1958 Ford Thunderbird Shop Manual

1958 FORD THUNDERBIRD
FORD DIVISION FORD MOTOR COMPANY
Copyright © 2009, Forel Publishing Company, LLC, Woodbridge, Virginia
All Rights Reserved. No part of this book may be used or reproduced in any manner whatsoever
without written permission of Forel Publishing Company, LLC. For information write to Forel
Publishing Company, LLC, 3999 Peregrine Ridge Ct., Woodbridge, VA 22192
1958 Ford Thunderbird Shop Manual
EAN: 978-1-60371-008-4
ISBN: 1-60371-008-6
Forel Publishing Company, LLC
3999 Peregrine Ridge Ct.
Woodbridge, VA 22192
Email address: [email protected]
Website: http://www.ForelPublishing.com
This publication contains material that is reproduced and distributed under a license from Ford
Motor Company. No further reproduction or distribution of the Ford Motor Company material is
allowed without the express written permission of Ford Motor Company.
Note from the Editor
This product was created from the original Ford Motor Company’s publication. Every effort has
been made to use the original scanned images, however, due to the condition of the material;
some pages have been modified to remove imperfections.
Disclaimer
Although every effort was made to ensure the accuracy of this book, no representations or
warranties of any kind are made concerning the accuracy, completeness or suitability of the
information, either expressed or implied. As a result, the information contained within this book
should be used as general information only. The author and Forel Publishing Company, LLC
shall have neither liability nor responsibility to any person or entity with respect to any loss or
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GROUP
POWER PLANT
CLUTCH, CONVENTIONAL TRANSMISSIONS,
ANO REAR AXLE
CRUISE-O-MATIC TRANSMISSION
CHASSIS SUSPENSION AND UNDERBODY
STEERINO
BRAKES
GENERATING AND STARTING SYSTEMS
1958 THUNDERBIRD
SHOP MANUAL
LIGHTS, INSTRUMENTS, AND ACCESSORIES
BODY MAINTENANCE AND REPAIR
DOORS, DECK LID, AND
FRONT SHEET METAL
INTERIOR TRIM, SEATS,
AND WINDOWS
SERVICE
DEPARTMENT
FORD
DIVISION
FORD
MOTOR
MAINTENANCE, LUBRICATION,
AND SPECIAL TOOLS
COMPANY
SPECIFICATIONS
1958
FORD
Reprinted
MOTOR
with
COMPANY, DEARBORN,
MICHIGAN
Ford Motor Company's Permission
FOREWORD
This
manual provides
information for the
proper
Thunderbird. Service information
a separate
manual.
The descriptions
on
servicing of the 1958
air
conditioning is
covered
and specifications contained
in
this manual were in effect at the time the manual was approved
printing.
is
models at
The Ford Division of Ford Motor Company,
one
of
continuous
any time,
and without
improvement,
whose
design,
for
policy
reserves the right to
or change specifications or
in
discontinue
without notice
incurring obligation.
SERVICE
DEPARTMENT
FORD
DIVISION
FORD MOTOR COMPANY
1958 THUNDERBIRD
SHOP MANUAL
GROUP 1
POWER PLANT
Page
PART 1
ENGINE
1-2
PART 2
IGNITION SYSTEM
1-44
PART 3
FUEL SYSTEM
1-58
PART 4
COOLING SYSTEM
1-77
1-2
GROUP
PART 1
Section
1
Page
Description
1-2
2 General Engine Trouble
3
Shooting
1-7
Tune-Up
1-10
4 Tests
and
Adjustments
(Engine In
Chassis)
1-11
Camshaft Lobe Lift
1-11
Valve
1-12
Timing
Valve Clearance
1-12
Manifold Vacuum Test
1-13
Engine Compression Test 1-13
5 Engine Removal
1-14
Disassembly and
Assembly (Engine Removed
7
Disassembly
of
and
1-16
Assembly
Component Parts
Section
Valve Rocker Arm Shaft
Camshaft
and
1-34
Bearings
Assembly
1-27
Crankshaft
1-35
Cylinder Heads
1-27
Connecting Rods
1-35
Hydraulic Valve Lifters
1-28
Piston, Pins,
Piston
and
Main
Connecting
Rod
1-28
Oil
1-30
Pump
8 Cleaning, Inspection,
1-35
Rings
and
Connecting
1-37
Rod Bearings
Conventional Flywheel
1-38
Cylinder Block
1-39
Oil Pan
1-30
Reconditioning
Intake Manifold
Exhaust Manifold
and
and
and
1-40
Oil Pump
9 Repair Operations (Engine
1-30
1-40
In Chassis)
and
Exhaust Gas Control
1-30
Valve Rocker Arm Shaft
Engine Supports
1-40
Intake Manifold
1-41
Cylinder Heads
1-42
1-30
Cylinder Front Cover
Push Rods
1-30
and
Cylinder Heads
1-30
Camshaft
Valves
1-32
Oil Pan
1-34
Oil Filter
1-43
1-34
Exhaust System
1-43
...
Hydraulic Valve Lifters
1-27
Page
Section
Page
Assembly
6 Engine
from Chassis)
ENGINE
Valve
and
Installation
POWER
Timing
Chain
Timing
1-42
Chain
1-42
and
Oil
1-42
Pump
DESCRIPTION
engine
(Figs. I
placement
pression
tified
by
name
by
the
a
FIG.
1 Interceptor V-8 "Thunderbird
Special"
Engine
4.00-inch bore
inches. It has
engine
on the air cleaner
of the engine.
number on
1722-A
cubic
of 10.2:1. The
decal
letter
a
Special"
stroke and a total piston
of 352
ratio
2) has
and
3.50-inch
and a
"Thunderbird
V-8
The Interceptor
It
"H"
at
the
can
a com
is iden
bearing
be identified
beginning
the patent plate.
dis
the
also
of the serial
1-3
PLANT
1723-A
FIG. 2-Engine
Sectional View
1-4
GROUP 1-POWER PLANT
CLOSED (HEAT
ON)
OPEN (HEAT OFF)
1001
1541
-A
FIG.
4 Exhaust Gas Control Valve
FIG.
6 Valve Port Arrangement
-A
3 Intake Manifold Exhaust Gas Passages
FIG.
buretor (Fig. 5). The
the
carburetor
and
7
cylinders
right
side
of
feeds Nos. 1, 4, 6,
and the left side feeds
Nos. 2, 3, 5, and 8 cylinders.
The distributor is mounted at the
left front of the intake manifold.
CYLINDER
HEADS
BLOCK
AND
The cylinders
front to rear on
3,
4
and
and on
are
numbered
from
bank 1, 2,
the left bank 5, 6, 7,
the right
8. The firing order is 1-5-4-2-63-7-8. The valves are arranged from
front to rear on both banks E-I-E-I-IE-I-E (Fig. 6).
The cylinder head assemblies con
and
1312-A
5 Intake Manifold Fuel Passages
FIG.
When the
MANIFOLDS
"heat
intake
The
serves
cover,
the
as
the
tappet
valve
through
center section and under
buretor,
are
gases
the
izing
through
directed to
3). The
exhaust
into
intake
the
mostatically
of
valve
the right
vapor
charge
are
manifold
controlled
(Fig. A). The
outlet
gases
exhaust
in
assist
incoming fuel
the car
hot
which
haust
position,
gases
part
of
in the
the
directed from
are
(Fig.
directed
by
a
ther
is located
at
the
manifold.
exhaust
right
heat
riser
manifold.
"heat
ex
the
manifold, through the
passage, to the left
When
off,"
more of
from the left
to flow
the
valve
exhaust
opens
the exhaust gases
manifold are permitted
directly
out the exhaust sys
tem in the normal manner.
has two
sets
fuel passages, each with its
inlet connection to the
own
The intake
exhaust valve
exhaust
or
closed
chamber
passage
a
contains
also
which
manifold,
is
valve
on"
of
separate
manifold
car
tain the valves and the valve rocker
arm shaft assembly.
The
combustion
in the head.
integral part of
chambers are machined
Valve
guides
an
are
head.
Both the intake
the
assemblies
which
rotate
valve stems
is
type valve
stem
top
springs
which
rotating-type
time
the
valve
Lubrication
of the
each
opens and closes.
the
and exhaust valve
the
are
controlled
seals
by
of the valve stems.
have
provide
equal
more
umbrella-
fit over
The valve
which
coil
spacings
positive
valve
1-5
PART 1-ENGINE
VALVE OPEN
LIFTER BODY
VALVE CLOSED
PUSH ROD CUP
PLUNGER
PLUNGER SPRING
DISC VALVE
DISC VALVE
SPRING
BASE CIRCLE
1717-A
7 Hydraulic Valve Lifter Operation Typical
FIG.
high
at
action
A
speed.
engine
damper spring is installed inside the
valve spring to assist in preventing
bounce
valve
floating
and
at
high
are
used
rpm.
Hydraulic
valve
provide
which
valve
minimizes
operation
zero
lifters
valve
train
and parts
lash
noise.
into the plunger. This creates a
differential above and below
the valve disc. The high pressure
above the valve disc forces the valve
disc open and the oil fills the area
below the plunger equalizing the
sure
pressure on
pressure
is
and
pressure
The
disc.
identification
on
each
of
the valve
disc
opens
the chamber can again be
filled.
This
cycle
The
oil
between the
clearance
in Fig. 7. When the valve is closed,
lifter assembly is on the base
circle of the camshaft lobe and the
valve push rod is in its lowest posi
tion. With the lifter assembly in this
to be present, the plunger spring ex
pands pushing the plunger until there
screws.
position, the plunger spring expands
opening) the
tion
is
arm
the plunger upward. This ac
transmitted to the valve rocker
via
the
is
solid
there
valve and
valve
(zero
end of
valve
rod
until
between the
contact
the valve
rocker arm
push
the valve
lash). In
this
position, the oil hole in the lifter and
plunger is indexed with the lifter oil
gallery
and oil
is forced
under pres
solid contact
between
all parts of
the valve train mechanism.
As
the
camshaft
the sudden
below the
disc
push rods are solid steel with
hydraulic
rocker
forcing
repeated at each revolu
cushioned
valve and the valve rocker arm tends
is
is
tion of the camshaft.
the hydraulic valve lifters are shown
the
the oil below the plunger
and the valve
sockets.
Inasmuch
as
there is no valve lash adjustment with
Whenever
of
side
so
relieved
plunger
closed and
hydraulic
rotates
(valve
lifter is raised and
increase in oil pressure
valve
ram.
forces the valve
becomes a
the lifter
During
this period a
from below the
plunger occurs. As the high point on
the camshaft lobe rotates past the
slight
leakage
lifter,
the push rod
lifter down
of oil
forces
and reseats
the valve
the valve. The
valve
arms
do
lifters,
not
the
valve
have adjusting
The camshaft is supported by five
insert-type bearings pressed into the
block. It is driven by a sprocket and
timing chain in mesh with a sprocket
on the crankshaft. Camshaft end
play
is controlled by a thrust button and
spring located between the camshaft
sprocket bolt and the cylinder front
An eccentric, bolted to the
front end of the camshaft, operates
the fuel pump.
cover.
The crankshaft is supported by
five insert-type main bearings. Crank
shaft end thrust is controlled
by the
1-6
GROUP 1-POWER PLANT
NO. 2 SUPPORT, LEFT HEAD
NO. 4 SUPPORT, RIGHT HEAD
CYLINDER HEAD
BOLT BORE
FROM NO. 2
CAMSHAFT
BEARING
TO LEFT CYLINDER
HEAD, AND
FROM NO. 4
CAMSHAFT
BEARING
TO RIGHT
CYLINDER HEAD.
1514-A
1725-A
8 Lubrication System
FIG.
flanges of the No. 3
The forged steel,
FIG.
bearing.
main
bypass
the
filter, if
9 Valve Rocker Arm Shaft Lubrication Passages
be
the element
For example, the No. 1
oils No. 5 cylinder,
cylinder wall.
"I"
section
con
necting rods contain a bronze piston
pin
bushing. The connecting rod
bearings are the insert-type.
The aluminum alloy, three ring,
flat head-type pistons are of the autothermic design. This design provides
binding
top
the
and
is
fits with
friction. The
piston
or excessive
compression
plated
ring
initial
closer
allows
out
which
expansion
piston
controlled
is
ring
lower
chrome-
compression
for
phosphate-coated
extra
protection against wear and scuffing.
The
oil
control
sists
of
a
serrated
spring
steel
chrome-plated
con
ring assembly
and
two
rails.
comes clogged.
From the
the
main oil
Oil from the
SYSTEM
in the front
of
the oil pan,
pump.
8) by
(Fig.
system
The
oil
located
is forced
lubrication
mounted
in the
front of the crankcase, is driven by
the distributor through an interme
diate drive
relief
A
shaft.
in
valve
the
by
the
loaded
pump limits the
maximum pressure of
relieved
spring
valve
the system.
Oil
is directed back
discharged
by the pump
passes through a full flow-type filter
before it enters the engine. The filter
All the
is
oil
mounted
in
a
vertical
position
at
the lower left front of the engine. A
relief valve
in
the
filter
permits oil
to
crankshaft turns, the hole
in the connecting rod bearing aligns
with the hole in the journal causing
the
cylinder
oil
main
allows
gallery
may be trapped
The
in
air
any
the
to
oil
is drilled from
Main
the
Connecting
Bearing
Rod
Bearing
No. 2
No. 3
No. 4
No. 5
ing
Serves
Serves
squirt
direct
and
5
6
and
7
and
groove
Oil
rod
at
the cap contacts the connect
This
groove
hole for
Oil
from
hole
is
used as an oil
cylinder wall
the
lubrica
connecting rod
lubricates the opposite
drilled from the
are
passages
gallery to each valve lifter
oil gallery. Oil from here feeds the
oil
main
at
lifter
oil
reservoir
lifter bore boss traps
is
that oil
so
A
assemblies.
valve
each
lifter lubrication
available
for
valve
as soon as the engine
starts.
An
2
oil passage
camshaft
from
web
lubricate the
to the left
and
6
valve rocker
assembly (Fig. 9). The
in the
passage
is drilled from No.
bearing
head between Nos. 5
cylinders to
oil
head is drilled
head bolt bore to
cylinder
the cylinder
No. 2 valve rocker arm shaft
support. The oil flows through the
the
valve
rocker
arm
holes in each
to lubricate the
arm
both
The
ends
push
valve
rocker
bushing
and
the valve rocker arm.
of
excess
through
shaft
drilled
tating
is located in the
the mating face
the cylinder
squirt of oil onto
oil
spirals
rods
push rod seats.
small
rod.
tion.
Nos. 2
Nos. 3
Nos. 4
No. 8
Serves
connecting
squirt
No. 1
Serves
Serves
No. 1
where
a
wall.
arm shaft
crankshaft
main bearings to the
connecting rod
bearings. The oil flow is as follows:
A
to the intake side of the pump.
connecting
etc. As the
valve
oil
rotor-type
a
pump,
which
gallery
flows into
is located
escape.
oil pan sump,
through the pressure-type
the oil
in the center of the valve chamber
floor. The oil gallery supplies oil to
each
individual camshaft bearing,
through drilled passages in the block.
Passages are drilled from each cam
shaft bearing to each main bearing.
Number 1 camshaft bearing feeds
No. 1 main bearing, and No. 2 cam
shaft bearing feeds No. 2 main bear
ing, etc. The oil then flows through
notches or grooves in the main bear
ings to lubricate the crankshaft jour
nals. A metering plug at the front of
that
LUBRICATION
filter,
rod
and
The
down the ro
lubricates the
right valve rocker
assembly is similarly lubri
from No. 4 camshaft bearing
arm shaft
cated
via
the
No. 4 valve rocker arm shaft
A baffle located under the
support.
valve
shields
splash.
rocker
the
arm
valve
Excess
oil
shaft
stems
is
assembly
from oil
returned
to the
1-7
PART 1-ENGINE
TO RADIATOR
SUPPLY TANK
1770-A
1515-A
10 Crankcase Ventilation System
FIG.
drain back holes lo
oil pan through
each
at
cated
end
the
of
cylinder
head and in the tappet chamber floor.
The timing chain and sprockets
are splash lubricated by a jiggle pin
in the main gallery front plug.
CRANKCASE
VENTILATION
A
tube is lo
crankcase ventilation
cated at
the rear of the engine. The
forward
motion of
vacuum
partial
tube. This
the car causes a
to be formed at the
vacuum action causes air
to be drawn through the engine from
few contaminating vapors. Here, the
incoming air has a chance to warm
up before contacting contaminating
vapors originating in the crankcase.
Warm ventilating air minimizes the
formation of crankcase sludge.
The ventilating air is directed by
a baffle, located on the underside of
the intake manifold, upward into the
front of both valve rocker arm cham
bers. The baffle also directs air to the
front of the lower crankcase and into
the
timing
rear of
rod chamber.
All
filler cap contains a filtering element
which filters the incoming air.
From the filler cap, the air flows
into the front section of the valve
out
there are
where
chamber
the valve push
is then directed
air
the crankcase ventilation tube.
The
the
the cylinder
of
rear
cored
length
of
Upon reaching
wall.
cylinder
each
block,
the
is directed upward into the
heads where it cools the
coolant
cylinder
combustion
its
and
valves,
chambers,
valve seats on
return
to the
front
of the engine.
from
coolant
each
head flows through the
in the intake
sages
into the
cylinder
water
pas
manifold and past
thermostat, if it is open,
supply tank. If the
the water
radiator
is closed, a small portion
is returned to the
for
recirculation. The
pump
system is pressurized to 13-15
thermostat
the
water
The coolant is drawn from the
lower tank of the radiator by the
travels through
coolant
cool
block (Fig. 11).
passages to cool the entire
of
COOLING SYSTEM
delivers the
which
pump
ant to the cylinder
The
Air from the valve rocker arm
from the crankcase
chamber
and
flows into the
rod
water
chain chamber.
the oil filler cap located at the front
of the intake manifold (Fig. 10). The
push
11 Cooling System
FIG.
entire
psi
coolant
by
a
pressure-type radiator
cap.
GENERAL ENGINE TROUBLE SHOOTING
Poor
gine
parts,
failure. A
can
be
the need of a general en
by
tune-up,
engine
or
good
indicate the
gine
performance
engine
by
caused
wear
gradual
by
a
sudden
of
parts
trouble diagnosis will
need
of a complete en
tune-up, individual adjustments,
misses;
rough
engine
celeration;
full power,
has
or
engine
poor
fails to reach
tion temperature.
ac
develop
high
speed
fuel
overheats;
engine
Table 1 is
poor
not
excessive
performance;
sumption;
idle;
does
engine
con
or
the
normal opera
a general
trouble
shoot
ing
haul.
troubles with procedures and checks
Engine
performance
complaints
usually fall under one of the follow
ing basic headings: engine will not
crank;
engine
will not
to
keep
cranks
normally, but
start; engine starts,
running;
engine
but fails
runs,
but
which
lists basic
to be performed to
cause
of
check
engine
help isolate
the
the trouble in a particular
The
system.
refers
after
reference
to
can not
by
a
a
various
trouble
be traced to
tems that
a
definite
system
check, the possible
simple
in the
in the
particular
made
When
systems.
be
could
order of
at
fault
are
sys
listed
their probable occur
rence; therefore, in most cases, the
part(s) replacement or overhaul, or
the need of a complete engine over
chart
to be
rections
that
part
in
each
of
the
detail,
manual
which
checking
procedures as well as cor
covers,
checks should
be
made
in the
order
listed. Some consideration, however,
should
be
given to logical order. For
if the spark plugs are re
for testing and they are not
example,
moved
the cause of the
checks
later
test,
to save
sion
while
trouble, and several
for a compression
calls
time,
the
check
spark
the compres
plugs
are
out.
1-8
GROUP 1-POWER PLANT
Separate trouble shooting charts
included in the ignition, fuel,
lar
under consideration. For
example, in Table 1 under Poor Ac
celeration, the ignition system is listed
are
and
cooling system sections of the
These charts list the basic
troubles listed in Table 1, but cover
only the items relating to the particu
manual.
system
are
acceleration
should all
the trouble. In
as a probable cause of
items that affect
listed. These items
be checked before proceed
the ignition
system
ing
Ignition System Trouble Shooting
Chart under Poor Acceleration, all
probable system
to the next
listed
in Table 1.
the
I ADLt 1 General Engine Trouble Shooting
The
in
ENGINE WILL
NOT CRANK
trouble is usually
cause of this
the
7
(Group
system
starting
Part 2).
If the starting
system is not at fault,
hydrostatic lock or a
engine.
Remove the spark
for
check
seized
a
plugs, then attempt to crank the
Check the fuel
If
ENGINE CRANKS
ENGINE
BUT
KEEP
supply.
fuel in the
sufficient
proba-
end
cranking the engine, hold the
the [od approximately 3/16
/from
inch
is
ignition wire from one
spark
plug, and insert a piece of
proper sized metal rod in the insulator so that it protrudes from the insulator. With the ignition on and the
the
If the
for
engine starts and runs
few seconds, then stops,
or
sPark
n0
the
ignition
2)
Tf the
weak
a
is
1 Part
fuel
the
fuel
(Group
system
is
system
Fuel
a
3). If
fault,
check
not at
1 Part
1).
(Group 1 Part 3).
(Group 1 Part 2).
system
the:
Ignition
is steady
Ignition
system
Engine
compression
check
check
1 Part
timing (Group
the valve
the
2). If
fault,
the spark plugs are not at
the
check
good
(Group
plugs
spark
1 Part
(Group
system
spark
STARTS,
FAILS TO
block-
the cyhnder
If tnere
spark, the cause of the trouble is in
isolate the cause:
Remove
cracks.
or the
_
To
with
starter
tank, the cause of the trouble
bly lies in either the ignition
fuel system.
NORMALLY, BUT
WILL NOT START
is
there
en-
the starter. If the engine
it indicates that water is leaking into the cylinders. Remove the
cylinder head(s) and inspect the gasket(s) and/or head(s) for cracks.
Also examine the cylinder block for
gine
cranks,
system
RUNNING
First, determine if
the miss
or erratic and at what speed the miss
by operating
occurs
the
Misses steady
r,
.
,
wire
wire
at a
u
from
removed
one
,.
a
checked.
spark
T
have
Ground\ the
11
.u
spark
plug
.
fault (page 1-13).
at
..
.
.
-
.
,
.
...
ticular cylinder,
'
.
gas
.
,
m
,
..
check
.
Exhaust
.
.
m.t
r*
is
the:
11/
control
(page
r
valve
igni-
until all cylinders
2)
determine
Misses erratically at all speeds. If
parthe miss cannot be isolated in a r
.
,
the engine with the
time,
1
,
is
.,
iU
.
.
plug
u
been
.
-,,
e
.
tion
BUT MISSES
.4.
m1_
by operating
RUNS,
.
the engine
with
by operating
r
7
j
cylinder not firing. This
done
,
ENGINE
,
Isolate
at all speeds.
r
,
the miss
one
T
1 Part
to
mechanical component of the
which
engine
...
..
at
engine
load.
various speeds under
(Group
~ft,
.
.,
,~
,
t>
.
-^
(Group 1 Part 2).
'
/
%
Fuel system
J
(Group 1 Part 3).
Ignition
J?
system
.
_.
_^
.
-
...
Engine
compression
removed
to
determine
which mechanical component of the
If the
a
engine speed changes when
particular
that
cylinder
before
in the
being
was
out,
If
shorted out.
engine
delivering
shorted
shorted
delivering
operation
the miss was caused
not
is
cylinder
by
power
check
the:
out,
power
no change
is evident,
that cylinder
before
being
engine
is
at
Exhaust
fault (page 1-13).
system
for
excessive
back
pressure.
Cooling
and/or
the
system
for
engine
operating
Part 4).
for internal leaks
a condition
from
that prevents
reaching
temperature
normal
(Group
1
1-9
PART 1-ENGINE
TABLE 1
General
Engine Trouble
Shooting (cont'd)
Check the:
Fuel system (Group 1Part 3).
Ignition system (Group 1 Part 2).
Vacuum booster pump, lines and
fittings for leaks.
Engine compression foT low com
pression (page 1-13).
Misses
ENGINE RUNS,
BUT MISSES
(cont'd)
idle
at
Check the:
Fuel system
ROUGH ENGINE
IDLE
(Group 1Part 3).
Ignition system (Group 1Part 2).
Exhaust
(page
gas control valve
1-30)
Vacuum booster pump, lines
fittings for leaks.
POOR
proper
adjustment
if
the
trouble
the engine
exists
at normal
at all en
temperatures.
Engine
cold.
Exhaust
Check the:
DEVELOP FULL POWER,
Fuel
OR HAS POOR HIGH
Cooling
control
gas
valve
(page
(Group
system
if
system
1 Part
engine
operating temperature slowly
1-Part 4).
Engine
at normal
3).
reaches
(Group
operating tempera
Exhaust
gas
control
valve
(page
Fuel
(Group
system
Determine
sumption
the
with
in the
stalled
CONSUMPTION
1 Part
actual
test
3).
fuel
equipment
con
in
car.
If the test indicates that the fuel
consumption
strate
(Group
to
driving
is
the
habits
sumption.
1 Part
2).
1-Part 3).
for overheating or
Cooling
internal leakage (Group 1Part 4).
Power brake
leaks (Group 6
Engine
vacuum
booster for
Part 2).
for looseness
supports
1-Part 1).
(Group
Improper
head bolt torque
cylinder
1-Part 1).
Clutch for slippageConventional
Drive and Overdrive Transmission
(Group 2-Part 1).
proper
transmission
(Group 3
adjustment
for
Part
All
engine
not
excessive, demon
owner
how improper
will
fuel
affect
con
temperatures.
Check
the:
Engine
compression
Ignition
system
system
1-13).
(page
1 Part
2).
(Group
1 Part
3).
(Group
Camshaft lobe lift (page 1-11).
Valve timing (page 1-12).
Cooling system if the engine
(Group 1 Part 4).
over
heats
system
for
excessive
back
pressure.
Torque
3).
Brake
1-30).
FUEL
(Group
system
Exhaust
ture. Check the:
EXCESSIVE
system
Fuel
1-30).
SPEED PERFORMANCE
system
2).
is cold,
operating temperature, or
gine
Check
speed only.
Cruise-O-Matic
Determine
when
DOES NOT
Fuel
1-30).
Brakes for
(Group 6).
ENGINE
Ignition
(Group
Check the:
high
at
the:
and
Ignition system (Group 1 Part 2).
Fuel system (Group 1 Part 3).
Exhaust gas control valve (page
ACCELERATION
Misses
only.
Tire
(Group
converter
3 Part
(Group 6).
(Group A Part
adjustment
pressure
3).
If the test indicates that the fuel
is excessive, make a
consumption
preliminary check of the following
items before proceeding to the fuel
and
ignition
systems.
Preliminary
Tires
checks
(Group
4
Part 3).
1-10
GROUP 1-POWER PLANT
I ABLE 1 General
Engine Trouble
Shooting (cont'd)
Wheel
alignment
4 Part
(Group
EXCESSIVE FUEL
Exhaust
CONSUMPTION
gas
control
valve
Engine
8
Torque
calibration
(Group
unit
Temperature
1-Part 1).
Cooling
8-
(Group
gauge
Part X)-
system
(Group
1 Part
4).
i
t
7it\
Valves
(page 1-32).
\r
Exhaust
gas
control
valve
Exhaust
(page
1-30).
TEMPERATURE
(Group 1 Part 4).
(Group 3 Part
converter
Cylinder head bolt torque (Group
(Group
,_
^
NORMAL OPERATING
system
2).
(page 1-13).
6).
Temperature sending
8-Part 1).
ENGINE FAILS TO REACH
compression
Cooling
Odometer
Part 1).
ENGINE OVERHEATS
2).
3).
system
(page
1-30).
(cont'd)
Ignition timing
Fuel
(Group 1 Part
(Group 1 Part
Part
Ignition system (Group 1
1).
Brakes (Group 6).
Brakes
Temperature sending
8-Part 1).
unit
Temperature
Part 1 )
(Group
gauge
Engine
(Group
system.
(Group 6).
(Group
thermostat
1
Part 4).
8
.
TUNE-UP
A tune-up is
them
The
within
a
systematic
to
Tune-Up Schedule
(Table
6000
2)
is
applicable
miles and a major
reference after each operation refers
be followed. Perform
TABLE
the operations
for
engine
engine
components, and,
efficiency
either a minor or major
tune-up is
recommended each
to that part of the manual which
in the
sequence
Perform
on
Major
SPARK PLUGS
12,000
minor
bringing
tune-up is
miles.
describes, in detail,
the procedure
Perform
adjust, and test.
X
X
Part 2
Minor
BATTERY
Clean battery
compression
reading
X
INTAKE MANIFOLD
and tighten
bolts.
Page 1-13
Group 1
X
X
Check
and
sion of all
adjust
the ten
drive belts.
X
cable clamps.
battery
X
X
X
X
output.
X
Part 4
Perform
draw.
primary
resistance test.
7
X
X
coil output.
a
Group
Part 1
starter motor
Group 1
Part 1
X
Part 1
Check
Group 7
state of
ELECTRICAL
Check generator
Check
Procedure
X
charge.
current
DRIVE BELTS
Major
cables and
terminals.
Grease battery terminals.
of each cylinder.
Recom
mended
Procedure
Group 1
on
Operation
Tighten
Check
tune-up. A
Recom
ENGINE COMPRESSION
Check
necessary,
listed.
mended
Minor
Take
if
and performance.
2 Tune-Up Schedule
Operation
Clean,
various
recommended specifications to restore
recommended each
The
for testing
procedure
Group
circuit
Part 2
X
1
1-11
PART 1-ENGINE
TABLE 2-Tune-Up Schedule (cont'd)
Perform
on
Operation
ELECTRICAL
Major
Group 1
Part 2
X
continuity test.
of
Replace the breaker
points
X
Check
Check
idle
Group
1
Part 2
through
and
point
Check
X
Add
and
X
X
X
X
X
X
X
engine
mixture.
Group 1
Page 1-13
manifold vacuum.
Group 1
exhaust gas con
Part 1
X
X
valve.
Inspect the radiator, hoses,
and engine for leaks.
X
rotor.
X
COOLING SYSTEM
and adjust vacuum
Clean distributor cap
Part 2
X
Part 3
Adjust idle fuel
trol
advance.
ignition
EXHAUST
X
adjust centrif
ugal advance.
adjust
and
Free the
Check
Group 1
and adjust
speed.
Check
X
X
VACUUM
X
adjust
X
timing.
X
the oil cup.
and
pressure
ADJUSTMENTS
breaker
Lubricate the distributor
cam. Oil the lubricating
wick. Lubricate the dis
Check
dwell.
Group 1
X
Clean carburetor fuel bowls
and adjust float setting.
X
spring tension.
bushing
X
X
and capacity.
the
and the condenser.
tributor
Procedure
Part 3
Check fuel pump
Check the condition
breaker points.
arm
Clean fuel pump filter bowl.
Replace fuel pump filter
bowl strainer.
DISTRIBUTOR
and adjust
Major
mended
Minor
Procedure
FUEL SYSTEM
(Confd)
Perform a secondary circuit
Check
Recom
Operation
mended
Minor
on
Perform
Recom
X
inhibitor
rust
Group 1
X
Part 4
to
X
radiator.
TESTS AND ADJUSTMENTS
(ENGINE IN
CHASSIS)
CAMSHAFT LOBE LIFT
Remove the valve rocker arm shaft assembly
install a solid tappet-type push rod in the
and
push rod
sure
bore
then install a
to
the valve to be checked.
Make
is in the lifter push rod cup,
dial indicator in such a manner as
of
the push rod
have the actuating
point of the
the push rod socket and
the push rod movement
crankshaft
in the
indicator in
same plane as
(Fig. 12). Rotate
slowly in the direction
the
of rotation
lifter is on the base circle of the cam
lobe. At this point, the push rod will be
in its lowest position. Set the dial indicator on
until the
shaft
BE SURE TO PLACE
Indicator TIP IN CENTER
OF PUSH ROD SOCKET
zero, then continue to rotate the damper slowly
is in the fully raised position.
until the push rod
Compare the total lift
1748-A
FIG.
12-Camshaft
Lobe Lift
shaft until
step is a
indicator
recorded on the
Continue to
the indicator reads
with specifications.
check on the
reading.
rotate
zero.
accuracy
of
indicator
the crank
This later
the original
1-12
GROUP 1-POWER PLANT
3 Valve Timing Specifications
TABLE
Intake Valve
Closes
Opens
Crankshaft
Degrees
21
B.T.C.
Camshaft
Lobe Lift
Crankshaft
Degrees
Camshaft
Lobe Lift
51
0.017
0.019
A.BC.
Exhaust Valve
Closes
Opens
1719-A
VALVE TIMING
The
valve
when
poor
noted
and
tor and continue
timing
should
engine
other
all
shaft
be
checked
performance
is
such
as
checks,
carburetion, ignition timing, etc. fail
to locate the cause of the trouble.
timing is checked,
check
for a bent timing pointer.
Bring the No. 1 piston to T.D.C. on
Before the
valve
the compression stroke and see if the
is
pointer
timing
T.D.C.
the
with
aligned
damper.
the
on
mark
If the
timing is not within
timing chain,
valve
camshaft
crankshaft
sprocket,
crankshaft
and
camshaft,
sprocket,
To
check the valve
installed,
engine
Install
timing
proceed
Remove
valve rocker arm shaft
second push
lifter
push
rod
dial indicator in
same
movement
shaft
of
the
crank
the
right
and
valve push
rod) and
cup, then
install
such a manner as
plane
as
the
( Fig. 12). Turn
push
the
rod
crank
damper slowly in the direction
rotation
until
the
lifter is
on
the
lobe. At
this point the push rod will be in its
lowest position. Zero the dial indica
base
Camshaft
Lobe Lift
Crankshaft
Degrees
9
0.019
A.T.C
circle
of the camshaft
dial indicator registers
camshaft lobe lift (Table
being
be
specified
crankshaft
degrees
quadrant with speci
fications (Table 3). After the valve
opening is checked, continue to ro
tate
damper to
the
the valve
check
If the first step
the
of
step
push rod.
the
A 0.060 inch
for
available
means
shorter
rod
is
provide
a
push
to
service
compensating for dimen
in the valve mechan
of
stem
0.062-0.1875
the
tioning
(valve
operations
seat
valve
will
refacing)
and/or
decrease
this clearance to the point that
compensated
for,
lifter
cease
would
determine
is
the
hydraulic
to
if
not
valve
function. To
whether a shorter push rod
necessary,
make
the
following
check:
1. Position the hydraulic lifter
pressor
tool
on
If the
sec
the
enters,
lifter is exces
sive which indicates that the incorrect
push rod has been installed or severe
has
occurred
the push rod
at
or
valve
stem.
In
this case, it will be necessary to de
termine the area of discrepancy and
incorrect or defective part(s)
be replaced. Before the clear
ance is checked position the crank
shaft as outlined in step 2 and 3.
the
should
inch
hydraulic lifter completely
collapsed.
Repeated valve recondi
with
gauge
to rocker arm clear
be
should
enter,
range of the
operating
ends, rocker arm,
VALVE CLEARANCE
will not
standard push rod with a
shorter service
ond
the
of
enters, the old push rod may
used.
wear
closing.
If the first step
checked.
replace
Compare the
indicated on the
the rocker arm of the valve
stem and
the
ance
have the actuating point of the
indicator in the push rod socket and
the
of rota
3).
ism. Valve
to
in
the crank
gauge
follows:
install
a solid tappet-type push rod in its
place. Make sure the push rod is in
(the
turning
slowly in the direction
with the
assembly
No. 1 intake
the
remove
as
on
quadrant
a
damper.
shaft
a
0.017
sional changes
the order of accessibility.
the
67B.B.C.
tion until the
specifications, check the
rod
Camshaft
Lobe Lift
13 Valve Clearance
FIG.
in
Crankshaft
Degrees
the
rocker
com
arm
and
slowly apply pressure to bleed down
the hydraulic lifter until the plunger
is completely bottomed (Fig. 13).
Hold the lifter in the fully collapsed
and
insert the clearance
position
gauge (Fig.
13) between the valve
2. Rotate the
1
piston
is
crankshaft until
T.D.C.
on
at
the compression stroke. With
piston
ing
T.D.C,
on
check
No.
the end of
No. 1
the follow
valves:
No. 1 Intake
No. 1 Exhaust
No. 3 Intake
No. 4 Exhaust
No. 7 Intake
No. 5 Exhaust
No. 8 Intake
No. 8 Exhaust
3. After these
valves
checked,
T.D.C.
position
and
No.
check
6
the
have been
piston
on
following
valves:
No. 2 Intake
No. 2 Exhaust
No. 4 Intake
No. 3 Exhaust
No. 5 Intake
No. 6 Exhaust
No. 6 Intake
No. 7 Exhaust
1-13
PART 1-ENGINE
When compressing the valve spring
push rods, be sure the pis
ton in the individual cylinder is be
low T.D.C. to avoid contact between
to remove
the
valve
the
and
damage could
To replace
necessary to
TABLE 4 Manifold
Gauge
Vacuum Gauge Readings
Engine Condition
Reading
piston or serious
result.
a push
19-20 inches.
Normal.
Low
by late
rod, it will be
remove the valve rock
in all cylinders caused possibly
ignition or valve timing, or loss of
compression due to leakage around the piston
Loss
er arm shaft
assembly as outlined on
page 1-16, step 2.
Upon replacement of a valve push
rod
and/or
valve
rocker
assembly, the engine
aim
and steady.
rings.
shaft
not be
hydraulic
should
cranked or rotated until the
Manifold,
Very low.
by using the tool shown
Fig. 13 on the valve rocker arm
accelerated
pressure
applying
in
manifold
determining
of
in
helping
engine
TEST CONCLUSIONS
vacuum
is
affected
by
adjustment, valve timing,
the condition of the valves, cylinder
compression,
manifold,
and
leakage
of
or
carburetor,
the
cylinder
head gaskets.
Because abnormal gauge readings
may indicate that more than one of
the above factors is at fault, exercise
caution
in analyzing an abnormal
reading. For example, if the vacuum
is low, the correction of one item
may increase the vacuum enough so
as to indicate that the trouble has
been corrected. It is important, there
fore,
that each cause of an abnormal
reading be investigated
tests conducted
order
where
further
necessary in
and
to arrive at the correct
nosis of the
diag
trouble.
Table 4 lists
ings and their
various
a
in
of power
by
a
leaking
one
valve,
head or intake manifold gasket leak,
defect in the ignition system, or a weak
drop in
Excessive back
reading
idle.
at engine
in the
pressure
exhaust sys
tem.
An
Intermittent fluctuation.
Slow fluctuation
of
ENGINE COMPRESSION TEST
above normal
1. Be sure the battery is good.
Operate the engine for a minimum
of Vi hour at 1200 rpm. Turn the
ignition switch off, then remove all
the spark plugs.
position.
3. Install a compression
No. 1 cylinder.
and
the
registers
number
of
engine
a
the
record
gauge
in
the
until
maximum
reading.
compression
reading
Note the
strokes
re
ing.
5. Repeat the test
on each
cylinder,
cranking the engine the same number
of strokes for each cylinder as was
required to obtain a maximum read
on
No. 1
cylinder.
affect of altitude on the gauge read
ing. The
engine vacuum will
with
increase in
altitude.
decrease
caused
possibly
in the
adjustment,
carbu
leak,
or pos
gasket
indicates
excessive
de
cylinder.
A reading of more than 20 pounds
below normal indicates leakage at
the cylinder
head gasket,
piston
rings,
or valves.
even
adjacent
compression
cylinders
in two
indicates
leak. This
a
cyl
inder head gasket
should
be checked before condemning the
rings or valves.
To determine
quired to obtain the maximum read
ing
posits
A low
2. Set the primary throttle plates
and the choke plate in the wide open
gauge
mixture
intake manifold
sibly late valve timing.
retor or
the needle.
4. Crank
of power
the ignition system or a stick
Improper idle
drifting
or
loss
occasional
by a defect in
ing valve.
the
valves
are
equivalent of a
oil
in the
the rings or
whether
fault,
at
squirt
tablespoon of
combustion
the
heavy
chamber, then
distribute the oil
and repeat the compression test. The
oil will temporarily seal leakage past
the rings. If approximately the same
reading is obtained, the rings are sat
isfactory, but the valves are leaking.
If the compression has increased 10
crank
the engine to
pounds
or
more
there
reading,
types of read
possible causes. This
table is merely a guide, however, and
not a firm standard.
Allowance should be made for the
an
loss
partial or complete
cylinder
to locate the
performance.
gauge.
Manifold
Needle fluctuates steadily
increases.
as speed
Gradual
test aids in
vacuum
poor
carburetor
gasket
valve spring.
To test manifold vacuum:
1. Operate the engine for a mini
mum of Vi-hour at 1200 rpm.
2. Install an accurate, sensitive
vacuum gauge on the fuel pump end
of the fuel pump vacuum line.
3. Operate the engine at recom
mended idle rpm.
4. Check the vacuum reading on
the
head
the condition of an en
gine and also
cause
cylinder
or more cylinders caused
direction to
a
MANIFOLD VACUUM TEST
A
A
lifter.
the
collapse
carburetor, or
leak.
lifters have had an opportunity to
leak down to their normal
operating
position. The leak down rate can be
in
of power
is
over
the
leakage
original
past
the
rings.
TEST CONCLUSIONS
A
variation of
specified
However,
inders
pressure
During
20
is
pounds
from
satisfactory.
the compression of all cyl
should
be
uniform within
10
pounds.
A reading
of more
than 20 pounds
test, if the
steadily and
remains the same
during the first two
successive strokes, but climbs higher
on the
succeeding strokes, or fails to
climb during the entire
test, it indi
cates a
sticking or stuck valve.
pressure
a compression
fails to
climb
1-14
GROUP 1-POWER PLANT
1727-A
14 Engine Installation
FIG.
15 Engine Lifting Brackets
FIG.
and
Sling
ENGINE REMOVAL AND INSTALLATION
The
procedures
given
for the
are
only without the transmission
attached. If the engine and transmis
engine
sion are removed as an assembly,
stall
standard
in
threads
the
of
exhaust
the
sling
to the eye
top
rear
Then
lifting bracket
engine
is
Vi-IA
with
at the
manifolds.
tach
stallation
bolts
eye
bosses
the
bolts. The
in
at
and
engine
in
in Fig. 14.
shown
On
cars
transmission
On
rod
dash
power
bracket from the
water
tery
ground cable
move
the
hood,
Re
at the engine.
radiator, and the
air
cleaner.
from
draining
2. Remove the
oil
level
dip
Disconnect the
sure
unit wire at
tank
line,
wiper
line
flexible
the
at
it
at
out
of
the
the fuel
disconnect
On
drive
ator.
ing
and
at
pump
Remove
way.
from the
the
pump
three
and
clips on
the
washer,
at
the
them out
conventional
disconnect
Remove the
spring.
drive
the
flexible
move
air
an
with
Isolate the
magnetic clutch wire.
compressor as outlined
Conditioner
Air
"1958
in
Shop
Manual."
3. Disconnect the heater hose
the
water
and
pump
at
the
at
accelerator retract
converter
and
ture sending
the
Remove the
unit.
engine
unit wire at
of
strap
retaining bracket
the right cylinder
move
the
of the car.
Re
the starter and dust seal (and
Cruise-O-Matic
fluid filler tube
to
converter
assembly
converter
housing
clamp from the
the
engine
conventional
or overdrive
flywheel
housing
cover and the clutch pedal
Disconnect
spring.
release
bracket
Remove
engine.
to
engine
at
the
upper
the
the equal
the bracket
rod and remove
housing
block.
drive
the
remove
retracting
izer
lower bolts, and
lines retaining
to engine
the oil cooler
remove
from
flywheel
bolts.
5. Lower the car, then support the
Remove the converter
transmission.
flywheel
bolts.
bracket
on
inder head
and
housing
Install the
install
bracket
at
upper
engine
retaining
left lifting
the front of the left cyl
where
the
the
coil
engine
mounts,
right
lifting
the rear of the right cyl
inder head, then
lifting
4. Raise the front
flywheel
the
in the housing. Remove the
engine ground
and the starter cable
rear
tempera
the sending
re
housing lower
the converter
or
over
acceler
the
Secure
nuts.
intake
manifold, the generator wires at the
Cruise-O-Matic,
with
inspection
conditioner,
the engine.
at
cars
Remove
the left valve rocker arm
line.
mani
left sup
access cover and the cover assembly.
On
head.
or
insulators
On
units,
the
exhaust
the engine right and
clutch
from the
way.
units,
cars
generator,
lines
position
the
from the
pipes
folds,
line from the
release
on
inlet
and
cars with a windshield
the
brackets
the
tion the wires out of the way.
of
the power brake line at the
manifold
then
On
valve rocker arm cover and posi
washer
line,
brakes, dis
stick
windshield
the vacuum
the wire loom
On
intake
power
out.
oil pres
the sending
unit, the flexible fuel line
left
connect
with
disconnect the
sending
position
cars
cover and remove the
and the coil.
pump, then
steering pump to the
hood left hinge in a position that will
REMOVAL
1. Drain the cooling system and
crankcase. Disconnect the bat
pump
crankcase ven
tilation tube. Disconnect the muffler
steering, dis
steering
wire the power
On
bracket). Remove the
port
power
with
the
prevent the oil
the
accelerator
and secure them
panel.
cars
connect
the
at
bracket
cross shaft
to the
Cruise-O-Matic dis
with
the accelerator rod and the
connect
attach
the
engine
sling (Fig. 15). Raise the
en
carefully pull it
from the transmission. Lift the en
gine
slightly
and
gine out of the
engine
compartment
1-15
PART 1-ENGINE
tainer securing the
trol valve, then connect both
to the
manifolds
tighten the
and
install the
(and the
starter
auto
filler tube
fluid
transmission
matic
pipes
to 23-28 foot
nuts
torque. Position the dust seal
pounds
and
exhaust
inlet
muffler
con
gas
exhaust
bracket).
Remove the
mission and
7. Connect the
intake
wires, the
unit
sending
the heater hose
connect
Connect the
manifold.
ground
car.
generator
engine temperature
and
from the trans
support
lower the
the
engine
install the
and
strap
wire,
at
starter
retaining clamp to the
the right cylinder head.
rear of
cable
8. Connect the flexible fuel line,
the oil
1728-A
FIG. 16-Engine
the
Work Stand
pressure
Install the
primary
the
stall
install it
and
(Fig.
on a work stand
gear) until the shaft
the
16).
disc
clutch
3. Install the
INSTALLATION
with a new gasket on each
tie
Temporarily
the
the
studs of
Loosen the
then
15),
from the
over
exhaust manifold.
the
at
left sup
chassis.
brackets
lifting
engine
(Fig.
left
the
gasket
new
a
to
valve
engine right and
insulators
port
the
Place
manifold.
the
side,
right exhaust manifold studs.
the
on
exhaust gas control
Attach
and
the
remove
sling
tighten
the
carefully into
Make sure
bolts.
the car. In
of
housing
con
or
lower retaining bolts
them to 45-50 foot
housing
tighten
and
the
flywheel
manifolds
exhaust
the
with
are
properly
inlet
muffler
in the block
and the dowels
the holes
in the flywheel
converter
housing.
pipes
engage
housing
or
move
cars
with
Cruise-O-Matic
cars with
the retainer securing the con
in the housing, then install the
flywheel to converter lockwashers
Tighten the
and nuts.
Cruise-O-Matic, start
into the crank
pilot
converter
shaft.
On
start
units,
drive
gear
the
the
clutch
adjust
transmission
engine
in
if the input
clutch
up"
after
crankshaft
drive
the
the
lower
housing
On
access
cover
to 25-28
nuts
plate
assembly.
lines retaining
nect
to
the
engine
"hangs
enters, turn the
(transmission
in
conventional
units, install the
position of
shaft will not enter
shaft
slowly
main
disc. It may
relation
disc. If the
loom in the retaining
the three
clips
cover.
arm
rocker
washer,
pump lines.
washer
On
Cruise-O-Matic,
cars with
con
the trans
mission rod.
On
conventional
drive
drive units, install the
tracting
Connect
spring.
and
over
accelerator re
the accelera
tor rod.
On
nect
cars with power steering, con
the
power
steering pump bracket
to the water pump.
nect
brakes,
power
cars with
the power
con
brake line to the in
take manifold and to the
flexible line
install the line in the retaining
clips on the left valve rocker arm
and
cover.
con
and
the
Install the
On
cars
air
conditioner,
connect the magnetic clutch wire and
the compressor
clamp.
an
with
lines.
or overdrive
transmission
into the
be necessary to
the
verter
oil cooler
conventional
re
verter
foot-pounds torque. Install the
On
In
level dipstick. Position
oil
cars with a windshield
On
On
the coil
wires.
torque.
pounds
engine compartment.
aligned
the
left
and
lifting sling
brackets.
lifting
line.
then
foot
engine
engine
the
engine
work stand.
engine
to
5. Raise the front
the
right
engine
Disconnect the
remove
On
connect
high tension
nect the accelerator rod and
insulator
support
stall
bolts,
and
coil
and
and
wire,
vacuum
wiper
the left valve
connect
45-50
to
wire
or con
torque.
4. Start the
and
housing
upper
bolts
the
pounds
verter
2. Lower the
housing
verter
the
on
crankcase ventilation
tube and the flywheel
1. Position the
valve,
splines mesh with
splines.
unit
sending
windshield
the
or overdrive
bracket. Con
the clutch release rod and install
clutch
the flywheel
retracting
housing
6. Tighten
port
drive
clutch
all
spring.
lower
Install
cover.
insulator bolts
and nuts
to 45-50
re
the
radiator.
Fill
and
the crankcase with the proper grade
and
the engine front sup
foot-pounds torque. Remove the
9. Install
bleed the cooling system. Connect the
heater hose at the water pump. Fill
quantity
of
engine
the engine at
fast idle
gaskets
hose
and
leaks. Install the
oil.
Operate
and check all
connections
air
cleaner.
for
1-16
GROUP 1-POWER PLANT
roo/-T53l-300-A
ENGINE DISASSEMBLY AND ASSEMBLY
(ENGINE REMOVED FROM
ENGINE
Standard Eye-Bolt
Y\6- 1 8 THREAD
CHASSIS)
DISASSEMBLY
INTAKE MANIFOLD
1. Disconnect the
wires at the spark plugs and remove
the wires from the ignition harness brackets on the valve
Remove the distributor cap
rocker arm covers.
Disconnect
Remove the
lines,
distributor
the
radiator
line
fuel inlet line,
carburetor
fuel pump
then remove the
Remove the
vacuum
and
heat
the automatic choke
the vacuum pump
discard the
gasket.
supply tank. Slide the clamp
pump bypass hose toward the
water
assembly.
distributor.
at the
Remove the
tube.
the
on
Remove
water pump.
valve rocker
arm covers.
FIG. 17 Intake
1
2. Crank the engine until the No.
is at T.D.C. at the end of the
piston
compression stroke.
damper
shaft
damper
the
cated
on
XX).
Starting
loosen
the
Rotate the
the
at
right
by
crank
45
an additional
(indi
the symbol
No. 4 cylinder,
valve
rocker
arm
bolts in sequence, two
time. After the bolts are all
shaft support
turns at a
loosened,
remove
arm shaft
assembly
Starting
plate.
follow
left
the
lowed to
rods
in
3.
procedure
must
be fol
damage to the
Remove the
manifold
valve
push
clamp and
Remove the
bolts
left front
""i
with
e-
the
intake
10
Install
1 8 threads
and right rear rocker
holes
arm cover screw
lifting
remove
bolts.
retaining
hold
and attach
sling (Fig.
the
from the
engine.
manifold
gaskets
and
manifold and
remove
seals.
4. Lift the hydraulic
from
them
the
in
cylinder
a
so
rack
installed in their
internal
that
lifters
and
place
they may be
original
parts of each
semblies
cleaned.
intact
assembly with the tool
in Fig. 20. After the lifter is
parts.
until
Keep
they
bolts and
inlet tube
the oil pump and
remove
assembly, and remove
as an
the oil pump drive shaft. Discard the
oil
gasket.
pump
plunger
shown
keep
removed,
EXHAUST
the parts together
MANIFOLD
CONTROL
GAS
all
intermix the
so as not to
Remove
Remove
the
tab washers
and
exhaust
exhaust
right
manifold
manifolds.
gas
control
exhaust
mani
fold.
1. Remove the fuel pump and dis
card the gasket. Disconnect the drive
belt adjusting arm at the generator.
Remove the generator support bolt
the
at
head bolts,
head holding
cylinder
then install the cylinder
tween the head
move
Lift
21).
the block.
off
the
Do
cylinder
not
pry be
the block. Re
and
discard the
and
the cylinder block.
cylinder
head
ley,
fan
and
2. On
remove
shaft.
shaft
the
the
oil
Remove the
and
oil
filter from the
filter adapter
oil
pressure
sending
Discard the
assembly.
an
power
steering,
gasket.
pulley.
Install the
the crank
puller on
22)
and
remove
damper.
3. If the
as
with
cars
pul
assembly.
the two cap screws and lock
damper (Fig.
stepped
assembly
an
pump,
Remove the large cap screw and
washer from the end of the crank
AND ADAPTER
Unscrew
as
drive
and
water
securing the power steering
pulley to the crankshaft damper, then
the
gasket.
OIL FILTER
brackets,
generator,
belts. Remove the
Remove
washers
HEADS
fixture (Fig.
bracket
the water pump and the
bolt
remove
Remove the
head
FRONT COVER
CYLINDER
at
exhaust
the
from the
valve
EXHAUST
VALVE
the
remove
parts.
AND
lower retaining bolts
and
unit
Installation
or
ends),
crankshaft
down (the
remove
it
same
sleeve
O.D.
is
on
not
both
in Fig. 23.
as shown
If the crankshaft sleeve is stepped
down (different O.D. on each end),
remove
it
with
three-jawed puller
a
(Tool 7675-N).
bore. The
hydraulic
valve
are matched sets.
lifter assembly
not intermix the
and
adapter.
valve
block
be
the
Raise
17).
it
carefully
Remove the intake
the
can not
fingers, remove the
lock ring (Fig. 18), and the push rod
cup (Fig. 19), and remove the lifter
CYLINDER
distributor
the
and
standard eye
engine
valve
sequence.
down bolt
the
the
on
procedure
support
Remove
distributor.
in
No. 5 cylinder,
shaft
avoid
mechanism.
the oil baffle
arm
rocker
This
valve
and
at the
same
valve
bolts.
the
rocker
If the hydraulic lifters
removed with
Manifold Removal
are
the
to
Do
as
be
OIL
PAN
AND
OIL
screws
card
and
4. Remove
PUMP
1. Remove the
oil
remove
the
pan
oil
retaining
pan.
Dis
the gasket.
2. Remove the
the
cylinder
the
front
pump attaching
gasket.
fastening
to the
block,
front
cover.
then remove the cylinder
5. Discard the
oil
screws
cover
cylinder
front
cover
1-17
PART 1-ENGINE
Tool HL1
FIG.
1731-A
18 Lock Ring Removal
Tool HL 1
FIG.
PUSH RODS
RINGS
CUPS
19 Push Rod Cup Removal
VALVE LIFTERS
Tool-T58P-6085-A
Too/ HI/
FIG.
VALVE UFTER RACK
1733-A
20 Hydraulic Valve Lifter Removal
1524-A
FIG.
m
21 Cylinder Head
Holding Fixture
m
Tool-T58P-6316-A
1551-B
FIG.
22 Crankshaft Damper Removal
Crankshaft Sleeve
FIG.
Tool T56P-6362-A
23 Crankshaft Sleeve Removal
1552-B
1-18
GROUP 1-POWER PLANT
I
Tool T52L-6261-CEE
ToolT54L-6250B
Detail 6-BEARING REMOVAL
BEARING REPLACER
Detail 8
56-A
FIG. 25 Camshaft Bearing
24 timing Chain
FIG.
Sprockets Removal
and
Replacement
or
Installation
been
SPROCKETS AND TIMING CHAIN
Remove the
slinger.
crankshaft
Remove the
button
and
screw,
the
tainer, and
Slide both
oil
thrust
camshaft
the
and
sprockets
timing
the
remove
and
chain as an as
timing
Carefully
(main
the camshaft
remove
caution to avoid
by
of the en
marked
their
damaging
flywheels,
conventional
be
replaced
in
the same posi
and remove the clutch pressure
plate
disc.
and
2. Remove the flywheel retaining
and remove the flywheel.
CRANKSHAFT AND CONNECTING ROD
and/or car
ridge
bon deposits from the upper
the cylinder bores. Move the
to the bottom of
the
its
head to
Remove
the
ridge with a
ridge cutter.
instructions
furnished
manufacturer.
area
removing
in
Never
piston
collect
cylinder
Follow the
by
cut
excess of
ridges.
end of
travel and place
on the piston
cuttings.
travel
with
the
or
tool
the
into the
\':vi inch
After the
ring
when
ridge
has
removed
nuts
from the connecting
nuts
the
rod and pis
top
handle
cylinder
wall
of the
end of a
cyl
ham
crankpin
when
removing
Remove the bear
ing
inserts from the connecting
rods
caps.
4. Remove the
Carefully
the cylinder
the
finished
rear
journal
and
rear
are
and
CAMSHAFT
Drill
shaft
a
rear
not
fracture
of
the thrust
damaged.
with
or
caps.
out
care
to
damage to
Remove the
from the block
surfaces.
oil
seal
bearing
cap to block
block
so that
crankshaft
avoid possible
bearing
crankshaft
block
surfaces
Handle the
main
main
lift the
cap,
side
and
seals.
remove
the
BEARINGS
plug.
cam
and use
ASSEMBLY
Camshaft
bearings
for
are
pre-finished to size
0.015-inch
available
standard and
journal diam
not inter
changeable from one bore to another.
The bearings must be installed in their
respective bores.
undersize
The
eters.
bearings
1. Position the
bearing bore,
are
bearing
new
and
press
at
it in
the
place
the tool shown in
Fig. 25. Align
holes in the bearings with the
holes in the cylinder block when
with
the oil
oil
bearings
are installed. Be sure the
front bearing is installed
0.005-0.020 inch below the front face
of the cylinder block (Fig. 26).
2. Clean out the camshaft rear
the
camshaft
bearing bore plug recess thoroughly.
Coat the flange of a new plug with
water
with
resistant
sealer
flange
the
install it
in (Fig. 27).
it is flush or
and
facing
Drive the plug in until
slightly below the casting
MAIN
BEARINGS,
surface.
REAR JOURNAL
OIL
SEALS, AND CRANKSHAFT
The crankshaft and related
are shown
1. Be
shaft
'/2-inch hole in the
bore plug
the
bearings (Fig.
CAMSHAFT BEARINGS
Remove
bearing inserts from
bearing caps.
bearing
remove
camshaft
25).
then pull the cap off the
piston and rod.
the
is
the
and
the
the
the
until
Avoid damage to the
mer.
bearing
ASSEMBLIES
1. Remove any
crankshaft
Push the connecting
rod.
and
bolts
a cloth
bolts,
inder
the pressure plate cover so that
can
hex head
caps
locations.
original
Remove the
ENGINE
bearing
ton assembly out the
FLYWHEEL
tion,
so
the
at
Tool T-7600-E to
remove
are
rod)
connecting
they can be installed in
connecting rod being
down. Remove the pal
rod
the journals and lobes.
it
and
carefully
all
sure
3. Turn the
pulling it toward the front
mark
stroke and
2. Make
sembly (Fig. 24).
1. On
the piston is
until
the cloth with the cuttings.
cap
button spring re
the fuel pump eccentric.
of
cutter
then turn the
thrust
CAMSHAFT
Use
its
bore,
top
sprockets and
gine.
cylinder
crankshaft
the
remove
removed,
from the
spring, the sprocket
forward,
chain
front
oil
sure that all
journals,
seal
and
grooves
new rear
parts
in Fig. 28.
journal
are
bearings,
the
rear
clean.
oil seal
crank
journal
Install
a
in the block
1-19
PART 1-ENGINE
INSTALL FRONT BEARING 0.005-0.020-INCH
BELOW FRONT FACE OF BLOCK
Tool-T58P-6266-A
FIG.
26 Camshaft Front Bearing Measurement
FIG.
1S45-A
27 Camshaft Rear Bearing Bore Plug
Installation
CYLINDER BLOCK JOURNAL SEAL
MAIN BEARING INSERTS
FLYWHEEL AND
RING GEAR
DAMPER
POWER STEERING
PUMP PULLEY
MAIN BEARING CAPS
WASHER
FIG.
28 Crankshaft
1537- A
and
Related Parts
1-20
GROUP 1-POWER PLANT
Too/-T58P-<570?-A
1360-A
29 Seal
FIG.
to Block Installation
(Fig. 29) and rear main bearing cap
(Fig. 30). After installation, cut the
ends
1459-A
the seals flush.
of
2. If the crankshaft main bearing
journals have been ground to a defi
nite
install
undersize,
Place the upper
serts in position in
in the
tang fitting
not get
the
dirt
bore
the
slot
the
the
Do
ing
material
the
the inserts. In time the dirt may
distort the bearing and cause bear
failure.
inserts in the
the
bearing
Be
bearing
bearing
main
caps.
block. If
The
crankshaft
sufficient
to damage
the
the
of
each
bearing following the procedure
under "Main Bearing
(page 1-37). If the bearing clearances
apply
a
light
coat of
to the journals and bear
then install all the
bearing caps,
except the thrust bearing cap (No. 3
bearing). Main bearing caps are num
bered 1 thru 5 starting at the front
of the engine. The arrows on the cap
should be pointed toward the front
of
the
engine.
bolts
cap
torque.
seals
to
Dip
in light
Tighten the
engine
use
seals
sealer
are
dipped in
on
designed
oil.
bearing
foot-pounds
95-105
bearing cap
the rear
side
oil, then immedi
ately install them in the
not
Do
grooves.
the side seals, the
to
Using
expand
sealer
when
may
re
tard this expansion. It may be neces
for the
sary to tap the seals into place
last Vi inch of travel. Do not cut the
seal
from the inside
bubbles
appear
projecting
ends.
of
in the
leakage.
oil
be
not
per
newly installed seals until
time has been allowed for
to
seals
into
expand
with
Check the
rear
the
limit, inspect
ing faces for
fective
not
dirty, they probably
or
aligned
bearing
lowing the recommended
(step 6), then recheck the
procedure
end
the
seal
play.
PISTON
AND
CONNECTING ROD
INSTALLATION
sure
to install the
pistons
the bolts finger tight, then pry
removed, or to
which
they
thrust
forward
31).
(Fig.
bearing
forward
the
against
half
Hold the
of
the
crank
pry the thrust
bearing cap to the rear (Fig. 32). This
will align the thrust surfaces of both
and
bearing. Retain the for
of the
ward pressure on the
and
crankshaft,
tighten the cap bolts to 95-105 foot
torque (Fig. 33).
pounds
7. Force
the
indicator
crankshaft
so
the contact
the crankshaft
indicator
toward
the engine. Install
rear of
axis
is
point
flange
parallel
dial
a
rests
and
to the crank
(Fig. 34). Set the dial
shaft
axis
zero,
then push the crankshaft
ward
and
note
the
the
reading
on
on
for
the
dial.
end
replace
play
exceeds
the thrust
the wear
bearing. If
were
were
fitted.
Each connecting rod and bearing cap
numbered from 1 to 4 in the
right
left
the
bank
from 5 to 8 in the
and
bank, beginning
The
engine.
necting
rod and
the same side
cylinder
ever
the
con
cap must be
when installed in
bore. If
a
connecting rod
one block or
transposed from
to
cylinder
rod
the front of
bearing
the
is
at
numbers on
on
another,
be fitted
be
should
the
spond with
1. Oil
the
bearings
new
the connecting
and
to
numbered
corre
new cylinder number.
piston
rings,
and cylinder walls with
pistons,
light
engine
oil.
2. Make
properly
ference
ring
If the
in the
they
are
should
against
the
the faces fol
and align
which
halves
de
were
Install
properly.
thrust
from
shaft
nicks,
are not
same cylinders
crankshaft
limit,
burrs,
scratches,
dirt. If the thrust faces
or
mini
the thrust bear
bearing cap
the
thrust surface of the upper
the
play is less than the
end
mum
Be
6. Install
Replacement"
are satisfactory,
air
the
grooves.
clearance
Installation
Bearing Cap
on
lower the
main
ings,
air
compressed
test should
above
formed
surfaces.
5. Check
oil
the seals
careful not
Carefully
place.
engine
Blow
outside.
oil, it indicates possible
3. Install the lower
4.
into
parting lines between the bear
and the cylinder block from
cap
against
the
cap side seals for leaks
few drops of oil into
a
squirting
with
foreign
or other
by
provided.
under
ing
bearing
main
bearing in
main
to Rear
correct
bearings.
undersize
30 Seal
FIG.
push
sure
spaced
of
the piston.
compressor
the
handle
the
piston
until
on
in
gaps
ring
around
Install
the
with
are
the circum
a piston
piston
a
and
hammer
it is slightly below the
1-21
PART 1-ENGINE
^
1 546-A
FIG.
31 Thrust Bearing
Alignment
Pry Crankshaft
Forward
32 Thrust Bearing
Alignment
-M
1547-A
Pry Cap
Backward
?
m
A-
FIG.
:
V- *
*
1505- A
FIG. 34-Crankshaft
1548-A
FIG.
33 Thrust Bearing
Alignment Tighten
Cap
End
Play
1-22
GROUP 1-POWER PLANT
Tool-6149-A
FRONT
/
ENTATIONS TO FRONT
OF ENGINE
1566- A
FIG.
1567-A
35 Piston Installation
FIG.
36 Connecting Rod Side Clearance
BEARINGS
CAMSHAFT REAR
BEARING BORE
PLUG
TIMING CHAIN AND
CAMSHAFT SPROCKET
FUEL PUMP ECCENTRIC
FIG.
top
37 Camshaft
of the cylinder
the
Install the
(Fig. 35). Be
rods
with
piston
to
TIMING MARKS
avoid
ing
the
of
be toward the
outside
3. Check
the
the
the bottom of its stroke, then push
the piston
all
the way down until the
bearing
connecting
rod
seats on
crankshaft
journal. Install the
the
con
each
procedure
the pal nuts and tighten them to 3-4
clearance
Rod
38 Aligning Timing Marks
necting rod cap, then tighten the nuts
to 45-50 foot-pounds torque. Install
engine.
bearing following
under "Connecting
FIG.
the indenta
head toward the
front of the engine. When installed,
the bearing lock slots in the connect
rod should
of
Bearing Re
(page 1-38). If the bear
foot-pounds torque.
ing
apply
a
journals
light
and
are
to specifications,
5. After the
coat of engine oil
to the
bearings.
4. Turn the
crankshaft
piston
stalled, check the side clearance
be
ing
have
to
connect
in
assemblies
tween the connecting
throw
and
been
rod
crankshaft
CAMSHAFT
The
camshaft and related parts are
shown
in Fig. 37. Oil the camshaft
slide it through the
and
carefully
the bearings.
TIMING CHAIN AND
rods
on
journal (Fig. 36).
each
SPROCKETS
1. Place the keys in
slots on
placement"
clearances
1539-B
sure
journals.
crankshaft
piston
tion in the
1 536-B
Related Parts
and
to guide the connecting
damaging
BOLT AND WASHER
2. Position the
ing
chain on
shaft
position
in the
the crankshaft and camshaft.
sprockets and tim
the camshaft and crank
(Fig. 24). Be
marks on
sure
the
timing
the sprockets and chain are
positioned as shown
in Fig. 38.
1-23
PART 1-ENGINE
REFERENCE POINT
RIGHT SIDE OF CHAIN
TAKE UP SLACK ON LEFT SIDE. ESTABLISH A REFERENCE POINT AND
MEASURE DISTANCE A. TAKE UP SLACK ON RIGHT SIDE AND FORCE
LEFT SIDE OUT WITH THE FINGERS AND MEASURE DISTANCE B.
DEFLECTION IS A MINUS B.
1511-B
FIG.
39 Timing Chain Deflection
DOWEL
FUEL PUMP ECCENTRIC
CRANKSHAFT FRONT OIL SLINGER
FIG.
1 540-B
40 Fuel Pump Eccentric
and
Front Oil Slinger
Installed
3. Rotate the
viewed
side of
crankshaft
in
a
clockwise
direction (as
from the front) to take up the slack on the left
the chain. Establish a reference point on the block
from this
and measure
point to the chain
(Fig. 39). Rotate
the crankshaft in the opposite direction to take up the
Tool-T58P-6700-B
slack on
of
the right side of the chain, then force the left side
the chain out with the fingers and measure the distance
between the
The deflection
reference point and the chain.
is the difference between the two
measurements.
flection
the
exceeds
Vi
inch,
replace
timing
If the de
chain and/or
sprockets.
4. Install the fuel pump
camshaft
retainer.
pounds
and
sprocket
cap
Tighten the
eccentric
screw
sprocket
(Fig. 40),
and
thrust
cap
screw
the
and
button spring
to 35-45 foot
torque. Install the camshaft thrust
button spring
thrust button. Install the crankshaft front oil slinger.
CYLINDER FRONT COVER AND FRONT OIL SEAL
Oil Seal Replacement. It is
1526-A
FIG. 41
oil seal each
1. Drive
Oil Seal Installation
out
out the recess
2. Coat
a
the old seal with a pin punch, then clean
in the
new
cover.
seal
(Fig. 41). Drive the
recess.
good practice to replace the
time the cylinder front cover is removed.
Check
seal
the seal
spring is properly
grease, then install the
with
in
until
after
positioned
it is
fully
installation
in the
seal.
seated
seal
in the
to be sure the
1-24
GROUP 1-POWER PLANT
Tool-
T 521-6306- AEE
1553-B
43 Crankshaft Sleeve Installation
FIG.
the gasket contacts the
adapter
face,
it Vi-turn.
then advance
OIL PUMP AND OIL PAN
1. Insert the
into the
(Fig. 46). Do
not attempt
The drive
seat readily.
1. Clean the
the
and
cylinder
faces. Coat the
block
block
cover
the
and
the cover bolt
Position
threads with sealer.
a
2. Install the
and
On
the
front
crankshaft
front
cover
keyway in
the
so
key
the
Position the
shaft.
in the
cover
pilot
and
to 23-28 foot-pounds torque.
3. Install the
front
cylinder
erator
adjusting
arm
bracket,
While
in
on
the
Remove the
4. Lubricate the
a white
lead
bricate the
with
sleeve
end
if
grease.
(Fig.
sleeve
O.D.
damper
seal
on
rubbing
with
7.
Using
front
with
stepped
each end).
keyway
lu
surface
crankshaft
with
cover
bore
down (differ
Line up the
the
key
brackets,
by
retained
and
on
the
pump
oil
2. Position
the
on
Install
oil
the
generator,
drive belts.
surfaces.
new
adapter
adapter
the
place
and
filter
the
filter
shown
screws
filter in
on
the
the oil pan assembly
Install the retaining
tighten
and
gasket
them
from the
12-15 foot-pounds
center outward to
torque.
FLYWHEEL
shaft
Tighten
On
on
the crank
install the retaining bolts.
and
the
bolts
75-85
to
foot
torque.
cars with conventional
transmissions,
overdrive
or
Tool
use
clutch
pressure plate.
drive
disc,
then
Tighten the
gasket.
to
CYLINDER HEAD
a
Clean
Coat the
with
position
torque.
adapter
sealer
recess.
filter
to
retaining bolts to 23-28 foot-pounds
gasket, and install the
gasket on a new
adapter.
oil
Apply
assembly
adapter
new
a
7563 to locate the
filter assembly is
in Fig. 45. Clean the
gasket
Tighten
screws
retaining
block.
install the
The
the intermedi
rotate
oil pan and place
pounds
gasket, install the
a new
pump.
the
hex may
distributor
a new position.
Position the flywheel
OIL FILTER AND ADAPTER
the smallest O.D.
cylinder
is
the
as
foot
pilot.
crankshaft
Install
43)
into the
the
ent
in
pilot,
and oil mixture and
oil
fan
pump retaining bolts.
water
into
to force
will not
install
and
steering, the
power
steering pump is
power
then
tighten the cover bolts to 12-15
pounds torque.
the pump
with
cars
gen
fuel
pushing
Position
cover
the bolts.
stall
gasket
pump
sealer.
assembly.
the gen
and
water
apply
the water pump, pulley, and
the
bracket
support
and
new gaskets on
On
bolts finger tight. Position the
erator
surfaces
an
the block (Fig. 42).
against
damper. Tighten the
6. Clean the
the
crank
the end of the crankshaft and
over
on
cover
screws
To align,
shaft
the
with
ate shaft
power
separate
a
with
cars
misaligned
in
and
23-28 foot-pounds torque.
steering pulley, install the pulley
cylinder
pilot aligns with
130-
145 foot-pounds torque.
tool on the cylinder
pilot
alignment
screw
it to
tighten
and
washer,
be
shaft.
5. Install the damper cap
new
the block.
gasket on
(Fig. 44).
on the crankshaft
sur
gasket
gasket surface of
cover
and
front
cylinder
install the damper
then
crankshaft,
new
as an assem
the pump into position if it
Cylinder Front Cover Installation
shaft
a
housing
the pump and shaft
stall
bly
Position
pump
1555-B
42 Cylinder Front Cover Alignment
pump drive
oil
pump.
gasket on the
rool-T58P-6019-A
FIG.
oil
oil, then
on
Hand tighten the filter
the
until
1. Clean
ket
head
ply
carbon
a
and
block
coating
deposits
from the
sealer residue
and gas
cylinder
gasket surfaces.
of
head
to both sides of a
gasket
Ap
sealer
head
gasket.
Use the brush furnished to
spread
new
1-25
PART 1-ENGINE
OIL PRESSURE
ADAPTER
SENDING UNIT
GASKET
Tool T52L-6306AEE
1SS4-B
FILTER ELEMENT
44 Crankshaft Damper Installation
FIG.
1528-A
FIG.
45 Oil Filter Assembly
haust
inlet
fold, using
the
of
valve
control
gas
muffler
Temporarily
to the exhaust
Position
a
inlet
new
tie
the
manifold.
the
over
gasket
pipe studs of the
left
ex
manifold.
2. Position the
exhaust
head
the cylinder
on
the
over
a new gasket on each side
valve.
muffler
haust
valve
pipe studs of the mani
manifold
install the
and
retaining bolts and tab washers.
Tighten the retaining bolts to 23-28
foot-pounds torque, working from the
the ends. Lock the bolts
center to
bending
46 Oil Pump
FIG.
and
a
Inlet Tube Installed
flat
by
one tab of the washer over
on
the bolt.
INTAKE MANIFOLD
the sealer evenly over the
ket
surface.
"front"
on
Guided
by
the
word
the gasket, install the
gasket over
the cylinder
2. Place the
cylinder
engine, then remove the
tures.
entire gas
is
progressive steps.
proper
sequence
them
to
on
the
holding fix
with
head bolt tighten
in three
Tighten the bolts to
torque
(Fig.
foot
torque in the same sequence.
pounds
head
performed
foot-pounds
Finally,
80-90
been tightened to specifications, the
bolts should not be disturbed.
sealer, then install the
cylinder
procedure
tighten
to
in
47),
the
then
70-80 foot-pounds
The intake
1. Coat the
draulic
provide
fill
1. Coat the mating
surfaces of the
light film
of
graphite grease.
On
using
matic
the
the
a
new
exhaust
gasket
manifold.
air
install the
chamber
Be
securely fastened.
manifold,
started, if
which
sure
the
Place
each
which
it
auto
cover
hy
each
Do
The lifters
after
to
not
will
the engine is
free
they
are
may
cause an oil seal
of
any
oil
be
and lifter body.
lifter in the bore from
plunger
was removed.
on
cover
Position the
of
with engine oil
with oil.
faster
much
film
outside
lifter
initial lubrication.
tween the
right
choke
valve
fill the lifters
EXHAUST MANIFOLDS
assembly is
manifold
in Fig. 48.
shown
head bolts have
cylinder
exhaust manifold with a
3. The
60-70
bolts
the
After the
bolts.
ing
tighten
head dowels.
Coat the head bolt threads
water resistant
head
torque in the
same sequence.
is
ex
2. Clean the mating
the
intake manifold,
surfaces
cylinder
of
heads,
1-26
GROUP 1-POWER PLANT
CRANKCASE
BREATHER CAP
OIL FILLER TUBE
V><5
WATER
MANIFOLD-TO-BLOCK FRONT SEAL
TEMPERATURE
SENDING
USE Too/-S-8683
1532-A
MANIFOLD-TO-HEAD
UNIT
GASKET
47 Cylinder Head Bolt
Tightening Sequence
FIG.
CRANKCASE
VENTILATION TUBE
CYLINDER HEAD GASKET TABS
INTAKE MANIFOLD LOCATING DOWEL
VACUUM PUMP
CONNECTION
INTAKE MANIFOLD
MANIFOLD-TO-HEAD
GASKET
FIG. 48-lntake
MANIFOLD-TO-BLOCK
REAR SEAL
Manifold
the
Assembly
compression
(indicated
XX).
rocker
baffle
POSITION NOTCH OVER
RIDGE ON SEAL
MANIFOLD
GASKET TABS
Install
arm
shaft
1520-B
the
by
rocker
shaft
Be
in
prene
sealer.
seal
surfaces
Position
cylinder
Be
with
head
the holes
being
the
on
gasket tabs.
gaskets are
intake
the
cylinder
placed
manifold
the
secure
in
each
in
is
seals
corner
of
the outside edge of the seal surface.
The
installation
correct
of
After the intake
seal
in
finger
a
run
to
area
head
the
position
pump
Be
in place,
and
manifold
Start
seals.
hose
by-pass
manifold.
the seals are
seals are not
the intake
remove
neoprene
bolts
intake
holes in the
the
sure
the
gas
gaskets
manifold
in
alignment.
23-28
Install the
bolts
taining
left
the
center
them
torque,
Remove
and eye
bolts. Install the
radia
will
bending
and
is
seals
in Fig. 49.
shown
additional
shaft
for
sup
time con
minimize the
possibility
of
the push rods, valves, or the
Be
sure
that the hydrau
lic lifters have leaked down to their
normal
kets
cylin
this procedure will permit
rocker arms.
lifting
5
procedure
arm
working
ends.
bolts
foot-pounds
hydraulic lifters to leak down.
to
This
to the
in
same
contact
the
the No.
at
rocker
bolts. The
sumed
tighten
and
valve
manifold re
the distributor and the engine
sling
are
the
foot-pounds
from the
manifold
and
Starting
der, follow the
fully
Tighten
45-50
to
sequence
water
bottom.
two turns at a
the supports
the cylinder head.
in
finger
the No. 4 cylinder, tighten
at
until
torque.
the
the
on
re
time,
with
the shaft is turned so
bolts in sequence,
the
the
make sure
If the
place.
is in place,
manifold
around
port
in the
the neoprene seals
positioned,
tape
with
keep
while
place
the cyl
the gasket rest
with
holes in the
the
aligned with
neo-
resistant
gaskets
new
and
heads
heads. To
oil
new seals on
on the cylinder
sure
block
cylinder
and
inder block
ing
block. Coat the intake
cylinder
and
manifold
the
place and the
that the oil holes are to the
Starting
valve
and
assembly
support
sure
the sym
right
plate on the cylinder
tight.
the
45
an additional
damper
the valve push rods
49 Intake Manifold Gasket Installation
FIG.
on the
Rotate
stroke.
damper
crankshaft
bol
1519-B
tor supply tank.
position
operating
before
cranking the engine. This is neces
3. Install the
eye
take manifold and attach the engine
lifting
sling
intake
manifold
and
carefully lower the
on
the engine (Fig.
17;. Position the intake
inserting
the
4. Install the
bolts in the in
manifold
distributor
in
push
their proper sequence,
the
lower
tioned
ends of
in the lifter
5. Crank the
by
place.
valve
1
piston
is
on
the
rods
making
rods
push
are
at
sure
posi
rod cup.
engine until the
T.D.C.
in
No.
the end of
sary in
age
order
to avoid possible dam
to the valves, push rods,
or valve
rocker arms.
6. Install
heat
tube.
damper
until
the
automatic
Rotate
the No.
the
choke
crankshaft
1 piston is
on
1-27
PART 1-ENGINE
T.D.C,
then position the distributor
in the block
1
firing
with
the rotor at the No.
position and the points open.
Install the hold down
Connect
line. Install the distributor
the
nect
spark
clamp.
distributor
the
spark
plug
Con
cap.
Be
wires.
the
sure
for No. 7
wires
plug
vacuum
and
8
See Fig. 9
positioned.
properly
are
cylinders
1-48. Install the
page
on
booster pump line
vacuum
the
and
fuel inlet line.
carburetor
SPRING WASHER
ROCKER ARM
SUPPORT
BOLT
ROCKER SHAFT
1527-B
COTTER PIN
50 Valve Rocker Arm Shaft Assembly
FIG.
DISASSEMBLY AND ASSEMBLY OF COMPONENT PARTS
ARM
VALVE
ROCKER
SHAFT
ASSEMBLY
of
DISASSEMBLY
end
of
the
valve
and
washers.
2. Slide the
rocker
arm
rocker
flat
the
remove
from
pins
cotter
shaft, then
spring
the
washers
ports,
in Fig. 50. Be
arms, springs,
Be
sure
from
each
end
remove
of
holes in
oil
remaining two flat
washers with
the
between them
washer
and
Working from
on
plug, then insert a
the
opposite
2. Install the
bly
knock
of
the
parts with engine
1. Clean the
head
carbon
out
combustion
before removing the
the
of
chambers
with
ends of
and
install
the
valve
51),
tainer
and
release
the shaft, use a
from
blunt tool
pin punch and
in
tainer,
and
seals.
valve.
dividers (Fig.
assembled
the spring.
inder head spring
re
spring to
bring
seal,
to
Discard the
valve
stem
15%4-15%4
all
valve
against a scale.
height is 15%4 inches
inch thick spacer(s) between the
stem
Identify
53).
greater, install the necessary 0.030-
assembly
spring
surface
springs
then remove the spring re
locks,
height
assembled
spring from the
Check the dividers
valves.
3. Remove the sleeve, spring
plugs were removed
large diameter
sleeve.
the cylinder head spring pad to
If the
oil.
or
assem
spring
the underside of the spring retainer
or
2. If
and
4. Measure the
HEADS
2. Compress
the
valve
3. Compress the spring
plug.
moving
a
in
DISASSEMBLY
(Fig.
all
Install
the valve.
the valve, then install the
retainer
of the valve
end.
ASSEMBLY
1. Oil
over
spring
the cotter pin.
cylinder
the open end,
the remaining
new stem seal on
the
steel
plug
was removed
to which it was fitted.
or
downward. Com
shaft,
rod through the plug and knock
out
the
sure
sup
the
CYLINDER
the
or pierce one
the
arms,
order shown
it
which
52) in
(Fig.
valve
each
from
the port
the retainer locks (Fig. 51).
drill
out
in the
by installing
spring
ASSEMBLY
1. Install
all parts.
3. If it is necessary to
plugs
each end
the assembly
stall
identify
rocker
facing
the shaft are
in
shaft.
arm
and springs
plete
and the supports off the shaft.
to
rocker
3. Install the
1. Remove the
each
plug, cup side out,
stall a
parts.
the
pad and
the assembled
recommended
inches.
cyl
the valve
height
dimension
Do
spacers unless necessary.
not
Use
of
install
of
spac-
1-28
GROUP 1-POWER PLANT
SLEEVE
Too/-65?3-EE
SERVICED AS
ASSEMBLY
AN
LOCKS
SPRING
RETAINER
OIL SEAL
DAMPER
SPRING
EXHAUST
VALVE
INTAKE VALVE
1525-
1542-B
51 Removing
FIG.
Valve
Installing
or
Spring
FIG. 52-Valve
Retainer Locks
ers
in
will
result
springs
excess
of
in overstressing the
lead to
will
which
load loss
recommendations
valve
excessive
spring breakage.
and
in
valve
the
position over
bottom
disc
valve
spring
Position the disc
the disc and
VALVE
HYDRAULIC
Each
sembly.
valve
improper
a
those
proper
lifter
of
valve operation
may
the lifter
result.
be installed in their
lifter
assemblies
that
so
sequence
are
another,
and assemble each
Keep
separately.
tainer
matched as
parts of one
with
Disassemble
in
lifter is
If the
inter-mixed
LIFTERS
can
they
plunger.
disc.
of the
top
valve retainer over
and
plunger
(open
Set the
push
the re
place on the plunger.
end
body. Place the
then
spring,
in the
push rod seat
in Fig. 18
1-17,
on page
install the lock ring in the lifter
then
body. Be
the lock ring is
sure
rod
in the
into
place.
Remove
lifter assembly
in Fig. 18
rod
push
spring.
by
1-17. Remove the
plunger
Invert the
the
remove
and
disc
screwdriver,
valve
and
plunger
and
plunger
assembly
retainer
valve
carefully prying up
then
the
the tool shown
with
on page
seat
ring
from
as
on
remove
it
with
the
a
disc
spring.
pistons
in
from
they
the
piston
pin
and
the
piston
same
to
2. Insert
by
Re
rings.
retainers,
Remove the
then drive
the
connecting
(Fig. 55). Discard the
retainers.
fingers. Do
the
bly
is
shown
Place the
a
clean
valve
lifter
plunger
work
upside
instructions
The piston, connecting
on
bench. Place the disc
lated
squirt
rod positioned
piston
pin
into the
retainers
piston with
not use pliers.
Follow
contained on the pis
rings.
the compression
side
clearance
rings with a
ring
Any
step
parts are shown
1. Lubricate
all
rod and re
in Fig. 56.
parts
with
light
feeler
inserted between the ring
gauge
freely
circumference
that
wear
around the entire
binding.
without
occurs
inner
the
at
and
gauge
form
will
portion of
a
the lower
land. If the lower lands have high
steps, the
piston should
4. Install the
connecting
get
assem
down
oil
pin
and
ton ring package and install the piston
fitting
ASSEMBLY
in Fig. 54.
spiraling
the
should slide
ASSEMBLY
The hydraulic
new
them
as
cylinder
were removed.
pin out of the piston and
rod
pins
with the same rod and
installation
move
the
its lower land (Fig. 58). The
assembly
which
piston
in Fig. 57.
shown
3. Check the ring
DISASSEMBLY
sure
with
hole in the connecting
groove.
Mark the
rod
the
push
and
Assemble the
seated
PISTON AND CONNECTING ROD
lock
the
piston
connecting
of
DISASSEMBLY
Position the connecting
oil.
engine
the
up) into the lifter
Position the lock ring in the
tool shown
in the
bore.
original
Place the
on
spring
down into
plunger
the oil hole on
the plunger.
of
Assembly
dirt
slots
or other
replaced.
bearing inserts
rod and
in the
be
cap
with
the tangs
provided.
foreign
in the
Do
not
matter under
the inserts. In time the dirt may dis
tort the
failure.
bearing
and
cause
bearing
1-29
PART 1-ENGINE
UNDERSIDE OF SPRING RETAINER
DISC VALVE
RETAINER
LOCK RING
mm\^^\A^MMmM
PUSH ROD
CUP
BODY
T
I
^
*
r\ier
\j a i we
DISC VALVE
SPRING
PLUNGER
SPRING
DISC VALVE
FIG.
1716-A
54 Hydraulic Valve Lifter
Assembly Typical
OIL RING ASSEMBLY
SURFACE OF SPRING PAD
1 530-A
FIG.
53 Valve Spring Assembled Height
BOLT
CONNECTING ROD
UPPER
'A'COMPRESSION
\$P
\
y^/
4Mf
ToolT52P-6135-DAD
RING
PISTON
^
'
*
^
RETAINER
BEARING INSERTS
1S59-A
FIG.
56 Piston, Connecting Rod,
and
Related Parts
1119-B
FIG.
55 Piston Pin Removal
RIGHT BANK
LEFT BANK
INDENTATION TO FRONT OF ENGINE
FIG.
57 Connecting Rod
and
i
Piston
1120-A
Assembly
mm.
FIG.
58 Ring Side Clearan ce
1 564-B
1-30
GROUP 1-POWER PLANT
OIL
PUMP
into
1.
Remove
pump
screws,
the
cover
retaining
the cover. Re
then remove
inner
the
sembly, then
3. Insert
rotor
self
and
shaft
the outer
remove
a
screw
INTAKE
as
threading
sheet
the proper diameter
of
dry
1. Oil
the
suitable
low the carburetor heat
be
This
riser.
insulator restricting
action of the hot exhaust
carbon acts as an
Inspect the
leaks,
or
it
make
place
manifold
defects
other
for further
unfit
all
that
studs
otherwise
damaged.
lings
foreign
and
have
for cracks,
that
Re
stripped
Remove
matter
baffle
fi
all
that
may
for looseness.
heat
inlet
right
Make
holes
outlet
Blow
open.
pletely
the
60).
(Fig.
and
choke air
of
exhaust
the
sure
open
sure
the
The
valve
the
engine
of
the exhaust gas control valve to make
spring stop is
housing
the
when
installed. The
the
at
top
valve
action
of
of
pin.
The
the valve
is properly
the valve is
To
check
is
weight
is
at
valve
cold.
by
normal
is
and
operating
high
operated at
trating
stuck valves with
a pene
oil and graphite mixture.
closed
Actuate
hand to
when the en
the
make sure
The
Install the
cover
retaining
foot-pounds torque.
push
rods
for
the oil
inlet
install the
and
be
maximum
the
rod.
limit
Do
they
by rotating
closed. They also
dial indicator.
checked with a
(Fig. 61). If the
visually
while
engine
them with the valve
can
be
can
straightness
installed in the
are
runout exceeds the
at
any point, discard
not attempt
to straighten
push rods.
CYLINDER
HEADS
CLEANING AND INSPECTION
Clean the
ARM
the
all
that
oil
thoroughly.
passages
between
the shaft
are
each
bore
and
the O.D. of the shaft. If the clearance
between
rocker
any
arm
the wear
the
and
limit,
replace
the shaft and/or the rocker arm.
the
shaft
and
In
the rocker arm
bore for nicks, scratches, scores, or
scuffs. Dress up minor surface de
pad at
rocker arms
If the
pad
rocker
arm.
for
the valve end of
a grooved radius.
is grooved,
Do
by
PUSH
replace
not attempt
the
to true
grinding.
Do
cylinder
Remove
all
and
crack
than
not plane or grind more
CYLINDER HEAD
head
burrs
or
the push
for nicks, grooves, roughness,
it
cessive wear.
rods
or ex
FLATNESS
Check the flatness
head
for flatness
cations
maximum
overall,
of
the cylinder
(Fig. 62). Specifi
gasket surface
0.006 inch
are
or
0.003 inch in
any 6 inches.
VALVE SEAT RUNOUT
valve
an accurate gauge
the
instructions
facturer. The
exceed the wear
limits
seat
runout with
(Fig. 63). Follow
of the
gauge
manu
total runout should not
limit.
SEAT WIDTH
Measure the
of
for burrs
scratches with an oil stone.
64).
ends
gasket
head for cracks,
0.010 inch from the
VALVE
RODS
Check the
old
Replace the head if it is
Check the
hone.
with a
Inspect the
the
ed.
with a
by checking
the I.D. of the rocker arm
fects
cylinder
gasket surface.
clearance
counter
moves
dirt,
remove
and the gasket surface
parts
all
bores
and grease.
Check the
SHAFT ASSEMBLY
sure
to
solvent
sealer,
ROCKER
valve guide
cleaning tool. Use clean
valve guide
ing
the exhaust gas control
the car, make sure the spring
holds the
gine
momentarily opens.
is designed to open when
this surface
illustrated in Fig. 4.
valve on
One
without
valve
Free
rpm.
spect
the stop
operating tempera
idle speed. How
the engine to make
accelerate
with compressed
on
the en
at
com
Check the thermostatic spring
it is hooked
outer
cover
a new gasket and
checked
to the counterweight. Ra
applied
shaft exceeds
are
air.
sure
the
tube on the oil pump
of
properly operating valve will
when very light finger pressure
Check the
out the automatic
heat tube
when
90
open.
CONTROL
out the automatic choke air
chamber
closed
at normal
rocker arm and
manifold
air
is
valve
Clean
VALVE
Clean
replaced
other.
6-9
to
Position
be
not
tighten
and
nicks.
MANIFOLD AND
EXHAUST GAS
approximately
without binding.
a
Make
EXHAUST
shaft, and the
the
The
retaining bolts.
a result
plate on the under
side of the manifold
plunger,
cap.
new
through
VALVE
the
relief valve
or
of repairs.
Check
and
would
service.
the manifold as
entered
and
is
ever,
is
thoroughly. Install
all parts
temperature
are
shown
screws
ture and running
pidly
gases.
pump assembly is
pressure
The
deposits
carbon
rotor and
race,
assembly.
AND RECONDITIONING
gine
all
the center exhaust passage
heating
oil
spring,
them with compres
Scrape
air.
a
inner
outer
and shaft
part should
in Fig. 59.
rotation
in
rotor
race are serviced as an assembly.
oil
freely
the manifolds
solvent, then
the
and
spring
inner
replacing the
The
race.
MANIFOLD
Clean
from
the
ASSEMBLY
CLEANING, INSPECTION,
sed
Remove
chamber.
the
out of
cap
and remove the gasket.
2. Remove
metal
the
pull
and
plunger.
the oil
move
inlet tube from
the oil
2. Install the
the oil pressure relief valve cham
ber cap
DISASSEMBLY
The
are
exhaust
valve seat width
intake
valve
seat
0.060-0.080 inch
valve
seat
0.070-0.090 inch.
width
(Fig.
width
and the
limits
are
1-31
PART 1-ENGINE
AIR INLET
DISTRIBUTOR INTERMEDIATE
DRIVE SHAFT
GASKET
INLET TUBE
Q*
ASSEMBLY
1 509-A
FIG.
60 Automatic Choke Heat Chamber
PLATE
1531
FIG.
59 Oil Pump Assembly
Ho/ding
FIG.
-A
fixture'
PUSH ROD
1003-A
(T) (3)
CHECK DIAGONALLY
(2)
CHECK ACROSS CENTER
1729- A
61 Push Rod Runout
FIG.
62 Cylinder Head Flatness
Runout Gauge
/
J
Seof Width Scale
'^^mmMmmtmr
O
a
FIG. 63-Valve Seat
Runout
'
'
1735-A
FIG. 64-Valve
Seat Width
S
1-32
GROUP 1-POWER PLANT
TO REMOVE STOCK FROM TOP OF
TO REMOVE STOCK FROM
30
SEAT, USE
15
SEAT, USE
INTAKE
BOTTOM OF EXHAUST
WHEEL
TO REMOVE STOCK FROM TOP OF
WHEEL
SEAT, USE
EXHAUST
5
60
WHEEL
60
OR
1738-A
66 Valve Seat Refacing
FIG.
1/32"
MINIMUM
TO SPECIFICATIONS
FOR CORRECT DIAMETER
MAXIMUM VALVE
.REFER
FACE RUNOUT
0.002
S
\
CHECK FOR BENT STEM
DO NOT REMOVE MORE THAN 0.010 INCH
65 Reaming Valve Guides
FIG.
45
30
GUIDES
VALVE
up pits,
If it becomes necessary to
(Fig. 65) to install
is
a
and
reaming kit
limits.
valve
with
follow
bring
If the
the
to an
face the
guide
is
in
sequence.
the
after
seat
valve
Always
re
valve
tom edge of the
the
angle
(raise the
VALVE
facing of the
valve
seat will match
face
the
with
coordinated
so
the
finished
face
the valve
re
and
be
This is important so that the
and seat will have a good com
the
seat
(lower the
wheel
grinding
from the top
of
the
The finished
tact
the
sure
that the re
are
properly
Grind the
true
seat
45
exhaust
angle
to a true
Remove only
and
30
valve seat
the
intake
angle
enough
to a
valve
(Fig. 66).
stock
to clean
to
seat
valve seat should con
valve
from the
buffing
or
in
carbon
valve with a
wheel.
of
valve
the valve head
or
Defects,
contact
is
If the blue is trans
center of
the valve
satisfactory.
face,
If the blue
is transferred to the top edge of the
valve face, lower the valve seat. If the
brush
inspec
face and the edge
for pits, grooves,
a
burning
pressure.
critical
defects. Inspect the
bent condition and the
end of the stem for grooves or scores.
Check the valve head for signs of
for
cracking.
the
varnish
wire
scores, or other
the
valve with
after
illustrated in Fig. 67.
Inspect the
face, coat
Prussian blue, then set
Rotate the
com
tion points and tolerances of the valve
the
place.
and
fine
The
the
the
the
and seat
INSPECTION
all
of
ferred to the
the
Remove
where
center
the
lapping
operation.
CLEANING AND
are
(lower the
all
valve
it is
in
VALVES
15
remove stock
face. To determine
seat with
light
dressed.
top
seat).
approximate
valve seat contacts
wheels
angle
lapping
the
stem
valve
fit. Be
60
seat
seat).
valve
facer grinding
the
valve seat, use a
centered.
pression tight
of
use a
a
from the
edge
seat,
grade
Remove
compound.
pound
valve
lightly lap
to
medium
a
bottom
raise the valve seat.
After refacing the
to remove
to remove stock from the
wheel
angle
of the valve seats should
Refacing
be closely
SEATS
use
seat,
wheel
and
seat)
the
reduce
(Fig. 66).
bottom
the
On the intake
REFACING
to
valve
grinding
from
stock
bot
edge and/or
seat
exhaust
enough
remove
width to specifications
of
reamed.
valve seat width exceeds the
limits,
from the top
stock
size
valve, always use
oversize
reamers
standard
within
maximum
30
valve
it
On
a
face,
practice
pilot.
When going from
transferred to the
the valve
good
0.003-inch O.S. pilot,
0.030-inch reamer with a
0.015-inch O.S.
blue is
of
64). Narrow the seat, if necessary to
a
with
is
ground, measure the seat width (Fig.
0.003-inch O.S. reamer with a stand
ard diameter pilot, a 0.015-inch O.S.
reamer
seat
a valve
combinations; a
reamer and pilot
the
correct
After the
valve
available which contains the
ing
runout.
1739-A
ream a
valve guide
with an oversize stem, a
to
or
grooves,
seat
INTAKE
67 Critical Valve Tolerances
FIG.
REAMING
EXHAUST
erosion,
may be
grooves, etc.
card
valves
that
warpage,
such as minor
are
and
pits,
Dis
severely dam
removed.
aged.
Inspect the
valve springs and valve
damper springs,
ers,
locks,
and
valve
spring retain
for defects.
sleeves
Discard any defective
parts.
1-33
PART 1-ENGINE
Model TV-2 Runout Gauge
1015-A
1
68Valve Face Runout
FIG.
FIG.
740- A
69 Valve Stem Clearance
Valve
Spring
Tester
NOT MORE
THAN
W
1017-A
1019-B
70 Valve Spring Pressure
FIG.
VALVE
FACE RUNOUT
Check the
68). The
total indicator
guide.
a
Position
flat tip
dial indicator
the
valve
clearance
guide
respective
of each
valve guide
to
valve
with
valve
plane
in its
arm
the tool
in Fig. 69 or its equivalent.
Install the tool on the valve stem
shown
until
fully
seated
to the valve stem.
Move the tool back
stem
and tighten
the set
screw, then permit the valve to drop
away from its seat until the tool con
that
action
parallels
and
the tool at
of
section
90
VALVE STEM CLEARANCE
with
against the center portion of
the spherical
reading.
a
approximately
Check
71 Valve Spring Squareness
tacts the upper surface of the valve
face runout (Fig.
limit is 0.002 inch
valve
wear
FIG.
and
forth
normal
take
the
on a
rocker
without
ceeds the wear
lifting
the tool
limit, try
Check the valve spring assembly
for proper pressure (Fig. 70). Weak
valve springs cause poor engine per
formance; therefore, if
of
any spring
limit,
the pressure
approaches
the wear
replace the spring.
indicator
from
the valve guide upper surface. Divide
the indicator reading by 2 (division
factor of the tool) to obtain the actual
stem clearance. If the clearance ex
reading
VALVE SPRING PRESSURE
a new valve.
SPRING SQUARENESS
VALVE
Check
a
using
plate
spring for squareness
square
and
a
surface
(Fig. 71). Stand the spring
square
Slide
each
steel
on end on
the
and
the surface plate.
spring up to the
square.
1-34
GROUP 1-POWER PLANT
A VS B
VS D
A VS C
VERTICAL TAPER
=
C
HORIZONTAL TAPER
=
OUT OF ROUND
AND B VS D
CHECK FOR OUT-OF-ROUND AT EACH END OF JOURNAL
LOBE
LIFT EQUALS
Revolve
the
spring slowly and ob
between the top coil
spring and the square. If the
the space
serve
the
spring is
Vi inch,
out
of
replace
than
more
square
and
valve
The
valve
be closely
coordinated with the valve
of
angle
that
the
face
will
that the valve
tant so
seat
and
If the
face
valve
to
and/or
sive
grinding
valve
45
true
to
valves
only
true
a
to
clean
If the
grooves.
is
runout
to correct the run
up
edge of
Vz2 inch
the
pits
and
the valve
head
replace
the valve as the valve
marks
then
the
after
grinding,
all
from the
more
or
score
the valve stem,
necessary.
than 0.010
Do
not
inch from
with
a
pound
remove
good
lightly lap in the valves
medium grade lapping com
to
to
stem
oversize
with
match
all
the
for
available
the
valve
next
over
(page
1-32). Valves
stem
diameters
0.030
and
of
inch
Always
service.
the valve
valve seat when
are
the seats.
compound
Be
If the
sure
from
to
the
have
check
the
be necessary to
clearance
between the
rocker
arm
pad
the
with
is
VALVE CLEARANCE
valve and/or valve seat
been refaced, it
reface
guide
ARM TO
ROCKER
the valve stem
and
train
valve
in the
stalled
will
in
assembly
(page 1-12).
engine
reamed.
TIMING
The
VALVE
lifter
kept in
can
LIFTERS
assemblies
Clean
proper sequence so
Inspect
sition.
separately
internal
as
so
lifter assembly
place
needs
they
each
lifter
intermix the
to
not
If any
parts.
that
original po
test
and
be
should
be installed in their
part
the
of
them
CHAIN
all parts
for cracks,
damaged teeth. It is
sprockets
that
clean
solvent and
them with
wipe
in
a
clean, lint free cloth.
Inspect the
shows
lifter
signs
parts
one
item
the plunger
is
any
pitting, scoring,
ing, or evidence
Also, replace the
The
discard the
if
assembly
of
of
not
for pitting, scoring,
normal wear. Lobe
eral
result
replacement.
area of
lobe. This pitting is
assembly if
free in the body.
to the bot
operation
therefore, the
the
until
loss has
exceeded
suspected
lobes
camshaft
and signs of ab
wear
character
not
of
gen
detrimental
the
camshaft,
cam should not
placed
of
solvent and
the nose portion of the
to
the
in
in pitting in the
part
non-rotation.
drop
camshaft
gall
entire
plunger should
or
recommended
needs
dry. Inspect the
istics may
and
the
and
worn
CAMSHAFT AND BEARINGS
wipe
the parts
clean all
and
Inspect
the components be replaced
all
if any
air.
for broken links
the chain
dry
solvent and
re
replacing,
the entire lifter assembly.
Thoroughly
in
compressed
with
Clean the
entire
stem.
After refacing the valves, it is
practice
valve
for the
CLEANING AND INSPECTION
grooves
end of
as
reamed
push rod cup.
will run
engine.
off
chamfer
remove
to
Remove
angle.
than
hot in the
and
exhaust valves
is less
Grind
be
and
limit,
wear
that
recommended
0.003, 0.015,
the
the
guide
exces
pits
Reface the intake
30
enough stock
or
out
angle.
size
to valve
stem
exceeds
HYDRAULIC
remove
grooves, reface the
VALVES
wheels
properly dressed.
are
too
will
fit. Be
a good compression tight
sure that the refacer
a
is impor
the valve seat. This
match
have
so
the valve
operation
refacing
finished
is
own weight.
assembly for freeness of
by pressing down on the
the
operation
guide
its
body by
Assemble the lifter assembly
SELECT FITTING
it
operation should
tom of the
check
If the
refacing
lapping
the
after
operation.
it.
REFACING VALVES
seat
1028-A
73 Crankshaft Journal Measurements
FIG.
clearance
seat
tmmwm*
1749-A
72 Camshaft Lobe Lift Measurement
FIG.
of
A MINUS B
=
camshaft
be
re
lobe lift
0.005 inch. The lift
worn
lobes
should
be
1-35
PART 1-ENGINE
by
checked
measuring
the
over
top
the lobe with a micrometer and
of
subtracting the measurement of the
base circle diameter (Fig. 72).
Check the camshaft journal to
bearing
by
clearances
diameter
measuring the
the journals and the I.D.
of
the bearings. If the clearance ex
of
the
ceeds
journals
bearings
size
limit,
wear
be
should
the camshaft
for
ground
the
or
placed, and/or the bearings
be
Bearings
replaced.
for
prefinished to size
0.015-inch
under
camshaft
re
Too/-RC-500
should
available
are
and
standard
journal diame
undersize
535-A
ters.
Check the distributor drive
for broken
or chipped
gear
Remove light scuffs, scores, or
from the camshaft machined
nicks
surfaces with a smooth oilstone.
74 Cleaning Ring Grooves
FIG.
teeth.
CONNECTING RODS
The connecting rods and related
should be carefully inspected
and
checked
for conformance to
specifications. Various forms of en
parts
CRANKSHAFT
CLEANING AND INSPECTION
Handle the
to
avoid
crankshaft
fractures
possible
to the finished
age
the
crankshaft
blow
dam
or
Clean
surfaces.
with
care
with
then
solvent,
out all oil passages with com
side
Inspect
main
journals
and
for
connecting
cracks,
rod
scratches,
grooves, or scores. Dress minor im
perfections with an oilstone.
severely marred journals.
Measure the diameter of
mine
least four
at
limit, they
for the
each
jour
to deter
or under
(Fig. 73).
If the journals
exceed
be
should
the
reground
next undersize
hole is
wear
to size
give
will
not
up"
to give the proper clear
with
bearing
the
maximum
undersize
available, replace the crank
reproduce
nal shoulder radius
nally.
Too
small
a
in fatigue failure
Too large
ing
the same
radius will result
of
the crankshaft.
in bear
radius ride of
the
After grinding,
holes,
chamfer
the
oil
then polish the journal with a
No. 320
grit
gine oil.
Crocus
also as a
polishing
polishing
cloth
cloth and en
may be
agent.
used
different
types
ring
Check the
be
improperly
crankpin,
necting
rod
or
ma
tapered con
a
tern, but
badly
twisted
not
dis
cause of excessive oil
CLEANING AND INSPECTION
twist on a suitable
rod
AND RINGS
CLEANING AND INSPECTION
Remove
carbon
the
cleaning
solution.
with
com
pressed air.
Inspect the connecting rods for
of fractures and the bearing
signs
piston
out-of-round and taper.
If
not use a caustic
brush to
ring
cleaner
pin
bosses,
Check the
rod
worn
that
honed for
fractured,
steps,
piston pin to
bushing
connecting
is
clearance.
rod
it
an
if the
cannot
connecting
Replace the
is
so
reamed
or
bushing
be
gum
oversize pin.
solution or
ring
Clean
groove
sure the oil
will
If the lower inner
ring
replace
interfere
cause
for scuffed, rough,
and
tion of the
rod
replaced.
cleaning
clean pistons.
(Fig. 74). Make
limits
if the
under
ring slots (or holes) are clean.
Carefully inspect the pistons for
fractures at the ring lands, skirt, and
scored skirts.
be
from the
head. Clean
grooves with a
the bore exceeds the recommended
and/or
deposits from the
from the piston skirt, pis
ton pins, and rings with solvent. Do
not use a
should
straight
PISTONS, PINS,
a wire
bores for
be
should
ened or replaced.
Clean the connecting rod in sol
including the connecting rod
bore and the back of the inserts. Do
passages
align
fixture. Follow the instructions
of the fixture manufacturer. If the
bend and/or twist is excessive, the
or varnish
vent,
all
rods are as
ment
side of the
out
new
the piston, check them
piston surfaces and
caustic
Fit
following
necessary,
pat
rods will
turb the action of the entire piston,
may be the
Fig. 77.
bearings that
After the connecting
connecting
bore.
Twisted connecting rods will
create an easily identifiable wear
scored,
For the
failures
the recommended procedure.
or
an
to
refer
satisfactory.
where
for bend
chined
bearing
of
clearance of
to
appear
bearings
a
surface.
worn
their causes
Abnormal connecting rod bearing
wear can be caused by either a bent
it
bearing.
or
to
that existed origi
a radius will result
failure due to
jour
chipped,
sembled
Blow
shaft.
Always
and
the
the next under
bearing. If the journal
ance
proper rela
skirt
consumption.
Regrind the journal to
"clean
in
not
piston
rings, and connecting rod assembly
bearing.
REFINISHING JOURNALS
size
the
or the
rod
bearing carefully. Re
each
bearings that have
grooves.
and
proper clearance with
to
connecting rod,
places
taper,
out-of-round,
size condition
Regrind
tion
pin
is bent
that a connecting rod
boss
indicates
the piston usually
of
Inspect
place
and
be readily identified.
A shiny surface on the
piston pin
in
these parts can
air.
pressed
nal
by
gine wear caused
Replace defective connecting
bolts.
nuts and
with
excessive
Spongy,
grooves
the piston.
ring
ring
or
por
have high
The step
operation and
side
clearance.
eroded areas near the edge
of the
top
caused
by detonation,
of
the piston are usually
or pre-ignition.
1-36
GROUP 1-POWER PLANT
I 1 74 1
75 Checking Piston Fit
FIG.
A shiny
center-
line between the piston pin holes, can
be caused by a bent connecting rod.
Replace pistons that show signs of
excessive
wear,
fractures,
from
with
the
and
following
tension
a
the
and
scale
side
ring
Replace
clearance
recommended
piston
fracture
Check the
and
or
pins
etching
piston pin
proce
Replace
all
side
and
to
practice
when
showing
and/or
fit in the
that
rings
wear.
piston
clearance.
always
install
overhauling the
should
not
piston
to
are
scored,
Check the
chipped, or cracked.
gap
signs
bushing.
rod
It is
new
engine.
end
good
rings
Rings
be transferred from
one
regardless
another
Calculate
of
Pistons
in
cylinders
Pistons
of
0.060-inch
and
that
for
service
for
oversizes
have been
rebored.
0.020, 0.030, 0.040,
oversize
in
use
are available
and
for
should
(70
F)
bore
a cylinder
be
to
piston
check
piston
be
when
at
and
cylinder
room
block
temperature
the piston fit is checked.
sure the piston and cylinder
clean
are
tension
gauge
dry.
and
Attach
that
ribbon
Vi-inch
wide
mended
thickness
After any refinishing operation,
al
ton.
for the
When
a
next
piston
size piston.
has been
it for assembly in the
to which it was fitted.
is free
of
ribbon
and
of
for
dents
should
the
the
or
be
recom
existing
Position the ribbon in the cylinder
bore so that it extends the entire
length of the piston at 90 from the
piston pin location. Invert the piston
and install it in the bore so that the
end of the piston is about 1 Vi inches
crankshaft
a
is
parallel
to the
axis.
straight
pull
is
slowly
line
pull
with
pull
the
required
the
rib
to re
(Fig. 75).
limits for the
the piston fit is
ribbon
within
existing condition,
scale
calculations
reading is
greater
to
be
sure
than
that the proper
has been selected,
damaged piston, then try
piston
piston.
and out-of-round con
of the cylinder
check
a new
bore
are within
new piston rings will give satis
factory
service
clearance
in the
installed in
a
the
provided
cylinder
new
piston
bore is
rings are
used cylinder
been refinished,
inder wall
not
remove
with
to be
that
has
the cyl
"glaze."
Select the
proper
size piston to
be
be
for
checked
cylinder
bore
clearance
in the
each
The
proper
and
set
ring
used.
for the
rings must
gap in the
for the
proper side
piston grooves.
ring for
proper
First,
gap
as
follows:
Position the ring in the cylinder
which it is going to be used.
Push the ring down into the cylinder
bore in
bore
not
satisfactory.
If the
limits,
check
piston and
noting the
move the feeler
If the
block
of the cylinder
the piston pin
in
If the taper
ditions
in limits. If the
below the top
fitted,
cylinder
a
condition.
a
pull, recheck cal
before trying another pis
If none can be fitted, refinish the
cylinder
feeler
to the end of a
scale
burrs. The feeler
for
reading is less than the
mark
bore
size
scale
culations
the desired clear
ance.
and
If the
minimum allowable
the maximum allowable pull, recheck
service.
The
before
cool
then select the proper size
bon,
are available
sizes
size
to provide
piston
scale
standard
81),
Hold the
PISTONS
bore to
the
by taking
used
(Fig.
mileage.
FITTING
cylinder
Make
bore
piston to cylinder
dures.
of
low the
the piston fit is checked.
or pre-ignition.
Check the
ribbon
lands,
ring
damage
and/or
detonation
clearance
wavy
76 Piston Ring Gap
FIG.
surface on the thrust surface
the piston, offset from the
of
-A
area where normal
encountered.
ring wear is
Use the head of a
piston to position the
ring is
Use
ring
ring
so
that the
square with the cylinder wall.
caution
to avoid damage to the
bore. Measure the
gap between the ends of the ring
with a feeler gauge (Fig. 76).
or
cylinder
1-37
PART 1-ENGINE
DIRT IMBEDDED
INTO BEARING MATERIAL
SCRATCHES
IMPROPER SEATING
LACK OF OIL
SCRATCHED BY DIRT
OVERLAY GONE
FROM ENTIRE SURFACE
TAPERED JOURNAL
RADIUS RIDE
CRATERS
77 Bearing Failures
FIG.
If the gap is less than the recom
lower limit, try another ring
mended
or worn surface
chipped,
replaced.
Typical
ing failures
set.
their
and
be
should
examples
of
bear
causes
are
FITTING PISTON PINS
fit should be a light
fit at normal tempera
(70
F). Standard piston pins
ture
are color coded green. Pins of 0.001inch oversize (color coded blue) and
0.002-inch oversize (color coded yel
The
piston pin
thumb press
low)
available.
are
If the
hole in the
pin
be reamed,
piloted
use
reamer.
an
expansion-type,
Place the
Set the
size of the pin
reamer
in
the piston around
a vise and revolve
reamer.
piston must
bore,
to
reamer
the
then expand the
slightly and trial ream the pin
bore. Take a light cut. Use a pilot
reamer
sleeve of
the nearest size to maintain
the bores.
alignment of
The main bearing inserts are selec
tive fit and do not require reaming
to size upon installation. Do not file
or
lap bearing
for fit in the respective
rod bushing. If necessary, ream or
hone the bushing to fit the pin.
Install the
and
rod.
each
end
piston pin
Install
of
a
the
in the
new
pin
caps or use shims
proper
two sizes and are
of
red
or
blue
identified
paint.
by
Red
a
daub
marked
bearings increase the clearance; blue
marked bearings decrease the clear
Undersize bearings,
not selective
fit,
which are
are available
journals that have been
for
evenly
and
are
However, if
a
not
bearing
to an out-of-round
to fit the
bearing
use
reground.
Normally, bearing journals
may
failure. It is
wear
out-of-round.
is
being
journal, be
fitted
sure
to the maximum
not
bearings be fitted to
which exceeds
bearings, it is
try to obtain
two blue
with
Do
get
not
matter under
dirt
good
the
the
maximum
bearing
dirt
bearing inserts
and caps
Inspect each
Bearings that have
bearing
Clean the
bearing
the
carefully.
a
scored,
and
bearing failure.
Main Bearings. The
is for the
cedure
following
engine
pro
installed in
the chassis with the crankshaft not
removed.
If the
engine
is
on a work
stand, follow steps 2-5. In step 4, it
is not necessary to support the crank
because the
shaft
engine
will
Place the Plastigage
verted.
be in
on
the
journal (Fig. 78) instead
the bearing surface if the en
crankshaft
of on
gine
1.
is
on a work stand.
Replace
leaving
the
one
other
bearing
at a
time,
bearings securely
fastened. Remove the
main
CHECK WIDTH OF PLASTIGAGE
0.002
78~~
foreign
the inserts. In time the
OF JOURNAL ABOUT
V. INCH OFF CENTER
FIG.
to first
halves.
CLEARANCE
AND CONNECTING
thoroughly.
re
new
clearance
other
or
PLACE PLASTIGAGE FULL WIDTH
INSTALLING PLASTIGAGE
When
with
practice
BEARINGS
CLEANING AND INSPECTION
that
crankshaft
proper
distort
may
cause
early
a
bearings
standard
an
recommended
at
it in
Spiral the retainers into posi
tion with the fingers. Do not use
pliers. Make sure the retainers are
properly seated in their groove.
ROD
clearance.
Selective fit bearings are available
for service in standard sizes only.
Standard bearings are divided into
place.
MAIN
bearing
to
causing
result,
piston
retainer
to hold
the
obtain
ence
placing
BEARING REPLACEMENT
on
the piston pin
clearance, interfer
minimum
out-of-round specifications.
the reamer slightly and make
another cut. Repeat the procedure
the proper fit is obtained. Check
ter with
journal
ance.
until
journal. If the bear
minimum diame
of the
is fitted to the
procedure.
Check the hole size, using the new
piston pin. If the bore is small, ex
pand
diameter
ing
in Fig. 77. Check the clear
ance of bearings that appear to be
satisfactory with Plastigage. Fit new
bearings following the recommended
shown
the
1030-A
FATIGUE FAILURE
RADIUS RIDE
MEASURING PLASTIGAGE
1031 -A
mstamn9 and Measuring Plastigage
Engine On Work Stand
bearing
1-38
GROUP 1-POWER PLANT
PLACE Plastigage FULL WIDTH OF
JOURNAL ABOUT Va INCH
OFF CENTER
CHECK WIDTH OF Plastigage
0.0015"
CLEARANCE
MEASURING Plastigage
INSTALLING Plastigage
1049-B
1558-B
FIG 79 Installing
Measuring
and
Plastigage
cap to which new bearings are to be
installed. Insert the upper bearing
6331) in
tool (Tool
removal
hole in the
force
to
rotation
Rotate the
crankshaft.
in the direction
crankshaft
the oil
of engine
bearing
the
out of
block.
the
ing,
place
ing
over
side
of
the upper main
bear
the plain end of the
bear
the block.
direction
bearing
locking tang
the shaft on the
Using
Tool 6331,
in the
the crankshaft
rotate
opposite
of engine rotation until the
seats
itself. Remove the tool.
Replace the cap bearing. Clean the
crankshaft journal and bearings.
Support the
3.
will
weight
crankshaft
compress
not
its
so
the Plasti
gage and provide an erroneous read
ing. Position
a
bear
the
against
on the
of the
off
Place
a
jack
center
pounds
it
is
which
piece
of
while
Do
Va inch
about
95-105 foot
not
turn
the
the Plastigage is in
check
get
in
the two
the
or
order
at
the
to get the
The
readings
difference
in
install
4.
After
apply
light
a
journal
maximum
clearance.
specified
the crankshaft
journal,
not
bearings.
has
bearing
been
coat of engine oil to the
limits,
then install the
rear
bearing
main
is
re
placed, replace the lower oil seal (in
the cap) and the side seals. The upper
oil seal
(in the
with
placed
block)
can not
be
re
the crankshaft installed.
between
Install the
connecting
necting
rod
bearings in the
new
rod and cap.
Pull the
assembly down
Plastigage
of
on
the
con
firmly
the crankshaft journal. Place
lower
Va
inch
off center.
tighten
bearing
Install the
the connecting
cap
and
nuts
to 45-50 foot-pounds torque. Do
not
turn
the
crankshaft
Plastigage is in
2.
Remove
while
rod
the
place.
the
cap,
then
using
of
the Plastigage at the widest point
in
order
the
combination
the
of
bearing
and
red
the
desired
the crankshaft
journal,
clearance
then
grind
install
After
been
within
bearings.
undersize
bearing
the
has
clearance
found to be satis
light coat of engine
checked and
factory, apply
oil to the
a
journal
bearings,
and
then
install the connecting rod cap. Tight
en
the nuts to 45-50 foot-pounds
torque, then install the
tighten
3-4
them
to
pal
nuts, and
foot-pounds
3.
Repeat the
procedure
rods
remaining connecting
quire
new
for the
that
re
bearings.
CONVENTIONAL
FLYWHEEL
INSPECTION
Inspect
heat
flywheel for cracks,
the
check,
would make
or
it
other
unfit
defects
for further
ice. Machine the friction
that
serv
surface
of
the flywheel if it is scored or worn.
the Plastigage scale check the width
to get
red
on
a piece
surface, the full width of the cap and
about
two
taper.
than
torque.
Connecting Rod Bearings.
1.
a
is the
is less
limits, try
or
The difference
two readings
clearance
the
at
to get the
order
blue depending upon the condition.
If the standard bearings do not bring
the
Tighten the cap bolts to
bearing
95-105 foot-pounds torque.
If the
halves
found to be satisfactory,
cap.
5.
between the
desired
bearings,
and
and
the
the
checked and
bearing
If the
undersize
in
point
bring
within
Plastigage
Check the
ance.
narrowest
of red
bearings do
standard
grind
the
the condition.
upon
clearance
then
narrowest
maximum
is the taper.
combination
a
depending
If the
the width of
the minimum clearance.
Check the Plastigage
point
blue
being
the full width
the bolts to
Plastigage scale,
clearance.
limits, try
halves
Plastigage
Remove the cap, then using the
to
is less than
two red
ad
the Plastigage at the widest point
order
clearance
will
(Fig. 79). Install the cap
torque.
crankshaft
so
counterweight
bearing surface
bearing cap and
and tighten
place.
small
bearing
the
joining
checked.
If the
specified
limits,
To install
2.
80 Flywheel Face Runout
FIG.
Engine in Chassis
minimum
clear
If it is necessary to
0.045 inch
thickness,
Inspect
remove more
of stock
from the
replace the
the
ring
than
original
flywheel.
gear
for worn,
1-39
PART 1-ENGINE
Check
ENGINE'
CENTERLINE OF
[Al
A-AT
nicks, scratches, and
burrs,
Remove
scores.
RIGHT ANGLE
Check the flatness
block
of the cylinder
following
the
imperfections
minor
with an oil stone.
TO CENTERLINE
OF ENGINE
sur
gasket
machined
all
faces for
cations recommended
surface
gasket
specifi
and
procedure
for the
cylinder
head (page 1-30).
B"
Replace
PARALLEL TO
that
CENTERLINE OF
leakage.
show evidence of
Inspect the
ENGINE
ing,
instructions
the
of
OUT-OF-ROUND
2. TAPER
=
=
-JSmmL
4
inder bore
DIFFERENCE BETWEEN A AND B
bottom
DIFFERENCE BETWEEN THE A MEASUREMENT AT TOP OF
OF CYLINDER BORE
the
at
with
1039-A
81 Cylinder Bore Out-of-Round And Taper
damaged,
are
If the teeth
to the
the
replace
ring
runout.
Install
dial indicator
a
point
bears
wheel
making
will not
play
wheel
that crankshaft
be indicated
fly
as
check
the
exceeds
remove
maxi
CYLINDER BLOCK
and
the face of the crankshaft
ing
flange. If
no
mount
burrs exist,
the runout of the crankshaft
check
mount
flange. Replace the flywheel
ing
machine
the
or
the crankshaft flywheel face
mounting
flange
runout
is
Heat the defective
blow torch
Do
ring
the
Heat the
onto
gear
off
ring
expands
flywheel.
the
is
when remov
gear
evenly
enough
Make
un
to slip
sure
the
properly against the
Do not heat any portion of
gear
to
a
temperature higher than
500 F. If this limit is exceeded, the
temper
gear
will
teeth.
be
removed
from the
ring
operation.
REFINISHING CYLINDER WALLS
of wear.
the walls have minor
CLEANING AND INSPECTION
light scuffs, scratches, etc.
The grade of hone to be used is deter
Thoroughly
from
block in
clean the
Remove
vent.
Remove
all machined surfaces.
then clean out
out all
all
in
the
true-up
etc. with
Make
sure
the
head
bolt
Dirt in the threads
are clean.
cause
holes,
cylinder
air.
compressed
passages,
the passages. Blow
passages, bolt
threads
sol
material
gasket
old
all pipe plugs which seal oil
binding
and
Use
reading.
in
result
to
tap
a
a
threads and to remove any
deposits.
Honing is
finishing
block has been thor
a
oughly cleaned, make
cracks. Minute cracks
the naked eye may
coating the
check
not visible to
be detected
suspected
area
25% kerosene
light motor oil. Wipe the
mixture of
and
immediately
zinc oxide
If
for
apply
dissolved in
a
by
with
and
a
75%
dry
part
coating
of
wood alcohol.
present, the coating will
discolored at the defective
cracks are
become
Replace
area.
cracked.
the
block
if
it
is
for
recommended
cylinder
walls
only
re
when
imperfections,
as
by
the amount of metal to be
Follow the instructions of
hone manufacturer. If coarse
mined
removed.
the
stones
are
used
to start the
operation, leave
that all
hone
the
with
honing
enough material
marks can
finishing
hone
be
so
removed
which
is
used
to obtain the proper piston clearance.
Cylinder
marred
limits
Before any
that
walls
and/or
specified
main
After the
the flywheel.
seated
shoulder.
the
the engine side of the
gear.
new
til the gear
gear with
for this
stone
block for engine overhaul,
closely inspect the wear pattern on
all parts to help diagnose the cause
false torque
ring
hit the flywheel
not
ing
on
knock it
gear, then
by honing the cylinder wall
installing new service piston rings
and
the cyl
of
inder
may
RING GEAR REPLACEMENT
limits, it
to remove the imper
providing the piston clearance is
limits. Use the finest grade of
disassembly
the
possible
minor
fections
honing
During
holes
excessive.
a
may be
limits.
out-of-
the
within
the flywheel and
for burrs between the flywheel
wear
have
round and taper are within
procedure
such
runout
limit,
the
walls
for checking the
drive plate for cars with
Cruise-O-Matic is covered in Group
3.
The
converter
runout.
If the
if
fly
fly
the
is full for
that it
sure
ward or rearward so
mum
that the
face (Fig. 80). Turn the
wheel
end
so
against
cylinder
deeply
out-of-round
when
imperfections, but
surface
FLYWHEEL FACE RUNOUT
indicator
centerlines
that are
cylinders
and/or
If the
gear.
With the flywheel installed on the
crankshaft, check the flywheel face
right
the engine (Fig. 81).
scored
CONVERTER DRIVE PLATE
placed at
the gauge
and/or taper exceed
or cracked teeth.
and
top, middle,
angles and parallel
of
Rebore
chipped,
cyl
each
of
-.,
CYLINDER BORE AND THE A MEASUREMENT AT BOTTOM
FIG.
the
following
manufacturer.
Measure the diameter
I.
out-of-
taper. Measure the bore
with an accurate gauge
|A>r.--
scor
signs of wear.
bore for
cylinder
and
round
for
cylinder walls
roughness, or other
Check the
plugs
expansion-type
all
severely
beyond
be
should
cylinder
bearing
are
worn
the
rebored.
is rebored, all
be in place
caps must
tightened to the proper torque so
and
that the crankshaft
not
bearing bores will
become distorted from the
boring
operation.
Rebore only the cylinder or cylin
ders that require it. All pistons are
the
same
weight, both standard and
oversize;
therefore,
tons
be intermixed
can
various sized pis
without up
setting engine balance.
Rebore the cylinder with the most
wear first to determine the
maximum
oversize.
If the cylinder
will not clean
1-40
GROUP 1-POWER PLANT
Straight Edge
Feeler Gauge
Feeler Gauge
1743-A
1742-A
82 Outer Race
FIG.
bored
when
up
for
Housing
to
the
maximum
oversize piston recommended, replace
foreign
within
the
of
diameter.
oversize
ap
re
This
will
for the final step
fin
honing
ish and pattern are obtained. Use
clean sharp hones of No. 220-280
grit for this operation.
For the proper use of the boring
allow enough
of
so
follow the instructions
equipment
form
should
be
the
to
per
two
operation
either
methods
de
checking the
pis
refinishing
fit, thoroughly
in
the cylinder
wash
walls with solvent to remove all abra
sive
particles,
Check the
the walls.
1-36). Mark the
to the
then
cylinders
thoroughly dry
piston fit (page
pistons
in
to correspond
which
they
are
to
be installed. When the refinishing of
all cylinders that require it has been
completed and all pistons
oughly
clean
the entire
fitted,
thor
block to
re
from the bearing
bores, oil passages, cylinder head bolt
holes, etc. Coat the cylinder walls
move
particles
all
with oil.
OIL
OIL
PAN
AND
OIL
and
dry
material
Wash the
it
particles
metal
pan.
Scrape
from the
pan
thoroughly.
in
Be
a
all
gasket
solvent
sure
all
Check the relief valve piston for
free operation in the bore.
scores and
for cracks, holes,
a loose
pan
and a nicked or warped gasket
REPAIR OPERATIONS
surface.
(ENGINE IN
Repair any damage, or replace the
if repairs can not be made.
CHASSIS)
pan
OIL
Wash
them
SUPPORTS
ENGINE
PUMP
in
all parts
a solvent and
Use
thoroughly.
inside
clean the
brush
a
dry
The front
pump
supports
the
of
to
rear
of the
side
each
housing
is located
support
mission
are
located
crankcase
on
the
and
the trans
at
housing.
extension
and the pressure relief valve chamber.
Be
sure all
dirt
ing
and chips are removed.
damage
or
wear.
excessive
Check the mating
for
cover
pump
replace
grooved,
Measure the
clearance
of
surface
wear.
If the
the
or
the cover.
to
outer race
housing
(Fig. 82).
With the
rotor
in the housing,
assembly installed
a straight edge
place
the hous
assembly
ing. Measure the clearance between
over
the
rotor
the straight
outer
race
The
and
edge
and
race,
only as
Check the drive
bearing
clearance
O.D.
the
an assembly.
shaft
by
shaft and
to
housing
sion.
valve
replace
spring for
spring ten
not within
the spring is de
the spring.
a
either
is
shown
procedures
given
support
or
right
left instal
Removal
1. Remove
insulator assembly
bolts, and insula
the
to engine retaining
tor to underbody retaining
nut
and
being
re
washer.
If only
support
one
is
moved, loosen the other support.
2. Raise the
with
a
move
jack
under
the
engine
the
oil
insulator
1-inch
about
block
a
and
of
wood
then
pan,
re
assembly.
Installation
1. Position the insulator
tor to engine
If the spring tension is
fective,
apply to
lation.
the I.D. of the
relief valve
specifications and/or
The
84.
Install, but do
a collapsed or worn condition.
relief
Fig.
in
front
engine
measuring the
bearing.
Check the
The
placed
shaft and rotor are
replaceable
of
the rotor and
(Fig. 83).
outer
FRONT SUPPORT
ENGINE
cover
is worn, scored,
surface
mating
pump hous
and rotor for
of the
the outer race
and
Inspect the
gasket
surface.
baffle,
housing
PAN
Scrape any dirt or
from the inside of the
old
PUMP
Play
from below
removed
Check the inside
scribed and prior to
ton
experienced
allowed
this work.
After the final
of
Only
manufacturer.
personnel
of
End
damaged drain plug threads,
stock
the correct surface
is
plate.
Check the
Rebore the cylinder to
proximately 0.0015 inch
the
matter
baffle
the
the block.
quired
FIG. 83-Rotor
Clearan ce
not
tighten,
lockwashers
assembly.
the
insula
and
bolts.
If both supports have been removed,
install the bolts on the opposite side
before proceeding with step 2.
2. Lower the engine, then install
the
underbody
washer
and
nut
to
and
insulator
lock
tighten the
to 40-45 foot-pounds torque.
nut
Tighten
1-41
PART 1-ENGINE
BRACKET ASSEMBLY
INSULATOR ASSEMBLY
INSULATOR
BOLT
SPACER
1 74 5- A
FIG.
1
84 Engine Front Support
the insulator to engine bolts to 35-40
foot-pounds torque.
FIG.
fold. Remove the
heat tube.
age at
The engine
in Fig. 85.
rear support
is
shown
support retainer to
bolts and washers,
the support assembly to
housing
underbody
bolts.
nuts,
2. Raise
the
lockwashers,
and
housing
extension
accelerator
link
the carburetor, the windshield
flexible line at the vacuum
and the booster pump vac
uum line at the intake manifold
fitting. Remove the carburetor fuel
inlet line. Disconnect the primary
wire at the distributor and the engine
wiper
temperature sending unit wire at the
sending unit.
On cars with power brakes, discon
slightly to relieve the pressure on the
support assembly to underbody bolts,
nect
retainer and
then release the line from the brack
support assembly.
Installation
1. Raise
bly
the
extension
housing
retainer.
and
Install the
retainer
to
washers,
lockwashers,
support
housing
extension
flat
bolts, the
underbody bolts,
and
support assembly to
lockwashers and nuts.
port
ex
housing,
retainer
then tighten the sup
bolts to 25-30 foot
pounds
torque,
sembly
nuts
to
and
the support as
40-45
foot-pounds
torque.
tributor
the line.
housing
Re-
manifold
to
housing for installation.
Remove the distributor hold down
bolt and clamp, then remove the dis
tributor. Remove the radiator supply
tank. Loosen the by-pass
clamp and
the
clamp back. Remove the
rocker
arm
4. Complete
system.
and
the position of the rotor and
distributor
dure
1. Drain the cooling
in
line,
Remove the distributor cap and
plug wire assembly. Disconnect
the distributor vacuum line at the
distributor. Scribe a line on the dis
valve
REMOVAL
the
spark
slide
INTAKE MANIFOLD
at
the left valve rocker arm cover
and remove
mark
2. Remove the jack from the
tension
brake line
take manifold and at the flexible
ets on
to position the support assem
enough
the power
covers.
the
by following
removal
steps
2
and
proce
3
under
Intake Manifold (page 1-16).
move the air cleaner.
2. Disconnect the
2. Install the distributor, using the
fines as guides to properly
position the rotor and housing.
3. Install the radiator supply tank.
4. Connect the heater hose and
scribed
"Tee"
1. Remove the
and remove
choke
booster,
Removal
extension
85 Engine Rear Support
automatic
3. Disconnect the
ENGINE REAR SUPPORT
the radiator upper hose and install
the automatic choke heat tube.
5. Connect the windshield wiper
flexible line at the vacuum booster.
Connect the booster pump vacuum
line at the intake manifold. Connect
the
accelerator
fuel
line.
upper
hose at the radiator supply tank, and
the heater hose at the intake mani-
INSTALLATION
1. Follow
under
steps
2, 3, 4,
and
5
and
ature
the
distributor
the engine temper
sending unit
distributor cap and
wire.
spark
Install the
plug
wire
assembly.
On
cars with
power
brakes,
con
brake line at the in
take manifold and to the flexible line.
6. Fill and bleed the cooling sys
tem. Connect the heater hose. Start
the engine. Adjust the ignition
timing
and check all hose connections and
gaskets for leaks. Connect the dis
tributor vacuum line. Install the valve
rocker arm covers and install the
spark plug wires in the brackets
on
the covers. Be sure the spark
plug
wires for No. 7 and 8 cylinders
are
nect
the power
properly positioned in the brackets.
See Fig. 9 on page 1-48. Position
the wire
loom in the retaining
clips
the left valve rocker arm cover.
Install the air cleaner.
on
cars with power
brakes, install
brake line in the
retaining
the left valve rocker arm
the power
Intake Manifold (page 1-25).
linkage. Install the
Connect
primary wire,
On
radiator
746- A
clips
cover.
on
1-42
GROUP 1-POWER PLANT
Manifold"
on page 1-41.
3. Remove the retaining bolts from
take
COAT GASKET WITH ENGINE OIL
the
the grille and three
center of
top
bolts from the bottom
and
the
push
top
Carefully
ward.
of
the
of
remove
the grille
for
grille
the camshaft
pulling it toward the front of the
engine. Use caution to avoid damag
ing the camshaft bearings.
by
INSTALLATION
1. Oil the camshaft and carefully
it through the bearings.
2. Follow steps 1 thru 3, under
slide
Sprockets"
"Timing Chain
on
and
1-22.
page
3. Replace the crankshaft front oil
(page 1-23). Install the cylinder
front cover, following steps 1 thru 7
seal
under
lation"
"Cylinder Front Cover Instal
on page 1-24.
4. Install the hydraulic
intake
the
and
following
parts
on page
5. Install the
the
the
86 Oil Filter Replacement
FIG.
the
oil
air
cleaner.
shaft sprockets
(Fig. 38). Remove the
REMOVAL
camshaft thrust
button
1. Drain the cooling system. Re
move the air cleaner. Remove the in
cap screw, the thrust button
spring retainer, and the fuel pump
eccentric. Remove the sprockets and
HEADS
take manifold and carburetor as an
Remove the
assembly.
folds
exhaust mani
cooling system.
Start the engine
the spark plugs.
and
If the left
21).
head
block. Do
off
the
tween the
head
Lift
and
cylinder
pry be
the block. Re
head
move the cylinder
the
not
gasket.
1. Follow
exhaust
plugs.
1, 2, 3
steps
the
under
Cyl
1-24.
intake manifold, the
and
manifolds,
Connect the
spark
FRONT
CYLINDER
the
spark
wires.
plug
COVER
CHAIN
AND TIMING
2. Replace the
1. Drain the cooling system and
the crankcase. Remove the hood, air
cleaner, radiator, fuel pump,
and
water
bolts,
inder front
shaft
ing
front
pump,
the oil
2. Remove the
retaining
crankshaft
front
oil
3. Install the
following
cylinder
1 thru 4
steps
front
cover
under
"Cyl
Installation"
(page
4. Install the
water
fan
assembly.
as
an
Install
pan.
damper.
pump, pulley, and
and
Install the
drive
the
adjust
belt(s).
Install
radiator
supply tank, and the hood.
bleed the cooling system. Fill
Fill
and
the
crankcase.
the
hose
fuel
oil
the
Start the
the
pump,
and
engine
ignition timing. Operate
fast idle
connections
and check all
for
gaskets
and
crankshaft
Remove the
leaks.
REMOVAL
Align the tim
the camshaft and crank
1. Follow
1
steps
and
"Cylinder Front Cover
Chain
OIL
PUMP
1. Drain the cooling
the
crankcase.
hose
system
Disconnect the
at
and
radia
the radiator supply
Remove the oil
screws and lower the
tank.
cross
pan
oil
retaining
to the
pan
member.
Position
the crankshaft so the counterweight
the oil pan and move the
will
clear
pan
forward.
2. Remove the
coil
retaining bolts
and position the coil out of
the way.
Install the engine lifting brackets and
sling. Raise the engine high enough
to place tension on the engine mounts.
Remove the
high
gine
of
engine
front insulator to
retaining bolts. Raise the
engine
the oil pump retaining
remove the
and
en
to permit removal
enough
bolts,
bolts. Remove the
then
oil pan
the oil pump.
INSTALLATION
1. Raise
the
engine
enough
to
installation of the oil pump and
the oil pan. Position a new gasket on
the oil pump
CAMSHAFT
cover
crank
AND
REMOVAL
pan.
front
the
allow
pan.
cylinder
oil slinger.
crankshaft
Install the
radiator
then remove the cyl
cover.
mark on
on
(page 1-23).
seal
PAN
underbody
the engine at
supply tank,
and
1-22.
page
adjust
REMOVAL
damper,
under
1-24).
on page
2. Install
4
thru
Sprockets"
Chain
"Timing
1
steps
inder Front Cover
INSTALLATION
inder Head
1. Follow
OIL
tor upper
INSTALLATION
head is to be
removed, remove the ignition coil.
2. Remove the cylinder head bolts,
then install the cylinder head holding
cylinder
fixture (Fig.
assembly (Fig. 24).
chain as an
and adjust
ignition timing.
spring, the
and
sprocket
timing
hood,
Fill and bleed
Fill the crank
case.
CYLINDER
1-25.
pan, the radiator,
supply tank, the
radiator
and
related
the procedure under
Manifold"
"Intake
lifters
valve
manifold and
Removal"
2. Follow
steps
and
in this
3
and
2
under
Timing
section.
4
under
"In
Place the
housing
oil
and on the oil
pump in the
oil pan
and position
the oil pan on the under
body
member.
cross
Insert the
oil
pump drive
shaft
housing
install the oil pump and
Do not attempt
and
into the
shaft as an assembly.
oil
pump
1-43
PART 1-ENGINE
MUFFLER
MUFFLER
FRONT CLAMP
REAR CLAMP
MUFFLER INLET PIPE
FRONT SECTION ASSEMBLY
MUFFLER
PIPE
OUTLET
INLET PIPE
MUFFLER
REAR SECTION
FRONT BRACKET
174 7- A
87 Exhaust System
FIG.
to force the pump into
will not seat readily.
hex may be
if it
position
The drive
misaligned with
shaft
the dis
tributor shaft. To align, rotate the
intermediate
into
shaft
new
a
posi
tion. Tighten the oil pump retaining
screws to 23-28 foot-pounds torque.
2. Hold
oil
in
pan
place
the cylinder block and install
against
a
the
retaining screw on each side
Install the remaining
oil pan.
and tighten
them
from the
of
the
center out
3. Lower the engine, then install
the engine right and left front support
retaining bolts. Tighten the bolts to
40-45
the
foot-pounds torque.
Install the
tor
lifting
engine
upper
and
sling.
hose. Fill the cooling
the
crankcase
and
proper grade
oil.
Remove
coil and connect the radia
Fill
tem.
bracket
Operate the
quantity
sys
the
with
of engine
engine and check
for
leaks.
OIL
filter
until
the
face,
tacts the adapter
then
FILTER
1. Place
a
advance
3. Operate the engine at fast idle
for leaks. If oil leaks are
pairs
the
perform
evident,
necessary
to correct the leakage. Check
fill the
the oil level and
crankcase
drip
follows:
pan under
the filter.
filter from the adapter.
Clean the adapter filter recess.
2. Coat the gasket on the new filter
Unscrew the
oil, then
place
the
filter in
posi
fold
if
on the exhaust mani
the extension of the
studs and on
front clamp into
Connect the inlet pipe to the
Slip
mufflers.
exhaust
the
manifolds
23-28
to
nuts
tighten
and
the
foot-pounds torque.
Align the inlet
necessary.
Position the inlet
valve.
assembly
manifold.
the exhaust
a new gasket on
control
place.
re
pipe
assembly
and
tighten the clamps.
EXHAUST SYSTEM
The
exhaust
system
is
shown
in
Fig. 87.
MUFFLER AND OUTLET PIPES
The
procedure applies to either a
right or
MUFFLER
INLET PIPE REPLACEMENT
left
assembly.
1. Loosen the
The right and left
front sections are
muffler
inlet
serviced
as
pipe
one
piece.
1. Loosen the
muffler
inlet
pipe
front support clamp bolt and slide the
clamp off the support. Disconnect the
inlet pipes at the exhaust manifolds.
pipe assem
gas control
from the right exhaust mani
fold and discard the gaskets.
2. Position the clamp on the front
section of the new
the
front
rear
and
new gasket on
inlet
rear
pipe.
sections.
Connect
Place
a
the exhaust manifolds,
then position the exhaust gas control
clamp,
and slide
the
valve
as
gas
pipe
and check
the right exhaust
valve on
Position
gasket con
it 14 -turn.
Remove the muffler inlet
bly. Remove the exhaust
Replace the filter
with
tighten the
screws
to 12-15 foot-pounds torque.
ward
tion on the adapter (Fig. 86). Hand
it
the
of
Remove the
clamp.
pipe
clamp
Remove
muffler
muffler
rear
from the
pipe.
2. Position the
new
outlet pipe
assembly
Slide
muffler
inlet
inlet
the
the muffler.
off
lower half
inlet
muffler
then spread
the
on
muffler
and
the inlet pipe.
forward into the
in the muffler
blocked. The overlap
pipe until the slots
extension
must not
Align the
are
be
greater than
IVa inches.
muffler and outlet pipe as
Position the muffler inlet pipe
clamp and install the retaining bolts.
Install the muffler rear clamp.
sembly.
1-44
GROUP 1-POWER PLANT
PART 2
IGNITION SYSTEM
Section
Page
1
1-44
Trouble Shooting
Ignition System Testing
2
3
4
SWITCH
Distributor Overhaul
1-52
of the ignition
purpose
low
electrical
voltage
supply
system
voltage electricity and to
to surges of
distribute
voltage to the proper spark
plug
this
I
r
S*-**K*
%&>L
DISTRIBUTOR
is to
electricity from
system
SPARK
PLUG
1-49
The
/l^.
acc^JTXam
and
Minor Repairs
transform
IGNITION
1-45
Distributor Tests, Adjustments,
the
high
high
at the right
time.
The ignition
system
of
consists
a
primary (low voltage) and a second
ary (high voltage) circuit (Fig. 1). The
battery, ignition
PRIMARY CIRCUIT
SECONDARY CIRCUIT
switch, primary cir
primary windings of the
ignition coil, breaker points, and the
cuit resistor,
1 Ignition Circuit
FIG.
in the primary circuit.
The secondary circuit is composed of
the secondary windings of the igni
tion coil, distributor rotor, distribu
tor cap, high tension wires, and the
1182-C
condenser are
When the breaker
primary
low
or
points are
closed,
voltage
current
flows from the battery through the
ignition switch to the primary wind
ings in the coil, then to ground
through
the
breaker
closed
When the breaker
points
magnetic
field built up in
windings
of
secondary
producing high
windings
voltage current
is
breaker
of
produced each
points
open.
flows through the
lead
of
peated
to
the rotor
the
spark
coil
High
a
tion timing.
CIRCUIT
shaft
A break down
energy loss in the
or
primary circuit can be caused by:
1. Defective primary wiring.
2. Burned breaker points or im
properly adjusted breaker points.
3. A defective coil, resistor, or con
denser.
plug terminals in the
This process is re
power stroke of
CIRCUIT
SECONDARY
high
distributor cap
distributes it to one
the
A break down
secondary
1. Fouled
or plugs
or
energy loss in the
or
be caused by:
broken spark plugs,
circuit
can
incorrectly
the
rotor.
be
worn, or
a
3. Defective
bent distributor
shaft.
vacuum advance sys
tem.
4. Defective
centrifugal
5. Preignition
plugs
of
properly
(caused
advance.
by
spark
the wrong heat range), im
adjusted
etc.
plugs,
If the cause of engine trouble has
been traced to the ignition system
(page 1-7), refer to the trouble in
Table 1
and
the items listed
The causes of the
listed in the order of
check
under the trouble.
are
their probable occurrence;
items should be
order listed.
the
therefore,
in the
checked
1 Ignition System Trouble Shooting
To determine if the
cause
of
the
trouble is in the primary or the sec
ondary circuit, pull the coil wire
from the top of the distributor and
ENGINE
CRANKS
NORMALLY,
WILL
can
Timing incorrectly adjusted.
bushing and/or
troubles
adjusted.
2. Defective high tension wiring.
3. High-tension leakage across the
coil, distributor cap, or
engine.
Incorrect ignition timing
caused by:
1.
PRIMARY
TIMING
IGNITION
2. Distributor
time
The high
coil
system troubles are caused
failure in the primary and/ or the
secondary circuit, or incorrect igni
cap.
for every
TABLE
the
voltage current.
tension
distributor
the
the primary
voltage
where
points.
open,
the coil moves through
the
the
Ignition
by
spark plugs.
the
TROUBLE SHOOTING
NOT
BUT
START
hold it approximately Ve inch from
the cylinder head, then with the igni
tion on and the engine
check
for
a
spark.
good, check the
If the
tion
spark
timing is
of the
turning
If the
over,
spark
is
ignition timing.
is
good and
not at
fault,
trouble is probably
the igni
the cause
in the:
Distributor
cap.
Rotor.
Spark plug
wires.
If there is
spark,
the
no
cause
spark
of
the
or
a
weak
trouble
probably in the:
Primary
circuit.
Coil to distributor high tension
lead.
Coil.
is
2
PART
TABLE
1-45
IGNITION SYSTEM
1 Ignition System Trouble
Shooting (Cont'd.
Resistor for
Check the:
ENGINE STARTS, BUT
FAILS TO KEEP
RUNNING
Breaker
Spark
Check for leaks in the high
points.
cylinder,
Secondary
Spark
perform a spark
Check
der.
If
of
across
does not occur, the
is in the secondary circuit
a good spark
a
good spark
If the
spark plug.
a
mechanical
gine
Coil.
occurs, check the
is
not at
component of
at
Condenser.
fault,
Breaker
the en
Ignition wiring for leakage.
Distributor shaft for excessive
AT
play.
Spark
points.
Condenser.
Breaker
Ignition timing.
Spark plugs.
ENGINE DOES NOT
DEVELOP FULL
for wear.
points.
Distributor
advance.
Rotor.
Distributor
advance.
the trouble
Distributor
shaft
exists
all
at
engine tem
Check the:
for
excessive
play.
Distributor
Ignition timing.
Coil.
Condenser.
POOR HIGH SPEED
PERFORMANCE
cam
The cause of this trouble usually
lies in the ignition system only when
peratures.
POWER, OR HAS
plugs.
Distributor
Check the:
POOR ACCELERATION
points.
Rotor.
fault.
MISSES ERRATICALLY
ALL SPEEDS. Check the:
Breaker
leakage
the:
spark
is probably
tension
the coil, rotor, or distributor
MISSES AT IDLE ONLY. Check
the system, check the:
If
plugs.
for high
cap.
Spark plug wire.
Distributor cap.
ENGINE RUNS,
BUT MISSES
wiring.
Coil.
test on the ignition lead of that cylin
trouble
tension
wiring.
plugs.
MISSES STEADY AT ALL
SPEEDS. If the miss is isolated in
a particular
an open circuit.
Spark
Breaker
EXCESSIVE FUEL
CONSUMPTION
Check the:
Ignition timing.
ENGINE OVERHEATING
Check the ignition timing.
Spark
cam.
plugs.
points.
plugs.
Distributor
advance.
IGNITION SYSTEM TESTING
A
check of
complete
system
includes the
the ignition
battery
and
distributor, primary and
secondary wiring, and the spark
plugs. This section describes the tests
cables, coil,
for
and
all
these units except the
the distributor.
it is
system, is
cause
part of
The battery, be
the
electrical
in
Group 7,
covered
Distributor testing is
tion 3.
battery
covered
supply
Part 1.
in Sec
and
the contacting surfaces on
the
battery,
engine, and relay are clean.
Tighten the cables securely upon in
stallation.
Test the
battery (Group 7,
Part 1).
Inspect
worn
all
the primary wiring for
insulation, broken
strands,
and
loose or corroded terminals. Replace
any defective wiring. Make sure all
connections are tight. Remove the
coil to distributor high tension lead
the spark plug wires one at a
time from the distributor cap and
and
PRELIMINARY
due to
CHECKS
battery for
Inspect the
acid and
move and clean the
with a
baking
brush. Be
corrosion
dirt. If necessary
battery
re
and cables
soda solution and wire
sure
the cable connectors
from the
spark plugs. Inspect the ter
for looseness and corrosion.
Inspect the wires for breaks and
cracked insulation. Replace all de
fective wiring.
minals
Clean the inside of the distributor
and inspect it for cracks, burned
cap,
contacts,
or permanent carbon
Remove dirt
tracks.
from the
sockets. Inspect the rotor for cracks
or a burned tip.
Replace the cap
and/or rotor if they are defective.
or
corrosion
PRIMARY CIRCUIT RESISTANCE
TEST
A
complete test of the
primary cir
checking for excessive
voltage drop from the
battery to the
coil and from the coil to ground. Ex
cuit consists of
drop in the primary
lessen the secondary out
put of the ignition
coil, resulting in
hard starting and poor performance.
cessive
voltage
circuit will
1-46
GROUP 1-POWER PLANT
VOLTMETER
VOLTMETER
1 173-C
2 Battery
FIG.
The
the
tests are made with
breaker
switch on and the
tension
lead
engine
while
drop. It
points closed.
If the
BATTERY
TO COIL TEST
the
battery
the
at
voltage
If the voltage is
below 8.5 volts, it will be necessary
to make the following checks to de
terminal of the coil.
termine the point of high
resistance
in the battery to coil circuit.
Connect the negative lead of
battery
to the
meter
the
and
resistor
terminal
positive
terminal of the
lead to
positive
battery
the
of
the
wiring
If
the
is 0.2
drop
the voltage
to the
the
is
resistor
voltage
drop
connected
minal
of
lead
battery
the
of the
If there is
the
of
and
volt
touch
lead to the
ignition
no
limit,
this
switch
the
coil
(Fig. 3).
Next,
lead to the
negative
ignition
terminal of the
(Fig. 3). If the reading
resistance
drops,
in the
Check the primary
touch
switch
there
is
switch.
resistor
by
con
necting an ohmmeter across its termi
nals (Fig. 4). Disconnect the battery
ance
is
the
resistor
is 1.3-1.4
to
prevent
The
ohmmeter.
damage
specified resist
If the reading
this limit replace the
ohms.
over or under
Check the
resistance
circuit
terminal of the
in the starting
connecting the
lead to the positive
by
voltmeter positive
battery
and
the
of
making the test.
nega
tive lead to the battery terminal of
the coil (Fig. 5). Disconnect the high
the
GROUND TEST
The
lead
positive
the
of
to the distributor terminal
and the negative lead to
The voltage drop should not
0.1 volt. If the voltage drop is
ground.
exceed
excessive,
each
test
drop
voltage
of
following:
the
of
the
the
breaker
breaker
can
be
made with the coil
test set.
on the engine or on a
coil'
include
tests
coil
heat,
sec
ondary continuity, and coil capacity.
A coil may break down after it has
operating temperature; there
heat test is made to test
reached
fore,
a
coil
the
ceil
The
coil
at
operating temperature.
secondary continuity test is
to test the coil secondary
performed
2. Distributor primary terminal
the movable breaker point.
movable
manufacturer
for high resistance. The coil
capacity test is made to determine the
windings
wire.
and
3. The
set
COIL
Coil tests
coil,
condition of the windings of
Perform
point and
structions
test
the
of
the coil.
following
all tests
plate.
set
the in
manufac
turer.
4. The breaker
and
plate
the dis
REMOVAL
tributor housing.
5. The
engine
distributor
housing
Disconnect the high tension lead
and
and
ground.
SPARK
INTENSITY
Disconnect
a
in
remove
one spark
plug
time and install a terminal
wire at
Vie inch from
approximately
haust
The
manifold and crank
spark should
jump
the
the ex
engine.
the gap
regu
larly.
If the
intensity
spark
of all
leads is
satisfactory, the coil, condenser,
tor, distributor cap,
sion cables are
spark
leads,
perform
of the
faulty
If the
weak
is
good
a
high
is
and
some
resistance
equal at all
intermittent,
resistance check of
tor cap,
only
the coil.
Place the
coil
in
position and
install
the mounting screws. Insert the high
tension lead into the coil socket. Push
the
weather
seal
tight
against
the
Connect the primary wires to
the coil. Be sure the wires are prop
erly installed.
socket.
RESISTOR
satisfactory.
at
coil.
screws and
test
The
resistor
(Fig.
6) is
excessive resistance as
plained under
"Battery
checked
previously
To Coil
for
ex
Test."
leads.
spark
or
probably
mounting
ro
the high ten
and
coil
INSTALLATION
adapter
the wire terminal. Hold the adapter
leads from the
the primary
Remove the
If the
resistor.
ignition
clean
in the reading,
change
voltmeter
to the
TO
voltmeter
ter
the
wire at
is excessive,
test
tions
when
If
the circuit is satisfactory.
excessive
drop
Connect the
to the positive ter
voltmeter negative
battery
volt.
exceed
high tension lead. Follow the instruc
as necessary.
BATTERY
volts or
satisfactory.
exceeds
positive
meter
minal
0.1
not
1. Coil to distributor
the primary circuit from the bat
leave
should
the
voltage
to Switch Test
installed
(Fig. 2).
less,
tery
the
observing
voltage
of the
a volt
at the coil and crank
tighten the terminals or replace
and
Check
3 Battery
FIG.
to Resistor Test
following
ignition
1175-C
the
leads, but
make
a
the coil, distribu
coil
SPARK PLUGS
high
to distributor
An 18-millimeter
7) is
a
used.
gasket.
spark
This plug does
plug (Fig.
not require
PART
2 IGNITION
1-47
SYSTEM
OHMMETER
VOLTMETER
JE"2el
1 1 74-C
FIG.
1 1 72-C
4 Resistor Test
FIG.
5 Starting Ignition Circuit Test
TERMINAL
**"*
INSULATOR
SHELL
60
TAPERED SEAT
GROUND E1ECTRODE
1771-A
FIG. 7-1 8-Millimeter Spark Plug
REMOVAL
Pull the
FIG.
6 Resistor
wire off each spark
plug,
and clean the area around each spark
with
plug
compressed
then
air,
re
the spark plugs.
move
CLEANING AND INSPECTION
Examine the
firing
ends
of
the
spark
plugs, noting the type of de
posits and the degree of electrode
erosion.
The
fouling
plug
various types of spark
and
the normal condi
tion of the spark
plug after usage are
shown
Oil
tified
are
the
in Fig. 8.
fouling
by wet,
(Fig. 8) is usually iden
sludgy deposits. These
traceable to excessive
combustion
worn
rings
and
pistons,
between
clearance
oil
chamber
and
entering
through
excessive
the valve
guides
loose bearings.
8) is usually iden
tified by dry, black,
fluffy deposits
which result from
incomplete com
bustion. Too rich a fuel-air mixture
stems, or worn
Gas fouling (Fig.
NORMAL CONDITIONS
NORMAL CONDITIONS
1179-B
FIG.
8 Spark Plug Visual Inspection
can
cause
addition,
a
or
incomplete burning. In
defective coil, defective
breaker points,
or
a
defective igni
tion cable can reduce the
voltage
sup-
1-48
GROUP 1-POWER PLANT
plied to
the spark plug
and cause mis
firing.
Burned or overheated spark plugs
(Fig. 8) are usually identified
by a
white, burned, or blistered insulator
nose and
badly
efficient
engine
In
improper
eroded electrodes.
cooling,
FIRING ORDER
ignition timing, the wrong type of
or loose spark plugs can cause
fuel,
general overheating.
Normal
where
have been
by
left)
usually identified
used are
a rusty-brown
dery deposit
to grayish-tan,
pow
and minor electrode ero
indicating
sion,
8
(Fig.
conditions
regular or unleaded gasolines
ignition
proper
and
combustion conditions.
Normal
been
8
(Fig.
conditions
highly leaded
where
right)
have
gasolines
usually identified by
white, powdery deposits. If the spark
used
plugs
are
are
intervals
cleaned
and
at
recommended
normal
service
condi
tions are encountered, these deposits
have little
effect on
However,
prolonged
performance.
plug
high-speed, high
load operation will fuse these deposits
form a yellowish glaze. At high
temperatures, this glaze may be con
ductive, resulting in spark plug "miss
9 Ignition Wiring Installation
FIG.
to
ing"
fouling.
or
Clean the
plugs
following
cleaner,
instructions. Do
on
the
insulator.
blast
sand
the manufacturer's
not
the abrasive blast
of
a
prolong the use
as it will wear
Remove
carbon
and
deposits from the threads with
wire brush. These threads are
other
a stiff
the means of carrying the heat away
from the spark plug. Any deposits
will
ing
heat flow from the
the
retard
plug to the
spark
spark
cylinder
head,
caus
pre-
and
plug overheating
Test for
insulator
insulator
flat
the center
file the
parallel
ground
other
Do
cracked
of
signs
too thin
as
or
pitted
plug
broken in
electrodes,
failure.
Replace
or
as
factory,
spark
0.036 inch)
plug
gap
plugs on a
by bending
the
ground
gap,
then
testing
the
test
machine.
spark
Compare
the sparking efficiency of the cleaned
plug.
it
regapped
spark
plug
with
a
new
Replace the plug if it fails to
requirements.
the
replace
spark
plug is
satis
loose terminals. Repair
or replace
REMOVAL
Disconnect
spark
plugs
plug
port
Install the
insure
to
seating.
plugs, then tighten
spark
them to 15-20
proper
spark
the
the
foot-pounds torque.
the
wires
from
molded
wire as
cap.
the
cap
the
To
spark
only.
Do
this may sepa
connection
wire
damage the
or
from
wires
distributor
wires
grasp the
cap
valve
the
and
the
remove
rate
the
around
in
the wires as required.
plugs,
clean.
area
and
insulation
for
Leak
INSTALLATION
HIGH TENSION
WIRES
(SECONDARY)
inside the
weather seal.
from the brackets
on
Pull
the
rocker arm covers and remove
the wires.
wires
wires
include the
connecting the distributor cap
to the spark plugs and the wire con
necting the
The
center terminal of the
high
center
dis
terminal of
wires
are
the
resistance-type
which
stamped on each cable.
The
resistance
of each wire should not exceed
Ohms. When checking the
the
timing,
wires or when
do
not
24,500
resistance
setting ignition
puncture
the
wires
each
wire
in the
proper
distributor cap socket. Be sure the
wires are forced all the way down
into their sockets. The No. 1 socket is
identified on the cap. Install the wires
in a counterclockwise direction in the
firing
tension
filter out
the high frequency electrical impulses
that are the source of ignition noise
interference. The wires can be identi
Resistance"
fied by the words "Radio
of
INSTALLATION
1. Insert
The high tension
radio
TESTING
meet
If the
wipe
and
service.
cracked
not pull on
(0.032-
electrode.
Set the
leakage,
compression
may cause a
A spark
spect the wires
bubbling
air
probe
conductor.
plug,
If the test indicates
through the oil.
spark plug.
by
in the
plug wire set is available for
At regular intervals, clean
spark
under pressure.
is indicated
The
with a probe.
separation
shell,
from the insulator. Place
the spark plug
ADJUSTMENT
and
project
age
the
of
top
cap to the
the ignition coil.
the
coating
the
the center electrode and termi
where
nal
the
tributor
required.
Set
to
and
the
examine
at
of oil
not
result.
After cleaning,
badly
both
on
surfaces
electrode
may
carefully for
to
electrodes
and side electrode.
pre-ignition
sulators,
surface with a
leakage
through the
projects
Clean the
Clean the electrode
file. Dress the
small
Apply
a
to the shoulder of the plug where the
ignition.
secure
compression
seal.
order
(1-5-4-2-6-3-7-8) starting
No.
1 socket. Cylinders are
from front to rear-right
bank, 1-2-3-4; left bank, 5-6-7-8.
2. Remove the brackets from the
at
the
numbered
old
spark
plug
them on the
wire
new set
set
and
in the
tive position. Install the wires
brackets
covers
on
(Fig.
the
9),
valve
in the
rocker
arm
then connect the wires
to the proper spark plugs.
coil
install
same rela
high tension lead. Be
Install the
No. 7
sure
2 IGNITION
PART
3
B.T.C.CONVENTIONAL
DRIVE AND OVERDRIVE
6
B.T.C
CRUISE-O-MATIC
1571-A
FIG.
plug wire is positioned in the
brackets as indicated in Fig. 9.
spark
TIMING
IGNITION
has a crankshaft dam
per having five timing marks (Fig.
10). The first long mark represents
top dead center (T.D.C.) and each
The
engine
2, 4,
top
(B.T.C.). The initial timing
succeeding
mark
center
be
should
ventional
set
3
at
drive
B.T.C.
represents
respectively, before
6, 8, 10,
6
<
10 Timing Marks
FIG.
B.T.C.
on
con
or overdrive units and
cars
on
Cruise-O-
with
Matic.
CHECKING TIMING WITH A TIMING
spark
the
plug
and
1. Disconnect the distributor
to the
battery
ter
distributor to determine if the ad
vance mechanism is operating. To do
trifugal
The timing light
advance.
flash just as the proper mark
lines up with the timing pointer, indi
cating correct timing. The operator's
eye should be in line with the center
of the damper and the timing pointer.
should
the
timing
proper
timing
do
pointer
mark and
not
line up,
the pointer are in line (Fig.
section covers
and
minor
the
until the correct
TESTS, ADJUSTMENTS,
tests, adjust
for the
indicated.
DIAPHRAGM LEAKAGE AND FREENESS
OF OPERATION
ADVANCE
SPARK
CONTROL
These tests
MECHANISM
The
mechanism should
tune-up,
when
hauled,
on
whenever
a
control
advance
be tested
during
the distributor
new
spark
is
installation,
advance
a
over
trouble
or
is
on a
can
be
distributor test
sufficient
for
made with
The tests are
tune-up. How
set.
an engine
advance
properly,
line,
tributor vacuum
then check the
this, hold the timing light
timing
that the
so
be seen,
If no ad
marks and pointer can
and accelerate the engine.
vance
is evident,
is the
one of the
probable
available
cause;
the
at
following
no
vacuum
distributor,
vacuum
diaphragm
connected from the
leaking
centrifugal
not
advance
advance
properly, breaker
housing
or dis
breaker plate,
plate
or on the
functioning
binding in the
bushing.
the engine and check
it
tor test set
the
under
following
"Spark
remove
is
not
Check the
the
on the engine or
ever, if there are indications that the
spark
5. After the ignition timing has
connect the dis
been properly set,
on a
distribu
instructions
Advance Tests
and
Adjustments."
distributor installed
spark
counterclockwise ro
AND MINOR REPAIRS
repairs
distributor.
body,
3. Operate the engine at idle speed.
Be sure the engine is idling below 550
rpm so that there will be no cen
mark and
This
by
tation.
light high tension lead to the No. 1
ments,
clock
2. Clean the dirt from the timing
and if necessary, chalk the
proper mark and the pointer to im
prove legibility.
marks,
distributor
DISTRIBUTOR
by
advanced
the distributor
and retarded
rotate the
then connect the
11). The timing is
wise rotation of
minals.
timing
line,
,1772-A
11 Checking Ignition Timing
the other two leads of
timing light
4. If the
LIGHT
vacuum
1-49
SYSTEM
functioning
the distributor from
nism
vacuum advance mecha
for freeness
of
operation
by
manually rotating the breaker plate
in the direction of rotation. Do not
rotate
the
plate
condenser or the
or
other
suitable
by pushing
on
the
hook
instrument in the
points,
use a
1-50
GROUP 1-POWER PLANT
breaker point and adjustment
The breaker plate should turn
binding
out
position when released.
binds,
plate
inspect,
To
its
and return to
slot.
with
the
speed
If the breaker
the
first
Clean,
lubricate the distributor.
and
diaphragm for leak
age:
Adjust the
the
ing
vacuum gauge
highest vacuum
the instructions
hose
test
the
of
the
diaphragm
the
on
follow
possible
Install
manufacturer.
to read
set
vacuum
line
vacuum
fitting. The vacuum gauge reading
should not fall off when the vacuum
is
applied to the
if
no
by
diaphragm assembly
If a leak is indicated
test, replace the diaphragm
leak
the
exists.
BREAKER
PLATE
is
advance
Increase
correct advance
at this
rpm, stop the
bend
and
the
primary
spring bracket to change tension (Fig.
12). Bend the bracket away from the
distributor
the
toward
and
decrease
to
shaft
the
breaker
worn
breaker
point
will
cause
dwell
angle
plate
and
gap
to change as engine speed and load
conditions are varied.
Install
following
set
test
set
on
instructions
the
test
a
the
of
Attempt
manufacturer.
to
"rock"
breaker
the
plate
by
applying
light thumb pressure, alternately, to
each side of the breaker plate (mov
inner
able section or
be
should
determine
slot and
spring is under ten
hook into the adjusting
which
sion, insert
a
each
move
repeated
spring.
minimum
the distrib
"rocking"
the
be
should
its
angle
while
determine
advances
checked
load.
calibrate
the
test
set
following
instructions of the manufacturer.
Check the dwell angle. If the dwell is
between
arm
and
points
as
required.
adjust
systems.
tension
it if
Each
(17-20
inch,
ounces),
necessary.
has two
inde
both up
listed in the
advance
is
adjusted
system
centrifugal ad
before adjusting the
the
zero
advance
uum
setting
If the
the
given
installing
at
vacuum
1000
at
advance
first
the
the
Do
The
nut.
addition
a
of
advance and
washer
a
the
increase
will
one point of the curve
change
should
the
be
original
is
ad
checked.
rpm
set-
going to a different vacuum
If they arc not within limits,
it indicates incorrect spring tension or
when
leakage in the
vacuum
chamber
the
ally the result of an
of
rotation
increase the
wise)
and
spark
begins
to
rpm
advance.
POINTS
The breaker
the
(counterclock
until the
Reduce the
point
assembly con
sists of the stationary point bracket
assembly, breaker arm, and primary
wire
terminal.
mounted
dirt
and
oil
equals
on
gener
accumulation of
the
This is
points.
usually caused by oil bleeding from
the distributor base bushing onto the
by
lubricant
improper
excessive or
cam
thrown off onto the
being
and/or
points,
neglect
to
the
clean
points periodically.
Excessive
breaker
by
incorrect
regulator
radio
points
point
between
transfer
metal
the
is generally
caused
alignment,
voltage
setting that is incorrect, a
installed to the dis
condenser
tributor side
condenser
of the
of
coil, an
ignition
improper capacity
operation
at
or
other
speeds
than normal.
Disconnect the primary and con
denser leads. Remove the screws that
the breaker point assembly to
breaker plate, then remove the
breaker point assembly.
INSTALLATION
1. Place the primary
leads on the breaker
and conden
point assem
primary terminal. Install the
lockwasher and nut, then tighten the
bly
nut securely.
2. Position
on
the
The assembly is
breaker plate as a
the
breaker
point
as
breaker plate, then
install the hold down screws. Make
terminal is on
furthest from the adjust
Adjust the breaker point
the ground wire
sure
the
the
on
sembly
screw
slot.
gap.
Breaker Point Gap. The breaker
can be adjusted with the dis
tributor installed on the engine or
points
on
distributor test
a
New
gap
1. Operate the distributor in
it
when
gap setting.
Burned breaker points are
points are
with
distributor
block
a
feeler
installed,
gauge.
until
cam
new
check
the
Rotate the
the
rubbing
lobe.
rests on the peak of a cam
Insert the
gauge
set.
Breaker Points. When
breaker
line.
BREAKER
direction
excessive
or
ment
advance.
CENTRIFUGAL ADVANCE
evident.
exceeds
or
between the
Metal transfer is
nut.
and
spring
setting.
and/or
assembly
burned
transfer
considered
or
the others
not
point
ser
the specifications.
decrease
of
When
is
points
bristle brush.
badly
are
metal
excessive
vac
advance.
justed,
contacts
with
cleaned
stiff
Replace the breaker
if the
scale.
removing the wash
the gasket in place and
ers, position
washer will
a
washers
chamber
tighten
be
can
and
the
is incorrect, change
between the
advance
spacing
After
in
chloroform
secure
speed range.
Operate the distributor
and
Points
vals.
be inspected,
inter
points should
and adjusted at regular
REMOVAL
the
check
Operate the distributor
down the
and
the
the
adjust
make
Next,
points
all
specifications.
ring
spark
Adjust the
and
the point
0.014-0.016
operated
separately.
or
Check the breaker
distributor
The
pendently
at
Breaker
cleaned,
extended
zero point and
two
removal
within
not
spring
vance
26-281/2
the points.
adjust
Recheck the
other
the distributor
not rotating.
vacuum
on a test set
the
gap it
3.
when
to
proper relation to engine
Mount the distributor
not
is
shaft
Check the
is
ignition timing
if the
in
speed and
and
tension (is slack)
1.
AND
advance
the
stop
secondary spring bracket to give the
correct advance. The secondary
spring is the spring that is not under
rpm
spark
bend
and
from
engine.
If
VACUUM ADVANCE
replaced.
ADJUSTMENTS
The
maximum.
to specifications,
not
distributor
advance
breaker plate, the bush
TESTS
is
this advance
nor
reading
4 degrees
than
ADVANCE
SPARK
with
If the dwell
more
changes
just below the
advance
without
replaced
distributor
the
removing
points,
advance
the specified rpm to give an
at
race).
various positions of
mal travel.
ing
utor
sec
less ten
under
than the primary
the
The
spring.
be
will
ondary spring
ments
in
plate
The test
the breaker
increase
to
shaft
The primary spring is the
spring that is under tension when the
distributor shaft is not rotating. To
the
distributor
the
advance
advance.
point again, then operate
A
for
specified
be
can
and
unit,
reading listed in the
If the
indicated
not
distributor
no
scale.
value
advance
2. Check
TEST
WEAR
the
to
specifications.
sion
assembly.
is
there
where
original
remove the plate.
check the
to
speed
and zero the advance
correct
between
blade
the
of
a
breaker
feeler
points
(Fig. 13). The correct gap should be
0.014-0.016 inch. If the fit is loose or
PART
CENTRIFUGAL ADVANCE ADJUSTMENT HOLE
2 IGNITION
1-51
SYSTEM
Tool-
Screwdriver
FIG.
13 New Breaker
Point
12150-D
Gap
Adjustment
128-A
FIG.
12 Centrifugal Advance Adjustment
Adjusting
Wrench 12150-D
CONTACT AREA
CENTERED
CORRECT ALIGNMENT
CONTACT AREA
NOT CENTERED
MISALIGNMENT
OF CENTERS
CONTACT AREA
NOT CENTERED
MISALIGNMENT OF
p| G.
if
is binding, loosen the
point
lockscrew
gap (Fig. 13).
A light film
and
the
the
when
installed. Do
new
be
applied
breaker
points
not use engine oil
lubricate the distributor
the breaker
point
the ignition
timing.
cam.
alignment
to
to
Check
then set
15 Aligning Breaker Points
Used Breaker Points. If the gap of
breaker points is being checked,
used
a
dwell
angle.
It is
feeler
gauge
use
grease should
cam
station
adjust
high-temperature,
of
non-fiber
are
FIG.
14 Breaker Point Alignment
there
ary
1129-B
POINT FACES
gap
of
used
meter to test the
not
advisable
to adjust or to
breaker
the roughness of the
to
dwell
use
check
points
the
points
gap reading or setting impos
Check the dwell angle following
make a
sible.
the
instructions
of the
dwell
ment, then
set
the
ignition timing.
a
because
breaker
manufacturer. The dwell angle should
be 26-28,/2. Check the point align
meter
BREAKER POINT ALIGNMENT
The
vented-type
breaker points
be accurately aligned and strike
squarely in order to realize the full
must
advantages provided
and
assure
normal
by
this
point
design,
Any
life.
1-52
GROUP 1-POWER PLANT
LESS TENSION
BREAKER POINT TENSION SPRING
MORE TENSION
17-20 OUNCES
1773-A
11 69- A
16 Spring Tension
FIG.
of
misalignment
the
point
surfaces
until the
breaker
open
ing
within specifications
and pitting.
that the breaker
cam so
points are closed and check the align
14). Align the breaker
points to make full face contact by
bending the stationary breaker point
(Fig.
ment.
bracket (Fig.
breaker
15). Do
not
After the breaker
arm.
have been properly aligned,
gap
bend the
points
adjust
the
dwell.
or
POINT
Correct breaker
is
sion
essential
operation
to
proper
engine
breaker
point
life. If the spring tension is too great,
wear of the breaker arm rub
rapid
block
bing
breaker
will
result,
gap to
causing the
up and re
If the spring
tension is too weak, the breaker arm
will flutter at high speed, resulting in
tard
To
point
To
check
high
over
the
tension,
movable
place
breaker
point, then pull the gauge at a
(90)
angle
to
Remove the distributor from the
Place the distributor in the
holding tool and clamp it in a vise.
Push the distributor shaft upward as
far as it will go, then check the end
(17-20 ounces),
spring tension (Fig.
17), disconnect the primary and con
denser leads at the breaker point
assembly primary terminal. Loosen
holding
the nut
then
arm pivot
in the
spring toward the
to decrease tension
direction to in
opposite
Tighten the locknut,
the spring tension. Repeat
tension.
then check
the
in position,
the spring
the
move
breaker
adjustment
the
until
spring tension is
Install the
leads with the
obtained.
nut
se
the
movable
right
ACCURACY
LOBE
cam
lobes
arm
feeler
a
the
gauge
centrifugal
plate and the
top
of the
placed
in
a
loss
Install the distributor
check
the cor
fire
to
out
of
of power.
on a test set
the accuracy of the cam
following
that any lobe
instructions
the
the manufacturer.
of
If the test indicates
is worn,
replace the cam.
be
advance
stop
bushing. The
be from 0.022-0.030
play is not to
specifications, check the location of
end
play
should
inch. If the
shaft end
the collar.
CONDENSER
A capacity test,
a series resistance
formed
be
can
on
a
leakage test,
and
test should be per
the condenser. The tests
made
with
the condenser
reliable test equipment and
will cause
cylinders
responding
lobes
tween
stalled
Worn
and
with
play
in the distributor or
condenser installed on a test
curely.
CAM
engine.
specified
primary and condenser
lockwasher and tighten the
time and result
rpm.
the spring
the hooked end of the spring tension
gauge
DISTRIBUTOR SHAFT END PLAY
close
the spark timing.
an engine miss at
adjust the
crease
spring ten
point
normal
and
TENSION
SPRING
to
not
start
the spring tension.
adjust
and
BREAKER
just
points
(Fig. 16). If the tension is
will cause premature wear, overheat
Turn the
17 Spring Tension Adjustment
FIG.
with
in
the
unit. Use
follow the
instructions of the manufacturer. The
capacity is 0.21-0.25 microfarads,
leakage should not be greater than 5
megohms
at
temperature, and
be 1 ohm or
less. The condenser should be re
placed if it does not meet the above
room
series resistance
.should
specifications.
DISTRIBUTOR OVERHAUL
The
dual
mounted
advance
at the
front
is
systems.
A
of the cylinder
advance
mechanism
distributor
the
block.
DESCRIPTION
AND OPERATION
The distributor (Fig. 1 8) has two in
dependently
operated
spark
advance
governor-type centrifugal
movable
is located below
breaker
plate
(Fig. 19),
cam to advance or move ahead with
respect to the
This
action
distributor drive
causes the cam
and a vacuum operated spark control
and
close the
diaphragm is located
The
weights turn the cam
the distributor
The
on
the side of
base (Fig. 20).
centrifugal
weights
cause
points
by
earlier.
means
stop plate that has two slots
which fit over pins in the weights. The
of
the
breaker
shaft.
to open
a
2 IGNITION
PART
1-53
SYSTEM
LUBRICATING WICK
PRIMARY TERMINAL
CAM ASSEMBLY
DISTRIBUTOR SHAFT
BREAKER PLATE
WEIGHT SPRING
DIAPHRAGM LINK RETAINER
WEIGHT
CONDENSER
WEIGHT
PRIMARY WIRE
STATIONARY BREAKER POCNT
ADVANCE
ADVANCE
ADJUSTING
ADJUSTING
ADJUSTMENT SLOT
BRACKET
BRACKET
STOP
WEIGHT SPRING
BREAKER ARM
GROUND WIRE
PLATE
STOP PLATE
CONDENSER WIRE
11
18 Dual Advance Distributor
FIG.
11 30- A
CONTROL SLOT
40- A
FIG.
19 Centrifugal Advance Mechanism
DISTRIBUTOR CAP
COIL
HIGH
CONDENSER
TENSION WIRE
TERMINAL
ROTOR
BREAKER POINTS
DIAPHRAGM
CAM
DIAPHRAGM
SPARK
VACUUM PASSAGE
TO DISTRIBUTOR
1757-A
BREAKER PLATE
FIG.
21 Vacuum Advance Controls
RETURN
SPRING
1131-A
20 Vacuum Advance Mechanism
FIG.
slots
determine the
of advance and
in
controlled
The
has
21)
by
vacuum
maximum amount
the rate of advance
calibrated springs.
advance
a spring-loaded
which
is
mechanism
diaphragm (Fig.
connected
to the breaker
The spring loaded side of the
diaphragm is air tight and is con
nected through a vacuum line to the
When the
carburetor throttle bore.
distributor
the
plates
throttle
open,
plate.
vacuum
fold
passage
vacuum
is
exposed
which
causes
to mani
the dia-
phragm
of
to move against the tension
the spring. This action causes the
breaker
plate
to
points open and
When the
a light load,
quired for
advance
engine
is
high
maximum
engine
enough
operated under
additional advance
power and economy.
dition,
necessary.
part
is
re
throttle
Under this
manifold
is
idle,
At low
engine
a retarded spark
Because the
vacuum
is
pas
opening,
in the carburetor, is
the closed throttle plate, there
is no vacuum to the diaphragm. The
above
breaker
plate
position
by
spring
is held in
the
which
a
retarded
calibrated
bears
against
return
the
dia
phragm.
con
vacuum
to actuate the diaphragm
and advance the spark.
speeds or at
the
and
close earlier.
sage
is
is
During acceleration or when
a heavy load on the
engine,
not enough vacuum
diaphragm,
once again
tion.
and
the
is held in
there
there
to actuate the
breaker
plate
a retarded posi
1-54
GROUP 1-POWER PLANT
Arbor Press Ram
ToolT52L-12390-CAD
Detail 1
1756-
22 Gear Pin Removal
FIG.
or
When the engine is being operated
light load, such as on a level
40 mph,
at
and
1763- A
FIG.
Installation
the throttle is
23 Gear Removal
loosened
assembly.
4. Remove
under a
road
A
from the
the
lubricating
wick
assembly, then remove
cam
a
the cam assembly retainer. Remove
the cam assembly and the upper
object.
diaphragm spring will quickly force
the breaker plate to a retard position.
thrust washer.
moved
However,
by
the distributor weight springs. If the
remains
two springs are not the same size or
the
advance
centrifugal
unchanged
changes.
provided
mechanism
the
until
engine
At
any particular
speed, there will be a certain
speed
engine
amount
5.
are
and
Carefully
attached.
the
vance.
distributor,
and
the
primary wire
advance line at the
remove
a mark on
and engine
block
position of the
body
scribe
mark
another
tor
body indicating
the
rotor.
These
as guides when
tor
in
3.
the distributor
indicating
the
in the block, and
on the distribu
the
marks
installing
position
can
the
of
be used
distribu
a correctly timed engine.
Remove the distributor
Remove the spring clip securing
link to the breaker
1.
the
DISASSEMBLY
diaphragm
plate, then disconnect the
diaphragm
from the distributor base
remove the diaphragm assembly.
assembly
and
2. Remove the nut, flat washer,
and bushing from the primary termi
nal
screw, then remove the terminal
screw
and
insulator.
3. Remove the breaker point as
and condenser. Remove the
two
screws and retainers
breaker
ing,
then
securing the
assembly in the hous
remove the breaker plate
plate
desig
are
which
spring
is
not
so
gear
pin
be easily
can
Remove
assembly.
(Fig.
to be
gear and shaft
holes
pin
for
roll
the
mark
that the
aligned
shaft are
22),
the
then remove
the gear (Fig. 23).
7. Remove the
it
shaft collar roll pin
on a support plate
that
allow
will
the parts with compressed
all foreign matter is re
from the ball bearings on the
breaker
plate
assembly.
Examine the bushing
the distributor shaft and
for
the
and
in a posi
distributor
not use
abrasive
other
or
sure
The
wear.
at
the
of
surface
the
bushing
allowable
minimum
diameter
0.4675 inch. The
shaft
is
bushing
maximum allowable
inside diameter of the bushing is
0.4690 inch. Replace worn parts.
Inspect the distributor cam lobes
for scoring and signs of wear. If any
lobe is scored or worn, replace the
assembly.
Inspect the breaker
for
signs
bearings,
plate
of
Replace
etc.
assembly
ball
worn
the
breaker
assembly if it is defective.
The
ever
plate
distortion,
breaker
point
condenser should
(Fig. 24). Invert the distributor
place
Dry
Be
cam
gear and
again,
be
the distributor
Inspect
all
is
in
and
when
overhauled.
electrical
fraying, breaks,
that are not
assembly
replaced
wiring
for
etc., and replace any
good condition.
shaft
to clear the support plate, then
Check the distributor base for
press
the shaft out of the collar and
cracks, stripped threads, or other
the distributor
the
move
housing
distributor
(Fig. 25). Re
bushing
shaft
(Fig. 26).
CLEANING
DISTRIBUTOR
AND
INSPECTION
Soak
all parts of the
distributor
as
sembly (except the condenser, breaker
point
assembly,
lubricating
diaphragm, primary
bushing and insulator, and
uum
in
wiring)
sembly
the
6. If the
tion
hold
down cap screw and clamp, then lift
the distributor out of the block.
DISTRIBUTOR
obtain the correct ad
weight springs
under tension.
used
2. Scribe
is
spring
the distribu
tor cap.
body
The
bending
will eliminate
nated primary (low speed) and sec
ondary (high speed). The secondary
REMOVAL
the vacuum
and
This
brackets to
of centrifugal advance plus a possible
1. Disconnect
remove
and
different colors, mark the springs
the brackets to which they are
vacuum advance.
DISTRIBUTOR
unhook
air.
the parts
scrub
soaking,
bristle brush. Do
brush, file
wire
suddenly opened further, the mani
fold vacuum will decrease and the
the
by
with a soft
mineral
wick, vac
terminal
electrical
a mild
spirits.
cleaning solvent or
Do not use a harsh
cleaning solution. Wipe all parts that
can not be immersed in a solvent with
a clean
dry
rag.
After foreign deposits have been
damage. Check the diaphragm hous
ing, bracket, and rod for damage.
Check the mounting hole and vacuum
line fitting threads for stripping or
other damage. Test the vacuum fit
diaphragm for leak
under "Distributor
Tests, Adjustments, and Minor Re
Replace all defective parts.
tings, case,
age
as
and
explained
pair."
DISTRIBUTOR ASSEMBLY
Refer to Fig. 27 for the correct
location of parts.
1. Oil the new bushing, and install
it on the bushing replacer tool, then
install the bushing (Fig. 28). When
the tool
bottoms
against
the distribu-
PART
1-55
SYSTEM
2 IGNITION
Arbor
Press Ram
Too/-T52L-I2l3J-CAD
17S5-A
24 Shaft Collar Roll
FIG.
Tooi-J2I32-B7
or
Pin Removal
or
Installation
N
BUSHING
Too/-T58P-J2l32-B
FIG.
25 Shaft Removal
599-A
FIG.
26 Bushing Removal
PRIMARY WIRE
NUT
WASHER
INSULATOR
BUSHING
CLAMP
SCREW
WEIGHT
BREAKER
DISTRIBUTOR
HOUSING
I^
POINT
<^
*
ASSEMBLY
CAM ASSEMBLY
INSULATOR
RETAINER
^ ^8)
*V
\
CONDENSER
/
xx
X>
CAM
PLATE
27 Distributor Assembly
scrIw
DIAPHRAGM
linkcsl;r,ng
CLIP
*V^ CLAMP
L/V
<
|j
*w
/
DIAPHRAGM HOUSING
WICK
BREAKER
J
RIVET
ASSEMBLY
UPPER THRUST
WASHER
DIAPHRAGM RETURN
"^
""
yx
niAPMDAr.M HOUSING
Mnn<;iKir, RETAINING
pftainikj^ SCREW
srPFW
DIAPHRAGM
LUBRICATING
SCREW
FIG.
\v^L^WE,GHT
/
bush,No
X
COLLAR
m-**
**% ^5?JJ*
DRIVE
GEAR
GE/
/
SCREW
-*-
SHAFT ASSEMBLY
p|N
OILER
RIVET */
GROUND WIRE
SPRING
CALIBRATION WASHER
STOP
GASKfT
VACUUM
CONNECTION
1752-A
1-56
GROUP 1-POWER PLANT
Arbor
Press Ram
PRESS ON
DISTRIBUTOR
BASE
Tool-T58P-12132-B
1577-A
20- A
Tool-T 571-1 21
29 Burnishing Bushing
FIG.
1753-A
28 Bushing Installation
FIG.
tor
base,
to
the
the
bushing
bushing
be installed
Burnish the
will
depth.
correct
29).
to the proper size (Fig.
2. If the
old
being installed,
shaft
and
are
oil the shaft and slide
it into
the distributor body.
collar
in
align the
gear
position
on
holes in the
the
Place the
shaft
and
collar and shaft,
then install a new pin (Fig. 24). Check
the shaft end play with a
between
placed
the
feeler
gauge
centrifugal
ad
adjusting bracket plate and the
bushing. If the end play is
vance
of the
top
limits (0.022-0.030 inch),
within
not
Press the
as
shaft
guides
holes. Check the
to align the pin
location dimen
gear
play removed (gear
toward the distributor base),
With
sion.
(Fig.
the shaft
on
the marks made on the gear
30), using
and
gear
pushed
all end
be 5.1 1 1-5.1 16
inches from the bottom face of the
gear to the bottom face of the dis
this dimension should
tributor
stall the
The
mounting pad (Fig. 30). In
pin (Fig. 22)
retaining
shaft and gear are replaced as
an assembly.
One
replaced without
If
a
new
installed,
shaft
oil
the
advance
the
and
the
part should not
be
replacing the
other.
and gear are
being
new
shaft
and
slide
backing
cate
collar as a
pilot.
24).
the
With
stalled, install the
a press
inch feeler
(Fig. 31). Insert
gauge
between the
a
0.022
centrif
(Fig.
drive
gear
(Fig. 30).
press
remove the
feeler
gauge.
supporting tool and
Drill a '/s-inch hole
oil.
3. Install the
fill the
then
pin
with
bearing
bracket
tion
are
(Fig. 22).
weights
plate.
ground
in the
groove
weight pivot
high melting point ball
lubricant. If a spring and
a
were
marked
for identifica
disassembly, be
upon
assembled
sure
they
of
high melting
lubricant. Install the
the cam assembly with a
ball
upper
bearing
thrust washer, then install the
cam and secure
are
Be
with the
spring
re
slots
on
light film
the
stop plate.
lubricant
of cam
to the cam lobes. Saturate the wick
with
the
point
the breaker plate
the ground wire
breaker
lug
is
plate retainer
Install the primary
sulator on
Be
retainers.
attaching
wire
and
and
base,
the
with
and
flat
then secure
washer
the link
the
breaker
it in
and
plate.
nut.
assem
hook the diaphragm link
on
in
Install
terminal screw in
7. Position the diaphragm
bly
screw.
the
the terminal screw.
bushing
the pin
sure
attached to the
over
Secure
spring retainer. Se
diaphragm assembly to the
distributor base.
with the
the
cure
the
adjust
tension, and adjust the
breaker points. Install the distributor
spring
on a test set, check the
dwell
and
resistance,
centrifugal and
breaker
and
point
adjust
the
vacuum advance.
sure the pins on the weights
in the
a
it
breaker
the
and
Install
assembly.
8. Align the breaker points,
together.
4. Lubricate the inside diameter
point
condenser
new
on
wire
lubri
engine
attaching screw furthest from the
breaker point adjustment slot. Install
place
and springs,
bearings
then
Install the breaker
6. Install a
breaker point
the distributor
a new pin
plate
10W
the
Install
assembly
S.A.E.
them with
through the gear and shaft, using the
gear shoulder as a pilot.
cam
explained,
previously
hole in the
Apply
in
pin
Remove the assembly from the
to the distributor and
bly
Install the
supporting tool and
the 0.022-inch feeler gauge still in
the
5. Clean the breaker
the tool enough
collar
in
wick
(Fig. 32).
in position and sup
port the shaft. While holding the col
lar in position against the distributor
housing drill a '/s-inch hole through
the shaft using the access hole in the
Place the
tainer.
the assem
screw on
the
stall
as
it into the distributor body. Attach
the Distributor Shaft Supporting Tool
place
top
adjusting bracket plate
the bushing. Tighten
of
to remove all shaft end play.
and
the shaft.
replace
ugal
S.A.E. 10W
engine
oil, then in
DISTRIBUTOR
INSTALLATION
The distributor installation is
shown in Fig. 33.
1. If the
crankshaft
was
rotated
PART
2 IGNITION
1-57
SYSTEM
NEW SHAFT WITH 0.022
Too/-T57L- J 2390-A
INCH FEELER IN
Detail 5
PLACE,
TIGHTEN SCREW TO
Tool-T57L-l 2390-A,
REMOVE END PLAY
Detail 3
1322-B
FIG.
31 New Shaft Installation
Tool-T57Ll 2390-A,
Detail 1
1751-A
30 Gear Installation
FIG.
while the distributor was removed
from the engine, it will be necessary
to retime the engine. Turn the engine
until No. 1 piston is on T.D.C. after
the
compression
T.D.C.
per with
the
distributor
firing
Align
stroke.
mark on the crankshaft
Install the
No. 1
the breaker points
timing
with
the
dam
pointer.
the rotor at the
position and
FIG.
open.
If the
has not been dis
turbed, install the distributor using
the
crankshaft
marks
distributor
scribed
previously
body
on the
block
and engine
as
guides.
Make
pump intermedi
properly engages the dis
tributor shaft. It may be necessary to
ate
sure
the
oil
shaft
crank
the
engine with
the distributor drive
engaged, in
the starter,
gear
to
order
after
is partially
engage
the
oil
pump intermediate shaft.
2. Install the rotor and the dis
tributor cap.
Connect the
tributor cap high
connect
coil to
dis
lead,
and
tension
the primary wire
at
the dis
tributor.
a
3. Check the ignition timing with
timing light and adjust it if neces
Connect the
sary.
check
light
1164-A
the
vacuum
advance
with
when the engine
is
line, and
timing
the
accelerated.
FIG.
33 Distributor Installation
32 Weights, Springs,
and
Cam Installed
1-58
GROUP 1-POWER PLANT
Section
PART 3
Page
Trouble
1
Shooting
2 Air Cleaner
3 Carburetor
FUEL SYSTEM
..
Page
Section
1-58
.
5 Fuel Pumps
Vacuum
and
1-72
1-59
Booster
1-60
6 Fuel Tank
and
1-75
Lines
4 Throttle Linkage
Adjustments
//
the cause of engine trouble
has been
TROUBLE SHOOTING
TABLE 1
Fuel System Trouble
1-72
traced to the
fuel
sys
(page 1-7), refer to the trou
ble in Table 1 and check the
items listed under the trouble.
tem
AUTOMATIC
CHOKE.
Check
is warm, the plate should be
plate is not open, the en
engine
open.
gine
If the
will
load up due to the
If the
engine
is cold, the plate should
plate is not operating
If the
closed.
The
check the
items:
following
cam
Thermostatic
justment
for binding.
housing
spring
ad
Choke
speed screw
for
proper ad
plate
valve
for
proper
op
heat chamber, air line,
housing for air leaks.
air
fuel inlet line
at
engine
reaching the
If fuel is
to catch the fuel.
to see
if fuel is
carburetor.
The fuel
not
reaching the
carbu
fuel
should spurt
from the
erating pump discharge
If fuel is discharged
If fuel is
by
the
accel
is probably
there is water in the fuel
erating pump, the
or
accel
nozzles.
engine
is
not
at
mechanical
item,
fault.
discharged
by
the ac
check:
The accelerating pump discharge
check for sticking.
The accelerating pump discharge
discharge holes for clogged
Idle fuel
pump.
mixture needles not
prop
The accelerating pump diaphragm
for defects.
The accelerating pump inlet ball
for freeness and inlet passages
for dirt, corrosion, etc.
check
The fuel inlet
including,
system
and
assembly, and the
seat
the
needle
float
as
Check for dirt in the carburetor,
allowing fuel to enter or be dis
charged from the idle system.
not
inlet
Fuel
system
not
operating
properly.
adjusted.
Engine idle
passages.
sembly.
The fuel pump flexible inlet line
for a collapsed condition.
The
Work the throttle by hand several
Each time the throttle is actu
fuel inlet screen, the fuel inlet
retor, check:
KEEP RUNNING
carbu
carburetor.
CARBU
carburetor
the carburetor. Use
a suitable container
Crank the
erly
in the
screw and
FUEL SUPPLY AT
RETOR. Disconnect the
TO
the
ball
eration.
Choke
STARTS,
the
times.
such as valves
and operation.
and choke
BUT FAILS
in
checked
If the fuel is reaching the
retor, the trouble is
celerating pump,
Fast idle
ENGINE
be
system, or an engine
justment.
NOT START
listed.
flooded,
linkage for binding.
choke
The fast idle
WILL
should
are
prob
therefore
occurrence;
items
ated
rich mixture and will not start.
properly,
NORMALLY, BUT
the order of their
order
exces
sively
be
CRANKS
able
trouble
of the
causes
Shooting
the position of the choke plate. If the
ENGINE
The
listed in
speed set
choke not
too low.
Dirt
or water
in fuel lines
buretor.
operating
Float setting incorrect.
properly.
Carburetor icing.
Fuel pump defective.
or car
LITHO
IN U.S.A.
FORM 7750-58