Ford - Falcon - Brochure - 1960 - 1962

Copyright © 2011, 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 1960-63 Ford Falcon Shop Manual EAN: 978-1-60371-181-4 ISBN: 1-60371-181-3 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 Publisher 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. GROUP INDEX 1 1 1 1 2 . · RbII SERVICE DEPARTMENT FORD @ DIVISION MOTOR COMPANY FIRST PRINTING - AUGUST, 1961 @ 1961 F O RO MOTOR CO .... PANY , OEARB O RN . M I CH I GAN FOREWORD This manual provides information for the proper servicing of the 1960, 1961 and 1962 Ford Falcon. The service procedures for the 1962 Ford Falcon Club Wagons are covered in the 1961 Ford Econoline Shop Manual and the 1962 Ford Econoline Shop Manual Supplement. The descriptions and specifications contained in this manual were in effect at the time the manual was approved for printing. The Ford Division of Ford Motor Company reserves the right to discontinue models at any time , or change specifications or design, without notice and without incurring obligation. SERVICE DEPARTMENT FORD DIVISION FORD MOTOR COMPANY FALCON IDENTIFICATION PLANT FIG. N1143_1 1-1960-61 Falcon Patent Plate PATENT PLATE Fig. 1 illustrates a Falcon patent plate and its elements. The plate is on the rear face of the left front door inner panel. The 1962 falcon patent plate is similar to the one use<1 in 1960·61 (Fig. 1). The serial number and vehicle data lines have exchanged locations for 1962. Also, a DSO space is shown on the vehicle data tine, and the axle and trans · mission codes exchanged locations. MODEL YEAR SERIES 20-STATION WAGONS 21. ... ........ . ... . 22. 26. . 21. 29. ... 2·0001 . ... 4·0001 .4·0001 Country Squlrl .. Ranchero . ........ .. Sedan O,lInry ENGINE Symbol o I 2 Year S. . .6 Cylinder OH V Hleublc Inch D. ..... 6 Cylinder OHV 144 cubic Inch (Low compresslon-84 octane) U. . ... . ............ .. 6 Cylinder 0 HV 170 cubic Inch E...... 6 Cyll nder OHV 170 cubic Inch ( Low compresslon-a4 Dchne) 1960 1961 1962 ASSEMBLY PLANT CONSfCUTIVE UNIT NUMBER A- Atlanta R-$a n Jose H-lonin K- Kansas Clly Each model year, each assembly plant begins with consecutive model numbers S- Pil ot Plant T - Metuchen 100001 and continues on for each car built. BODY MODEL The model code number shows the product line series in the first digit. The second digit shows the body type: an odd number shows a two·door model, while an even number shows a four-door model. SERIES 10-PASSENGER CARS II. 12 .. .. ............. . 17 . . . 2· 000r . ........... . 4· 000r .2· 000r Futun 58A .. 59 A. . 64A . 64A (RPO) .. 64 C. 66A . 71A .. 71 B.. 78 A. .4· Door Sed.ln 2· 000r Walon .. .. 2· 000r Sedan 1961 2·000r Furur, .1962 2· Door Futun . Ranchero . .... . 4-000r Walon . 4· Door Country Squire Walon . Sedan Delivery COLOR TRIM Two-tone paint codes use the same symbols as the single colors except that two symbols are used. The first symbol is the lower color, the second symbol is the upper color. The trim code includes 2 digits. M30J Numb. Color All 1714 1139 Black light Turq uoise Raven Black 1961 light Blue Starlight Blue Promotional Nam First DiCit Material Typo Second DiCit Color Scheme 1 1 4 Vi nyl and Body Cloth Vinyl and Body Cloth Vinyl and Tweed Gody Cloth All Vinyl Vinyl and Woven Plastic or Body Cloth 0 1 1 Silver or White 3 4 7 Vinyl and Vinyl 5 Red or Red 8 Futura Vinyl 6 Black or Black 7 and White Turquoise Cod. liar A C 1961 1961 1361 1451 1960 1961 1115 1364 Medium Blue Metallic Belmont Blue Medium Green Laurel Green 1961 1448 Medium Blue Metallic Viking Bl ue F 1960 1961 1116 1449 light Blue light Blue Sky Mist Blue H 1960 1961 1961 1130 1367 1447 Beige Metallic Dark Blue Metallic Dark Blue Metallic Chesapeake Blue Oxford Blue • 1960 1961 1961 1131 Red Montecarlo Red January 1515 Red Rangoon Red K 1960 1961 1133 1369 Turquoise Metallic Bronze Metallic Sultana Turquoise March April May Algiers Bronze M All 1138 White Corinthian White p 1961 1454 Medium Green Silver Moss D E J Medium Turq uoise Metallic Aquama rine 5 6 Gray Bl ue or Light Blueand Medium 81ue Green Brown, Tan, or Beige Ming Green and White Metallic Baffin Blue DATE A number signifying the date precedes the month code letter. CODE Beachwood Brown Metallic Q 1961 1961 1371 light Gray Metalli<: R 1961 1961 1371 1456 Medium Blue Metalli<: Cambridge Blue Yellow Dorado Gold S 1961 1373 light Green Mint Green 1960 1173 Meadowv.le Greon 1961 1543 Medium GrH" Metallic Honey Beige Sand,hell Tan W 1960 1961 1174 1385 light Greon Turquoi,e MetJllic Ad riatic Green Garden Tu rquoise Z 1960 1961 1187 1417 light GllY MetJllic Beige MetJllic Platinum Month CODE Arsl Yur SICInd A B C D E F N P Q R February June Yllr S T M.nth July August September October November Docember Alii Yllr S..... V,ar G U H V W J K L M X Y Z DSO Units built on a Domestic Special Order, Foreign Special Order, or other special orders will have the complete order number in this space. If the unit is a regular production unit. this space will be blank. Silver Gray TRANSMISSION T AXLE RATIO CODE Fieldstone Tin ... .. M..... ·S~1It . ..... ford •• •1Ic 1. 3. ..... . 1....... . .......... . 2.......... . ........... . ... . 3.......... . ........ . . . ... . 4........ •••..•.....•••. . .•• 5........ . . . ...... . ... . t ......... .. ............... . J ......•. . ... .... . • .•...... lHO 3.11 3.11 lMI 3.tO 4.00 3.20 3.11 1112 3.10 3.,. 4." GROUP I ENGINES AND EXHAUST SYSTEM PAGE PART 1-1 ENGINES ..... . ...... ... . .. . . .. .... . . .. ... . . . 1-2 PAR T 1 - 2 EXHAUST SYSTEM . . . . . • . . . . • . . . . . . . . . . . . . . . .. 1-37 1-2 Section ENGINES Page Section 1 Description.. . . . . . . . . . . . .. 2 Engine Trouble Diagnosis . .. 3 Engine Tests and Adjustments. . . . . . . . . . . . .. 4 Engine Remova l and Installation ........ .. ..... 5 In-Chassis Repair Operations. . . . . . . . . . . . . .. Engine Supports. , .... . .. Exhaust Manifold ... . .. . D 1- 2 1- 5 1- 9 1-11 1-13 1-13 1-14 Page. Section Positive C rankcase Ventilation Sys tem. . . . .. Valve Rocker Arm Shaft Assembly. . . . . . . .. Cylinder Head and Valves Val ve Stem Seal Replacement. . . . . . . . . . .. Cylinder Front Cover and Timing Chain ... .. . .. . .. Camshaft. . . . . . . . . . . . . .. 1-14 6 1-14 1-15 1-19 1-20 1-20 7 Ca msha ft Rear Bearing Bore Plug Replacement .. Va lve Tappet Replacement C ranks haft Lower Rear Oir Seal Replacement .... Main and Connecting Rod Bearing Replacement . ... Pistons and Connecting Rods . .. .............. . Flywheel. ....... ...... . C lu tch Pilo t Bushing Replacement ..... . ..... . Oil F ilter Replacement .. . O il Pan ........... .... . Oil Pump ... . .... . .... . Work Stand Repai r Operations .......... .... . C rankshaft ......... . .. . Camsha ft Bearing Replacement ..... . . . ... . Eng ine Disassembly ..... . Cylinder Block ... . . .... . Engine Assembly, ... . . , . Cra nkcase Ventilation System Maintenance .. ... , t-22 t-22 t-22 1-22 1-23 1-27 1·28 1-28 1-28 t-29 1-30 t- 30 1-32 1-32 1-33 t-34 1-36 DESCRIPTION The Falcon 144 and 170 Six engines (Figs. I , 2, and 3) have the sa me basic design with a compression r atio of 8.7: 1. The 144 Six engine h as a piston disp lacement of 144 cubic inches and the patent p late identification symbol is "S". The 170 Six. eng ine has a piston displacement of 170 cubic inches and the patent plate identification symbo l is "U", The engines can be further id entified by the letter " N" (144 Six) and the letter "T" ( 170 Six) stamped on a boss located to the right of the crankcase vent tube outlet. MANIFOLDS Exhaust gases provide the heat FIG. 1-% Left Front View-Typical necessary to assist in vaporizi ng the incoming fuel mixture. To prevent carburetor icing at the throttle plate, an engine coo lant heated spacer is located between the carburetor and the intake manifold (Fig. 4). The coolant flows from the front of the engine through the spacer inlet hose into the carb uretor coolant spacer. The coolant circulates through the spacer and flows into the heater inlet hose and into the heater. On cars th at do not have a heater, there is no hose connection to the coolant spacer. CYLINDER HEAD The cylinder head carries the valves, valve rocker arm shaft assem- FIG. 2-% bly, intake manifold assembly, the coolant outlet and thermostat. Valve guides are integra l with the head . The valves are arra nged from front to rear E-I-I-E- I-E-E-I-E-I-I-E. CYLINDER BLOCK Th e cyli nd ers are numbered from 1-6 starting at the fro nt of the eng ine . The firing order is 1-5-3-6-2-4. T he distributor, located on the left fro nt of the engine, drives the oil pump through an intermediate drive shaft. The crankshaft is supported by four main bearings. Crankshaft end thrust is con trolled by the flanges of the No. 3 main bearing. Right Front View-Typical PART 1-1- ENGINES 1-3 A 1354-C FIG. 3-Sedional A 1356-C View-Typi(al The pistons have two compression rings and one oil control ring. The top compression ring is chromeplated and the lower compression ring is phosphate-coated. The oil control ring assembly consists of a serrated sp ring and two chrome-plated steel rails. VALVE TRAIN The intake and exhaust valve assemblies are the rotating-type. The push rods are tubular steel wi th oil cushioned sockets. The tappets are the barrel-type. Valve lash is maintained by self-locking adjusting screws. The camshaft is supported by four bearings pressed into the block and is driven by a sprocket and timing chain in mesh with a sprocket on the crankshaft. Camshaft thrust is controlled by a thru st plate located between the camshaft sprocket and the front journal of the camshaft. An eccentric on the camshaft operates the fuel pump. LUBRICATION SYSTEM Oil from the oil pan sump is forced through the pressure-type lubrication system (Fig. 5) by a rotor pump. A spring-loaded re lief valve in the pump limits the maximum pressure of the sys tem. Oil relieved by the valve is directed back to the intake side of the pump. All the oil discharged by the pump passes through a full flow-type filter before it enters the engine. The filter FIG. 5-Lubri(alion Syslem-Typi(al has an integral relief valve and mounting gasket. The relief valve permits oil to by-pass the filter if it becomes clogged, thereby maintaining an emergency supply of oil to the engine at a ll times. An anti-drain back diaphragm prevents a reverse flow of oil when the engine is stopped . From the filter, the oil Haws into the main oil gallery. The oil ga llery supplies oil to all the camshaft and mai n bearings through a drilled passage in each main bearing web. The timing chain and sprockets are sp lash lubri cated from the oil pan. Oi l slin gers prevent leakage by directing oil away from the crankshaft fr ont and rear oil seals. Cylinder walls, pistons, and piston pins are lubricated through a drilled hole in each connecting rod which indexes with a drilled hole in the connecting rod journal of the crankshaft. Oil under reduced pressure is fed to the valve rocker arm shaft assembly through a drilled passage in the cylinder block at the No.4 camshaft bearing. The oil is metered by a groove in the camshaft journal. The passage in the block indexes with a hole in the cylinder head. The oil passage in the cylinder head is drilled from the cylinder head bolt bore to the No. 6 valve rocker arm shaft support. The oil flows through the valve rocker arm shaft through drilled holes in each rocker arm to lubri cate the valve and the ball end of the rocker arm. The excess oil spirals down the rotating push rod and assists in lu bricating the tappet and push rod seat. An oil outlet in the No. 1 rocker arm shaft support, exhausts excess oil from the valve rocker arm shaft. The oil from each rocker arm drains into the push rod chamber through the push rod bore holes in lhe cylinder head. The oil in the push rod chamber drains back into the oil pan through cored openings in the block. CRANKCASE VENTILATION A 1355-C FIG. 4-Waler Healed Spa(erTypi(al The engines are equipped with either a vent tube-type crankcase ventilation system or a positive crankcase venti lation. system. In the vent lube-type system, the crankcase va- 1·4 GROUP 1 - ENGINES AND EXHAUST SYSTEM A 1357-8 FIG. 6-Vent Tube·Type Crank(ase Ventilation SystemTypi(al pors are discharged to the atmosphere. In the positive system, the crankcase vapors are returned to the intake manifold. VENT TUBE-TYPE CRANKCASE VENTILATION SYSTEM A crankcase venti lation tube is located at the left front of the engine. The forward motion of the car causes a partial vacuum to be formed at the tube outlet. This vacuum act ion causes air to be drawn through the engine from the combination oil filler and breather cap located in the front of the valve push rod chamber cover (Fig. 6). The filler cap contains a maze filtering element. Filtered a ir from the breather cap flows into the front section of the valve rocker arm shaft chamber. Here the air normalizes its temperature before contacting contaminating vapors originating in the crankcase. Warm ventilating air minimizes the formation of crankcase sludge. The ventilating air moves down past the push rods and into the crankcase. Air is diverted from lhe front section of the crankcase through holes in the front of the cylinder block wall to ventilate the timing chain chamber. The air from the crankcase is then directed into the crankcase ventilation tube by the rotating action of the crankshaft. POSITIVE CRANKCASE VENTILATION SYSTEM Ventilating air enters the engine in the normal manner through the breather cap and is distributed FIG. 7-Positive Crank(ase Ventilation SystemTypi(al through the engine in the same manner as in the vent tube-type system. However, instead of the ventilating a ir being discharged to the atmosphere, it is returned to the intake manifold. The air is returned to the intake manifold through an exhaust tube which extends from the crankcase ventilation outlet in the left side of the cylinder block to a springloaded regulator valve assembly installed in the carburetor spacer (Fig. 7). The valve regulates the amount of air to meet changing operating conditions. During idle, intake manifold vacuum is high. The high vacuum over- comes the tension of the spring pressure and seats the valve (Fig. 8). With the va lve in this position, all the ventilating air passes through a caJibrated orifice in the valve. With the va lve seated there is minimum ventilation. As engine speed increases and manifold vacuum decreases, the spring forces the valve off its seat and to the full open position. This increases the flow of ventilating air. COOLING SYSTEM The coolant is drawn from the bottom of the radiator by the water pump which delivers the coolant to the cylinder block (Fig. 9). fROM CRANKCASE OUTlET TO INTAKE MANifOLD lOW INTAKE MANifOLD VACUUM HIGH SPEED OPERATIONS fROM CRANKCASE OUTlET TO INTAKE MANifOLD HIGH INTAKE MANifOLD VACUUM LOW SPEED OPERATIONS FIG. 8-Positive Crank(ase Ventilation Regulator Valve A1458-B PART 1-1 - ENGINES Al 35 8 -1 FIG. 9-Cooli"9 Syslem EJ 1-5 As the coolant enters the block. it travels through cored passages to cool the entire length of each cylinder wall. Upon reac hing the rear of the cylinder block, the coolant is directed upward into the cylinder head where it cools the combustion chambers, valves, and valve seats on its return to the front of the engine. At thi s point, the coolant flows into the coolant outlet connection, past the thermostat if it is open, and into the top of the radiator. If the thermostat is closed, a small portion of the coola nt is ret urned to the water pump for recirculatio n. The entire system is pressurized to 13-1 5 psi. ENGINE TROUBLE DIAGNOSIS Engine performance complai nts usually fall under onc of the basic he adi ng s li s ted in the "Engine Trouble Diagnosis Guide," When a particular trouble can not be traced to a definite cause by a simple check, the possible items th at could be at fault are listed in the order of their probab le occurrence, Therefore, in most cases, the items should be checked in the order listed. For example, under Poor Acceleration, the ignition system is listed as a probable cause of th e troub le. All the ignition system items that affect acceleration are listed. These items should all be checked before proceeding to the next probable cause. ENGINE TROUBLE DIAGNOSIS GUIDE ENGINE WILL NOT CRANK ENGINE CRANKS NORMALLY, BUT WILL NOT START The cause of this trouble is usually in the starting syste m (Part 10·2). If the startin g system is not at fault, check for a hydrostatic lock or a seized engine as follows: Remove the spark plugs, then attempt to crank the engine with the starter. If the engine cranks. it indicates that water is leaki ng into the cylinders. Remove the cylinder head and inspect the gasket and/ or head for cracks. Examine the cylinder block for cracks. Check th e fuel supply. If there is sufficient fuel in the tank, the cause of the trouble probably lies in either the ignition Or the fuel system. To determine which system is at fault, perform the following test: Disconnect a spark plug wire. Check the spark intensity at the end of the wire by installing a terminal adapter in the terminal of the wire to be checked. Hold the adapter approximately o/to inch from the exhaust manifold and crank the engine. tension lead from the top of the distributor and hold it approxi mately ~o inch from the cylinder head. With the ignition on, crank the engine and check for a spark. If the spark at the coil high tension lead is good, the cause of the trouble is probably in the distributor cap or rotor. If there is no spark or a weak spark at the coil high tension lead, the cause of the trouble is probably in the primary circuit, coil to distributor high te nsion lead, or the coil. IF THERE IS NO SPARK OR A WEAK SPARK AT THE SPARK PLUGS: IF THERE IS A GOOD SPARK AT THE SPARK PLUGS: Check the spark plugs. If the spark The ca use of the trouble is in the ignition system. To determine if the ca use of the trouble is in the primary or the secondary circuit, remove the coil high plugs are not at fault, check the following items: CHOKE C heck the choke linkage for binding or da mage. Make certain the CONTINUED ON NEXT PAGE 1-6 GROUP 1- ENGINES AND EXHAUST SYSTEM ENGINE TROUBLE DIAGNOSIS GUIDE (Continued) ENGINE CRANKS NORMALLY, BUT WILL NOT START (Continued) choke plate closes when the choke knob on the instrument panel is pulled out and that the plate completely opens when the knob is pushed in. fUEl SUPPLY AT CARBURETOR Work the throttle by hand several tim es. Each time the throttle is actuated, fuel should spurt from the accelerating. pump discharge nozzle or po rt. If fuel is discharged by the accelerating pump, the engine is probably flooded, or there is water in the fuel system, or an engine mechanical item, such as valves, is at fault. If fuel is not discharged by the accelerating pump, disconnect the carburetor fuel inlet line at the car- FUEL SYSTEM ENGINE STARTS, BUT FAILS TO KEEP RUNNING Idle fuel mixture needle not properly adjusted. Engine idle speed set too low. The choke not operating properly. bUTelor. Use a suitable container to catch the fuel. Crank the engine to see if fuel is reach ing the carburetor. If fuel is not reaching the carburetor, check: The fuel filter. The fuel pump. The carburetor fuel inlet line for obstructions. The fuel pump flexible inlet line for a collapsed condition. The fuel tank line for obstructions. The fuel tank vent. If fuel is reaching th e carburetor, check: The fuel inlet system induding the fuel inlet needle and seat assembly, and the float assembly. Dirt or water in the fuel lines or fuel lilter. Carburetor icing. Fuel pump defecti ve. Check for dirt in the carburetor not allowing fuel to enter or be discharged from the idle system. Float setting incorrect. Fuel inlet system not operating properly. ENGINE RUNS, BUT MISSES Determine if the miss is steady or erratic and at what speed the miss occurs by ope rating the engine at various speeds under load. MISSES STEADILY AT ALL SPEEDS Isolate the miss by operating the engine with one cylinder not firing. This is done by operating the engine with the ignition wire removed (:"Jm one spark plug at a time, until all cylinders have been checked. Ground the spark plug wire removed. If the engine speed changes when a particular cylinder is shorted out, that cylinder was delivering power before being shorted out. If no change in the engine operation is evident, the miss was caused by that cylinder not delivering power before being shorted out. In this case, check the: IGNITION SYSTEM If the miss is isolated in a particular cylinder, perform a spark plug test on the ignition lead of that cylinder. IGNITION SYSTEM Leakage in the high tension wiring. If a good spark does not occur, the trouble is in the seco ndary circuit of the system. Check the spark plug wire and distributor cap. If a good spark occurs, check the spark plug. If the spark plug is not at fault, a mechanical component of the engine is probably at fault. ENGINE Perform a compression test to determine which mechanical component of the engine is at fault. MISSES ERRATICALLY AT ALL SPEEDS EXHAUST SYSTEM Exhaust system restricted. IGNITION SYSTEM Defective breaker points, condenser, secondary wiring, coil, or spark plugs. High tension leakage across the coil, rotor, or distributor cap. CONTINUED ON NEXT PAGE PART 1-1- ENGINES 1-7 ENGINE TROUBLE DIAGNOSIS GUIDE (Continued) ENGINE RUNS, BUT MISSES (Continued) fUEL SYSTEM IGNITION SY5TfM Float setting incorrect. Fuel inlet system not operating properly. Dirt or water in fuel lines o r carburetor. Restricted fuel filter. Excessive play in the di stributor shaft. Worn distributor cam. COOLING SYSTEM Check the cooling system for intern al leakage and /or for a co nditio n that prevents the engin e from reaching norm al operating temperature. ENGINE Perform a compression test to determine which mech an ical component of the engine is at fault. MISSES AT HIGH SPEED ONLY FUEL SYSTEM ENGINE Perform a com pression test to determine which mechanical component of the engine is at fault. MISSES AT IDLE ONLY FUEL SYSTEM ROUGH ENGINE IDLE Idle fuel mixture needle not properl yadj usted. COOLING SYSTEM FUEL $YSTEM Fouled o r improperly adjusted spark plugs. Incorrect ignition timing. Spark plug mi sfi ring. Engine id le speed set too low. Idle fuel mixture needle not properlyadjusted. F loa t se tting incorrect. A ir leaks between the car buretor. space r, and the manifold and / or fillin gs. Fuel leakage at the carbu retor fuel bowl. Idle fuel sY3 tem ai r bleeds or fuel passages restricted. Fuel bleedi ng from the acce lera ting pump discharge nozz le or port. IGNITION SYSTEM Improperly adjusted o r defective breaker poi nts. IGNITION SYSTEM POOR ACCELERATION Power valve clogged or damaged. Power va lve diaphragm leaking (1960 and 196 1 models). Low or erratic fuel pump pressure. Fuel inlet system not operating properly. Restricted fuel filter. Inco rrect ignition timi ng. Fo ul ed or improperly ad justed spark plugs. Imp roperly adjusted or defective breake r points. D ist ributor not adva ncing properly. Defective spark con trol valve. FUEL SYSTEM Inoperati ve accelerati ng pump inlet ball c heck. Inoperative acce lerating pump discharge ball check. Engine overheating. VACUUM BOOSTER PUMP Leaking pump. li nes. or fillings. ENGINE Loose engine mou ntin g bolts or worn insulator. Cylinder head bolts not properly torqued. Valve lash set too tight. Cra nkcase ve ntilati on regu lator valve defective or a restricted tube (Positive Cra nkcase Venti lati on System). Accelerating pump di aphr agm de fective ( 1960 a nd 1961 models). F loat setti ng incorrect. Throttle linkage not properly adjusted. Accelerating pump stroke no t properly ad justed . Leaky power va lve gasket. Dirt or corrosio n in accelera ting system . Dist ributo r vacuum passages in the ca rbu retor blocked. Restr icted fuel filter . BRAKES Imprope r ad justment. CONTINUED ON NEXT PAGE 1-8 GROUP 1 - ENGINES AND EXHAUST SYSTEM ENGINE TROUBLE DIAGNOSIS GUIDE (Continued) TRANSMISSION POOR ACCELERATION (Continued) Clutch slippage (manual- shift transmission). Improper band adjustment (Fordo- Converter One-Way C lutch (Fordomatic). Improper linkage adjustment (Fordomatic). matic), FUEL SYSTEM ENGINE DOES NOT DEVELOP FULL POWER, OR HAS POOR HIGH SPEED PERFORMANCE Restricted air cleaner. Restricted fuel filter. Clogged or undersize main jets and/ or low float setting. Power valve clogged or damaged. Power valve diaphragm leaking (1960 and 1961 models). Fuel pump pressure incorrect. Distributor vacuum passage in the carburetor blocked. IGNITION SYSTEM Ignition timing not properly adjusted. EXCESSIVE FUEL CONSUMPTION EXHAUST SYSTEM Rest-riction in system. COOLING SYSTEM Thermostat inoperative or incorrect heat range. Thermostat installed incorrectly. Check the cooling system for internal leakage andlor for a condition that prevents the engine from reaching normal operating temperature. ENGINE Defective coil, condenser, or rotor. Oistributor not advancing properly. Excessive play in the distributor shaft. , Distributor cam worn. Fouled or improperly adjusted spark plugs. Imp roperly adjusted or defective breake r points. Perform an engine compression test to determine which mechanical component is at fault. One or more camshaft lobes worn beyond wear limit. Determine the actual fuel consumption with test equipment installed in the car. If the test indicates that the fuel consumption is not excessive, demonstrate to the owner how improper driving habits will affect fuel consumption. If the test indicates th at the fuel consumption is excessive, make a prelimin ary check of the following items before proceeding to the fuel and igniti on systems. ENGINE PRELIMINARY CHECKS CHASSIS ITEMS Check: Tires for proper pressure. Front wheel alignment. Brake adjustment. ODOMETER Check calibration. IGNITION SYSTEM Check: Distributor breaker points. Ignitio n timing. TRANSMISSION Improper band adjustment (Fordomatic). Crankc ase ventilation regulator valve defective or a restricted tube (positive Crankcase Ventilat ion System). Exhaust system restricted. FINAL CHECKS FUEl SYSTEM Check: Fuel pump pressure. Engine idle speed. Idle fuel mixture needle for proper adjustment. Accelerating pump stroke adj ustment. Anti-stall da sh pot for proper adjustment. Air cleaner for restrictions. Float setting or fu el level. Jet for damage. Powe r va lve operation. Air bleeds for obstructions. Accelerating pump discharge nozzle or port for siphoning. CONTINUED ON NEXT PAGE PART 1-1- ENGINES 1-9 ENGINE TROUBLE DIAGNOSIS GUIDE (Continued) EXCESSIVE FUEL CONSUMPTION (Continued) ENGINE OVERHEATS Spark control valve for proper seating. A ccelerator linkage for binds. Choke adjustment. Perform an engine compression test to determine which mechanical component of the engine is at fault. Check valve lash adj ustment. IGNITION SYSTEM COOLING SYSTtM Check: Spark plug condition and adjl,lstment. Distributor spark advance operation. Check thermostat operation and heat range. TEMPERATURE SENDING UNIT AND GAUGE Unit or gauge defective (not indicating correct temperature), or constant voltage regulator defective. ENGINE Cylinder head bolts not properly torqued. Incorrect valve lash. Low oil level or incorrect viscosity oil used . COOLING SYSTEM LOSS OF COOLANT ENGINE Leaking radiator. Loose or damaged hose connections. TRANSMiSSION Check band adj ustment (Fordomalic) COOLING SYSTEM Insufficient coolant. Cooling system leaks. Drive belt tension incorrect. Radiator fins obstructed. Thermostat defective. Thermostat improperly installed. Cooling system passages blocked. Water pump inoperative. IGNITION SYSTEM Incorrect ignition timing. ENGINE Cylinder head gasket defective. Cylinder head bolts not properly torqued , Cylinder block core plugs leaking. Water pump leaking. Radiator cap defective. O ve rheating. ENGINE FAILS TO REACH NORMAL OPERATING TEMPERATURE II TEMPERATURE SENDING UNIT AND GAUGE Unit or gauge defective (not indicating correct temperature) or constant voltage regulator defective, Tempera ture sending unit leaking. Cracked cylinder head or block, or warped cylinder head or block gasket surface, COOLING SYSTEM Thermostat inoperative or of correct heat range. in~ ENGINE TESTS AND ADJUSTMENTS CAMSHAFT LOBE LIFT 1. Remove the air cleaner and the valve rocker ann cover. Slide the rocker arm assembly se rving the camshaft lobe to be checked to one side. Secure it in this position. To remove the rocker arm on either end of the shaft, it will be necessary to remove the retaining pin and spring washer and slide the rocker arm off the shaft. 2. Make sure the push rod is in the tappet socket. Install a dial indicator in such a manner as Lv have the actuating point of the indicator in the push rod socket and in the same plane as the push rod movement (Fig. 10). 3. Turn the crankshaft pulley or damper slowly in the direction of GROUP 1- ENGINES AND EXHAUST SYSTEM 1-10 TABLE I-Manifold Vacuum Gauge Readings E ngi ne Cond iti o n Gauge Readi ng FIG. I O-(amshaft Lobe Lift rotation until the tappet is o n th e base ci rcle of the camshaft lobe. At thi s po int, th e push rod will be in its lowest posi ti on. 4. Zero the dial ind icator, then conti n ue to ro tate th e pulley or dam per slow ly until th e push rod is in the full y raised posi ti on. S. Comp are the to tal lift recorded on the indicator wi th spec ifications. 6. T o check th e accuracy of the o ri gin al ind icator reading , continue to rotate th e pulley or dam per until the indicator reads zero. 7. Remove the dial ind icator. Secure the valve rocker arm. If an end val ve roc ker arm was removed, slid e it into pos it ion on the s:haft and install the spring washer and retai ning pin. Perform a prelim inary valve lasb adjustm ent as necessary. Operate the engine until normal operating temperature has been reached. C heck and adjust the valve lash . 8. Install the valve rocker arm cover and the air cleaner. MANIFOLD VACUUM TEST A manifold vacuum test aids in determining the conditio n of an engine and also in helping to locate the cause of poor en gine perform ance. To test manifold vacuum : 1. Operate the engine for a minimum of 30 m inutes at 1200 rpm. 2. Install an 3ccurate, sensiti ve vacuum gauge o n the fu el pump end of the manifo ld vac uum line. 3. O perate the engine at the recommended idle rpm. 4. C heck the vac uum reading on the gauge. 18 inches. N orm al. Low and steady. Loss of power in all cylind ers caused possibly by late ignition or valve timing, or loss of compression du e to leakage aro und the piston rin gs or valves. Very low. Carb ureto r or cylinder head gasket leak. Need le fluctuates stead il y as speed in creases. A partia l or co mplete loss of power in one or more cyl in ders ca used by a le akin g va lve, cylinde r head gasket leak, a defec t in the ignitio n system, o r a weak va lve spring. Gradua l d rop in readi ng at engi ne id le. Excess ive back pressu re in the exhaust sys tem. Int ermi tte nt fl uc tua ti on. An occasio nal loss of power poss ibly caused by a defect in the ignit io n system o r a sti cking valve. Slow flu ctua ti on or d riftin g of the need le. Im proper idle mix ture adjustment , carburetor gaske t leak. the conditio n of the valves, cylinder compress io n, and lea kage of the carburetor o r cylinder head gaskets. Beca use ab normal ga uge readings may ind ica te th at more th an o ne of the above fac tors is at fa ult , exerc ise cautio n in analyz in g a n abnorm al reading. Fo r exa mple, if the vacuum is low, the correc tio n of o ne item may increase th e vacu um enough so as to ind ica te that the trouble has been correc ted . It is im portant , therefore, that eac h ca use of an abnormal reading be investiga ted and further tests conducted where necessary in order to a rrive at the co rrec t diag nosis of the tro uble. T ab le I lists va ri ous types of readings and their poss ible causes. Allowance should be made for the effect of a lti tuae on the gauge reading. The engine vacuum will decrease with an increase in altitude. COMPR ESSION TEST TEST CONCLUS IONS Be sure the battery is properly charged. Operate the engine for a minimum of 30 minutes at 1200 rpm. Turn the ignition switch off, then remove all the spark plugs. Remove the coil high tension lead at the distributor cap. 'Set the throttle plate and choke plate in the wide open position. Manifold vacuum is affected by carbu retor adj ustment, valve tim ing , Install a compression gauge in the No. I cylinder. Using a remo te starter sw itch, crank the engine several times and record th e highest read in g registered . Note th e number of compress ion stro kes req uired to ob tai n the hi ghest read ing. Repea t the test o n eac h cylinder, cran kin g the engi ne the sa me number of times fo r each cylind er as was required to obta in the hi ghest reading o n the No. 1 cylinder. A va ri ation o f ± 20 pounds from specified pressure is sati sfactory. However, tbe compression of aU cylin ders should be unifo nn within 10 pounds. A read ing of mo re than the allowable tolerance above no rm al indicates excess ive deposits in the cylinder. A reading o f more than the a llowab le to lerance below normal indica tes lea kage at the cylinder head gasket, piston rin gs, o r valves. A lo w even co mpressio n in two adj acent cylinders ind icates a cylinder head gasket leak. This should be checked before co ndemning the rings or valves. T o determine whether the r ings or the va lves are at fault, squirt the equivalent of a tablespoon of heavy o il into the combustion chamber. C rank the engine to distribute the oil and repeat the co mpression test. The oil will temporar ily seal leakage pasl the rings. If approxi mately the same reading is obtained, the rings art: PART 1-1- ENGINES satisfactory, but the valves are leaking. If the compression has increased 10 pounds or more over the original reading, there is leakage past the rings. During a compression test, if the pressure fails to climb steadily and remains the same during the first two successive strokes, but climbs higher on the succeeding strokes, or fails to climb during the entire test, it indicates a sticking valve. VALVE LASH COLD VALVE LASH If the valve rocker arm shaft as- sembly has been removed and installed, it will be necessary to make a preliminary (cold) valve lash adjustment before starting the engine. If tbe adjustment is made for an engine STEP l - SET NO. I PISTON ON T,D.C. AT END O F COMPRESSION STROKE ADJUST NO. 1 INTAKE & EXHAUST 4 -ADJ UST NO . 6 INTAKE & EXHAUST .s INTAKE & EXHAUST SliP S- ADJUST NO. 2 INTAKE & EXHAUST 3 INTAKE & EXHAUST SliP 6 - ADJUS T NO . .. INTAKE & EXHAUST A 1360-A FIG. II-Preliminary Valve lash Adjustment-Typical D tune-up, follow the final adjustment procedure. The cylinders are numbered from front to rear, 1-2-3-4-5-6 and the valves are arranged from front to rear, E-I-I-E-I-E-E-I-E-I-I-E. 1. Turn all the valve adjusting screws until interference is noted. Check the torque required to turn the screw further. If the torque required to turn a screw is less than 3 ft-Ibs (36 in-Ibs), try a new self-locking adjusting screw. If this is still unsatisfactory, replace the rocker arm and adjusting screw. 2. Make two chalk marks on the crankshaft pulley or damper (Fig. 11). Space the marks approximately 120 0 apart so that with the timing mark, the pulley or damper is divided into three equal parts (120 0 represents VJ of the distance around the pulley or damper circumference). 3. Rotate the crankshaft until the No. 1 piston is near TDe at the end of the compression stroke. The No.1 piston is on TDC at the end of the compress ion stroke when both valves are closed and the timing mark on the crankshaft pulley or damper is in line with the timing pointer. 4. Adjust the intake and exhaust valve lash for No. 1 cylinder (Fig. 12). Refer to Group 13 for the specified preliminary (cold) intake and exhaust valve lash. Use a steptype feeler gauge ("go" and " 00 go") to adjust the valves. S. Repeat this procedure for the remaining set of valves, turning the crankshaft VJ turn at a time, in the direction of rotation, while adjusting the valves in the firing order sequence. 1-11 If the lash is set too close, the valve will open too early and close too late, resulting ' in rough engine idle. Burning and warping of the valves will occur also because the valves cannot make firm contact with the seats long enough to cool properly. If the lash is excessive, it will cause the valve to open too late and close too early causing valve bounce. In addition, damage to the camshaft lobe is likely because the tappet foot wiU not follow the pattern of the camsbaft lobe causing a shock contact between these two parts. Be sure the engine is at normal operating temperature before attempting to set the valve lash. With the engine idling, set the valve lash (Fig. 12) using a step-type feeler gauge only ("go" and "no go"). Refer to Part 13-4 for the specified final (hot) intake and exhaust valve lash. For example, to obtain the correct setting if the valve lash is O.016)nch. use a step-type feeler gauge of 0.015 inch ("go") and 0.017 inch("no go"). The "go" step should enter, and the "no go" step should not enter. The resultant setting will be to the required specification (0.016 inch). HOT VALVE LASH It is very important that the valve lash be held to the correct specifications because: FIG. 12-Valve lash Adjustment ENGINE REMOVAL AND INSTALLATION A typical engine installation is shown in Fig. 13. REMOVAL 1. Remove the hood. 2. Drain the cooling system and the crankcase. J. Remove the air cleaner. Disconnect the battery ground cable at the cylinder head. Disconnect the radiator upper ho:se at the water outlet housing and the radiator lower hose at the water pump. 4. Remove the radiator. Remove the drive belt, fan, and pulley. s. Disconnect the heater hoses at the water pump and the carburetor spacer. Disconnect the generator wires at the generator, the starter cable at the starter, the accelerator rod and the choke control cable at the carburetor. 6. Disconnect the windshield wiper vacuum hose at the vacuum pump. Remove the fuel pump sediment bowl. Disconnect the flexible fuel line at the fuel tank line and plug the fuel tank line. 7. Disconnect ' the coil primary 1-12 GROUP 1- ENGINES AND EXHAUST SYSTEM To oI-T52T·6005 ·CJD ISPLINEO SHAfTl Too/-6001 -FSA FIG. FIG. 13-Engine Installation-Typical wire at the coil. Disconnect the oil pressure and the water temperature sending unit wires at the sending units. 8. Remove the statter and dust seal. On a car with a m anual-shift transmission, disconnect the clutch retracting spring. Disconnect the clutch equalizer shaft and arm bracket at the underbody rail and remove the arm bracket and equalizer shaft. 9. Raise the car. Remove the flywheel or converter housing upper retaining bolts through the access holes in the underbody. 11. Lower the car. Support the transmission and flywheel or CODverter housing with a jack. 12. Attach the engine lifting hook (Fig. 14). Carefull y lift the engine out of the engine compartment. Install the engine on a work stand (Fig. 15). INSTALLATION 1. InstaU guide pins in the flywheel or converter housing bolt holes in the rear of the engine. Place a new gasket over the studs of the exhaust manifold. 10. Disconnect the muffler inlet pipe at the exhaust manifold. Loosen the inlet pipe clamp and slide it off the support bracket on the engine. Disconnect the engine righ t and left mount at the underbody bracket. Remove the flywheel or converter housing cover. On a car with a manual-shift transmission, remove the flywheel housing lower retaining bolts. On a car with Fordornatic, disconnect the converter from the flywheel. Remove the converter housing lower retaining bolts. FIG. 14-Engine Lifting HookTypical A 1364-8 15-Engine Work Stand 2. Carefully lower the engi ne into the engi ne compartment. 3. Make sure the studs on the exhaust manifold are aligned with the holes in the muffler inlet pipe and the guide pins in the block engage the holes in the flywheel housing. On a car with Fordomatic, start the converter pilot into the cra nkshaft. On a car with a m anual-shift transmission, start the transmission main drive gear into the clutch disc. It may be necessary to adj ust the position of the transmission in relation to the engine if the input shaft will not enter the clutch disc. If the engine "hangs up" after the shaft enters, tum the crankshaft slowly (transmission in gear) until tbe sbaft splines mesb with the clutch disc splines. 4. Remove the engine lifting hooks. Install the flywheel or converter housing upper retaining bolts. 5. Remove the jack from the transmission. Raise the car. 6. Remove the guide pin and install the flywheel or converter housing lower retaining bolts. On a car wi th Fordomatic, attach the co nverter to the flywheel and torque the retaining nuts to specifications. 7. Install the flywheel or converter housi ng dust cover. On a car with a manual-shift transmission, install the clutch equalizer shaft and arm bracket. Connect the clutch retracting spring. S. Install the engine left and right mount to the underbody bracket. Install the sediment bowl on the fuel pump. 9. Remove the plug from the fuel tank line and connect the flexible fuel PART 1-1- ENGINES line to the fuel tank line. Install the exhaust manifold to muffler inlet pipe retaining lock washers and nuts. Torque the nuts to specifications. Position the inlet pipe clamp on the support bracket on the engine and tighten the clamp. 10. Lower the car. Connect the oil pressure and the engine temperature sending unit wires. Connect the coil primary wire. Connect the windshield wiper vacuum hose to the vac- D uum pump. Connect the accelerator rod. Connect and adjust the choke control cable. 11. Install the starter motor and dust seal. Connect the starter cable. Connect the generator wires. Connect the heater hose at the water pump and carburetor spacer. Connect the battery ground cable. 12. Install the pulley. fan. and drive belt. Adjust the drive belt tension. Install the radiator. Connect 1-13 the radiator upper and lower boses. Fill and bleed the cooling system. Fill the crankcase with the proper grade and quantity of engine oil. 13. Install and adjust the hood. 14. Operate the engine at fast idle and check all gaskets and hose connections for leaks. On a car with Fordomatic, adjust the transmission control linkage. 15. Install the air cleaner. IN-CHASSIS REPAIR OPERATIONS ENGINE SUPPORTS ENGINE FRONT SUPPORT The engine front support is shown in Fig. 16. 1. Remove the engine support to underbody nuts. The nuts must be removed from both supports so that the engine can be raised. 2. Raise the engine slightly with a jack and a wood block placed under the oil pan. 3. Remove the engine support to engine bolts. Remove the support. 4. Place the engine support into position. Install the support to engine bolts. 5. Lower the jack and guide the support studs through the holes in the underbody. Remove the jack and wood block. 6. Install the support to underbody nuts and lock washers. ENGINE SINGLE-POINT REAR SUPPORT The engine single-point rear support used on 1960 and 1961 early production cars is shown in Fig. 17. 1. Support the transmission with a floor jack and remove the support assembly to underbody bolts. Remove the support assembly to insulator bolts and remove the support assembly. 2. Remove the insulator to extension housing bolt and remove the insulator. 3. Install the insulator assembly on the support assembly. 4. Place the assembly in position and install the support assembly to underbody lock washers and bolts. 5. Install the insulator to extension housing lock washer and bolt. Remove the transmission jack. ENGINE TWO-POINT REAR SUPPORT The engine two-point rear support used on 1960 and early production 1961 Station Wagons and Rancheros is shown in Fig. 18. 1. On a model with a manual-shift transmission, drain the transmission. 2. Remove the insulator nuts and washers. 3. Support the transmission with a floor jack and remove the cross member bolts. Remove the cross member and the insulators. 4. Remove the engine support bolts and loc k washers. Remove the support. 5. Position the engine support and install the bolts and lock washers. 6. Place the insulators in the cross member mounting holes. Position the cross member to the underbody and install the bolts. 7. Make sure the insulators are seated properly on the cross member, and then install the washers and nuts. Remove the transmission jack. On a model with a manual-shift transmission, fiU the transmission. ENGINE CANTILEVER LEAF-SPRING REAR SUPPORT The engine cantilever leaf-spring rear support used on all late production 1961 and 1962 models is shown in Fig. 19. 1. Disconnect the parking brake equalizer lever from the support bracket. , • ,: I :" I I . ' I .. INSUlATOR+~ /~ SUPPORT ASSEM BLY FIG. l6-Engine Front Support FIG. ! Y, 0 A1548-A 17-Engine Single-Point Rear Support FIG. l8-Engine Two-Point Rear Support GROUP 1- ENGINES AND EXHAUST SYSTEM 1-14 INSTAllATION ~ 1. Place a new exhaust manifold to muffler inlet pipe gasket over the CllP~~P ER SPRING NUT RETAINER ." ~IN SUlATOR '1P!l~ . SUPPORT~ ' '~.. ASSEMB.lY BRACKET ....::,~ \ LEAF · SPRING RUBBER Fl:T WASHER ~ -~ ~ . J a i y CENTER BOLT lOWER~~ INSULATOR A1521-A FIG. 19-Engine Cantilever Leaf-Spring Rear Support 2. Support the transmission with a floor jack. Remove the leaf-spring center bolt and lower insulator. Dis- connect the leaf-spring from the transmi ssion extension housing and remove th e leaf-spring and flat rubber washer. 3. Disconnect the support bracket from the body cross member and remove the support, upper insulator, and spring clip nut retainer. 4. Position the upper insulator and spring clip nut retainer in the support bracket and connect the support bracket to the body cross memher. Make sure there is a minimum clearance of 0.20 incb between tbe transmission extension housing and tbe upper insulator. 5. Position the flat rubber washer on top of the leaf-spring and connect the leaf-spring to the transmission extension housing. Torque the bolts to spec ifications. 6. Install the lower insulator and the center bolt. Torque the center bolt to specifications. Remove the transmission jack. 7. Connect the parking brake equalizer lever to the support bracket. stud s of the ex haust man ifold. 2. Place the exhaust manifold into posi tion on the muffler inlet pipe and against the cylind er head. Install the exhaust man ifold to cylinder head retaining bolts and tab washers. Torq ue the retaining bolts to specific ati ons. Lock th e bolts by bending one tab of the washer over a flat on th e boll. 3. ]nstall the muffler inlet pipe to exhaust manifold lock washers and nuts. Torque the nuts to specifications. Insta ll the air clea ner. .,.-.:;_~_- a - - VAlVE CLEANING AND INSPECTION Scrape the old gasket material from the flanges of the muffler inlet pipe and from the exhaust manifold inlet pipe flange. Inspec t the manifold for cracks, leaks, or other defects that would make it unfit for further service. POSITIVE CRANKCASE VENTILATION SYSTEM The regulator va lve used for these engin es can be identified by 3 an nul ar grooves on the regul ator valve body. REMOVAL 1. Remove the crankcase ventilation exhaust tube by disconnecting the exhaust tube from the crankcase venti lation outlet adapter and from the regulator va lve assembly (Fig. 20). 2. Remove the regulator valve assembly from the fitting in the carburetor spacer. 3. Remove the crankca se outlet adapter. INSTALLATION 1. I nstall the crankcase outlet adapter. Be sure the outlet adapter A146,_B FIG. 21-Regulalor Valve Assembly is not loose. To avoid restricting the ventilation system, do not install tbe adapter into the cylinder block more than 1/2 -inch. 2. Install the regulator valve assembly in the carburetor spacer. 3. Connect the exhaust tube to the regulator valve assembly and to the crankcase ventilation outlet adapter. REGULATOR VALVE DISASSEMBLY Place the large hex end of the regulator valve body in a vise. Remove the connector, valve, and spring. CLEANING Clean the valve parts, tub ing, and outlet ad apter in clean carburetor so lvent and dry with compressed air. C lean the rubber hose connections with a low volatility petroleum base so lvent and dry with compressed air. REGULATOR VALVE ASSEMBLY Position the spring and valve inside the regulator valve body (Fig. 2 1). Install the regulator valve connector. VALVE ROCKER ARM SHAFT ASSEMBLY REMOVAL 1. Remove the va lve rocker a rm cover and di sca rd the gasket. EXHAUST MANIFOLD REMOVAL 1. Remove the air cleaner. Disconnect the muffler inlet pipe from the exhaust manifold . 2. Bend the exhaust manifold retaining bolt lock tabs back and remove the retaining bolts. Remove the exhaust manifold. SPRING FIG. 20-Regulator Valve Exhaust Tube-Typi(al and FIG. 22-Valve Ro(ker Arm Shaft Removal PART 1-1- ENGINES 2. Slide the valve rocker arms, springs, and supports off the shaft. Be sure to identify the parts. FIG. 23-Valve Rocker Arm (over Gasket Installation 2. Loosen all the valve rocker arm adju sting screws two turns at a time in sequence, to remove the valve spring load from the rocker arms. Remove the valve rocker arm shaft assembly (Fig. 22). INSTALLATION 1. Apply Lubriplate to both ends of the push rods and to the valve stem tip. 2. Position the valve rocker arm shaft assembly on the head. 3. Tighten all the valve rocker arm shaft retaining bolts two turns at a time in sequence. Torque the bolts to specifications. 4. Perform a preliminary valve lash adjustment. 5. Clean the valve rocker arm cover. Coat one side of a new valve rocker arm cover gasket with oil resista nt sealer. Lay the cemented side of the gasket in place in the cover (Fig. 23). Install the cover, making sure that the gasket seats evenly around the head . The cover is tightened in two steps. First torque the retaining bolts to specifications. Two minutes after the initial ti ghteni ng, torque the bolts to the same specification. 3. If it is necessary to remove the plugs fro m each end of the shaft. drill or pierce the plug on one end. Use a steel rod to knock out the plug on the opposite end. Working from the open end, knock out the remaining plug. CLEANING AND INSPECTION Clean all the parts thoroughly. Make sure that all oil passages are open. Check the clearance between each rocker arm and the shaft by checkin g the 10 of the rocke r arm bore and the 00 of the shaft. If the clearance between any rocker arm and the shaft exceeds the wear lim it, replace the shaft and/ or the rocker arm. Inspect the shaft and the rocker bore fo r nicks, scra tches, scores, or scuffs. Dress up minor surface defects with a hone. Inspec t the pad at the valve end of the rocker arms for a grooved radius. If the pad is grooved, replace the rocker arm. Do not attempt to true this s urface by grinding. ASSEMBLY 1. Lubricate all parts with engine oil. Apply Lubriplate to the valve and push rod ends of the rocker arm. 2. If the plugs were removed from the ends of the shaft, use a blunt tool or large di ameter pin punch and install a plug, cup side out, in each end of the shaft. DISASSEMBLY 3. Install the spring washer and pin on one end of the shaft. 1. Remove the pin and spring washer from each end of the valve rocker arm shaft. 4. Install the valve rocker arms, supports, and springs in the order shown in Fig. 24. Be sure the oil 1-15 holes in the shaft are facing downward. Complete the assembly by installing the r~m a ining spring washer and pin. CYLINDER HEAD AND VALVES CYLINDER HEAD REMOVAL 1. Dra in the cooli ng system. Remove the air cleaner. Disconnect the battery cable at the cylinder head. 2. Disconnect the muffler inlet pipe at the exhaust manifold. Loosen the inlet pipe clamp and slide it off the su pport bracket on the engine. Pull the muffl er inlet pipe down. Remove the gasket. 3. Disco nnect the accelerator rod retracting spring. Disconnect the choke control cable and the accelerator rod at the carburetor. 4. Disconnect the fuel inlet line and the distributor vacuum line at the carbure tor. Disconnect the vacuum line at the carburetor spacer or intake manifold . 5. Disco nn ect the carburetor spacer outlet line at the spacer. Disconnec t the rad iator upper hose ·at the coolant outlet elbow. Disconnect the heater hoses at the water pump and at the cylinder head. 6. Disconnect the distrib uto r vacuum line at the distributor. Disconnect the carburetor fuel inlet line and the vacuum line at the fuel pump. Remove the three lines as an assembly. On an engine with positive crankcase ve nti lation , disconnect the exhaust tube at the regulator va lve and crankcase outlet. Remove the regu lator va lve and crankcase outlet adapter. Disconnect th e vacuum line at the regu lator valve fitting and fuel pump. I\ ADJUSTING SCREW SUPPORT ~ ROCK ER ARM t: RETAINING BOLT ~ WASHER NO. 1 SUPPORT WASHER ~, SPRING I ~ ~V1 ~ i & rYm l i ta Jm !& i!l rrrrn ~S? . mm llt~ PlN~ P\t;;;; 5 ~ ;;;: ( Va \ l \ SPRING WASHER SHAFT PLUG FIG. 24-Valve Ro(ker Arm Shaft Assembly SUPPORT SOlT HOLES - - - fRONT Of ENGINE - -...~ It. 1385.1 1·16 GROUP 1- ENGINES AND EXHAUST SYSTEM the exhaust tube at the regulator valve and crankcase outlet adapter. FIG. 25-Valve Push Rod Removal 7. Disconnect the spark plug wires at the spark plugs and the tempera· ture sending unit wire at the sending unit. 8. Remove the valve rocker arm cover. 9. Remove tbe valve rocker arm shaft assembly. Remove the valve push rods in sequence (Fig. 25). 10. Remove one cylinder head bolt from each end of the head and install the cylinder head guide studs (Fig. 26). Remove the remaining cylinder head bolts and remove the cylinder head. Do not pry between the cylinder head and block as the gasket surfaces may become damaged. CYLINDER HEAD INSTALLATION 1. Clean the head and block gas· ket surfaces. If the cylinder head was removed for a gasket change, check the flatness of the cylinder head and block. 2. Apply cylinder head gasket sealer to both sides of a new gasket. Use the brush furnished to spread the sealer evenly over the entire gasket surface. Position the gasket over the guide studs on the cylinder block. 3. Install a new gasket on the flange of the muffler inlet pipe. 4. Lift the cylinder head over the guides and slide it down carefully, guiding the exhaust manifold studs into the muffler inlet pipe. S. Coat the threads of the No. 1 and 6 bolts for the right side of the cylinder head with a small amount of water resistant sealer. Install, but do not tighten two bolts at opposite ends of the head to hold the head and gasket in position. Remove the guides, then install the remaining bolts. FIG. 26-Cylinder Head Guide Studs A 1369-A FIG. 27-Cylinder Heod Bolt Tightening Sequence 6. The cylinder head bolts are tightened in three progressive steps. Torque all the bolts in sequence (Fig. 27) to 55 ft·lbs, th en to 65 ft·lbs, and finally to 75 ft·lbs. After the cyl. inder head bolts have been torqued to specifications, the bolts should not be disturbed. 7. Apply Lubriplate to both ends of the push rods. Install the push rods in their original bores, positioning the lower end of the rods into the tappet sockets. Apply Lubriplate to the valve stem tips and to the rocker arm pads. ·8. Install the valve rocker arm shaft assembly following steps 2 and 3 under " Valve Rocker Arm Shaft Insta ll ation." 9. Perform a preliminary (cold) valve lash adjustment. 10. Install the muffler inlet pipe lock washers and retaining nuts. Position the inlet pipe clamp on the support bracket on the engine and tighten the clamp. 11. Connect the radiator upper hose at the coolant outlet elbow. Connect the heater inlet and outlet hoses at the water pump. Connect the carburetor spacer outlet line at the spacer. 12. Position the distributor vacuum line, the carburetor fuel inlet line, and the vacuum line on the engine. Connect the fuel inlet line and the distributor vac;uum line at the carburetor, Connect the vacuum line at the carburetor spacer or intake manifold. Connect the battery cable to the cylinder head. On an engine with positive crankcase ventilation, position and connect the vacuum line at the regulator valve fitting and fuel pump. Clean the regu· lator valve parts, exhaust tube, rubber hose connections, and outlet adapter. Install the regulator valve. Install the crankcase outlet adapter. Be sure the outlet adapter is not loose. To avoid restricting the ventilation system, do not install the adapoter into the cylinder block more than lh-inch. Position and connect 13. Connect the accelerator rod retracting spring. Connect the choke control cable and the accelerator rod at the carburetor. Adjust the choke control cable. 14. Connect the distributor vacuum line at the distributor. Connect the carburetor fuel inlet line and the vacuum line at the fuel pump. IS. Co nnect the temperature sending unit wire at the sending unit. Connect the spark plug wires. Be sure the wires are forced all the way down into their sockets. 16. Fill and bleed the cooling system. Start the engine and operate it for a minimum of 30 minutes at 1200 rpm to stabilize engine temperatures. Check for coolant and oil leaks. Adjust the engine idle speed and the idle fuel mixture. Check the valve lash with the engine idling and adjust the lash, if necessary, using a step·type gauge. 17. Install the valve rocker arm cover following step 5 under "Valve Rocker Arm Installation," Install the air cleaner. CYLINDER HEAD DISASSEMBLY 1. Install the cylinder head hold· ing fixtures (Fig. 28). Remove de· posits from the combustion chambers and valve heads with a scraper and a wire brush before removing the valves. Be careful not to scratch the cylinder head gasket surface. 2. Compress the valve SpI iogs (Fig. 29). Remove the valve retainer locks and release the spring, If the valve locks are stuck, place a piece of steel tubing (% -inch OD, 'h -inch ID and 3-inches long) over the end of the valve stem squarely against the sleeve surface. Tap the tube with a steel hammer to dislodge the locks. A 1386-8 FIG. 2B-Cylinder Head Holding Fixtures PART 1-1- ENGINES Tool_13·93 20 FIG. 29-(ompressing Valve Spring ~ 3. Remove the sleeve, spring retainer, stem seal, and valve. Discard the valve stem seals. Identify all valve parts. FIG. 31-Valve Seat Runout CYLINDER HEAD CLEANING After the valves are removed, clean the valve guide bores with a valve guide cleaning tool. Use cleaning solvent to remove dirt, grease, and other deposits. CYLINDER HEAD INSPECTION Check the cyl inde: head for cracks, and the gasket surface for burrs and nicks. Replace the head if it is cracked. Do not plane or grind more than 0.010 inch from the cylinder head gasket surface. Remove all burrs or scratches with an oil stone. Cylinder Head Flatness. Check the flatness of th e cylinder head gasket surface (Fig. 30). Valve Seat RUDoUt. Check the valve seat runout with an accurate gauge (Fig. 31). Follow the instructions of the gauge manufacturer. Valve Seat Width. Measure the valve seat width (Fig. 32). Reaming Valve Guides. If it becomes necessary to ream a valve guide (Fig. 33) to install a valve with an oversize stem. a reaming kit is available which contains the following reamer and pilot combinations: a FIG. 3D-Cylinder Head Flatness FIG. 32-Valve Seat Width 1-17 0.003-inch O.S. reamer with a standard diameter pilot. a 0.0 IS-inch O.S. feamer with a 0.003-inch O .S. pilot, and a 0.030-inch reamer with a 0.015inch O.S. pilot. When going from a stand ard size valve to an oversize valve, always use the reamers in sequence. Always reface the valve seat after th e valv e guide h as b een reamed. Refacing Valve Seats. Refacing of the valve seats should be closely coo rdinated with refacing of the valve face so that the finished seat will match the valve face and be cen· tered o This is important so that the valve and seat will have a good compression tight fit. Be sure that the refacer grinding wheels a re properly dressed. Grind the valve seats to a tnTe 45° angle (Fig. 34). Remove only enough stock to clean up pits, grooves, or to correct the valve seat runout. After the seat has been refaced. measure the seat width (Fig. 32). Narrow the seat, if necessary to bring it within lim its. If the valve seat width exceeds the maximum limit, remove enough stock from the top edge and/ or bottom edge of the seat to reduce the width to specifications (Fig. 34). Use a 30° angle grind ing wheel to remove stock from the top of the seats (raise the seats) and use a 60° angle wheel to remove stock from the bottom of the seats (lower the seats). The finished valve seat should contact the approximate center of the valve face. It is good practice to determine where the valve seat contacts the face. To do this, coat the seat with Prussian blue, then set the valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of the valve face, the contact is satisfactory. If the blue is transferred to the top edge of the valve face, lower the va lve seat. If the blue is transferred to the bottom edge of the valve face. raise the valve seat. TO REMOVE STOCK fROM TOP O f SEAT, USC 300 W HEEL FIG. 33-Reaming Valve Guides TO REMOVE STOCk fROM 80TTOM O f SEAT, USE 60 0 W HEEL FIG. 34-Valve Seat Refacing GROUP 1- ENGINES AND EXHAUST SYSTEM 1-18 (HECK FOR BENT STEM DO NOT REMOVE MORE THAN 0.010 INCH VALVE FACE RUNOUT DIAMETER FOR DIMENSIONS REFER TO SPECIFICATIONS VALVE SEAT ANGLE FIG_ 35-Critical Valve Tolerances Tool- 6505·G FIG_ A 1403_B 37-Valve Stem Clearance VALVE (LEANING Remove all deposits from the valve with a fine wire brush or buffing wheel. VALVE AND PUSH ROD INSPECTION The critical inspec tion points and tolerances of the valves are illustrated in Fig. 35. Inspect the valve face and the edge of the valve head for pits, grooves, scores, or other defects. Inspect the stem for a bent condition and the end of the stem for grooves or scores. Check the valve head for signs of burning or erosion, warpage, and cracking. De- fects, such as minor pits, grooves, etc., may be removed. Discard va lves that are severely damaged. Inspect the valve springs, valve spring retainers, locks, and sleeves for defects. Discard any defective parts. Valve Face Runout. Check the valve face runout (Fig. 36). It sho uld not exceed the wear limit. Valve Stem Clearance. Check the va lve stem to valve guide clearance of each valve in its respective valve guide with the tool shown in Fig. 37 or its equivalent. ]f the clearance exceeds the wear limit , try a new valve. Valve Spring Pressure. Check the spring for proper pressure (Fig. 38). Weak valve springs cause poor engine performance; therefo re, if the pressure of any spring approaches the wear limit, replace the spring. Valve Spring Squareness. Check eac h spring for sq uareness usin g a steel squa re and a surface plate (Fig. 39). Stand the sprin g and square on end on the surface plate. Slide the spring up to the squ are. Revolve the spring slowly and observe the space between the top co il of the spring and the square. If th e spr ing is out of square more than inch, repl ace it. *0 Valve Push Rods. C heck the ends of the push rod s for nicks, grooves, roughness, or excessive wear. The push rods can be visually checked for straightness while they ' are installed in the engine by rotating them with the valve closed. They also ca n be checked wi,th a dial indicator (Fig. 40). If the runout exceeds the maximum limit at any point, dis- ~---Model TV -2 Runoul Gauge FIG. 3S-Valve Face Runout FIG. 38-Valve Spring Pressure FlG_ 39-Valve Spring Squareness card th e rod. Do not attempt to straighten push rods. Refacing Valves. The valve refacing operation should be closely coordinated with the valve seat refacing operation so that the finished angle of the va lve face w.ill match the valve sea t. This is important so that the valve and seat w ill have a good compress ion tight fit. Be sure that the refacer grinding whee ls are properly dressed. If the valve face runout is excessive and / or to remove pits and grooves, reface the valves to a true 44 0 angle. Remove only enough stock to correct the runout or to clean up the pits and grooves. If the edge of the valve head is less than %2 inch after grinding, replace the valve as the valve will run too hot in the engine. Remove all grooves or score marks from the end of the valve stem, then chamfer as necessa ry. Do not remove more than 0.010 inch from the stem. After refacing the valves, it is good practice to lightly lap in the valves with a medium grade lapping compound to match the seats. Be sure to remove all the compound from the valve and seat after the lappin g operation. Select Fitting Valves. If the valve stem to va lve guid e clearance exceeds the wear limit, ream the va lve guide for the next oversize valve stem. Va lves with oversize stem diameters FIG. 40-Push Rad Runout PART 1-1- ENGINES 1·19 5. Measure the assembled height of the valve spring from the surface of tbe cylinder head spring pad to the underside of the spring retainer with dividers (Fig. 42). 6. Check the dividers against a scale. If the assembled height is greater than specifications, install the necessary 0.030-incb thick spacer(s) between the cylinder head spring pad and the valve spring to bring the assembled height to the recommended dimension. Do not install spacers unless necessary. Use of spacers in ex.· cess of recommendations will result in overstressing the valve springs and overloading the camshaft lobes which could lead to spring breakage and worD camshaft lobes. VALVE INTAKE 11'-- VALVE A1388-8 FIG. 41-Valve Assembly of 0.003, 0.015, and 0.030 inch are available for service. Refer to "Reaming Valve Guides." CYLINDER HEAD ASSEMBLY 1. Lubricate the valve guides and valve stems with engine oil. Apply Lubriplate to the tip of the valve stems. 2. Install each valve (Fig. 41) in the valve guide from which it was removed or to which it was fitted. Install a new stem seal on the valve. 3. Install the valve spring assembly over the valve . Install the spring retainer and sleeve. VALVE STEM SEAL REPLACEMENT 1. Remove the air cleaner and the valve rocker arm cover. Remove the applicab le spark plug. 2. Crank the engine until the applicable cylinder is on TOC after the compression stroke. Be sure that both va lves are closed. 3. Loosen the valve rocker arm adjusting screw to remove the valve spring load. Remove the valve push rod. 4. Install an air line with an adapter in the spark plug hole. S. Push the rocker arm to one side and secure it in this position (Fig. Tool-KO · 9J5 SECURE ROCKER ARM 4. Compress the spring and install the retainer locks (Fig. 29). SPRING RETAINER SPRING PAD A 13 89-A AIR LINE A1461-B FIG. 42-Valve Spring Assembled FIG. 43-Compressing Valve Height Spring FIG. 44-Valve Stem Seal Removal 43). To move the rocker arm on either end of the shaft, it will be necessary to remove the retaining pin and spring washer and ~lide the rocker arm off the shaft. 6. Turn on the air supply. Using the valve spring compression tool shown in Fig. 43, compress the valve and remove the valve spring retainer locks, the sleeve, spring retainer, and the valve spring. 7. Remove the valve stem seal (Fig. 44). 8. Install a new valve stem seal. Place the spring in position over the valve. Install the spring retainer and sleeve. Compress the valve spring and install the valve spring retainer locks. 9. Apply Lubriplate to both ends of the push rod, the valve and push rod end of the rocker arm, and the valve stem tip. InstaH the push rod making sure the lower end of the rod is positioned in the tappet push rod cup. 10. Remove the wire securing the valve rocker arm and slide the rocker arm into position. If an end valve rocker arm was removed , slide it into position on the shaft and install the spring washer and retaining pin. Turn off the air and remove the air line and ad apter. Install the spark plug and spark. plug wire. H. Perform a preliminary valve lash on the applicable valve. Operate the engine until normal operating temperature has been reached and perform a fin al valve lash adjustment. 12. Tnstall the valve rocker arm cover followin g step 5 under " Valve Roc ker Arm Installation." Install the air cleane r. GROUP 1- ENGINES AND EXHAUST SYSTEM 1-20 CYLINDER FRONT COVER AND TIMING CHAIN REMOVAL 1. Drain the cooling system and the crankcase. Disconnect the radiator upper hose at the coolant outlet elbow and the radiator lower hose at the water pump. 2. Remove the radiator. Remove the drive belt, fan and pulley, and the crankshaft pulley. If equipped with a crankshaft vibration damper, remove the damper using tool T58P6316-A. 3. Remove the cylinder front cover and gasket (the crankcase ventilation tube bracket is retained by onc cylinder front cover bolt). Remove the crankshaft front oil slinger. 4. Establish a reference point on the block and measure from this point to the chain. Rotate the crankshaft in the opposite direction to take up the slack on the right side of the chain. Force the left side of the chain out with the fingers and measure the distance between the reference point and the chain. The deflection is the difference between the two measurements. If the deflection exceeds 112 inch, replace the timing chain and sprockets. 5. Crank the engine until the timing marks are aligned as shown in Fig. 45. Remove the camshaft sprocket retaining bolt and washer. Slide both sprockets and timing chain forward and remove them as an assembly (Fig. 46). 6. Remove the oil pan and related parts. INSTALLATION 1. Position the sprockets and timing chain on the camshaft and crankshaft. Be sure the timing marks on the sprockets and chain are positioned as show n in Fig. 45. Install the camshaft sprocket retaining bolt and washer. Torque the bolt to specifications. Install the oil slinger so th at the timing pointer on the slinger is TIMING MARKS A 1370- B FIG. 45-Aligning Timing Marks FIG. 46-Timing Chain and Sprockets Removal aligned with the camshaft sprocket timin g mark. 2. Clean the cylinder front cover and the gasket surface of the cylinder block. Apply sealer to a new cylinder front cover gasket and position the gasket on the cylinder front cover. Install th e cylinder front cover using the tool shown in Fig. 47 (the crarikcase ventilation tube bracket is retained by one cylinder front cover bolt). Torque the retaining bolts to specifications. 3. Install the crankshaft pulley. If equipped with a crankshaft vibration damper, install the damper using tool T52L-6306-AEE. Torque the retaining bolt to specifications. 4. Install the oil pan and related parts. 5. Install the fan, pulley, and drive belt. Adjust the drive belt. 6. Install the radiator. Co nnect the radiator upper and lower hoses. 7. Fill and bleed the cooling system. Fill the crankcase with the proper quantity and grade of engine oil. 8. Start the engine and check the ignition timing. Adjust th e ignition timing if necessary. Operate the engine at fast idle and check aU hose connections and gaskets for leaks. CLEANING AND INSPECTION Clean all parts in solvent and dry FIG_ 47-Cylinder Front Coyer Alignment-Typical FIG_ 4B-Crankshaft Front Oil Seal Replacement-Typical them with compressed air. Inspect the chain for broken links and the sprockets for cracks, and worn or damaged teeth. Replace all components of the timing chain and sprocket assembly if anyone item needs replacement. FRONT OIL SEAL REPLACEMENT 1. Drive out the old seal with a pin punch. Clean out the recess in the cover. 2. Coat a new seal with grease and install the seal (Fig. 48). Drive the seal in until it is fully seated in the recess. Check the seal after installation to be sure the spring is properly positioned in the seal. CAMSHAFT The camshaft and related parts are shown in Fig. 49. REMOVAL 1. Drain the cooling system and the crankcase. Remove the air cleaner and gasket. Disconnect the battery cable at the cylinder head. 2. Disconnect the radiator hoses at the coolant outlet elbow and the water pump. Remove the radiator. Remove the grille. 3. Disconnect the accelerator rod retracting spring. Disconnect the choke control cable and the accelerator rod at the carburetor. 4. Disconnect the fuel inlet line and the distributor vacuum line at the carburetor. Disconnect the vacuum line at the carburetor spacer or intake manifold. S. Disconnect the carburetor spacer outlet line at the carburetor spacer. Disconnect the heater hose at the water pump and at the cylinder head. PART 1-1- ENGINES w F BEARINGS ~ ~ T~I:~~T','WI.ASHER ~~~~i , ~ CAMSHAFT REAR SEARING BORE PLUG -.....--- ~ CAMSHAFT ~ TIMING CHAIN ANO"--'- CAMSHAFT SPROCKET A 1395-& FIG. 49-Camshaft and Related Paris 6. Disconnect the muffler inlet pipe at the exhaust manifo ld. Loosen the inlet pipe clamp and slide it o ff the support bracket on the engine. Pull the muffler inlet pipe down. Remove the gasket. 7. Disconnect the distrib utor vacuum line at the distributor. Disconnect the carburetor fuel inlet line and the vacuum line at the fuel pump. Remove the three lines as an assembly. D isconnect the windshield wiper vacuum line at the fuel pump. On an engine with positive crankcase ventilation, di sco nnect the exhaust tube at the regulator valve and crankcase outlet. Remove the regulator va lve and crankcase outlet adapter. Disconnect the vacuum line at the regulator valve fittin g and fuel pump. 8. Disco nnect the spark plug wires at the spark plugs and the coil high tension lead at the coi l. Remove the distributor cap and spa rk plug wires as an assembly. Disconnect the primary wire at the coil and remove it from the retaining clip on the cylinder head. 9. Disconnect the engine temperature sending unit wire at the sending unit. Disconnect the flexible fuel line at the fuel tank line and plug the line. Remove the distribu tor, the fuel pump, and the oil filter. 10. Remove the valve rocker arm cover. Follow steps 9 and 10 under "Cylinder Head Removal" and remove the cylinder head. 11. Using a ~ag~ et, remove the tappets and keep them in order so that they can be installed in their original location (Fig. 50). 12. Remove the drive belt, fan and pulley. and the crankshaft pulley. If eq uipped with a crankshaft vibration damper, remove the damper using tool T 58P-63 16-A. 13. Remove the oil level dipstick. Remove the oil pan. Remove the oil pump and inlet tube assembly. 14. Remove the cylinder front cover and gasket (the crankcase ventilation tube bracket is retai ned by o ne cylinder front cover bolt). Remove the : rankshaft front o il slinger. 15. Push the camshaft toward the rear of the engine. ]nstall a dial indicator so th at the indicator point is on the camshaft sprocket cap screw (Fig. 5 1). Zero the dial indicator. Position a large screw driver between the camshaft sproc ket and the block. Pull the ca mshaft fo rward and rele ase it. Co mpare the dial indicator re adi ng with specifications. If the end play is excessive, replace the thrust p late. 16. Remove the dial indicator. Remove the timing chain and sprockets fo llowing steps 4 and 5 under "Cylinder Front Cover and T im ing C bain Removal." 17. Remove the camshaft thrust plate. Carefully remove the camshaft by pulling it toward the front of the FIG. 50-Valve Tappet Removal FIG. 51-Camshaft End Play 1-21 engine. Use caution to avoid damaging the journals and lobes. INSTALLATION 1. C lean the oil passage th at feeds the rocker arm shaft by blowing compressed air into the opening in the block. Oil the camshaft and appl y Lubriplate to all the camshaft lobes. Carefully slide the camshaft through the bearings. 2. Install the thrust plate and to rque the retaining screws to specific ations. Replace the crankshaft front oil seal. 3. Foll ow steps 1, 2, and 3 under "Cylinder Front Cover and Timing C hain Installation" and instaH tbe sproc kets and timing chain, o il slinger, the cylinder front cover, and tbe crankshaft pu lley or damper. 4. Clean the oil pump inlet tube screen, and the oil pan and block gasket surfaces. Install the oil pump inlet tube, oil pump, and the oil pan and related parts. ]nstall the oil level dipstick. 5. Install the fan and fan pulley. and drive belt. Adjust the belt tension. Install the rad iator and the gri lle. 6. Dip the tappet foot in Lubriplate. Coat the remainder of each valve tappet with engine o il Install the tappets in their original bores. 7. Install the cylinder head. push rods, and the valve rocke r arm shaft assembly (including a preliminary valve lash adj ustment ) by following steps I through 9 under "Cylinder H ead Installation." 8. Using a new gasket, install tbe fue l pump and connect the flexible fuel li ne. Install the oil filter. 9. Position the distributor in the block with the rotor at the No. 1 firing position and the breaker points open. ]nstall the distributo r hold down clamp. 10. Connect the engine temperature sending unit wire. Connect the coil primary wire. Install the distributo r cap. Connect the spark plug wires and the coil high tension lead. 11 . Install the distributor vacuum line, tbe carburetor fue l inlet line, and the vacuu m line. Co nnect the windshield vacuum line. On an engine with positive crankcase ven til atio n, position and con nect the vac uum line at the regulator valve fitting and fue l pump. Clean the regulator valve parts, exhaust tube, rubber hose connections, and outlet adapter. Install the regul ator valve. Insta ll the cra nkc a'Se ou tlet adapter. 1-22 GROUP 1- ENGINES AND EXHAUST SYSTEM Be sure the outlet adapter is not loose or installed more than Jh·inch in the- cylinder block. Position and con nec t th e exhaust tube at the regul ator valve and crankcase out let adapter. 12. Using a new gasket, install the muffler in let pipe, lock was hers, and retaining nuts. Position the inlet pipe clamp on the support bracket o n the eng in e and tighten the clamp. 13. Co nn ect the radiator upper and lower hoses. Co nnect the hea ter hoses at the water pump and the coolant outlet elbow. Co nnect the carburetor spacer hose at the carburetor spacer. 14. Connec t the accelerator rod retracting spring. Connect the choke control cable and th e accelerator rod at the carburetor. Adjust th e choke contro l cable. Connec t the battery cable at the cylinder head. 15. Fill and bleed the coo ling system. Fill the crankcase. 16. Start the eng in e and check and ad just the ignition timing. Op~ erate th e engine for a minimum of 30 minutes at 1200 rpm to stabili ze engine temperatures. Check for coolant and oil leaks. Adju st the engine idle speed a nd the idl e fue l mixture. C heck the valve lash with the engine idling and adjust th e lash, if necessa ry, using a step-type gauge. On a car with Fordomatic, adjust the transmission co ntrol linkage. 17. Install the valve rocker arm cover following step 5 under " Valve Rocker Arm Install atio n." Install the air cleaner and gasket. CLEANING AND INSPECTION C lea n the camshaft in solvent and wipe it dry. Inspec t the camshaft lobes for scori ng, and signs of abnormal wear. Lobe wear may r esu lt in pitting in the general area of the nose portion of the lobe. This pitting is not detrimental to the operation of the camshaft, therefore, the camshaft shou ld not be replaced until the lobe lift loss has exceeded 0.005 inch. The lift 'of camshaft lobes can be accurately checked only with the camshaft installed in the engine. Refer to "Camshaft Lobe Lift. .. C heck the distributor drive gear for broken or chipped teeth. Remove light scuffs, scores, or nicks from the camshaft machined surfaces with a smooth oilstone. CAMSHAFT REAR BEARING BORE PLUG REPLACEMENT (Fig. 52). After insta llatio n, cut the ends of the seals flush . 1. On a car with a m anual-shift transmiss ion, slid e the transm ission to the rear and remove the clutch pressure plate and disc following the procedure in Part 5-1. On a car with Fordomatic, remove the transmiss ion and converter hou sing fo ll owi ng the procedure in Part 6-4. 2. Remove the flywheel reta ining bolts and remove the flywheel. 3. Drill a Ih-i nch hole in the camshaft rear bearing bore plug and use tool T 58L- I OI-A to remove the plug (Fig. 78). 4. Apply a thin coating of o il resistant sealer to the rear m ain bearing cap at the rear of the top m ating surface (F ig. 52). Do not apply sealer to the area forward of the oil slinger groove. Insta ll the rear m ai n bearing cap. Torque th e cap bolts to specifications. 4. Clean out the plug bore recess thoroughly. 5. Coat the fl ange of a new plug with wa ter resistant sealer and install it with the fla nge faci ng o ut (Fig. 79). 6. Install the flywheel. On a ca r with a manual-shift transmission , install the clutch pressure plate and disc and insta ll the transmission following the procedure in Part 5- 1. On a car with Fordomatic, install the transmiss ion and converter housing foll owi ng the procedure in Part 6-4. VALVE TAPPET REPLACEMENT 1. Remove the cylinder head · and related pa rts following the procedure under "Cylinder Head Rem oval." 2. Using a magnet, remove and install one tappet at a time (Fig. 50). Apply Lubriplate to each tappet foot and coa t the remainder of the tappet with engine oil before install ation. 3. After th e tappets are installed , install the cylinder head and related parts fo ll owing th e procedure under "Cylinder H ead Install ation." 5. Install the o il pan and related parts. MAIN AND CONNECTING ROD BEARING REPLACEMENT The main and conn ecting rod bearing inserts are se lec ti ve fit. Do not file or lap bearing caps or use bearing shims to obtain the proper bearing clearance. Selective fil bearings are avail able for service in standard s izes only. Standard bearings are divided into two sizes a nd are identified by a daub of r ed or blue paint. Refer to the Parts Ca talog for the available sizes. Red marked bearings increase the clearance; blue marked bearings decrease the clearance. Undersized bearings, which are not selective fit, are ava ilab le for use on journals that have been refinished. MAIN BEARING 1. Drain the crankcase. Remove the oil level dipstick. Remove the oil pan and related parts. 2. Remove the o il pump inlet tube assemb ly and the o il pump. 3. Replace one leaving the other fastened. Rem ove cap to which new installed. bearing at a time, bearings securely the main bearing bearings are to be CRANKSHAFT LOWER REAR OIL SEAL REPLACEMENT The upper oi l sea l in the block cannot be repl aced with th e crankshaft installed. To replace the lower rear o il seal: 1. Remove the o il pan and related parts. 2. Remove the rear m ain bearing cap. Remove and discard the rear seal. 3. C lea n the rear journal oil seal groove. Install a new rear journal oil sea l in the rear m ain bearing cap FIG. 52-Seal To Rear Bearing Cap Installation PART 1-1- ENGINES 4. Insert the upper bearing removal tool (tool 6331) in the oil hole in the crankshaft. 5. Rotate the crankshaft in the direction of engine rotation to force the bearing out of the block. 6. Clean the crankshaft journal. When replacing standard bearings with new bearings, it is good practice to first try to obtain the proper clearance with two blue bearing halves. 7. To install the upper main bearing, place the plain end of the bearing over the shaft on the locking tang side of the block. Using tool 6331 in the oi l hole in the crankshaft, rotate the crankshaft in the opposite direction of engine rotation until the bearing seats itself. Remove the tool. 8. Replace the cap bearing. 9. Support the crankshaft so that its weigbt will not compress the Plasligage and provide an erroneous reading. Position a jack so that it will bear against the counterweight adjoining the bearing which is being checked. 10. Place a piece of Plastigage on the bearing surface the fu ll width of the bearing cap and about JA inch off center (Fig. 53). 11. Install the cap and torque the bolts to specifications. Do not tum th e crankshaft while the Plastigage is in place. 12. Remove the cap. Using the Plastigage scale, check the width of the Plastigage. When checking the width of the Plastigage, check at the widest point in order to get the minimum clearance. Check at the narrowest point in order to get the maximum clearance. The difference between the two readings is the taper. PLACE Plosl "go ge FULL W IDTH OF JOURNAL A80UT 1/4 INCH OFF CENTER CHECK WIDTH OF Plosli goge 13. If the clearance is less than the specified limits, try two red bearing halves or a combination of red and blue depending upon the condition. If tbe standard bearings do not bring the clearance with in the desired limits, refinish the crankshaft journal, then install undersize bearings. 14. After the bearing has been fitted, apply a light coat of engine oil to the journal and bearings, then install the bearing cap. Torque the cap bolts to specifications. 15. Repeat the procedure for the remaining bearings that require replacement. 16. If the rear main bearing is replaced, replace the lower oil seal in the rear ma in bearing cap as outlined under "Crankshaft Lower Rear Oil Sea l Repl acement." The upper oi l seal in the block cannot be replaced with the crankshaft installed. 17. If the thrust bearing cap (No. 3 main bearing) has been removed, install it as follows: Install the thrust bearing cap with the bolts finger-tight. Pry the crankshaft forward again st the thrust surface of the upper half of the bearing (Fig. 75). Hold the crankshaft forward and pry the thru st bearing cap to the rear (Fig. 75). This will align the thrust surfaces of both halves of the bearing. Retain the forward pressure on th e crankshaft. Torque the ca p bolts to specifications (Fig. 75). 18. Clean the oil pump in let tube screen. Install the oil pump and the inlet tube assembly. 19. Position the oil pan gaskets on the oil pan . Position the oil pan front seal on the cylinder front cover. Position the oi l pan re ar seal on the rear main bearing ca p. Install the oi l pan and related parts. Install the oil level dipstick. 20. Fi ll the crankcase. Start the engine and check for oil pressure. Operate the eng ine at fast idle and check for oil le aks. 21. Check and adjust the ignition timing. CONNECTING ROD BEARING P/osligoge P/ostigoge A 1 022-A FIG. 53-Installing and Measuring Plastigage-Engine Installed 1. Follow steps I and 2 under "Ma in Bearing Rep lacement. " 2. Turn the crankshaft until the connecting rod to which new bearings are to be fitted is down. Remove the connectin g rod cap. Remove the bearing inserts from the rod and cap. 3. Be sure the bearing inserts and the bearing bore in the connecting rod 1-23 and cap are clean. Foreign material under the inserts may distort the bearing and cause a failure. 4. Clea n the crankshaft journal. When replacing standard bearings with new bearings, it is good practice to first try to obtain the proper clear· ance with two blue bearing halves. 5. Install the bearing inserts in the co nnecting rod and cap with the tangs fitting in the slo t provided. 6. Pull the connecting rod assembly down firmly on the cra nkshaft journal. 7. Place a piece of Plastigage on the lower bearing surface, the full width of the cap and about Y