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

1955 Ford Car Shop Manual EAN: 978-1-60371-004-6 ISBN: 1-60371-004-3

Forel Publishing Company, LLC 3999 Peregrine Ridge Ct. Woodbridge, VA 22192 Email address: webmaster@ForelPublishing.com 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.

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

FOREWORD
This Cars
manual

contains
all

complete

service

all

body

components,

information for
and

1955

Ford Passenger
Step-

and

alignment

including adjustment of doors, hoods, and fenders.

the

new

Ford Thunderbird.
for
trouble

by-step
cleaning

procedures
and

shooting,
and
re

In addition, given in this Part

mation

window glass adjustments are

part.

inspecting,

repairing,

FOUR CHASSIS contains

on

infor

placing the
systems on

various

parts, assemblies,

and

the

entire

power

train

these

vehicles are presented

here.
conventional

(clutch,
gear

This

transmissions, Overdrive, drive

and

manual also contains maintenance and as well

lubrication data

as a

tabulation

lines,

rear

axles, etc.)

the running

of

service specifications.
of

Detailed illustrations
the

(frames,
Service

springs, suspension,

many

of

the

tires, steering gear, steering

procedures
mission are published

brakes, wheels, linkages, etc.).

service operations are given

for the Fordomatic trans

here. Disassembled
units show

views

of

principal order of

in

a separate manual.

the

various parts
or

in the

their

disassembly
a glance at you need
all

assembly.

In

many
tell

Part FIVE
tenance

MAINTENANCE AND

cases,
you

these

illustrations
about

will

SPECIFICATIONS gives complete main

and

to know

how the

lubrication

information,

and

parts go together.

contains all

the

specifications of

necessary for

the

proper

The Table
Under
the

material presented

in this

manual

is

servicing

Ford Cars.
of each

arranged
of

in five

main parts as on

listed in the
pages.

Throughout this manual, the top

Contents
part,

the

following

left-hand,
name of

even-numbered
and

page

gives

the

each

chapter

headings covering
title

the chapter,

the

top
on

of each

major subjects

in

each part are given.

right-hand,
name of

odd-numbered
section

page

gives

the

The section headings

indicate the
Part

under each chapter

the

involved
open

the

page.

subjects covered

in the

chapter.

Thus,
you

wherever

you
of

the

manual,

glance at

the

ONE POWER

PLANT has engines and

top

the two

pages will

tell

to
the

exactly

what subject matter

is discussed

do

with

the 6

and

8-cylinder
are

at

that

point.

various systems
operation.

that

necessary to their

These include the fuel, ignition,

systems.

This
you

manual

has been

prepared

to

help

and

cooling

in

Cars. Part

TWO

ELECTRICAL
the

AND

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

readily

for

reference at all

times.

ACCESSORIES covers all of

systems and units

electrical

(except the ignition

accessories

sys

tem)

and all of

the

(except

the

Overdrive

and

Fordomatic).

FORD
contains

DIVISION
COMPANY
DEPARTMENT

Part THREE
formation
on

BODIES

in

FORD MOTOR SERVICE

the

maintenance and repair of

TABLE OF CONTENTS
Page

Foreword

Part

ONE POWER PLANT

I GENERAL

CHAPTER

ENGINE REPAIR
Page

Page

Section 1 2 3 4 5
6

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

5 8 10 13
. .

Section 7 8
9
10

Flywheel, Crankshaft, Main Bearings,

and

Connecting Rod Bearings

and Oil Pump Pressure Relief Valve

19

Oil

Pan, Oil Filter,

and

23
24 27

14 18

Cylinder Block, Pistons, Piston Rings, and Connecting Rods Exhaust System

CHAPTER Section 1
2

II 6-CYLINDER

223 CUBIC INCH 28 29

(EBP)

ENGINES

Engine Front

Steady Rest
and

Section 5
6 7 8 9

Manifolds Cylinder Heads

Valves

3 4

30 32

Oil Pan and Oil Pump and Pressure Relief Valve

.

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

...

33 34 36 37 39

CHAPTER

III 8-CYLINDER

(ECJ
Section 1 2 3
4

and

INTERCEPTOR) CUBIC
42 44

272 (ECG and ECH) AND 292 INCH ENGINES

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

Section 5
6

Timing Chain, Sprockets, Camshaft,

Tappets
and

Bearings
aftcl

48

46
and

Flywheel, Crankshaft
Exhaust System

Bearings^.
and

51

7
47

Connecting Rods, PistogjF, Pins,

Rings
t

53
55

CHAPTER
Section 1 2 3 4
,

IV

IGNITION, FUEL, AND COOLING SYSTEMS

57
....

5 6

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

Section 7
8

61

Carburetor Operation, Adjustment and Overhaul Four-Barrel

Fuel Pumps Fuel Tanks
and

81 92 94 95

64

Vacuum Booster

and

Lines

70 75 78

10
11 12

Fans

and

Belts
.

Water Pumps

96 98

Radiator, Hoses,

and

Thermostats

Part

TWO ELECTRICAL
I GENERATING

AND ACCESSORIES
SYSTEM AND BATTERY Section 3 4

CHAPTER
Section 1 2

Trouble Shooting
Generator

101

Generator Regulator

105

Battery

m H6

CHAPTER
Section 1

II STARTING

SYSTEM Starter Drive

Trouble Shooting Starter and Circuit

120 123

Section 3

128

CHAPTER
Section 1

III LIGHTING

SYSTEM, HORNS AND INSTRUMENTS

130

Trouble Shooting. Lighting System CHAPTER

133

Section 3 4

Horns Instruments

133 139

IV ACCESSORIES

Section 1

2 3

Trouble Radio Heater

Shooting

143 146 151

Section 4 5

Windshield Wiper Miscellaneous Accessories

154 155

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

Section 1
2

Construction Details

and

Sealer Application.

Undercoating

the

Body
CHAPTER
II

Body Alignment

157 163 166

Section 4 5

Quarter Panel Repair General Body Maintenance

167 169

TRIM, UPHOLSTERY,
171 1 74 176 178

AND WINDOW GLASS Door Glass Quarter Glass Windshield and Rear Window
179

Section 1
2 3 4

Door

and

Quarter Trim Panels

Headlining Replacement Window Regulators

Door Ventilator

Section 5 6 7

183
188

Assembly
CHAPTER

III REMOVABLE

SHEET METAL ASSEMBLIES

Section 1
2

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

193 196 199

201

Section 5
6

Grille

and

Hood
and

203

Hood Alignment

Lock Adjustment

205 207 208

7
8

Thunderbird Grille
Front Fenders

and

Hood

CHAPTER

IV POWER

INSTALLATIONS AND SPECIAL ITEMS

211

Section 1
2

Power Windows Power Seats

Convertible

Top

215 219

Section 4 5

Care of Country Squire Paneling Crown Victoria Transparent Top

224 225

Part FOUR-CHASSIS
CHAPTER
I

CLUTCH,

3-SPEED STANDARD TRANSMISSION, AND GEAR SHIFT LINKAGE

Section 1 2

Trouble Clutch

Shooting
CHAPTER

229 230

Section 3 4

3 -Speed Standard Transmission Gear Shift Linkage

233 238

II OVERDRIVE
.
.

TRANSMISSION

Section 1
2

Overdrive Overdrive

Operating Operating

Principles Principles

Mechanical. Electrical

240 242

Section 3 4

Trouble Shooting
Overhaul

243 245

CHAPTER Section 1 2

III REAR

AXLES AND DRIVE LINES

Section 3 4 Integral Housing Hypoid Rear Axle Drive Lines 260 265

Trouble Shooting Banjo Housing Hypoid Rear Axle

CHAPTER

252

252

IV RUNNING

GEAR
Shock Absorbers Steering Gear Steering Linkage Wheels and Tires Hubs and Bearings 278 279 284 286 289

Section 1 2 3 4 5

Trouble Shooting Wheel Alignment Frames Front Suspension

Rear Springs

267 269 271 273 277

Section 6 7 8 9
10

CHAPTER
Section 1 2
Construction Inspection
and

V POWER

STEERING
Overhaul
302

and

Operation Trouble Shooting

292

Section 3

299

CHAPTER Section 1 2 3 4

VI BRAKES

Trouble Shooting Adjustments Hydraulic System

Power Brakes

316 317 319 322

Section 5
6

Brake Assemblies
Brake Drums

325

326
.

Parking Brakes

326

Part
Section 1

FIVE MAINTENANCE
CHAPTER

AND SPECIFICATIONS
Section 2
Lubrication
331

I MAINTENANCE

Preventive Maintenance CHAPTER

329

II SPECIFICATIONS

Section 1 2

3 4 5 6 7

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

Steering

Engines Clutch and Transmission

334 334 335 335 336 336 338

Section 8 9
10 11 12

Cooling
Fuel System Generating System Starting System

13 14

Ignition Lights and Horns Tools and Equipment

338 339 339 339 340 340

340

Part ONE

POWER PLANT
Chapter

General Engine Repair

Section
Page

1. 2.

Trouble Shooting Engine Tune Up

Engine Removal
Intake
Rocker
and
and

5
8

3.
4.

Installation

10
13
and

Exhaust Manifolds
Valve

5.
6. 7. 8. 9.
10.

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

Timing

14 18
19

23
24 27

Trouble shooting, tune-up, inspection,

cedures,
applicable

and repair pro

shooting

section

is

presented

first.

to

all

engines,

are given

in this

chapter.

performance

can

be
or

attributed a

Many defects in engine directly to a maladjust

of

For the

removal and

installation

of engine

components,

ment of one

part,

combination

parts; therefore,
shoot

refer to the chapter

covering the specific

of

engine.

general engine

tune-up logically follows the trouble

actual repair work.

Inasmuch

as a

determination
any

the basic cause

of en

ing

section, and precedes the

gine trouble should precede

repair

work, the trouble

1.
Trouble shooting is the
cedure, in
a application of a

TROUBLE SHOOTING
definite
pro

start, the fault is

logical sequence, to locate

and eliminate

the

Perform the
cause of

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

cause of trouble

in

a particular system or unit.

It

should

the trouble is determined:

be borne in mind,
the

when

trouble shooting, to first look for

such as : an

(a)
it,

Check

Battery.

Try

the

horn

or

lights. If

obvious causes of

trouble
or

empty gas tank,

or

they do

not operate

properly, test the battery. Recharge

a wet or cold
other such

engine, loose

disconnected wiring,

any

replace

it,

or check

further,
at

as necessary.
or

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

(b)
ground.

Check

the

Battery Cables. Check for loose

the starter, relay,
them

corroded

connections

battery,

and

are outlined

Clean, tighten,
the

or replace

as necessary.

a.

Engine.
Poor
engine performance can on

(c)
be attributed to the
engine

Check

surfaces seldom

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

or

to forces

the

vehicle

that tend to retard

its in

motion.
which

An

example of a

retarding force is
to
work

dragging brakes
and results

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

However,
(Refer

necessary.

cause the engine

harder

poor en

(d)

Check

the

Starter

or

Starter Drive. If the

the trouble is prob
starter

gine performance.

above components

are not at

fault,

Engine

performance

depends

on proper

fuel distribu

ably in the ning, but

starter or starter

drive. If the

is

run

tion, correctly timed ignition, normal and uniform com pression, properly regulated flow of the fuel-air mixture
to the cylinders, and unobstructed flow
of exhaust gases.

not

engaging the

flywheel,

remove

the starter

and make
rare

the necessary repairs to the starter

starter

drive. In flywheel.

cases, the
can

drive may lock up

with

the

Engine trouble

symptoms are

discussed

under

the head
the

This

be

corrected

by loosening

the starter

and releas

ings below
above

with

instructions
and

on what
good

to do to

correct

ing

the

starter

drive. If the

starter

does

not

operate,

conditions

regain

engine

performance.
starter

remove

it

and make

the necessary

repairs.

(1)
not

ENGINE WILL NOT CRANK. If the

or

does

(2)
The

ENGINE

CRANKS,

BUT WILL NOT START.

this trouble is a

turn the engine over,

turns it

over

too slowly to

most probable cause of

defect in the

Chapter
ignition
tion
of

I General

Engine Repair
be

system.

The

next most

likely

cause

is

a malfunc

(4)
tested

If the

weak

spark

persists, the

coil

should

the fuel

system.

simple check will

determine
a spark

and replaced

if

necessary.

which system is at

fault. Remove

one wire

from

(c)
(1)

Good Spark. If
system as

a good spark was

observed, check

plug,

and

insert

a piece of proper sized metal rod so

it

the fuel

follows:
at

will protrude

from the insulator. With the ignition

the
engine over,

on and

Check the fuel supply

the fuel tank. Do

not

the starter
rod

turning

hold the

end of

the

attempt

approximately %G-inch from

check the
check

the block. If no

spark spark

is
is

(2)

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

doing
see

this.

if it is

obtained,

ignition

system.

If

good

reaching the

Remove the
while

air

cleaner, and look

obtained,

the fuel

system.

down the follow the

necessary

carburetor

throat

working the throttle

a
spurt

(a)
steps

No Spark. If

no spark was obtained,

cause and make

by

hand.'

Each time the throttle is worked,

of

below to determine the

gasoline

should

be

emitted

from the
at

accelerator

pump
engine

repairs or replacements.

discharge from the top

the
of

nozzle.

If there is fuel

this point, the

(1)

Pull the

coil wire

the

distributor,
over,
see

and with

the ignition
a spark at

on and

engine

turning
a good or

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

if there is

this

point.

If there is

spark, the

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

line
line

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

spark

plug

not

defective.

If fuel

runs out

freely,

the

line is

clean.

If not, blow the

end.

Repair

out

or replace as necessary.

by

air pressure

from the fuel pump

gas

(2)
and

If there

was no spark

in

(1)
If

clean

the

coil

tower
coil

NOTE:

Check

the

flexible

line for

collapsed

socket or replace

the high tension

wire

between the

condition.

distributor
points
are

and check again.

a weak spark

exists,

the

probably

arcing.

replace

if necessary

and adjust

Test the condenser, the points. If a weak spark

if
necessary.

(4)

If the fault has

not

been found,

check

the fuel
or

pump pressure, then

carburetor.

repair or replace

the fuel pump

persists, test the coil and

replace

(3) ENGINE STARTS BUT FAILS TO KEEP

distribu
an

(3)

If there
see

was no spark

in

(2),

remove the
and or and

RUNNING. The
is the fuel
cause

most probable cause of

this

malfunction

tor cap and

electrical
necessary.

if the
to

points are

"breaking"

there is
replace

system.

The ignition

system

sometimes

can

charge

the

points.

Adjust

as

If there is

spark at

the points,

properly, the secondary

there is
no spark at

circuit of

the

coil

they break is defective. If

between
then

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

the fuel system first.

the

the points; install a the

coil and

"jumper"

(a) Check

fuel supply
the

at

the

gas

tank.
operate with and
check

the distributor
check

post of

the

distributor,
a

for

spark at

the

points.

If there is
wire.

(b) Try
constant

to

start

vehicle.

If it

will

spark,

replace

the

coil

to distributor primary
"jumper"

If there is
coil

foot throttle,
adjustment.

adjust

the idle

speed

no

spark,

the choke

install
and

between the two primary

coil

terminals
at

recheck. points.

Replace the
a

if

spark now exists

(c)
to the

If it
the

will not operate with constant

foot throttle,

the

If not, install
post of

"jumper"

remove

air

between the
check

battery
wiring

cleaner,

and check

to

carburetor.

This is done

and the

battery
If
switch

the coil, then

the

spark at

by

if fuel is getting looking down the car

see

the

points.

a spark

exists, the ignition

coil

switch or and must

from the

to the

is defective

be

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

re

flooded

or

the fuel system has

water

in it.

paired or replaced.

(d)
spark

If

no accelerator

pump discharge is

observed

in

(b)
showed

Weak Spark. If the

a
weak

test at the

spark

plug

the carburetor

spark,

perform

the

following

checks

in

line

at

the fuel

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

the

order

listed:
may be
weak.

If fuel

runs out

freely,

the line is

clear.

If not, blow the

end.

1)

Battery

Test,

recharge, or

replace,

line

out with air pressure

from the fuel pump

gas

the battery.

(2)
tion
of

Remove the distributor cap,

the
points.

and check or

the

condi

NOTE:

Check

the

flexible

line for

collapsed

Adjust,
is

clean,

replace
an

them

condition.

as

necessary.

Severly

pitted points are

usually

indication
the
con

(e)
check

If the

cause of

the trouble has not been

found,
the

that the

voltage

regulator

improperly

set or

the fuel pump pressure, and repair

or replace

denser is faulty.

(3)
and

Check the
wires.

condition of
wires must

the rotor, distributor cap,

plug

The

be clean, dry,

and must

be

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

fully

seated

in the terminals. Always

or

replace

any

wire

breaking

down

under

operating temperature. Check

and

which

is damaged

has

corroded

terminals.

replace as necessary.

Section

1Trouble

Shooting
However,
certain

(4) ENGINE CONTINUALLY MISSES

When the
engine

AT IDLE.

compression.

some

preliminary

checks should

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

be

made.

Make

that the throttle

opens all

the way

and

that the choke

remains open.

(a)
at a

Isolate

the miss

by

pulling

one spark

plug

cable

time from the

and adjust

plugs.

inspect,
fouled.

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

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

(a)

ternal

components are

operating

properly.

(b) If the
Check the
spark

compression checks within

limits,
and

check

the

(b)
tion

for

signs of

deteriora

ignition system,
operation.

including

initial timing

distributor

and corrosion.

Replace

as necessary.

(c)
and

Remove the distributor cap and rotor, inspect them. Replace if necessary.
If
none of

then

clean

(c)
and

If the

compression

and

the ignition

system

are

satisfactory,
check

check

the fuel system,

including

carburetion

(d)
the

the above corrects the condition,

compression and

fuel pump

pressure.

compression

to determine if

intake

(d)

If the

problem still

exists, a

check of mechanical valve

manifold passages are satisfactory.

components must

be

made.

Check the

lash, lift,

and

(5)
the

ENGINE MISSES ERRATICALLY AT IDLE.

caused

timing. Repair

or replace as necessary.

This may be

by

a combination of

things. Check

following (a) Carburetor, including

sequence : and

in

b. Fuel System.
choke operation,

idle

mix

The fuel
carburetor,

system consists of

the fuel

tank, fuel pump,

and other

ture setting,

float level.

and

ignition system, starting with the spark plugs, if the carburetor adjustment does not eliminate the
trouble. Make necessary
repairs.

(b) The

connecting lines. Dirt

foreign

material are a major source of

fuel

system

problems, and

all components should

be kept

as clean as possible.

(c)
if the

The
miss

vacuum

lines for leaks

at all

lines

and

fittings
repairs.

(1)

EXCESSIVE is usually

FUEL

CONSUMPTION.

Faulty
con

is

still present.

Make any necessary

carburetion

responsible

for

excessive

fuel

(d)

Valve

operation and make a compression

test if

sumption. should

However,
made.
and

the

following

preliminary

checks
check

be

Check for fuel leaks in the system,

adjustment,

miss persists.

(6)
tion
of

ENGINE MISFIRES OR HESITATES ON AC

malfunction

choke operation
accelerator

and make certain see

the
are

linkage is free. Check to

adjust

if the brakes

CELERATION. This
be

faults in the ignition

and

is usually a combina fuel system, but also can

Perform the

dragging. Then

the

carburetor.

caused

by

the exhaust

system.

following

(a) Verify
in the
tion
of

the

complaint with

test

equipment

installed
opera

vehicle.

checks

in the

Show the

customer

how improper

sequence given:

(a) (b)
valve.

Check the

the

vehicle will affect

fuel

consumption.

operation of

the

accelerator pump.

Check the Check the

If the

operation

of

the exhaust thermostat

(b)
remove

If test
the

shows

fuel

consumption

to be excessive,
carburetion

If sticking, free up is

carburetor and rebuild.

or replace as necessary.

Since poor

(c)
be
the

paint on

the intake

manifold

heat

riser

is usually
usually
the

combination

of

internal malfunctions, it is
to
repair

passage.

paint

not

burned off, the

may
not

not advisable

to

passage

may

try

only

one system

in

obstructed and

the

carburetor

be vaporizing

carburetor.

Time

will

be

saved

by

a complete

car

buretor

overhaul.

gasoline properly. spark

(d ) Remove the
Replace any
plugs

plugs,

inspect,
or

clean and re-gap.

(2)
defects.
the

CARBURETOR FLOODS. Make

the
carburetor

visual

in

that

are

defective

lead fouled.
check

spection of

for

leaking

gaskets or

casting
stops,

(e) Remove
gap, distributor
and
points.

the distributor cap and

shaft

the

point

Tap

the

carburetor

bowl. If the

flooding

clearance,

condition of cam

lobes,

needle

was

held

open

by

foreign

material.

If the

Make necessary if

repairs

or

replacements.

flooding

persists, follow the

steps

below:

Check the high tension wiring for

and replace
necessary.

signs of

deterioration,

(a ) (b)
seat.

Remove the

air cleaner and check choke operation.

Check the float level

float. Check the
necessary.

and

the

condition

of

the

(f)
units.

Make

a coil and condenser check.

Replace

faulty

carburetor

condition of

the needle and

Replace if

(g)

Check fuel pump

pressure and adjust carburetor

(c)

Check fuel pump

was

pressure.

If the
past

pressure

is

ex

float level.

cessive, the pump

problem
check

forcing

fuel

the float needle

(h)
spring

If the
and

still

persists, take
action.

compression
valve

and should

be

rebuilt or replaced.

readings

the

valve

Check the

rates and assembled

height. Repair

or replace as

c.

Cooling
The cooling

System.
system

necessary.

is thermostatically controlled to
and provide

(7)

ENGINE

DOES
power

NOT

DEVELOP
caused

FULL

regulate engine

operating temperature
period.

for

POWER.

Lack

of

is usually

by

poor

short engine

warm-up

Chapter

I General

Engine Repair

(1) ENGINE OVERHEATS. Usually,

engine

over

(e)
heat

Check the thermostat for

If defective
or of

proper

operation

and

heating

is the

result of

insufficient

coolant supply.

Check
of

range.

the wrong heat range, replace

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

cause

the thermostat.

(a)
system,

If the supply is low,

(f ) Check the ignition timing

and adjust

if

necessary.

check

for leaks in the cooling

make repairs as necessary.

(g)

Check the

radiator

for

proper

flow. Flush if

necessary. proper

(b)
adjust

Check the
if loose.

water

pump belt for

tension

and

(h)

Remove the

water

pump

and check

for

defective

impeller

or water passage obstruction.

Repair

or replace

(c) Inspect
dirt,

the

radiator

fins for

obstructions

(bugs,
the

etc.) Clean if
a

as necessary.

clogged.
check

(d) Using
gauge

thermometer in the radiator, reading for accuracy.

(2)

ENGINE FAILS TO REACH NORMAL OPER

caused

ATING TEMPERATURE. Generally, this is

the thermostat sticking
or

by
not

being

of

the wrong heat range.

engine

NOTE: Inaccurate

readings are sometimes caused

by

Check the thermostat first. If the

reach

still

does

insufficient

clearance

the temperature sending

place as necessary.

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

operating temperature,
with a

check

the

gauge and

sending

unit,
place

thermometer in radiator, for

unit.

accuracy.

Re

the defective

2.
During
receive

ENGINE TUNE-UP
should

the life

of

an

automotive

vehicle, it

A reading

of more

than 10 pounds

above normal

indi

regular

maintenance

and

inspection

services.
an engine

cates carbon or

lead deposits in the

normal

cylinder.
at

However,
tune-up

to

maintain

satisfactory performance,

A reading below
valves,
or

indicates leakage

the rings,

should

be

performed periodically.

head

gasket.

Any
make

type

of

engine

test

equipment

may be

used

to

(3) CLEAN, ADJUST,

PLUGS. Sandblast the
clean, file the
gap.
electrode

AND
plugs,

INSTALL
wipe

SPARK
porcelain

the tests
are

outlined

in the checking
make
a

procedures.

As
of

spark

the

the

checks

performed,

visual

inspection

tips
an

flat,

and

adjust
spark

the

spark

the wiring,

vacuum

hose,

cooling

system

hose, heater

Test the

plugs

in

approved

plug tester.
porcelain,

hoses,
a.

etc.

Replace any

plugs

that have broken

or

or chipped

badly burned

electrodes,

that do
spark

not check satisfac plugs and

Minor Tune-Up.
A
minor

torily
the

on

the tester. Install the

tighten

tune-up

consists of

following

operations:

to

specifications.

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

(4)

CHECK AND ADJUST TIMING AND INSPECT

vacuum

BREAKER POINTS. Disconnect the

tween the
and

line be
engine

ignition

cables

for

worn or

damaged

distributor
it
at

and

carburetor.

Start the

operate

insulation. Make
seated

idle

speed.

sure

that the

spark

plug

wires are

firmly
and

Check the timing

line
after

with

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

timing light
nect
adjustments.

and make

the necessary

adjustments.

Con

the distributor

vacuum

completing the

Inspect the distributor

and

points

for pits,
points

exces which

battery

case

for

cracks

and

leaks. Check
cable con

sive

metal

transfer,
up

burns. Replace

level in the battery. Inspect

and clean

battery

cannot

be

cleaned

nections

for corrosion,

if

necessary.

Brush the

by light

application of a point

file.

cable connectors with grease

to

retard

further corrosion,

(5)

CHECK

ENGINE IDLE.

VACUUM
Check
the

AND
engine

ADJUST
manifold

CARBURETOR
vacuum at

then tighten the

connectors securely.

idle

speed.

(2)
the

TEST

CYLINDER

COMPRESSION.
Remove

Operate
reached.

If the
at

vacuum

engine until normal

operating temperature is

the

vacuum

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

Turn the ignition

the throttle to the test.

switch off.

all spark plugs.

Set for

carburetor

idle

adjustment.

wide open position

and

leave it

open

If the

vacuum
of

is

still

below

normal or

is erratic, it is

an

Using

a compression

of each cylinder.
pression strokes.

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

indication
or

leaky
Set the

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

All

be tested the

same

reported

to the

number of strokes

to

assure accurate readings.

all

carburetor

idle

speed

to

specifications.

Set the

The
within

compression

of

cylinders

should

be

uniform

idle fuel
at

adjustment to obtain

the

smoothest engine

idle

10

pounds.

Record the

compression

of each cyl

the highest manifold

speed

vacuum

and/or

engine

r.p.m.

inder.

Reset the idle

if

required.

Section

2 Engine

Tune-Up
(8) TIME
IGNITION. Before connecting the
and
vacuum

(6) CLEAN

AIR

CLEANER AND FUEL PUMP

cleaner,
and
re-oil
oil

BOWL. Clean the

air

the

element
refill

line between the distributor

engine and operate

carburetor,

start

the
with

(dry-type). If the
viscosity.

air cleaner

is the

bath-type,
of

it

at

idle

speed.

Check the timing

to the indicated level

with

engine

oil

the

specified

timing light

and

make

the

necessary

adjustments.

Connect the distributor

and clean

vacuum

line

after

completing

Remove

the fuel pump bowl. Install

a new

the adjustment,

and check

for ignition

advance.

filter. Install the

sediment

bowl

and a new gasket.

(9 ) CHECK IGNITION PRIMARY CIRCUIT. Check

the primary circuit
amperage with a suitable

b. Major Tune-Up.
A
major

test

machine.

The
checking the
cylinder com
engine

amperage

draw

with

the

engine

stopped

should

be

tune-up

consists of

5-5.5
the

amps.

With the

engine

operating

at

idle speed, the

inspect

pression, the ignition system, the fuel system, the

vacuum,
and

amperage
wires

draw
for

should

be 2.75-3.0

amps.

Visually

adjusting the

valves.

faulty

insulation

and poor connections.

(1) CLEAN
Remove the
terminals

AND INSPECT BATTERY CABLES.

from the battery. Clean the

(10)
spark

TEST SPARK INTENSITY. Determine if the

each spark

cables

and cable connectors.

Inspect the

battery battery case

level. Re

from

plug

wire will

jump
cap,

%6"

inch

gap.

If the
exists

spark

is unsatisfactory
in the

at all spark

plugs, trouble the

for

cracks and

leaks. Fill to the

proper water

in the coil, condenser,

or

rotor or

internally in
but
wire

place
or

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

distributor,
If the
the
spark

external

primary
at

circuit.

spark

is unsatisfactory
in the

some

not all

of

grease

Connect the

cables

to the

plug wires, the trouble is in the

itself,

the

battery.

wire

is

not seated

housing

socket,

or

the distributor

(2)
ble

TEST CHARGING SYSTEM. Test the battery,

cap is

shorted.

and recharge or replace

service.

it, if

necessary, to insure dependa

generator

Check the charging circuit, the

the
regulator.
or replace

(11)

CHECK AND ADJUST VALVE LASH. Check

the
valve

and adjust

lash

after

the

engine

output,

and

Repair
the

is thoroughly

or

replace

faulty

warmed up.

generator.

Adjust

regulator

if

necessary.

(3) TEST CYLINDER COMPRESSION.

procedure given under,

Follow the

(12)

TEST FUEL PUMP PRESSURE. Check the

pressure should

"a. Minor

Tune-Up."

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

be

within

4.0-5.0

(4)

CHECK MANIFOLD BOLT TORQUE. Tighten

and exhaust manifold

the intake

bolts

and nuts

to 23-28

(13) TEST FUEL PUMP VACUUM. Check

pump
vacuum.

the fuel
of

If the

vacuum

is below 10.5 inches

when

foot-pounds torque.

mercury,

or

if the

vacuum

drops rapidly
the pump.

the

engine

(5) CLEAN, ADJUST,

PLUGS. Sandblast the
clean, file the
gap.
electrode

AND
plugs,

INSTALL
wipe

SPARK
porcelain

is stopped,

repair or replace

spark

the

tips
an

flat,

(14) INSPECT AND CLEAN

Remove
and clean

THE FUEL PUMP.

and

adjust

the

spark

Test the

plugs

in

the fuel pump bowl.

Install

new

approved

spark

plug tester.

filter. Install the

sediment

bowl

and a new gasket.

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

(15) CLEAN CARBURETOR.

fuel bowl. Set the float
pump
operation.

Clean the

carburetor

torily

on

the tester. Install the

specified

spark

plugs,

and

tighten

level,

and check

the accelerator

them to the

torque.

(6)
make

TEST

DISTRIBUTOR.

Test

the

distributor
and

vacuum advance on a suitable

distributor test stand,

adjustments, repairs,
point

or
at

replacements as required.

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

Set the distributor der engine)

or

gap

0.014-0.016 inch (8-cylin

engine).

0.024-0.026 inch (6-cylinder

check

After

(17)
If the
at

TEST ENGINE VACUUM. Check the idle

speed.

engine

setting the gap,

should

the

point

dwell. The

point
and

dwell

manifold vacuum at
vacuum

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

engine).

26-28 Vi

is lower than specified,

and

check

for leakage
car

degrees (8-cylinder
correct at
worn

If the dwell

angle

is

not

the

vacuum

lines

intake

manifold.

Check the

the

specified point

gap, the distributor

cam

is

buretor idle
If the
an

adjustment.

or

the

point

assembly is damaged.

Replace the
cam

vacuum
of

necessary
with

parts.

Lubricate the distributor

cam

lightly

indication
or

distributor

lubricant.

springs,
should

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

is

below

(7)

CLEAN AND INSPECT THE DISTRIBUTOR

cracks
or
other

be

reported

to the

customer. a

CAP. Inspect the distributor cap for

damage. Terminal
corrosion.

(18) ADJUST CARBURETOR IDLE. Connect

vacuum

housing

sockets

should

be free from

gauge,

and

set

the idle speed to specifications

on

with

tachometer installed

the engine.

Set the idle

10

Chapter

I General

Engine Repair

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

check on ance of

the

work performed.

the transmission, axle,

Also, notice brakes, and

the

perform
optional

any

if

required.

accessories.

(19) ROAD TEST.

Road test the

vehicle as a

final

when

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

required

3.
Separate
procedures
are

ENGINE REMOVAL AND INSTALLATION

given

for the

conventional

at

the

cylinder

block,

and

the flex fuel line

at

the fuel

passenger car and the

Thunderbird.

pump.

Remove the fan.

windshield wiper

a.

Conventional Passenger Car.

The

Disconnect the
perature
conventional
unit wire.

vacuum

hose,

tem

sending

unit

wire, and the oil pressure sending

at

following

procedures

apply to

all

Disconnect the primary wire

the
starter

the

coil.

Remove
starter. engine.

passenger cars.
vehicles

Differences in the
with exist. an

procedures peculiar to

the

starter cable at

then remove the

rear of

equipped

or

6-cylinder

engine

are

Disconnect the Remove the

Disconnect the
the
accelerator

ground cable

from the

the

noted when

they

air

cleaner, then tape the

air

horn

closed.

The

procedures given are

attached.

for the

engine

only, without
toler
engine

choke cable at

the carburetor.

Disconnect

the transmission
ances make
with

Engine

compartment

linkage.
muffler

it impractical to

remove or

install the

Disconnect the
manifold.

inlet

pipes

at

the

exhaust

the transmission

attached.

(1) REMOVAL.
(c). If the
steps
vehicle

If the

vehicle

is

equipped

with

Attach the

engine

lift bracket
left front

or

sling (fig. 1

or

2).

standard or overdrive

transmission, follow
equipped with

steps

(a)

and

Remove the

right and

splash aprons.

is

Fordomatic, follow
or

Loosen the two

Raise the

engine

front steady
safety

rest

to frame bolts.

(b)

and

(c).
Overdrive
spring.

vehicle and position

stands.

(a)

Steps Peculiar To Standard

the
clutch

Transmission. Disconnect
Remove the
screws

release

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

retaining the

equalizer

bar

support and

the

engine.

to the flywheel

housing,

then remove the

support

bushing. Disconnect the

accelerator

linkage

at

the

mani

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

fold bellcrank. Remove the two bolts. Remove the flywheel

transmission
with
a

upper

flywheel

housing
the

the

engine.

housing

cover,

support

Raise the

engine

slightly, then carefully pull the engine

jack,

then remove the remaining

from the transmission.

the
engine

Carefully
Do
not

lift the
let the

engine

out

of

flywheel

housing

bolts.

compartment. grille.

engine

swing

(b)

Steps Peculiar To Fordomatic. Disconnect the

cross

against

the

transmission throttle linkage at the

shaft,

and

tie

Install the
priate

engine on

work stand
or

using the

appro

the linkage to the dash

panel.

Remove the idler

remove

arm

engine mount

(fig. 3

4). Remove the

engine

bracket. Fold back the floor mat,

plugs, then
engine
remove

the two

rubber

the two

top

converter

housing

to

lifting bracket or sling. (2) INSTALLATION.

with a

If

the

vehicle

is

equipped
steps

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

standard or overdrive
and

transmission, follow
is
equipped with
and

(a), (b),

(d). If the

vehicle

Fordo

remaining
converter
six

converter

housing

to

engine

bolts.

matic, follow steps

(a), (c),
or

(d).
appropriate
engine

Remove the
remove

housing lower
to
assembly.
control

access

cover, then

(a)
engine

Engine Installation. Install the

the the

converter
stick

flywheel assembly bolts.

lift bracket
stand.

sling, then remove the

engine

from

Remove

dip

tube

the
splash shield

work

Lower the

carefully into the

Remove the transmission

linkage
the

engine compartment.

from the

cylinder

block,
the

then

remove

oil

filter.

On 8-cylinder engines, lower the

pump to
oil pan

engine until

the

oil

(c)
cooling

Engine Removal. Remove the hood. Drain the

system

line

clears

the

left-hand
drive
gear

engine support.

and

crankcase.

Remove the heater

Start the transmission

main

into the

clutch

hoses.

disc. On Fordomatic units,

vehicles

start

the converter

pilot

into

On

equipped

with

an

8-cylinder

engine,

the crankshaft.

remove

the heater inlet duct.

vehicles equipped with

NOTE:
a

On

standard
adjust

or

overdrive

units, it may

be

On
remove

6-cylinder

engine,

necessary to
with

the

position

of the transmission

the heater blower

upper

motor.

relation
will

to the engine
enter

if

the transmission

input

Remove the
remove

and

lower

radiator

hoses,

then

shaft

not

the

clutch

disc.

If

the

engine
crank-

the

radiator.

Disconnect the

battery

ground cable

"hangs

up"

after

the shaft enters, turn the

Section

3 Engine

Removal

and

Installation

11

Too/-T52L-6000-C

\ToolT54T6005-D (SPLINED SHAFT) I r00/ 7547 6Q05-E (KEYED SHAFT)

6288

Fig.

3 Engine Mounf 8-Cylinder

Engine

mounting
two
6286

nuts

and

bolts to

specifications.

Tighten the
speci

engine

front steady

rest

to

frame bolts to

fications.

On the 8-cylinder engine,

Fig.lLift
Bracket 6-Cylinder

align

the holes in the

engine

Engine
until

left

support

insulator

with

the mounting holes in the the

right side of

shaft

slowly (with the transmission in gear)

splines
mesh

block. Install the two cap

engine.

screws on

the

the

shaft

with

the

clutch

disc

Tighten

the two engine front steady rest to

frame

splines.

bolts to
and

specifications.

Install the

right

and

left front

Make

sure

the studs

on

the manifolds
with

of

both the 6

splash aprons.

8-cylinder
muffler

engines

are

aligned

the

holes in the

Connect the

manifold
connect

to the
the

muffler

inlet

pipe.

Install

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

the starter, then

matic).

starter cable

(except Fordo
rear
of

Connect the

ground

cable

to the

the

engage

the holes

on

the

converter

engine, the temperature sending unit and oil pressure

housing).

sending

unit

wires, the generator wires,

coil.

and

the ignition
switch wire

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

switch wire

to the

Connect the ignition

accelerator

to the
the

engine clips.

Connect the

linkage

and

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

Connect
vacuum

the windshield

Tool-T53L-300-A

the fan assembly, then

adjust

the fan belt.

Install the

radiator

and

connect

the

radiator
engine.

hoses.

Connect the

battery

ground cable

to the

Remove

Tool-T53L-6000-B

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

6287

6289

Fig.

Lifting

Sling 8-Cylinder

Engine

Fig.

4 Engine

Mount Adapter 6-Cylinder Engine

12

Chapter
horn

I General

Engine Repair
the remaining flywheel

the tape from the carburetor

cleaner.

air

and

install the

air
en

mission with a

jack,

then

remove

Install the heater blower

motor

(6-cylinder

housing bolts.

gine)

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

(b)

Steps Peculiar

to

Fordomatic. Disconnect the

and

transmission throttle linkage at the cross shaft,

tie

Install the hood. Fill

crankcase.

the

cooling

system

and

the

the linkage to the dash

panel.

Remove the idler

arm

bracket. Jack up the front

stands. of

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

(b) Connect

the vehicle, and

with a

position

safety

Support the

transmission

jack,

then

remove

the converter

the transmission to flywheel

them to 40-50

housing bolts,

and

tighten

foot-pounds
Connect

torque. Install the flywheel

release spring.

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

housing

cover.

the clutch

tube

assembly.

Remove the transmission

control

Remove the jack supporting the transmission. Check

the clutch
pedal

linkage

splash shield.

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

(c)
cooling

Engine Removal. Remove the hood. Drain the

system and

free play if

necessary.

the

crankcase.

Remove the fan, then

Remove
the

(c) Connect Fordomatic Transmission. Install the two converter housing to engine lower bolts, and tighten
them to 40-45 foot-pounds torque.

remove

the

radiator and shroud as an assembly.

the

air cleaner.

Disconnect the

engine ground wire at

dash
and

panel.

Disconnect the
the

battery
pump

ground cable at cable at

and

the

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

engine and

evenly to

avoid

battery
pump.

to

starter

relay

the bat

tery. Disconnect the

vacuum

line,

the fuel inlet the

line
to
engine upper en

at

the fuel

Disconnect the
remove

starter cable at at

Install the two

gine

converter

housing

starter

solenoid, then

the cable clamp

switch

the dash

bolts,

and

tighten them to 40-45 foot-pounds torque.

pan

panel.
coil.

Disconnect the ignition

wires.

to

coil wire at

the

Install the floor

plugs,

and position plate

the floor mats.

with

Disconnect the two heater hoses. Remove the

Remove the
wires

gen

Align the flywheel

verter, install the

and
six

drive

holes

the

con

erator

from the

oil

pressure

bolts,

and

tighten them to 25-28

sending

unit and

the temperature sending

assembly.

unit.

Remove

foot-pounds

torque.

the heater blower

cable.

Disconnect the tachometer

rod, then

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

Disconnect the

accelerator

disconnect
serves as

the link bracket at the block (this bracket also the ignition cable bracket).

bracket. Tighten the idler

arm

bracket

28-43 foot-pounds torque. Install the

lower
access covers.

converter

Raise the
the

vehicle and position

safety

stands.

Disconnect

housing

exhaust pipes at

the

exhaust manifold.

Remove the
engine

Install

and connect

the throttle linkage and make the

engine

front

mount

bolt

and

insulator. Remove the

necessary linkage

adjustments.

Remove the jack

support

right and

left insulator

support
side

bolts
so

at

the engine, then

will clear

ing

the transmission.

turn the insulator to

or

one

the

engine

(d)
check

Check Engine For Oil

engine

Coolant Leaks.

them

upon removal.

Warm the

to

normal

operating temperature, then

connections

Remove the safety

stall

stands and

lower the

vehicle.

In

all gaskets and

hose

for leaks.

the engine

lifting

sling (fig. 2). Raise the

the
engine
out

engine

slightly, then carefully

pull

from the transmis

the
engine
com

b. Thunderbird.
The
engine

sion.

Carefully lift

the engine

of

may be

removed with or without

the trans

partment.

mission attached.

Install the
remove

engine on a work

stand, using the engine

engine

(1)

REMOVAL. To

the

engine

only, from a transmis

engine

mount shown

in fig. 3. Remove the

to

lifting

sling.

vehicle equipped with a standard or overdrive

(d)
in step

Steps Peculiar
as an

Removing

the

Engine
is

and

sion, follow

steps

(a)

and

(c). To
with

remove

the

Fordomatic

Assembly. While the

vehicle

raised

only, from
steps

vehicle

equipped

Fordomatic, follow
Fordomatic

(c),

perform the

following

additional operations: at

(b)

and

(c). To

remove steps

the

engine and

Disconnect the
and

shift control

linkage

the transmission
speedometer

as an assembly,

follow

(c)

and

(d).
or

the throttle

control rod.

Disconnect the
Remove the

(a)
move

Steps Peculiar

to

Standard

Overdrive

cable.

Remove the drive shaft, and plug the transmission

Transmission. Disconnect the

the
screws

clutch release spring.

equalizer

Re
to

with an extension

housing

cap.

converter air

retaining the

bar

support

duct

assembly.

Remove the

the flywheel

housing,
the

then remove the support and

upper

bush

Remove

engine rear mount

dip stick tube assembly. bolt, raise the transmission,

that
serves as

ing.

Remove

two

flywheel
cover,

housing bolts.
the trans

and remove the cross member

rear mount.

the engine

Remove the flywheel

housing

support

Section

3 Engine

Removal

and

Installation

13

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

vehicle.

the

battery
air

ground cable

to the

engine

and

the

starter

slightly,

solenoid cable.

Connect the
Install the

engine ground wire.

radiator

Install

transmission forward.
engine

the

cleaner.

and

shroud, then
system.

Carefully

lift the

engine and

transmission from the

install the fan. Install the hood. Fill the cooling

compartment.

Fill the
install the
engine

crankcase with
oil.

the

correct

quantity

and

grade

(2) INSTALLATION. To
mission, follow
engine steps
steps
a

only in
trans

of engine

a vehicle equipped with a standard or overdrive

(b) Connect
sion.

Standard

or

Overdrive Transmis
equalizer

(a), (b),

and

(e). To install the

follow Fordo
(e).
engine and
and

Install the bushings in the

support on

bar support,

only in

Fordomatic

equipped vehicle,

then install the

the flywheel housing. Install

(a), (c),

and

(e). To install the

steps

the transmission to flywheel

housing bolts,

and

tighten

matic as an

assembly, follow

(a), (d),

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

(a)
the

Engine Installation. Install the

engine

engine

lifting
Lower

housing

cover.

Connect the

clutch release spring.

sling, then remove the

engine

from the

work stand.

carefully into the

engine compartment.

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

Start the transmission

the crankshaft.

main

drive
the

gear

into the

clutch

disc. On Fordomatic units,

start

converter pilot

into

(c)

Connect Fordomatic Transmission. Install the

converter

two lower
overdrive

housing

to

engine

bolts,

and

tighten

NOTE:

On

standard or
adjust

units, it may be

them to 40-45 foot-pounds torque.

necessary to
with

the position of the transmission

NOTE:

Tighten
on

relation

to

the engine,

if

the

input

shaft

will
up"

binding

bolts slowly the dowel pins.

the
converter

and

evenly to

avoid

not enter
after

the

clutch

disc.

If

the engine
the

"hangs

Install the

the

shaft

enters,

turn

crankshaft

slowly

housing
with

to

engine

bolts,

and

(with
mesh

the transmission
with

in gear)

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

wheel

until

the

shaft splines

fly

and

the

clutch

disc

drive

plate

holes

the converter, install

splines.

the
aligned with

six

bolts,

and

tighten them to

25-28 foot-pounds

Make block

sure

the studs on the manifold are

muffler

torque.

the holes in the

engage

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

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

matic units

the block dowels must engage the holes

bracket. Tighten the idler

arm

bracket

the

converter

housing).
safety
stands.

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

Raise the
engine

vehicle and position and

Install the

housing

lower

access covers.

front insulator
support

bolt. Install the

right and

left

Install

and connect

the throttle

linkage,

and make

the

insulator
exhaust

bolts. Connect the

exhaust pipe
stand and

to the

necessary linkage

adjustments.

Remove the jack sup

as an

manifold.

Remove the safety

lower

porting the transmission.

the

vehicle.

(d)
accelerator

Install Engine
vehicle

and

Fordomatic

Assem
the

Connect the
ator

rod, then connect the

acceler

bly.

While the

is

raised

in step (a),

perform

link bracket to the block. Connect the tachometer

Install the heater blower
sending
unit and
assembly.

following

additional

operations:

cable.

Install the

oil

pressure
wires.

the temperature sending

wires.

unit

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

Connect the

generator

Connect the two

to
coil wire. and

bolt. Install the

converter

air

duct

assembly. extension

heater hoses. Connect the ignition

Install the
connect
vacuum starter

switch

Install the

dip

stick

tube

assembly.

Remove the

cable

clamp

on

the dash panel,

starter.

the

starter

cable

to the

Connect the

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

pump line

and

the fuel pump inlet line. Connect

linkage

and

the throttle control

rod.

4.
The following inspection
new and used manifolds.

INTAKE AND EXHAUST MANIFOLDS

to

procedures are applicable

Inspect the mating flanges

cracks, nicks,

of

the intake manifold for

burrs,

or scratches.

a.

Cleaning
Remove the
outside
of

and

Inspection.

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

manifolds.

the

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

their respective cylinder

head

ports.

Improper

alignment

may

result

in

loss

manifold with a wire

round, bristle brush attached to a flexible

with compressed air.

of power.

handle.

Dry

Inspect the

entire

intake

manifold

for

cracks or visible

14

Chapter

I General

Engine Repair

casting defects

which would make the manifold unfit

for

Remove
passages.

all

obstructions

from the intake

severely

manifold

further

service.
exhaust
manifold

Replace

cracked or

warped manifolds

Inspect the
cracks,

for burned

out

spots,

and

those manifolds

which contain unremovable obstruc

deep

nicks,

and scratches.

tions. Replace defective

exhaust manifolds.

b. Repairs.
Dress
plate.
with a

nicked or warped

mating

surfaces on a surface

CAUTION:
that

Remove

all

filings

and

foreign
as a

matter

Minor nicks, burrs,

file.

or scratches

may be

removed

may have

entered

the

manifold

result

of

repair work.

5.

ROCKER MECHANISM, CYLINDER HEAD, VALVES, VALVE LASH

ADJUSTMENT, AND VALVE TIMING

Check the
push

rods

for bend between ball

and

cup
end

centers with a and

dial indicator (fig. 5). Check the ball

of

socket

end

the push

rods

for nicks, grooves,

or

roughness.

NOTE:

rough

check

for bent

push

rods

can

be

made while

Holding

fixture'

PUSH ROD

6263

them

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

by rotating runout. If
the
rod

Fig.

5 Push

Rod Runout Check

and
repair proce

any

is observed, be between centers as described

runout

to

check

above.

This dures

tion covers the inspection

applicable

to the

rocker

mechanism,

cylinder

head,

(2)
and
and/or

REPAIRS. If the
arms
rocker

clearance
.004

between the
replace rocker

shaft

rocker

exceeds arms.

and valves.

In addition, the

inch,
all

the
arms

shaft

methods used

to

check valve

the

Replace

that

timing
a.

are given.

Rocker Mechanism.
Remove
and

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

disassemble the

Dress up

minor nicks or scratches.

Replace

all

damaged

rocker arm

(1)
of

CLEANING AND INSPECTION. Check the I. D.

arm

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

the rocker
at

bore
of

and

the O. D.
rocker

of

the rocker

arm

shaft,

the location
sure

the

sharp bend.
runout of a push rod exceeds rod.

arms,

against specifi
of

cations.

Make

these

surfaces are

free

0.020 inch,
to

at

scuffs, scores,

nicks,
pads.

or scratches.

Inspect the

rocker arms

for

grooved nuts

any point, discard the

push rods.

Do

not attempt

straighten

Check the
or

rocker

adjusting screws and lock

and

for

stripped

broken threads

the ball end of the

sure

b. Cylinder Head.
Remove the
cylinder

screw

for

nicks and scratches.

Make
arms.

the adjusting

head.
carbon

screws turn

Inspect
of

freely in the rocker the locating springs

oil

for

cracks or

other signs

(1)

CLEANING AND INSPECTION. Remove

brush. Be

deposits from the

combustion chamber and valve

careful not

heads

failure.

with a scraper and a wire

to

scratch

Inspect the

drain tube for

cracks or

sharp bends.

the gasket

surface.

Clean the
sealer.

gasket surface with solvent

to remove any gasket

\D,(3) check diagonally

(5) CHECK
Fig.
6

ACROSS CENTER

6262

6264

Checking Flatness

of

the Cylinder Head

Fig.

Gasket Surface

Checking Flatness of the Mating Surfaces

Intake Port

Section

5 Rocker

Mechanism, Cylinder Head, Valves, Valve

Lash Adjustment,

and

Valve

Timing

15

6268

Fig.

10

Measuring I.

D.

of

the Valve Guide

c.

Valve Mechanism.
Valve
guides are made
oversized

integral

with

the

cylinder

heads.

6266

Valves
ments

with

stems

are

available

as

replace

Fig.

8 Valve

Face Runout Check Check the

see

Check the head for Make

cracks.

gasket surfaces

(1)
the
seals,

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

cylinder
and

head. Discard
with

umbrella-type

valve

stem wire

for flatness (fig. 6). Check to

are open.
sure

that

all water passages

replace

new seals.
and

Scrape
stem of

and/or

the gasket surfaces of both head

or scratches.

and

brush

carbon

from the head from the

for

the

valves. clean

block
port

are

free from burrs

surfaces

Check the intake

in fig. 7.
evidence
of

Remove

varnish

valve stems.

mating

for flatness
head

Carefully
brush.

as shown

all carbon

from the
valve

valve seat with a wire

Check the
leakage.

cylinder

core

plug for

Check the

evidence
or

of

imperfect seating,
of

heavy discoloration, burning

all

erosion, or evidence

(2)

REPAIRS. Remove

burrs

or

scratches

with

warpage.

Check the
for

valve

face

runout

(fig;

8),

and also

an oil stone.

Replace the head if it is

cracked.

check

the face for pits and grooves. Inspect the ends of

grooves or scores.

If the

cylinder

head

core

plug

leaks,

replace

it.

the

valve stem

Inspect the
Valve

valve springs

for

cracks or other signs of

pressure

Spring

failure. Check the

valve

spring

(fig.

9), free

Tester

length,

and squareness.

Check the

valve

spring

retainers

for

wear or signs of

failure. Check the tapered in the

noted
retainer.

seat where are

the

valve

locks

These locks

split,

and wear
of

by

ridges

left between the halves

may be the locks.

Micrometer

^*~
9 Valve

6269
of

Fig.

Spring

Pressure Check

Fig. ?

Measuring

O. 0.

Valve Stem

16

Chapter

I General

Engine Repair

Seat Width Scale

6271

Fig.
6209
ends.

14

Measuring Valve Seat

not remove more

Width

However, do
the

than 0.010 inch from

Fig.

12

Reaming
the

Valve Guides
(fig.

the

end of

stem. valve

Check the I. D. O. D.
of

of

valve guides

10)

and

the

(3)
to

REFACING VALVE SEATS. Grind the

(fig. 16). Remove only in the
(fig.
seat.

the intake

and exhaust valve stems

(fig.

11)

seat with a grinder clean

enough stock
valve seat enough
reduce

against specifications.
and

If the

clearance

is

not within

the diameter

of

the

valve stem

is

on

the

limits, lower limit,

the
upper ream

up

pits or grooves

If the

width exceeds specifications stock

17),
to

remove

just
to

select a new valve with a stem

diameter

on

from the top

and

bottom

edge of

the

seat

limit. If the
valve guide

clearance

is

still not within

limits,

the

the

width.

Use
of

30

angle wheel
60

remove stock

from

(fig.

12)

for the

next oversize valve stem.

the bottom
stock

the seat

and a

angle wheel

to

remove
center

Check the
as shown

valve seat runout and

the

valve seat width

from the top.

Keep

the

seat as near

to the

in figs. 13

and

14.
or

of

the valve face as

possible.

Discard any defective valves, springs, locks,

tainers.

re

After refacing

valves and

seats, it is good

practice

to

lightly lap in
REFACING VALVES. Grind the
a
valve

the

valves with a medium grade

lapping
or soft

(2)
45

valve

face
off

at a

compound

to
the

match

the seat

and

the

valve.

Check the

angle on

grinder

(fig. 15). Grind

head is less than
valve.

only
valve

mating

of

seat and valve with

Prussian Blue

enough stock to remove pits and grooves

from the

lead

pencil.

face. If the
wide after

edge of

the

valve

%2

inch

grinding,

replace

the

If the
the

valve

face

runout exceeds

specifications,

grind

valve

face. If the

runout still exceeds specifications

valve.

after

grinding, discard the

Grind

all grooves or score marks

from the

valve stem

Runout Gauge

Pilot

for Removing and Installing Gauge

13 Valve

6270

6341

Fig.

Seat Runout Check

Fig.

IS

Refacing Valves

Section

5 Rocker

Mechanism, Cylinder Head, Valves,

Valve Lash Adjustment,

and

Valve

Timing

17

Combination

Adjusting

Tool

30

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

Feeler Gauge

6210

Fig.
6272

18 Valve

Lash Check

Check the intake

Fig.
16

and

exhaust

valve

lash for No. 1

not

Refacing

Valve Seat

cylinder with a

feeler

gauge

(fig. 18). If the lash is

screw until

d. Valve Lash Adjustment.

Valve lash is
lock
nut

to specifications, loosen the adjusting

clearance

this

is

obtained.

Tighten the lock

nut without mov

adjusted
on

by

means of

the

set screw and rocker arm.

ing

the adjusting

screw.

located

the
or

push rod end of

the

Make two
120

chalk

marks

on

the

crankshaft
(120

damper

If the

cylinder
and

head

the

rocker mechanism

has been
make

away from the timing

of

mark

represents
around

Vz

removed

installed, it
is

will

be necessary to
for the

turn

the

crankshaft or

Vz Vz

of

the way

the damper

preliminary
valve

adjustment

before starting the

made

engine.

If the

circumference

lash

adjustment

purpose of engine

Turn the

crankshaft

turn in the direction

of rota

tune-up,
the

omit

step

(a)

and proceed with

step

(b)

under

tion,
this

and check

the

valve

lash

of

No. 5

cylinder.

Repeat

procedure

for the

applicable engine.

operation

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

and

No. 4

cylinders.

(1) 6-CYLINDER

ENGINE.
rocker

(b)
speed

Final Adjustment. Run the

for approximately 30
minutes

engine at

fast idle
normal

to

(a)
arm

Preliminary Adjustment. Remove the Rotate the

center

bring
the

it to

operating temperature. Check the

ance

valve

lash for

conform

cover.

crankshaft until

No. 1
of

piston

is

to

specifications

(fig.

19)

with

engine

idling.

near

top dead
No. 1

(T.D.C.)
is
near

at

the end

the

com

pression stroke.

ADJUSTING SCREW
piston

Valve

gapper

NOTE:

T.D.C.

at

the

end

of the

compression stroke when

both

valves are closed and

the

timing

mark on

the

crankshaft

damper is in line

with

the pointer.

REFER TO SPECIFICATIONS

VALVE SEAT

6292

6273

Fig. 17-Valve Seat Width

Fig. 19-Valve Lash Check

18

Chapter

I General

Engine Repair

Repeat the
Dial Indicator

procedure

for

each set of valves,

turning
in the

the crankshaft

V*

turn

while

checking the

valves

firing (b)
speed

order

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

Final Adjustment. Run the

fast idle

for approximately 30 minutes to bring it to normal operating temperature. With the engine idling, check the
BE SURE TO PLACE INDICATOR TIP IN CENTER OF PUSH ROD CUP
valve

lash

as

shown

in figs. 18

or

19. Adjust the lash,

if

necessary.

Install the
gasket

valve rocker arm

cover, cementing

a new

to the

cover

if

necessary.

Tighten the
not exceed

cover nuts

to 2.0-2.5 foot-pounds torque. Do

the torque

limit
e.

or

the cover

will

be distorted.

Valve Timing.
checks should

Valve timing performance is

FABRICATED CLIP

be

made when poor engine

noted and all other

checks,
correct

such as

car

6274

buretion, ignition timing,

The
taken

etc., fail to

the trouble.

Fig.

20- Camshaft

Lobe Lift Check

following
on one

procedure
side

the opening

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

the
crankshaft

this

point a

degree

change of

is ap

Adjust the lash, if

cover, cementing

necessary.

Install the
to the to

valve rocker arm

proximately

equal

to 0.0004 inch

change-in cam

lift.

a new gasket
nuts

cover

if

necessary.

Remove the
engine.

rocker chamber cover on

remove

the 6-cylinder the

right-hand

Do

not

tighten the cover

or

more

than 2.0-2.5 foot

On 8-cylinder engines,

pounds

(2)

torque, 8-CYLINDER ENGINES.

cover will

the

be distorted.

rocker chamber cover.

Turn the
rocker

engine over until

cam

No. 1 intake tappet is

on

(a)

Preliminary Adjustment. Remove the

Rotate the
center crankshaft until

the heel

of
off

No. 1 intake

lobe.
valve

arm cover.

No. 1
of

piston

is

near

Back

the No. 1 intake

arm

adjusting screw,
a

push

top dead
NOTE:

(T.D.C.)
is

at

the end

the

compres

the rocker
as shown

to

one

side, then install

dial indicator
rotate

sion stroke.

in fig. 20. Zero the dial indicator, then

until

the

No. 1

piston

near

T.D.C.

at

the

end

of the

engine

slowly

the desired lift is

on

obtained

(Table 1).

compression stroke when

both

valves

are closed and or

Compare the degrees

Table 1
Engine

the pulley

with

the

specifications.

the

timing

mark on

the

crankshaft

pulley

damper

Valve

Timing

Specifications

is in line

with

the

pointer.

Camshaft

Check the intake

fications (fig. 18).
NOTE:
with

valve

lash for

conformance

to

speci

Intake Valve Opens Crankshaft Degrees at Cam Lift

13

223
the possibility of interference

EBP-6250-C
B5A-6250-A B5A-6250-A

BTDC

To

eliminate

272
292

12

@ BTDC @

.013

Cam Lift
Cam Lift Cam Lift

.016

the

exhaust

manifolds while

adjusting the
stock

valve
60

12

BTDC

.016

lash, bend
angle
about

the

proper

gauge

feeler

to
an

a
angle

one

inch from

the end or use

If the
for
a

valve

timing is

not within

specifications,

check

type

feeler blade holder.

and adjust

Loosen the lock nut,

tions.

the

screw

to

specifica screw. and

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

Bring
pointer

the No.

is

aligned

Tighten the lock

nut

nut

without

moving the

the T.D.C.
pointer

mark on not at

the

crankshaft
check

pulley

or

damper.
cam

Tighten the
adjust

to 30-35 foot-pounds torque. Check

valve

If the
shaft

is

fault,

the

timing chain,

the

exhaust

lash to

specifications

in the

sprocket,

crankshaft

sprocket, camshaft, crankshaft

order of accessibility.

same manner.

pulley,

and crankshaft

in the

6.

CAMSHAFT

SPROCKET, CAMSHAFT, AND CAMSHAFT BEARINGS

and repair of

Procedures for the inspection

ponents are contained

these

com

the

outward

deflection

exceeds

V2 inch,

replace

the

timing

in the

following
and

paragraphs.

chain.

Replace the

sprockets

if

necessary.

a.

Camshaft Sprocket
Before the timing
chain

Timing
the
chain

Chain.
the
out

(1) INSPECTION.
and

Remove the

camshaft

sprocket

is removed,

measure

timing

chain.

Inspect the

sprocket

for

worn or

dam

ward

deflection

of

the

slack side of

(fig. 21). If

aged

teeth. Inspect the chain for broken links.

Section

6 Camshaft

Sprocket, Camshaft,
the

and

Camshaft Bearings

19

(2) REPAIRS.
chain as

Replace the

sprocket

or

timing

SLACK SIDE OF CHAIN

DRIVING SIDE OF CHAIN

deemed necessary by inspection.

and

b. Camshaft
The
to
such

Camshaft Bearings.
replaced when
cam

camshaft must
an extent

be

any lobe is

worn

that the

lobe lift (intake

allowable

or

ex

haust)

is less than the Check

will

minimum

tolerance.

The tappet
replaced.

which mates with

cam

the

worn

lobe

must also as shown

be
in

lift

with a

dial indicator

fig. 20. It
push rod.

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

ing iron. (1) INSPECTION.

check

camshaft

the

end

play for

conformance

to

specifications

the

following

manner:

Push the
a

camshaft

toward the the

rear of

the
of

engine.

Place

dial indicator

against

rear

side

the

camshaft

flange. Set the dial to zero, then

ward.

push

the

camshaft
with

for

Compare the dial indicator reading

speci
l/2"

fications.

MAXIMUM LATERAL

FIRST,
OF

TAKE UP SLACK ON THIS SIDE OF

Remove the
for
of

camshaft.

Thoroughly

check

the

camshaft and signs

MOVEMENT OF CHAIN

CHAIN TO ESTABLISH STRAIGHT POSITION

cracks.

Examine

the lobes for pitting, scoring,

abnormal wear.
worn sure

Check the lobes

should

with

micrometer.

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

Suspected lobe to be
for
wear

lobes

be

compared with a good

diagnosis is

correct.

Measure the journal

camshaft

Fig.

21

Timing

Chain Deflection Check

and

out-of-roundness.

Measure the

front bearing. The

amount of clearance

between the bear

exceed

same manner.

ing

surface and

the journal should not

gear

0.003 inch.
or
worn

If the front journal to it

can

bearing

clearance are

is excessive,
and need

Check the distributor drive

teeth. Check the fuel pump

for broken for

wear.

be

assumed

that

all

bearings

worn

eccentric

replacement.

(2 ) REPAIRS. Replace
or
or

all camshafts

that

have

cracks
scuffs

severely
scores

scuffed

or scored

lobes. Remove light

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

with

lobes
nicks

with crocus

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

If the

end

play is excessive,

replace

the thrust plate

and

abrasions

the

camshaft

in the

and/or spacer.

7.

FLYWHEEL, CHANKSHAFT, MAIN BEARINGS, AND CONNECTING

ROD BEARINGS
these

Procedures for the inspection

ponents are contained

and repair of

com

(2) REPAIRS.
inch
and

If the flywheel

runout exceeds

0.010

in the

following

paragraphs.

the flange is not at

fault,

the flywheel should be

replaced or machined.

Machine

the friction surface of the

a.

Flywheel.
The flywheel
and

flywheel if it is
ring
gear

scored. of

are

shrink

fit

and

are

than 0.045 inch

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

replaced.
are

replaceable as separate parts.

flywheel
runout

should

be

(1)
with a

INSPECTION. Check the flywheel face

dial indicator (fig. 22 ). Be
or rearward so

If the ring
worn,
or

gear

teeth

chipped,

sure

to hold the flywheel

end

if the

runout exceeds

broken, cracked, or 0.010 inch, replace the ring

blow torch
off on

full forward
not
show

that crankshaft

play

will

gear as

follows:
gear with a

up

as

flywheel
the

runout.

If the
and

runout

exceeds

Heat the defective ring

engine side of

the

0.010
of

inch,
the

remove

flywheel,

check

the

runout

the gear, then knock

it

the

flywheel. removing

the

crankshaft

mounting flange. It

will

be necessary to

remove

crankshaft

if the flange

CAUTION:
the

Do

not

hit

the

flywheel

when

requires machining.
or

Inspect the ring

gear

for worn, chipped,

cracked

ring

gear.

teeth. Check the ring gear runout as

indicated in fig. 23.

Heat the

new

ring

gear

evenly

until

the

gear

expands

20

Chapter

I General

Engine Repair
is installed, per ring gear and flywheel.
gear

gear teeth.

When the

new

ring

form

a runout check on

the

b. Crankshaft.
(1)
for

CLEANING

AND

INSPECTION.
end

Before

the

crankshaft

is removed, the
to
crankshaft

play

should

be

checked

conformance

specifications

in the

following manner :
of

Push the

toward the

rear

the
the

engine.

Place
shaft

dial indicator

against

the

rear side of

crank

flange. Set the dial

on zero

then

push

the

crankshaft
with

forward. Compare the reading

specifications.

on

the dial indicator

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

solvent,

air.

Exam

ine the

shaft

for

cracks or other signs of

failure.
con

Measure

each crankpin and

specifications.

journal diameter for

shaft

formance to
taper

Check the

journals for
the

and out-of-roundness at several places around

circumference.

(2) REPAIRS.
tions,
6085
replace

If the

end

play is

not within specifica

the

number

three

main

bearing.
signs of

Replace the Dress

crankshaft

if it

shows

failure.

minor nicks or scratches.

Fig.
enough seated

22 Flywheel

Runout Check

If the
specified

pins

or

journals

are

out-of-round

beyond the
for the
next

limits,

the

shaft should

be

ground

to slip

onto

the flywheel. Make sure the gear is

undersize

bearing. Calculate the

correct undersize

bearing

properly

against the shoulder.

not

to be

used as

follows:

CAUTION:
a

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

Do

EXAMPLE:
up"

//

the

main

bearing

journal

will

"clean

before it is ground

to

2.4990.010=2.489 inches

exceeded, the temper

be

removed

from

the ring

diameter, finish
inch
undersize

it to that

diameter,
journals

and

install 0.010

bearings.
grind
or

CAUTION:
excess

Never

crankpins

in

of 0.030 inch

undersize.

6084

1158

Fig.

23

Ring Gear Runout

Check

Fig.

24

Bearing

Failure Lack of

Oil

Section

Flywheel, Crankshaft,

Main Bearings,

and

Connecting

Rod Bearings

21

OVERLAY GONE FROM ENTIRE SURFACE

1161

Fig. 27 Bearing
pin or oil.

Failure Tapered

Journal

journal

with

No. 320
also

grit

polishing

cloth and engine

Crocus

cloth

may

be

used as a

polishing

agent.

c.

Main

and

Connecting
copper-lead,
or main and

Rod Bearings.
connecting
rod

Steel-backed,
serts are used

lead babbitt bearings in

bearings.
evi of

for both

Check the bearings for scratches, improper seating,

1159

dence

of

radius

ride,
are
all

and

worn

overlay.

Examples

Fig. Always
pin or

25 Fatigue

Failure

of

Bearing
corners of

bearing
and

failures

29. Replace

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

AND

reproduce

the

same radii

in the

the

(1) FITTING
procedure applies
either

MAIN

CONNECTING

ROD

journal that in in

existed originally.

Too

small a radius a radius

BEARINGS PLASTIGAGE

may
will

result

crankshaft

failure,
the

while

too large

METHOD. The following to fitting main bearings with the engine

in the
vehicle.

result

bearing failure.
chamfer
oil

installed

on a workstand or

After grinding,

holes,

then polish the

If the

bearing fits

are

to be

checked with

the

engine

DIRT IMBEDDED IN BEARING MATERIAL FATIGUE FAILURE FROM EXCESSIVE LOAD

"7
RADII RIDE 1160
28

SCRATCHES

1162

Fig.

26

Bearing Scratched by Dirt

Fig.

Bearing Showing Radius Ride

22

Chapter IGeneral Engine Repair

BRIGHT

(POLISHED) SECTIONS

1163

Fig.

29

Bearing

Bright

Spots Improper

Seating
Tool T52L-6701- AGD

in the vehicle,
a small

support

the weight

of

the

crankshaft with

63 73

jack

positioned

to hold the
the
main

crankshaft upward

against the

block half
bear

of

bearing

inserts. The

Fig.

31 Rear

Journal Oil Seal to Cylinder Block

Installation Typical

jack

should

against

the crankshaft

counterweight

adjoining the
ance.

bearing

which

is

being

checked

for

clear

The

shaft can also

be

supported

by

thin
of

rubber

pad

between the cap insert

are not

and

the journal

two bear

Install the cap fications.

center.

and

tighten the

bolts to

speci

ings that bolts just

upper

being

checked.

Tighten the bearing cap

up
against

CAUTION:

Do

not

turn

the

crankshaft

while

the

enough

to hold the

crankshaft

the

Plastigage is in

place.
check

bearing inserts.
It is necessary
when

Remove the cap,

to
support

the width

of

the

Plastigage,
another

at

NOTE:

the

weight

of the

the

widest

point,

with

the Plastigage

scale

(fig. 30).
selec-

crankshaft

checking

main

bearing

If the
clearances,

clearance

is

not within

limits, try

to

prevent

the

weight

of the

crankshaft

from
an

com erro

pressing the
neous

Plastigage, thereby

providing

reading.

Place

a piece of

Plastigage,
the

the full
surface

width of

the bear
crank

ing

cap

insert,

on

bearing
is

(or

on

the

shaft

journal if the

engine

inverted)

about

Va inch

off

Too/-T52L-6707-AGD

CLEARANCE

Flattened Plastic

GRADUATED CONTAINER

1282

6374

Fig.
Fig.
30

32 Rear

Journal Oil Seal to Seal Retainer

Measuring

Plastigage

Installation Typical

Section
tive fit

Flywheel, Crankshaft, Main Bearings,

within

and

Connecting

Rod Bearings

23

bearing

to

bring

the clearance

the desired

SEALS. Remove
seal groove

the journal
old

oil seal

from the
and

cylinder

limit. Red
marked

bearings increase clearance; blue bearings decrease clearance. If the various selec
marked
not

block. Remove the

in the for the

sealing material,

clean

the

cylinder

block. Repeat this Remove the

procedure

tive fit

bearings do
will

bring

the clearance

within specifi

oil seal retainer cap.

oil seal retainer

cations, it

journals
NOTE:
and

and

be necessary to regrind the install undersize bearing inserts.

main

chankshaft

cap to block

seals.

Install
shown

a new

journal

oil seal

in the

cylinder

block

as

Normally,
not

are

out-of

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

in fig. 31. The

cylinder

block journal

seal and without

the

retaining cap journal

seal must

be

cut

flush

any

being fitted to an out-of-round journal, be sure to fit the bearing to the maximum diameter of the journal. the If bearing is fitted to the minimum diameter with
minimum
an

frayed
in the

edges overlapping.
oil seal retainer

Install

a new

journal

oil seal

cap

as shown

in fig. 32. On 6-cyl

cylinder

inder engines, install

seals.

new retainer

cap to

block

clearance, interference may result, causing early failure, lt is not recommended that bearings
to
a crankshaft

Install the
with

main

bearing
to

caps and

inserts. Lubricate
then install the

the seals
retainer

grease

reduce

friction,

be fitted

journal

which

is

in the

cylinder

block.
main

more than

0.001 inch

out-of-round.

On 8-cylinder engines, install the

and

(2) ALIGNING main bearing caps,

bearing
half
of

THRUST
except

BEARING.

Install
cap,

the
and

the thrust

bearing
then

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

bearing bearing oil

caps

tighten the cap bolts to

specifications.

Install the thrust

pry the
upper

cap

with

the

bolts

finger-tight,

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

grooves.

seals

into

place

crankshaft

forward

against

the thrust

surface of

the

Check the

retainer

to

cylinder

block

seal

for leaks.
seals on
air
air

the bearing. While

holding the
of

crankshaft

forward,
align

Squirt

few drops
of

of oil

into the

corners of

the

pry the thrust

the thrust

bearing

cap to the

rear.

This

will

the outside

the

cylinder

block. Blow
of

compressed

surfaces of

both halves
on

the bearing. Retain

and

into the bubbles

sure all repeat

seal corners

from the inside

the block. If

the forward pressure

the crankshaft,

tighten the

appear

in the oil,

remove the seal retainer.

Be

cap bolts to

specifications.

Check the

crankshaft end play.

mating
air

surfaces are clean.

Install

new seals and

(3) REPLACING

REAR

MAIN

BEARING

OIL

the

test.

8.

OIL PAN, OIL FILTER, AND OIL PUMP AND PRESSURE RELIEF VALVE
and repair procedures applicable

The inspection

to the

it,

the pressure difference between the inner and

of

outer

above components are presented

below. In addition, the

of

faces

the

valve

is

not great enough

valve.

to overcome the
element
of

removal,
oil

disassembly,
also

assembly, and installation

the

spring

pressure
and will

behind the
not

When the

is

filter is

given,

inasmuch

as

these

procedures are

dirty

permit

a
of

sufficient

flow

oil, the
and

applicable

to

all engines.

pressure on pressure
cause

the inner face

the valve
valve

drops,

the

a.

Oil Pan.
Remove the
oil pan.
of

difference between the

valve

faces is

enough

to

the

to

open.

from the inside

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

particles
material

Oil then by-passes the element,

of oil

thereby maintaining
cation system.

supply

to the

engine

lubri

from the

gasket surface.

in

a solvent and

dry

it thoroughly.
pan

(1) REMOVAL.
for cracks,

Remove the filter from the bottom

a pan on

Check the

holes, damaged drain

plug

of

the

vehicle.

Place

the floor

directly

under

the

threads,
not

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

repairs can

ENTER TUBE BOLT

be

made.

FILTER HOUSING SPRING

b. Oil Filter.
The full flow-type
the
entire output of
oil

SPRING RETAINER
GASKET

filter,

used on all

engines, filters
oil enters

GASKET
BY-PASS VALVE SPRING

the pump before the

the

ADAPTER FITTING

engine

lubrication

system.

FILTER ELEMENT
ANTI- DRAWBACK'

A built in by-pass
filter
element

provides oil
clogged.

to the

system

in

case

the

BY-PASS VALVE

becomes

The by-pass is located in

of a

DIAPHRAGM

6080

the hollow
valve.

center

bolt

and

consists

spring loaded

Fig.

33 Oil Filter Disassembled

Metal Type

When the

element

is

clean and oil will

flow through

Element Shown

24

Chapter
TOP

I General

Engine Repair
fibre
the

CYLINDER BLOCK

(4)
center

ASSEMBLY. Install

new

gasket

on

bolt,

then place the

and
seat

bolt through the filter housing.

seat
are

Install the spring

making
sure

spring
tangs

assembly

on

the

bolt,

the

engaged

in the
filter

spring.

Install
over

a new neoprene gasket and a new

element

the center bolt. The pressed paper type

not use

element

does

the

neoprene gasket.

(5)

INSTALLATION.
oil

Be

sure

the
at

two

elongated
when

holes in the
positioned on neoprene

filter diaphragm

are

the top,

the

block,

as shown

in fig. 34. Install

recess.

a new

gasket

in the filter

housing

Place the

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

direction,

to

make

sure

the gasket is
complete

evenly.

Tighten the

center

bolt 3/4-l

turn (20-25 foot-pounds torque).

With the
operating
at

engine at normal

operating temperature
oil

and

fast

idle,
the

check

for

leaks

past

the

housing
past

gasket or around

center

bolt

gasket.

If

oil

leaks

Fig.

34 Oil

Filter Diaphragm Position

the

housing
leaks

gasket,
past

check

the

housing for

proper seating.

If

oil

the

center

bolt gasket,

check

the

center

bolt for

proper

torque

or replace

the gasket.
-

filter. Remove the filter filter assembly

NOTE:
and gasket.

center

bolt,

then remove the

c.

Oil

Pump
and

and

Pressure Relief Valve.

oil

On

vehicles

equipped

with

power

steering,
to the
oil

Remove

disassemble the
all

pump

and pressure

it

will

be necessary
position

to turn the
to

front

wheels

relief valve.

Wash
a

parts

in

a solvent and

dry

them

full

right

facilitate

removal

of the

thoroughly. Use

brush to

clean

the inside
valve

of

the pump
sure
all

filter.

housing
DISASSEMBLY.

and

the pressure relief

bore. Be

(2)
and

Remove

the

filter

element,

dirt
rial

and chips are removed.

Remove

all old gasket mate

neoprene gasket

(with

metal

type element only), spring,

from the pump

body

and cover.

seat, then
cover.

remove

the

center

bolt

and

fibre

gasket

Check the pump

Check the pump
the
compression

housing for damage

teeth for
relief

or excessive wear.
or wear.

from the The

oil

Discard the filter

element and all gaskets.

gear
of

damage

Check

filter is

shown

disassembled in fig. 33.

all parts

the

valve

spring.

Check the

(3)
them
center

CLEANING. Wash
thoroughly.

in
the

a solvent and

dry

relief valve clearance

in the

relief valve

bore. Check the

Make

sure

all

openings

in the

driven

shaft clearance.
worn or

bolt

are clean.

Replace any

defective

parts.

9.

CYLINDER BLOCK, PISTONS, PISTON RINGS, AND CONNECTING RODS

cylinder

Procedures for checking the

ing, inspecting,
and

and

fitting

pistons; for
rod

block; for clean fitting piston rings;

are

bore

gauge.

Only

experienced personnel should

be

per

mitted

to take these measurements.

cylinder
when

for checking connecting

alignment

given

Rebore the

the taper

and/or

out-of-

below.
a.

roundness exceed

the

maximum allowable

tolerances.

Cylinder Block.
Make
a

b.
for
cracks.

Pistons, Piston Pins,

and

and

Rings.
avoid

thorough

check

Minute

cracks not

To facilitate
the piston rings

piston removal and

to

damage to
ridges

visible

to the

naked eye

suspected area with a

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

part

ring
with

bands,
the

remove

any

that

may be
as

present

along

upper part of each cylinder

light
a

motor oil. of

Wipe the
oxide

dry

and

immediately
wood

apply

follows:
Move the
piston

coating

zinc

dissolved in
will

alcohol.

If
at

to the bottom

of

its travel,

and place

cracks are

present, the coating

area. cylinder

become discolored

a cloth on

the

piston

head to

collect the cuttings.

Remove
to the

the defective

the cylinder ridge as shown in fig.

35, according
of

Inspect the

bores for

scores.

Check the

cylin

instructions furnished
remover

by

the manufacturer

the ridge

der bore for taper,

out of

round, and wear,

with a cylinder

being

used.

Section
CAUTION:
excess

9Cylinder

Block, Pistons, Piston Rings,

in

and

Connecting

Rods

25

Never

cut

into the ring

removing

travel area
ridges.

of 1/32 inch
ridge

when

Remove the
Turn the
from the
stroke and

remover

from the
piston

cylinder

bore.
of

crankshaft until

the

is

at

the

top

its

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

cuttings

( 1 ) CLEANING AND INSPECTION. Clean the piston

ring
the
grooves with a
piston

Groove Cleaning Tool T52L-6110-AAD

ring

groove cleaner

(fig. 36). Clean

cleaning
solu

in

solvent.

Do

not use a caustic

slots

tion. Make

sure

the

oil

ring

(or

holes)

are clean.

Inspect
and pin

pistons

for fractures

at

the ring

lands,

6097

skirt,

bosses.

Spongy,
on

eroded areas near

the

edge of

the
are

Fig.

36

Cleaning Ring Grooves

upsetting
engine

piston caused

top, usually

the side opposite the valves,

or pre-ignition.

by detonation,
pin

can

be intermixed

without

balance.

Inspect the
Check the

piston pins

for

signs of

fracture

or etching.

for

proper

fit in the

piston and rod

bushing.

Rebore only the

cylinder or cylinders which require

it.

(2)
cessive

REPAIRS. Replace
skirt

pistons

showing

signs of ex or

(4) FITTING
rod and

PISTON PINS. The

clearance

piston pin should

clearance, wavy

ring lands, fractures

signs of

have 0.0001-0.0003 inch

the
piston.

in both the connecting

damage from detonation.

Replace
ing. Piston
or

piston pins pins

showing

fracture

or etch

that

show wear or

fit

loosely in
Replace

the
all

piston
piston

If the

piston pin

hole

must

be reamed,

use an expan

rod

bushing

should

be

replaced.

sion-type,
revolve

piloted reamer.

Place the
the

reamer

in

a vise and
reamer reamer

pin retainers.

the
size
and

piston

around pin

reamer.

Set the
the

(3) FITTING
der bore,
gauge
attach

PISTONS. To fit
a

a piston

in the
of a

cylin

to the

of

the

bore,

then

expand

tension scale to the end

feeler

slightly
of

trial ream the pin

bore,

using

a pilot sleeve

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

the

nearest size

to
a

maintain alignment of

the bores.

hole. Invert the piston, then

so

push

the piston

CAUTION:

Take

very light

cut.

feeler into the bore

the end

of

the

piston

is ap

Check the
the
piston

reamed

proximately 1 Vz inches below the

top

of

the block.

Keep
Hold

hole size, using the

piston pin

for
the

the

piston pin

bore

parallel

to the

crankshaft axis.

being

reamed.

If the bore is small,

expand

the piston

and

pull

out

the feeler

ribbon,

noting the

reading

on

the

pull scale

(fig. 37).
than the
maximum allow

If the
able or

scale

reading is

greater

pull,

check

for

hone the
If the

cylinder

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

scale

reading is less than the

pull,

try

another piston.

If

none can

be fitted,

rebore

the

cylinder

to the

next oversize piston.

NOTE:
ard and

All

pistons are

the

same

weight, both

stand

oversize;

therefore,

pistons

of

various sizes

Piston

pull

scale

Thickness

scale

6215

Fig.

35 Cylinder

Ridge Removal

Fig. 37-Piston Fit Check

26

Chapter

I General

Engine Repair
the inserts.

bore
PISTON

and

the back

of

Make

sure

the

squirt

holes have

are clean.

Check the
a

piston pin

to

bushing
clearance

fit The

pin

should

0.0001-0.0003 inch
each

in the

rod

bushing.

Check
after

connecting rod for

piston pins

alignment on a

fixture

fitting

the

(fig. 39).
nicks, signs
of

Inspect the
check

rods

for

deep
rod
or

fractures,

and

the bore for

out-of-roundness.

Check the connecting

bolts

and nuts

for damaged

threads,
ance

signs of

nicking,

damaged

corners.

(2 ) REPAIRS. If the
is excessive,
ream

piston pin

to rod

bushing

clear

the

bushing for
bent
more

the

next oversize

pin,

or replace

the bushing.
or

If the
6216
should

rod

is twisted

than specified, it

be

straightened or replaced.

Fig.
reamer

38

Ring Clearance Check

trial cut. Repeat the

Replace defective connecting

Rods
with

rod

nuts and/or

bolts.
the

deep

nicks, signs of
more

fractures,

or with should

bore

out-of-round

than

0.0004 inch

be

slightly

and make another

procedure until

the

proper

fit is

replaced. obtained.

(5) FITTING
push

PISTON RINGS. Install the

and use

ring in
top
to
square

d.

the cylinder bore. Invert the piston,

the

Fitting Connecting
Plastigage Method.
a piece of

Rod Bearings
the

the ring

about

halfway
the

down the bore to

with a

the

ring.

Measure the ring gap

to

feeler

gauge.

Place

Plastigage

on

bearing

surface, the

Be in

sure

identify
are

rings with used.

the

piston and

bore

full

width of

the

bearing,

about
rod

V* inch

off center.

Install

which

they
on

to be

the cap the

and

tighten the

bolts to 45-50 foot-pounds

Check the installed

oil rings

ring

to

groove side clearance with

ring

torque.

the

proper piston

(fig. 38). Side sealing type installed in

NOTE: in
place.

Do

not

turn the crankshaft with

Plastigage

have

no side clearance.
a used

Whenever
the
"glaze"

piston rings are

cylinder,
aid

on
seating.

the bore

should

be

removed

to

in
to

Remove the
measure

bearing

cap,

and use

the Plastigage scale

of plastic at

ring
c.

the

width of

the flattened piece

the

widest point.

Select fit bearings to

obtain

the

proper

Connecting
(1)
passages

Rod.
all parts

clearance.

CLEANING AND INSPECTION. Clean

in
solvent

NOTE:

and

Never

use

caustic

cleaning
them if
the
rod

fit the
pin.

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

not
or

to

crank'

solution.

Remove the
to be

bearing inserts (identify

thoroughly
clean

It is

recommended

to use

they

are

used again), then

any type,
to
adjust

to

file

or

lap

the

bearing shims of bearing caps in order

the

bearing

clearance.

ROTATE PISTON AND OBSERVE INDICATOR

Tool
M-120-RA-72

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

If the
tive fit

clearance

is

not within

limits, try

another selec

bearing

to

bring

the

clearance within

the limit.
marked

Red

marked

bearings increase the clearance, blue

clearance.

bearings decrease the

If the

various selective

fit bearings do

not

bring

the

clearance within specifica

tions, it
APPLY PRESSURE TO HOLD ROD DOWN

will

journals

and

be necessary to regrind the install undersize bearing inserts.

crankshaft after
not

chankshaft

Rotate the
Alignment Check

the

bearing is installed

to

Pig,

39

Connecting Rod

be

sure

the

bearing is

too tight.

Section 10

Exhaust System

27

10.
The
to the exhaust system

EXHAUST SYSTEM
(2)
REPAIRS. Remove the
mating
surfaces with

following general inspection and repair procedures

of all engines.

nicks and
an or

burrs from the

Replace
all

pertain

manifold sections
exhaust

oil stone.

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

showing

signs of

leaking

burning

through.

The

thermostat

control

valve

assembly does

not re
or

severly

warped mat

ing

surfaces.

Check the

various sections of
or

the

exhaust

quire replacement unless

valve

it becomes inoperative,

the

system

for

signs of

leaking
valve

burning

through. Check the

is burned. Free up frozen heat

penetrating
oil.

control valves with

exhaust

thermostat

for

proper operation.

graphited

SERVICE
Letter No.

LETTER
Subject

REFERENCE
Changes Information on Page No.

Date

Part ONE

POWER PLANT
Chapter

6-Cylinder 223 Cubic Inch

Section

(EBP)

Engines
Page

Engine Front Manifolds

Steady Rest
and

28
29

2
3 4

Cylinder Heads Oil Pan

and

Valves
and

30

Oil

Pump

Pressure Relief Valve

32
33 34 36

5
6

Crankshaft

Damper,

Cylinder Front
and

Cover,

and

Oil Seal

Camshaft Sprocket, Camshaft,

Bearings

7 8
9

Flywheel, Crankshaft,
Exhaust System

and

Bearings
and

Connecting Rods, Pistons, Pins,

Rings

37
39

The 6-cylinder 223

cubic

inch

car engine

(figs. 1

and

It has

a compression ratio of

7.5 to 1.

2)

has

bore

of

3.62 inches

and a stroke of

3.6 inches.

1.
The
engine

ENGINE FRONT STEADY REST

and

front steady
weight

rest

(figs. 3
as

support

any engine

and,

its

name

4) does not implies, acts

at

one

bolt from the

the bracket

right

side

of

the

ngine

block,
the

then

remove

assembly.

as a stabilizer only.

(2)
the
rest,
rest.

INSTALLATION.
the steady
rest

Before

installing
and

steady

(1)
front
retains

REMOVAL. Remove the two clamp bolts

of

check

bracket for

cracks or

broken
of
corn-

the steady

Remove the
rest

spacer

bolt that

welds.

Check the insulators for damage

Replace defective
on

loss

the insulators in the steady

bracket. Remove
side and

pressibility. rest

parts.

Install the steady

the insulators. Remove two bolts from the left

bracket

the

cylinder

block. Tighten the bolts to

T~

46 H'Z
V^^l'll*fr^l<Wj<^^; liy^WMW

"~~^

6377

6219

Pig.

J 223

Cubic Inch

Engine Right

Side

Fig. 2-223 Cubic inch Engine-Left Side View

28

Section
23-28 foot-pounds torque. Install the

1 Engine

Front

Steady

Rest

29

insulators,

spacer

frame brackets. Then tighten the

spacer

bolt to 20-25
is
not

bolts,

clamp bolts. Do not tighten the spacer bolt or clamp bolts. If necessary, center the spacer bolt in the frame bracket by shifting the engine front mounts in their
and

foot-pounds torque. Make

transferred to the steady

sure engine weight

being

rest

insulators,

then tighten the

clamp bolts to 25-30 foot-pounds torque.

6220

6221

Fig.

Steady

Rest Left

Side View

Fig.

Steady

Rest Right

Side View

2.
A
tion
chamber

MANIFOLDS
graphite and insert

is built into the intake

manifold center sec

it through the
slot

valve.

Rotate the
same as

shaft
was

where

the carburetor

and exhaust manifold are at control

in the

valve until

the

is

positioned

the

it

tached. An exhaust thermostat

valve,
gases

located in into this

originally.

Weld the

valve to

the

shaft. shaft

the

exhaust

manifold,

directs

exhaust

chamber

when

the

engine

is

cold

to provide for faster

Install the thermostat spring in the the spring ZA turn, and hook the open
over

slot, tighten
the spring

end of

intake

manifold warm-up.

the stop

pin.

NOTE:

Do

not remove manifolds when

and make

They
a.

may warp

they are hot. reassembly difficult.

open when

the

The spring should hold the thermostat manifold is cold. Install the stop spring,
Install the
counterweight on the
shaft and

washer, and
shaft

cotter pin.

in its

original position.
pin.

Drill through the

Removal.
Disconnect
the throttle

install the retaining linkage

at

the manifold bell

carburetor.

NUT-*LOCK

WASHER

crank.

Remove the

air cleaner and

the

Disconnect the

muffler

inlet

pipe.

Remove the bolts

lift the
manifold

LOCK WASHER -*^

NUTV
GASKET

fastening

the manifold to the

head,

and

assembly from the head. Remove the

gaskets and

inserts.
INTAKE MANIFOLD

Remove the
separate

nuts and
manifolds.

bolts

joining

the manifolds, then

view of

the

A disassembled

the

mani

folds is

shown

in fig. 5.

WINDSHIELD WIPER

CONNECTOR

+0<

b. Exhaust Thermostat Valve

Replacement.
The
exhaust

EXHAUST MANIFOLD
not

thermostat valve does

require

re

placement unless

it becomes inoperative.
valve

SHIELD

(1)
note

REMOVAL. Before removing the

position of

assembly,

7 SPRING

the

the counterweight

and of

the thermo

stat

spring

slot with relation

to the valve plate. Drive out

the retaining
shaft.

pin and remove

cotter

the counterweight from the

COTTER PIN
and

Remove the

pin, washer, stop spring,

of

thermostat spring from the other end

the

shaft.

Cut

THERMOSTAT
SPRING

SHaFT

the shaft
and

on

both

sides of

the valve.

Remove the

BUSHING^

BOLT-

valve

the

shaft pieces.

LOCK WASHER
a new valve

CLAMP WASHER

BUSHING GASKET
STUD

(2)

INSTALLATION. Position
Lubricate

inside the
oil and

6256

manifold.

a new shaft with

penetrating

Fig.

5 Manifold

Disassembled

30

Chapter ll-6-Cylinder 223 Cubic Inch (EBP) Engines

hold-down bolts
lockwashers.

c.

Installation.
Place the intake
manifold over

Install the
the studs
on

manifold

and

Tighten the bolts to 23-28 foot-pounds torque, tightening

the
exhaust

manifold.

Install the
and

lockwashers,
manifold

nuts,

and

bolts,
new

then

from the

center

to the ends. Tighten the bolts and nuts

and exhaust manifolds

tighten the nuts

and gaskets on

bolts finger tight. Install

inserts

joining
pounds

the intake
torque.

to 23-28 foot
outlet

the intake

parts, coat the mating

and place

Install
the

new

exhaust

flange
studs.

surfaces

lightly

with graphite

grease,

the

mani

gasket, and

position

muffler

inlet

pipe over

the

fold assembly in
NOTE:

position against

the cylinder head.

Install the

nuts and

lockwashers,

and

tighten the nuts to

Make

23-28 foot-pounds torque.

certain

the

openings

in the

manifold

assembly are in proper in the cylinder head.

alignment with

the openings

Connect the throttle linkage. Install the

connect

carburetor and
air cleaner.

the

carburetor

linkage. Install the

3.
The
iron
as

CYLINDER HEADS AND VALVES

same

cylinder

head is

cast

from the

high

grade

and

the fuel pump. Disconnect the distributor

at

vacuum

is

used

for the

cylinder

block. Cylinder head dis

expansion and same

line

the

carburetor and at

the distributor. Disconnect the

tortion is kept to
contraction

a minimum

because the
change
carries

manifold

line

the

manifold and

booster pump, then

re

due to temperature
and

is the

for

move all

three lines. Remove the

screw and

valve rocker arm cover.

both head

block. The head

mechanism, the

the valves and

Remove the cap

rocker arm support

clip from the Number 6

oil

valve rocker arm

manifold

assembly, and

bracket. Pull the

out of

feed line

out of

the

the

water outlet.

bracket,
integral
part of

then

pull

it

the block with

pliers

(fig. 6).

Valve
Valves
the

guides are an

the cylinder head.

Be

careful not

to damage the line.

with oversize stems are available

for

service when

Loosen
valve

all rocker arm

adjusting
rocker

screws

to

remove remove

the the

valve guides

become

worn or scored.

Both the intake

spring load from the

arms, then

and exhaust valve assemblies are

the rotating-type, and

umbrella-type valve

rocker arm assembly.

both

valve

assemblies

incorporate

Remove the
them
so

valve

push

rods

in

sequence.

Identify

stem seals.

they

can

be installed in their
upper
radiator

original position.

a.

Cylinder Head Removal.

Drain the cooling
system.

Disconnect the
air

hose

at

the radiator.

Remove the distributor

cleaner, then

cap.

Remove the

manifold

hold from
inlet

Remove the
closed.

down

tape the

carburetor air at

horn

Disconnect the bat

wind

bolts,

and pull

the manifold assembly away

supported

tery

cable

the

cylinder

head. Disconnect the

accelerator

the head allowing it to be

pipe.

by

the

muffler

shield

wiper

vacuum

line
unit

rod,

choke

cable,

temperature sending
unit wire.

wire,

and oil pressure

NOTE:
sending

Brace

the

intake

manifold

assembly

so

the

inlet

pipe will not

be damaged.
head

Disconnect the high tension

remove

wire

the

coil

from the head

and

from the coil, then allow it to hang from

wires and remove at

Install the
shown

cylinder

holding fixtures (which

are

installed

on

the head in fig. 7

for

convenience

in

the distriutor. Remove the

the
spark plugs.

spark

plug

lifting the head and to protect the gasket surfaces.

Remove
all

Disconnect the fuel line

the

carburetor

cylinder

head bolts. Install the

in fig. 8. Lift the

cylinder

head
REMOVE SCREW

guide studs shown off

cylinder

head

assembly

the engine.

BOLT BRACKETS TO INTAKE PORTS

!#
N^

%>3 ^mr

^af ^"

Wt

\m

A
_

/%,

I
>

PRY UP OIL LINE WITH PLIERS

1224

TIGHTEN SCREW SECURELY

Tool-T 52P-6085DAD
7 Cylinder

1276

Fig.

6 Oil

Line Removal

Fig.

Head

Holding Fixture

Section

3 Cylinder

Heads

and

Valves

31

BOLT CUT OFF HEAD, TAPER END AND SLOT FOR SCREW DRIVER AS SHOWN
uttUmiiUhmiil

7/1614x6"

Fig.

8 Cylinder

Head Guide Studs

with a screw

1234

CAUTION: Do

not

pry the head loose

gasket surfaces

Fig.
moved or

9 Valve

Stem Lock Removal

driver
block

or wedge. must not

The

of the head

and

be

scratched or gouged.

to

which

it

was

fitted. Install

a new

umbrella-

type

seal on

the

valve.

Install the

valve

spring

with

the

b. Cylinder Head Disassembly.

Pull the
oil

closed coil near

the

head,

then install the

valve

spring

drain line

and

clip

out of

the Number 1

retainer,

and sleeve.

Compress the spring,

and

install the

locks

as shown

in fig. 9.

bracket. Remove the

arm

cotter pins at each end of

the

rocker

shaft,

and remove

the flat

washers and

spring washers.
rocker

Remove the plugs

arms, springs,

at each end of

the

shaft.

Slide the

d. Cylinder Head Installation.

Apply a coating 19554-B) to both
brush furnished to
of

and

brackets

off

the shaft. Be sure to

cylinder

head

gasket sealer
gasket

(8A-

identify the
Clean the

parts.
carbon out of

sides

of

the

new

Use the
over

the

combustion chambers

be

spread

the

sealer

evenly

the

fore removing the valves. Compress the valve springs with the tool shown in fig. 9, remove the valve stem locks, and
release

entire gasket surface.

studs on

Position the

gasket over
cylinder

the guide

the

cylinder

block. Lift the

head

over

the

springs.

Remove the sleeve,

valve

spring

re

the guides

and slide

the head down carefully.

tainer,

spring, and valve.

Discard the

umbrella-type valve

Before
threads

installing
bolt

the

cylinder

head

bolts,

coat

the

stem seals.

Identify

all valve parts.

of each

with a small amount of water resist

ant sealer.

Install two bolts

and

at opposite ends of

the head

c.

Cylinder Head Assembly.

Oil
all

to hold the head

gasket

in

position.

Remove the
cylinder

guides, then install the remaining bolts. The

head

moving

parts with engine oil.

Lay

out

the

shaft

bolt tightening
steps.

procedure
cylinder

is

performed

in

progressive

and rocker mechanism parts as shown

in fig. 10. Install

After the
the

head is

flat washer, spring washer,

side

another

flat washer, plug

the shaft.

bolts, in

sequence shown

installed, tighten the in fig. 11, to 55 foot-pounds

and

(cup
peen

out),
an

and a cotter pin

in

one end of

torque (cold). Repeat the operation,

tighten the bolts

The plug is
the

interference fit in the shaft;

however, do not
order
shown

to 65 foot-pounds torque (cold). Remove the cylinder

plug.

Install the

parts

in the

in

head
their

holding fixture brackets. Install

proper

the

push rods

in

fig. 10.
Install
each valve

location. Position the

oil

valve rocker arm as

in the

port

from

which

it

was

re-

sembly, install the

drain line, clip,

and

retaining

screw

ROCKER ARM
FLAT WASHER

MOUNTING BRACKET

COVER RETAINING STUD

FLAT WASHER

/OOO
COTTER PIN

jpwpp
SPRING
yO

mmm

%YYYYYYlft
30 V
SPRING WASHER
1265
PLUG

SPRING
WASHER PLUG

ROCKER SHAFT

FRONT

Fig.

70 Rocker Mechanism Disassembled

32

Chapter

II6-Cylinder

223 Cubic Inch (EBP) Engines

hose. Install

21

(?)

CO

00

wiper

dip

stick.

Connect the
system.

battery

cable

If

to the head. Fill the cooling

Remove the tape

the choke
wire.

from the

carburetor air

horn, then

connect

ik@oo@oo@oo@oovoo^
1225

Start the
at

it for approximately 30 minutes 1200 r.p.m., then check for coolant or gas leakage past
engine and run
warmed

the cylinder head gaskets. With the engine tighten the cylinder head

up,

Fig. ]
on

7 Cylinder

Head Bolt

Tightening
the

Sequence line
enters
on

bolts, in

proper

sequence, to

75

foot-pounds torque (hot). Check the

engine

valve

lash

with

the

the Number 1

bracket,

make sure

oil

idling

after

the

engine

is thoroughly

warmed.

the shaft

locating

hole. Position the

oil

feed line

the

NOTE: After

the

cylinder

head bolts have been

Number 6 bracket, install the bolt, then tighten all the retaining bolts to 45-55 foot-pounds torque. Perform a
preliminary Install the
spark plugs.
valve

tightened to specifications,

additional

tightening is

not

lash

necessary Coat

and

the

bolts
the

should not

be disturbed.

setting.

manifold

assembly, the ignition coil, and

spark

one side of

valve chamber cover gasket with

Connect the
wire,

plug wires, temperature

oil resistant rubber

cement,

and

lay

the cemented

side of

sending
nect

unit

and oil pressure

sending

unit wire.

Con

the gasket in

place

in the

cover.

Install the

valve cham

the

upper radiator

hose. Install the

lines
and

accelerator rod.
on

Position the two

vacuum

fuel line

the engine,

ber cover, making sure that the gasket seats evenly all around the head. Install and tighten the retaining nuts to
2-5 foot-pounds torque. Be
place
sure

then connect the lines. Install the distributor cap. Connect the high tension lead to the coil. Connect the
windshield

the

rubber washers are

in

in the

cover.

4.

OIL PAN, OIL PUMP, AND PRESSURE RELIEF VALVE

removal
and

Procedures for the

installation

of

the

coolant

leaks.

above components are presented

below.

b. Oil
a.

Oil Pan. (1)

REMOVAL. Drain the
Drain the
coolant crankcase.

Pump

and

Pressure Relief Valve.

mounted

gear-type oil
with

pump is

inside the
hex drive

crankcase

Remove the

oil

in line

the distributor.

dip
the

stick.

from the

engine and radiator.

Disconnect the
engine

upper radiator
support of

hose

at

the

engine.

Remove
steady

The pump is driven shaft is pinned in the

by

means of a

shaft.

The

end of

the distributor drive

shaft oil

front

bolts. Remove the

engine

by

a roll

pin,

and

the

other end seats

in the

end of

the

rest.

Raise the front

the left
and

the

engine about two

inches. Re
Block

move

right

engine

front

splash aprons.

pump drive rated in the

shaft.

The

pressure relief valve

is incorpo

the engine

and

lower the

engine on

the block.

oil pump housing. 1 ( ) REMOVAL. Drain the oil

and remove

the

oil pan.

Remove the flywheel housing inspection cover. Remove

the
oil

Remove the two nuts

to the
cylinder

pan

retaining

screws

and

remove

the

pan

and

lockwashers retaining the pump block. Remove the pump and gasket
and
screen

gasket.

(2)
INSTALLATION. Make
clean and sure

DISASSEMBLY. Remove the

screen

assembly

(2)
of

the gasket

surface

retaining screws, the

move

assembly,

and

gasket.

Re

the block is

free from burrs. Coat the block

in

the

cover

retaining screws, cover,

shaft and

and gasket.

Push

surface and oil pan gasket surface with sealer and position

the pump drive

drive

gear

assembly from the

the gasket

on

the

oil

pan, hold the

a

pan

place against

pump housing. Remove the driven

pressure relief valve

gear.

Remove the

oil

the the

block,
pan.

and

install

screw, finger

tight,

at each end of

plug, spring, and

plunger. and
and

screws

Install the remaining screws, then tighten the from the center outward in each direction to 12-15

Remove the snap wire retaining the pump screen, remove the screen from the housing. The oil pump
screen are shown

foot-pounds torque.

dissambled in fig. 12.

groove on

Install the flywheel

the
engine

housing inspection
Install the
of

cover.

Install
engine

steady

rest.

right and

left

(3 ) ASSEMBLY. Place the snap ring on the the upper end of the lower drive shaft Slide the drive gear
and shaft

front

splash aprons.

Raise the front

engine.

the engine, remove

engine

assembly into the housing.

then

the blocks then lower the

support

Install the

front

Position the Plastigage

the

gasket on

the

housing,
of

lay

a piece of

bolts.
upper radiator

directly

over

the face

the

gear and

install
on

Connect the

hose. Install the

cocks.

dip

stick.

cover.

Remove the

cover and note

the reading
-

the

Close the

radiator and engine

drain

Fill the

radiator

Plastigage. The
A
clearance of

gear end
-

with coolant and

the

crankcase with

the

proper grade and

0.0015

play may be 0.0015 0.0055 inch. 0.003 inch, however, is preferred.

quantity

of engine oil.

Run the

engine until normal operat

An

alternate method of

checking

gear end

play is

as

ing

temperature has

been

reached and check

for

oil and

follows:

Section
Position the
edge across
gear end

4 Oil

Pan, Oil Pump,

and

Pressure Relief Valve

33

gasket on

the gasket

housing, and lay a straight directly over the gear. Check the
the

GASKET

play

gear and

placing the tip of a dial indicator on the moving the gear back and forth, between the

by

NUT

SCREW

LOCKWASHER

housing

and straightedge.

Subtract 0.0005 inch from the

of

HOUSING PLUG SPRING

DRIVING GEAR

reading to allow for the compression Install the pump driven gear, the
the cover plate, and the retaining
screws

the

gasket.

cover plate

gasket,

screws.

Tighten the

to 12-15 foot-pounds torque.

pressure relief valve

Install the
plug.

plunger, spring,

and

Tighten the plug to 33-38 foot-pounds torque.

screen

Install the
the snap

in the

screen cover and secure

it

with

DRIVEN GEAR

wire.

bly,

and

Install the gasket, screen and cover assem retaining screws. Tighten the screws to 10-12
torque. Rotate the pump
shaft

COVER

COVER

GASKET

foot-pounds
make sure

by

hand to
the

SCREW

STRAINER GASKET

it turns freely.
Place
a new gasket on

(4) INSTALLATION.
taining bolts,
retaining
slide

re

SCREW
over

the pump mounting flange

the
STRAINER HOUSING

bolts,

and

install the lockwashers

Fill the
oil.

and

nuts.

Tighten the

nuts

to 30-35 foot-pounds torque.

crankcase with

Install the
grade and

oil pan.

the

proper

SCREEN
SNAP WIRE

quantity

of

6331

Run the engine,

whether or not

and check oil pressure

to determine

the pump is operating

properly.

Fig.

12 Oil PumpDisassembled

5.
The
the

CRANKSHAFT DAMPER, CYLINDER FRONT COVER, AND OIL SEAL

removal and

installation

procedures applicable

to

retained with a capscrew and washer. are provided

Two threaded holes

removal.

above components are presented

below.

in the damper to facilitate its

a.

Crankshaft Damper.
The damper (fig.

(1)
to the crankshaft and

REMOVAL. Remove the

radiator.

Remove the

generator

13) is keyed

belt. Remove the retaining bolt and washer from the end of the crankshaft Install the tool shown in

fig. 14,
VIBRATION DAMPER

and pull

the damper from the

crankshaft

TIMING POINTER

TIMING MARKS

(2)

INSTALLATION. Lubricate the

crankshaft with

Too/T52L-63J6-FEE

CYLINDER FRONT COVER

RETAINING SCREW

6122

Fig.

73 Vibration

Damper

Fig.

14 Damper

Removing

Tool

34

Chapter
lead

II 6-Cylinder

223 Cubic Inch (EBP) Engines

the front end
the oil
pan

an oil and white seal

mixture and

lubricate the damper

key-

of

to the

cover and

loosen the
retaining
the old

rubbing
with

surface with grease.

Align the damper

start

remaining

screws

slightly.

Remove the

cover

way
on

the

key on
and

the crankshaft, and

the damper

screws, the cover,

and

the

gasket.

the

shaft.

Press the damper on the

retaining

shaft

(fig. 15). In

(2) OIL
cover.
with

SEAL REPLACEMENT. Drive

punch, then
clean out

out

stall

the washer

bolt,

and

tighten the bolt to

seal with a pin

the recess

in the
it is
the

85-95 foot-pounds torque. Install the

just the belt tension. Install the

generator

belt. Ad

Coat

a new seal with

grease, then install the seal

seal

radiator.

the tool
seated

shown

in fig. 16. Drive the

Check the

in

until

fully

in the

recess.

seal

to be

sure

b. Cylinder Front Cover

The
engine

and

Oil Seal.
cylinder

spring did

not come out

during

the installation.
surface
and

(3)
block
place

INSTALLATION.

Coat the block

front

cover

is fastened to the
to the
oil pan

cover with

sealer, then position a

cylinder

new gasket on

the

block,
re

by

ten hex-head

screws and

by

two

screws.

the cover on the

screws.

block,

and

install the

Two dowels

are used

to locate the

cover on

the block.

taining

Tighten the

screws

to 6-9

foot-pounds
Install the
cover and center

The ignition timing

pointer

is

torque. Install the damper. Install the

welded

radiator.

to the cover.

two screws that fasten the tighten

all cover screws

oil pan

to the front

(1) REMOVAL. Remove the

crankshaft

radiator.

Remove the
that fasten

evenly working from the

damper. Remove the two

screws

outward

in

each

direction.

Tool

T52L-6700-Bee

Tool T521-6306- AEE

CYLINDER FRONT COVER

1232

6389

Fig. 1 5 Damper Installation

Fig.

76 Oil

Seal Installation

6.

CAMSHAFT

SPROCKET, CAMSHAFT, AND BEARINGS

radiator, crankshaft

The camshaft, supported by four bearings pressed into the block, is driven by a sprocket and timing chain in
mesh with a sprocket on

damper,
Before

and cylinder

front
the

cover. camshaft

(1)

REMOVAL.

removing
align

the

crankshaft

An

eccentric on
camshaft a

the

camshaft

operates

the

fuel

pump.

The

sprocket, it is advisable to shown in fig. 18.

the

timing

marks

as

sprocket, keyed to the camshaft, is retained

washer.

by

bolt

and

Remove the
washer.

camshaft

sprocket

retaining bolt

and

Camshaft thrust is
the block. The

controlled

by

a spacer and a

Slide the

camshaft

sprocket,
until

timing chain,

and

thrust plate behind the sprocket, the plate is bolted to the

crankshaft sprocket
comes off camshaft.

forward

the camshaft sprocket

front

of

plate

is located between the

the
camshaft.

cam

the camshaft. Do not

lose the

key

from the

shaft sprocket and

the

shoulder on

The
If the
able.

removal and

installation
the engine

procedures given

below

are applicable when

engine

is installed in the
any

vehicle.

(2 ) INSTALLATION. Place the timing chain over the crankshaft sprocket, and insert the camshaft sprocket in
the

is removed,

eliminate

steps not applic

timing

chain so

the

The

camshaft and related parts are shown

in fig. 17.

properly

positioned

both sprockets are (fig. 18). Align the key in the cam

timing

marks of

shaft with

a.

Camshaft Sprocket
To
make

and

Timing

Chain.
the

the camshaft sprocket

position.

keyway,

and slide the

assembly into
washer and

the

sprocket and chain

accessible,

remove

Recheck the timing. Install the retaining bolt. Tighten the bolt to 45-50 foot-

Section

6 Camshaft

Sprocket, Camshaft,

and

Bearings

35

BEARING (FRONT
DRIVE CHAIN
REAR BEARING,

CAMSHAFT

LOCKWASHER

SCREW

6298
DRILL % INCH HOLE IN PLUG

CYLINDER BLOCK

Fig.
pounds

17 Camshaft and

Related Parts
Fig.
19 Camshaft

CORE PLUGS

6388

torque.
cylinder

Bore

Plug
pull

Removal

Install the
radiator.

front cover,

crankshaft

damper, and
position

it front

end

up,

and

the tappets away

from

the the

camshaft oil pan

to

facilitate

camshaft removal.

Be

b. Camshaft.
Camshaft
worn
replacement

sure

is

either

drained

or removed

before

to

such an extent

is necessary when the lobes are that cam lift intake and exhaust is
is encountered, mating be replaced. Check push rods for
wear

inverting

engine.

less than 0.242 inch. If lobe

tappet
or

Remove the distributor. Remove the fuel

move

pump.

Re

the

camshaft sprocket and

tappets

must

timing

chain.

Remove

straightness

(1)

before replacing camshaft for lobe wear. REMOVAL. Remove the radiator. Remove the
damper
and

the screws retaining the thrust plate and remove the thrust
plate and spacer.

crankshaft

the

cylinder

front

cover.

Remove

Remove the
camshaft

camshaft
with

carefully to
cam

avoid

damaging

the

the rocker
move

arm cover and

the

valve push rod cover. and all push rods.

Re

bearings

the

lobes.
camshaft

the

rocker arm

assembly

Lift the
re

(2) INSTALLATION.
cure

Slide the

carefully

tappets

and

hold them

with window regulator

spring

into the bearings. Install the thrust

the thrust plate
with

plate and spacer.

screws.

Se

tainers (bend the

or

closed end

approximately 30

degrees)
stand,

the retaining

Tighten
cam

spring

clothes pins.

the

screws

to 12-15 foot-pounds torque. Check the

shaft end play.

If the

end

NOTE:

//

the

engine

is

play is excessive,

replace

the

mounted

on

work

thrust plate if it is

worn.

Check the thickness

at

of

the

spacer

if the thrust
CAMSHAFT SPROCKET TIMING MARK

plate

is

not

fault. Install the

camshaft

12 PINS BETWEEN MARKS

sprocket,
er.

timing

chain, front cover, and crankshaft

damp

Install the

generator
and

belt

and adjust
push

belt tension. Re
rods, then install

lease the tappets

the

install the

rocker arm assembly.

and adjust

Install the distributor

stall

the initial timing. In

chamber cover with

the fuel

pump.

Install the tappet

a new gasket cemented

to the cover, and tighten the re

taining

screws

to

15-20 inch-pounds torque. Check the

Adapter

Tool T 521-626 1

-CEE,

DRIVING

'SIDE

OF CHAIN

CRANKSHAFT SPROCKET TIMING MARK 1244

1246

Fig.

18

Aligning Timing Marks

Fig.

20 Camshaft Bearings Removal or

Installation

36

Chapter

II6-Cylinder

223 Cubic Inch (EBP) Engines

c.

Camshaft
Replace

Bearing

Replacement.
clearance

camshaft

bearings if the

exceeds

0.005 inch.

It

will

be necessary to
to

remove

the engine from the

ve

hicle to

replace camshaft size

bearings. The bearings

and

are avail

able pre-finished size

for standard
bearings.

0.015 inch
not

under

journal diameters. Number 3

the
other

bearing is

inter

changeable with

( 1 ) REMOVAL.

Remove the

camshaft.

Drill

Vz inch

hole in the plug at the rear camshaft the tool shown in fig. 19 to remove the
ToolT52L-6266~BGD I
CYLINDER BLOCK CORE PLUGS
camshaft

bearing bore. Use

plug.

Remove the

bearings

with

the tool

shown

in fig. 20.

(2) INSTALLATION. Position the bearing at the bearing bore, and press it in place with the tool shown in fig. 20. No. 1 cam bearing must be pressed in 0.005 0.025 inch below the front face of the bearing bore. Press the
-

1271

remaining bearings in sufficiently to holes.

align

the

oil

supply

Fig.
valve

21 Camshaft

Bore

Plug Installation

Clean

out

the plug recess in the camshaft

rim of a

rear

bore.
sealer

Coat the

outer

new

plug

lightly
the

with

lash (hot). Install the if necessary,

and

rocker arm cover with a new

gasket
pounds

tighten the nuts to 2.0-2.5 foot

radiator.

(8A-19554-A). Install the plug in fig. 21.

Install the
camshaft.

with

tool

shown

torque. Install the

7.
The

FLYWHEEL, CRANKSHAFT, AND BEARINGS

in fig. 22.
the flywheel housing. Mark the
clutch

crankshaft and related parts are shown

assembly

so

it

can

be
a.

replaced

in the

same

position,

and remove

the retaining

Flywheel.
Flywheels

screws.

Remove the

clutch

assembly through the flywheel

and

having

burned

or scored surface should

be

housing lower
pull
wheel

opening.
off

Remove the flywheel bolts

crankshaft.

replaced.

the flywheel
through the

the

Remove the

fly

(1)

REMOVAL. Remove the transmission. Remove

housing

lower

access opening.

CRANKSHAFT SPROCKET 6306

REAR OIL SEAL-6701.

FRONT OIL SEAL-6700

WASHER 6378

LOCKWASHER 34846-S
SCREW

6379

SCREW 20655-S
DAMPER 6316

BEARING INSERT (FRONT AND INT.)-6333

THRUST BEARING

/REAR

INSERT-6342

BEARING 'NSERT-6331

flr-T-REAR
__J

\yj

OIL SEAL-6701
REAR MAIN BEARING CAP

CLUTCH PILOT
BEARING 7600

LOCKWASHER-

34849-S FRONT AND INT.

SCREW-

6345

-A

BEARING CAP

BEARING CAP OIL SEALS-6336

FLYWHEEL ASSEMBLY-6375

1350

Fig.

22 Crankshaft and

Related Parts

Section

Flywheel, Crankshaft,
on

and

Bearings

37

(2) INSTALLATION.
crankshaft
en

Position the flywheel

the

Use the Plastigage

method

to

check

connecting

rod

bear

flange, then install the mounting screws. Tight

in
sequence across

ings. Install the connecting

rods and

bearing

caps.

the

screws

from

each other

to 75-85

Install the
the
and
clutch

engine rear plate. compress

Install the flywheel. Align

springs,

foot-pounds torque. Position the

plate on

clutch

disc

and pressure and

disc,

the

clutch pressure plate

assembly.

the

flywheel,

align

the

clutch

disc

install

install the

pressure

plate

Install the

fly

the

clutch

assembly retaining

screws.

Install the flywheel

wheel

housing. Install the

sprocket, the

starter motor.

Install the

crank

housing. Install the transmission.

shaft
chain.

camshaft
cover.

sprocket, and the

timing

Install the front

in the

Install the damper. Install

b. Crankshaft.
is precision-molded, alloy iron with in tegral counterweights and is statically and dynamically
crankshaft

the

engine

vehicle.

The

c.

Main Bearings.
Steel-backed,
copper-lead-insert

type bearings are

used

balanced. Oil distribution holes

shaft

are

drilled through the

connecting
rod

to

support

the

crankshaft.

Use the Plastigage

method

to

to

pressure

lubricate the

main and

check

bearings.
NOTE:

bearing

fit.
end

Crankshaft
Do
not

play is

controlled

by

the No. 3

main

drop
not

the

crankshaft when

handling.
to

bearing flanges.
If the
can
crankshaft

The
in

precision-molded

iron shaft,

when not supported

resist

has been removed, the

bearing inserts
can

bearings, does
loads
and

have

sufficient strength

be easily

replaced.

However,
the

the inserts

be

re

shock

may

crack when

dropped only

a short

moved and replaced with without

engine as

in the

chassis and

distance.

removing the crankshaft,

follows:

(1)
on a

REMOVAL. Remove the

stand.

engine

and

install it
clutch clutch

Remove the bearing cap, then insert the upper bearing insert removal tool in the oil hole in the crankshaft (fig.
23). When the
posite crankshaft

work

Remove the flywheel

and engine rear plate.
so

housing,
Mark the

is

rotated
will

assembly, starter,
pressure plate

to

engine

rotation, the tool

should

in the direction op force out the bearing

assembly

it

can

be

reinstalled

in the

insert. This tool

be

used with caution to avoid

same position on

the flywheel. Remove the flywheel. Re

damaging the bearing.

To install the
end of
of upper main

move

the

damper, front
Remove the

cover,

camshaft

sprocket,

and

timing

chain.

oil pan and

the

oil

pump

screen

housing

assembly.

the

bearing over the shaft. Using the same tool,

the

bearing insert, place the plain shaft on the locking tang side
rotate

the crankshaft in

Make

sure all

bearing
original

caps are marked so

they

can

be

the direction

of engine rotation until

the

bearing

seats

installed in their
rod

locations. Remove

all connect main

itself.
MAIN BEARING INSERT

ing bearing caps and bearings. If the same bearings bearing installed, identify all bearings so they can be
caps
and

bearings. Remove the

are

to be

installed

in their

original

locations. Remove the

sure

crankshaft.

bearing inserts, bores, and the crankshaft journals are clean. Apply a light coat of engine oil to the journals and bearing inserts. In stall the inserts in the block. Carefully lower the crank
that
all

(2 ) INSTALLATION. Be

shaft

into the bearings. Be

careful

not

to damage the
method

thrust
check

bearing
main

surfaces.

Use the Plastigage

Install
the
all

to

bearings.
and

main

bearing

cap

inserts in the caps,

except

install
cap.

the caps in the block

CRANKSHAFT JOURNAL Tool-6331 1046

Tighten the cap bolts to 95-105 foot-pounds torque. Install the thrust bearing cap,
the thrust

bearing

Fig.

23 Main

Bearing

Insert Removal

then

align

the thrust

bearing

using the

specified procedure.

8.
The
piston and

CONNECTING RODS,
rod are shown

PISTONS, PINS, AND RINGS

a

connecting

disassambled

piston,

remove

any ridge

at

the

top

of

the cylinder bore

in fig. 24.

caused

by

piston

ring

wear. rod

a.

Piston

and

Connecting

Rod Removal.
head. Before removing

Remove the connecting

cap
out
off

lock

nuts and nuts.

Pull the

the rod, then push the connecting rod

and piston

Remove the

oil pan and cylinder

the

top

of

the cylinder.

38

Chapter

II 6-Cylinder

223 Cubic Inch (EBP) Engines

OIL RING

PAL NUT

ASSEMBLY

SPRING SPACER

CONNECTING ROD CAP

STEEL RAILS
24 Piston and

PRESSURE RINGS

6385

Fig.
CAUTION: Do
not
scratch

Connecting
the c.

Rod Disassembled

the

crankpin

or

Assembly.
Lubricate
all parts with

cylinder wall when

removing the

piston and rod.

light

engine oil.

b. Disassembly.
Mark the
the bore
pistons

NOTE: Assemble the

the
of
oil squirt

piston and

connecting

rod with shown

hole in

the rod positioned as

in

for identification

the piston

with

fig. 27.
Position the connecting
rod

and rod

for assembling
rings

purposes.

in the

piston and push

the

Remove the
Remove the
out of

piston

with

the tool

shown

in fig. 25.
pin

pin

into

place. new piston pin retainers

piston pin

retaining clips,

and

drive the

Insert
the

by

spiraling them into

to install

the

piston and rod

(fig. 26).
after

piston with

the fingers. Do

not use pliers

Remove the

bearing

inserts

identifying the inserts

cap if the inserts

retainers.

for reassembly with the are to be used again.

same rod and

Install the
position

oil

ring spring

spacer

in the

oil

ring

groove,

the gap in line

with either piston pin

boss. Spiral
the
oil

the

steel rail

ring

segment

into the

upper side of

NOTE: 1
to

Each

rod and

bearing

cap is

numbered

from The
the

ring

groove, position the gap approximately 1 inch to the the spring spacer gap.
support steel

right side of
engine.

6 from the front to the

the
rod and

rear end

of the

numbers on

bearing
is
ever

cap

must

be

on

NOTE:

Firmly
of the

the spring spacer

during

in

same side when

installed in their

respective cylinder

stallation

rails,

being

sure

that the spring

bores. block
and

If a connecting rod
or cylinder

transposed

from

one

to another, the

bearings

must

fitted,

the

rod must

be

numbered

to correspond with the

new cylinder number.

Piston Pin Remover

EXPAND RING BY CATCHING TIPS OF TOOL IN RING ENDS

1272

6386

Fig.

25

Removing

Rings

Fig.

26 Piston

Pin Removal

Section
spacer

Connecting Rods, Pistons, Pins,

ends must

and

Rings

39

ring

ends are not overlapped.

as

These

tigage

method. sure

Oil the

cylinder wall with

light

engine oil.

be butted together
compressed

this permits the spacer to

be

Make

the ring

gaps are
piston.

properly

spaced around

the

during

installation of

the steel rails.

circumference of

the

Compress the rings

piston

with a

Spiral the remaining steel oil ring segment into posi tion at the lower side of the oil ring groove. Position the
gap approximately 1 inch to the left
spacer gap.
side of

compressing tool,

and push

the

in

with a

hammer
of

handle (fig.
cylinder.

28)

until

it is slightly below the top

the

the spring

NOTE:
oil

Install

the

piston with

the indentation in the

engine.

NOTE: Flex the

ring assembly in its

with

groove
sure

by
the

piston

head

toward the

front of the

compressing the ring

the

the

fingers

to

be

that

ring

segments are

free

prior to

installation in

Turn the
Oil the
until

crankshaft

throw to the bottom of its the

piston all

stroke.

cylinder

bores.
compression

crankpin and push

the way down

Install the lower

with

the rod

ring into its

bearing
nuts
and

seats on

the

crankpin.

Install the
and

groove

the inside counterbore toward the

bearing
new

cap (line up the

stamped

numbers),

tighten

top

of

the piston.

Position the gap to the spark plug side of the cylinder bore. Install the upper compression ring with the word
"TOP"

the retaining
pal

to 45-50 foot-pounds torque. Install

tighten them to 3-3
plus

nuts,

Viz foot-pounds

torque (or finger tight

1/3 turn).

toward the

top

of

the

piston.

Position the gap

side of

to the

side or opposite

the

spark

plug

the

Install the
case with

oil pan and cylinder

head. Fill the it

crank

cylin

der bore.
Install the

the

proper grade and amount of

lubricant Fill
at

bearing halves in

the rod and cap.

the cooling system. Start the

speed.

engine and run

idle

Make

sure

there is
to

sufficient oil pressure. sure

Check
not

d. Installation.
Check the connecting
rod

the

temperature

make

the

engine

does

overheat.

bearing fit

using the

Plas-

INSTALL PISTON WITH INDENTATION TOWARD

TIGHTEN COMPRESSOR

Tool

FLM

FRONT OF ENGINE

SECURELY

6749

POSITION OIL SQUIRT HOLE TO RIGHT WITH PISTON DOT FORWARD

6387

INSTALL RING COMPRESSOR WITH RETAINER TOWARD SKIRT 1259

Fig.

27 Correct

Position

of

Oil Squirt Hole

Fig.

28 Piston

Installation

9.
The
a
exhaust system on

EXHAUST SYSTEM
of

the 6-cylinder car consists

a.

Muffler Replacement.
Extra heavy, double-wall
construction mufflers
are

muffler,

an exhaust outlet

pipe,

and a muffler

inlet

pipe

(fig. 29).

available

for

service.

The following

procedures cover

the replacement of the

(1)

REMOVAL. Loosen the

Slide the
and

muffler

inlet

and outlet
on

exhaust system components.

pipe clamps.

clamps

away from the muffler,

the inlet pipe,

the

outlet pipe.

Loosen front
to the rear.

and rear

NOTE:

After

replacing
to

any

part all

of

the

exhaust

outlet pipe

hangers

and

disengage the
outlet pipe

outlet pipe

system, it is

advisable

loosen

the

frame attaching

from

the

muffler muffler

by

sliding the

Remove
the

bracket

clamps

to relieve twists in the system and then

the

from the inlet

pipe. muffler clamps on

retighten

the clamps.

(2 ) INSTALLATION. Place the

40
inlet
on

Chapter

II6-Cylinder

223 Cubic Inch (EBP) Engines

bracket clamp
clamp
tighten the nut. Position
rear

and outlet

pipes,

respectively.

Position the

muffler

front
the
en

support

and

the inlet

pipe and slide

the

outlet pipe

into the
in

muffler. position

rear outlet pipe

nut.

on

the

bracket

and

tight

Place the inlet

on

pipe and outlet pipe clamps

the

the

muffler and

tighten the clamps. Tighten the front

and rear outlet pipe

hangers.

c.

Inlet Pipe Replacement.

The
muffler

b. Outlet Pipe Replacement.

The
sound
outlet pipe

inlet

pipe

is designed to

give

the

exhaust

gases

leaving
of

the

exhaust manifolds a

direct through
over-all

pas
effi

is

attached

to the frame

by flexible
prevent

sage

to the muffler,
the

thereby increasing the

muffler

deadening

materials which not

only

the

ciency

exhaust system.

exhaust noises

from

being

conducted through the chassis

(1)

REMOVAL. Loosen the

nuts

inlet

pipe clamp.
exhaust

frame but
or

also relieve
stresses.

the exhaust system from

twisting
clamp,

Remove the two

holding the inlet pipe to the

bending

manifold, then remove the gasket.

muffler outlet pipe
pipe

Disengage the inlet in the

(1)
front
pipe

REMOVAL. Loosen the

clamp
on

from the

muffler

by sliding the inlet pipe forward.

pipe
muf
exhaust outlet

leaving the

the muffler. Remove the

outlet pipe
outlet

(2 ) INSTALLATION. Place the inlet

fler. Install
studs.

and rear support clamps and

disengage the

new

gasket on the
pipe

flange
secure

from the

muffler.

Slide the inlet

flange

over

the studs and

(2)

INSTALLATION. Position the

tighten the
clamp.

outlet pipe

in the

the pipe to the

exhaust manifold with

the two

nuts and

muffler and

Place the

outlet pipe rear

lockwashers.

Tighten the
muffler

nuts

to

23-28

foot-pounds

support

bracket clamp

on

the outlet pipe. Install the

torque. Tighten the

inlet

pipe clamp.

34846-S 33798-S
;'';&.

aa&feat.

MUFFLER OUTLET
PIPE5255

23438-S
5270

SUPPORT

55260

He

34846-S

33*&->^^
33797-S

~^5265^
^34846-S

^*N^[ X
\"''
..-'///

'

/ V 'W/*.^ J
-t5^S^V

^^^
:

/
.

v*-*r^t7 ::

'**'/''''

SCREW

^
MUFFLER5230

ill ^V
SUPPORT5261

39935-S

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

*fg&.

MUFFLERINLET PIPE-.

CLAMP5260

34846-S 33797-S
1822

Fig.

29 Exhaust System 6-Cylinder

Engine

SERVICE
Letter No.

LETTER
Subject

REFERENCE
Changes Information on Page No.

Date

Part ONE

POWER PLANT
Chapter

8-Cylinder 272 (ECG

and

ECH)

and

292

(ECJ
Section

and

Interceptor) Cubic Inch Engines

Page

Manifolds
Cylinder Heads
Oil Pan
and
and

42
Valves
and

2
3

44
Pressure Relief Valve
and

Oil

Pump

46
47 48

4 5
6

Crankshaft Damper, Pulley,

Cylinder

Front Cover
and

Timing Chain, Sprockets, Camshaft, Tappets,

Flywheel, Crankshaft,
and

Bearings

Bearings
and

51
Rings

7
8

Connecting Rods, Pistons, Pins,

Exhaust System

53

55

The 8-cylinder, 272

used

cubic

inch
a a

engine
of

(fig. 1

and

2)

models

have

bore

of

3.75 inches

and a stroke of

3.30
com-

in the

passenger car,

has

bore 7.6:1

3.62 inches

and

inches. The

police

interceptor

engine

has

7.6:1

a stroke of

3.30 inches. It has

cubic

compression ratio.

pression ratio. or

The
or

ECJ

engine

has

an

8.1:1 (Standard

The 8-cylinder, 292

police

inch

engine

is

used

in the

Overdrive)
Repair

8.5:1

(Fordomatic)

compression ratio.

interceptor

unit and

the

ECJ

version of

the engine
engine

and maintenance procedures

for these

engines

is

used

in the Thunderbird (figs. 3

and

4). Both

are

same unless otherwise noted.

mmmmmmmmmm

6324

6325

Fig. 1

9A Front

View 272

Cubic Inch Engine

Fig. 2% Rear

View 272

Cubic inch Engine

41

42

Chapter

III 8-Cylinder

272 (ECG

and

ECH)

and

292 (ECJ

and

Interceptor) Cubic Inch Engines

6326

6327

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

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

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

sage,

rather

than from left to right as in the single exhaust

system.

some

differences

exist

between the

(1) REMOVAL.
cleaner closed).

Drain the

radiator.

Remove the
air

air

(on the two-barrel carburetor, tape the

horn

a.

Intake Manifold.
The intake
manifold

Disconnect the
cylinder

choke control cable

if

so equipped.

is bolted to the
of

heads

and
at

Disconnect the
the

windshield wiper
and

hose,

the vacuum line

the

straddles

the

center portion

the cylinder
choke
on

block. The
engines
so

intake manifold,

the fuel line

at

manifold,

carburetor,

automatic

and at

the carburetor. Remove the vacuum

and remove

fuel pump lines from the

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

fuel pump,

the three lines as

vacuum

an assembly.
at

All

8-cylinder intake
center

manifolds
and

contain

passage

Disconnect the distributor

tor. Disconnect the throttle

line

the distribu

through the through

section

under

the carburetor,
assist

linkage. Remove the throttle

manifold.

which

hot

exhaust gases are

directed to

in

linkage bracket from the intake

vaporizing the
carburetor

incoming fuel charge, thus, stalling and icing is minimized during cold engine opera
diverted into the intake
control valve.

NOTE: On the
pull

Thunderbird,

disconnect the throttle

back

spring.

tion. The

exhaust gases are

mani
of

fold

by

an exhaust

thermostat

Part

the

Disconnect the primary

coil.
vacuum control nect

and

secondary

wires

at

the

exhaust gases

flow from the left-hand

exhaust

manifold,
exhaust

Disconnect the heater inlet hose

line
at

and

the heater

through the heat riser passage, to the right-hand

the

water control valve. and

Discon

manifold,

until

the

thermostatically
the
exhaust

controlled

valve

the

upper radiator

hose

the

water

pump by-pass

opens, allowing
manifold

more of

from the left-hand

assembly

hose. Remove the

manifold

to flow

directly out the

exhaust system

retaining bolts, nuts,

and

four

in the

normal manner. vehicles equipped with a

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

On

dual

exhaust

system, the the

outlet

buretor,
The
gine

and coil as an assembly.

exhaust of

thermostat

control valve

is installed

at

standard manifold used on

shown

the 272 cubic inch

en

the right-hand

exhaust manifold.

Therefore, the exhaust

riser pas

is

in fig. 5.
new

gases

flow from

right

to left through the heat

(2) INSTALLATION. Using

gaskets, install the

Section

1Manifolds

43

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

MANIFOLD

GASKET

holes in the
cylinder

CARBURETOR GASKET

manifold

gaskets

and

manifold

with

the

head tapped holes. Position the

manifold

manifold

clamps,

install the

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

to the ends.
GASKET'

Connect the

upper radiator

hose

and

the

water

pump
and

WATER OUTLET
WASHER

by-pass hose. Connect the heater

vacuum control and

line

the heater inlet hose. Connect the primary

coil wires.

secondary

PLUG
VACUUM CONNECTOR

NOTE:
pull

On the
spring.

Thunderbird,

connect

the

throttle
INTAKE
MANIFOLD

back

Install the throttle linkage bracket

on

the intake
the

mani

MANIFOLD GASKET

fold. Connect the throttle linkage. Connect

vacuum

distributor
6334

line.
windshield wiper

Install the
and

line, intake
as

vacuum an

line,

Fig.

5Standard

Intake

Manifold272

Cubic

the fuel pump to carburetor line the three lines

at

assembly.
over pipe on

Inch Engine
the
manifold studs, and
nuts

Connect

the fuel pump. Connect the

install the retaining

windshield wiper

hose,

then connect the vacuum line to

at

nuts.

Tighten the
inlet

to 23-28 foot-pounds torque. Install

the intake manifold and the fuel line

the

carburetor.

the

muffler

pipe with a new gasket.

Connect the
from the
air

choke control cable and remove the tape

on

horn

two-barrel

carburetors.

Install the

(3)

REMOVALDUAL

EXHAUST SYSTEM. The from the Re

removal procedure

for both exhaust manifolds is the same.

inlet
pipe manifold.

air cleaner.

Fill the

radiator.

Disconnect the
move

muffler

the

b. Exhaust Manifolds.
The
The
exhaust manifolds and crossover pipe

bolts, flat

washers,

spark

plug heat shields, and

the

manifold

(and heat

control valve on

the

right-hand

for the

single

manifold).

exhaust system are shown

in fig. 6.
manifold,
of

(4)
the dual
with a exhaust
over

INSTALLATION

DUAL
surfaces of

EXHAUST
the

SYS
bolt
rear

right-hand exhaust

TEMS. Coat the mating

light film

manifolds with a

equipped

vehicles, is

of standard

design

cap

of graphite grease. cylinder

Start the

manifold rear

the front opening

where

the

crossover pipe

is

attached
mani

into the

head. Hook the

spark

manifold on

the

on single exhaust equipped vehicles.

The left-hand
to the

bolt,

then install the

plug heat shields, washers,

and

fold is

of special

design to

provide an outlet

separate

the remaining
center

bolts. Tighten the

bolts,

working from the

left-hand

exhaust

system.

The heat

control

valve

is

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

located
NOTE:

at

the

rear of

the

right-hand exhaust manifold.

right-hand

manifold, install the heat

control

valve, using

Do

not remove manifolds when

they

are

hot.
re

a new gasket on

both

sides.

Install the

muffler

inlet

pipe

may warp, making assembly sulting in leaks.

They

difficult,

and

with a new gasket.

T THERMOSTAT CONTROL VALVE

(1)
move
valve.

REMOVALSINGLE
crossover pipe

EXHAUST
from both
inlet

SYSTEM.
Re

Disconnect the

manifolds.

the crossover pipe and the manifold heat control

Disconnect the

muffler

pipe

from the

right-

hand heat

manifold.

Remove the

bolts, flat washers, spark plug

EXHAUST
SYS-

shields and manifolds.

(2)

INSTALLATIONSINGLE

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

head. Hook the

spark

manifold on
shields

the rear

bolt,

then install the

washers and

plug heat

and

remaining
MUFFLER INLET PIPE
FLANGE-

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

Install the
manifold

manifold
a

heat

control valve on
on

the

right-hand
Install
one

6339

with

new

gasket

both

sides.

Fig.

6 Exhaust

crossover pipe gasket on

the left

manifold.

Place the

cross-

Manifolds and Crossover Pip* Single Exhaust System

44

Chapter

III 8-Cylinder

272 (ECG

and

ECH)

and

292 (ECJ

and

Interceptor) Cubic Inch Engines

2. CYLINDER HEADS AND VALVES

The
cylinder

head

contains

the valves

and

the

rocker

VALVE SPRING

SLEEVE.

LOCKS

arm mechanism.

OIL SEAL-^

The left

and right-hand cylinder

heads

are

interchange
VALVE SPRING RETAINER

able provided a water outlet

plug

or

temperature sending

unit new

insert is
plug
or

removed

from

one end of the

head

and a

6074

insert is installed in the

to the field
so
will not

other end.

Cylinder

Fig.

8 Valve

Assembly
on

heads
plug
or

serviced

have the
used

water outlet either right

or

insert installed

they

can

be

for

Release the spring tension

the

rocker

arms

by

left-hand installations.

loosening
rear water outlet

the adjusting screws, then

and oil

remove

the

rocker

The plug is installed in the

of

opening
shown

arm

assembly

baffle

plates.

Remove the

valve push

the right-hand

cylinder

head

by
the

using the tool

rods

in

sequence.

Identify

the

push rods so

they

can

be

in fig. 7. The temperature sending

the left-hand
cylinder

unit

insert is installed in

replaced

in their

original positions.

Disconnect the

wire

head

with

same tool.

Be

sure

to

from the

temperature sending unit (left-hand

cylinder

head).
cylinder

apply

light

coat of water resistant sealer

to the sealing

Remove the

head bolts. Install the

surface of

the plug or insert before

installation.
the rotating type
and

head

holding fixtures.
The distributor location head in its
on

The intake
incorporate

and exhaust valves are

umbrella-type valve stem seals

(fig. 8).

NOTE:

the Thunderbird

will not permit

the installation of the rear

holding

fix In

a.

Cylinder Head Removal.

ture

on

the

right-hand

normal position.

stall the

fixture

one

hole forward.
head
off

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

Lift the

cylinder

the block. Do

not

pry be

Remove the

spark plugs.

Remove the intake

tween the head

and

block. Remove the head

gasket.

The

Remove the ignition harness bracket from the

head is

shown mounted

in the

holding fixtures in fig. 9.

right-hand cylinder

head.
right-

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

b. Cylinder Head Disassembly.

Remove the
shaft, then
plugs.
shaft.

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

cotter pins at each end of

the

rocker arm

remove

the

flat washers, spring

arms, springs,
so
and

washers, and
off

Slide the
Be
sure

rocker

brackets
can

the

bracket to

cylinder

head bolt,

remove

the

to

identify the parts

The

they

be installed

generator

front mounting bolt,

way.

and move

the

generator

in their
shown

original positions.

rocker arm mechanism

is

out of

the

disassembled in fig. 10.

carbon out of

Clean the
chamber.

the cylinder head combustion

the tool
shown

Compress the
remove

valve springs with

in fig. 1 1, then

the

valve stem

locks,

and sleeve.

Use

(4) long

intake

manifold

mounting bolts

TEMPERATURE SENDING UNIT

Tool T 531-200- A Tool T53P -33623 -A

(Handle)

(Adapter)

6065

ToolT54L-6085-A (Detail 1

and

2)

6066

Fig.

7 Cylinder

Head Water Outlet

Plug

Installation

Fig.

9 Cylinder

Head

Holding

Fixture Typical

Section

2 Cylinder

Heads

and

Valves

45

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

Remove the

valve.

c.

Cylinder Head Assembly.

Oil
all

moving parts

with engine oil.

Be

sure

the

oil

plugs are

installed in

each end of

the

rocker shaft.

The

plug

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

Install

flat washer, spring washer,

in
one end of

another

and a cotter pin

the

rocker

flat washer, shaft. Install

the parts in the

order shown

in fig. 10.

After grinding grinding seats it is

with a seat. medium

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

Install
moved or
seal.

each valve

in the
was

port

from

which

it

was re

to

which

it

fitted. Install
with

a new valve stem

Install the

valve

spring

the

tightly

wound coil

against

the head. Install the spring retainer.

Using the tool

and

6370

illustrated in fig.

11,

compress

the spring

spring

re

tainer, then install the

sleeve and

the locks.

Fig. 7

Removing

or

Installing Valve Locks

proper

d. Cylinder Head Installation.

Using
position
a new gasket with sealer applied

Install the
to both sides,
the
oil on

push rods

in their

locations. Position
rocker assem

baffle

plates on

the head. Place the

the cylinder head

on

the

engine.

Remove the

bly
end of

the plates, then install the bracket retaining

screws

holding fixture
and

brackets. Install the

cylinder

head

tighten them to
proper
sequence

55 foot-pounds torque
(fig.

bolts, (cold) in

and nuts.

Be

sure

to install the
which
enter

oil

drain tube

on

the

same
end

bracket from

it

was removed.

The bracket

the

12). Repeat the operation,

the tube must

the

locating hole in

the rocker

tightening
NOTE :

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

proper wrench

shaft.

The

to

use

for

each

bolt is in
CAUTION :

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

Be

sure

the rocker shaft support

when

brackets

are not upside

down

the assembly

is installed.
when

force the

socket extension past

There is a 0.020 inch difference in bracket height

reversed.

Fordomatic
socket on

oil

level indicator tube in

order

to get

Tightening
in
a

the screws

with

the

brackets

re

the

bolt head.

versed can result

broken

rocker shaft.

LOCK

NUT-

**o

WASHERS

ADJUSTING SCREW

OIL OUTLET TUBE

SPRING WASHER
COTTER PIN

PLUG

ROCKER SHAFT

6184

Fig.

70 Rocker

Arm

Mechanism Disassembled

46

Chapter

III 8-Cylinder

272 (ECG

and

ECH)

and

292 (ECJ

and

Interceptor) Cubic Inch Engines

RIGHT-HAND AND LEFT-HAND

generator

front mounting bolt, then fasten the

cylinder

generator

bracket to the
cable and the

head. Connect the

battery
the

ground

dipstick bracket.
right-hand cap. on

After installing the

head

on

Thunder

bird, install
cylinder
spark

the distributor

Install the ignition harness bracket head. Install the intake

the

right-hand

manifold.

Install the
exhaust

plugs, then install the heat shields and the

RIGHT-HAND AND

RIGHT-HAND,
LEFT-HAND,

USE

n/i6"

Sockef,

l5/i6"

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

6299

manifold.

USE S-8663-A Wrench

Fill the cooling

reached normal

system and run

the

engine until

it has

operating temperature. Tighten the head

valve

Fig.

12 Cylinder

Head Bolt

Tightening Sequence
screws and nuts

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

lash
on

and adjust rocker

the lash if
arm

necessary.

Cement

a new gasket

Tighten the bracket retaining foot-pounds torque.

Make
a

to 12-15

the

cover

if necessary, then install the

nuts

cover.
adjustment

Tighten the

cover

to 2.0-2.5

foot-pounds

preliminary

valve

lash

Connect

torque.

the temperature sending

unit wire

(left-hand head).
ex

NOTE:

After

the

cylinder

head

bolts

have

been

After
cept

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

tightened to specifications, no

additional

tightening is

the

necessary

and

the

bolts

should not

be disturbed.

3. OIL PAN AND OIL PUMP AND PRESSURE RELIEF VALVE

The
hand
ate
oil

pump is externally
the engine,

mounted on

the lower leftan

Remove the
the
oil

nut

securing the
the
oil

oil

pump inlet tube to

screen and

corner of

and

is driven

by

intermedi
shaft.

pan, then

remove

pump

inlet

shaft

which

fits in the distributor drive

tube to
pick

The
oil

tube assembly from the oil pan.

pump
pan

uses a one piece

oil

up the

oil

from the

(2)
taining

INSTALLATION. Coat the

nut with oil
resistant

screen

assembly

re

(fig. 13). The

inlet

screen and cover

assembly is

sealer, install the

copper

attached to the oil

pan

by

a nut.

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

the

a.

Oil Pan.
The
oil pan

nut
sealed

to 10-12 foot-pounds torque. Coat both

sides of a new

is

to the cylinder block and

front
pan

pan gasket with sealer.

Position the
the

gasket on
and

the

oil

pan,
of

cylinder cover

by

a one-piece cork

gasket,

and

the

hold the

pan

in

place against

block,

install two

is

retained

by

18 cap screws, 2

nuts on studs at

the rear,

the retaining screws on each

side of

the

pan.

Install the
cen

and

nuts and

bolts

at

the

front.
crankcase.
on

remaining screws,

and

tighten the screws, from the

(1)
engine

REMOVAL. Drain the

front
splash pans
oil

Remove the
Re

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

(except

the Thunderbird).
the
oil pump.

Using
the

a new

seal, connect the oil pump

oil

inlet tube to

Disconnect the
move

pump inlet tube

at

the

oil pan

retaining

screws and remove must

the

oil pan.

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

Tighten the

tube to

oil

NOTE:

No, 1
the
oil

cylinder

be

on

top dead

(except
center

on

the Thunderbird). Fill the

crankcase

with

before

pan

can

be

the

proper grade and

removed.

quantity

of

lubricant.

b. Oil
A

Pump

and

Pressure Relief Valve.

to supply
pressure
oil

gear-type

pump is

used

to the

engine

lubrication
mounted

system.

The

oil

relief

valve

is
an

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

by

(1) REMOVAL.
the pump, and

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

three cap screws and lock

securing the pump

the

body

to the block. Remove the pump

6383
mediate shaft

and gasket and

pump.

the inter

if it

comes out with

Fig.

13 Oil

Inlet Tube272 Cubic Inch Engine

Pump

and

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

Section
Do

3 Oil

Pan

and

Oil

Pump and Pressure

Relief Valve

47

cover plate and gasket.

not

tap

the pump drive

shaft

GASKET

to drive the pump

GASKET
oil C

cover off

the pump body. Remove the

and oil

gear and shaft

assembly

pump idler

gear.
and

DRIVEN

Remove the
plunger.

oil pressure relief

plug, gasket, spring,

the
oil

INTERMEDIATE SHAFT

DRIVING

GEAR

GEAR HOUSING

A disassembled

view of

pump is

COVER
"O"

shown

SCREW

in fig. 14,

PLUNGER-WI

RING SEAL

(3) ASSEMBLY.
and gasket.
and shaft

Oil

all parts

thoroughly. Install the

and cover
oil

SPRING-J

TTING

oil pressure relief valve

plunger, spring
gear and

plug,
gear

Install the idler

the

pump

GASKET-^Q PLUG-*^
COPPER WASHE INLET TUBE
PASSENGER

assembly.

Install the

cover plate with a new

gasket,
pounds a

and

tighten the

cover plate screws oil

to 12-15 foot

torque. Check the

or

INLET TUBE
THUNDERBIRD

pump

shaft end

play

with

dial indicator

Plastigage (0.0015-0.0055 inch).

Insert the
shaft.
oil

CAR AND
INTERCEPTOR

(4) INSTALLATION.
ate shaft

pump intermedi
position of

6340

in the

oil

pump

Note the
pump

the

distributor shaft,

and set

the

oil

shaft so
shaft.

the inter

Fig. 14-Oil

Pump
the
seat

mediate shaft will engage

the distributor

Coat both
ate shaft

sides of a new gasket with sealer, position

the pump hous

may be
shaft.

out

of

alignment with

in the

ing

and gasket on

the

block, install

distributor

Align

the seat and shaft

the three retaining

if

necessary.

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

Install the
posi

oil

pump inlet tube

oil

and a new seal

in the

CAUTION :
tion

Do

not attempt

to

force

the pump in

pump.

Tighten the
oil pan nut

tube to oil pump nut and the oil

if it will

not seat against the

block. The

intermedin

tube to

to 10-12 foot-pounds torque.

4. CRANKSHAFT DAMPER, PULLEY, AND CYLINDER FRONT COVER

a.

Crankshaft Damper
The damper
and

and

Pulley.
pressed

b. Cylinder Front Cover.

on, and

pulley assembly is
the
crankshaft and

The

cylinder

front

cover

is

a one piece oil seal.

casting
water

which

keyed to, the front cap

of

is

retained

by

contains
and

the

crankshaft

front

The

pump

screw and washer.

fuel pump
retaining

are mounted on

the front cover. The front

cover

screws also retain

the

engine

front steady

(1)
the

REMOVAL. Drain the cooling

Loosen the
arm
generator

system.

Remove
and

rest

(front

support on

Thunderbirds).

radiator.

mounting bolts
generator

fan belt adjusting

the fan

bolt. Pivot the

to loosen

(1) REMOVAL.
the fuel
pump.

Drain the cooling

system.

Remove

belt,

then

remove

the fan belt. Remove the cap

crankshaft.

the radiator. Remove the fan

blades

and

hub. Remove
and

screw and washer

from the

Install

a standard

Loosen the
arm

generator

mounting bolts

two-jawed

puller on

the pulley,

and remove

the pulley

fan belt adjusting

Remove the
gine

bolt,

then remove the

fan belt.
at

from the

crankshaft.

generator

mounting bracket bolts

the bracket

the

en

front cover,

and move

out of

the

way.

(2)
a

INSTALLATION. Lubricate the

and oil
mixture and

crankshaft with oil

seal

Loosen the
of

generator

adjusting bracket

and move

it

out

whitelead

lubricate the

the

way.

Remove the

crankshaft pulley.

Remove the

rubbing
with

surface with grease.

Line up the pulley

keyway
on

engine

front steady
oil pan

rest.

Remove the four bolts that

the

key

on

the
a

crankshaft.

Drive the pulley

the

fasten the
the
water

to the cylinder front cover.

Disconnect

crankshaft

using

soft

metal

hammer. Install the cap

screw

bypass

tube.

Remove the

seven

remaining front
and cylinder

screw and washer.

Tighten the cap

to 85-95 foot

cover

bolts,

then remove the

water

pump

pounds torque.

Install the fan belt. Adjust the fan belt

front

cover as an assembly.

tension

and

tighten the adjusting arm nut.

Tighten the Fill the

generator

mounting bolts. Install the

radiator.

(2 ) FRONT OIL SEAL REPLACEMENT. Drive

the old
seal with a pin punch.

out

cooling

system.

Clean the

seal recess thor-

48

Chapter

III 8-Cylinder

272 (ECG

and

ECH)

and

292 (ECJ

and

Interceptor) Cubic Inch Engines

Tool-6700-BEE

Tool-6059-AAE

6203
Alignment Typical

Fig. Fig.
15 Oil

16 Front

Cover

Seal

Installation Typical

alignment

with

the

crankshaft.

Install the bolts

cover

at

the

front
oughly. with until

of

the

oil

pan.

Coat the

bolt threads
the engine
and

with

Coat the

recess with

sealer,

and

install

a new seal recess

sealer.

Install the
rest

bolts,
on

making

sure

front

the tool

shown

in fig. 15. Drive the

seal

seal

into the
the

steady
support

(support
are

Thunderbirds)
and

generator

it bottoms. Check the

sure

spring

after

seal

has

bracket

installed. Tighten the Vs inch bolts

the

been installed to be
seal.

it is properly

positioned

in the

to 23-28 foot-pounds torque

%6

inch bolts to

12-15 foot-pounds torque.

(3) Apply

INSTALLATION. Clean the

a

cylinder

front

cover.

Install the
pulley.

water a new
and

by-pass tube. Install the

gasket, install the fuel

crankshaft

light film

of grease

to the rubbing
sides of

surface of

the

Using

pump.

Install

crankshaft oil seal.

Coat both it
on

the

cover gasket

the fan blades

hub. Install

and adjust

the fan belt.

with sealer and position cover

shown

the

block. Position the front

Install the radiator, then fill the cooling

engine
until

system.

Run the

assembly

on

the

block,

and align

it

with

the tool
proper

normal check

operating

temperature

has been

in fig. 16 to

make sure

the

oil seal will

be in

reached, then

for

coolant and oil

leaks.

5.
The

TIMING CHAIN, SPROCKETS,

is driven

CAMSHAFT, TAPPETS,
water

AND BEARINGS
Crank the
engine until

camshaft

by

means

of a

timing

chain

pump,

and

fan
the

as a unit.

the

which connects

the

camshaft sprocket

to the crankshaft

timing

marks on

sprockets are positioned as shown

sprocket

(fig. 17).

in fig. 18. Remove the fuel pump eccentric and

cap
screw.

a.

Camshaft Sprocket, Fuel Pump Eccentric, and Timing Chain.

The
camshaft sprocket of

camshaft sprocket

Remove the fuel pump

camshaft.

eccentric and counter

weight

from the
chain

Slide both
the

sprockets and

the

is

slip fit on,

and

is keyed to,

timing

forward,

and remove

camshaft sprocket

the end

the

camshaft.

The

camshaft

sprocket, fuel

and chain as an assembly.

pump

eccentric

counterweight, eccentric, spacing washer,

camshaft washer, and lockwasher are retained on the

by

(2) INSTALLATION.
and

Position the

camshaft sprocket
sure

cap

screw.

timing
on

chain on the camshaft.

Be
and

the

timing
there

marks

the

camshaft

sprocket

the

crankshaft
and

(1)

REMOVAL.

Remove the

cylinder

front cover,

sprocket are

positioned as shown

in fig. 18,

Section

Timing Chain, Sprockets, Camshaft, Tappets,

CAMSHAFT SPROCKET

and

Bearings

49

COUNTERBALANCE
SPACER
BOLT

SCREW

(jJmmmWIL)

(J

WASHER
LOCK

WASHER

ECCENTRIC

KEY

OIL DRIP TROUGH

TIMING CHAIN
6207

Fig.
are

17 Camshaft and

Related Parts
pulley, fuel pump,
water

12 timing

chain

link

pins

between the

marks.

Install
and

crankshaft

pump

and

fan blade

the fuel pump

eccentric

counterweight, eccentric,

assembly,

and

the

cylinder

front

cover. and coil

as

spacing
screw,

washer on

the

camshaft.

Install the

sprocket

cap

Remove the intake manifold, carburetor,

an assembly.

and

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

Remove the

rocker arm

covers, then remove

push rods.

Install

a new oil seal cover.

in the

cylinder

front cover, then

pulley,
and

both

rocker arm assemblies.

Remove the

Re

install the

Install the fuel pump, Fill the cooling

crankshaft

move

the valve

push rod chamber cover.

fan,

and

radiator.

system.

Check

Crank the

engine until

the timing

marks on

the cam

adjust

the ignition timing.

shaft sprocket and

as shown

the

crankshaft sprocket are positioned

in fig. 18.
and scribe a

b. Camshaft.
The
camshaft

Remove the distributor cap,

supported

line

on

the

is

by five steel-backed babbit,

cylinder

distributor

housing

and cylinder

block to

mark

the

posi-

insert-type, bearings in
of

the

block. End thrust

THRUST PLATE
mounted

the camshaft is

controlled
at

by

thrust plate
end of

SPACING RING

on

the cylinder block

the forward

the camshaft

(fig. 19).

(1)

REMOVAL. Remove the radiator,

KEYWAY

radiator

grille,

TIMING MARK

KEYWAY

TIMING MARK 12 PINS BETWEEN MARKS

CAMSHAFT

6360

6206

Fig.

18

Aligning Timing Marks

Fig. 7 9 Camshaft Thrust Plate

50

Chapter

III 8-Cylinder

272 (ECG

and

ECH)

and

292 (ECJ

and

Interceptor) Cubic Inch Engines

TAPPET

slide

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

key in

the

camshaft.

Install the

camshaft sprocket, crankshaft

sprocket, and the

camshaft

timing

chain.

Be

sure

the timing

marks on

sprocket and crankshaft sprocket are positioned as shown

in fig. 18,

and

there

are

12 link

pins

between the

marks.

Install the fuel pump

spacer, washer, and

eccentric

counterweight, eccentric,

camshaft sprocket

bolt.
the
camshaft

Install
MAKE FROM W WELDING ROD
play.

dial indicator
play
should

and

check

end end

The

end

be 0.003-0.007 inch. If the

the thrust
plate and check

play is excessive,
end

replace

the

play

again.

Remove the dial indicator, then

in the

remove

the tappet holders.

Install the
6362

push rods

same

holes from

which

they

were removed.

Install the

rocker arm assemblies.

Install
scribed

Fig.
tion
of

20 Tappet

Replacing

Tool

the distributor in the

cylinder

block, using
the

the

lines
the rotor and distributor housing. Remove the

as guides

to properly

position

rotor and

housing.

Install the distributor Install the

crankshaft
assembly.

cap.

distributor.

cylinder

front
the

cover.
water

Install the fuel pump,

pump
and

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

pulley,

and

fan blade

Install the fan belt, radiator, Connect the

and radiator grille.

key,

and spacer ring.

Use

a magnetic

lifter to

Install the
manifold.

valve push rod chamber cover and

radiator

the

intake
and

lift the tappets, then install

lator spring clips,
on each

clothes

pins,

or window regu

hoses,

vacuum and

lines,
the

tappet to

keep

the tappets up.

fuel lines. Connect the

wire at

accelerator

linkage

choke

Carefully
front
of

remove

the camshaft

by

pulling toward the

the carburetor. Fill the cooling

a

system.

the

engine.

Make
caution to avoid

preliminary
warm

valve

lash

adjustment

(cold),
valve

and

NOTE: Exercise the necessary

damag

thoroughly
adjustment

up the

engine.

Make

final

lash

ing

the

camshaft

bearings.
camshaft and

(hot). Install the

rocker

arm

covers.

(2)

INSTALLATION. Oil the

Tool T521
-6261-

carefully

c.

Tappet Replacement.
To
replace

CEE

the

valve

tappets

with

the

engine

installed

Remover Replacer

adapter

T541

6250. A
-A

adapter

T541

-6250

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

in the vehicle,
Remove the
move
rest.

proceed as

follows:
Re

radiator and radiator grille support. pump.

the fuel

Remove the

engine
gear

Remove

the

cylinder

timing

front steady front cover.

Remove the

Remove the intake manifold, carburetor,

assembly.

and coil as an

Remove the
covers,

valve push rod cover.

rocker arm

rocker arm

assemblies,

and valve push

rods.

Remove the
-6266
-A

distributor. Remove the

camshaft

Tool T 541

(Adapter)

Adapter

~~

Clamp
Removal

ToolT53L-200-A[Handle)

6095

Pig,

21 Camshaft

Bearing

Fig.

22 Camshaft

Rear

Bearing

Bore

Plug

Removal

Section

Timing Chain, Sprockets, Camshaft, Tappets,

camshaft until

and

Bearings

51

sprocket and

timing

chain.

Turn the

the

bearings
tool

out of

the block

with

the

bearing

replacement

tappets
raise

can

be lifted

with either a magnet or

of

the

fingers,
clips.

shown

in fig. 2 1.
same tool shown

the tappets clear

the camshaft

lobes,

and secure

(2)
is
used

INSTALLATION. The

in fig. 21

them

with clothespins or window regulator

spring

to install the bearings. A

used

bearing

adapter with a

Remove the
install
one

camshaft.

Remove the

oil pan.

Remove

and

larger flange is

to install the bearings in the

cylinder

tappet

at a

time through the bottom of the

or a

block.

block. A

Bonney flexible tappet replacing tool

as shown

holder,
opera with

NOTE: The No. 1

camshaft

fabricated
tion. As

in fig. 20,
tappet is

can

be

bearing

has

one oil oil

hole.

used

for this

The

other

four

camshaft

bearings have five

holes

each

new

installed,

secure

it

and are

interchangeable.
to
align

clothespin or window regulator clip.

Install the

camshaft.

Be

sure

the

oil

holes in the block

camshaft when

bearings

d. Camshaft
Remove the
move

Bearing
spark
oil

Replacement.
it
on a workstand.

with

the oil holes in the

cylinder

the bearings
with

engine and mount

Re

are

installed. Particular

care should

be taken

No. 3
After

the

distributor,

plugs,

rocker arm oil

cam

assemblies,
all

bearing

since

it

supplies oil

to the

rocker arms.

push

the bearings

are

rods, generator,

pump assembly,
sprockets,

pan,

cylinder

installed,

coat a new camshaft rear

front cover, timing

chain and

clutch

assembly,

bearing bore
plug

plug

with oil resistant sealer and

install the

as shown

flywheel,
necting

in fig. 22.
valve

crankshaft, camshaft,

and valve

tappets. Push.
the con

Install the
wheel,
clutch

tappets, camshaft, crankshaft,

the pistons to the

fly

top

of

the

cylinders to move

assembly,
oil

timing
oil

chain and

sprockets, cylin

rods out of

the

way.

der front cover,

push

pan,

pump assembly, generator,

plugs,
and

(1) REMOVAL.
at

Drill

V2-inch hole through the plug

rods,

rocker arm assemblies, spark

engine.

dis

the camshaft
the clutch

rear

with

pilot

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

tributor.

Install the

Set

and

adjust

the ignition

timing

and valve

lash.

6.
The
a.

FLYWHEEL, CRANKSHAFT, AND BEARINGS

in fig. 23.

crankshaft and related parts are shown

(2)

INSTALLATION

STANDARD

OR
and

OVER
on

DRIVE TRANSMISSION. Position the flywheel

the

Flywheel.
The flywheel is
piloted on a shoulder and

crankshaft.

Tighten the bolts alternately

to

evenly, to

is

retained

seat

the

flywheel,

75-85 foot-pounds
clutch

torque.

Using

on

the crankshaft
on

by

six

bolts. The flywheel

can

only be

pilot shaft

to locate the

disc, install
release

the rod,

pressure

bolted
shrink

in
on

one

position.

The flywheel ring

gear

is

plate

and
and

disc. Install the

clutch

bearing,
cover.

fit

the flywheel.
or overdrive equipped as a

spring,
vehicles, the
rear

hub. Install the flywheel

housing dust

On face

standard

Install the transmission.

of

the flywheel is used

friction

surface which

(3)
verter

REMOVALFORDOMATIC.

Remove the two

remove

is

engaged

by the clutch disc. The flywheel can be

removed,
and

checked
engine

rubber plugs

from the floor pan, then

to
engine

the

con

for

runout,

installed

with

the

housing
the

block

upper

bolts. Raise the

stands.

mounted

in the

vehicle.

front
Fordomatic
plates

of

vehicle and position control

safety

Remove
con

The flywheel
has two
edge
180

used

on

equipped vehicles

the transmission
verter

linkage shield, the torque

converter air
access plate.
at

spring-steel

drive

riveted

to the

outer

lower
and

access

plate, the torque

inlet

apart, to

which

the

converter cover

is

attached

shield,

the torque converter front

converter until

Turn

(fig. 24).

the torque
removal and
a

the drain plug is

and

the lower

The

following
all

installation

procedures
equipped

edge.

Drain the transmission

shaft.

torque converter.
speedometer

apply to

vehicles,

except

Fordomatic

Remove the drive

cable and

Disconnect the
rod
at

Thunderbird.

transmission control

the transmission.
remove

NOTE:
separate

The Fordomatic

cannot

be

removed

as

Remove the
the
starter.

battery

cable

from the starter, then

assembly from the

to

Thunderbird; therefore,
the
engine

Remove the transmission

dipstick,

then

re

it

will

be necessary
in
order

remove

from the

move

the filler tube.

vehicle

to

replace

the flywheel.
a

(1)
the

REMOVAL

STANDARD

OR

OVERDRIVE

Install the drain plug in the torque converter. Position jack under the transmission. Remove the transmission
bolts. Remove the frame
the transmission.
cross member at

support
rear

the

TRANSMISSION. Remove the transmission. Remove flywheel

of

Remove the two lower bolts

housing
and

dust

cover.

Remove the

clutch

securing the torque

converter

housing to the
enough

engine

block.

release

rod, spring,

bearing. Remove the

clutch pres

Move the transmission back far drive

plate.

to clear the flex

sure plate and

disc. Remove the flywheel.

Secure the torque

converter to the

housing.

52

Chapter

III 8-Cylinder

272 (ECG

and

ECH)

and

292 (ECJ

and

Interceptor) Cubic Inch Engines

MAIN BEARINGS

JOURNAL SEAL TO CYLINDER BLOCK

FLYWHEEL AND

RING GEAR

CRANKSHAFT SPROCKET

-SEAL

RETAINER

CAP TO BLOCK SEALS BOLT

LOCKWASHER

MAIN BEARING CAPS

6343

Fig.
CAUTION:
will slide

23 Crankshaft and

Related Parts
plate on

If

the torque converter

is

not

secured, it

flex drive

the

engine

crankshaft.

Tighten the

off the splines. Remove the flex drive plate from the

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

crankshaft. converter pilot and

(4)

INSTALLATION

FORDOMATIC. Install the

the lower torque

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

Install the flex

cross member.
rear support

plate

to

converter

bolts. Install the frame

Remove the jack. Install the transmission

bolts.
control

Connect the transmission throttle

manual control
stall

linkage,

the

linkage,

and the speedometer cable.

In

the torque

converter air

inlet shield,

control

linkage

shield, torque

converter

housing front
access

access

cover, the
oil

torque
pipe.

converter

lower

cover, and the

filler

Install the starter, then

the
starter.

connect
shaft.

the

battery

cable

to

Install the drive

stands and

lower the

vehicle.

Remove the safety Install the converter hous

rubber plugs and

ing

to

engine

block bolts. Install the

mat.
with

position

the floor

Fill the transmission

fluid. Start the

add

engine

to

fill the torque converter, then level is

6086
and adjust

fluid

until

the

proper

reached on

the dipstick. Check for leaks.

Check

the manual control, the neutral switch, the

Fig.

24 Flywheel Assembly Fordomatic

throttle

linkage,

the

engine

idle,

and

the dash pot.

Section

Flywheel, Crankshaft,
water

and

Bearings

53

b. Crankshaft.
The
crankshaft

pump

as an assembly.

Install the
and oil

crankshaft pulley.
pipe.

is

made

from

a cast

iron
and

alloy.

It has

Install the

oil

pan,

oil

pump,

pump inlet

integral

counterweights and

is statically
the

dynamically
vehicle

Install the fuel pump

with

and generator.

Fill the

crankcase

balanced.

the proper

grade and

( 1 ) REMOVAL. Remove
and mount

the engine. Check and

engine

quantity of lubricant. Install adjust the ignition timing.

from the
oil.

it

on an engine stand.
and

Drain the
oil

Remove

C.

Main Bearings.
The
number

the generator
remove

fuel

pump.

Remove the
inlet

pump, then
assembly.
cylinder

three

main

the

oil

pan and oil

bearing is

the

crankshaft

pipe as an

Remove the front Remove the

thrust bearing.

crankshaft

pulley.

Remove the
pump

cover with

the fan and

The bearings
removed,
or

can

be

replaced when

the

crankshaft

is

water

as an assembly.

crankshaft

pulley

spacer and woodruff

key.

they

can

be

replaced without

removing the

Remove the

crankshaft as

follows:

crankshaft and camshaft sprockets with the

timing

chain.

Remove the

clutch assembly.

Remove the

flywheel. Remove the

crankshaft rear oil seal retainer.

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

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

bearing

at a

fig. 25. Rotate the

the block. Install

crankshaft

to

slide

the
on

bearing
the

out of

a new

bearing

insert

crankshaft

bearing

caps,

and

mark

them for the

crank sur

installation
shaft out of

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

on

the same

journals. Carefully lift

so

the cylinder block

the thrust

bearing

the

notched

end

faces
so

are not
can

damaged. Be

sure all parts are

identified

it

will seat when rotated

of the bearing is into position.

as

they

be installed in their

original positions.

Check the
and
outlined

(2) INSTALLATION. Be
crankshaft

sure

that

all

bearings

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

bearing

journals
in the

are

clean.

Install

a new crankshaft a

Install the
shaft

new

bearing
main

insert in the cap,

oil

the

crank

rear oil

seal

cylinder

block.

Apply
and

light

coat

journal

with

engine

oil, and install the cap and

of engine oil

to the crankshaft journals

the

bearing

insert. Tighten the

pounds

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

inserts.

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

bearing

bearings if they

need replacement.

Install the

oil pan.

MAIN BEARING INSERT

play

with a

dial indicator.

CAUTION:

The

thrust

bearing

inserts

must

be in

proper alignment with

the crankshaft

or premature

bearing

failure may

occur.

Pull the
shaft, and

piston and rod assemblies against

the

crank

install the
caps

bearing inserts
and

and caps.

Tighten

the

bearing

to 45-50 foot-pounds torque.

the clutch assembly. Install
CRANKSHAFT JOURNAL

Install the flywheel

the

crankshaft and camshaft sprockets with

the

timing
and

Too/-'6337

1046

chain.

Install the

cylinder

front

cover with

the fan

Fig.

25Main

Bearing Insert Removal

7. CONNECTING RODS, PISTONS, PINS, AND RINGS

The
piston

and

connecting

rods

are

shown

disas

Turn the
removed
nuts

crankshaft until the rod of the piston

pal nuts and

being

sembled

in fig. 26.
and
oil

is down. Remove the

the hex head

a.

Piston

Connecting
pan

Rod Removal.
heads. Before
any
ridge at

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

Remove the
moving the

and

cylinder
remove

re

the cap

the rod,
the

and

mark

both halves to
rod.

assure
rod

piston

assemblies,

the

assembly

with

same

connecting
the

Push the

top

of

the

cylinder

bore

caused

by

piston

ring

wear, and

and piston

assembly
end of a

out of

top

of

the cylinder with the

crank-

clean

the

carbon

from the

cylinder

bore.

the

handle

hammer. Do

not scratch

54

Chapter

III 8-Cylinder

272 (ECG

and

ECH)

and

292 (ECJ

and

Interceptor) Cubic Inch Engines

OIL RING
PAL NUT
ASSEMBLY

SPRING SPACER

CONNECTING ROD CAP

STEEL RAILS

PRESSURE RINGS

6385

Fig.
pin or rod.

26 Piston and

Connecting

Rod Disassembled

the cylinder

wall when

removing the

piston and

then remove the

piston pin

(fig. 27). Discard the

retain

Repeat this

procedure

for

each assembly.

ing
c.

clips.

NOTE:

Connecting
the

rod

and

bearing
the
right at

cap

assemblies

Assembly.
Lubricate
all

are numbered

from 1

to

4 in

bank

and

from

parts

with

light
rods

engine and

oil.

to

8 in

left

bank, beginning
the

the

front of the

engine.

The

be

on

the

respective

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

Assemble the connecting in figs. 28 and 29.

Install the
piston pin

pistons

as shown

through the

piston and

rod, then

install the
with

pin retainers

by

spiraling them into the piston

transposed

from

one

block

or

cylinder

to another,

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

with

make sure all

on

bearings

are new and

that the number the new

starting

the

oil

ring first. Position the butt

toward the
the
center

ends of

the

rod

is

restamped

to

correspond with

the oil ring

then
spiral

expander

of

the engine,

the

steel rails onto

expander and position

expander

cylinder number.

the gaps

one

inch to

either side of

the

butt

ends.
120

b. Disassembly.
Mark the
rod and pistons

Position the
to
assure

compression rings so

that

all gaps are

assembly

with

the

apart.

same and
which

Install the insert bearings in the connecting

cap.

rod

installation in the
removed. pin

same

cylinder

from

the connecting rod

they
the

were

Remove the
at each

piston
end

rings.

Remove
pin,

d. Installation.
NOTE: Install the
piston

piston

retainers

of

the

piston

piston with

the indentation

in the

head

toward the
rod

stalled, the
rod should

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

of the
engine
"F."

be

toward the outside

Piston Pin Remover

FRONT

POSITION NUMBERS

TO LEFT WITH PISTON DOT FORWARD

6386

6395

Fig.

27 Piston

Pin Removal

Fig.

28 Position of

Rod

Numbers Left

Bank

Section

Connecting Rods, Pistons, Pins,

and

Rings

55

FRONT

Tool 61 49- A

INDENTATION

TO

FRONT OF ENGINE

POSITION NUMBERS

TO RIGHT WITH PISTON DOT FORWARD

6394

6071

Fig.

30 Piston

Installation

Fig.

29 Position of

Rod

Numbers Right

Bank
stroke.

Oil the crankpin,

rod

and push

the

piston

downward

Oil the

piston

rings, piston, connecting rod

bearings,
a piston

until

the

bearing
rod

seats

in the

crankpin.

and cylinder walls with

light

engine oil. and

Install

Be

careful not

to damage the

crankpin
piston

journals

with

ring
the

compressor on

the piston,
to install
were

insert the
in the
or

piston

in

cylinder.

Be

the connecting

bolts

when

the

is

pushed

into

sure

pistons

same cylin

ders from
were

the
to
which

cylinder

bore. Check the

which

they

removed

they
the

bearing fit

using the Plas

fitted. If

a new piston and

connecting

rod

is to be

tigage

method as outlined

in the General Engine Repair

installed, be
connecting
will

sure

to stamp the

cylinder number on
rod

Chapter.

rod and

connecting
the

cap

so

the

numbers

After the connecting

specifications,

rod caps
oil

have been tightened to Install the

cylinder
proper

face the

outside of

engine when

the assembly is

install the

pan.

installed. Push the fig. 30. Turn the

piston

into the

cylinder as shown
of

in
its

heads

and manifolds.

Fill the

crankcase with

the

crankshaft

throw to the bottom

grade and

quantity

of engine oil.

Fill the cooling

system.

8. EXHAUST SYSTEM
The
single exhaust system

(fig.

31)

consists of a

muffler,

a.

Muffler Replacement.
Raise the
vehicle and

a muffler pipe.

inlet pipe,

a muffler outlet

pipe,

and a crossover

position

safety

stands.

Loosen
clamps
outlet

the

muffler

inlet

and outlet pipe clamps.

Slide the

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

away from the

pipe.

muffler on

the inlet

pipe and

the

Loosen the

outlet pipe
pipe
rear.

front

and rear clamps and

muffler

The dual

exhaust system

is

also sys and a

disengage the
the
outlet pipe

outlet

from the On

by

sliding

installed
tem

on other models as optional equipment.

This

to the

Thunderbirds,
Remove the

disconnect

consists of
outlet

two

muffler

inlet pipes, two mufflers,

the inlet
the inlet

pipe

from the

manifold.

muffler

from

two

pipes.

In addition, the Thunderbird has

pipe.

muffler outlet pipe extension.

The dual

exhaust system
of

is

Place the
slide

new muffler
pipe

in

position on muffler.

the

inlet

pipe

then
pipe
and

designed to facilitate
gases,

rapid

scavenging

the

exhaust

the outlet

into the
in

Place the inlet

on

thereby, minimizing

exhaust gas

back

pressure.

and outlet pipe

clamps

position

the

muffler

Inlet pipes, mufflers,

tensions

outlet

pipes,

and outlet pipe ex

tighten the clamps.

clamps.

Tighten the front

and rear outlet pipe

(Thunderbird)

are provided as

individual

serv

Remove the safety

stands and

lower the

vehicle.

ice

parts.

b. Outlet Pipe Replacement.

apply to
all models unless other

The

procedures given

To
the

replace an outlet pipe

(except

wise stated.

The

outlet pipe replacement

procedure
of

for

Thunderbirds), raise
Loosen the
outlet
outlet pipe support

vehicle and position

safety

stands.

the Thunderbird
pipe
extension.

varies

slightly because

the

outlet
pipe

clamp

at

the

muffler.

Remove the

clamps, then pull the outlet pipe

exhaust

from the muffler. Position

not

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

sys

the

muffler

clamp

on

the new outlet pipe, then slide the

clamps

to

pipe port

into the
clamps.

muffler.

Install, but do

tighten, the sup

muffler

twists in the system, then tighten the

clamps.

Tighten the

outlet pipe

to

clamp,

56

Chapter

Ml 8-Cylinder

272 (ECG

and

ECH)

and

292 (ECJ

and

Interceptor) Cubic Inch Engines

then tighten the

and

support clamps.

Remove the safety stands

the

muffler

inlet

pipe clamp.

On

Thunderbirds,
remove

remove

lower the

vehicle.

the left-hand exhaust manifold to

outlet pipe and outlet pipe ex

the left-hand

On

Thunderbirds,
can

the

inlet

pipe.

tension

be

replaced as separate parts.

It

is, however,
when one

On

vehicles

equipped

with

standard

or

overdrive

good practice to replace

both
a

of

these parts

is

transmission,
manifold.

remove
nuts

the

clutch

retracting
pipe

spring.
exhaust

being
to

replaced

due to

rusting
stands.

condition.

Raise the
extension

Remove the

retaining the inlet

to the

vehicle and position

outlet pipe

safety

Loosen the

clamp, then
of

slide

the extension pipe to the

pipe.

NOTE: On
system,

vehicles equipped with a single exhaust

rear until

it is free
at

the outlet

Loosen the

outlet
off

or when

replacing the
remove the

right

inlet

pipe on a

pipe

clamp

the muffler, then pull the outlet pipe

dual

exhaust
and

system,

heater inlet duct

and

the

muffler. muffler

motor,

the starter
number

motor and seal. spark plug.

muffler

Position the
pipe
on

clamp

and

the

extension
slide

to outlet

Remove the
remove

two

On

clamp

on

the

Thunderbirds,

new outlet

pipe, then

the

pipe

the muffler. Remove the

inlet pipe through Install

the

muffler and on

the extension. Tighten the clamps.

the bottom of the vehicle.

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

Place the
gasket
and

new

inlet

pipe

in the

muffler.

a new

secure

the

pipe

to the

exhaust

manifold.

loosen the
extension

extension

to outlet pipe clamps. Slide the

Tighten the
muffler
plug.

nuts

to 23-28

to the

rear until

it is free
it
comes

foot-pounds
Install the

torque. Tighten the

number

of

the
of

outlet

pipe,

inlet

pipe clamp.

two

spark

then

pull

it forward
at

until

free

the

support

Install the
and

starter motor

and seal and

the heater

hanger located Position

the bumper.
through the support hanger
exhaust outlet

inlet duct
in the
can

motor, if

they

were removed.

Remove the

a new extension

(this is

slip

fit)

and

into the

safety

stands and

lower the

vehicle.

bumper. Slide the

aligned with
outlet pipe.

extension

to the

rear until

it

be

d. Crossover Pipe Replacement.

Remove the
of

the

outlet pipe. and

Slide the

extension clamp.

into the

Position
the

tighten the

the pipe

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

NOTE:!/

both

manifold
outlet pipe and outlet pipe exten

heat

valve,

and gaskets.

sion are to

be replaced,

Position the
remove

manifold

the extension, then

heat

control valve on

the right-

remove the outlet pipe.

hand

manifold with a new gasket on each side.

Position

a new gasket on

the left-hand manifold, then install the

nuts

c.

Inlet Pipe Replacement.

Raise the
vehicle

crossover
stands.

pipe.

Tighten the

to 23-28 foot-pounds

and position

safety

Loosen

torque.

SUPPORT 5277

34806-S

^33798-S

5259

23438-S

24387
MUFFLER

5230

23438-S
CLAMP 5270

34806-S

5287
SUPPORT 5261

/
*-*--39935

EXHAUST MANIFOLD

-9430

EXHAUST THERMOSTAT

CLAMP 5251

CONTROL-9685^

352479-S

\ JF*J&*

^88393-S

34806-S

MUFFLER CROSSOVER

PIPE-5267

33816-S 34808-S
EXHAUST MANIFOLD 9431

6217
PartsSingle

Fig.

31 Muffler and

Related

Exhaust System

'

'

'

"..

FORD

CAR
SHOP MANUA1

FORM 7098-55