Download Ford Thunderbird 58 Shop Manual...
1958 FORD THUNDERBIRD
FORD DIVISION FORD MOTOR COMPANY
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
1958 Ford Thunderbird Shop Manual EAN: 978-1-60371-008-4 ISBN: 1-60371-008-6 Forel Publishing Company, LLC 3999 Peregrine Ridge Ct. Woodbridge, VA 22192 Email address:
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GROUP
POWER PLANT
CLUTCH, CONVENTIONAL TRANSMISSIONS, ANO REAR AXLE
CRUISE-O-MATIC TRANSMISSION
CHASSIS SUSPENSION AND UNDERBODY
STEERINO
BRAKES
GENERATING AND STARTING SYSTEMS
1958 THUNDERBIRD SHOP MANUAL
LIGHTS, INSTRUMENTS, AND ACCESSORIES
BODY MAINTENANCE AND REPAIR
DOORS, DECK LID, AND FRONT SHEET METAL
INTERIOR TRIM, SEATS, AND WINDOWS
SERVICE
DEPARTMENT
FORD
DIVISION
FORD
MOTOR
MAINTENANCE, LUBRICATION, AND SPECIAL TOOLS
COMPANY
SPECIFICATIONS 1958
FORD
Reprinted
MOTOR
with
COMPANY, DEARBORN,
MICHIGAN
Ford Motor Company's Permission
FOREWORD
This
manual provides
information for the
proper
Thunderbird. Service information a separate
manual.
The descriptions
on
servicing of the 1958
air
conditioning is
covered
and specifications contained
in
this manual were in effect at the time the manual was approved
printing.
is models at
The Ford Division of Ford Motor Company, one
of
continuous
any time,
and without
improvement,
whose
design,
for
policy
reserves the right to
or change specifications or
in
discontinue
without notice
incurring obligation. SERVICE
DEPARTMENT
FORD
DIVISION
FORD MOTOR COMPANY
1958 THUNDERBIRD SHOP MANUAL
GROUP 1 POWER PLANT Page
PART 1
ENGINE
1-2
PART 2 IGNITION SYSTEM
1-44
PART 3 FUEL SYSTEM
1-58
PART 4
COOLING SYSTEM
1-77
1-2
GROUP
PART 1
Section
1
Page
Description
1-2
2 General Engine Trouble
3
Shooting
1-7
Tune-Up
1-10
4 Tests
and
Adjustments
(Engine In
Chassis)
1-11
Camshaft Lobe Lift
1-11
Valve
1-12
Timing
Valve Clearance
1-12
Manifold Vacuum Test
1-13
Engine Compression Test 1-13 5 Engine Removal
1-14
Disassembly and Assembly (Engine Removed
7
Disassembly of
and
1-16
Assembly
Component Parts
Section
Valve Rocker Arm Shaft
Camshaft
and
1-34
Bearings
Assembly
1-27
Crankshaft
1-35
Cylinder Heads
1-27
Connecting Rods
1-35
Hydraulic Valve Lifters
1-28
Piston, Pins,
Piston
and
Main
Connecting
Rod
1-28
Oil
1-30
Pump
8 Cleaning, Inspection,
1-35
Rings
and
Connecting 1-37
Rod Bearings Conventional Flywheel
1-38
Cylinder Block
1-39
Oil Pan
1-30
Reconditioning Intake Manifold Exhaust Manifold
and
and and
1-40
Oil Pump
9 Repair Operations (Engine
1-30
1-40
In Chassis)
and
Exhaust Gas Control 1-30
Valve Rocker Arm Shaft
Engine Supports
1-40
Intake Manifold
1-41
Cylinder Heads
1-42
1-30
Cylinder Front Cover
Push Rods
1-30
and
Cylinder Heads
1-30
Camshaft
Valves
1-32
Oil Pan
1-34
Oil Filter
1-43
1-34
Exhaust System
1-43
...
Hydraulic Valve Lifters 1-27
Page
Section
Page
Assembly
6 Engine
from Chassis)
ENGINE
Valve
and
Installation
POWER
Timing
Chain
Timing
1-42
Chain
1-42
and
Oil
1-42
Pump
DESCRIPTION
engine
(Figs. I
placement pression
tified
by
name
by
the
a
FIG.
1 Interceptor V-8 "Thunderbird
Special"
Engine
4.00-inch bore
inches. It has engine
on the air cleaner
of the engine.
number on 1722-A
cubic
of 10.2:1. The
decal
letter
a
Special"
stroke and a total piston
of 352
ratio
2) has
and
3.50-inch
and a
"Thunderbird
V-8
The Interceptor
It
"H"
at
the
can
a com
is iden
bearing
be identified
beginning
the patent plate.
dis
the also
of the serial
1-3
PLANT
1723-A
FIG. 2-Engine
Sectional View
1-4
GROUP 1-POWER PLANT
CLOSED (HEAT
ON)
OPEN (HEAT OFF)
1001 1541
-A
FIG.
4 Exhaust Gas Control Valve
FIG.
6 Valve Port Arrangement
-A
3 Intake Manifold Exhaust Gas Passages
FIG.
buretor (Fig. 5). The the
carburetor
and
7
cylinders
right
side
of
feeds Nos. 1, 4, 6, and the left side feeds
Nos. 2, 3, 5, and 8 cylinders. The distributor is mounted at the left front of the intake manifold. CYLINDER
HEADS
BLOCK
AND
The cylinders front to rear on
3,
4
and
and on
are
numbered
from
bank 1, 2, the left bank 5, 6, 7, the right
8. The firing order is 1-5-4-2-63-7-8. The valves are arranged from front to rear on both banks E-I-E-I-IE-I-E (Fig. 6). The cylinder head assemblies con
and
1312-A
5 Intake Manifold Fuel Passages
FIG.
When the
MANIFOLDS
"heat intake
The serves
cover, the
as
the
tappet
valve
through
center section and under
buretor, are
gases
the
izing
through
directed to
3). The
exhaust
into
intake
the
mostatically
of
valve
the right
vapor
charge
are
manifold
controlled
(Fig. A). The outlet
gases
exhaust
in
assist
incoming fuel
the car
hot
which
haust
position, gases
part
of
in the the
directed from
are
(Fig.
directed
by
a
ther
is located
at
the
manifold.
exhaust
right
heat
riser
manifold.
"heat
ex
the
manifold, through the
passage, to the left
When
off,"
more of
from the left to flow
the
valve
exhaust
opens
the exhaust gases
manifold are permitted
directly
out the exhaust sys
tem in the normal manner.
has two
sets
fuel passages, each with its inlet connection to the
own
The intake
exhaust valve
exhaust
or
closed
chamber
passage
a
contains
also
which
manifold,
is
valve
on"
of
separate
manifold
car
tain the valves and the valve rocker arm shaft assembly.
The
combustion
in the head. integral part of
chambers are machined
Valve
guides
an
are
head. Both the intake
the
assemblies which
rotate
valve stems
is
type valve
stem
top
springs which
rotating-type time
the
valve
Lubrication
of the
each
opens and closes.
the
and exhaust valve
the
are
controlled seals
by
of the valve stems.
have provide
equal more
umbrella-
fit over The valve
which
coil
spacings
positive
valve
1-5
PART 1-ENGINE
VALVE OPEN LIFTER BODY
VALVE CLOSED
PUSH ROD CUP
PLUNGER
PLUNGER SPRING DISC VALVE
DISC VALVE SPRING
BASE CIRCLE
1717-A
7 Hydraulic Valve Lifter Operation Typical
FIG.
high
at
action
A
speed.
engine
damper spring is installed inside the valve spring to assist in preventing
bounce
valve
floating
and
at
high
are
used
rpm.
Hydraulic
valve
provide
which
valve
minimizes operation
zero
lifters valve
train
and parts
lash
noise.
into the plunger. This creates a differential above and below the valve disc. The high pressure above the valve disc forces the valve disc open and the oil fills the area below the plunger equalizing the sure
pressure on
pressure
is
and
pressure
The
disc.
identification
on
each
of
the valve
disc
opens
the chamber can again be
filled.
This
cycle
The oil
between the
clearance
in Fig. 7. When the valve is closed, lifter assembly is on the base circle of the camshaft lobe and the valve push rod is in its lowest posi tion. With the lifter assembly in this
to be present, the plunger spring ex pands pushing the plunger until there
screws.
position, the plunger spring expands
opening) the
tion
is
arm
the plunger upward. This ac
transmitted to the valve rocker
via
the
is
solid
there
valve and
valve
(zero
end of
valve
rod
until
between the
contact
the valve
rocker arm
push
the valve
lash). In
this
position, the oil hole in the lifter and plunger is indexed with the lifter oil
gallery
and oil
is forced
under pres
solid contact
between
all parts of
the valve train mechanism.
As
the
camshaft
the sudden
below the disc
push rods are solid steel with
hydraulic rocker
forcing
repeated at each revolu
cushioned
valve and the valve rocker arm tends
is
is
tion of the camshaft.
the hydraulic valve lifters are shown
the
the oil below the plunger and the valve
sockets.
Inasmuch
as
there is no valve lash adjustment with
Whenever
of
side
so
relieved
plunger
closed and
hydraulic
rotates
(valve
lifter is raised and increase in oil pressure valve
ram.
forces the valve becomes a
the lifter
During
this period a
from below the plunger occurs. As the high point on the camshaft lobe rotates past the slight
leakage
lifter,
the push rod
lifter down
of oil
forces
and reseats
the valve
the valve. The
valve
arms
do
lifters, not
the
valve
have adjusting
The camshaft is supported by five insert-type bearings pressed into the block. It is driven by a sprocket and timing chain in mesh with a sprocket on the crankshaft. Camshaft end play is controlled by a thrust button and spring located between the camshaft sprocket bolt and the cylinder front An eccentric, bolted to the front end of the camshaft, operates the fuel pump.
cover.
The crankshaft is supported by five insert-type main bearings. Crank shaft end thrust is controlled by the
1-6
GROUP 1-POWER PLANT
NO. 2 SUPPORT, LEFT HEAD NO. 4 SUPPORT, RIGHT HEAD
CYLINDER HEAD BOLT BORE
FROM NO. 2
CAMSHAFT BEARING TO LEFT CYLINDER
HEAD, AND FROM NO. 4 CAMSHAFT
BEARING TO RIGHT CYLINDER HEAD. 1514-A
1725-A
8 Lubrication System
FIG.
flanges of the No. 3 The forged steel,
FIG.
bearing.
main
bypass
the
filter, if
9 Valve Rocker Arm Shaft Lubrication Passages be
the element
For example, the No. 1 oils No. 5 cylinder,
cylinder wall.
"I"
section
con
necting rods contain a bronze piston pin bushing. The connecting rod bearings are the insert-type.
The aluminum alloy, three ring, flat head-type pistons are of the autothermic design. This design provides
binding
top
the
and
is
fits with friction. The
piston
or excessive
compression
plated
ring
initial
closer
allows
out
which
expansion
piston
controlled
is
ring lower
chrome-
compression
for
phosphate-coated
extra
protection against wear and scuffing.
The
oil
control
sists
of
a
serrated
spring
steel
chrome-plated
con
ring assembly and
two
rails.
comes clogged.
From the the
main oil
Oil from the
SYSTEM
in the front
of
the oil pan,
pump.
8) by
(Fig.
system
The
oil
located
is forced
lubrication
mounted
in the
front of the crankcase, is driven by the distributor through an interme
diate drive relief
A
shaft.
in
valve
the
by
the
loaded
pump limits the
maximum pressure of relieved
spring
valve
the system.
Oil
is directed back
discharged
by the pump passes through a full flow-type filter before it enters the engine. The filter All the
is
oil
mounted
in
a
vertical
position
at
the lower left front of the engine. A relief valve
in
the
filter
permits oil
to
crankshaft turns, the hole in the connecting rod bearing aligns with the hole in the journal causing
the
cylinder
oil
main
allows
gallery
may be trapped
The
in
air
any
the
to
oil
is drilled from
Main
the
Connecting Bearing
Rod
Bearing No. 2 No. 3 No. 4 No. 5
ing
Serves Serves
squirt
direct
and
5 6
and
7
and
groove
Oil
rod
at
the cap contacts the connect
This
groove
hole for Oil
from
hole
is
used as an oil
cylinder wall
the
lubrica
connecting rod lubricates the opposite
drilled from the
are
passages
gallery to each valve lifter oil gallery. Oil from here feeds the oil
main
at
lifter
oil
reservoir
lifter bore boss traps
is
that oil
so
A
assemblies.
valve
each
lifter lubrication
available
for
valve
as soon as the engine
starts.
An 2
oil passage
camshaft
from
web
lubricate the
to the left and
6
valve rocker
assembly (Fig. 9). The
in the
passage
is drilled from No.
bearing
head between Nos. 5
cylinders to
oil
head is drilled head bolt bore to
cylinder
the cylinder
No. 2 valve rocker arm shaft support. The oil flows through the the
valve
rocker
arm
holes in each to lubricate the
arm
both The
ends
push
valve
rocker
bushing
and
the valve rocker arm.
of
excess
through
shaft
drilled
tating
is located in the the mating face
the cylinder
squirt of oil onto
oil
spirals
rods
push rod seats.
small
rod.
tion.
Nos. 2 Nos. 3 Nos. 4 No. 8
Serves
connecting
squirt
No. 1
Serves Serves
No. 1
where
a
wall.
arm shaft crankshaft
main bearings to the connecting rod bearings. The oil flow is as follows:
A
to the intake side of the pump.
connecting etc. As the
valve
oil
rotor-type
a
pump,
which
gallery
flows into is located
escape.
oil pan sump,
through the pressure-type
the oil
in the center of the valve chamber floor. The oil gallery supplies oil to each individual camshaft bearing, through drilled passages in the block. Passages are drilled from each cam shaft bearing to each main bearing. Number 1 camshaft bearing feeds No. 1 main bearing, and No. 2 cam shaft bearing feeds No. 2 main bear ing, etc. The oil then flows through notches or grooves in the main bear ings to lubricate the crankshaft jour nals. A metering plug at the front of that
LUBRICATION
filter,
rod
and
The
down the ro lubricates the
right valve rocker
assembly is similarly lubri from No. 4 camshaft bearing
arm shaft cated via
the
No. 4 valve rocker arm shaft A baffle located under the
support.
valve shields
splash.
rocker
the
arm
valve
Excess
oil
shaft
stems
is
assembly from oil
returned
to the
1-7
PART 1-ENGINE
TO RADIATOR SUPPLY TANK
1770-A
1515-A
10 Crankcase Ventilation System
FIG.
drain back holes lo
oil pan through each
at
cated
end
the
of
cylinder
head and in the tappet chamber floor. The timing chain and sprockets are splash lubricated by a jiggle pin in the main gallery front plug.
CRANKCASE VENTILATION A
tube is lo
crankcase ventilation
cated at
the rear of the engine. The
forward
motion of
vacuum
partial
tube. This
the car causes a
to be formed at the
vacuum action causes air
to be drawn through the engine from
few contaminating vapors. Here, the incoming air has a chance to warm up before contacting contaminating vapors originating in the crankcase. Warm ventilating air minimizes the formation of crankcase sludge. The ventilating air is directed by a baffle, located on the underside of the intake manifold, upward into the front of both valve rocker arm cham bers. The baffle also directs air to the front of the lower crankcase and into the
timing
rear of
rod chamber.
All
filler cap contains a filtering element which filters the incoming air. From the filler cap, the air flows into the front section of the valve
out
there are
where
chamber
the valve push
is then directed
air
the crankcase ventilation tube.
The
the
the cylinder
of
rear
cored
length
of
Upon reaching
wall.
cylinder
each
block,
the
is directed upward into the heads where it cools the
coolant cylinder
combustion
its
and
valves,
chambers,
valve seats on
return
to the
front
of the engine.
from
coolant
each
head flows through the
in the intake
sages
into the
cylinder
water
pas
manifold and past
thermostat, if it is open, supply tank. If the
the water
radiator
is closed, a small portion is returned to the for recirculation. The pump system is pressurized to 13-15
thermostat the
water
The coolant is drawn from the lower tank of the radiator by the
travels through
coolant
cool
block (Fig. 11).
passages to cool the entire
of
COOLING SYSTEM
delivers the
which
pump
ant to the cylinder
The
Air from the valve rocker arm from the crankcase chamber and flows into the
rod
water
chain chamber.
the oil filler cap located at the front of the intake manifold (Fig. 10). The
push
11 Cooling System
FIG.
entire psi
coolant
by
a
pressure-type radiator
cap.
GENERAL ENGINE TROUBLE SHOOTING Poor gine
parts,
failure. A
can
be
the need of a general en
by
tune-up,
engine
or
good
indicate the gine
performance
engine
by
caused
wear
gradual
by
a
sudden
of
parts
trouble diagnosis will
need
of a complete en
tune-up, individual adjustments,
misses;
rough
engine
celeration;
full power,
has
or
engine
poor
fails to reach tion temperature.
ac
develop
high
speed
fuel
overheats;
engine
Table 1 is
poor
not
excessive
performance; sumption;
idle;
does
engine
con or
the
normal opera
a general
trouble
shoot
ing
haul.
troubles with procedures and checks
Engine
performance
complaints
usually fall under one of the follow ing basic headings: engine will not crank;
engine
will not
to
keep
cranks
normally, but
start; engine starts, running;
engine
but fails
runs,
but
which
lists basic
to be performed to cause
of
check
engine
help isolate
the
the trouble in a particular
The
system.
refers
after
reference
to
can not
by
a
a
various
trouble
be traced to
tems that
a
definite
system
check, the possible
simple
in the
in the
particular
made
When
systems.
be
could
order of
at
fault
are
sys
listed
their probable occur
rence; therefore, in most cases, the
part(s) replacement or overhaul, or the need of a complete engine over
chart
to be
rections
that
part
in
each
of
the
detail,
manual
which
checking
procedures as well as cor
covers,
checks should
be
made
in the
order
listed. Some consideration, however, should
be
given to logical order. For if the spark plugs are re for testing and they are not
example, moved
the cause of the checks
later
test,
to save
sion
while
trouble, and several for a compression
calls
time, the
check
spark
the compres
plugs
are
out.
1-8
GROUP 1-POWER PLANT
Separate trouble shooting charts included in the ignition, fuel,
lar
under consideration. For example, in Table 1 under Poor Ac celeration, the ignition system is listed
are
and
cooling system sections of the These charts list the basic troubles listed in Table 1, but cover only the items relating to the particu manual.
system
are
acceleration should all
the trouble. In
as a probable cause of
items that affect listed. These items be checked before proceed
the ignition
system
ing
Ignition System Trouble Shooting Chart under Poor Acceleration, all
probable system
to the next
listed
in Table 1.
the
I ADLt 1 General Engine Trouble Shooting
The in
ENGINE WILL NOT CRANK
trouble is usually
cause of this
the
7
(Group
system
starting
Part 2). If the starting
system is not at fault, hydrostatic lock or a engine. Remove the spark
for
check seized
a
plugs, then attempt to crank the
Check the fuel If
ENGINE CRANKS
ENGINE BUT
KEEP
supply.
fuel in the
sufficient
proba-
end
cranking the engine, hold the the [od approximately 3/16
/from
inch
is
ignition wire from one spark plug, and insert a piece of proper sized metal rod in the insulator so that it protrudes from the insulator. With the ignition on and the the
If the
for
engine starts and runs
few seconds, then stops,
or
sPark
n0
the
ignition
2)
Tf the
weak
a
is
1 Part
fuel
the
fuel
(Group
system
is
system
Fuel
a
3). If
fault,
check
not at
1 Part
1).
(Group 1 Part 3). (Group 1 Part 2).
system
the:
Ignition
is steady
Ignition
system
Engine
compression
check
check
1 Part
timing (Group
the valve
the
2). If
fault,
the spark plugs are not at the
check
good
(Group
plugs
spark
1 Part
(Group
system
spark
STARTS,
FAILS TO
block-
the cyhnder
If tnere
spark, the cause of the trouble is in
isolate the cause:
Remove
cracks.
or the
_
To
with
starter
tank, the cause of the trouble bly lies in either the ignition fuel system.
NORMALLY, BUT WILL NOT START
is
there
en-
the starter. If the engine it indicates that water is leaking into the cylinders. Remove the cylinder head(s) and inspect the gasket(s) and/or head(s) for cracks. Also examine the cylinder block for gine
cranks,
system
RUNNING
First, determine if
the miss
or erratic and at what speed the miss
by operating
occurs
the
Misses steady
r,
.
,
wire
wire
at a u
from
removed
one
,.
a
checked.
spark
T
have
Ground\ the
11
.u
spark
plug
.
fault (page 1-13).
at
..
.
.
-
.
,
.
...
ticular cylinder, '
.
gas
.
,
m
,
..
check
.
Exhaust .
.
m.t
r*
is
the:
11/
control
(page r
valve
igni-
until all cylinders
2)
determine
Misses erratically at all speeds. If parthe miss cannot be isolated in a r
.
,
the engine with the
time, 1
,
is
.,
iU
.
.
plug u been
.
-,,
e
.
tion
BUT MISSES
.4.
m1_
by operating
RUNS,
.
the engine with by operating r 7 j cylinder not firing. This done
,
ENGINE
,
Isolate
at all speeds. r
,
the miss one
T
1 Part
to
mechanical component of the
which engine
...
..
at
engine
load.
various speeds under
(Group
~ft,
.
.,
,~
,
t>
.
-^
(Group 1 Part 2). ' / % Fuel system J (Group 1 Part 3).
Ignition J?
system
.
_.
_^
.
-
...
Engine
compression
removed
to
determine
which mechanical component of the
If the a
engine speed changes when
particular
that
cylinder
before in the
being
was
out,
If
shorted out.
engine
delivering
shorted
shorted
delivering
operation
the miss was caused not
is
cylinder
by
power
check
the:
out,
power
no change
is evident,
that cylinder
before
being
engine
is
at
Exhaust
fault (page 1-13).
system
for
excessive
back
pressure.
Cooling and/or
the
system
for
engine
operating Part 4).
for internal leaks
a condition
from
that prevents
reaching
temperature
normal
(Group
1
1-9
PART 1-ENGINE
TABLE 1
General
Engine Trouble
Shooting (cont'd)
Check the: Fuel system (Group 1Part 3). Ignition system (Group 1 Part 2). Vacuum booster pump, lines and fittings for leaks. Engine compression foT low com pression (page 1-13). Misses
ENGINE RUNS, BUT MISSES
(cont'd)
idle
at
Check the: Fuel system
ROUGH ENGINE IDLE
(Group 1Part 3). Ignition system (Group 1Part 2). Exhaust
(page
gas control valve
1-30) Vacuum booster pump, lines fittings for leaks.
POOR
proper
adjustment
if
the
trouble
the engine
exists
at normal
at all en
temperatures.
Engine
cold.
Exhaust
Check the:
DEVELOP FULL POWER,
Fuel
OR HAS POOR HIGH
Cooling
control
gas
valve
(page
(Group
system
if
system
1 Part
engine
operating temperature slowly 1-Part 4).
Engine
at normal
3).
reaches
(Group
operating tempera
Exhaust
gas
control
valve
(page
Fuel
(Group
system
Determine sumption
the
with
in the
stalled
CONSUMPTION
1 Part
actual
test
3).
fuel
equipment
con
in
car.
If the test indicates that the fuel consumption strate
(Group
to
driving
is
the
habits
sumption.
1 Part
2).
1-Part 3).
for overheating or Cooling internal leakage (Group 1Part 4).
Power brake leaks (Group 6
Engine
vacuum
booster for
Part 2).
for looseness
supports
1-Part 1).
(Group
Improper
head bolt torque
cylinder
1-Part 1).
Clutch for slippageConventional Drive and Overdrive Transmission (Group 2-Part 1).
proper
transmission
(Group 3
adjustment
for Part
All
engine
not
excessive, demon
owner
how improper
will
fuel
affect
con
temperatures.
Check
the:
Engine
compression
Ignition
system
system
1-13).
(page
1 Part
2). (Group 1 Part 3). (Group
Camshaft lobe lift (page 1-11). Valve timing (page 1-12).
Cooling system if the engine (Group 1 Part 4).
over
heats
system
for
excessive
back
pressure.
Torque 3). Brake
1-30).
FUEL
(Group
system
Exhaust
ture. Check the:
EXCESSIVE
system
Fuel
1-30).
SPEED PERFORMANCE
system
2).
is cold, operating temperature, or gine
Check
speed only.
Cruise-O-Matic
Determine when
DOES NOT
Fuel
1-30).
Brakes for (Group 6).
ENGINE
Ignition
(Group
Check the:
high
at
the:
and
Ignition system (Group 1 Part 2). Fuel system (Group 1 Part 3). Exhaust gas control valve (page
ACCELERATION
Misses
only.
Tire
(Group
converter
3 Part
(Group 6). (Group A Part
adjustment
pressure
3).
If the test indicates that the fuel is excessive, make a
consumption
preliminary check of the following items before proceeding to the fuel and
ignition
systems.
Preliminary Tires
checks
(Group
4
Part 3).
1-10
GROUP 1-POWER PLANT
I ABLE 1 General
Engine Trouble
Shooting (cont'd)
Wheel
alignment
4 Part
(Group
EXCESSIVE FUEL
Exhaust
CONSUMPTION
gas
control
valve
Engine
8
Torque
calibration
(Group
unit
Temperature
1-Part 1).
Cooling
8-
(Group
gauge
Part X)-
system
(Group
1 Part
4).
i t 7it\ Valves (page 1-32). \r
Exhaust
gas
control
valve
Exhaust
(page
1-30).
TEMPERATURE
(Group 1 Part 4). (Group 3 Part
converter
Cylinder head bolt torque (Group
(Group
,_
^
NORMAL OPERATING
system
2).
(page 1-13).
6).
Temperature sending 8-Part 1).
ENGINE FAILS TO REACH
compression
Cooling
Odometer Part 1).
ENGINE OVERHEATS
2).
3).
system
(page
1-30).
(cont'd)
Ignition timing
Fuel
(Group 1 Part (Group 1 Part Part Ignition system (Group 1
1). Brakes (Group 6).
Brakes
Temperature sending 8-Part 1).
unit
Temperature Part 1 )
(Group
gauge
Engine
(Group
system.
(Group 6).
(Group
thermostat
1
Part 4). 8
.
TUNE-UP A tune-up is them
The
within
a
systematic
to
Tune-Up Schedule
(Table
6000
2)
is
applicable
miles and a major
reference after each operation refers
be followed. Perform
TABLE
the operations
for
engine
engine
components, and,
efficiency
either a minor or major
tune-up is
recommended each
to that part of the manual which
in the
sequence
Perform
on
Major
SPARK PLUGS
12,000
minor
bringing
tune-up is
miles.
describes, in detail,
the procedure
Perform
adjust, and test.
X
X
Part 2
Minor BATTERY Clean battery
compression
reading
X
INTAKE MANIFOLD and tighten
bolts.
Page 1-13
Group 1 X
X
Check
and
sion of all
adjust
the ten
drive belts.
X
cable clamps.
battery
X
X
X
X
output.
X
Part 4
Perform
draw.
primary
resistance test.
7
X X
coil output. a
Group Part 1
starter motor
Group 1
Part 1
X
Part 1
Check
Group 7
state of
ELECTRICAL Check generator Check
Procedure
X
charge.
current
DRIVE BELTS
Major
cables and
terminals.
Grease battery terminals.
of each cylinder.
Recom mended
Procedure
Group 1
on
Operation
Tighten
Check
tune-up. A
Recom
ENGINE COMPRESSION
Check
necessary,
listed.
mended
Minor
Take
if
and performance.
2 Tune-Up Schedule
Operation
Clean,
various
recommended specifications to restore
recommended each
The
for testing
procedure
Group
circuit
Part 2 X
1
1-11
PART 1-ENGINE
TABLE 2-Tune-Up Schedule (cont'd) Perform
on
Operation
ELECTRICAL
Major
Group 1 Part 2 X
continuity test.
of
Replace the breaker
points
X
Check Check
idle
Group
1
Part 2
through
and
point
Check
X
Add
and
X
X
X
X
X
X
X
engine
mixture.
Group 1
Page 1-13
manifold vacuum.
Group 1
exhaust gas con
Part 1
X
X
valve.
Inspect the radiator, hoses, and engine for leaks.
X
rotor.
X
COOLING SYSTEM
and adjust vacuum
Clean distributor cap
Part 2 X
Part 3
Adjust idle fuel
trol
advance.
ignition
EXHAUST
X
adjust centrif
ugal advance.
adjust
and
Free the Check
Group 1
and adjust
speed.
Check X
X
VACUUM
X adjust
X
timing.
X
the oil cup. and
pressure
ADJUSTMENTS
breaker
Lubricate the distributor cam. Oil the lubricating wick. Lubricate the dis
Check dwell.
Group 1
X
Clean carburetor fuel bowls and adjust float setting.
X
spring tension.
bushing
X
X
and capacity.
the
and the condenser.
tributor
Procedure
Part 3
Check fuel pump
Check the condition breaker points.
arm
Clean fuel pump filter bowl. Replace fuel pump filter bowl strainer.
DISTRIBUTOR
and adjust
Major
mended
Minor
Procedure FUEL SYSTEM
(Confd)
Perform a secondary circuit
Check
Recom
Operation
mended
Minor
on
Perform
Recom
X
inhibitor
rust
Group 1
X
Part 4
to
X
radiator.
TESTS AND ADJUSTMENTS (ENGINE IN
CHASSIS)
CAMSHAFT LOBE LIFT Remove the valve rocker arm shaft assembly install a solid tappet-type push rod in the
and
push rod sure
bore
then install a to
the valve to be checked.
Make is in the lifter push rod cup, dial indicator in such a manner as of
the push rod
have the actuating
point of the
the push rod socket and the push rod movement crankshaft
in the
indicator in
same plane as
(Fig. 12). Rotate
slowly in the direction
the
of rotation
lifter is on the base circle of the cam lobe. At this point, the push rod will be in its lowest position. Set the dial indicator on until the
shaft
BE SURE TO PLACE Indicator TIP IN CENTER OF PUSH ROD SOCKET
zero, then continue to rotate the damper slowly is in the fully raised position.
until the push rod
Compare the total lift 1748-A
FIG.
12-Camshaft
Lobe Lift
shaft until
step is a indicator
recorded on the
Continue to the indicator reads
with specifications.
check on the
reading.
rotate
zero.
accuracy
of
indicator
the crank
This later
the original
1-12
GROUP 1-POWER PLANT
3 Valve Timing Specifications
TABLE
Intake Valve
Closes
Opens
Crankshaft Degrees
21
B.T.C.
Camshaft Lobe Lift
Crankshaft Degrees
Camshaft Lobe Lift
51
0.017
0.019
A.BC.
Exhaust Valve
Closes
Opens
1719-A
VALVE TIMING The
valve
when
poor
noted
and
tor and continue
timing
should
engine
other
all
shaft
be
checked
performance
is
such
as
checks,
carburetion, ignition timing, etc. fail to locate the cause of the trouble.
timing is checked, check for a bent timing pointer. Bring the No. 1 piston to T.D.C. on Before the
valve
the compression stroke and see if the
is
pointer
timing T.D.C.
the
with
aligned
damper.
the
on
mark
If the
timing is not within timing chain,
valve
camshaft
crankshaft
sprocket,
crankshaft
and
camshaft,
sprocket,
To
check the valve
installed,
engine
Install
timing
proceed
Remove
valve rocker arm shaft
second push
lifter
push
rod
dial indicator in
same
movement
shaft
of
the
crank
the
right and
valve push
rod) and
cup, then
install
such a manner as
plane
as
the
( Fig. 12). Turn
push
the
rod
crank
damper slowly in the direction
rotation
until
the
lifter is
on
the
lobe. At this point the push rod will be in its lowest position. Zero the dial indica base
Camshaft Lobe Lift
Crankshaft Degrees
9
0.019
A.T.C
circle
of the camshaft
dial indicator registers camshaft lobe lift (Table
being be
specified
crankshaft
degrees
quadrant with speci
fications (Table 3). After the valve opening is checked, continue to ro tate
damper to
the
the valve
check
If the first step the
of
step
push rod.
the
A 0.060 inch
for
available means
shorter
rod
is
provide
a
push
to
service
compensating for dimen in the valve mechan
of
stem
0.062-0.1875
the
tioning
(valve
operations seat
valve
will
refacing)
and/or
decrease
this clearance to the point that compensated
for,
lifter
cease
would
determine
is
the
hydraulic
to
if
not
valve
function. To
whether a shorter push rod
necessary,
make
the
following
check:
1. Position the hydraulic lifter pressor
tool
on
If the
sec
the
enters,
lifter is exces sive which indicates that the incorrect push rod has been installed or severe
has
occurred
the push rod
at or
valve
stem.
In
this case, it will be necessary to de termine the area of discrepancy and
incorrect or defective part(s) be replaced. Before the clear ance is checked position the crank shaft as outlined in step 2 and 3. the
should
inch
hydraulic lifter completely collapsed. Repeated valve recondi
with
gauge
to rocker arm clear
be
should
enter,
range of the
operating
ends, rocker arm,
VALVE CLEARANCE
will not
standard push rod with a
shorter service ond
the
of
enters, the old push rod may
used.
wear
closing.
If the first step
checked.
replace
Compare the indicated on the
the rocker arm of the valve
stem and
the
ance
have the actuating point of the indicator in the push rod socket and the
of rota
3).
ism. Valve
to
in
the crank
gauge
follows:
install a solid tappet-type push rod in its place. Make sure the push rod is in (the
turning
slowly in the direction
with the
assembly
No. 1 intake
the
remove
as
on
quadrant
a
damper.
shaft
a
0.017
sional changes
the order of accessibility.
the
67B.B.C.
tion until the
specifications, check the
rod
Camshaft Lobe Lift
13 Valve Clearance
FIG.
in
Crankshaft Degrees
the
rocker
com
arm
and
slowly apply pressure to bleed down the hydraulic lifter until the plunger
is completely bottomed (Fig. 13). Hold the lifter in the fully collapsed and insert the clearance position gauge (Fig. 13) between the valve
2. Rotate the 1
piston
is
crankshaft until
T.D.C.
on
at
the compression stroke. With piston
ing
T.D.C,
on
check
No.
the end of
No. 1
the follow
valves:
No. 1 Intake
No. 1 Exhaust
No. 3 Intake
No. 4 Exhaust
No. 7 Intake
No. 5 Exhaust
No. 8 Intake
No. 8 Exhaust
3. After these
valves
checked,
T.D.C.
position and
No.
check
6
the
have been piston
on
following
valves:
No. 2 Intake
No. 2 Exhaust
No. 4 Intake
No. 3 Exhaust
No. 5 Intake
No. 6 Exhaust
No. 6 Intake
No. 7 Exhaust
1-13
PART 1-ENGINE
When compressing the valve spring push rods, be sure the pis ton in the individual cylinder is be low T.D.C. to avoid contact between
to remove
the
valve
the
and
damage could To replace
necessary to
TABLE 4 Manifold Gauge
Vacuum Gauge Readings
Engine Condition
Reading
piston or serious
result. a push
19-20 inches.
Normal.
Low
by late
rod, it will be
remove the valve rock
in all cylinders caused possibly ignition or valve timing, or loss of compression due to leakage around the piston Loss
er arm shaft
assembly as outlined on page 1-16, step 2. Upon replacement of a valve push rod
and/or
valve
rocker
assembly, the engine
aim
and steady.
rings.
shaft
not be hydraulic
should
cranked or rotated until the
Manifold,
Very low.
by using the tool shown Fig. 13 on the valve rocker arm
accelerated
pressure
applying
in
manifold
determining of
in
helping engine
TEST CONCLUSIONS vacuum
is
affected
by
adjustment, valve timing,
the condition of the valves, cylinder
compression, manifold,
and
leakage
of
or
carburetor,
the
cylinder
head gaskets. Because abnormal gauge readings may indicate that more than one of the above factors is at fault, exercise caution in analyzing an abnormal reading. For example, if the vacuum
is low, the correction of one item may increase the vacuum enough so as to indicate that the trouble has been corrected. It is important, there
fore,
that each cause of an abnormal
reading be investigated tests conducted order
where
further necessary in and
to arrive at the correct
nosis of the
diag
trouble.
Table 4 lists ings and their
various
a
in
of power
by
a
leaking
one
valve,
head or intake manifold gasket leak, defect in the ignition system, or a weak
drop in
Excessive back
reading
idle.
at engine
in the
pressure
exhaust sys
tem.
An
Intermittent fluctuation.
Slow fluctuation of
ENGINE COMPRESSION TEST
above normal
1. Be sure the battery is good. Operate the engine for a minimum of Vi hour at 1200 rpm. Turn the ignition switch off, then remove all the spark plugs.
position.
3. Install a compression No. 1 cylinder.
and
the
registers
number
of
engine
a
the
record
gauge
in
the
until
maximum reading.
compression
reading Note the
strokes
re
ing. 5. Repeat the test
on each
cylinder,
cranking the engine the same number of strokes for each cylinder as was required to obtain a maximum read on
No. 1
cylinder.
affect of altitude on the gauge read
ing. The
engine vacuum will
with
increase in
altitude.
decrease
caused
possibly
in the
adjustment,
carbu
leak,
or pos
gasket
indicates
excessive
de
cylinder.
A reading of more than 20 pounds below normal indicates leakage at the cylinder
head gasket,
piston
rings,
or valves.
even
adjacent
compression
cylinders
in two
indicates leak. This
a
cyl
inder head gasket should be checked before condemning the rings or valves.
To determine
quired to obtain the maximum read
ing
posits
A low
2. Set the primary throttle plates and the choke plate in the wide open
gauge
mixture
intake manifold sibly late valve timing.
retor or
the needle.
4. Crank
of power
the ignition system or a stick
Improper idle
drifting
or
loss
occasional
by a defect in ing valve.
the
valves
are
equivalent of a oil
in the
the rings or
whether
fault,
at
squirt
tablespoon of
combustion
the
heavy
chamber, then
distribute the oil and repeat the compression test. The oil will temporarily seal leakage past the rings. If approximately the same reading is obtained, the rings are sat isfactory, but the valves are leaking. If the compression has increased 10 crank
the engine to
pounds
or
more
there
reading,
types of read
possible causes. This table is merely a guide, however, and not a firm standard. Allowance should be made for the
an
loss
partial or complete
cylinder
to locate the
performance.
gauge.
Manifold
Needle fluctuates steadily increases.
as speed
Gradual
test aids in
vacuum
poor
carburetor
gasket
valve spring.
To test manifold vacuum: 1. Operate the engine for a mini mum of Vi-hour at 1200 rpm. 2. Install an accurate, sensitive vacuum gauge on the fuel pump end of the fuel pump vacuum line. 3. Operate the engine at recom mended idle rpm. 4. Check the vacuum reading on the
head
the condition of an en
gine and also cause
cylinder
or more cylinders caused
direction to
a
MANIFOLD VACUUM TEST A
A
lifter.
the
collapse
carburetor, or
leak.
lifters have had an opportunity to leak down to their normal operating position. The leak down rate can be
in
of power
is
over
the
leakage
original past
the
rings.
TEST CONCLUSIONS
A
variation of
specified
However, inders
pressure
During
20 is
pounds
from
satisfactory.
the compression of all cyl
should
be
uniform within
10
pounds.
A reading
of more
than 20 pounds
test, if the steadily and remains the same during the first two successive strokes, but climbs higher on the succeeding strokes, or fails to climb during the entire test, it indi cates a sticking or stuck valve. pressure
a compression
fails to
climb
1-14
GROUP 1-POWER PLANT
1727-A
14 Engine Installation
FIG.
15 Engine Lifting Brackets
FIG.
and
Sling
ENGINE REMOVAL AND INSTALLATION The
procedures
given
for the
are
only without the transmission attached. If the engine and transmis
engine
sion are removed as an assembly, stall
standard
in
threads the
of
exhaust
the
sling
to the eye
top
rear
Then
lifting bracket
engine
is
Vi-IA
with
at the
manifolds.
tach
stallation
bolts
eye
bosses
the
bolts. The
in
at and
engine
in
in Fig. 14.
shown
On
cars
transmission
On
rod
dash
power
bracket from the
water
tery
ground cable
move
the
hood,
Re
at the engine.
radiator, and the
air
cleaner.
from
draining
2. Remove the
oil
level
dip
Disconnect the
sure
unit wire at
tank
line,
wiper
line
flexible
the at
it
at
out
of
the
the fuel
disconnect
On drive ator.
ing
and
at
pump Remove
way.
from the
the
pump
three
and
clips on
the
washer, at
the
them out
conventional
disconnect
Remove the
spring.
drive the
flexible
move
air
an
with
Isolate the
magnetic clutch wire.
compressor as outlined
Conditioner
Air
"1958
in
Shop
Manual."
3. Disconnect the heater hose the
water
and
pump
at
the
at
accelerator retract
converter
and
ture sending
the
Remove the
unit.
engine
unit wire at
of
strap retaining bracket
the right cylinder
move
the
of the car.
Re
the starter and dust seal (and
Cruise-O-Matic
fluid filler tube
to
converter
assembly converter
housing
clamp from the
the
engine
conventional
or overdrive
flywheel
housing
cover and the clutch pedal
Disconnect
spring.
release
bracket
Remove
engine.
to
engine
at
the
upper
the
the equal
the bracket
rod and remove
housing
block.
drive
the
remove
retracting
izer
lower bolts, and lines retaining
to engine
the oil cooler
remove
from
flywheel
bolts.
5. Lower the car, then support the Remove the converter
transmission.
flywheel
bolts.
bracket
on
inder head and
housing
Install the
install
bracket
at
upper
engine
retaining left lifting
the front of the left cyl where
the
the
coil
engine
mounts,
right
lifting
the rear of the right cyl
inder head, then
lifting
4. Raise the front
flywheel
the
in the housing. Remove the
engine ground
and the starter cable rear
tempera
the sending
re
housing lower
the converter
or
over
acceler
the
Secure
nuts.
intake
manifold, the generator wires at the
Cruise-O-Matic,
with
inspection
conditioner,
the engine.
at
cars
Remove
the left valve rocker arm
line.
mani
left sup
access cover and the cover assembly.
On
head. or
insulators
On
units,
the
exhaust
the engine right and
clutch
from the
way.
units,
cars
generator,
lines
position
the
from the
pipes
folds,
line from the
release
on
inlet
and
cars with a windshield
the
brackets
the
tion the wires out of the way.
of
the power brake line at the
manifold
then
On
valve rocker arm cover and posi
washer
line,
brakes, dis
stick
windshield
the vacuum
the wire loom
On
intake
power
out.
oil pres
the sending
unit, the flexible fuel line
left
connect
with
disconnect the
sending
position
cars
cover and remove the
and the coil.
pump, then
steering pump to the hood left hinge in a position that will
REMOVAL 1. Drain the cooling system and crankcase. Disconnect the bat
pump
crankcase ven
tilation tube. Disconnect the muffler
steering, dis
steering
wire the power
On
bracket). Remove the
port
power
with
the
prevent the oil
the
accelerator
and secure them
panel.
cars
connect
the
at
bracket
cross shaft
to the
Cruise-O-Matic dis
with
the accelerator rod and the
connect
attach
the
engine
sling (Fig. 15). Raise the
en
carefully pull it from the transmission. Lift the en
gine
slightly
and
gine out of the
engine
compartment
1-15
PART 1-ENGINE
tainer securing the
trol valve, then connect both
to the
manifolds
tighten the
and
install the
(and the
starter
auto
filler tube
fluid
transmission
matic
pipes
to 23-28 foot
nuts
torque. Position the dust seal
pounds
and
exhaust
inlet
muffler
con
gas
exhaust
bracket). Remove the mission and
7. Connect the
intake
wires, the unit
sending
the heater hose
connect
Connect the
manifold.
ground
car.
generator
engine temperature
and
from the trans
support
lower the
the
engine
install the
and
strap
wire,
at
starter
retaining clamp to the the right cylinder head.
rear of
cable
8. Connect the flexible fuel line, the oil 1728-A
FIG. 16-Engine
the
Work Stand
pressure
Install the primary the
stall
install it
and
(Fig.
on a work stand
gear) until the shaft
the
16).
disc
clutch
3. Install the
INSTALLATION
with a new gasket on each
tie
Temporarily
the
the
studs of
Loosen the
then
15),
from the
over
exhaust manifold.
the
at
left sup
chassis.
brackets
lifting
engine
(Fig.
left
the
gasket
new
a
to
valve
engine right and
insulators
port
the
Place
manifold.
the
side,
right exhaust manifold studs.
the
on
exhaust gas control
Attach
and
the
remove
sling
tighten
the
carefully into Make sure
bolts.
the car. In
of
housing
con
or
lower retaining bolts them to 45-50 foot
housing
tighten
and
the
flywheel
manifolds
exhaust
the
with
are
properly
inlet
muffler
in the block
and the dowels
the holes
in the flywheel
converter
housing.
pipes
engage
housing
or
move
cars
with
Cruise-O-Matic
cars with
the retainer securing the con
in the housing, then install the flywheel to converter lockwashers Tighten the
and nuts.
Cruise-O-Matic, start into the crank
pilot
converter
shaft.
On
start
units,
drive
gear
the
the
clutch
adjust
transmission
engine
in
if the input
clutch
up"
after
crankshaft
drive
the
the
lower
housing On
access
cover
to 25-28
nuts
plate
assembly.
lines retaining
nect
to
the
engine
"hangs
enters, turn the
(transmission
in
conventional
units, install the
position of
shaft will not enter
shaft
slowly
main
disc. It may
relation
disc. If the
loom in the retaining
the three
clips
cover.
arm
rocker
washer,
pump lines.
washer
On
Cruise-O-Matic,
cars with
con
the trans
mission rod.
On
conventional
drive
drive units, install the
tracting
Connect
spring.
and
over
accelerator re
the accelera
tor rod.
On nect
cars with power steering, con
the
power
steering pump bracket
to the water pump.
nect
brakes,
power
cars with
the power
con
brake line to the in
take manifold and to the
flexible line
install the line in the retaining clips on the left valve rocker arm and
cover.
con
and
the
Install the
On
cars
air
conditioner,
connect the magnetic clutch wire and
the compressor
clamp.
an
with
lines.
or overdrive
transmission
into the
be necessary to the
verter
oil cooler conventional
re
verter
foot-pounds torque. Install the
On
In
level dipstick. Position
oil
cars with a windshield
On On
the coil
wires.
torque.
pounds
engine compartment.
aligned
the
left
and
lifting sling brackets.
lifting
line.
then
foot
engine
engine
the
engine
work stand. engine
to
5. Raise the front the
right
engine
Disconnect the remove
On
connect
high tension
nect the accelerator rod and
insulator
support
stall
bolts,
and
coil
and
and
wire,
vacuum
wiper
the left valve
connect
45-50
to
wire
or con
torque.
4. Start the
and
housing
upper
bolts
the
pounds
verter
2. Lower the
housing
verter
the on
crankcase ventilation
tube and the flywheel
1. Position the valve,
splines mesh with
splines.
unit
sending
windshield
the
or overdrive
bracket. Con
the clutch release rod and install clutch
the flywheel
retracting
housing
6. Tighten port
drive
clutch
all
spring.
lower
Install
cover.
insulator bolts
and nuts
to 45-50 re
the
radiator.
Fill
and
the crankcase with the proper grade and
the engine front sup
foot-pounds torque. Remove the
9. Install
bleed the cooling system. Connect the heater hose at the water pump. Fill
quantity
of
engine
the engine at
fast idle
gaskets
hose
and
leaks. Install the
oil.
Operate
and check all
connections
air
cleaner.
for
1-16
GROUP 1-POWER PLANT
roo/-T53l-300-A
ENGINE DISASSEMBLY AND ASSEMBLY (ENGINE REMOVED FROM
ENGINE
Standard Eye-Bolt
Y\6- 1 8 THREAD
CHASSIS)
DISASSEMBLY
INTAKE MANIFOLD
1. Disconnect the
wires at the spark plugs and remove
the wires from the ignition harness brackets on the valve
Remove the distributor cap
rocker arm covers.
Disconnect
Remove the
lines,
distributor
the
radiator
line
fuel inlet line,
carburetor
fuel pump
then remove the
Remove the
vacuum
and
heat
the automatic choke
the vacuum pump
discard the
gasket.
supply tank. Slide the clamp
pump bypass hose toward the
water
assembly.
distributor.
at the
Remove the
tube.
the
on
Remove
water pump.
valve rocker
arm covers.
FIG. 17 Intake
1
2. Crank the engine until the No. is at T.D.C. at the end of the
piston
compression stroke.
damper
shaft
damper
the
cated
on
XX).
Starting
loosen
the
Rotate the
the
at
right
by
crank
45
an additional
(indi
the symbol
No. 4 cylinder,
valve
rocker
arm
bolts in sequence, two time. After the bolts are all
shaft support
turns at a
loosened,
remove
arm shaft
assembly
Starting
plate.
follow
left
the
lowed to rods
in
3.
procedure
must
be fol
damage to the
Remove the
manifold
valve
push
clamp and Remove the
bolts
left front
""i
with
e-
the
intake
10
Install
1 8 threads
and right rear rocker
holes
arm cover screw
lifting
remove
bolts.
retaining
hold
and attach
sling (Fig.
the
from the
engine.
manifold
gaskets
and
manifold and
remove
seals.
4. Lift the hydraulic from them
the
in
cylinder
a
so
rack
installed in their internal
that
lifters
and
place
they may be
original
parts of each
semblies cleaned.
intact
assembly with the tool in Fig. 20. After the lifter is
parts.
until
Keep
they
bolts and inlet tube
the oil pump and
remove
assembly, and remove
as an
the oil pump drive shaft. Discard the oil
gasket.
pump
plunger
shown
keep
removed,
EXHAUST
the parts together
MANIFOLD
CONTROL
GAS
all
intermix the
so as not to
Remove
Remove
the
tab washers
and
exhaust exhaust right
manifold
manifolds. gas
control
exhaust
mani
fold.
1. Remove the fuel pump and dis card the gasket. Disconnect the drive
belt adjusting arm at the generator. Remove the generator support bolt
the
at
head bolts, head holding
cylinder
then install the cylinder
tween the head move
Lift
21).
the block.
off
the
Do
cylinder
not
pry be
the block. Re
and
discard the
and
the cylinder block.
cylinder
head
ley,
fan
and
2. On
remove
shaft. shaft
the
the
oil
Remove the and
oil
filter from the filter adapter
oil
pressure
sending Discard the
assembly.
an
power
steering,
gasket.
pulley.
Install the
the crank
puller on
22)
and
remove
damper.
3. If the
as
with
cars
pul
assembly.
the two cap screws and lock
damper (Fig.
stepped
assembly
an
pump,
Remove the large cap screw and washer from the end of the crank
AND ADAPTER
Unscrew
as
drive
and
water
securing the power steering pulley to the crankshaft damper, then
the
gasket.
OIL FILTER
brackets,
generator,
belts. Remove the
Remove
washers
HEADS
fixture (Fig.
bracket
the water pump and the
bolt
remove
Remove the
head
FRONT COVER
CYLINDER
at
exhaust
the
from the
valve
EXHAUST
VALVE
the
remove
parts.
AND
lower retaining bolts and
unit
Installation
or
ends),
crankshaft
down (the
remove
it
same
sleeve
O.D.
is
on
not
both
in Fig. 23.
as shown
If the crankshaft sleeve is stepped down (different O.D. on each end), remove
it
with
three-jawed puller
a
(Tool 7675-N).
bore. The
hydraulic
valve
are matched sets.
lifter assembly not intermix the
and
adapter.
valve
block
be
the
Raise
17).
it carefully Remove the intake
the
can not
fingers, remove the lock ring (Fig. 18), and the push rod cup (Fig. 19), and remove the lifter
CYLINDER
distributor
the
and
standard eye
engine
valve
sequence.
down bolt
the
the
on
procedure
support
Remove
distributor.
in
No. 5 cylinder, shaft
avoid
mechanism.
the oil baffle
arm
rocker
This
valve
and
at the
same
valve
bolts.
the
rocker
If the hydraulic lifters removed with
Manifold Removal
are
the to
Do as
be
OIL
PAN
AND
OIL
screws
card
and
4. Remove
PUMP
1. Remove the
oil
remove
the
pan oil
retaining pan.
Dis
the gasket.
2. Remove the
the
cylinder
the
front
pump attaching
gasket.
fastening
to the
block,
front
cover.
then remove the cylinder
5. Discard the oil
screws cover
cylinder
front
cover
1-17
PART 1-ENGINE
Tool HL1
FIG.
1731-A
18 Lock Ring Removal
Tool HL 1
FIG. PUSH RODS
RINGS
CUPS
19 Push Rod Cup Removal
VALVE LIFTERS
Tool-T58P-6085-A
Too/ HI/
FIG.
VALVE UFTER RACK
1733-A
20 Hydraulic Valve Lifter Removal
1524-A
FIG.
m
21 Cylinder Head Holding Fixture
m
Tool-T58P-6316-A
1551-B
FIG.
22 Crankshaft Damper Removal
Crankshaft Sleeve
FIG.
Tool T56P-6362-A
23 Crankshaft Sleeve Removal
1552-B
1-18
GROUP 1-POWER PLANT
I Tool T52L-6261-CEE
ToolT54L-6250B
Detail 6-BEARING REMOVAL BEARING REPLACER Detail 8
56-A
FIG. 25 Camshaft Bearing
24 timing Chain
FIG.
Sprockets Removal
and
Replacement
or
Installation
been
SPROCKETS AND TIMING CHAIN
Remove the slinger.
crankshaft
Remove the
button
and
screw,
the
tainer, and Slide both
oil
thrust
camshaft
the
and
sprockets
timing the
remove
and
chain as an as
timing
Carefully
(main
the camshaft
remove
caution to avoid
by
of the en
marked
their
damaging
flywheels,
conventional
be
replaced
in
the same posi
and remove the clutch pressure
plate
disc.
and
2. Remove the flywheel retaining and remove the flywheel.
CRANKSHAFT AND CONNECTING ROD
and/or car
ridge
bon deposits from the upper the cylinder bores. Move the to the bottom of
the
its
head to
Remove
the
ridge with a
ridge cutter.
instructions
furnished
manufacturer.
area
removing
in
Never
piston
collect
cylinder
Follow the
by
cut
excess of
ridges.
end of
travel and place
on the piston
cuttings.
travel
with
the
or
tool
the
into the
\':vi inch
After the
ring
when
ridge
has
removed nuts
from the connecting
nuts
the
rod and pis
top
handle
cylinder
wall
of the
end of a
cyl
ham
crankpin
when
removing Remove the bear
ing
inserts from the connecting
rods
caps.
4. Remove the
Carefully
the cylinder
the
finished
rear
journal
and
rear
are
and
CAMSHAFT
Drill shaft
a
rear
not
fracture
of
the thrust
damaged.
with
or
caps.
out
care
to
damage to
Remove the from the block
surfaces. oil
seal
bearing
cap to block
block
so that
crankshaft
avoid possible
bearing
crankshaft
block
surfaces
Handle the
main
main
lift the
cap, side
and
seals.
remove
the
BEARINGS
plug.
cam
and use
ASSEMBLY
Camshaft
bearings for
are
pre-finished to size
0.015-inch
available
standard and
journal diam not inter changeable from one bore to another. The bearings must be installed in their respective bores. undersize
The
eters.
bearings
1. Position the
bearing bore,
are
bearing
new
and
press
at
it in
the
place
the tool shown in
Fig. 25. Align holes in the bearings with the holes in the cylinder block when
with
the oil oil
bearings
are installed. Be sure the front bearing is installed 0.005-0.020 inch below the front face of the cylinder block (Fig. 26). 2. Clean out the camshaft rear
the
camshaft
bearing bore plug recess thoroughly. Coat the flange of a new plug with water with
resistant
sealer
flange
the
install it in (Fig. 27). it is flush or
and
facing
Drive the plug in until slightly below the casting MAIN
BEARINGS,
surface.
REAR JOURNAL
OIL
SEALS, AND CRANKSHAFT The crankshaft and related
are shown
1. Be shaft
'/2-inch hole in the
bore plug
the
bearings (Fig.
CAMSHAFT BEARINGS
Remove
bearing inserts from bearing caps.
bearing
remove
camshaft
25).
then pull the cap off the
piston and rod.
the
is the
and
the
the
the
until
Avoid damage to the
mer.
bearing
ASSEMBLIES
1. Remove any
crankshaft
Push the connecting
rod.
and
bolts
a cloth
bolts,
inder
the pressure plate cover so that
can
hex head
caps
locations.
original
Remove the
ENGINE
bearing
ton assembly out the
FLYWHEEL
tion,
so
the
at
Tool T-7600-E to
remove
are rod) connecting they can be installed in
connecting rod being down. Remove the pal
rod
the journals and lobes.
it
and
carefully
all
sure
3. Turn the
pulling it toward the front
mark
stroke and
2. Make
sembly (Fig. 24).
1. On
the piston is
until
the cloth with the cuttings.
cap button spring re the fuel pump eccentric.
of
cutter
then turn the
thrust
CAMSHAFT
Use
its
bore,
top
sprockets and
gine.
cylinder
crankshaft
the
remove
removed,
from the
spring, the sprocket
forward,
chain
front
oil
sure that all
journals,
seal
and
grooves
new rear
parts
in Fig. 28.
journal
are
bearings, the
rear
clean.
oil seal
crank
journal Install
a
in the block
1-19
PART 1-ENGINE
INSTALL FRONT BEARING 0.005-0.020-INCH BELOW FRONT FACE OF BLOCK
Tool-T58P-6266-A
FIG.
26 Camshaft Front Bearing Measurement
FIG.
1S45-A
27 Camshaft Rear Bearing Bore Plug Installation
CYLINDER BLOCK JOURNAL SEAL MAIN BEARING INSERTS
FLYWHEEL AND RING GEAR
DAMPER
POWER STEERING
PUMP PULLEY
MAIN BEARING CAPS WASHER
FIG.
28 Crankshaft
1537- A
and
Related Parts
1-20
GROUP 1-POWER PLANT
Too/-T58P-
