valve

exhaust

is installed

exhaust manifold.

right

windshield wiper

the

intake manifold,

and at

and

hose,

the fuel line

the vacuum line

at

fuel pump lines from the

the

the carburetor. Remove the vacuum and remove

the three lines as

Disconnect the distributor tor. Disconnect the throttle

vacuum

NOTE: On the back

an assembly.

line

at

the distribu

linkage. Remove the throttle

linkage bracket from the intake

pull

so equipped.

manifold.

Thunderbird,

disconnect the throttle

spring.

Disconnect the primary coil.

secondary

Disconnect the heater inlet hose

vacuum control nect

and

the

line

at

upper radiator

the

hose

wires

and

the heater

water control valve. and

the

water

the

at

Discon

pump by-pass

hose. Remove the

manifold

retaining bolts, nuts,

and

four

clamps, then remove the manifold (and gaskets), car

normal manner.

exhaust of

to flow

the

Disconnect the

if

mani

manifold,

through the heat riser passage, to the right-hand

choke control cable

fuel pump,

equipped, and coil, can be removed as an assembly.

All

at

Disconnect the

system, the

at

the

outlet

Therefore, the exhaust

to left through the heat

riser pas

buretor, The gine

is

and coil as an assembly.

standard manifold used on shown

the 272 cubic inch

en

in fig. 5.

(2) INSTALLATION. Using

new

gaskets, install the

Section

43

1Manifolds

holes in the

manifold

gaskets

and

manifold

head tapped holes. Position the

cylinder

install the

CARBURETOR GASKET

the

with

manifold

GASKET

MANIFOLD

manifold, coil, and carburetor as an assembly. Align the

clamps,

retaining bolts and nuts, and tighten them to 23-28 foot-pounds torque, working from the center

manifold

to the ends. GASKET'

Connect the

hose

upper radiator

by-pass hose. Connect the heater

the

and

water

the heater inlet hose. Connect the primary

and

pump

line

vacuum control

WATER OUTLET

and

WASHER

secondary

PLUG

coil wires.

On the

NOTE:

back

pull

Thunderbird,

VACUUM CONNECTOR

throttle INTAKE

spring.

MANIFOLD

Install the throttle linkage bracket

the intake

on

fold. Connect the throttle linkage. Connect

mani

MANIFOLD GASKET

distributor

the

6334

line.

vacuum

Install the

line, intake

windshield wiper

the fuel pump to carburetor line

and

the

connect

Connect

the three lines

windshield wiper

hose,

from the

air

air cleaner.

an

then connect the vacuum line to

the

at

carburetor.

two-barrel

on

Fill the

Install the

carburetors.

radiator.

over pipe on

nuts.

muffler

The

vehicles, is

equipped

the front opening

manifold,

of standard

where

of special

design to

left-hand

exhaust

located

the

at

the

NOTE:

Do

the

of

The heat

cap

control

over

attached mani

separate

is

valve

right-hand exhaust manifold.

REMOVALSINGLE

they

difficult,

the

and

re

to 23-28 foot-pounds torque. Install

EXHAUST SYSTEM. The

for both exhaust manifolds is the same.

muffler

bolts, flat

manifold

install the retaining

inlet

washers,

(and heat

pipe

from the

spark

manifold.

Re

plug heat shields, and

control valve on

the

right-hand

manifold).

TEMS. Coat the mating light film

into the

bolt,

surfaces of

of graphite grease.

the remaining

spark

EXHAUST the

Start the

head. Hook the

cylinder

then install the

center

DUAL

INSTALLATION

SYS

manifolds with a

manifold rear

manifold on

the

plug heat shields, washers,

bolts. Tighten the

bolt rear

and

working from the

bolts,

to the ends, to 23-28 foot-pounds torque. On the

right-hand

manifold, install the heat

a new gasket on

both

sides.

control

Install the

valve, using

muffler

inlet

pipe

with a new gasket.

T THERMOSTAT CONTROL VALVE

EXHAUST from both

crossover pipe

hot.

are

Cubic

SYSTEM.

manifolds.

Re

the crossover pipe and the manifold heat control

move valve.

heat

to the

not remove manifolds when

Disconnect the

is

exhaust

The left-hand

may warp, making assembly sulting in leaks.

hand

with a

crossover pipe

They

(1)

the dual

provide an outlet

system.

rear of

single

Manifold272

pipe with a new gasket.

removal procedure

(4)

design

on single exhaust equipped vehicles.

fold is

for the

in fig. 6.

right-hand exhaust

inlet

nuts

REMOVALDUAL

(3)

the

exhaust manifolds and crossover pipe

Intake

manifold studs, and

Tighten the

move

exhaust system are shown

the

Disconnect the

b. Exhaust Manifolds. The

5Standard

Inch Engine

the

choke control cable and remove the tape

horn

Fig.

assembly.

the fuel pump. Connect the

at

the intake manifold and the fuel line

Connect the

as

line,

vacuum

Disconnect the

manifold.

muffler

Remove the

inlet

pipe

from the

right-

bolts, flat washers, spark plug

shields and manifolds.

(2)

INSTALLATIONSINGLE

SYS-

EXHAUST

TEM. Coat the mating surface of the manifold with a light film of graphite grease. Start the manifold rear bolt into the

cylinder

head. Hook the

then install the

spark

manifold on

plug heat

the rear

and

shields

bolt,

remaining

retaining bolts. Tighten the bolts, working from the center to the ends, to 23-28 foot-pounds torque. washers and

Install the manifold

manifold

with

a

heat

new

control valve on

gasket

crossover pipe gasket on

on

the left

both

the

sides.

manifold.

MUFFLER INLET PIPE

FLANGE-

right-hand Install

Place the

one

cross-

6339

Fig.

6 Exhaust

Manifolds and Crossover Pip* Single Exhaust System

44

III 8-Cylinder

Chapter

272 (ECG

ECH)

and

and

292 (ECJ

Interceptor) Cubic Inch Engines

and

2. CYLINDER HEADS AND VALVES The

head

cylinder

contains

the valves

the

and

able provided a water outlet

insert is

new

plug

heads plug

or

from

removed

plug

or

to the field

insert installed

so

interchange

are

temperature sending

head

one end of the

insert is installed in the

serviced

or

heads

and right-hand cylinder

unit

have the

will not

they

can

other end.

be

used

Cylinder

the right-hand

cylinder

by

in fig. 7. The temperature sending

for

either right

the left-hand

apply

a

light

surface of

cylinder

head

with

the

The intake incorporate

shown

insert is installed in

same tool.

coat of water resistant sealer

the plug or insert before

opening

using the tool

unit

Be

sure

to

to the sealing

installation.

and exhaust valves are

arm

assembly

rods

in

and oil

sequence.

Remove the intake

Remove the

manifold.

Remove the ignition harness bracket from the

right-

When removing the right-hand head from all other vehicles, disconnect the battery ground cable, and the oil dipstick tube bracket from the cylinder head. Remove

out of

the

Remove the

bracket to

cylinder

front mounting bolt,

head bolt,

and move

remove

the

the

generator

on

The distributor location

the

head is

one

cylinder

tween the head

on

cylinder

the Thunderbird

and

head in its

fix

holding

the installation of the rear

right-hand

fixture

Lift the

normal position.

In

hole forward. head

off

the block. Do

block. Remove the head

shown mounted

in the

not

pry be

gasket.

The

holding fixtures in fig. 9.

b. Cylinder Head Disassembly. Remove the shaft, then

shaft.

Be

remove

in their

sure

rocker

to

flat washers, spring

the

arms, springs,

identify the parts

original positions.

The

they

washers, and

brackets can

off

the

be installed

rocker arm mechanism

is

the cylinder head combustion

carbon out of

Compress the

in fig. 1 1, then

remove

valve springs with

the

Use

valve stem

(4) long

manifold

Tool T53P -33623 -A

so

and

rocker arm

disassembled in fig. 10.

chamber.

Tool T 531-200- A

the

cotter pins at each end of

Slide the

plugs.

shown

way.

intake

mounting bolts

the tool

locks,

shown

and sleeve.

TEMPERATURE SENDING UNIT

(Handle)

(Adapter)

ToolT54L-6085-A (Detail 1

6065

7 Cylinder

head).

head bolts. Install the

cylinder

wire

holding fixtures.

Clean the

Fig.

Disconnect the

temperature sending unit (left-hand

original positions.

be

can

head.

Remove the distributor cap when removing the hand head from the Thunderbird.

generator

they

push rods so

from the

ture

manifold.

generator

the

Identify

rocker

valve push

in their

stall the

the

Remove the

plates.

replaced

NOTE:

(fig. 8).

Drain the cooling system. Clean the outside of the valve chamber cover. Remove the cover. Remove the exhaust

right-hand cylinder

baffle

the

remove

by

arms

rocker

and

Cylinder Head Removal.

spark plugs.

the

on

the adjusting screws, then

will not permit

a.

Assembly

Release the spring tension

head

the rotating type

umbrella-type valve stem seals

6074

water outlet

rear water outlet

head

8 Valve

Fig.

loosening

The plug is installed in the of

VALVE SPRING RETAINER

and a

left-hand installations.

or

LOCKS

OIL SEAL-^

arm mechanism.

The left

SLEEVE.

VALVE SPRING

rocker

Head Water Outlet

Plug

Installation

Fig.

9 Cylinder

Head

and

Holding

2)

6066

Fixture Typical

2 Cylinder

Section

Heads

and

45

Valves

Release the spring compression and remove the tool. Remove the valve spring retainer, valve spring, and the valve stem seal.

Remove the

valve.

Cylinder Head Assembly.

c.

Oil

all

moving parts

installed in

plugs are

with engine oil.

each end of

the

Be

sure

the

rocker shaft.

oil

The

be installed cup side out. The plug is an inter ference fit in the shaft; however, do not peen the plug. should

plug

Install

flat washer, spring washer,

a

in

and a cotter pin

the parts in the

order shown

After grinding grinding seats it is with a

one end of

the

flat washer, shaft. Install

another

rocker

in fig. 10.

installing new valves and good practice to lightly lap in the valves grade lapping compound to match the

medium

valves

or

seat.

Install moved or seal.

to

which

Install the

against

in the

each valve

it

was

valve

from

port

fitted. Install with

spring

the

11,

tightly

the spring

compress

tainer, then install the

sleeve and

was re

a new valve stem

the head. Install the spring retainer.

illustrated in fig.

it

which

wound coil

Using the tool and

spring

6370

re

Fig. 7

the locks.

Install the

d. Cylinder Head Installation. Using position

a new gasket with sealer applied

the cylinder head

holding fixture and

the

tightening NOTE :

the

sequence

to both sides,

engine.

brackets. Install the

tighten them to proper

on

Remove the

cylinder

head

55 foot-pounds torque (fig.

bolts, (cold) in

12). Repeat the operation,

the bolts to 65 foot-pounds torque (cold).

The

proper wrench

to

use

for

each

the

Fordomatic

the

socket on

and

oil

the

force the

oil

bly

on

baffle

of

plates on

Installing Valve Locks

in their

proper

locations. Position

the head. Place the

rocker assem

the plates, then install the bracket retaining

and nuts. end

push rods

or

Be

sure

bracket from

the tube must

to install the which enter

it

oil

drain tube

was removed.

the

on

screws

the

same

The bracket

locating hole in

end

the rocker

bolt is in

socket extension past

level indicator tube in

the

Removing

shaft.

dicated in fig. 12. When using the socket and extension on a Fordomatic equipped vehicle, work from the top of the manifold,

?

order

to get

bolt head.

CAUTION :

Be

are not upside

sure

the rocker shaft support

down

when

brackets

is installed.

the assembly

There is a 0.020 inch difference in bracket height reversed.

Tightening

versed can result

in

a

the screws

broken

with

the

when

brackets

re

rocker shaft.

LOCK

NUT-

**o

WASHERS

ADJUSTING SCREW

SPRING WASHER

OIL OUTLET TUBE

COTTER PIN

PLUG

ROCKER SHAFT

6184

Fig.

70 Rocker

Arm

Mechanism Disassembled

46

Chapter

III 8-Cylinder

272 (ECG

ECH)

and

and

RIGHT-HAND AND LEFT-HAND

292 (ECJ

generator

Interceptor) Cubic Inch Engines

and

front mounting bolt, then fasten the

bracket to the cable and the

cylinder

head

right-hand

the distributor

spark

RIGHT-HAND AND

LEFT-HAND,

n/i6"

USE

RIGHT-HAND,

l5/i6"

Sockef,

LEFT-HAND, USE S-8663-A Wrench long, plus SX-5 Extension

USE S-8663-A Wrench

head. Install the intake

12 Cylinder

Make

a

Fill the cooling

the temperature sending

lash

unit wire

adjustment

to 12-15

Connect

the

on

right-hand

Install the

manifold.

exhaust

the

it has

engine until

operating temperature. Tighten the head

Tighten the

installing the right-hand head on all vehicles the Thunderbird, position the generator, install

Cement

necessary.

valve

a new gasket

if necessary, then install the

cover

arm

rocker

cover

foot-pounds

to 2.0-2.5

nuts

torque.

After

NOTE:

(left-hand head).

After cept

system and run

the lash if

and adjust

cover.

lash

valve

preliminary

screws and nuts

the

on

bolts to 75 foot-pounds torque (hot). Check the

Tightening Sequence

Tighten the bracket retaining foot-pounds torque.

Thunder

manifold.

6299

Head Bolt

the

on

plugs, then install the heat shields and the

reached normal

Fig.

ground

cap.

Install the ignition harness bracket cylinder

battery

dipstick bracket.

After installing the

bird, install

head. Connect the

generator

the

ex

tightened to specifications, no

the

necessary

and

the

bolts

been

have

bolts

head

cylinder

tightening is

additional

be disturbed.

should not

3. OIL PAN AND OIL PUMP AND PRESSURE RELIEF VALVE The hand ate

pump is externally

corner of

shaft

pump pan

oil

the engine,

and

is driven

by

an

fits in the distributor drive

which

tube to

uses a one piece

(fig. 13). The

attached to the oil

oil

inlet

by

pan

up the

pick

intermedi

The

shaft.

from the

oil

oil

assembly is

screen and cover

The

retained

and

2

by

a one-piece cork

bolts

at

the

front

splash pans

Disconnect the the

NOTE:

before

oil

oil pan

No, 1 the

oil

cylinder

pan

can

and

front

the

pan

the rear,

front. crankcase.

(except

on

Remove the

the Thunderbird).

at

the

oil pump.

be

be

on

Re

the

oil pan.

top dead

center

screws and remove must

securing the

nut

pan, then

the

remove

oil

oil

pump inlet tube to

inlet

screen and

pump

tube assembly from the oil pan.

(2)

INSTALLATION. Coat the

taining

nut with oil

resistant

screen

assembly

sealer, install the

re

copper

the

to 10-12 foot-pounds torque. Coat both

pan gasket with sealer.

hold the

pan

in

Position the

place against

the retaining screws on each

remaining screws,

pump inlet tube

retaining

gasket,

nuts on studs at

REMOVAL. Drain the

engine

oil

washer on

to the cylinder block and

18 cap screws, 2

nuts and

(1)

move

sealed

by

cylinder cover

the

nut

is

oil pan

Remove the

tube, then install the oil pump screen and inlet tube assembly in the oil pan. Tighten the retaining

a nut.

Oil Pan.

a.

is

the lower left-

mounted on

and

the

sides of a new

gasket on

block,

side of

and

the

the

oil

pan,

install two

pan.

of

Install the

tighten the screws, from the

cen

ter to the ends, to 12-15 foot-pounds torque.

Using

a new

inlet tube to

seal, connect the oil pump

Tighten the

pump nut to 10-12 foot-pounds torque. Install the engine front splash pans

the

pump.

(except the

on

proper grade and

A

Pump

gear-type

lubrication

tube to

oil

the Thunderbird). Fill the

removed.

b. Oil

oil

quantity

system.

with

lubricant.

Pressure Relief Valve.

and

pump is

of

crankcase

used

The

to supply

oil

pressure

oil

to the

relief

engine

valve

in the pump housing. The pump is driven intermediate shaft from the distributor shaft.

mounted

by

is an

(1) REMOVAL. the pump, and

Disconnect the pump inlet tube at loosen the tube at the pan. Remove the

three cap screws and lock

washers

to the block. Remove the pump 6383

Fig.

Inlet Tube272 Cubic Inch Engine

13 Oil

Pump

and

mediate shaft

if it

securing the pump

and gasket and

comes out with

the

body

the inter

pump.

(2 ) DISASSEMBLY. Remove the four cap screws re taining the pump cover to the pump body. Remove the

3 Oil

Section

cover plate and gasket.

to drive the

Remove the

assembly

oil pressure relief

the pump drive

GASKET

shaft

GASKET

pump idler

and oil

oil

\

C

gear. and

plug, gasket, spring,

DRIVEN

GEAR

the

view of

pump is

oil

"O"

Oil

oil pressure relief valve

and gasket. and shaft

a

all parts

oil

oil

pump

RING SEAL

plug,

GASKET-^Q

gear

pump

PLUG-*^

to 12-15 foot

shaft end

COPPER WASHE INLET TUBE

INLET TUBE

with

play

THUNDERBIRD

PASSENGER

Plastigage (0.0015-0.0055 inch).

or

SCREW

TTING

SPRING-J

cover plate with a new

cover plate screws

torque. Check the

dial indicator

and cover

the

gear and

Install the

tighten the

thoroughly. Install the

plunger, spring

Install the idler

assembly.

and

pounds

COVER

shown

PLUNGER-WI

(3) ASSEMBLY.

GEAR

DRIVING

INTERMEDIATE SHAFT

in fig. 14,

gasket,

47

Relief Valve

Pump and Pressure

HOUSING

A disassembled

plunger.

tap

not

Oil

and

the pump body. Remove the

cover off

gear and shaft

pump

Do

Pan

CAR AND INTERCEPTOR

(4) INSTALLATION. in the

ate shaft

oil

distributor shaft,

Insert the

pump

and set

mediate shaft will engage

Note the

shaft.

the

pump intermedi

oil

oil

position of

shaft so

pump

the distributor

shaft.

6340

the

Fig. 14-Oil

the inter

Coat both

may be

ate shaft

sides of a new gasket with sealer, position

ing

the

and gasket on

block, install

the pump hous

distributor

Do

if it will

tion

not attempt

force

to

not seat against the

Align

shaft.

alignment with

of

the

if

the seat and shaft

the three retaining

screws, an tighten them to 12-15 foot-pounds torque.

CAUTION :

out

Pump

the pump in

block. The

Install the posi

intermedin

pump inlet tube

oil

Tighten the

pump.

tube to

seat

in the

necessary.

and a new seal

in the

tube to oil pump nut and the oil

oil

to 10-12 foot-pounds torque.

oil pan nut

4. CRANKSHAFT DAMPER, PULLEY, AND CYLINDER FRONT COVER Crankshaft Damper

a.

The damper

keyed to, the front cap

pulley assembly is

and

of

the

b. Cylinder Front Cover.

Pulley.

and

pressed

crankshaft and

is

The

on, and

retained

by

a

contains

cover

(1) the

REMOVAL. Drain the cooling Loosen the

radiator.

fan belt adjusting the fan

belt,

then

screw and washer

two-jawed

from the

arm

generator

from the

puller on

mounting bolts

bolt. Pivot the

remove

Remove

system.

generator

to loosen

a

and

and remove

the pulley

fan belt adjusting

the

key

crankshaft

on

using

the a

screw and washer.

pounds torque.

tension

and

generator

cooling

mixture

and

lubricate the

Line up the pulley

crankshaft.

soft

crankshaft with

metal

oil

seal

keyway

Drive the pulley

on

the

hammer. Install the cap

Tighten the cap

screw

to 85-95 foot

Install the fan belt. Adjust the fan belt

tighten the adjusting arm nut.

mounting bolts. Install the

system.

pump.

Remove the

surface with grease.

rubbing with

oil

water

pump

the front cover. The front

the

engine

Drain the cooling

the radiator. Remove the fan

the fuel

crankshaft.

whitelead

The

oil seal.

which

casting

front steady

Thunderbirds).

support on

a standard

INSTALLATION. Lubricate the

front

screws also retain

(1) REMOVAL.

gine

(2)

a one piece

are mounted on

Install

crankshaft.

is

cover

crankshaft

retaining

(front

rest

front

and

the fan belt. Remove the cap

the pulley,

the

fuel pump

and

screw and washer.

cylinder

the

way.

fasten the water

cover

front

mounting bolts

the bracket

at

out of

the

the

and move

en

way.

it

out

Remove the

Remove the four bolts that

to the cylinder front cover.

tube.

and

fan belt.

then remove the

crankshaft pulley.

rest.

Remove

hub. Remove

mounting bracket bolts

Remove the

oil pan

bolts,

bolt,

and

adjusting bracket

generator

bypass

generator

and move

front steady

engine

the

arm

generator

front cover,

Loosen the of

Loosen the

blades

system.

Remove the

then remove the

seven

water

Disconnect

remaining front

pump

and cylinder

cover as an assembly.

Tighten the

radiator.

Fill the

(2 ) FRONT OIL SEAL REPLACEMENT. Drive the old

seal with a pin punch.

Clean the

out

seal recess thor-

48

Chapter

III 8-Cylinder

272 (ECG

ECH)

and

and

292 (ECJ

Interceptor) Cubic Inch Engines

and

Tool-6700-BEE

6203

Tool-6059-AAE 16 Front

Fig. Fig.

15 Oil

Installation Typical

Seal

alignment

front oughly.

Coat the

the tool

with until

recess with

shown

sealer,

and

in fig. 15. Drive the

it bottoms. Check the

been installed to be

sure

seal

install

seal

into the the

after

spring

it is properly

a new seal recess

seal

has

in the

positioned

INSTALLATION. Clean the

(3) Apply

a

light film

Coat both

with sealer and position cover

assembly

on

in fig. 16 to

shown

5. The

on

the

block,

make sure

sides of

surface of

the

the

cover gasket

block. Position the front

and align

the

cover.

it

with

oil seal will

the tool

be in

proper

TIMING CHAIN, SPROCKETS,

camshaft

which connects

sprocket

the

it

front

cylinder

to the rubbing

of grease

crankshaft oil seal.

oil

sealer.

Install the

steady

rest

support

Coat the

pan.

bolts,

(support

bracket

Install the bolts cover

on

the

at

bolt threads

with

the engine

front

sure

making

Thunderbirds)

generator

and

installed. Tighten the Vs inch bolts

are

to 23-28 foot-pounds torque

and

the

inch bolts to

%6

is driven

the

by

means

camshaft sprocket

timing

of a

chain

to the crankshaft

(fig. 17).

of

the

eccentric

pump

is

camshaft.

a

slip fit on,

The

and

by-pass tube. Install the

Using

a new

gasket, install the fuel

pulley.

the fan blades

hub. Install

and adjust

Install the radiator, then fill the cooling engine

normal

until

reached, then

water

pump,

timing

camshaft

cap

check

and

marks on

screw.

weight

sprocket, fuel

operating

for

fan

pump.

Install

the fan belt.

system.

temperature

coolant and oil

Run the

has been

leaks.

AND BEARINGS

as a unit.

the

crankshaft

Crank the

engine until

the

sprockets are positioned as shown

timing

Remove the fuel pump

from the

camshaft.

forward,

chain

eccentric and counter

Slide both

and remove

camshaft sprocket

the

sprockets and

the

camshaft sprocket

and chain as an assembly.

counterweight, eccentric, spacing washer,

by

(2) INSTALLATION. and

screw.

timing

marks

(1)

and

Remove the fuel pump eccentric and

is keyed to,

camshaft washer, and lockwasher are retained on the

cap

water

in fig. 18.

camshaft sprocket

the end

Install the

CAMSHAFT, TAPPETS,

Camshaft Sprocket, Fuel Pump Eccentric, and Timing Chain. The

a

the

crankshaft.

12-15 foot-pounds torque.

seal.

a.

of

the

with

Alignment Typical

Cover

REMOVAL.

Remove the

cylinder

front cover,

on

Position the

chain on the camshaft.

the

sprocket are

camshaft

sprocket

positioned as shown

camshaft sprocket

Be

sure

and

the

in fig. 18,

the

timing

crankshaft and

there

Section

5

Timing Chain, Sprockets, Camshaft, Tappets,

and

49

Bearings

CAMSHAFT SPROCKET

COUNTERBALANCE SPACER BOLT

SCREW

A

(jJmmmWIL)

(J

^

P

WASHER LOCK

KEY

ECCENTRIC

WASHER

OIL DRIP TROUGH

TIMING CHAIN 6207 17 Camshaft and

Fig.

12 timing

are

the fuel pump

spacing screw,

Install

fan,

and

adjust

the

between the

marks.

Install and

counterweight, eccentric,

camshaft.

Install the

sprocket

cap

tighten the screw to 35-45 foot-pounds torque.

a new oil seal

install the

pins

eccentric

washer on

and

link

chain

cover.

in the

cylinder

Install the fuel pump,

radiator.

Fill the cooling

front cover, then

crankshaft

system.

pulley,

Check

and

the ignition timing.

Related Parts

crankshaft

assembly,

is

on

the camshaft is

cylinder

front

an assembly.

both

Remove the

supported

the

controlled

the cylinder block

at

by five steel-backed babbit, cylinder

by

a

and

rocker arm assemblies.

move

the valve

Crank the

fan blade

cover. and coil

as

covers, then remove

Remove the

push rods.

Re

push rod chamber cover.

engine until

the

the timing

marks on

the cam

crankshaft sprocket are positioned

in fig. 18.

distributor

housing

and scribe a

and cylinder

block to

line

mark

on

the

the

posi-

block. End thrust

thrust plate

the forward

pump

rocker arm

Remove the distributor cap,

insert-type, bearings in of

the

shaft sprocket and

b. Camshaft. camshaft

and

water

Remove the intake manifold, carburetor,

as shown

The

pulley, fuel pump,

end of

THRUST PLATE

SPACING RING

mounted

the camshaft

(fig. 19).

(1)

REMOVAL. Remove the radiator, KEYWAY

KEYWAY

Fig.

18

radiator

grille,

TIMING MARK

TIMING MARK 12 PINS BETWEEN MARKS

Aligning Timing Marks

CAMSHAFT

6360

Fig. 7 9 Camshaft Thrust Plate

6206

50

Chapter

III 8-Cylinder

272 (ECG

and

ECH)

and

292 (ECJ

and

Interceptor) Cubic Inch Engines

it through the bearings. Install the thrust plate and foot-pounds torque. spacer ring. Tighten the bolts to 12-15

TAPPET

slide

Install the

Install the

timing

key in

wodruff

the

camshaft.

camshaft sprocket, crankshaft

Be

chain.

the

marks on

the timing

sure

sprocket, and camshaft

sprocket and crankshaft sprocket are positioned as shown

in fig. 18,

there

and

Install the fuel pump spacer, washer, and

Install MAKE FROM W WELDING ROD

a

The

play.

end

again.

play

and

bolt. the

check

end

camshaft

be 0.003-0.007 inch. If the the thrust

replace

marks.

counterweight, eccentric,

camshaft sprocket

should

play

between the

pins

eccentric

dial indicator

play is excessive, end

12 link

are

plate and check

Remove the dial indicator, then

end

the

remove

the tappet holders.

Install the

were removed.

Fig.

20 Tappet

Replacing

Tool

the rotor and distributor housing. Remove the

of

Install the

Remove the fuel pump eccentric, camshaft sprocket, and timing chain. Remove the camshaft thrust plate,

key,

and spacer ring.

lift the tappets, then install lator spring clips,

Carefully front

of

remove

the

on each

the

(2)

Use

clothes

the camshaft

or window regu

keep

by

crankshaft assembly.

lifter to

a magnetic

pins,

tappet to

the tappets up.

pulling toward the

camshaft

bearings.

Tool T521

Replacer

adapter

adapter

-6261-

T541

T541

.

camshaft and

-6250

-A

[Detail No. 2) (Detail No. 1)

rotor and

warm

front

cover.

the

water

radiator

replace

the

in the vehicle, the fuel

move rest.

and

pump

valve

up the

lash

engine.

vacuum

linkage

Remove

assembly.

valve

tappets

proceed as

Make

rods.

pump.

the

21 Camshaft

Bearing

Removal

covers,

intake

lines, the

and

choke

system.

(cold),

final

a

arm

valve

and

lash

covers.

the

with

engine

-6266

Remove the

cylinder

engine

timing

gear

-A

and coil as an

valve push rod cover.

assemblies,

Re

front steady front cover. Remove the

and valve push

distributor. Remove the

camshaft

(Adapter)

ToolT53L-200-A[Handle)

Fig.

installed

follows:

rocker arm

Remove the

Tool T 541

Pig,

the

radiator and radiator grille support.

Remove the

rocker arm

Clamp

and

adjustment

rocker

fan blade

and radiator grille.

Remove the intake manifold, carburetor,

~~

housing.

Install the fuel pump,

hoses,

accelerator

(hot). Install the

Remove the

Adapter

scribed

Tappet Replacement.

c.

To

CEE

6250. A

carefully

the

position

valve push rod chamber cover and

preliminary

thoroughly

the

block, using

they

Install

rocker arm assemblies.

the carburetor. Fill the cooling a

which

cap.

and

fuel lines. Connect the wire at

holes from

Install the fan belt, radiator,

adjustment

INSTALLATION. Oil the

Remover

damag

cylinder

Connect the

manifold.

Make caution to avoid

to properly

pulley,

Install the

engine.

NOTE: Exercise the necessary

ing

as guides

same

cylinder

Install the distributor

distributor.

woodruff

Install the

the distributor in the

lines tion

in the

push rods

6362

22 Camshaft

Rear

6095

Bearing

Bore

Plug

Removal

5

Section

sprocket and

tappets

timing

them

camshaft until

the camshaft

of

lobes,

with clothespins or window regulator

Remove the install

one

block. A

Remove the

camshaft.

tappet

spring

Bonney flexible tappet replacing tool

fabricated tion. As

in fig. 20,

as shown

each

can

tappet is

new

clips.

and

time through the bottom of the

at a

be

used

installed,

clothespin or window regulator clip.

bearings tool

holder,

or a

for this

secure

Install the

it

opera with

a

is

Remove the

push

distributor,

the

move

engine and mount

flywheel,

chain and

top

(1) REMOVAL. the camshaft the clutch

with

Re

The

and are

Drill

a

assembly,

cylinders to move

the con

pilot

V2-inch hole through the plug

sure

to

align

the

bearing

since

the bearings

it

Install the clutch

wheel,

push

installed,

timing

when

the bearings

be taken

to the

with oil resistant sealer and

install the

in fig. 22.

assembly, oil

bolted

on

shrink

fit

On face

is

in on

bolts. The flywheel

position.

timing oil

pan,

sprockets, cylin

chain and

pump assembly, generator,

Set

engine.

adjust

and

The flywheel has two

180

is

a

vehicles, the

friction

installed

rear

INSTALLATION

(2)

used

apart, to

checked

the

with

engine

the ignition

OVER

OR

STANDARD

-

apply to

all

Fordomatic

on

drive

which

plates

the

equipped vehicles

riveted

to the

converter cover

is

removal

vehicles,

installation

and

except

a

Fordomatic

it

will

vehicle

to locate the

plate

cannot

assembly from the

be necessary in

order

to

to

rubber plugs

REMOVAL

flywheel

release

the

the transmission

the

engine

from the

OR

OVERDRIVE

housing

rod, spring,

sure plate and

and

dust

cover.

Remove the

bearing. Remove the

disc. Remove the flywheel.

clutch

clutch pres

a

the

pressure

rod,

bearing, cover.

con

bolts. Raise the

safety

stands.

Remove

linkage shield, the torque

shaft.

and

cable

con

converter air

inlet

access plate.

Turn

the drain plug is

at

the lower

torque converter.

Disconnect the

transmission control

battery

the

remove

upper

plate, the torque

access

converter until

starter.

move

Remove the two

the torque converter front

Remove the

the flywheel.

STANDARD

control

Remove the drive

the

block

engine

Drain the transmission

edge.

equipped

a

to

vehicle and position

and

TRANSMISSION. Remove the transmission. Remove the

of

shield,

as

Using

housing dust

from the floor pan, then

housing

verter

lower

removed

release

REMOVALFORDOMATIC.

(3)

attached

Thunderbird; therefore,

remove

replace

be

clutch

evenly, to

torque.

disc, install

clutch

hub. Install the flywheel

and

and

the

on

Install the transmission.

a

(1)

and

cable and

The Fordomatic

75-85 foot-pounds

disc. Install the

verter

procedures

to

pilot shaft

outer

Thunderbird.

separate

Tighten the bolts alternately

flywheel,

the torque

following

NOTE:

the

front

(fig. 24).

The

seat

surface which

vehicle.

spring-steel

edge

as a

and

removed,

dis

and

plugs,

lash.

and valve

spring,

or overdrive equipped

in the

mounted

gear

by the clutch disc. The flywheel can be

runout,

only be

can

The flywheel ring

the flywheel is used

engaged

retained

the flywheel.

standard

of

for

by

one

is

piloted on a shoulder and six

fly

tappets, camshaft, crankshaft,

valve

Install the

crankshaft.

the crankshaft

After

coat a new camshaft rear

DRIVE TRANSMISSION. Position the flywheel

on

No. 3

with

rocker arms.

rocker arm assemblies, spark

rods,

tributor.

care should

bearings

camshaft

block

cylinder

supplies oil

are

plug

as shown

plug

holes in the

oil

the oil holes in the

bearing bore

in fig. 23.

crankshaft and related parts are shown

The flywheel is

holes

oil

FLYWHEEL, CRANKSHAFT, AND BEARINGS

Flywheel.

a.

hole.

interchangeable.

der front cover,

bearing bore, then remove the plug bearing remover (7600-E). Pull the

rear

cylinder

one oil

bearings have five

camshaft

cylinder

pan,

tappets. Push.

and valve

has

bearing

camshaft

installed. Particular

are

cam

clutch

four

other

assemblies,

way.

6. The

sprockets,

the

of

the

rods out of

oil

pump assembly,

crankshaft, camshaft,

the pistons to the

necting

oil

adapter with a

bearing

to install the bearings in the

used

NOTE: The No. 1

with

on a workstand.

rocker arm

plugs,

to install the bearings. A

block.

all

rods, generator,

front cover, timing

at

spark

it

in fig. 21

same tool shown

camshaft.

Replacement.

Bearing

replacement

in fig. 2 1.

larger flange is

Be

d. Camshaft

bearing

the

with

INSTALLATION. The

used

51

Bearings

and

the block

out of

shown

(2)

and secure

Remove

oil pan.

the

fingers,

the

with either a magnet or

the tappets clear

raise

Turn the

chain.

be lifted

can

Timing Chain, Sprockets, Camshaft, Tappets,

rod

at

speedometer

the transmission.

from the starter, then

Remove the transmission

dipstick,

remove

then

re

the filler tube.

Install the drain plug in the torque converter. Position jack under the transmission. Remove the transmission

support rear

of

bolts. Remove the frame the transmission.

securing the torque

plate.

member at

the

Remove the two lower bolts

converter

housing to the

Move the transmission back far drive

cross

Secure the torque

enough

engine

block.

to clear the flex

converter to the

housing.

52

Chapter

III 8-Cylinder

272 (ECG

and

ECH)

and

292 (ECJ

Interceptor) Cubic Inch Engines

and

FLYWHEEL AND

JOURNAL SEAL TO CYLINDER BLOCK

MAIN BEARINGS

RING GEAR

CRANKSHAFT SPROCKET

-SEAL

RETAINER

CAP TO BLOCK SEALS BOLT

LOCKWASHER

6343

MAIN BEARING CAPS

Fig. CAUTION:

If

the torque converter

is

off the splines. Remove the flex drive plate from the

23 Crankshaft and

not

secured, it

INSTALLATION

flex drive

the

on

plate

crankshaft.

engine

Tighten the

retaining bolts to 75-85 foot-pounds torque. Align the

will slide

(4)

Related Parts

housing dowel holes, then install converter housing to engine block bolts.

converter pilot and

crankshaft.

FORDOMATIC. Install the

the lower torque

Install the flex cross member. rear support

the

plate

to

converter

bolts. Install the frame

Remove the jack. Install the transmission

bolts.

Connect the transmission throttle

linkage,

manual control

the torque

stall

shield, torque

torque

converter

lower

linkage,

the

and the speedometer cable.

converter air

converter

control

inlet shield,

housing front access

control

access

In

linkage

cover, the

cover, and the

oil

filler

pipe.

Install the starter, then the

starter.

stands and

ing

to

Install the drive

lower the

engine

position

vehicle.

with

fill the torque converter, then reached on

and adjust

Fig.

24 Flywheel Assembly Fordomatic

throttle

cable

to

Remove the safety Install the converter hous rubber plugs and

mat.

Fill the transmission

level is

battery

shaft.

block bolts. Install the

the floor

6086

the

connect

fluid. Start the add

fluid

until

engine

the

to

proper

the dipstick. Check for leaks.

Check

the manual control, the neutral switch, the

linkage,

the

engine

idle,

and

the dash pot.

6

Section

Flywheel, Crankshaft,

b. Crankshaft. The

is

crankshaft

integral

water

from

made

counterweights and

iron

a cast

is statically

alloy.

It has

dynamically

and

balanced.

it

the

remove

fuel

and

oil

Remove the front

the

inlet

pan and oil

pump, then

oil

pipe as an

assembly.

water

pump

cylinder

crankshaft

Remove the

crankshaft and camshaft sprockets with the

flywheel. Remove the

key.

spacer and woodruff

pulley

Remove the

chain.

Remove the

clutch assembly.

crankshaft rear oil seal retainer.

Remove the connecting rod bearing caps, using care not to intermix the bearing inserts or caps, then carefully push the piston and rod assemblies down against the head. Remove the

installation

damaged. Be

journals

rear oil

in the

seal

of engine oil

are

the thrust

the

that

Install

clean.

block.

cylinder

sur

identified

original positions.

sure

and

a new crankshaft

Apply

to the crankshaft journals

light

a

the

and

coat

bearing

inserts.

Carefully lay the crankshaft in the bearings. Install the main bearing caps and tighten all the caps, except the thrust bearing cap, to 95-105 foot-pounds torque. Align the thrust bearing. Using new seals, install the crankshaft rear bearing oil seal retainer. Check the crankshaft end

The

CAUTION:

proper alignment with

bearing

failure may

Pull the

the

bearing

caps

quantity of lubricant. Install adjust the ignition timing.

grade and

The

three

number

main

bearing is

the

crankshaft

thrust bearing.

The bearings

they

or

removed,

crankshaft as

be

can

replaced when

be

can

the

crankshaft

is

removing the

replaced without

follows:

time, leaving the other bear ings securely fastened. Remove the bearing cap and the insert Install the bearing removing tool as shown in Replace

one

bearing

fig. 25. Rotate the the block. Install

at a

crankshaft

a new

to

bearing

slide

the

insert

on

bearing the

out of

crankshaft

journal. Rotate the crankshaft, in the opposite direction to that used for removal, until the insert is in place. NOTE: Be placed so

outlined

it

of the bearing is into position.

end

fit using the Plastigage^method Repair." "General Engine in Chapter I

journal

bearing

new

bearing

insert in the cap,

oil

the

as

crank

oil, and install the cap and

engine

with

insert. Tighten the pounds

notched

will seat when rotated

Install the shaft

the

sure

cap bolts to 95-105 foot torque. Repeat the procedure for the remaining

bearings if they

main

bearing

need replacement.

Install the

oil pan.

MAIN BEARING INSERT

be in

or premature

bearing inserts

the

and caps.

crank

Tighten

to 45-50 foot-pounds torque. the clutch assembly. Install

and

crankshaft and camshaft sprockets with

Install the

chain.

crankcase

occur.

Install the flywheel the

the crankshaft

must

piston and rod assemblies against

install the

shaft, and

inserts

bearing

thrust

Fill the

dial indicator.

with a

play

and generator.

pipe.

Main Bearings.

C.

Check the

bearings

all

pump inlet

and oil

crank

bearing

sure all parts are

(2) INSTALLATION. Be crankshaft

so

them for

mark

journals. Carefully lift

be installed in their

can

and

caps,

the cylinder block

are not

they

so

the same

on

shaft out of

faces

bearing

main

the proper

as an assembly.

Remove the

timing

pump,

crankshaft pulley.

vehicle

Remove

oil.

Remove the

pulley.

the fan and

cover with

Drain the

Remove the

pump.

crankshaft

from the

engine

on an engine stand.

the generator

oil

pan,

the engine. Check and

( 1 ) REMOVAL. Remove and mount

oil

Install the fuel pump with

Install the

as an assembly.

pump

Install the

53

Bearings

and

cylinder

front

cover with

the

CRANKSHAFT JOURNAL

Too/-'6337

timing

the fan

Fig.

and

25Main

1046

Bearing Insert Removal

7. CONNECTING RODS, PISTONS, PINS, AND RINGS The

piston

sembled

and

connecting

rods

shown

are

disas

in fig. 26.

Turn the

crankshaft until the rod of the piston

is down. Remove the

removed

pal nuts and

being

the hex head

from the connecting rod bolts. Lift the cap and the bearing insert from the rod then remove the insert from

nuts

Piston

a.

and

Remove the moving the

top

of

clean

the

the

oil

piston

cylinder

carbon

Rod Removal.

Connecting pan

and

cylinder

assemblies,

bore

caused

from the

remove

by

heads. Before any

piston

cylinder

bore.

ridge at

ring

re

the

wear, and

the cap

and

assembly

with

and piston

the

the rod,

handle

the

and

same

assembly end of a

mark

both halves to

connecting

out of

the

top

hammer. Do

rod.

of

assure

Push the

rod

the cylinder with

not scratch

the

crank-

54

Chapter

III 8-Cylinder

272 (ECG

and

ECH)

and

292 (ECJ

Interceptor) Cubic Inch Engines

and

OIL RING ASSEMBLY

PAL NUT

SPRING SPACER

PRESSURE RINGS

CONNECTING ROD CAP STEEL RAILS

Fig. pin or

the cylinder

Repeat this

rod.

NOTE:

8 in

to

on

the

respective

and

4 in

piston and

from

rod

is

one

bearings

the

to

piston pin

clips.

bearing

c.

Assembly.

the

at

assemblies

cap

right

or

bank

the

cylinder

are new and

restamped

then remove the

ing

and

from

front of the

rod and

block

Rod Disassembled

each assembly.

bank, beginning

numbers on

make sure all

the

to

for

removing the

Connecting

bearing cap must same side when installing them into their cylinder bores. If a connecting rod is ever

transposed

on

rod

from 1

left

the

The

engine.

be

procedure

Connecting

are numbered

5

wall when

26 Piston and

to another,

that the number

correspond with

the new

6385

Lubricate

parts

all

with

Assemble the connecting in figs. 28 and 29. Install the

install the with

pin retainers

light

engine and

rods

through the

by

retain

oil.

as shown

pistons

piston and

rod, then

spiraling them into the piston

the fingers. Do not use pliers. Install the piston rings,

starting

with

the oil ring then

piston pin

(fig. 27). Discard the

spiral

the

ring first. Position the butt

oil

expander

the

toward the

steel rails onto

the

center

of

ends of

the engine,

expander and position

cylinder number.

the gaps

one

inch to

either side of

the

expander

butt

ends. 120

Position the

b. Disassembly. Mark the and

rod

they the

pistons

to

assure

installation in the

were

piston

removed. pin

assembly

same

Remove the

retainers

at

each

with

cylinder

piston end

of

from

rings.

the

the

and

Remove

piston

that

all gaps are

Install the insert bearings in the connecting

apart.

same which

compression rings so

the connecting rod

rod

cap.

d. Installation.

pin,

NOTE: Install the piston

head

stalled, the rod should

piston with

the indentation

in the

front of the engine. When in bearing lock slot in the connecting

toward the rod

be

toward the outside

of the

engine

"F."

Piston Pin Remover

FRONT

POSITION NUMBERS

TO LEFT WITH PISTON DOT FORWARD

6395

6386

Fig.

27 Piston

Pin Removal

Fig.

28 Position of

Rod

Numbers Left

Bank

Section

7

Connecting Rods, Pistons, Pins,

55

Rings

and

?

FRONT

TO

INDENTATION

Tool 61 49- A

FRONT OF ENGINE

POSITION NUMBERS

TO RIGHT WITH PISTON DOT FORWARD

6071

6394

Fig.

Fig.

29 Position of

Numbers Right

Rod

piston

rings, piston, connecting rod

light

and cylinder walls with compressor on

ring the

Be

cylinder.

ders from

installed, be connecting will

sure

were

pistons

connecting

outside of

installed. Push the fig. 30. Turn the

the

piston

in the

a piston

in

piston

connecting

they

which

is to be

rod

the

cylinder number on rod

cap

into the

the

so

Oil the crankpin,

the

Be

rod

the connecting

in

cylinder as shown

throw to the bottom

its

of

and push

in the

seats

rod

bolts

downward

piston

crankpin

the

when

the

crankpin.

to damage the

journals

is

piston

bearing fit

bore. Check the

cylinder

tigage

with

into

pushed

using the Plas

in the General Engine Repair

method as outlined

Chapter.

After the connecting

numbers

the assembly is

bearing

careful not

same cylin

to

or

engine when

crankshaft

until

the

removed

to stamp the

rod and

insert the

and

a new piston and

sure

face the

to install

they

which

fitted. If

were

the piston,

bearings,

Install

engine oil.

Installation

Bank stroke.

Oil the

30 Piston

install the

specifications,

heads

quantity

have been tightened to Install the

pan.

oil

Fill the

and manifolds.

grade and

rod caps

crankcase with

of engine oil.

cylinder

the

Fill the cooling

proper

system.

8. EXHAUST SYSTEM The

single exhaust system

a muffler

inlet pipe,

(fig.

31)

a muffler outlet

consists of a

pipe,

muffler,

and a crossover

Muffler Replacement.

a.

Raise the

vehicle

pipe.

the

The Interceptor, Thunderbird, Station Wagon, and Fairlane models are equipped with a dual exhaust system

away from the

The dual

as standard equipment.

installed

exhaust system

on other models as optional equipment.

tem

consists of

two

outlet

two

pipes.

muffler

designed to facilitate

scavenging

rapid

thereby, minimizing

Inlet pipes, mufflers, tensions

ice

sys

the

and

the inlet

This

exhaust gas

outlet

(Thunderbird)

pipes,

exhaust system of

back

the

a

is

exhaust

pressure.

individual

serv

parts.

The

The

the Thunderbird pipe

apply to

all models unless other

outlet pipe replacement

varies

slightly because

for

procedure of

the

pipe

rear.

On

muffler

Thunderbirds,

manifold.

clamps

the

outlet

and rear clamps and

from the

in

Remove the

the

by

sliding

disconnect

muffler

from

in

muffler.

position

then

Place the inlet

pipe

on

Tighten the front

Remove the safety

inlet

pipe

position on

into the

clamps

tighten the clamps.

To

the

muffler

and

and rear outlet pipe

stands and

the

replace an outlet pipe

vehicle and position

outlet pipe

extension.

clamp

at

the

(except

safety

muffler.

lower the

vehicle.

NOTE: After replacing any part of the tem, loosen all the frame attaching bracket

sys

muffler

clamp

on

Loosen the

outlet

outlet pipe support

from the muffler. Position

the new outlet pipe, then slide the

to

pipe

into the

muffler.

clamps.

port

clamps.

Tighten the

clamps

twists in the system, then tighten the

the

Thunderbirds), raise

stands.

Remove the

clamps, then pull the outlet pipe exhaust

relieve

pipe and

pipe

new muffler

the outlet

clamps.

Slide the

pipe.

Place the slide

from the

front

Loosen

b. Outlet Pipe Replacement.

procedures given

wise stated.

the inlet

to the

and outlet pipe

and outlet pipe ex

are provided as

pipe

outlet pipe

outlet

outlet pipe

the inlet

muffler on

stands.

safety

and outlet pipe clamps.

Loosen the

pipe.

disengage the

In addition, the Thunderbird has

The dual

inlet

also

inlet pipes, two mufflers,

muffler outlet pipe extension.

gases,

is

muffler

position

and

Install, but do

not

outlet pipe

tighten, the sup

to

muffler

clamp,

56

Chapter

then tighten the

lower the

and

On

Ml 8-Cylinder

support clamps.

be

can

the

a

due to

replaced

vehicle and position

pipe

the

at

the

these parts

slide

when one

is

pipe

Raise the

Loosen the

Loosen the

pipe.

the

and

clamp

new outlet

muffler and on

NOTE: On

outlet

the

extension

pipe, then

dual

to outlet

the

slide

pipe

the extension. Tighten the clamps.

extension

extension

to the

then

it forward

pull

hanger located Position

(this is

a

it is free

rear until

until

it

a new extension

slip

aligned with

fit)

outlet pipe.

the

sion are to

and

free

the of

outlet

the

pipe,

support

outlet pipe. and

exhaust

to the

rear until

Slide the

tighten the

in the

outlet

it

be

can

remove

the extension, then

Raise the

and position

vehicle

Place the gasket

secure

Tighten the muffler plug.

nuts

inlet

SUPPORT 5277

stands.

Loosen

34806-S

remove the

spring.

retracting pipe

overdrive

or

standard

to the

exhaust

right

inlet

pipe on a

heater inlet duct

and

motor and seal.

two

spark plug.

pipe

the

muffler

and

in the

pipe

to 23-28

On

Thunderbirds,

inlet pipe through

to the

Install the

starter motor

motor, if

stands and

muffler.

foot-pounds

pipe clamp.

Install the

safety

inlet

new

and

they

lower the

Install

a new

manifold.

exhaust

torque. Tighten the

two

number

and seal and

were removed.

spark

the heater

Remove the

vehicle.

d. Crossover Pipe Replacement. Remove the the pipe

hand

lockwashers retaining each end to the manifolds. Remove the crossover pipe,

heat

nuts and

control

valve,

manifold

heat

and gaskets.

control valve on

the right-

manifold with a new gasket on each side.

crossover

safety

clutch

the muffler. Remove the

a new gasket on

Inlet Pipe Replacement.

a

replacing the

number

Position the remove

the left-hand

remove

retaining the inlet

system,

outlet pipe and outlet pipe exten

be replaced,

remove

the bottom of the vehicle.

of

clamp.

remove the outlet pipe.

c.

Thunderbirds,

vehicles equipped with a single exhaust

Remove the

into the

extension

nuts

the starter

and

manifold

the

On

with

the

remove

exhaust

inlet duct

through the support hanger

into the

extension

Position

both

comes

of

the bumper.

at

bumper. Slide the

NOTE:!/

to outlet pipe clamps. Slide the

equipped

or when

system,

off

Remove the safety stands and lower the vehicle. To replace the extension pipe only on a Thunderbird,

loosen the

pipe clamp.

manifold.

motor,

clamp

the

vehicles

Remove the

extension

the muffler, then pull the outlet pipe

on

inlet

transmission,

the extension pipe to the

the outlet

muffler

Interceptor) Cubic Inch Engines

pipe.

On

is, however,

condition.

stands.

safety

of

and

muffler

inlet

muffler.

Position the

on

of

rusting

clamp, then

it is free

clamp

It

replaced as separate parts.

being

rear until

Remove the safety stands

outlet pipe and outlet pipe ex

both

outlet pipe

292 (ECJ

and

the left-hand exhaust manifold to

good practice to replace

to

ECH)

and

vehicle.

Thunderbirds,

tension

272 (ECG

pipe.

Position

the left-hand manifold, then install the

Tighten the

nuts

to 23-28 foot-pounds

torque.

^33798-S

5259

23438-S

24387 MUFFLER

5230

23438-S CLAMP 5270

5287

34806-S

SUPPORT 5261

/ *-*--39935

EXHAUST MANIFOLD

-9430

CLAMP 5251

EXHAUST THERMOSTAT

CONTROL-9685^

352479-S

\ JF*J&*

^88393-S

34806-S

MUFFLER CROSSOVER

PIPE-5267

33816-S 34808-S EXHAUST MANIFOLD 9431

Fig.

31 Muffler and

Related

6217 PartsSingle

Exhaust System

'

'

'

.

"..

FORD

CAR SHOP MANUA1

FORM 7098-55