foreword...

This 1977 Car Shop Manual has been prepared to provide information
covering normal service repairs and maintenance for 1977 Ford Passenger
Cars manufactured in the United States and Canada. It is divided into five
volumes, each covering a specific major area:
Volume 1 — Chassis
Volume 2 — Engine
Volume 3 — Electrical
Volume 4 — Body
Volume 5 — Maintenance and Lubrication.

Information in each volume is divided into Groups covering a general

system. The table of contents on the cover of each volume indicates the
Group title, number, and volume in which each Group is located.

For 1977, the basic part number for components covered in the Group is also
included in parenthesis after the Group number.

Example: Cooling System Group 27 (8000)

General System Covered Group Number Basic Part Number
in Group for Cooling System
Components

Some components covered within a Group do not have the same basic part
number. In these cases, more than one basic part number will appear on the
Group index.

Example: Gasoline Engines Group 21 (6000 & 9000)

General System Basic Part Intake and
Covered in Group Number for Exhaust Manifold
Gasoline Basic Part
Engine Number Only
Components

For easy reference, information in each Group has been divided into smaller
units or Parts. There is one Part for each component in the system, as well as
a General Service Part in some Groups to cover procedures common to
several components within the Group. In general, each Part contains the
Description, Operation, Diagnosis and Testing, Removal and Installation
and Disassembly and Assembly procedures for the component covered in
the Part. Diagnosis Charts are also included in some Parts to help you
systematically locate and correct problems encountered. In most cases,
specifications are included at the end of each Part.
To aid in locating specific items in this manual, the index at the front of each
volume provides an alphabetical listing, with page number, for all Parts in
the volume. The tab locator on the right side of this index will help you find
the first page of each Group.

On the first page of each Group there is an index listing the Part title and Part
number for each component covered within the Group. The first page of
each Part contains an index to locate service operations covered in that
Part. This Group-Part breakdown is also indicated in the page number
located at the top of each page.

Example: 11-02-21 = (Group) 11 — (Part) 02 — (Page) 21

Metric conversion tables have been included at the back of each volume to
aid in converting specifications in this manual to the metric equivalent.

The descriptions and specifications in this manual were in effect at the time
this manual was approved for printing. Ford Motor Company reserves the
right to discontinue models at any time, or change specifications or design
without notice and without incurring obligation.

Ford Parts and Service Division

Training and Publications Department
20-00-1
VEHICLE IDENTIFICATION
Vehicle Identification
GENERAL DESCRIPTION
OFFICIAL VEHICLE
IDENTIFICATION NUMBER
The official Vehicle Identification
Number (VIN) (Fig. 1) for title and
registration purposes is stamped on a
metal tab that is fastened to the
instrument panel close to the windshield
on the driver's side of the car and is
visible from outside.
VEHICLE CERTIFICATION LABEL
The Vehicle Certification Label (V.C.
Label) (Fig. 1) is affixed on the left front
door lock face panel or door pillar. The
upper half of the label contains the name
of manufacturer, month and year of
manufacture, Gross Vehicle Weight
Rating (GVWR), Gross Axle Weight
Rating (GAWR), and the certification
statement.
The V.C. label also contains the
Vehicle Identification Number. This
number is also used for warranty
identification of the vehicle. The first
number indicates the model year. The
Identification Codes
letter following the model year number
indicates the manufacturing assembly
plant. The next two numbers designate
the Body Serial Code followed by a letter
expressing the Engine Code.
The last six digits of the Vehicle
Identification Number indicate the
Consecutive Unit Number of each unit
built at each assembly plant. The
Consecutive Unit Numbers begin as
follows:
100,001—Ford, Maverick, Pinto,
LTD II, Ranchero, Mustang and
Thunderbird.
500,001—Mercury, Bobcat, Comet,
Cougar, and Monarch.
800,001— Lincoln Continental and
Continental Mark V.
The remaining information on the
V.C. Label consists of the following
vehicle identification codes:
The BODY code is two numerals and
a letter identifying the body style.
20-00-1
GROUP
The COL (color) code is a number
and letter indicating the exterior paint
color code and vinyl roof type and color
(if equipped).
The TRIM code consists of a two-
letter or a letter-number combination
designating the interior trim.
The AXLE code is a number or letter
indicating the rear axle ratio and
standard or locking type axles.
The TRNS. code is a number or letter
indicating the type of transmission.
The DSO code, consisting of two
numbers, designates the district in which
the car was ordered and may appear in
conjunction with a Domestic Special
Order or Foreign Special Order number
when applicable. Ford of Canada DSO
codes consist of a letter and number.
The following charts provide the
various codes and their respective
identification:
20-01-2 Car Identification Codes 20-01-2

<^7S63H 100001^ MFD. BY FORD MOTOR CO. IN U.S.A.

(VEHICLE IDENTIFICATION NUMBER)
MFD. BY FORD MOTOR CO. IN U.S.A. DATE: 07/76 GVWR 5892
DATE: 07/76 GVWR 5892 GAWR: FRONT 2964 REAR 2928
GAWR: FRONT 2964, REAR 2928 THIS VEHICLE MANUFACTURED FOR
EXPORT ONLY ON DATE
THIS VEHICLE CONFORMS TO ALL SHOWN ABOVE.
APPLICABLE FEDERAL MOTOR
VEHICLE SAFETY STANDARDS IN 7S63H100002 PASSENGER
EFFECT ON THE DATE OF MANU-
VEH IDENT. NO. | TYPE
FACTURE SHOWN ABOVE.
BODY | COLOR | TRIM | TRANS. | AXLE | DSO
FOO33/RO155 53H 1C-CA D X 6 90
7S63H100001 PASSENGER^
I^ENT. NO. I TYPE
(EXPORT)
MFD. BY FORD MOTOR CO.
OF CANADA LTD.

n(T)(T) (Y) (Mi) 0i THIS VEHICLE CONFORMS TO

(UNITED STATES)
CONSECUTIVE UNIT NO.
2 ) BODY SERIAL CODE
>« s
ALL APPLICABLE FEDERAL MOTOR
VEHICLE SAFETY STANDARDS IN
(T) VINYL ROOF TYPE/COLOR EFFECT ON THE DATE OF
MANUFACTURE SHOWN ABOVE
M TRIM CODE

VEH.ipENT.NO I TYPE
3) MODEL YEAR CODE j o ) TRANSMISSION CODE
s. S BODY I COLOR I TRIM I TRANS. I AXLE I DSO
^—<v
4) ASSEMBLY PLANT CODE MADE IN CANADA
j j ) REAR AXLE CODE
>« s

5 ) BODY TYPE CODE U 2 ) DISTRICT - SPECIAL EQUIPMENT

b ) ENGINE CODE ( J J ) VEHICLE TYPE

7 ) BODY COLOR CODE 14) ACCESSORY RESERVE LOAD

Y1410-J

FIG. 1 Vehicle Identification and Certification Labels

20-01-3 Car Identification Codes 20-01-3

1977 IDENTIFICATION CODES DISTRICT CODES DISTRICT CODES

ASSEMBLY PLANT COOES LINCOLN-MERCURY FORD

Code Letter Code District Code District

District

A Atlanta 00 Special 00 Special

B Oakville (Canada) 11 Boston 11 Boston
E Mahwah 15 New York 12 Buffalo
F Dearborn 16 Philadelphia 13 New York
G Chicago 17 Washington 14 Pittsburgh
H Lorain 21 Atlanta 15 Newark
J Los Angeles 22 Dallas 16 Philadelphia
K Kansas City 23 Jacksonville 17 Washington
P Twin Cities 26 Memphis 21 Atlanta
R San Jose 31 Buffalo 22 Charlotte
S Allen Park (Pilot) 32 Cincinnati 23 Memphis
T Metuchen 33 Cleveland 24 Jacksonville
U Louisville 34 Detroit 25 Richmond
W Wayne 41 Chicago 26 New Orleans
X St. Thomas 42 . ' St. Louis 28 Louisville
Y Wixom 46 Twin Cities 41 Chicago
Z St. Louis 51 Denver 42 Cleveland
52 Los Angeles 43 Milwaukee
53 Oakland 45 Lansing
ENGINE CODES 54 Seattle 46 Indianapolis
84 Home Off. Reserve 47 Cincinnati
No. of 90's Export 48 Detroit
Codes Cyls. Displacement
52 Dallas
53 Kansas City
54 Omaha
A 8... 4604V FORD OF CANADA
r 460-4V (Police) 55 St. Louis
8
F '.'.'.'.'.'. ^'.'.'.'.'.'.'.'.'. 302-2V Mercury Ford 56 Davenport
H 8 351-2V Code 'Region Code 57 Houston
L 6 ... 250-1V 58 Twin Cities
' 8 400-4V 71 Los Angeles
A1 . . . Central B1
S 8 400-2V 72 San Jose
A2 . . . Eastern B2
T 6 200-1V 73 Salt Lake City
A3 Atlantic B3
Y 4 139-2V (2.3L) 74 Seattle
A4 . . . Midwestern B4
Z 6 169-2V (2.8U 75 Phoenix
A6 Western B6
76 Denver
A7 Pacific B7
83 Government
12 . . . Export 12
84 Home Off. Reserve
TRANSMISSION CODES
85 American Red Cross
86 Recreational Veh. Pool
Codes Type REAR AXLE RATIO CODES
87 Body Company
89 Transportation Services
Conventional Lock Ratio 90'a Export
MANUAL
1 3 Speed
6 4 Speed @ B 2.47
7 4 Speed (b) 1 J 2.50
AUTOMATIC 8 2.73
V XP(C-3) 2 2.75
W XP(C-4)' 3 2 79
X FMX] 6 0 3 00
U • XPL(C-6) 4 3 18
Z XPL (Special) 7 3 40

EXTERIOR PAINT COLOR CODES

Code Ref.# Color Code Ref. # Color Code Ref. # Color

1C. 1724 Black 7 0 . . . .. 5479 Lt. Aqua Mt.. 7T 5490 Med. Emerald Met.
1G.. 5299 Silver Met. 7 S . . . .. 5489 Dk. Emerald Met. 8J 5484 Med. Tan Met.
IN.. 5476 Dove Gray 8G... .. 5466 Vista Orange 8W 5491 Chamois Met.
1P.. 5523 Med. Gray Met.(Tie Tone only) 8 H . . . .. 5470 Tan
10.. 5527 Med. Silver Met. 8 K . . . .. 5486 Brt. Saddle Met. (RPO) DIAMOND BRIGHT (POLISH) "W"
2M.. 3413 Dark Red 8 N . . . .. 5496 Dk. Cordovan Met.
2R.. 5440 Brt. Red 8 P . . . .. 5471 2S... .. 5444 Dk. Red Met.
Lt. Cordovan
2U.. 5455 Lipstick Red 8 Y . . . .. 5494 2G... .. 5070 Med. Red Met.
Champagne Met.
3G.. 5094, 83 . . . . . 5524 32... .. 5511 Med. Blue Met.
Brt. Dk. Blue Met. Chamois
3U.. 5467 8 4 . . . .. 5525 8V... .. 5495 Med. Ember Met.
Lt. Blue Dk. Cordovan
31 . . 5499 9 D . . . .. 5418 8Z... .. 5510 Med. Nectarine Met.
Midnight Blue White
34.. 5041 Med. Blue 1R... .. 5512 Lt. Silver Met.
46.. 5328 Dk. Jade Met. (RPO) UNIQUE COLORS (NON POLISH) "D'
47.. 5404 Lt. Green (RPO) DIAMOND FLARE (POLISH) " G "
2Y.. 5492 Rose Met.
4V.. 5233 Dk. Yellow Green Met. 3V.. 5480 Brt. Blue Met. U . . . . . 5411 Silver Met.
50.. 5477 Dk. Brown Met. 6V.. 1L... . . 5472 Black Met.
6E..
5298 Tan Met.
5080 Brt. Yellow 5460 Med. Gold Met. 2 T . . . . . 5462 Rose Met.
6P.. 5406 Cream 6 Y . . . . . 5461 Brt. Yellow Gold Met
7H.. 5482 Brt. Aqua Met.
6U.. 5441 Lt. Tan 7 B . . . . . 5463 Crystal Jade Met.
7L.. 5483 Lt. Jade Met.

CY1411-K
20-01-4 Car Identification Codes 20-01-4

BODY SERIAL AND STYLE CODES

Body Body Body Body
Vehicle Serial Style Body Type Model Vehicle Serial Style Body Type Model
Code Code Code Code

PINTO 10 62B 2-Dr. Sedan Base 43 71K LTD II Squire Wagon

11 64B 3-Dr. Sedan Base 47 97D 500 LTD II
12 73B Wagon Base 48 97R GT Ranchero
49 97K Squire
BOBCAT 20 64H 3-Dr. Sedan U. S. A. & Canada
22 73H Wagon U. S. A. & Canada COUGAR 90 53D 4-Dr. Pillar Hardtop Cougar
23 62 B 2-Dr. Sedan Canada Only 91 65D 2-Dr. Hardtop Cougar
24 64B 3-Dr. Sedan Canada Only 92 71D Cougar Wagon
25 73B Wagon Canada Only 93 65 L 2-Dr. Hardtop CougarXR VII
94 53K 4-Dr. Pillar Hardtop Cougar Brougham
MUSTANG II 02 60F 2-Dr. Notchback Base
95 65K 2-Dr. Hardtop Cougar Brougham
03 69 F 3-Dr. Hatchback Base
96 71K Cougar Villager Wagon
04 60H 2-Dr. Notchback Ghia
05 69 R 3-Dr. Hatchback Mach 1 THUNDERBIRD 87 60H 2-Dr. Pillar Hardtop Base

MAVERICK 91 62A 2-Dr. Sedan Base FORD 52 60 D 2-Dr. Pillar Hardtop Custom 500
92 54A 4-Dr. Sedan Base 53 53D* 4-Dr. Pillar Hardtop Custom 500
62 60 H 2-Dr. Pillar Hardtop LTD
COMET 30 54B 4-Dr. Sedan Base
63 53H 4-Dr. Pillar Hardtop LTD
31 62B 2-Dr. Sedan Base
64 53L 4-Dr. Pillar Hardtop LTD Landau
GRANADA 81 54H 4-Dr. Sedan Base LTD Landau
65 60 L 2-Dr. Pillar Hardtop
82 66H 2-Dr. Sedan Base Wagon
72 71D* Custom 500 Ranch
83 54 K 4-Dr. Sedan Ghia 74 71H Wagon
LTD**
84 66K 2-Dr. Sedan Ghia
MERCURY 50 53H 4-Dr. Pillar Hardtop Marquis (FLU)
MONARCH 34 54H 4-Dr. Sedan Base Canada Only
52 65H 2-Dr. Hardtop
35 66H 2-Dr. Sedan Base Grand Marquis
60 53L 4-Dr. Pillar Hardtop
37 54 K 4-Dr. Sedan Ghia Grand Marquis
61 65L 2-Dr. Hardtop
38 66 K 2-Dr. Sedan Ghia Marquis Brougham
62 53K 4-Dr. Pillar Hardtop
84 54M 4-Dr. Sedan Lincoln 5700 Marquis
63 53H 4-Dr. Pillar Hardtop
LTD II 25 65B 2-Dr. Hardtop LTD II S 64 65K 2-Dr. Hardtop Marquis Brougham
27 53B 4-Dr. Pillar Hardtop LTD I I S 66 65H 2-Dr. Hardtop Marquis
30 65D 2-Dr. Hardtop LTD II 76 71K Marquis*** Wagon
31 53D 4-Dr. Pillar Hardtop LTD II
MARK V 89 65D 2-Dr. Hardtop Base
32 65K 2-Dr. Hardtop LTD II
33 53K 4-Dr. Pillar Hardtop Brougham LINCOLN 81 60B 2-Dr. Pillar Hardtop Base
40 71B LTD II S Wagon 82 53B 4-Dr. Pillar Hardtop Base
42 71D LTD II Wagon

'Released and scheduled for Canada and for fleet only in U. S. A. — **Also Squire Option — ***Also Colony Park and Decor Option.

CY1615-D

VINYL ROOF TYPE/COLOR CODE

(FIRST LETTER OF CODE = TYPE OF ROOF) (SECOND LETTER OF CODE = COLOR OF ROOF)

Code Vinyl Type Code Vinyl Type Code Vinyl Color Code Vinyl Color

B Cross Hatch Full 2-Door Q Cayman Full A Black Q Emeald Dk

C Cross Hatch Halo Style R Cross Hatch (1/2) B Blue R Jade Dk.
4-Door T Valino Coach C Ember S Med. Blue
G U Cayman (1/2) D Red T Brown
H Odense (3/4) H Rose U Char lois
Valino Full
W Lugano Full J Taupe V Crean
N Odense (1/2) L Aqua
P Cross Hatch (3/4)
X Lugano (1/2) w Whitn
Y Valino (1/2) M Lt. Jade Y Gold
IM Red, Lipstick
Example Code:.^— G A ^ P Silver

1
Odense F u l l ' Black
CY1615-D
20-01-5 Car Identification Codes 204)1-5

INTERIOR TRIM CODES

Code Trim Scheme Code Trim Scheme Code Trim Scheme Code Trim Scheme

PINTO MD Red LD Red Corinth. Vinyl

Colton/Corinth. Vinyl MG Green LG Green (L/B Bucket)
(H/B Bucket) MT Chamois LT Chamois GA Black
AA Black Carerra/Corinth. Vinyl Ruffino/Corinth. Vinyl GD Red
AB Blue (H/B Bucket) (L/B Bucket) GN W/Red
AD Red NT Chamois MA Black GW W/Black
A6 Green MB Blue G5 W/Emerald
AT Chamois BOBCAT MD Red Corinth. Vinyl
Alpine B/Cloth & Colton/Corinth. Vinyl MG Green (L/B Bucket)
Corinth. Vinyl (H/B Bucket) MT Chamois HA Black
(L/B Bucket) AA Black HD Red
DB Blue AB Blue MUSTANG HN W/Red
DD Red AD Red Corinth. Vinyl HW W/Black
DG Green AG Green (L/B Bucket) H5 W/Emerald
DT Chamois AT Chamois AA Black Sterling B/Cloth &
Kirsten B/Cloth & Alpine B/Cloth & AD Red Corinth. Vinyl
Corinth. Vinyl Corinth. Vinyl AK Aqua (L/B Bucket)
(H/B Bucket) (L/B Bucket) AN W/Red KD Red
GA Black DB Blue AT Chamois K5 W/Emerald
GB Blue DD Red AV Cream Corinth. Vinyl
GD Red DG .. Green AW W/Black (L/B Bucket)
GG Green DT Chamois A2 W/Chamois LT Chamois
GT Chamois Kirsten B/Cloth & A5 W/Emerald Sterling B/Cloth &
Ruffino/Corinth. Vinyl Corinth. Vinyl A7 W/Aqua Corinth. Vinyl
(L/B Bucket) (H/B Bucket) A8 W/Gold (L/B Bucket)
HA Black GA Black QD Red
GB Blue Corinth. Vinyl
HB Blue QK Aqua
GD Red CL/B Bucket)
HD Red Sterling B/Cloth &
GG Green BA Black
HG Green Corinth. Vinyl
GT Chamois BD Red
HT Chamois (L/B Bucket)
Ruffino/Corinth. Vinyl BK Aqua
Colton/Corinth. Vinyl RD Red
(L/B Bucket) BN W/Red
(H/B Bucket) RK Aqua
HA Black BT Chamois
BV Cream Corinth. Vinyl
J8 Blue HB Blue (L/B Bucket)
HD Red BW W/Black
JD Red SA Black
HG Green B2 W/Chamois
JG Green SD Red
HT Chamois B5 W/Emerald
JT Chamois SK Aqua
Colton/Corinth. Vinyl B7 W/Aqua
Alpine B/Cloth & SN W/Red
(L/B Bucket) B8 W/Gold
Corinth. Vinyl ST Chamois
(L/B Bucket) JA Black Media B/Cloth & SW W/Black
KB Blue JB Blue Corinth. Vinyl S2 W/Chamois
KD Red JD Red (L/B Bucket) S5 W/Emerald
KG Green JG Green CK Aqua S7 W/Aqua
KT Chamois JT Chamois CT Chamois S8 W/Gold
Kirsten B/Cloth & Alpine B/Cloth & CV Gold/Cream Corinth. Vinyl
Corinth. Vinyl Corinth. Vinyl (L/B Bucket)
(H/B Bucket) (L/B Bucket) Corinth. Vinyl
TA Black
LA Black KB Blue (L/BBucket)
TD Red
LB Blue KD Red DT Chamois
TK Aqua
LD Red KG Green Sterling B/Cloth &
TN ....W/Red
LG Green KT Chamois Corinth. Vinyl
TT Chamois
LT Chamois (L/B Bucket) TW W/Black
Kirsten B/Cloth &
Ruffino/Corinth. Vinyl Corinth. Vinyl ED Red T2 W/Chamois
(L/B Bucket) (H/B Bucket) EK Aqua T5 W/Emerald
MA Black LA Black EV Gold/Cream T7 W/Aqua
MB Blue LB Blue E5 W/Emerald T8 W/Gold
CY1419-H
20-01-6 Car Identification Codes 20-01-6

INTERIOR TRIM CODES - Continued

Code Trim Scheme Code Trim Scheme Code Trim Scheme Code Trim Scheme
Media B/Cloth & Alpine B/Cloth & Barletta B/Cloth & AV Cream
Corinth. Vinyl Corinth. Vinyl Corinth. Vinyl Kasman B/Cloth &
(L/B Bucket) (L/B Bucket) (L/B Bench) Corinth. Vinyl
UK Aqua QB Blue JA Black (L/B Flight Bench)
UT Chamois QG Green JB Blue BB Blue
UV Gold/Cream QU Tan JG Green BD Red
Sterling B/Cloth & JU Tan BR Jade
Corinth. Vinyl Corinth. Vinyl BS Gray
Corinth. Vinyl (L/B Bucket)
(L/B Bucket) (L/B Bench) BU Tan
SA Black KA Black
VD Red SB Blue Corinth. Vinyl
VK Aqua KB Blue (L/B Bucket)
SD Red KD Red
VV Gold/Cream SU Tan CB Blue
V5 W/Emerald KG Green CD Red
V7 W/Aqua Alpine B/Cloth & KU Tan CR Jade
Corinth. Vinyl Corinth. Vinyl
Corinth. Vinyl CS Gray
(L/B Bucket) (L/B Bucket)
(L/B Bucket) CU Tan
TB Blue LA Black CV Cream
WA Black
TG Green LB Blue
WD Red Corinth. Vinyl
TU Tan LD Red
WN W/Red (L/B Flight Bench)
Barletta B/Cloth & LU Tan
WW W/Black DV Cream
Corinth. Vinyl Corinth. Vinyl
W5 W/Emerald Corinth. Vinyl
(L/B Bench) (L/B Bucket)
Corinth. Vinyl (L/B Flight Bench)
UA Black PB Blue
(L/B Bucket) EB Blue
UB Blue PU Tan
YA Black ED Red
UG Green Alpine B/Cloth &
YD Red ER Jade
UU Tan Corinth. Vinyl
YN W/Red ES Gray
(L/B Bucket)
YW W/Black Corinth. Vinyl EU Tan
QB Blue
Y5 W/Emerald (L/B Bench) EV dream
QG Green
Sterling B/Cloth & VA Black Natural Grain Leather
QU Tan
Corinth. Vinyl VB Blue Alpine B/Cloth & (L/B Bucket)
(L/B Bucket) VD R6d Corinth. Vinyl FB Blue
ZD Red VG Green (L/B Bucket) FD Red
VU Tan RB Blue FR Jade
MAVERICK
RG Green FS Gray
Random Stripe B/Cloth & Sterling B/Cloth & FU Tan
Corinth. Vinyl RU Tan
Corinth. Vinyl FV Cream
(L/B Bench) Corinth. Vinyl
(L/B Bucket) Corinth. Vinyl
BA Black (L/B Bucket)
WU Tan (L/B Flight Bench)
BB Blue SA Black
SB Blue GB Blue
BD Red COMET
SD Red GD Red
BG Green Random Stripe B/Cloth &
Corinth. Vinyl SU Tan GR Jade
BU Tan
(L/B Bench) Alpine B/Cloth & GS Gray
Tooled/Corinth. Vinyl Corinth. Vinyl GU Tan
(L/B Bench) BA Black
BB Blue (L/B Bucket) GV Cream
HA Black TB Blue Westminster B/Cloth &
HB Blue BD Red
BG Green TG Green Corinth. Vinyl
HD Red (L/B Flight Bench)
BU Tan TU Tan
HG Green HB Blue
GRANADA
HU Tan HD Red
Tooled/Corinth. Vinyl Corinth. Vinyl
Corinth. Vinyl (L/B Bench) (L/B Bucket) HR Jade
(L/B Bucket) HA Black AB Blue HU Tan
PA Black HB Blue AD Red Corinth. Vinyl
PB Blue HD Red AR Jade (L/B Bench)
PD Red HG Green AS Gray JB Blue
PU Tan HU Tan AU Tan JD Red
CYI419-H1
 20-01-7 Car Identification Codes 20-01-7
INTERIOR TRIM CODES - Continued
Code Trim Scheme Code Trim Scheme Code Trim Scheme Code Trim Scheme

JR Jade ED . Red Natural Grain Leather DT Chamois

JU Tan ER .. Jade (L/B Bucket) DZ Saddle
JV Cream ES . Gray UB Blue Mateao/Corinth.
EU . . Tan UF Cordovan Vinyl
Natural Grain Leather
EV . Cream UQ W/Blue (L/B Split Bench)
(L/B Bucket)
Natural Grain Leather US Gray EB Blue
MD Red
(L/B Bucket) UT Chamois ED Red
MM Lt/DkJade
FB Blue U2 W/Chamois EL W/Lip Red
MS Gray
FD Red U6 W/Cordovan EN W/Red
MU Tan
FR Jade Wilshire B/Cloth & EQ W/Blue
Chainmail Vinyl
FS Gray Corinth. Vinyl ER . . Jade
(L/B Bucket)
FU Tan (L/B Flight Bench) ES Gray
PD Red
FV Cream VB Blue ET Chamois
PU Tan VF Cordovan
Corinth. Vinyl EZ ............... Saddle
Touraine B/Cloth & VS Gray E2 W/Chamois
(L/B Flight Bench)
Corinth. Vinyl VT Chamois E3 ' ..'. . . . Sadle/Whte
GB Blue
(L/B Flight Bench) E5 W/Jade
GD Red THUNDER BIRD
QD Red E9 ............. W/Saddle
GR Jade Wilshire B/Cloth &
QR Jade
GS Gray Corinth. Vinyl Natural Grain Leather
QS Gray
GU Tan (L/B Bench) & Mateao Vinyl
QU Tan
GV Cream AB Blue (L/B Split Bench)
Natural Grain Leather Westminster B/Cloth & AD Red FB Blue
(L/B Flight Bench) Corinth. Vinyl AR Jade FD fled
RD Red (L/B Flight Bench) AS Gray FL W/Lip Red
RM Lt/Dk Jade HB Blue AT Chamois FN W/Red
RS Gray HD Red AZ Saddle FQ W/Blue
RU Tan HR Jade Kiwi/Corinth. Vinyl FR Jade
HU Tan (L/B Bench) FS Gray
MONARCH
BB Blue FT Chamois
Corinth. Vinyl
Corinth. Vinyl BD Red FZ Saddle
(L/B Bucket)
(L/B Bench) BR Jade D2 W/Chamois
AB Blue
JB Blue BS Gray F3 Sadle/Whte
AD Red
JD Red BT Chamois F5 W/Jade
AR Jade
JR Jade BZ ". " Saddle F9 .W/Saddle
AS Gray
JU Tan Lamar Vinyl Lamar Vinyl
AU Tan
JV Cream (L/B Bucket) (L/B Bucket)
AV Cream
Chainmail Vinyl CB Blue GB Blue
Kasman B/Cloth & (L/B Bucket) CD Red GD Red
Corinth. Vinyl PD Red CL W/Lip Red GL W/Lip Red
(L/B Flight Bench) PU Tan CN W/Red GN W/Red
BB Blue Dorchester B/Cloth & CQ W/Blue GQ W/Blue
BD Red Corinth. Vinyl CR Jade GR Jade
BR Jade (L/B Flight Bench) CS Gray GS Gray
BS Gray SB Blue CT Chamois GT Chamois
BU Tan SF Cordovan CZ Saddle GZ Saddle
Corinth. Vinyl SS Gray G2 W/Charmois
C2 W/Chamois
(L/B Bucket) ST Chamois G3 Sadle/Whte
C5 W/Jade
CB Blue Natural Grain Leather C9 W/Saddle G5 W/Jade
CD Red (L/B Flight Bench) G9 W/Saddle
CR Jade TB Blue Ardmore B/Cloth & Newberry B/Cloth &
CS Gray TF Cordovan Corinth. Vinyl Corinth. Vinyl
CU Tan TQ W/Blue (L/B Split Bench) (L/B Bucket)
CV Cream TS Gray DB Blue HB Blue
Corinth. Vinyl TT Chamois DO Red HD Red
(L/B Flight Bench) T2 W/Chamois DR Jade HR Jade
EB Blue T6 W/Cordovan DS ^Gray HS Gray
CY1419-H2
20-01-8 Car Identification Codes 20-01-8

INTERIOR TRIM CODES - Continued

Code Trim Scheme Code Trim Scheme Code Trim Scheme Code Trim Scheme

HT Chamois Kiwi/Corinth. Vinyl Mateao/Corinth. Vinyl Newberry B/Cloth &

HZ Saddle (L/B Bench) (L/B Flight Bench) Corinth. Vinyl
Newberry B/Cloth & DB Blue KB Blue (L/B Split Bench)
Corinth. Vinyl DD Red KD Red CB Blue
(L/B Bucket) DR Jade KR Jade CD Red
JB Blue DS Gray KS Gray CR Jade
JD Red DT Chamois KT Chamois CS Gray
JR Jade DZ Saddle KZ Saddle CT Chamois
JS Gray CZ Saddle
Doral B/Cloth &
JT Chamois Ardmore B/Cloth &
Corinth. Vinyl Mateao/Corinth. Vinyl
JZ Saddle Corinth. Vinyl
(L/B Split Bench) (L/B Split Bench)
Mateao/Corinth. Vinyl (L/B Flight Bench)
EB Blue DB Blue
(L/B Bucket) LB Blue
ED , Red DD Red
PS Gray/Red LD Red
ER Jade DL W/Lip Red
Mateao/Corinth. Vinyl LR Jade
ES Gray DN W/Red
(L/B Split Bench) LS Gray
ET Chamois DQ W/Blue
QS Gray/Red LT Chamois
EZ...... Saddle DR Jade
LZ Saddle
Media Velour B/Cloth DS Gray
Mateao/Corinth. Vinyl
(L/B Split Bench) DT Chamois
(L/B Split Bench) Mateao/Corinth. Vinyl
RB Blue DZ Saddle
FB Blue (L/B Flight Bench)
RD Red D2 W/Chamois
FD Red MB Blue
RR Jade D3 Sadle/Whte
FR Jade MD Red
RS Gray D5 W/Jade
FS Gray MR Jade
RT Chamois D9 W/Saddle
FT Chamois MS Gray
Natural Grain Leather FZ Saddle MT Chamois Natural Grain Leather
(L/B Split Bench) F3 Sadle/Whte MZ Saddle (L/B Split Bench)
SB Blue Mateao/Corinth. Vinyl
Lamar Vinyl EB Blue
SD Red (L/B Split Bench)
(L/B Bucket) ED Red
SR Jade PV Cream/Blue
GB Blue EL W/Lip Red
SS Gray
ST Chamois GD Red EN W/Red
COUGAR EQ W/Blue
GR Jade
LTD Gray Ashton B/Cloth & ER Jade
GS
Kirsten B/Cloth & Corinth. Vinyl ES Gray
GT Chamois
Corinth. Vinyl (L/B Flight Bench) ET Chamois
GZ Saddle
(L/B Bench) G3 Sadle/Whte AB Blue EZ Saddle
AB Blue AD Red E2 W/Chamois
AD Red Lamar Vinyl AR Jade E3 Sadle/Whte
AR Jade (L/B Bucket) AS Gray E5 W/Jade
AT Chamois HB Blue AT Chamois E9 W/Saddle
HD Red AZ Saddle
Colton/Corinth. Vinyl
HR Jade Lamar Vinyl
(L/B Bench)
HS Gray Mateao/Corinth. Vinyl (L/B Bucket)
BB Blue
HT Chamois (L/B Flight Bench) FB Blue
BD Red
HZ Saddle BB Blue FD Red
BR Jade
H3 Sadle/Whte BD Red FL W/Lip Red
BT Chamois
BL W/Lip Red FN W/Red
Porto B/Cloth & Ardmore B/Cloth & BN W/Red FQ W/Blue
Corinth. Vinyl Corinth. Vinyl BQ W/Blue FR Jade
(L/B Bench) (L/B Flight Bench) BR Jade FS Gray
CB Blue JB Blue BS Gray FT Chamois
CD Red JD Red BT Chamois FZ Saddle
CR Jade JR Jade BZ Saddle F2 W/Chamois
CS Gray JS Gray B2 W/Chamois F3 Sadle/Whte
CT Chamois JT Chamois B5 W/Jade F5 W/Jade
CZ Saddle JZ Saddle B9 W/Saddle F9 W/Saddle
CYI419-H3
20-01-9 Car Identification Codes 20-01-9

INTERIOR TRIM CODES - Continued

Code Trim Scheme Code Trim Scheme Code Trim Scheme Code Trim Scheme

Newberry B/Cloth & Lamar Vinyl UR Jade Logan B/Cloth &

Corinth. Vinyl (L/B Bucket) US Gray Corinth. Vinyl
(L/B Bucket) MB Blue UT Chamois (LB Bench)
GB Blue MD Red UZ Saddle CB Blue
GO Red ML W/Lip Red CD Red
Doral B/Cloth &
GR Jade MN W/Red CR Jade
Corinth. Vinyl
GS Gray MQ W/Blue CY Gold
(L/B Split Bench)
GT Chamois MR Jade CZ Saddle
VB Blue
GZ Saddle MS Gray Redondo B/Cloth &
VD Red
Newberry B/Cloth & MT Chamois VR Jade Corinth. Vinyl
Corinth. Vinyl MZ Saddle VS Gray (L/B Bench)
(L/B Split Bench) M2 W/Chamois VT Chamois DB Blue
HB Blue M5 W/Jade VZ Saddle DD Red
HD Red M9 W/Saddle DR Jade
Newberry B/Cloth & Mateao/Corinth. Vinyl DS Gray
HR Jade
Corinth. Vinyl (L/B Split Bench) DY Gold
HS Gray
(L/B Flight Bench) WB Blue DZ Saddle
HT Chamois
N2 W/Chamois WD Red
HZ Saddle Ruffino Corinth. Vinyl
Newberry B/Cloth & WR Jade
Mateao/Corinth. Vinyl (L/B Bench)
Corinth. Vinyl WS Gray
(L/B Split Bench) EB Blue
(L/B Bucket) WT Chamois
JB Blue ED Red
P2 W/Chamois WZ Saddle
JD Red ER Jade
Newberry B/Cloth & W3 Sadle/Whte
JL W/Lip Red ES Gray
Corinth. Vinyl Lamar Vinyl EY Gold
JN W/Red
(L/B Split Bench) (L/B Bucket) EZ Saddle
JQ W/Blue
QT Chamois YB Blue Ardmore B/Cloth &
JR Jade
Porto B/Cloth & YD Red Corinth. Vinyl
JS Gray
Corinth. Vinyl YR (L/B Split Bench)
JT Chamois
(L/B Bench) YS Gray FB Blue
JZ Saddle
RB Blue YT Chamois FD Red
J2 W/Chamois
RD Red YZ Saddle FR Jade
J5 W/Jade
RR Jade Y3 Sadle/Whte FS Gray
J9 W/Saddle
RS Gray FY Gold
Natural Grain Leather Lamar Vinyl FZ Saddle
RT Chamois
(L/B Split Bench) (L/B Bucket Ruffino/Corinth. Vinyl
RZ Saddle
KB Blue Kiwi/Corinth. Vinyl ZB . . . Blue (L/B Split Bench)
KD Red (L/B Bench) ZD . . . Red GB Blue
KL W/Lip Red SB Blue ZR . . . Jade GD Red
KN W/Red SD Red ZS . . . Gray GR Jade
KQ W/Blue SR Jade ZT Chamois
GS Gray
KR Jade SS Gray ZZ Saddle
GY Gold
KS Gray ST Chamois Z3 Sadle/Whte
GZ Saddle
KT Chamois SZ Saddle Ardmore B/Cloth &
KZ Saddle Ardmore B Cloth &
FORD
Corinth. Vinyl
K2 W/Chamois Barletta B/Cloth &
Corinth. Vinyl (L/B Flight Bench)
K5 W/Jade Corinth. Vinyl
(L/B Flight Bench) HB Blue
K9 W/Saddle (L/B Bench)
TB Blue HD Red
Newberry B/Cloth & AB Blue
TD Red HR Jade
Corinth. Vinyl AD Red
TR Jade HS Gray
(L/B Bucket) AZ Saddle
TS Gray HY Gold
LB Blue TT Chamois Ruffino/Corinth. Vinyl HZ Saddle
LD Red TZ Saddle (L/B Bench) Ruffino/Corinth. Vinyl
LR Jade Mateao/Corinth. Vinyl BB Blue (L/B Split Bench)
LS Gray (L/B Flight Bench) BD Red JB Blue
LT Chamois UB Blue BR Jade JD Red
LZ Saddle UD Red BZ Saddle JR Jade

CY1419-H4
20-01-10 Car Identification Codes 20-01-10

INTERIOR T R I M COOES - Continued

Code Trim Scheme Code Trim Scheme Code Trim Scheme Code Trim Scheme

JS Gray Natural Grain Leather Ardmore B/Cloth & Natural Grain Leather
JY Gold (L/B Split Bench) Corinth. Vinyl & Mateao Vinyl
JZ Saddle YB Blue (L/B Bench) (L/B Split Bench)
YD Red LB Blue BA Black
Ardmore B/Cloth &
YR Jade LD Red BB Blue
Corinth. Vinyl
YS Gray LR Jade BD Red
(L/B Split Bench)
YV Gold/Cream LZ Saddle BF Cordovan
KB Blue
YZ Saddle BN W/Red
KD Red Wilshire B/Cloth &
Y3 Sadle/Whte BQ W/Blue
KR Jade Corinth. Vinyl
BR Jade
KS Gray (L/B Split Bench)
MERCURY BT Chamois
KY Gold MB Blue
KZ Saddle Natural Grain Leather BW W/Black
MD. Red
(L/B Split Bench) BY Gold
Dynasty Polyknit & MR Jade
FB Blue B2 W/Chamois
Corinth. Vinyl MS Gray
FD Red B5 W/Jade
(L/B Split Bench) MY Gold
FR Jade B6 W/Ccrdovan
NB Blue MZ Saddle
FS Gray B8 W/Gold
ND Red Kasman B/Cloth
FV Gold/Cream Romano/Media Ve our
NR Jade (L/B Split Bench)
FZ Saddle B/Cloth
NU Saddle/Tan NS Gray
F3 Sadle/Whte /L/B Split Bench I
Kasman B/Cloth & Wilshire B/Cloth & CF Ccrdovan
Corinth. Vinyl Redondo B/Cloth & Corinth. Vinyl CY Gold
(L/B Split Bench) Corinth. Vinyl Natural Grain Leather
(L/B Flight Bench)
PB Blue (L/B Bench) & Mateao Vinyl
RB Blue
PD Red GB Blue (L/B Split Bench I
RD Red
PR Jade GD Red DF Ccrdovan
RR Jade
PS Gray GR Jade DH Red/Rose
RY Gold
PY Gold GS Gray DR Jade/Lt
RZ Saddle
PZ Saddle GY Gold DS Gray
Valino/Corinth. Vinyl
Valino Vinyl GZ Saddle DT Chamois
(L/B Flight Bench)
(L/B Split Bench) DV Gold/Cream
Ruffino/Corinth. Vinyl SB Blue
QB Blue Natural Grain Leather
(L/B Bench) SD Red
QD Red (L/B Split Bench I
HB Blue SR Jade
QR ..Jade EB Blue
HD Red SV Gold/Cream
QS Gray Kasman B/Cloth !i
HR Jade SZ Saddle
QV Gold/Cream Corinth. Vinyl
HY Gold
QZ Saddle Valino/Corinth. Vinyl (L/B Split Bench I
HZ Saddle
Q3 Sadle/Whte (L/B Split Bench) FS Gray
Touraine B/Cloth & VB Blue Majestic B/Cloth &
Valino Vinyl
Natural Grain Leather VD Red Corinth. Vinyl
(L/B Split Bench)
(L/B Split Bench) VR Jade (L/B Split Bench'
RV Cream/Blue
Ruffino/Corinth. Vinyl JB Blue VS Gray GB Blue
(L/B Split Bench) JD Red VV Gold/Cream GD Red
SB Blue JR Jade VZ Saddle GR Jade
SD Red JS Gray Natural Grain Leather
JY Gold
MARKV
SR Jade (L/B Split Bench!
Venezia B/Cloth &
SY Gold JZ Saddle JS Gray
Corinth. Vinyl
SZ Saddle
Ruffino/Corinth. Vinyl (L/B Split Bench) LINCOLN
Dynasty Polyknit & (L/B Bench) AA Black Kasman B/Cloth &
Corinth. Vinyl KB Blue AB Blue Corinth. Vinyl
(L/B Bench) KD Red AD Red (L/B Bench)
UB Blue KR Jade AF Cordovan BB Blue
UD Red KS Gray AR Jade BD Red
UR Jade JY Gold AT Chamois BF Cordovan
UU Saddle/Tan KZ Saddle AY Gold BR Jade

CV1419-H5
20-01-11 Car Identification Codes 20-01-11

INTERIOR TRIM CODES-Continued

Code Trim Scheme Code Trim Scheme Code Trim Scheme Code Trim Scheme

BT Chamois EQ W/Blue HT Chamois KY Gold

BY Gold ER Jade HY Gold K2 W/Chamois
Natural Grain Leather ET Chamois K5 W/Jade
& Mateao Vinyl EW W/Black Media Velour B/Cloth K6 W/Cordovan
(L/B Bench) EY Gold (L/B Split Bench) K8 W/Gold
DA Black E2 W/Chamois JA Black
DB Blue E5 W/Jade JB Blue Natural Grain Leather
DD . . , . Red E6 W/Cordovan JD Red & Mateao Vinyl
DF Cordovan E8 W/Gold JF Corddvari (L/B Bench)
DN W/Red JR Jade LF Cordo/Whte
Kasman B/Cloth & Natural Grain Leather
DQ W/Blue JS Gray
Corinth. Vinyl & Mateao Vinyl
DR Jade JT Chamois
(L/B Split Bench)
DT Chamois JY Gold (L/B Split Bench)
FB Blue MF Cordo/Whte
DW W/Black FD ..Red
Natural Grain Leather Natural Grain Leather
DY Gold FF Cordovan
& Mateao Vinyl NV Cream/Cordo
D2 W/Chamois FR Jade
(L/B Split Bench) Westminster B/Cloth &
D5 W/Jade FT Chamois
KA Black Corinth. Vinyl
D6 W/Cordovan FY Gold
KB Blue (L/B Bench)
D8 W/Gold
Natural Grain Leather KD Red PB Blue
Natural Grain Leather
& Mateao Vinyl KF Cordovan PD Red
&Mateao Vinyl
(L/B Bench) KN W/Red PF Cordovan
(L/B Split Bench)
HA Black KQ W/Blue Mateao Vinyl
EA Black
HB Blue KR Jade (L/B Bench)
EB Blue
HD Red KS Gray QB Blue
ED Red
HF Cordovan KT Chamois QD Red
EF Cordovan
HR Jade KW W/Black QF Cordovan
EN W/Red

CY1419-H6
21-00-1 Gasoline Engines 21-00-1

GROUP
GASOLINE ENGINES
(6000)
PART TITLE PART NO. PART TITLE PART NO.

General Gasoline Engine Service 21-01 302 and 351W CID V-8 Engines 21-21
2300 cc Four-Cylinder Engine 21-05 351M and 400 CID V-8 Engines 21-22
200 and 250 CIO Six-Cylinder Engines 21-10 460 CID V-8 Engine 21-24
2800 cc V-6 Engine 21-12 460 CID Police Interceptor Engine 21-27

CA4181-A

PART
General Gasoline Engine Service 21-01

SUBJECT PAGE SUBJECT PAGE

GENERAL INFORMATION REMOVAL AND INSTALLATION (Cont'd.)
Engine Identification 01-2 Crankshaft Rear Oil Seal 01-11
Flywheel Ring Gear - Manual Shift
DIAGNOSIS AND TESTING
Transmission 01-11
Camshaft End Play 01-6
Rocker Arm Stud Nut Replacement
Camshaft Lobe Lift 01-4
- 3 0 2 V-8 01-9
Compression Test 01-4
Rocker Arm Stud Replacement -
Crankshaft End Play 01-6
302 and 351W V-8 01-9
Flywheel Clutch Face Runout -
Manual Shift Transmissions 01-7 OVERHAUL
Flywheel Runout - Automatic Camshaft Repair 01-15
Transmissions 01-7 Cleaning and Inspection 01-17
Hydraulic Valve Lifter and Crankshaft 01-15
Hydraulic Lash Adjuster 01-5 Cylinder Block 01-16
Positive Closed-Type Crankcase Cylinder Head 01-14
Ventilation System 01-4 Fitting Main or Connecting Rod
Timing Chain Deflection 01-6 Bearings 01-15
Timing Gear Backlash - V-6 Engine 01-6 Interpretation of "Service Limit"
Timing Gear Runout 01-6 Specifications 01-14
ADJUSTMENTS Pistons, Pins and Rings 01-15
Hydraulic Valve Clearance - Except Valves 01-14
2.3L and 2.8L Engines 01-8
REMOVAL AND INSTALLATION SPECIAL SERVICE TOOLS 01-22
Core Plugs 01-10
CA4182-A
21-01-2
GENERAL INFORMATION
All passenger car engines incorporate
a closed-type crankcase ventilation
system and exhaust emission control
system on all engines. All engine emission
control systems are covered in detail in
Group 29 (Diagnosis) and Volume 5
(Maintenance).
To maintain the required exhaust
emission levels, the fuel system, ignition
system and engine must be kept in good
o p e r a t i n g c o n d i t i o n and meet
recommended adjustment specifications.
When performing tests, adjustments
or repairs to the engine, ignition system
or fuel system, it is essential to follow the
procedures and specifications in Groups
21, 23, 24 and 29 of this Manual.
Before replacing damaged or worn
engine components such as the
crankshaft, cylinder heads, valve guides,
General Gasoline Engine Service
valves, camshafts or cylinder block, be
sure the part(s) are not repairable.
The following sections cover engine
tests, adjustment and repair procedures.
In addition, the cleaning and inspection
procedures are covered. Engine assembly
and repair specifications are at the end of
each specific Part.
For engine removal, disassembly,
assembly, installation and adjustment
procedures, refer to the pertinent Part of
this Group.
ENGINE IDENTIFICATION
For quick engine identification, refer
to the Safety Certification Decal shown
in Fig. 1. The decal is mounted on the left
front door lock face panel. Find the
engine code (letter or number) on the
decal, then refer to the engine
21-01-2
identification chart to determine the
engine type and size. An engine
identification tag is also attached to the
engine. The symbol code on the
identification tag (Fig. 1) identifies each
engine for determining parts usage; for
instance, engine cubic inch displacement
and model year.
The change level and engine code
number determine if parts are unique to
specific engines. The engine plant codes
designate where engines were built. It is
imperative that the codes on the engine
identification tag be used when ordering
parts or making inquiries about the
engine. The pertinent codes are shown in
the Master Parts Catalog to designate
unique parts.
21-01-3 General Gasoline Engine Service 21-01-3

(VEHICLE IDENTIFICATION NUMBER)

SAFETY CERTIFICATION DECAL (TYPICAL)

MFD. BY FORD MOTOR CO. IN U.S.A.

DATE: 07/76 GVWR 5892
GAWR: FRONT 2964, REAR 2928

THIS VEHICLE CONFORMS TO ALL ( V ) CONSECUTIVE UNIT NO. ( T ) VINYL ROOF TYPE/COLOR
APPLICABLE FEDERAL MOTOR
VEHICLE SAFETY STANDARDS IN \2j BODY SERIAL CODE ( j T ) TRIM CODE
EFFECT ON THE DATE OF MANU
\ F A C T U R E SHOWN ABOVE (T) MODEL YEAR CODE ( U ) ) TRANSMISSION CODE
. \ ^ F0033/R0155
•-7S63H100001 PASSENGER-* (T) ASSEMBLY PLANT CODE ( j n ) REAR AXLE CODE
^ V l H. l^fcNT. NO. I TYPI
COLOR | TRIM | TRANS. | AXL1- | DSO BODY TYPE CODE (u) DISTRICT - SPECIAL EQUIPMENT
ITCDA] ( \ r l m f ~
ENGINE CODE (u) VEHICLE TYPE

1)(ZJ (%J (10 BODY COLOR CODE Qi) ACCESSORY RESERVE LOAD

(UNITED STATES)

LINCOLN
LTD 11/ CONTI-
PINTO/ GRANADA COMET/ THUNDER-
CODE FORD COUGAR/ MUSTANG MERCURY NENTAL,
BOBCAT MAVERICK MONARCH BIRD
RANCHERO MARKV

ENGINES
!
5
-I
I if H
- J UJ

2300CC-2V

2800CC-2V

200-IV

250-IV

302-2V

351W-2V H**

351M-2V

400-2V

460-4V

460-4V PI 8

**Granada/Monarch Only

FIG. 1 Engine Identification

21-01-4 General Gasoline Engine Service 21-01-4

DIAGNOSIS AND TESTING

POSITIVE CLOSED-TYPE
CRANKCASE VENTILATION
SYSTEM
All emission system related
components testing and diagnosis is
covered in Part 29-02, Light Duty Engine
Diagnosis and Testing.
COMPRESSION TEST
Compression Gauge Check
1. Be sure the oil in the crankcase is at
the proper level and the battery is
properly charged. Operate the vehicle
until the engine is at normal operating
temperature. Turn the ignition switch
off; then remove all the spark plugs.
2. Set the carburetor throttle plates and
choke plate in the wide open position.
3. Install a compression gauge in No. 1
cylinder.
4. Install an auxiliary starter switch in
the starting circuit. Using the
auxiliary starter switch, crank the
engine (with the ignition switch off)
at least five compression strokes and
record the highest reading.
Note the approximate number of
compression strokes required to
obtain the highest reading.
5. Repeat the test on each cylinder as
was required to obtain the highest
reading on the No. 1 cylinder.
Test Conclusion
The indicated compression pressures
are considered within specification if the
lowest reading cylinder is within 75
percent of the highest. (See the
percentage chart given in Fig. 2.)
If one, or more cylinders read low,
squirt approximately one (1) tablespoon
of engine oil on top of the pistons in the
low reading c y l i n d e r s . Repeat
compression pressure check on these
cylinders.
1. If c o m p r e s s i o n i m p r o v e s
considerably, the piston rings are at
fault.
2. If compression does not improve,
valves are sticking or seating poorly.
3. If two adjacent cylinders indicate low
compression pressures and squirting
oil on the pistons does not increase
the compression, the cause may be a
cylinder head gasket leak between the
cylinders. Engine oil and/or coolant
in the cylinders could result from this
problem.
It is recommended the following
quick reference chart (Fig. 2) be used
when checking cylinder compression
pressures. The chart has been
calculated so that the lowest reading
number is 75 percent of the highest
reading.
Example
If, after checking the compression
pressures in all cylinders, it was found
that the highest reading obtained was 196
PSI and the lowest pressure reading was
155 PSI, the engine is within
specifications and the compression is
considered satisfactory.
CAMSHAFT LOBE LIFT
All Except 2300cc Engine
Check the lift of each lobe in
consecutive order and make a note of the
readings.
1. Remove the air cleaner and the valve
rocker arm cover(s).
2. On the rocker shaft mounted rocker
arms, remove the valve rocker arm
shaft(s) assembly as detailed n the
pertinent part.
On the stud mounted rocker arms,
remove the rocker arm stud nut,
fulcrum seat, oil deflector and -ocker
arm. Use the adapter for ball-end
push rods.
3. Make sure the push rod is in tht: valve
lifter socket. Install a dial indicator in
such a manner as to have the ball
socket adapter of the indicator on the
end of the push rod and in tht; same
plane as the push rod movemert (Fig.
3 or 4).
4. Connect an auxiliary starter switch in
the starting circuit. Crank the engine
with the ignition switch OFF.
"Bump" the crankshaft over until the
tappet or lifter is on the base circle of
the camshaft lobe. At this po nt, the
push rod will be in its lowest position.
5. Zero the dial indicator. Continue to
rotate the crankshaft slowly until the
push rod is in the fully raised position
(highest indicator reading).
6. Compare the total lift recorded on the
indicator with specifications.
7. To check the accuracy of the original
indicator reading, continue tc rotate
the crankshaft until the indicator
reads zero. If the lift on any lobe is
below specified service limits, the
camshaft and the valve lifters
operating on the worn lobe(s) must be
replaced, as well as any lifter that

Maximum Minimum Maximum Minimum Maximum Minimum

PSI PSI PSI PSI PSI PSI
134 101 174 131 214 160
136 102 176 132 216 162
138 104 178 133 218 163
140 105 180 135 220 165
142 107 182 136 222 166
144 108 184 138 224 168
146 110 186 140 226 169
148 111 188 141 228 171
150 113 190 142 230 172
152 114 192 144 232 174
154 115 194 145 234 175
156 117 196 147 236 177
158 118 198 148 238 178
160 120 200 150 240 180
162 121 202 151 242 181
164 123 204 153 244 183
166 124 206 154 246 184
168 126 208 156 248 186
170 127 210 157 250 187
172 129 212 158
U1005-A
FIG. 2 Quick Reference Compression Pressure Limit Chart
21-01-5
shows pitting or having contact face
worn flat or concave.
8. Remove the dial indicator and
auxiliary starter switch.
On the rocker shaft type mounted
rocker arms, install the rocker arm
shaft assembly(ies) as detailed in the
applicable engine Part.
Install the stud mounted or
pedestal mounted rocker arms as
detailed in the applicable engine Part.
Adjust the valve clearance as detailed
in the pertinent Part.
After installing the rocker arms, do
not rotate the crankshaft until the
hydraulic valve lifters have had
sufficient time to bleed down. To do
otherwise may cause serious valve
damage. Manually bleeding down will
reduce the waiting time.
9. Install the valve rocker arm cover(s)
and the air cleaner.
2300cc Engine
Check the lift of each lobe in
consecutive order and make a note of the
readings.
1. Remove the air cleaner and the valve
rocker arm cover.
2. Measure the distance between the
major (A—A) and minor (B—B)
diameters (Fig. 6) of each cam lobe
with a Vernier caliper and record the
readings. The difference in the
readings on each cam is the lobe lift.
3. If the readings do not meet
specifications, replace the camshaft
and all cam followers that show
excessive wear.
4. Install the valve rocker arm cover and
the air cleaner.
HYDRAULIC VALVE LIFTER AND
HYDRAULIC LASH ADJUSTER
The hydraulic lash adjusters used in
the overhead cam 23OOcc engine are a
zero-lash hydraulic device, similar in
construction and operation to the
hydraulic valve lifters used on push-rod
engines. They are cleaned, inspected and
checked in the same manner. The
instructions below apply equally to the
lash adjuster and the hydraulic lifter.
Leak-down rates for the lash adjuster and
hydraulic lifter are covered in the
Specifications Section of the engine Part.
Hydraulic valve lifter noise may be
caused by any of the following:
1. Excessive collapsed valve lifter gap.
2. Sticking valve lifter plunger.
3. Valve lifter check valve not
functioning properly.
4. Air in lubrication system.
5. Leakdown rate too rapid.
6. Excessive valve guide wear.
Excessive collapsed valve lifter gap
may be caused by loose rocker arm nuts,
incorrect initial adjustment, or wear of
valve lifter face, pushrod, rocker arm,
General Gasoline Engine Service 21-01-5
rocker arm fulcrum or valve tip. With 5. Work the valve lifter plunger up and
valve lifter collapsed (Part 21-01) check down until the lifter fills with fluid
gap .between valve tip and rocker arm to and all traces of air bubbles have
determine if any other valve train parts disappeared.
are damaged, worn, or out of adjustment. 6. Allow the ram and weight to force the
A sticking valve; lifter plunger may be valve lifter plunger downward.
caused by dirt, chips, or varnish inside Measure the exact time it takes for the
the lifter. The sticking condition can be pointer to travel from the Start
corrected by disassembling the lifter and Timing to the Stop Timing marks of
removing the dirt, chips or varnish that the tester.
is causing the condition. 7. A valve lifter that is satisfactory must
A valve lifter ch'bck valve that is not have a leak-down rate (time in
functional may be caused by an seconds) within the minimum and
obstruction such as dirt or chips maximum limits specified.
preventing it from closing when the cam 8. If the valve lifter is not within
lobe is lifting the v; tlve lifter, or it may specifications, replace it with a new
be caused by a broken check valve spring. lifter. It is not necessary to
Air bubbles in t|ie lubrication system disassemble and clean new valve
will prevent the valve lifter from lifters before testing, because the oil
supporting the valve spring load and may contained in new lifters is test fluid.
be caused by too hjgh or too low an oil 9. Remove the fluid from the cup and
level in the oil pan, or by air being drawn bleed the fluid from the lifter by
into the system through a hole, crack, or working the plunger up and down.
leaking gasket on the oil pump pickup
tube. Tool-6565
If the leakdovn time is below the PUSH ROD
specified time focused lifters, noisy
operation may result. If no other cause
for noisy valve lifters can be found, the
leakdown rate should be checked and any
outside the specification should be
replaced.
Assembled valve lifters can be tested
with Tool 6500-E to check the leak down
rate. The leak down rate specification is
the time in seconds for the plunger to
move a specified distance of its travel
while under a 50 1^. load. Test the valve
lifters as follows:
1. Disassemble and clean ,the lifter to Too(-6565-AB
remove all traces of engine oil.
NOTE: Do not mix parts from A3129-A
different valve lifters. Parts are select-
fitted and are not interchangeable. FIG. 3 Testing Camshaft Lobe Lift—
Lifters cannot be checked with Rocker Shaft Mounted Rocker
engine oil in them. Only the testing Arms
fluid can be used.
2. Place the v ilve lifter in the tester, Too/-6565
with the plunger facing upward. Pour
hydraulic tester fluid into the cup to
a level that will cover the valve lifter
assembly. The fluid can be purchased
from the manufacturer of the tester.
Using kerosene or any otherfluidwill
not provide an accurate test.
3. Place the 5/16-inch steel ball
provided with the tester in the
plunger cap (Fig. 7).
4. Adjust the length of the ram (Fig. 8)
so that the pointer is 1/16 inch below
the starting mark when the ram
contacts the valve lifter plunger, to
facilitate timing as the pointer passes
the Start Timing mark.
Tool-6565-AB Tool-4201-C
Use the center mark on the pointer A2958-A
scale as the Stop Timing point instead
of the original Stop Timing mark at FIG. 4 Testing Camshaft Lobe Lift—
the top of the scale. Stud Mounted Rocker Arms
21-01-6
This step will aid in depressing the
lifter plungers when checking the
valve clearance.
CAMSHAFT END PLAY
2300cc Engine
Remove the camshaft drive belt
cover. Push the camshaft toward the rear
of the engine. Install a dial indicator so
that the indicator point is on the
camshaft sprocket attaching screw or
gear hub. Zero the dial indicator.
Position a large screwdriver between the
camshaft sprocket or gear and the
cylinder head. Pull the camshaft forward
and release it. Compare the dial indicator
reading with specifications. If the end
play is excessive, replace the thrust plate
at the rear of the cylinder head (Fig. 9).
Remove the dial indicator and install the
camshaft drive belt cover.
All Except 2300cc Engine
On all V-8 engines, prying against the
aluminum-nylon camshaft sprocket, with
the valve train load on the camshaft, can
break or damage the sprocket. Therefore,
the rocker arm adjusting nuts must be
backed off, or the rocker arm and shaft
assembly must be loosened sufficiently to
free the camshaft. After checking the
camshaft end play, adjust the valve
clearance.
Push the camshaft toward the rear of
the engine. Install a dial indicator so that
the indicator point is on the camshaft
sprocket attaching screw (Figs. 10, 11
and 12). Zero the dial indicator. Position
a large screwdriver between the camshaft
sprocket or gear and the block. Pull the
camshaft forward and release it.
Compare the dial indicator reading with
specifications. If the end play is excessive,
replace the thrust plate.
Remove the dial indicator.
TIMING GEAR BACKLASH—V-6
ENGINE
Remove the valve spring load on the
camshaft by backing off the adjusting
screws. Install a dial indicator on the
cylinder block (Fig. 13). Check the
backlash between the camshaft gear and
the crankshaft gear with a dial indicator.
Hold the gear firmly against the block
while making the check. Refer to the
specifications for the backlash limits. If
backlash exceeds specifications, replace
both gears.
Readjust valve clearance according to
procedure.
TIMING GEAR RUNOUT
NOTE: Valve spring lead must not be
on camshaft when making this check.
Install a dial indicator on the cylinder
block as shown in Fig. 14. Hold the
camshaft gear against the camshaft
thrust plate and zero the indicator.
General Gasoline Engine Service 21-01-6
UNACCEPTABLE
ACCEPTABLE
(CONTACT FACE
CONVEX & SMOOTH)
FLAT CONCAVE
A4290-A
FIG. 5 Lifter Wear Inspection
Rotate the crankshaft to turn the DIMENSION A MINUS
camshaft, while holding the camshaft DIMENSION B EQUALS
THE CAM LOBE LIFT
gear against the thrust plate. Check the
gear runout through one complete
revolution of the camshaft. If the gear
runout exceeds specifications, remove it
and check for burrs or foreign particles
on or between the camshaft and gear pilot
diameter and/or mating flanges. Recheck
the r u n o u t ; if it still exceeds
specifications, replace the gear. Recheck
runout on new gear following same
procedure.
TIMING CHAIN DEFLECTION
1. R o t a t e the c r a n k s h a f t in a A3454-B
counterclockwise direction (as viewed
from the front) to take up the slack
FIG. 6 Measuring Camshaft Lobe Lift
on the left side of the chain.
2. Establish a reference point on the
block and measure from this point to
the chain (Fig. 15).
3. Rotate the crankshaft in the opposite
direction to take ap the slack on the
right of the chain. Force the left side
of the chain out with the fingers and
measure the distance between the
reference point and the chain. The
deflection is the difference between
the two measurements.
If the deflection exceeds
specifications, replace the timing Tool-6500-E
chain and sprockets.
FIG. 7 Placing Steel Ball in Valve
Lifter Plunger
CRANKSHAFT END PLAY
1. Force the crankshaft toward the rear
of the engine.
2. Install a dial indicator so that the
contact point rests against the
crankshaft flange and the indicator
axis is parallel to the crankshaft axis
(Fig. 16).
3. Zero the dial indicator. Push the
crankshaft forward and note the
reading on the dial.
4. If the end play exceeds the wear limit,
replace the thrust bearing. If the end
play is less than the minimum limit
inspect the thrust bearing faces for FIG. 8 Adjusting the Ram Length
21-01-7 Generol Gasoline Engine Service 21-01-7

scratches, burrs, nicks, or dirt. If the mounting flange runout exceeds

thrust faces are not damaged or dirty, specifications. Replace it or reinstall it on
they probably were not aligned the flywheel. Refer to Ring Gear
properly. Install the thrust bearing Replacement in this Part for the proper
and align the faces following the procedure.
procedure recommended under Main
Bearing Replacement in the pertinent
engine section. Recheck the end play.
FLYWHEEL R U N O U T -
AUTOMATIC TRANSMISSIONS
Remove the spark plugs.
Install a dial indicator so that the
indicator point rests on the face of the
ring gear adjacent to the gear teeth.
Hold the flywheel and crankshaft
forward or backward as far as possible to FIG. 13 Checking Timing Gear
prevent crankshaft end play from being Backlash - V-6 Engine
indicated as flywheel runout.
Set the indicator dial on the zero
mark. Turn the flywheel one complete
revolution while observing the total
indicator reading (TIR). If the TIR
exceeds specifications, the flywheel and
ring gear assembly must be replaced. A2988-A

FLYWHEEL CLUTCH FACE FIG. 10 Checking Camshaft End Tool- 4201 - C

RUNOUT—MANUAL-SHIFT Play—V-8 Engine

TRANSMISSIONS
Install a dial indicator so that the
indicator point bears against the flywheel
face (Fig. 17). Turn theflywheelmaking
sure to hold it in the full forward or
rearward position so that crankshaft end
play will not be indicated as flywheel
runout.
If the clutch face runout exceeds
specifications, remove the flywheel and
check for burrs between theflywheeland
the face of the crankshaft mounting FIG. 14 Checking Timing Gear
flange. If no burrs exist, check the runout Runout
of the crankshaft mounting flange.
Replace the flywheel or machine the
crankshaft-flywheel mounting face
sufficiently to true up the surface if the

FIG. 11 Checking Camshaft End

p| a y—V-6 Engine

TOOL-4201-C
CAMSHAFT

THRUST PLATE

SCREWS WASHER
REFERENCE
A3722-A POINT A2952-B

FIG. 9 Cam Shaft Thrust Plate FIG. 12 Checking Camshaft End FIG. 15 Checking Timing Chain
Installation—2300cc Play—200/250 CID Six Deflection—Typical
21-01-8
roo/-6565
FIG. 16 Checking Crankshaft End
Play
ADJUSTMENTS
HYDRAULIC VALVE
CLEARANCE—EXCEPT 2.3L AND
2.8L ENGINES
The 2.3L engine is an overhead cam
engine with hydraulic lash adjusters.
Refer to Part 21-05 for adjustment
procedures. The 2.8L engine has
mechanical lifters. Refer to Part 21-12 for
adjustment procedures.
On 8-cylinder engines, the valve
arrangement on the left bank is E-I-E-I-
E-I-E-I and on the right bank is I-E-I-E-
I-E-I-E. For the 6-cylinder engine, the
valve arrangement is E-I-I-E-I-E-E-I-E-
I-I-E.
A 0.060-inch shorter push rod or a
0.060-inch longer push rod is available
for service to provide a means of
compensating for dimensional changes in
the valve mechanism. Refer to the Master
Parts List for the color code.
Valve stem to valve rocker arm
clearance should be within specifications
with the hydraulic lifter completely
collapsed. Repeated valve reconditioning
operations (valve and/or valve seat
refacing) will decrease the clearance to
the point that if not compensated for, the
hydraulic valve lifter will cease to
function and the valve will be held open.
To determine whether a shorter or a
longer push rod is necessary, make the
following check:
1. Connect an auxiliary starter switch in
the starting circuit. Crank the engine
with the ignition switch OFF until the
No. 1 piston is on TDC after the
compression stroke.
2. With the crankshaft in the positions
designated in Steps 3,4 and 5 position
the hydraulic lifter compressor tool
on the rocker arm. Slowly apply
pressure to bleed down the hydraulic
lifter until the plunger is completely
bottomed (Fig. 18). Hold the lifter in
this position and check the available
General Gasoline Engine Service 21-01-8
T o o / - 4 2 0 1-C A1408-C
TooJ-4207-C A2987-B
FIG. 17 Checking Flywheel Face
Runout
clearance between the rocker arm and Engines With Positive Stop Rocker
the valve stem tip with a feeler gauge. Arm Studs
The feeler gauge width must not Each stud nut should be removed
exceed 3/8-inch, in order to fit and inspected for conditions shown in
between the rails on the rocker arm. Fig. 20 when adjusting valve
If the clearance is less than clearance.
specifications, install a shorter push
rod. If the clearance is greater than
specifications, install a longer push
rod.
3. With the No. 1 piston on TDC at the
end of the compression stroke
(POSITION NO. 1 in Fig. 19),
check the following valves:
302 and 460 Engines
No. 1 Intake No. 1 Exhaust
No. 7 Intake No. 5 Exhaust
No. 8 Intake No. 4 Exhaust
351- W, 351-M and 400 Engines
No. 1 Intake No. 1 Exhaust
No. 4 Intake No. 3 Exhaust
No. 8 Intake No. 7 Exhaust Too/-T77P-6573-A
4. Rotate the crankshaft to POSITION
NO. 2 in Fig. 18 and check the
following valves:
302 and 460 Engines
No. 5 Intake No. 2 Exhaust
No. 4 Intake No. 6 Exhaust
351- W, 351-M and 400 Engines
No. 3 Intake No. 2 Exhaust
No. 7 Intake No. 6 Exhaust
5. Rotate the crankshaft to POSITION
NO. 3 in Fig. 18 and check the
following valves:
302 and 460 Engines
No. 2 Intake No. 7 Exhaust
No. 3 Intake No. 3 Exhaust
No. 6 Intake No. 8 Exhaust
351- W, 351-M and 400 Engines
No. 2 Intake No. 4 Exhaust
No. 5 Intake No. 5 Exhaust FIG. 18 Checking Valve Clearcmc*
No. 6 Intake No. 8 Exhaust Hydraulic Valve Lifters
21-01-9
TIMING
POINTER
With No. 1 at TDC at end of compres-
sion stroke make a chalk mark at points
2 and 3 approximately 90 degrees apart.
FIG. 19 Position of Crankshaft for Checking and Adjusting Valve Clearance
REMOVAL AND INSTALLATION
ROCKER ARM STUD NUT
REPLACEMENT—302 and 351-W
V-8
If the rocker arm stud nut breakaway
torque is less than specified, install a new
standard stud nut and recheck the
breaking torque. Refer to Valve
Clearance Adjustment in the applicable
Part for the torque procedure.
ROCKER ARM STUD
REPLACEMENT—302 AND 351-W
V-8
If it is necessary to remove a rocker
arm stud, tool kit T62F-6A527-B is
available which contains the following: a
stud remover, a 0.006-inch oversize
reamer and a 0.015-inch oversize reamer.
For 0.010-inch oversize studs, use reamer
T66P-6A527-B. To press in replacement
studs, use stud replacer T69P-6049-D.
Rocker arm studs that are broken or
have damaged threads may be replaced
with standard studs. Loose studs in the
head may be replaced with 0.006, 0.010
or 0.015-inch oversize studs which are
available for service.
General Gasoline Engine Service 21-01-9
POSITION 1 - No. 1 at TDC at end of compres-
sion stroke.
POSITION 2 - Rotate the crankshaft 180 degrees
(one half revolution) clockwise
from POSITION 1.
POSITION 3 Rotate the crankshaft 270 degrees
(three quarter revolution) clock-
wise from POSITION 2.
A3234-D
s
GOOD POOR
A3193-C
FIG. 20 Inspection of Rocker Arm
Stud Nut
Standard and oversize studs can be it is fully bottomed. Hold the sleeve
identified by measuring the stud diameter with a wrench, then rotate the puller
within 1-1/8 inch from the pilot end of clockwise to remove the stud (Fig.
the stud. The stud diameters are: 21).
Standard... 0.3714-0.3721
0.006 oversize... 0.3774-0.3781
0.010 oversize... 0.3814-0.3821
0.015 oversize... 0.3864-0.3871
When going from a standard size
rocker arm stud to a 0.010 or 0.015-inch
oversize stud, always use the 0.006-inch Tool-
oversize reamer before finish reaming T62F-6A527
with the 0.010 or 0.015-inch oversize
reamer.
1. Position the sleeve of the rocker arm
stud remover (Tool T62F-6A527-B)
over the stud with the bearing end
down. When working on a 302 or 351-
W CID cylinder head, cut the
threaded part of the stud off with a
hack saw. This is necessary due to the
puller being designed for 3/8-inch
studs and it will not grip the 5/16-
inch thread on a 302 or 351-W CID
cylinder head stud. Thread the puller
into the sleeve and over the stud until FIG. 21 Removing Rocker Arm Stud
21-01-10 General Gasoline Engine Service 21-011-10

If the rocker arm stud was broken Installation

off flush with the stud boss, use an Cup-Type
easy-out to remove the broken stud Cup-type core plugs (Fig. 24) are
following the instructions of the tool installed with the flanged edge oui ward.
manufacturer. The maximum diameter of this plug is
2. If a loose rocker arm stud is being located at the outer edge of the flange.
replaced, ream the stud bore using the The flange on cup-type plugs flares
proper reamer (or reamers in outward with the largest diameter at the
sequence) for the selected oversize outer (sealing) edge.
stud (Fig. 22). Make sure the metal
It is imperative to install the plug in
particles do not enter the valve area.
the machined bore using a properly
Coat the end of the stud with
designed tool. Under no circumstances is
Lubriplate or equivalent. Align the
the plug to be driven into the bore; using
stud and installer T69P-6049-D with
a tool that contacts the flange. This
the stud bore, then tap the sliding
method will damage the sealing edge and
driver until it bottoms (Fig. 23).
will result in leakage and/or plug blow
When the installer contacts the stud
out. The flanged (trailing) edge must be
boss, the stud is installed to its correct
below the chamfered edge of the bore to
height.
effectively seal the plugged bore. If the
CORE PLUGS core plug replacing tool has a depth
POSITIVE STOP TYPE STUDffl|A3-j
Removal seating surface, do not seat the tool-
To remove a large core plug, drill a FIG. 23 Installing Rocker Arm Stud
against a non-machined (casting) surface.
1/2-inch hole in the center of the plug
and remove with a clutch pilot bearing SEALING
puller (Tool T59L-1OO-B and T58L-1OO- EDGE
BEFORE
A) or pry it out with a large drift punch. INSTAL LATION
On a small core plug, drill a 1/4-inch hole
in the center of the plug and pry it out
with a small pin punch. Clean and inspect
the plug bore.
Prior to installing a core plug the plug
bore should be inspected for any damage
that would interfere with the proper
sealing of the plug. If the bore is damaged
it will be necessary to true the surface by xxxxxxxxxxxxxxxxxxxxxxxxxxxxyyyyyyyy
boring for the next specified oversize
plug.
Oversize (OS) plugs are identified by
the OS stamped in the flat located on the
cup side of the plug.
Coat the plug and/or' bore lightly
with an oil-resistant (oil galley) or water-
resistant (cooling jacket) sealer and
install it following the procedure for cup
type or expansion type?

EXPANSION TYPE CORE

PLUG REPLACER TOOL

I A2912-A
A3217-B
FIG. 22 Reaming Rocker Arm Stud
Bore FIG. 24 Typical Core Plugs and Installation Tools
214)1-11
Expansion-Type
Expansion-type core plugs (Fig. 24)
are installed with the flanged edge
inward. The maximum diameter of this
plug is located at the base of the flange
with the flange flaring inward.
It is imperative to push or drive the
plug into the machined bore by using a
properly designed tool. Under no
circumstances is the plug to be driven
using a tool that contacts the crowned
portion of the plug. This method will
expand the plug prior to installation and
may damage the plug and/or plug bore.
When installed, the trailing (maximum)
diameter must be below the chamfered
edge of the bore to effectively seal the
plugged bore. If the core plug replacing
tool has a depth seating surface, do not
seat the tool against a non-machined
(casting) surface.
FLYWHEEL RING GEAR—
MANUAL-SHIFT TRANSMISSION
Removal
To replace a damaged or worn ring
gear, heat the ring gear with a blow torch
on the engine side of the gear, and knock
it off theflywheel.Do not hit the flywheel
when removing the ring gear.
Installation
Heat the new ring gear evenly until
the gear expands enough to slip onto the
flywheel. Make sure the gear is seated
properly against the shoulder. Do not
heat any portion of the gear to a
temperature higher than 500 degrees F.
If this limit is exceeded, the temper will
be removed from the ring gear teeth.
CRANKSHAFT REAR OIL SEAL—
EXCEPT 2.8L ENGINE
A split-lip type crankshaft rear oil
seal is provided for servicing all car
engines except the above. The complete
seal may be replaced without removing
the crankshaft (Fig. 25).
Removal
1. Remove the oil pan and the oil pump
(if required).
2. Loosen all the main bearing cap bolts,
thereby lowering the crankshaft
slightly but not to exceed 1/32 inch.
3. Remove the rear main bearing cap,
and remove the oil seal from the
bearing cap and cylinder block. On
the block half of the seal use a seal
removal tool, or install a small metal
screw in one end of the seal, and pull
on the screw to remove the seal.
Exercise caution to prevent
scratching or damaging the
crankshaft seal surfaces.
4. Remove the oil seal retaining pin from
the bearing cap if so equipped. The
pin is not used with the split-lip seal.
General Gasoline Engine Service
Installation
1. Carefully clean the seal grooves in the
cap and block with a brush and
solvent such as lacquer thinner,
chlorothane or tri-chlor-ethylene.
Also clean the area where sealer is
later to be applied (Fig. 26). Dry the
area thoroughly, so no solvent
touches the seal.
2. Dip the split-lip type seal halves in the
clean engine oil.
3. Carefully install the upper seal
(cylinder block) into its groove with
undercut side of seal toward the
FRONT of the engine (Fig. 25), by
rotating it on the seal journal of the
crankshaft until approximately 3/8
inch protrudes below the parting
surface.
Be sure no rubber has been shaved
from the outside diameter of the seal
by the bottom edge of the groove. Do
not allow oil to get on the sealer area
(Fig. 26).
4. Tighten the bearing cap bolts and
torque to specifications.
5. Install the lower seal in the rear main
bearing cap with undercut side of seal
toward the FRONT of the engine
(Fig. 25). Allow the seal to protrude
approximately 3/8-inch above the
parting surface to mate with the
upper seal when the cap is installed.
On 2.3L engines, install the seals
so that the locating tab faces the rear
of the engine (Fig. 27).
6. Apply an even 1/16 inch bead of RTV
silicone rubber sealer to the areas
shown in Fig. 26, following the
procedure given in the illustration.
3-'8"
_u
SEAL HALVES TO PROTRUDE BEYOND PARTING FACES
THIS DISTANCE TO ALLOW FOR CAP TO BLOCK ALIGNMENT
REAR FACE OF REAR MAIN
BEARING CAP AND CYLINDER BLOCK
FIG. 25 Installing Crankshaft Rear Oil Seal
21-01-11
NOTE: This sealer sets up in 15
minutes. Install the rear main bearing
cap. T o r q u e the cap bolts to
specifications.
7. Install the oil pump and oil pan. Fill
the crankcase with the proper amount
and viscosity oil.
8. Operate the engine and check for oil
leaks.
CRANKSHAFT REAR OIL SEAL—
2.8L ENGINE
Removal
1. Remove the transmission assembly.
Remove clutch pressure plate and
clutch disc, if so equipped.
2. Remove the flywheel and rear plate.
3. Use an awl to punch two holes in the
crankshaft rear oil seal. Punch the
holes on opposite sides of the
crankshaft and just above the bearing
cap to cylinder block split line. Install
a sheet metal screw in each hole (Fig.
28). Use two large screwdrivers or
small pry bars and pry against both
screws at the same time to remove the
crankshaft rear oil seal. It may be
necessary to place small blocks of
wood against the cylinder block to
provide a fulcrum point for the pry
bars. Use caution throughout this
procedure to avoid scratching or
otherwise damaging the crankshaft
oil seal surface.
4. Clean the oil seal recess in the
cylinder block and main bearing cap.
Inspect and clean the oil seal contact
surface on the crankshaft, following
the procedure in this Part. •
INSTALL SEAL WITH LIP
TOWARDS FRONT OF ENGINE
FRONT OF ENGINE
VIEW LOOKING AT PARTING FACE
OF SPLIT, LIP-TYPE CRANKSHAFT SEAL
A2639-C
21-01-12 General Gasoline Engine Service 21-01-12

Installation
1. Coat the oil seal to cylinder block FROM FORWARD FACE
surface of the oil seal with oil. Coat OF SLINGER GROOVE
TO REAR FACE OF
the seal contact surface of the oil seal BLOCK-
and crankshaft with Lubriplate or
equivalent. Start the seal in the recess
and install it with the tool as shown
in Fig. 29. Drive the seal into position
until it is firmly seated.
2. Install the rear plate and the flywheel.
T i g h t e n f l y w h e e l b o l t s to APPLY 1/16" DIA BEAD OF
C3AZ-19526-A(OR-B) SEALER IN
specification. SHADED AREA OF CYLINDER BLOCK
PRIOR TO ASSEMBLY OF BEARING
3. Install the clutch disc and clutch CAP- (BOTH SIDES)
pressure plate, if so equipped. Align DO NOT PERMIT SEALER LEAVE 1/8 GAP
TO GET ON I.D. OF SPLIT LIP FOR SEALCR
clutch disc before tightening pressure SEAL EXPANSION
plate attaching screws.
4. Install the flywheel housing. APPLY 1/16" DIA BEAD OF C3AZ-19526-A(OR-B)
SEALER AS INDICATED ON BEARING
5. Install the transmission. CAP - (BOTH SIDES)

SEALER APPLICATION SKETCH

SPLIT LIP TYPE SEAL SHOWN
BASIC APPLICATION AREAS FOR
OTHER SEAL INSTALLATIONS
ARE THE SAME.

A:i724-B

FIG. 26 Applying RTV Sealer To Main Bearing Cap and Block—Typical for 6
and 8-Cylinder Engines
21-01-13 General Gasoline Engine Service 21-01-13

REAR BEARING CAP

DIP SEALS IN ENGINE

OIL BEFORE INSTALLING

REAR OIL SEAL

UPPER AND LOWER SEAL

ENDS TO BE FLUSH IN
BLOCKANDCAP

SEALER NOTE: CLEAN THE AREA WHERE SEALER

IS TO BE APPLIED BEFORE INSTALLING THE SEALS.
USE FORD SPOT REMOVER B7A-19521-A OR EQUIVALENT.
AFTER THE SEALS ARE IN PLACE, APPLY A 1/16 INCH
BEAD OF C3AZ-19562-A OR -B SEALER AS SHOWN.
SEALER MUST NOT CONTACT SEALS.

A3761-B

FIG. 27 Rear Oil Seal Installation—2.3L Engine

A3574-A
A3575-B

FIG. 28 Removing Crankshaft Rear FIG. 29 Installing Crankshaft Rear

Oil Seal—2.8L Engine Oil Seal—2.8L
21-01-14
OVERHAUL
INTERPRETATION OF "SERVICE
LIMIT" SPECIFICATIONS
"Service Limit" specifications shown
in each engine Part are intended to be a
guide only, to be used when overhauling
or reconditioning an engine or engine
component. A determination can be made
whether a component is suitable for
continued service or should be replaced
for extended service while the engine is
disassembled.
In the case of "Valve Stem To Valve
Guide Clearance," the "Service
Clearance" is intended as an aid in
diagnosing engine noise only, and does
not constitute a failure or indicate need
for repair. However, when overhauling or
reconditioning a cylinder head, the
service clearance should be regarded as
a practical working value, and used as a
determinant for installing the next
oversize valve to assure extended service
life.
CYLINDER HEAD
Replace the head if it is cracked. Do
not plane or grind more than 0.010 inch
from the cylinder original head gasket
surface. Remove all burrs or scratches
with an oil stone.
Reaming Valve Guides
If it becomes necessary to ream a
valve guide (Fig. 30) to install a valve
with an oversize stem, a reaming kit is
available which contains the following
reamer and pilot combinations: a 0.003-
inch OS reamer with a standard diameter
pilot, a 0.015-inch OS reamer with a
0.003-inch OS pilot, and a 0.030-inch
reamer with a 0.015-inch OS pilot.
When going from a standard size
valve to an oversize valve always use the
reamer in sequence. Always reface the
valve seat after the valve guide has been
reamed, and use a suitable scraper to
break the sharp corner (ID) at the top of
the valve guide.
Refacing Valve Seats
Refacing of the valve seat should be
closely coordinated with the refacing of
the valve face so that the finished seat and
valve face will be concentric and the
specified interference angle will be
maintained. This is important so that the
valve and seat will have a compression-
tight fit. Be sure that the refacer grinding
wheels are properly dressed.
Grind the valve seats of all engines to
a true 45 degree angle (Fig. 31). Remove
only enough stock to clean up pits and
grooves or to correct the valve seat
runout. After the seat has been refaced,
use a seat width scale or a machinist scale
to measure the seat width (Fig. 32).
Narrow the seat, if necessary to bring it
within specifications.
General Gasoline Engine Service 21-01-14
If the valve seat width exceeds the are available for service for all engines
maximum limit, remove enough stock except 23OOcc and 28OOcc. For these
from the top edge and/or bottom edge of engines, oversize valve stems are
the seat to reduce the width to available in diameters of 0.008, 0.016,
specifications. and 0.032 inch oversize. Always reface
On the valve seats of all engines, use the valve seat after the valve guide has
a 60 degree angle grinding wheel to been reamed. Refer to Reaming Valve
remove stock from the bottom of the Guides.
seats (raise the seats) and use a 30 degree
angle wheel to remove stock from the top
of the seats (lower the seats).
The finished valve seat should contact
the approximate center of the valve face.
It is good practice to determine where the
valve seat contacts the face. To do this,
coat the seat with Prussion blue and set
the valve in place. Rotate the valve with
light pressure. If the blue is transferred
to the center of the valve face, the contact
is satisfactory. If the blue is transferred
to the top edge of the valve face, lower
the valve seat. If the blue is transferred
to the bottom edge of the valve face, raise
the valve seat.
VALVES
Minor pits, grooves, etc., may be
removed. Discard valves that are severely
damaged, if the face runout cannot be
corrected by refinishing or stem
clearance exceeds specifications. Discard
any excessively worn or damaged valve
train parts.
Refacing Valves
The valve refacing operation should
be closely coordinated with the valve seat FIG. 30 Reaming Valve Guides-
refacing operations so that the finished Cylinder Shown
angles of the valve face and of the valve
seat will be to specifications and provide T O REMOVE STOCK TO REMOVE
a compression-tight fit. Be sure that the
FROM TOP OF SEAT, STOCK FROM
USE 3 0 ° WHEEL BOTTOM OF SEAT,
refacer grinding wheels are properly USE 6 0 ° WHEEL
dressed.
If the valve face runout is excessive
and/or to remove pits and grooves, reface
the valves to a true 44 degree angle.
Remove only enough stock to correct the
runout or to clean up the pits and
grooves. If the edge of the valve head is
less than 1/32 inch thick after grinding
(Fig. 33), replace the valve as the valve A2897-B
will run too hot in the engine. The FIG. 31 Refacing Valve Seat
interference angle of the valve and seat
should not be lapped out. Remove all
grooves or score marks from the end of
the valve stem, and chamfer it as
necessary. Do not remove more than
0.010 inch from the end of the valve stem.
If the valve and/or valve seat has been
refaced, it will be necessary to check the
clearance between the rocker arm pad
and the valve stem with the valve train
assembly installed in the engine.
Select Fitting Valves
If the valve stem to valve guide
clearance exceeds the service clearance,
ream the valve guide for the next oversize
valve stem. Valves with oversize stem
diameters of 0.003, 0.015 and 0.030 inch FIG. 32 Checking Valve Seat Width
21-01-15
CAMSHAFT REPAIR
Remove light scuffs, scores or nicks
from the camshaft machined surfaces
with a smooth oil stone.
PISTONS, PINS AND RINGS
Fitting Pistons
Pistons are available for service in
standard sizes and the oversizes shown in
Specification section at the end of each
engine Part.
The standard size pistons are color
coded red or blue, or have 0.003 OS
stamped on the dome. Refer to the
Specifications for standard size piston
dimensions.
Measure the cylinder bore and select
the piston to assure the proper clearance.
When the bore diameter is in the lower
one third of the specified range, a red
piston should be used. When the bore
diameter is in the middle one third a blue
piston should be used. When the bore
diameter is in the upper one third the
0.003 OS piston should be used.
Measure the piston diameter to
ensure that the specified clearance is
o b t a i n e d . It may be n e c e s s a r y
periodically to use another piston (within
the same grade size) that is either slightly
larger, or smaller to achieve the specified
clearance. If none can be fitted, refinish
the cylinder to provide the proper
clearance for the piston. When a piston
has been fitted, mark it for assembly in
the cylinder to which it was fitted. If the
taper, out-of-round and piston to cylinder
bore clearance conditions of the cylinder
bore are within specified limits, new
piston rings will give satisfactory service.
If new rings are to be installed in a used
cylinder that has not been refinished,
remove the cylinder wall glaze (Refer to
Cylinder Block, Refinishing Cylinder
Walls). Be sure to clean the cylinder bore
thoroughly.
1. Calculate the size piston to be used by
taking a cylinder bore check. Follow
the procedures outlined under
Cleaning and Inspection.
2. Select the proper size piston to
provide the desired clearance (refer to
the specifications). Measure the
piston diameter in line with the
centerline of the piston pin and at 90
degrees to the piston pin axis.
3. Make sure the piston and cylinder
block are at room temperature (70
degrees F.). After any refinishing
operation allow the cylinder bore to
cool, and make sure the piston and
bore are clean and dry before the
piston fit is checked.
Fitting Piston Rings
1. Select the proper ring set for the size
cylinder bore.
General Gasoline Engine Service 21-01-15
2. Position the ring in the cylinder bore obtained with a standard bearing, try
in which it is going to be used. one half of a 0.001 or 0.002 inch
3. Push theringdown into the bore area undersize in combination with a
where normal ring wear is not standard bearing to obtain the proper
encountered. clearance.
4. Use the head of a piston to position 2. Iffittinga main bearing in the vehicle,
the ring in the bore so that the ring position a jack under counterweight
is square with the cylinder wall. Use adjoining bearing which is being
caution to avoid damage to the ring checked. Support crankshaft with
or cylinder bore. jack so its weight will not compress
5. Measure the gap bet wen the ends of Plastigage and provide an erroneous
the ring with a feeler gauge (Fig. 34). reading.
If the ring gap is less or greater than
the specified limits, try another ring
set.
6. Check the ring side clearance of the
compression rings with a feeler gauge
inserted between the ring and its
lower land (Fig. 35). The gauge
should slide freely around the entire FOR DIMENSIONS
ring circumference without binding. REFER TO
SPECIFICATIONS
Any wear that occurs will form a step
at the inner portion of the lower land.
If the lower lands have high steps, the
piston should be replaced.
1/32" M I N I M U M
Fitting Piston Pins
Install the piston pin, following the
procedure under Piston Assembly in the
applicable engine part.
A3453-A
CRANKSHAFT FIG. 33 Critical Valve Dimensions
Dress minor scores with an oil stone.
If the journals are severely marred or
exceed the wear limit, they should be
refinished to size for the next undersize
bearing.
Refinishing Journals
Refinish the journals to give the
proper clearance with the next undersize
bearing. If the journal will not clean up
to maximum undersize bearing available,
replace the crankshaft.
Always reproduce the same journal
shoulder radius that existed originally.
Too small a radius will result in fatigue
failure of the crankshaft. Too large a __ A2902-B
radius will result in bearing failure due
to radius ride of the bearing. FIG. 34 Checking Piston Ring Gap
After refinishing the journals,
chamfer the oil holes; then polish the
journal with a No. 320 grit polishing
cloth and engine oil. Crocus cloth may
also be used as a polishing agent.
FITTING M A I N OR CONNECTING
ROD BEARINGS WITH
PLASTIGAGE
1. Clean crankshaft journals. Inspect
journals and thrust faces (thrust
bearing) for nicks, burrs or bearing
pickup that would cause premature
bearing wear. When replacing
standard bearings with new bearings, A1020-B
it is good practice to fit the bearing
to minimum specified clearanpe. If FIG. 35 Checking Piston Ring- Side
the desired clearance cannot be Clearance
21-01-16
3. Place a piece of Plastigage on bearing
surface across full width of bearing
cap and about 1/4 inch off center
(Fig. 36).
4. Install cap and torque bolts to
specifications. Do not turn crankshaft
while Plastigage is in place.
5. Remove cap. Using Plastigage scale,
check width of Plastigage at widest
point to get minimum clearance.
Check at narrowest point to get
maximum clearance. Difference
between readings is taper of journals.
6. If clearance exceeds specified limits,
try 0.001 or 0.002 inch undersize
bearings in combination with the
standard bearings. Bearing clearance
must be within specified limits. If
0.002 undersize main bearings are
used on more than one journal, be
sure they are all installed in cylinder
block side of bearing. If standard and
0.002 inch undersize bearings do not
bring clearance within desired limits,
refinish crankshaft journal, then
install undersize bearings.
7. After bearing has been fitted, apply
light coat of engine oil to journal and
bearings. Install bearing cap. Torque
cap bolts to specifications.
8. Repeat procedure for remaining
bearings that require replacement.
CYLINDER BLOCK
Refinishing Cylinder Walls
Honing is recommended for
refinishing cylinder walls only when the
walls have minor scuffs or scratches, or
for fitting pistons to the specified
clearance. The grade of hone to be used
is determined by the amount of metal to
be removed. Follow the instructions of
the hone manufacturer. If coarse stones
are used to start the honing operation,
leave enough material so that all hone
marks can be removed with the finishing
hone which is used to obtain the proper
piston clearance.
Cylinder walls that are severely
marred and/or worn beyond the specified
limits should be refmished. Before any
cylinder is refinished, all main bearing
caps must be in place and tightened to the
proper torque so that the crankshaft
bearing bores will not become distorted
from the refinishing operation. Refinish
only the cylinder or cylinders that require
it. All pistons are the same weight, both
standard and oversize; therefore, various
sizes of pistons can be used without
upsetting engine balance. Refinish the
cylinder with the most wear first to
determine the maximum oversize. If the
cylinder will not clean up when
refinished for the maximum oversize
piston recommended, replace the block.
Refinish the cylinder to within
approximately 0.0015 inch of the
General Gasoline Engine Service
required oversize diameter. This will
allow enough stock for the final step of
honing so that the correct surface finish
and pattern are obtained. For the proper
use of the refinishing equipment follow
the instructions of the manufacturer.
Only experienced personnel should be
allowed to perform this work. Use a
motor-driven, spring pressure-type hone
at a speed of 300-500 rpm. Hones of grit
sizes 180-220 will normally provide the
desired bore surface finish of 15/32 RMS.
When honing the cylinder bores use
a lubricant mixture of equal parts of
kerosene and SAE No. 20 motor oil.
Operate the hone in such a way to
produce a cross-hatch finish on the
cylinder bore. The cross-hatch pattern
PLACE Plastigage FULL CHECK WIDTH OF
WIDTH OF J O U R N A L , ^ ^ Plastigage
ABOUT VA INCH
OFF CENTER
MEASURING
INSTALLING « 0.0015" Plastigage
CLEARANCE
Plastigage
A2868-A
FIG. 36 Installing and Measuring
Plastigage
SHADED AREAS MAY BE REPAIRED WITH EPOXY
FRONT AND L E F T SIDE
TYPICAL FOR 6-CYUNDER ENGINE
REAR AND RIGHT SIDE
FIG. 37 Typical Cast Iron Cylinder Block Areas Repairable with Metallic Plastic
21-01-16
should be at an angle of approximately
30 degrees to the cylinder bore. After the
final operation in either of the two
refinishing methods described ami prior
to checking the piston fit, thoroughly
clean and oil the cylinder walls. Mark the
pistons to correspond to the cylinders in
which they are to be installed. When the
refinishing of all cylinders that require it
has been completed and all pistons are
fitted, thoroughly clean the entire block
and oil the cylinder walls.
Repairing Sand Holes or Porous
Engine Castings
Porosity or sand hole(s) whish will
cause oil seepage or leakage can occur
with modern casting processes. A
complete inspection of engine and
transmission should be made. If the leak
is attributed to the porous condition of
the cylinder block or sand hole(s). repairs
can be made with metallic plastic (part
No. C6AZ-19544-A or equivalent). Do
not repair cracks with this material.
Repairs with this metallic plastic must be
confined to those cast iron engine
component surfaces (Fig. 37) where the
inner wall surface is not exposed to
engine coolant pressure or oil pressure,
for example:
1. Cylinder block surfaces extending
along the length of the block, upward
from the oil pan rail to the cylinder
water jacket but not including
machined areas.
2. Lower rear face of the cylinder block.
3. Intake manifold casting. Repairs are
not recommended to the intake
FRONT AND LEFT SIDE
TYPICAL FOR V-8 ENGINE
REAR AND RIGHT SIDE
A2386-C
21-01-17
manifold exhaust crossover section,
since temperatures can exceed the
recommended temperature limit of
500 degrees F.
4. Cylinder front cover on engines using
cast iron material.
5. Cylinder head, along the rocker arm
cover gasket surface.
The following procedure should be
used to repair porous areas or sand holes
in cast iron.
1. Clean the surface to be repaired by
grinding or rotary filing to a clean
bright metal surface. Chamfer or
undercut the hole or porosity to a
greater depth than the rest of the
cleaned surface. Solid metal must
surround the hole. Openings larger
than 1/4 inch should not be repaired
using metallic plastic. Openings in
excess of 1/4 inch can be drilled,
tapped and plugged using common
tools. Clean the repair area
thoroughly. Metallic plastic will not
stick to a dirty or oily surface.
2. Mix the metallic plastic base and
hardener as directed on the container.
Stir thoroughly until uniform.
3. Apply the repair mixture with a
suitable clean tool, (putty knife, wood
spoon, etc.) forcing the epoxy into the
hole or porosity.
4. Allow the repair mixture to harden.
This can be accomplished by two
methods, heat cure with a 250 degree
watt lamp placed 10 inches from the
repaired surface, or air dry for 10-12
hours at temperatures above 50
degrees F.
5. Sand or grind the repaired area to
blend with the general contour of the
surrounding surface.
6. Paint the surface to match the rest of
the block.
CLEANING AND INSPECTION
The cleaning and inspection
procedures are for a complete engine
overhaul; therefore, for partial engine
overhaul or parts replacement, follow the
pertinent cleaning or inspection
procedure.
Intake Manifold
Cleaning
Remove all gasket material from the
machined surfaces of the manifold. Clean
the manifold in a suitable solvent and dry
it with compressed air.
Inspection
Inspect the manifold for cracks,
damaged gasket surfaces, or other defects
that would make it unfit for further
service. Replace all studs that are
stripped or otherwise damaged. Clean the
EGR exhaust passages. Remove all
filings and foreign matter that may have
entered the manifold as a result of
repairs. Check the baffle plate on the
General Gasoline Engine Service
underside of the manifold if so equipped.
The baffle should be securely fastened at
all attaching points.
Exhaust Manifolds
Cleaning
Remove all gasket material from the
manifolds.
On the right exhaust manifold of the
V-8 engines, make sure the automatic
choke air inlet and outlet holes are
completely open and the cover does not
leak (if so equipped).
Inspection
Inspect the cylinder head joining
flanges of the exhaust manifold(s) for
evidence of exhaust gas leaks.
Inspect the manifolds for cracks,
damaged gasket surfaces, or other defects
that would make them unfit for further
service.
Valve Rocker Arm and/or Shaft
Assembly
Cleaning
Clean all the parts thoroughly. Make
sure all oil passages are open.
Make sure the oil passage in the push
rod end of the rocker arm is open.
Inspection
Inspect the shaft and the rocker arm
bore for nicks, scratches, scores or scuffs.
Replace any damaged parts.
Inspect the pad at the valve end of the
rocker arm for indications of scuffing or
abnormal wear. If the pad is grooved,
replace the rocker arm. Do not attempt
to true this surface by grinding. On stud-
mounted rocker arms, check the rocker
arm pad, side rails and fulcrum seat for
excessive wear, cracks, nicks or burrs.
Check the rocker arm stud and nut for
stripped or broken threads. On positive
stop rocker arm stud nuts, check the
shoulder for damage as shown in Fig. 38.
Replace all damaged nuts.
On pedestal mounted rocker arms,
check the rocker arm pad and fulcrum
seat for excessive wear, cracks, nicks or
burrs. Replace all damaged rocker arms.
Push Rods
Cleaning
Clean the push rods in a suitable
solvent. Blow out the oil passage in the
push rod with compressed air.
Inspection
Check the ends of the push rods for
nicks, grooves, roughness or excessive
wear. Replace damaged push rods.
The push rods can be visually checked
for straightness while they are installed
in the engine by rotating them with the
valve closed. They also can be checked
with a dial indicator (Fig. 39).
If the push rod is bent beyond
specifications, it should be replaced.
21-01-17
Cylinder Heads
Cleaning
With the valves installed to protect
the valve seats, remove deposits from the
combustion chambers and valve heads
with a scraper and a wire brush. Be
careful not to damage the cylinder head
gasket surface. After the valves are
removed, clean the valve guide bores. Use
cleaning solvent to remove dirt, grease
and other deposits. Clean all bolt holes.
Remove all deposits from the valves with
a fine wire brush or buffing wheel.
Inspection
Check the cylinder head for cracks
and inspect the gasket surface for burrs
and nicks. Replace the head if it is
cracked.
The following inspection procedures
are for a cylinder head that is to be
completely overhauled. For individual
repair operations, use only the pertinent
inspection procedure.
When a cylinder head is removed
because of gasket leaks, check the flatness
of the cylinder head gasket surface (Fig.
40) for conformance to specifications. If
necessary to refinish the cylinder head
gasket surface, do not plane or grind off
more than 0.010 inch.
Check the valve seat runout with an
accurate gauge (Fig. 41). Follow the
instructions of the gauge manufacturer.
If the runout exceeds the wear limit,
reface the valve and valve seat. Measure
the valve seat width (Fig. 31). Reface any
valve seat whose width is not within
specifications.
OVER
1/16"
GOOD POOR
A3193-C
FIG. 38 Positive Stop Rocker Arm
Stud Nut
HoWih/fixhii* A1003-B
FIG. 39 Checking Push Rod Runout
21-01-18
The critical inspection points of the
valves are illustrated in Fig. 33. Refer to
the specifications for wear limits.
Inspect the stem for a bent condition
and the end of the stem for grooves or
scores. Check the valve head for signs of
burning, erosion, warpage and cracking.
Minor pits, grooves etc., may be
removed. Discard valves that are severely
damaged.
Inspect the valve spring, valve spring
retainers, locks and sleeves for wear or
damage. Discard any visually damaged
parts.
Check the valve stem to valve guide
clearance of each valve in its respective
valve guide with the tool shown in Fig.
42 or its equivalent. Use a flat end
indicator point.
0 ( g f c H E C K DIAGONALLY
CHECK ACROSS CENTER
A 2895-A
FIG. 40 Typical Cylinder Head
Flatness Check
Install the tool on the valve stem until
it is fully seated, and tighten the knurled
set screw firmly. Permit the valve to drop
away from its seat until the tool contacts
the upper surface of the valve guide.
Position the dial indicator with its flat
tip against the center portion of the tool's
spherical section at approximately 90
degrees to the valve stem axis. Move the
tool back and forth in line with the
indicator stem. Take a reading on the dial
indicator without removing the tool from
the valve guide upper surface. Divide the
reading by two, the division factor for the
tool.
Check the springs for proper pressure
(Fig. 43) at the specified spring lengths
(Tool-6513-DD). Manually rotating the
valve spring assemblies while installed in
the engine, must not be used to determine
good and/or bad valve springs. Weak
valve s p r i n g s c a u s e p o o r e n g i n e
performance. Replace any spring not
within specifications.
Check each spring for squareness,
using a steel square and a flat surface
(Fig. 44). Stand the spring and square on
end on the flat surface. Slide the spring
up to the square. Revolve the spring
slowly and observe the space between the
top coil of the spring and the square. The
out-of-square limits are 5/64-inch.
Follow the same procedure to check
new valve springs before installation.
Make certain the proper spring (Color
coded) is installed. Visually inspect the
valve spring retainer to determine if the
General Gasoline Engine Service 21-01-18
damper spring coil has been hitting the Camshaft
retainer. This interference will also cause Cleaning and Inspection
a clicking noise when the engine is Clean the camshaft in solvent and
operating. The damper spring is properly wipe it dry. Inspect the camshaft lobes for
installed in the valve spring when scoring and signs of abnormal wear. Lobe
positioned so that the end of the damper wear characteristics may result ir pitting
spring bottom coil is 135 degrees in the general area of the lobe toe. This
counterclockwise from the end of the pitting is not detrimental to the operation
valve spring lower coil. of the camshaft; therefore, the cimshaft
Hydraulic Valve Lifters and should not be replaced unless the lobe lift
Hydraulic Lash Adjusters loss has exceeded 0.005 inch.
The valve lifter (or lash adjusters) The lift of the camshaft lobes can be
assemblies should be kept in proper checked with the camshaft instilled in
sequence so that they can be installed in the engine or on centers. Refer to
their original position. Inspect and test Camshaft Lobe Lift.
each lifter separately so as not to intermix Check the distributor drive gear for
broken or chipped teeth. Replace the
the internal parts (see Fig. 45). If any part
camshaft if this condition exists
of the lifter assembly needs replacing,
replace the entire assembly. Oil Pan
Cleaning Cleaning
Thoroughly clean all the parts in Scrape any dirt or metal particles
clean solvent and wipe them with a clean, from the inside of the pan. Scrape all old
lint-free cloth. gasket material from the gasket surface.
Inspection
Inspect the parts and discard the
entire lifter assembly if any part shows
pitting, scoring, galling, excessive wear or
evidence of non-rotation. Replace the
entife assembly if the plunger is not free Runout Gauge x ^
in the body. The plunger should drop to
the bottom of the body by its own weight
when assembled dry.
Assemble the lifter assembly and
check for freeness of operation by
pressing down on the push rod cup. The
lifters can also be checked with a
hydraulic tester to test the leakdown rate.
Follow the instructions of the test unit
manufacturer or the procedure under
Diagnosis and Testing.
Timing Chain and Sprockets
Cleaning
Clean all parts in solvent and dry
them with compressed air. FIG. 41 Checking VaJve Seat Runout
Lubricate the timing chain with
engine oil before installing it on the
sprockets.
Inspection
Inspect the chain for broken links.
Inspect the sprockets for cracks and worn
or damaged teeth. Replace all the
components of the timing chain and
sprocket assembly, if any one item needs
replacement.
Fuel Pump Eccentric
Cleaning
Clean the fuel pump eccentric in
solvent and dry with compressed air.
Inspection
Inspect the fuel pump drive eccentric
for scores, nicks and excessive wear. If
the eccentric surface is scored, nicked or TOOL 6505-E 2.3L, 302, 351 AND 4 CID
TOOL 6505-F 460 CID
worn, replace it. TOOL 6505-G 2.8L, 200 AND 250 CID
On two-piece designs, inspect inner A3131-E
and outer rings for scoring, nicks, and
excessive wear. Replace any part FIG. 42 Checking Valve Stem
indicating scoring or excessive wear. Clearance
21-01-19
Wash the pan in a solvent and dry it
thoroughly. Be sure all foreign particles
are removed from below the baffle plate.
Check the pan for cracks, holes,
damaged drain plug threads, and a loose
baffle or a damaged gasket surface.
Inspect for damage (uneven surface)
at the bolt holes caused by over-torquing
the bolts. Straighten surfaces as required.
Repair any damage, or replace the pan if
repairs cannot be made satisfactorily.
Oil Pump
Cleaning
Wash all parts in a solvent and dry
them thoroughly with compressed air.
Use a brush to clean the inside of the
pump housing and the pressure relief
valve chamber. Be sure all dirt and metal
particles are removed.
Inspection
Refer to the specifications for
clearances and wear limits.
Check the inside of the pump housing
and the outer race and rotor for damage
or excessive wear.
Check the mating surface of the pump
cover for wear. If minor scuff marks are
normal, but if the cover mating surface
is worn, scored or grooved, replace the
cover. Inspect the rotor for nicks, burrs
or score marks. Remove all high points
by stoning.
Measure the outer race to housing
clearance (Fig. 46).
With the rotor assembly installed in
the housing, place a straight edge over the
rotor assembly and the housing. Measure
the clearance (rotor end play) between
the straight edge and the rotor and outer
race (Fig. 47). The outer race, shaft and
rotor are replaceable only as an
assembly. Check the drive shaft to
housing bearing clearance by measuring
the OD of the shaft and the ID of the
housing bearing. Inspect the relief valve
spring for a collapsed or worn condition.
Check the relief valve spring tension. If
the spring tension is not within
specifications and/or the spring is worn
or damaged replace the spring. Check the
relief valve piston for free operation in the
bore.
Connecting Rods
Remove the bearings from the rod
and cap. Identify the bearings if they are
to be used again. Clean the connecting
rod in solvent, including the rod bore and
the back of the inserts. Do not use a
caustic cleaning solution. Blow out all
passages with compressed air.
Inspection
The connecting rods and related parts
should be carefully inspected and
c h e c k e d for c o n f o r m a n c e to
specifications. Various forms of engine
General Gasoline Engine Service 21-01-19
APPLY TORQUE UNTIL
wear caused by these parts can be readily CLICK IS HEARD, READ
identified. Torque Wrench A N D
MULTIPLY READING
A shiny surface on either pin boss side BY TWO (2).
of the piston usually indicates that a
connecting rod is bent.
Abnormal connecting rod bearing
wear can be caused by either a bent
connecting rod, worn or damaged
crankpin, or a tapered connecting rod
bore. SET KNOB TO
COMPRESSED
Twisted connecting rods will not LENGTH OF
create an identifiable wear pattern, but SPRING
badly twisted rods will disturb the action A2917-C
of the entire piston, rings and connecting
rod assembly and may be the cause of FIG. 43 Checking Valve Spring
excessive oil consumption.
Pressure
Inspect the connecting rods for signs
of fractures and the bearing bores for out-
of-rourid and taper. If the bore exceeds
the recommended limits and/or if the NOT MORE
connecting rod is fractured, it should be THAN 5/64"
replaced. Check the ID of the connecting
rod piston pin bore. If the pin bore in the
c o n n e c t i n g rod is larger than
specifications, install a 0.001 inch
oversize piston pin. First, prefit the
oversize piston pin to the piston pin bore
by reaming or honing the piston to
provide 0.0002-0.0004 inch clearance
(light slip fit). Then, assemble the piston,
piston pin and connecting rod following 2900-1
the procedures for the specific engine
being worked on. It is not necessary to FIG. 44 Checking Valve Spring
ream or hone the pin bore in the Squareness
connecting rod. Replace damaged
connecting rod nuts and bolts. Check the PUSH ROD SOCKET
connecting rods for bend or twist on a METERING VALVE
suitable alignment fixture. Follow the CHECK VALVE
instructions of the fixture manufacturer.
If the bend and/or twist exceeds CHECK VALVE SPRING
specifications, the connecting rod must
be straightened or replaced. LOCK RING
Pistons, Pins and Rings
Cleaning PLUNGER
Remove deposits from the piston
surfaces. Clean gum or varnish from the CHECK VALVE
RETAINER
piston skirt, piston pins and rings with A2867-B
solvent. Do not use a caustic cleaning
solution or a wire brush to clean pistons. FIG. 45 Hydraulic Valve Lifter
Clean the ring grooves with a ring
groove cleaner (Fig. 48). Make sure the
oil ring slots (or holes) are clean.
Inspection
Carefully inspect the pistons for
fractures at the ring lands, skirts and pin
bosses, and for scuffed, rough or scored
skirts. If the lower inner portion of the
ring grooves has a high step, replace the
piston. The step will interfere with ring
operation and cause excessive ring side
clearance.
Spongy, eroded areas near the edge of
the top of the piston are usually caused
by detonation or pre-ignition. A shiny A1026-C
surface on the thrust surface of the
piston, offset from the centerline between FIG. 46 Checking Outer Race to
the piston pin holes, can be caused by a Housing Clearance
21-01-20
bent connecting rod. Replace pistons that
show signs of excessive wear, wavy ring
lands or fractures or damage from
detonation or pre-igniton.
Check the piston to cylinder bore
clearance by measuring the piston and
bore d i a m e t e r s . Refer to the
specifications for the proper clearance.
Refer to Cylinder Block Inspection for
the bore measurement procedure.
Measure the OD of the piston with
micrometers at the centerline of the
piston pin bore and at 90 degrees to the
pin bore axis. Check the ring side
clearance following the procedure under
Fitting Piston Rings in this section.
Replace piston pins showing signs of
fracture, etching or wear. Check the
piston pin fit in the piston and rod. Refer
to Piston and Connecting Rod Assembly,
in the pertinent engine section.
Check the OD of the piston pin and
the ID of the pin bore in the piston.
Replace any piston pin or piston that is
not within specifications.
Replace all rings that are scored,
broken, chipped or cracked. Check the
end gap and side clearance. Rings should
not be transferred from one piston to
another regardless of mileage.
Main and Connecting Rod
Bearings
Cleaning
Clean the bearing inserts and caps
thoroughly in solvent, and dry them with
compressed air. Do not scrape gum or
varnish deposits from the bearing shells.
Inspection
Inspect each bearing carefully.
Bearings that have a scored, chipped or
worn surface should be replaced. Typical
examples of unsatisfactory bearings and
their causes are shown in Fig. 49. The
copper lead bearing base may be visible
through the bearing overlay. This does
not mean that the bearing is worn. It is
not necessary to replace the bearing if the
bearing clearance is within recommended
limits. Check the clearance of bearings
that appear to be satisfactory with
Plastigage as detailed under Main and
Connecting Rod Bearings.
Crankshaft
Cleaning
Handle the crankshaft with care to
avoid possible fractures or damage to the
finished surfaces. Clean the crankshaft
with solvent, then blow out all oil
passages with compressed air.
Inspection
Inspect the main and connecting rod
journals for cracks, scratches, grooves or
scores. Inspect the crankshaft oil seal
surface for nicks, sharp edges or burrs
that might damage the oil seal during
installation or cause premature seal wear.
General Gasoline Engine Service
Measure the diameter of each journal
in at least four places to determine an
out-of-round, taper or undersize
condition (Fig. 50).
Inspect the pilot bearing (roller
bearing) when so equipped, for
roughness, evidence of overheating or
loss of lubricant. Replace it if any of these
conditions are found.
Crankshaft Vibration Damper
and Sleeve
Cleaning
Clean the oil seal contact surface on
the crankshaft damper or sleeve with
Straight Edge
Feeler Gauge lik
A1027-
FIG. 47 Checking Rotor End Play
Ring Groove Cleaner
A2918-B
FIG. 48 Cleaning Piston Ring
Grooves
OVERLAY GONE
FROM ENTIRE SURFACE
TAPERED JOURNAL
FIG. 49 Typical Bearing Failures
21-01-20
solvent to remove any corrosion, sludge
or varnish deposits. Excess deposits that
are not readily removed with solvent may
be removed with crocus cloth. Use crocus
cloth to remove any sharp edges or burrs
which might damage the oil seal during
installation or cause premature sea] wear.
Do not use crocus cloth to the extent that
the seal surface becomes polished. A
finely polished surface may produce poor
sealing or cause premature seal wear.
Inspection
Inspect the crankshaft damper seal
surface for nicks, sharp edges or burrs
that might damage the oil seal during
installation or cause premature sea.1 wear.
Flywheel—Manual-Shift
Transmission
Inspection
Inspect the flywheel for cracks, heat
check, or other damage that would make
it unfit for further service. Machine the
friction surface of the flywheel if it is
scored or worn. If it is necessary to
remove more than 0.045 inch of stock
from the original thickness, replace the
flywheel.
Inspect the ring gear for worn,
chipped, or cracked teeth. If the teeth are
damaged, replace the ring gear.
With the flywheel installed on the
crankshaft, check the flywheel face
runout, following the procedure under
Diagnosis and Testing.
Flywheel—Automatic
Transmission
Inspection
Inspect the flywheel for crucks or
other defects that would make it unfit for
further service. Inspect the flywheel ring
gear for worn, chipped or cracked teeth.
If the teeth are damaged, replace the ring
gear and flywheel assembly.
With the flywheel installed on the
crankshaft, check the gear face runout.
RADIUS RIDE CRATERS OR POCKETS
RADIUS RIDE FATIGUE FAILURE
A2903-A
21-01-21
Cylinder Block
Cleaning
After any cylinder bore repair
operation, such as honing or deglazing,
clean the bore(s) with soap or detergent
and water. Then, thoroughly rinse the
bore(s) with clean water to remove the
soap or detergent, and wipe the bore(s)
dry with a clean, lint-free cloth. Finally
wipe the bore(s) with a clean cloth dipped
in engine oil. If these procedures are not
followed rusting of the cylinder bore(s)
may occur.
If the engine is disassembled,
thoroughly clean the block with solvent.
Remove old gasket material from all
machined surfaces. Remove all pipe
plugs that seal oil passages; then clean out
all the passages. Blow out all passages,
bolt holes, etc., with compressed air.
Make sure the threads in the cylinder
head bolt holes are clean. Dirt in the
threads may cause binding and result in
a false torque reading. Use a tap to true-
up threads and to remove all deposits.
Thoroughly clean the grooves in the
crankshaft bearings and bearing
retainers.
Inspection
After the block has been thoroughly
cleaned, check it for cracks. Minute
cracks not visible to the naked eye may
be detected by coating the suspected area
with a mixture of 25 percent kerosene
General Gasoline Engine Service 21-01-21
and 75 percent light engine oil. Wipe the AVS B = = VERTICAL TAPER
part dry and immediately apply a coating CVS D = HORIZONTAL TAPER
AVS CANDBVS D = = OUT-OF-ROUND
of zinc oxide dissolved in wood alcohol. CHECK FOR OUT-OF-ROUND AT
If cracks are present, the coating will EACH END OF JOURNAL
become discolored at the defective area.
Replace the block if it is cracked.
Check all machined gasket surfaces
for burrs, nicks, scratches and scores.
Remove minor imperfections with an oil
stone.
Replace all expansion-type plugs that
show evidence of leakage.
Inspect the cylinder walls for scoring,
roughness, or other signs of wear. Check
the cylinder bore for out-of-round and FIG. 50 Crankshaft Journal
taper. Measure the bore with an accurate Measurement
bore gauge following the instructions of
-•—CENTER LINE OF ENGINE
the manufacturer. Measure the diameter
of each cylinder bore at the top, middle
and bottom with the gauge placed at right
angles and parallel to the centerline of the
engine (Fig. 51). Use only the
measurements obtained at 90 degrees to
the engine centerline when calculating
the piston to cylinder bore clearance.
Refinish cylinders that are deeply
scored and/or when out-of-round and/or
taper exceed the wear limits. If the
cylinder walls have minor surface
1. OUT-OF-ROUND = DIFFERENCE BETWEEN
imperfections, but the out-of-round and A AND B
taper are within limits, it may be possible 2. TAPER = DIFFERENCE BETWEEN THE A
to remove the imperfections by honing MEASUREMENT AT TOP OF
the cylinder walls and installing new CYLINDER BORE AND THE A
service piston rings providing the piston MEASUREMENT AT BOTTOM OF
clearance is within specified limits. CYLINDER BORE A 2905-A
FIG. 51 Cylinder Bore Out-of-Round
and Taper
21-01-22 General Gasoline Engine Service 21-01-22

SPECIAL SERVICE TOOLS

SPECIAL SERVICE TOOLS

Application Engine Size

2300 2800
Ford Tool Former CC CC 200/ 302-351-W 351 M& 460
Description No. No. Four V-6 250 Six V-8 400 V-8 V-8

Hydraulic Lifter Remover T70P-14151 X X X X X

Crankshaft Front Seal Installing Tool T70P-6B070-A X
Crankshaft Front Seal Removing Tool T70P-6B070-B X
Impact Hammer T50T-100-A X X X X
Puller Attachment Use with
T50T-100-AorT59L-100-B T58L-101-A X X X X
Handle Adapter T53L-200-A X X X X
Differential Backlash and
Runout Gauge, with Universal
Bracket and Dial Indicator
(1-1/4 inch range). Includes
Indicator TOOL-6565 TOOL-4201-C X X X X X X
Engine Lifting Hook T60K-6000-A 200
Engine Lifting Hook T65L-6000-A X
Engine Lifting Brackets T58P-6000-A X X X
Cam Bearingjtore Plug Installing Tool T70P-6001-A X
Core Plug Replacer T54L-6015-A 200
Cylinder Front Cover Pilot T61P-6019-B 6059-F 200
Front Cover Alignment Tool T61K-6019-A X
Cylinder Front Cover Pilot T68P-6019-A X
Valve Spring Compressor, on Engine T70P-6049-A X X
Valve Guide Reamer Kit T52L-6085-AEE X X X
Engine Lifting and Head Holding Brackets * * T62F-6085-A 6005-BDA X
Piston Pin Remover and Replacer Kit T68P-6135-A X x+ X X X
Camshaft Bearings Remover and
Replacer Adapters T65L-6250-A T52L-6261-CEE X X X X
Camshaft Rear Bearing Bore
Plug Replacer-Adapter-Use
withT53L-200-A T62F-6266-A X X
Cylinder Block Core Plug Replacer T68P-6266-A X
Core Plug Replacer T52L-6266-BGD X
Crankshaft Damper Replacer T64T-6306-A X X X X
Camshaft Timing Gear Replacer
Screw Adapter T65L-6306-A
Crankshaft Damper Installer T52L-6306-AEE X X X
Camshaft Gear Installer T65L-6306-A
Crankshaft Damper Remover T58P-6316-B 200
Cylinder Block Core Rug Replacer T72C-6015 X X
Valve Guide Reamer Kit T72C-6085 X X
Crankshaft Rear Oil Seal Replacer T72C-6165 X X
Cam Bearing Remover and Replacer Adapter Tube T72C-6250 X X
Cam Bearing Bore Plug Replacer T72C-6266 X X
Cover Plate Retaining Studs T72C-7007 X X
Front Cover Aligner, Seal Replacer and
Timing Gear Replacer T74P-6019-A X X
Piston Pin Remover and Replacer/Adapter T74P-6135-A X X
Crankshaft Timing Gear Remover Adapter T74P-6136-A X X
Crankshaft Damper Pulley Remover and Replacer T74P-6316-A X X
Crankshaft Damper Pulley Replacer T74P-6316-B X X
Valve Spring Compressor Lever T74P-6565-A X X
Valve Spring Compressor Bar T74P-6565-B X
Front Cover Seal Remover T74P-6700-A X X
Pilot Bearing Replacer Adapter* T74P-7137-A X
Pilot Bearing Replacer Adapter* T74P-7137-B X
+
*UsewithTOOLT71P-7137-HorT74P-7137-H Use with TOOL T68P-6135-A
**When Removing Engine with Exhaust Manifolds Attached CA1327-E
21-01-23 General Gasoline Engine Service 21-01-23
SPECIAL SERVICE TOOLS (Continued)

Application Engine Size

2300 2800
Ford Tool Former CC CC 200 302-351-W 351 M& 460
Description No. No. Four V-6 250 Six V-8 400 V-8 V-8

Camshaft Damper Remover

Adapter Screw T64T-6316-A X
Crankshaft Damper Remover T52L-6316-FEE 6316-FF X
Upper Main Bearing Insert
Remover and Replacer TOOL-6331 X X X
Upper Main Bearing Remover
and Replacer TOOL-6331-E X
Hydraulic Tappet Leakdown Tester TOOL-6500-E X X X X
Hydraulic Tappet Plunger
Remover and Replacer TOOL-6500-F X X X X
Valve Stem Deburring Tool T70P-6505-A X
Valve Stem Clearance Checking Tool TOOL-6505-E X X X
Valve Stem Clearance Checking Tool TOOL-6505-F 200 X
Valve Gauge T64L-6507-A X X X X
Valve Spring Compressor T65P-6513-A 200
Valve Spring Compressor T71P-6513-A X X
Air Adapter and Hose-Valve Holdup T00L-6513-ABA 6513-AB X X X
Compressor-Tappet Bleed-Down T00L-6513-AC X X
Valve and Clutch Spring Tester TOOL-6513-DD X X X X
Valve Spring Compressor T00L-6513-H X
Rocker Arm Stud Kit T62F-6A527-B X X
Rocker Arm Stud Installer
(Supplements T62F-6A527-B) T65P-6A527-A X X
Hydraulic Tappet Bleed-Down Tool T70P-6564-A X
Cup Shaped Adapter to TOOL-6565 T00L-6565-AB X X X X
Crankcase Ventilation System
Tester (Kit) C8AZ-6B627-A X X X X
Cylinder Block Front Cover
Oil Seal Replacer Adapter T60K-6700-A 6700-C 200
Cylinder Block Front Cover
Oil Seal Replacer-Adapter
UsewithT53L-200-A T58P-6700-B 250 X X X
Front Cover Oil Seal Replacer T68P-6700-A X
Crankshaft Rear Oil Seal Forming Tool T60K-6701-A 200
Crankshaft Rear Seal Replacer T62F-6701-A X
Crankshaft Rear Seal Replacer T65P-6701-A
Crankshaft Rear Seal Replacer T68P-6701-A X
Fibre Block for 6701 Tools T58P-6701-AC 200 X X
Clutch Disc Pilot T58P-7563-A X
Clutch Pilot Bearing Replacer TOOL-7600-H 7600-H X X
Clutch Pilot Bearing Replacer T65L-7600-A X
Rocker Arm Stud Driver T69P-6049-D 351W
Clutch Disc Aligner T71P-7137-H X
Clutch Disc Aligner T74P-7137-H X*
Clutch Disc Aligner T74P-7137-K X

•Mustang Only CA1327-E

21-05-1 2300cc Four Cylinder Engine 21-05-1

PART
2300 cc Four Cylinder Engine 21-05
Pinto/Bobcat/Mustang

SUBJECT PAGE SUBJECT PAGE

DESCRIPTION Main Bearings 05-21
Crankcase Ventilation System . . . 05-1 Oil Filter 05-24
Exhaust Emission Control System 05-1 Oil Pan 05-20
Oil Pump 05-21
ADJUSTMENTS Pistons and Connecting Rods 06-23
Camshaft Timing 05-3 Seals - Cylinder Front Cover,
Valve Clearance . 05-3 Camshaft and Auxiliary Shaft 06-12
Timing Belt Tensioner 06-15
REMOVAL AND INSTALLATION Valve Rocker Arm (Cam Follower) and
Auxiliary Shaft and Bearings . . . 05-15 Hydraulic Lash Adjuster Q5-8
Camshaft Drive Sprocket Valve Rocker Arm Cover Q5-7
Camshaft Timing Belt 05-14 Valve Spring, Retainer and
Clutch Pilot Bearing 05-15 Stem Seal 05-8
Connecting Rod Bearings 05-23 Water Pump 05-11
Crankcase Ventilation System . . 05-7
Crankshaft Rear Oil Seal 05-21 DISASSEMBLY AND ASSEMBLY
Cylinder Front Cover 05-15 Cylinder Head 05-25
Cylinder Head 05-11 Hydraulic Lash Adjuster 05-28
Engine Assembly 05-5 Oil Pump 05-27
Engine Front Support 05-6 Piston and Connecting Rod 05-28
Engine Rear Supports 05-7
Exhaust Manifold 05-10 SPECIAL TOOLS 05-29
Flywheel 05-15
Intake Manifold 05-9 SPECIFICATIONS 05 30

CA4183 A

Water pump and fan are separately

DESCRIPTION
The 4 - c y l i n d e r 23OOcc (2.3L)
overhead cam engine is of lightweight
iron construction. The crankshaft is
supported on five main bearings and the
camshaft by four. Main, connecting rod,
camshaft and auxiliary shaft bearings are
all replaceable.
The camshaft is driven from the
crankshaft by a cogged belt, which also
operates the auxiliary shaft, and through
this shaft, the oil pump, fuel pump and
the distributor. Tension on the cam drive
belt is maintained by a pre-loaded and
locked idler pulley bearing on the outside
of the belt.
driven from the c r a n k s h a f t by a
conventional V-belt, which also drives
the alternator.
Hydraulic valve lash adjusters are
used in the valve train. These units are
placed at the fulcrum point of the cam
followers (or rocker arms). Their action
is similar to the hydraulic valve lifters
used in push-rod engines and they are
constructed and serviced in the same
manner. The cylinder head has drilled oil
passages to provide engine oil pressure to
the lash adjusters (Fig. 3).
A set of metric wrenches is required
to service the 23OOcc (2.3L) engine.
EXHAUST EMISSION CONTROL
SYSTEM
Operation, removal, installation and
required maintenance of the exhaust
emission control devices used on this
engine are covered in Group 29 of this
Volume, and Part 50-29 of Volume 5.
CRANKCASE VENTILATION
SYSTEM
This engine is equipped with a
positive, closed-type crankcase
ventilation system re-cycling crankcase
vapors to the intake manifold.
21-05-2 2300cc Four Cylinder Engine 21-05-2

A3727-C

FIG. 1 Left Front View-2300cc (2.3L) Engine

21-05-3 2300cc Four Cylinder Engine 21-05-3

hydraulic lash adjuster must be

collapsed after re-installation of the
camshaft follower, and then released.
This step must be taken prior to any
rotation of the camshaft.

CAMSHAFT TIMING
Checking Timing
An access plug is provided in the cam
drive belt cover so that camshaft timing
can be checked without removal of the
cover or any other parts.
1. Remove the access plug (Fit;. 4) from
the cam drive belt cover.
2. Set the crankshaft to TDC by aligning
the timing pointer on the belt cover
with the O mark on the crankshaft
damper. Always turn the engine in the
direction of normal rotation.
Backward rotation may cause the
timing belt to jump time, due to the
arrangement of the belt tensioner.
3. Look through the access hole in the
belt cover to be sure that the timing
mark on the cam drive sprocket (Fig.
4) is lined up with the pointer on the
inner belt cover.
4. Remove the distributor cap and check
FIG. 2 Valve Train Lubrication System that the distributor rotor is facing the
N O T E : For any repair that No. 1 position on the distributor cap.
ADJUSTMENTS requires the removal of the camshaft 5. Install the distributor cap.
VALVE CLEARANCE—HYDRAULIC follower (rocker arm), each affected 6. Install the belt cover access plug.
VALVE LASH ADJUSTERS
1. Position the camshaft so that the base
circle of the lobe is facing the cam
follower of the valve to be checked
(Fig. 2).
2. Using the tool shown in Fig. 3, slowly
apply pressure to the cam follower
until the lash adjuster is completely
collapsed. Hold the follower in this
position and insert the proper size
feeler gauge between the base circle of
the cam and the follower.
3. If the clearance is excessive, remove
the cam follower and inspect for
damage.
4. If the cam follower appears to be
intact, and not excessively worn, CAM ON BASE CIRCLE
measure the valve spring assembled
height to be sure the valve is not
sticking.
5. If the valve spring assembled height
is correct, check the dimensions of the FEELER GAUGE
cam shaft following the procedure
under Checking Cam Shaft Lobe Lift
in Part 21-01.
6. If the camshaft dimensions are to
specifications, remove, clean and test
the lash adjuster, following the
procedures given in Part 21-01.
7. Re-install the lash adjuster and check
the clearance. Replace damaged or
worn parts as necessary.
FIG. 3 Checking Hydraulic Valve Lash Adjuster
21-05-4 2300cc Four Cylinder Engine 21-05-4

Adjusting Timing
1. Refer to Fig. 5 and remove the timing
belt outer cover.
2. If the belt timing is incorrect, loosen
TIMING POINTER MUS the belt tensioner adjustment screw
INDEX WITH TIMING
MARK ON SPROCKET
(Fig. 6), position the tension adjusting
tool shown on the tension spring
rollpin and release the belt tensioner.
Tighten the adjustment screw to hold
the tensioner in released position.
3. Remove the crankshaft damper and
belt guide (Fig. 6).
4. Remove the drive belt and inspect it
for wear or damage. If the belt is
damaged, replace it.
5. Position the crankshaft sprocket and
the camshaft sprocket as shown in
Fig. 5. Remove the distributor cap
and set the distributor rotor to No. 1
firing position by turning the
DISTRIBUTOR ROTOR MUST
ALIGN WITH NO. 1 FIRING
auxiliary shaft.
POSITION 6. Install the timing belt over the
crankshaft sprocket and then
counterclockwise over the auxiliary
TIMING POINTER
MUST ALIGN WITH
and camshaft sprockets. Align the
TDC MARK ON DAMPER
A 3373B
belt fore and aft on the sprockets.
FIG. 4 Camshaft Drive Train Installation

BELT OUTER
COVER 6E0O4

BELT INNER COVER

PLUG

A3735-C
FIG. 5 Timing Belt Outer Cover, Crankshaft Belt Guide and Pulley Installation
21-05-5
FIG. 6 Releasing Belt Tension — Typical
REMOVAL AND INSTALLATION
When installing nuts or bolts (refer to
torque specifications), oil the threads
with light-weight engine oil. Do not oil
threads that require oil-resistant or
water-resistant sealer.
ENGINE
Removal
1. Raise the hood and secure it in the
vertical position.
2. Drain the coolant from the radiator
and the oil from the crankcase.
3. Remove the air cleaner and the
exhaust manifold shroud.
4. Disconnect the ground cable from the
battery.
5. Remove the radiator upper and lower
hoses.
6. Remove the radiator and fan.
7. Disconnect the heater hose from the
water pump and carburetor choke
fitting.
8. Disconnect the alternator wires from
the alternator, the starter cable from
the starter, and the accelerator cable
from the carburetor. On a vehicle
with air conditioning, remove the
2300cc Four Cylinder Engine
A3734-B
compressor from the mounting
bracket, and position it out of the
way, leaving the refrigerant lines
attached.
9. Disconnect theflexiblefuel line at the
fuel pump line and plug the fuel line.
10. Disconnect the coil primary wire at
the coil. Disconnect the oil pressure
and the water temperature sending
unit wires from the sending units.
11. Remove the starter.
12. Raise the vehicle. Remove the
flywheel or converter housing upper
attaching bolts.
13. Disconnect the muffler inlet pipe at
the exhaust manifold. Disconnect the
engine right and left mount at the
underbody bracket. Remove the
flywheel or converter housing cover.
On a vehicle with a manual-shift
transmission, remove the flywheel
housing lower attaching bolts.
On a vehicle with automatic
transmission, disconnect the
converter from theflywheel.Remove
the converter housing lower attaching
bolts.
21-05-5
7. Loosen the tensioner adjustment bolt
to allow the tensioner to move against
the belt. To be sure that the belt does
not jump time during rotation in Step
8, remove the spark plugs.
8. Rotate the crankshaft two complete
turns in normal rotation to remove
the slack from the belt. Torque
tensioner adjustment and pivot bolts
to specifications. Re-check the
alignment of the timing marks (Fig.
4).
9. Install the crankshaft damper and
belt guide (Fig. 5).
10. Install the timing belt outer cover and
the spark plugs.
11. Start the engine and check the
ignition timing. Adjust the ignition
timing to specification as required.
14. Lower the vehicle. Support the
transmission and flywheel or
converter housing with a jack.
15. Attach the engine lifting hooks to the
existing lifting brackets. Carefully lift
the engine out of the engine
compartment. Install the engine on a
work stand.
Installation
1. If clutch was removed, re-install per
Group 16. Carefully lower the engine
into the engine compartment.
2. Make sure the studs on the exhaust
manifold are aligned with the holes in
the muffler inlet pipe.
On a vehicle with automatic
transmission, start the converter pilot
into the crankshaft.
On a vehicle with a manual-shift
transmission, start the transmission
main drive gear into the clutch disc.
It may be necessary to adjust the
position of the transmission in
relation to the engine if the input shaft
will not enter the clutch disc. If the
engine hangs up after the shaft enters,
turn the crankshaft in the clockwise
21-05-6 2300cc Four Cylinder Engine 21-05-6

direction slowly (transmission in 11. Install the pulley, fan, and drive belt. 4. Remove the support bracket (between
gear), until the shaft splines mesh Adjust the drive belt tension. On a front engine mount and side rail)
with the clutch disc splines. vehicle with air conditioning, install attaching bolts and nuts.
3. Install the flywheel or converter the compressor on the mounting 5. Raise the engine sufficiently to
housing upper attaching bolts. bracket, and adjust the belt tension to remove the support bracket from the
Remove the engine lifting sling hooks. specification. Install the fan and the vehicle.
4. R e m o v e t h e j a c k from t h e radiator. Connect the radiator upper 6. Remove the engine insulator
transmission. Raise the vehicle. and lower hoses. Fill and bleed the assembly to cylinder block attaching
5. Install the flywheel or converter cooling system. Fill the crankcase bolts and lockwashers. Remove the
housing lower attaching bolts. with the proper grade and quantity of engine mount assembly.
On a vehicle with automatic engine oil. Installation
transmission, attach the converter to 12. Connect the battery ground cable. 1. Position the engine mount assembly
the flywheel and torque the attaching 13. Operate the engine at fast idle and to the cylinder block. Install the
nuts to specifications. check all g a s k e t s and hose bracket bolts and lockwashers and
6. Install the flywheel or converter connections for leaks. torque the bolts to specifications.
housing dust cover. 14. Install the air cleaner and connect the 2. Install the support bracket to the
7. Install the engine left and right mount positive closed type crankcase frame side rail with attaching bolts
to the underbody bracket. ventilation hose. and nuts. Torque the nuts to
8. Remove the plug from the fuel line specifications.
and connect the flexible fuel line to 3. Lower the engine until the engine
the fuel pump line. Install the exhaust ENGINE FRONT SUPPORTS mount insulator assembly lines up
manifold to muffler inlet pipe nuts. with the support bracket to allow
Torque the nuts to specifications. Removal installation of the through bolt.
9. Lower the vehicle. Connect the oil 1. Remove the fan shroud attaching Install the through bolt and locknut
pressure and the engine temperature screws. and torque to specifications.
sending unit wires. Connect the coil 2. Support the engine using a wood 4. Remove the jack and wood block
wires. Connect the accelerator cable. block and jack placed under the oil from the engine pan.
10. Install the starter motor. Connect the pan. 5. Install the fan shroud attaching
starter cable. Connect the alternator 3. Remove the through bolt and lock nut screws and torque the screws to
wires. Connect the heater hose to the attaching the insulator to the specifications.
water pump and the carburetor choke insulator support bracket (Fig. 7
N602569-S100
and 8).
3 REQ'D. •382802-S2
35-60 FT-LB 20-30 FT-LB ENGINE SUPPORT (REAR -
6D089
TRANSMISSION
ENGINE SUPPORT - N602569-S100* 386321-S2*
6C010(R.H.) 3 REQ'D. 20-30 FT-LE
35-60 FT-LB N-800005-S101.
•56753-S2
—*® ENGINE SUPPORT - 40-60 FT-LB
6C060 (L.H.) 56748-S2
2REQ/D.
20-30 FT-LB
56753-S2 VIEWX 382802-S2'
W/AUTOMATIC 2 REQ'D.
TRANSMISSION 5059 ASSY.
(SAME AS MANUAL 34670-S2
_ TRANSMISSION 2 REQ'D.
EXCEPT AS SHOWN) 30^»5 FT-LB
VIEWZ (CRIMP AFTER
VIEWX
382802-S2 INSTALLATION 382873-S100
4REO/D. TO LOCK) V I E W X
2 REQ'D.
MAIN VIEW VIEWY
V I E W Z 20-30 FT-LB
PINTO/BOBCAT INSTALLATION W/MANUAL TRANSMISSION
FIG. 7 Engine Supports - Pinto/Bobcat w/2300cc Engine
A4184-A
ENGINE SUPPORT - N602569-S100 ENGINE SUPPORT 57481-S2 ASSY.'
6C060 (L.H.) / 6 REQ'D. (REAR)-6068 4 REQ'D.
/ 35-60 FT-LB 35-50 FT-LB
56747-S2 6A088 ASSY. (L.H.)
4 REQ'D. 382802-S2"
/2REQ'D.
<S> 20-30 F T - L B
ENGINE SUPPORT
-6C010(R.H.)

VIEWZ
(SAME AS VIEW Y EXCEPT AS SHOWN)

386099-S2
4 REQ'D.
(NOTE: THESE BOLTS 386040-S100
MUST BE INSERTED 368041-S100
2 REQ'D. 2 REQ'D.
AS SHOWN BOTH R.H. 85-110 FT-LB
VIEWZ AND L.H. SIDES). 85-110 FT-LB

MAIN VIEW A3729C

FIG. 8 Engine Supports — Mustang w/2300cc Engine
21-05-7 2300cc Four Cylinder Engine 21-05-7

ENGINE REAR SUPPORT

Pinto and Bobcat FILTER PACK

Removal FILTER RETAINER \

1. Remove the engine rear insulator ELBOW - 382956-S
attaching nuts at the crossmember AIR CLEANER
SHELL (REF.)
(Fig. 7).
2. Support the transmission with a block
of wood and a jack. GROMMET
-382156-S
3. Remove the bolt or bolts attaching
the rear support to the transmission. OIL FILLER CAP. UPPER CRANKCASE
-6766 VENT HOSE
4. Raise the transmission slightly and -6853
remove the support.
Installation
1. P o s i t i o n t h e s u p p o r t t o t h e
PC si PORT OF
transmission and install the attaching CARBURETOR
bolt or bolts. Torque the bolts to SPACER
specifications.
2. Lower the transmission until the ADJUSTABLE
support seats on the crossmember. RUNDLING
STRAP-95J:73-S
Remove the jack and block of wood.
3. Install and torque the attaching nuts. OIL {SEPARATOR
-6A"'85
Mustang
Removal OIL FILTER
1. Place a block of wood and a jack REF.

under the transmission to remove the

w e i g h t from t h e s u p p o r t i n g
crossmember.
2. Remove the two nuts holding the
VIEW A
insulator bracket to the crossmember. A3736-D

3. Remove the crossmember-attaching FIG. 9 Positive Crankcase Ventilation System

through-bolts and the two bolts
h o l d i n g t h e i n s u l a t o r to t h e
transmission.
INSTALL AND TORQUE THESE 8 SCREWS
4. Raise the transmission sufficiently to
slide the crossmember and insulator ROCKER ARM COVER
rearward.
5. Remove both the crossmember and
the insulator.
Installation
1. P o s i t i o n t h e i n s u l a t o r to t h e
crossmember and loosely install the
two attaching nuts. Do not tighten.
2. Slide the crossmember and insulator
into position under the transmission.
Loosely install the crosmember
through-bolts and nuts.
3. Install the insulator to transmission
attaching bolts and torque the bolts to
specifications.
GASKET
4. I n s e q u e n c e — t o r q u e t h e
crossmember through-bolts and then
the insulator attaching nuts to
specifications.
5. Remove the jack and wood block
from the transmission.
CRANKCASE VENTILATION
SYSTEM
The positive crankcase ventilation
system components are shown in Fig. 9.
Disconnect and connect points are shown
on the illustration.
VALVE ROCKER ARM COVER
I n s t r u c t i o n s for r e m o v a l and A3737-C
installation of the rocker arm cover and
FIG. 10 Installing Valve Rocker Arm Cover — Typical
gasket are given in Fig. 10.
 21-05-8
VALVE ROCKER ARM (CAM
FOLLOWER) AND HYDRAULIC
LASH ADJUSTER
Removal
1. Remove the valve rocker arm cover
and associated parts as required.
2. Rotate the camshaft so that the base
circle of the cam is facing the
applicable cam follower.
3. Using the tool shown in Fig. 4,
collapse the lash adjuster and/or
depress the valve spring if necessary
and slide the cam follower over the
lash adjuster and out.
4. Lift out the hydraulic lash adjuster.
Installation
1. Rotate the camshaft so that the base
circle of the cam is facing the
applicable cam follower.
2. Place the hydraulic lash adjuster in
position in the bore.
3. Using the tool shown in Fig. 4,
collapse the lash adjuster as necessary
to position the cam follower over the
lash adjuster and the valve stem. It
may also be necessary to compress the
valve spring, using the tool shown in
Fig. 11.
A3739-B*
FIG. 11 Removing Valve Spring
Retainer
4. Before rotating the camshaft to the
next position, be sure the lash
adjuster just installed is fully
compressed and released.
5. Clean the gasket surfaces of the valve
cover and cylinder head.
6. Coat the gasket contact surfaces of
the valve cover and the "UP" side of
the valve cover gasket with oil
resistant sealer. Allow to dry and then
install gasket in valve cover, making
sure locating tabs are properly
positioned in slots in cover (Fig. 10).
2300cc Four Cylinder Engine 21-05-8
7. Install 8 screws and torque to 5. Inspect the valve stem for damage.
specification. Rotate the valve and check the stem
8. Install the air cleaner and all other tip for eccentric movement. Move the
hardware removed. valve up and down through normal
9. Run the engine at fast idle and check
travel in the valve guide and check the
for oil leaks. stem for binds. If the valve has been
VALVE SPRING, RETAINER AND damaged, it will be necessary to
STEM SEAL remove the cylinder head and repair
as outlined in Part 21-01.
If the valve or valve seat has not been Installation
damaged; valve springs, seals and
retainers may be replaced by holding the 1. Install a new valve stem seal using a
plastic installation cap. Use the tool
affected valve against its seat using
compressed air. Use the tool shown in shown in Fig. 12 and the procedure
given in Fig. 13. Install the valve
Fig. 11 installed in the spark plug hole.
A minimum of 140 PSI line pressure is spring, retainer and locks. Turn off
required. If air pressure does not hold the
valve shut, the valve is damaged or burnt
and the cylinder head must be removed
and repaired (Part 21-01).
Removal
1. Remove the valve rocker arm cover
and associated parts as required.
2. Remove the cam follower.
3. Using the tool shown in Fig. 11,
compress the valve spring and remove
the retainer locks, spring retainer, and
valve spring. Remove and discard the
stem seal.
4. If air pressure has forced the piston
to the bottom of the cylinder, any
removal of air pressure will allow the
valve(s) to fall into the cylinder. A
rubber band, tape or string wrapped
A3299-B
around the end of the valve stem will
prevent this condition and will still
allow enough travel to check the valve FIG. 12 Valve Stem Seal Installation
Tool
for binds.
TOOL T73P-6571-A SHOULD
PLASTIC INSTALLATION CAP CONTACT SHOULDER
(OIL SURFACE OF CAP
TO FACILITATE
SEAL INSTALLATION)
STEP STEP- # 2 STEP # 3
STEP #1 - WITH VALVES IN HEAD. PLACE PLASTIC INSTALLATION CAP OVER END OF VALVE STEM.
STEP # 2 - START VALVE STEM SEAL CAREFULLY OVER CAP. PUSH SEAL DOWN UNTIL JACKET
TOUCHES TOP OF GUIDE.
STEP # 3 - REMOVE PLASTIC INSTALLATION CAP. USE INSTALLATION TOOL- T73P-6571-A
SCREWDRIVERS TO BOTTOM SEAL ON VALVE GUIDE.
OR
A3451-D
FIG. 13 Valve Stem Seal Installation
21-05-9 2300cc Four Cylinder Engine 21-05-9

the air and remove the air line and

adapter.
FITTINGS
Apply Lubriplate or equivalent to
all contact surfaces of the cam
follower and install in position.
Install the spark plug. Be sure that
the affected lash adjuster has been
collapsed and released before ro-
tating the camshaft.
3. Install the rocker arm cover following
the information given in Fig. 10.
INTAKE MANIFOLD
Information necessary to properly
remove and install the intake manifold is
given in Figs. 15, 16 and 17.
The special tool required to remove
and install the carburetor is illustrated in TORQUE THE MANIFOLD BOLTS
Fig. 14. Carburetor installation is shown TO SPECIFICATIONS IN TW D
PROGRESSIVE STEPS IN THE
in Fig. 15. SEQUENCE SHOWN
A3740-C

TOOL- FIG. 15 Intake Manifold Installation

T74P-9510-A

84-108 IN-LB OIL LEVEL

INDICATOR: - 6 7 5 9

40°-50° TO COVER
MOUNTING FACE

PARALLEiLTO COVI
MOUNTING FACE±

FIG. 14 Special Carburetor Wrench MANIFOLD COVER

9E434

71-106 IN-LB
(4 PLACES)

PLUG - 120-180 IN-LB (NON-A/C)

PVS - 12A091 - 120-180 IN-LB

(AND THEN ROTATE TO PROPER POSITION.)
A/C EQUIPPED ENGINES

A3742-C

FIG. 16 Water Manifold Installation

214)5-10 2300cc Four Cylinder Engine 21-05-10

NUT-120-168 IN.-LB.
(4REQ'D)

GASKET-9447
(WORDS "TOP FRONT"
SHOWN ON TOP OF TAB)

FIG. 17 Carburetor Installation

A3741-C
EXHAUST MANIFOLD
Information necessary to properly
remove and install the exhaust manifold
is given in Fig. 18.

APPLY GRAPHITE
GREASE LIGHT APPLY SEALER TO THREADS-BOTH ENDS-
UNIFORM FILM PRIOR TO INSTALLATION
ON MOUNTING
SURFACE

TORQUE THE MANIFOLD BOLTS TO SPECIFICATIONS IN

TWO PROGRESSIVE STEPS IN THE SEQUENCE SHOWN
A3743-B

FIG. 18 Exhaust Manifold Installation

21-05-11 2300cc Four Cylinder Engine 21-05-11

CYLINDER HEAD TORQUE THE CYLINDER HEAD BOLTS TO SPECIFICATIONS

IN TWO PROGRESSIVE STEPS IN THE SEQUENCE SHOWN.
Information necessary to properly
remove and install the cylinder head is
given in Fig. 19. A disassembled view of
the cylinder head is given in Fig. 41.
Refer to the various other illustrations
covering installation of the associated
parts.

WHEN INSTALLING CYLINDER

HEAD, POSITION THE CAMSHAFT
AS SHOWN TO AVOID DAMAGE
TO PROTRUDING VALVES.

Fig. 19 Cylinder Head Installation

8594-OUTLET CONNECTION 8575-THERMOSTAT-OUTLET

WATER PUMP SIDE TO RADIATOR
Provision for wrench clearance has
been made in the timing belt inner cover,
so only the outer cover must be removed
in order to replace the water pump.
Water pump and associated parts 6E009-SEALS TO
BE FLUSH WITH
installation is illustrated in Fig. 20. TOP OF COVER

STUD AND WASHER

SEALING TYPE

6E005-BELT
COVER INNER
A3745-B

FIG. 20 Water Pump, Thermostat and Inner Timing Belt Cover Installation
21-05-12 2300cc Four Cylinder Engine 21-05-12

CYLINDER FRONT COVER, T74P-6256-A

CAMSHAFT AND AUXILIARY
SHAFT SEALS
The cylinder front cover, camshaft
and the auxiliary shaft seals are replaced
in the same manner with the same tools
after the respective gear has been
removed. NOTE: Always use a new
attaching bolt when replacing the
camshaft sprocket or use new Teflon
or equivalent sealing tape on the
threads of the old bolt.
Sprocket Removal And
Installation
Fig. 21 shows the multi-purpose tool
being used to pull the cam drive sprocket.
This same tool is used in exactly the same
manner to remove the auxiliary shaft
sprocket.

A3746-C

FIG. 21 Removing Cam or Auxiliary Shaft Sprocket

Fig. 22 shows the same multi-purpose

tool with the threaded puller insert
removed, being used to hold the cam
sprocket while the attaching bolt is
installed and torqued. This is also typical NOTE: CENTER
ARBOR REMOVED
of the auxiliary shaft sprocket
installation.

A3747-C

FIG.22 Installing Cam or Auxiliary Shaft Sprocket

21-05-13 2300cc Four Cylinder Engine 21-05-13

Fig. 23 shows the multi-piece tool

used to pull the crankshaft drive sprocket
off the crankshaft.
No special tool is required for
installing the crankshaft sprocket on the
crankshaft.

A3748-A

FIG. 23 Removing Crankshaft Sprocket

Seal
Removal
One common seal removal tool is
used to remove all the seals.
Fig. 24 shows the tool being used to
remove the camshaft seal. When
positioning this tool, be sure that the jaws
are gripping the thin edge of the seal very
tightly before operating the jack-screw
portion of the tool.

A3749-C

FIG. 24 Removing Cam or Auxiliary Shaft Seal

21-05-14 2300cc Four Cylinder Engine 21-05-14

Fig. 25 shows the tool being used to

remove the cylinder front cover seal.

A3750-A

FIG. 25 Removing Cylinder Front Cover Seal

Installation
One common tool with a stepped,
threaded arbor is used to install all the
seals. The tool acts as a press, using the
internal threads of the various shafts as
a pilot.
Fig. 26 shows the special tool being
used to install the camshaft seal. This is
typical of the other seal installations.

CAMSHAFT TIMING BELT

Installation information for the
complete cam drive mechanism is given
in Fig. 29. Associated parts are illustrated
in Figs. 41 and 42.

FIG. 26 Installing Camshaft Seal—Typical of Crankshaft and Auxiliary Shaft

Seal Installation
21-05-15
TIMING BELT TENSIONER
Illustrated instructions are given in
Fig. 29 covering installation of the timing
belt tensioner. A close-up view of the
tensioner assembly is shown in Fig. 32.
AUXILIARY SHAFT AND
BEARINGS
Refer to Fig. 30 for installation
information on the auxiliary shaft.
If necessary, the auxiliary shaft
bearings can be removed using the slide-
hammer Tool T58L-1O1-A.
Install new bearings using a driver,
Tool T57T-7OO3-A. Be sure to align the
oil holes in the bearings with those in the
block when installing.
CYLINDER FRONT COVER
The front seal has been designed so
that it is not necessary to remove the
cylinder front cover with the engine in
the chassis.
When disassembling the engine, first
remove the front seal from the cover
while the cover is still on the engine,
using the tool and procedure shown in
Fig. 25.
When assembling the engine, install
the cover on the engine without the seal
and then use the special tool shown in
Fig. 26 to press the seal into place. This
will avoid damage to the seal.
Before finally adjusting the cover into
position and torquing the attaching bolts,
2300cc Four Cylinder Engine 21-05-15
use the tool shown in Fig. 32 to position PILOT BEARING
the cover in relation to the crankshaft. Tool T58L-101-A or
Torque the bolts to specifications with J600-E
this tool in place. This will assure that the
timing belt does not interfere with the
front cover when operating.
F i g . 33 s h o w s t h e m e t h o d of
overlapping the front and side pan
gaskets when assembling.
Refer to Fig. 35 as a guide for further
assembly information.
FLYWHEEL
Information on installation of both
automatic and manual transmission FIG. 27 Removing Pilot
Bearing—Typical
flywheels is given in Fig. 34.
CLUTCH PILOT BEARING
PILOT BEARING
This engine is equipped with a sealed TOOLT71P-/137-C
roller bearing clutch pilot (Fig. 32).
Inspection procedures are outlined fSf
under Flywheel Cleaning and Inspection
in Part 21-01.
Removal
1. Remove the transmission, clutch
pressure plate, and disc following the
procedures in Volume One, Group
16—Clutch.
2. U s i n g T o o l s T59L-1OO-B a n d A3430-B
T58L-1O1-A, remove t h e pilot
bearing (Fig. 27). FIG. 28 Installing Clutch Pilot
Installation Bearing—Typical
1. Using Tool T 7 1 P - 7 1 3 7 - C a n d
T71P-7137-M, install the pilot service
bearing (Fig. 28).
21-05-16 2300cc Four Cylinder Engine 21-05-16

BELT GUIDE-6B260
CAMSHAFT
SPROCKET -6256

CAMSHAFT
TIMING MARK

USE A NEW BOLT OR

NEW TEFLON TAPE
ON BOLT THREADS
WHEN INSTALLING

BELT 6268

VIEW FOR
CRANKSHAFT ALIGNMENT

AUXILIARY SHAFT
TIMING BELT SPROCKET - 6256

BELT GUIDE
SPROCKET
BELT GUIDE

RECESS IN SPROCKET CRANKSHAFT

KEY

CAMSHAFT
CRANKSHAFT

SECTIONAL VIEW FOR

SPROCKET INSTALLATION
SECTIONAL VIEW FOR SECTIONAL VIEW FOR
CRANKSHAFT BELT GUIDE CAMSHAFT BELT GUIDE
INSTALLATION INSTALLATION

A37S2-B
FIG. 29 Installing Cam Drive Belt, Sprockets and Tensioner
21-05-17 2300cc Four Cylinder Engine 21-05-17

GEAR AND FUEL PUMP

ECCENTRIC MUST NOT BE
ALLOWED TO TOUCH
BEARING SURFACES
DURING INSTALLATION

AUXILLIARY SHAFT-6K230

RETAINING PLATE-6A222

p)N DIP SHAFT COMPLETELY IN ENGINE

OIL BEFORE INSTALLING

NOTE: CUT GASKET

FOR SEPARATE
REMOVAL OR
INSTALLATION OF
COVERS

AUXILLIARY SHAFT
COVER-6E007

COVER ALIGNMENT
PADS-3 PLACES

FRONT COVER
ALIGNMENT TOOL
(T74P-6O19-B)

A3754-A

FIG. 30 Installing Auxiliary Shaft and Bearings and Cylinder Front Cover
21-05-18 2300cc Four Cylinder Engine 21-05-18

FIG. 31 Timing Belt Tensioner

TOOL-T74P-6019-B

A3755-B

FIG. 32 Positioning Front Cover

A3756-A

FIG. 33 Gasket Installation

21-05-19 2300cc Four Cylinder Engine 21-05-19

APPLY LUBRIPLATE TO
CRANKSHAFT PILOT HOLE

AUTOMATIC TRANSMISSION

FLYWHEEL-6375

REFINFORCING PLATE - 6A366

REAR COVER PLATE-6A373

ROCKER ARM COVER SHIELD-6C509

NOTE: TRANSMISSION CLUTCH

HOUSING ATTACHES TO
ENGINE WITH METRIC BOLTS

FLYWHEEL AND PRESSURE PLATE

FRICTION SURFACES MUST BE
FREE OF DIRT, GREASE AND OIL
PRIOR TO INSTALLATION

REAR COVER PLATE - 6A373

FLYWHEEL-6375

MANUAL TRANSMISSION

PRESSURE PLATE - 7563

ROLLER PILOT BEARING - 7600

INSTALL WITH SEAL

TOWARD TRANSMISSION

A3757-C

FIG. 34 Flywheel Installation

21-05-20 2300cc Four Cylinder Engine 21-05-20

2. Install the clutch pressure plate, disc,

and the transmission following the
procedure in Volume One, Group
16—Clutch.
OIL PAN
Oil pan removal and installation
instructions are given in Fig. 35.

DRAIN P L U G - 6 7 3 0 M6X 16.0 MM LONG SCREW

AND WASHER-18 PLACES

OILPAN-6675

M8X 20.0 LONG

SCREW AND WASHER
-4 PLACES PAN GASKET (R)
6710

PAN GASKET (L)

6711 SEAL-6723
(SEE NOTE BELOW)
(SEE BONDING NOTE BELOW)

SEAL-6722
HOLE"A"

OIL-RESISTANT SEALER APPROX. 0.125" WIDE BEAD

TO JOINT OF BLOCK AND FRONT COVER

OIL PAN GASKET (REF.)

BLOCK

FRONT
SEAL TAB

1. APPLY GASKET ADHESIVE EVENLY TO OIL PAN FLANGE AND TO PAN SIDE
GASKETS. ALLOW ADHESIVE TO DRY PAST WET STAGE, THEN INSTALL
GASKETS TO OIL PAN.
2. APPLY SEALER TO JOINT OF BLOCK AND FRONT COVER. INSTALL SEALS TO
FRONT COVER AND REAR BEARING CAP AND PRESS SEAL TABS FIRMLY INTO
BLOCK. BE SURE TO INSTALL THE REAR SEAL BEFORE THE REAR MAIN
BEARING CAP SEALER HAS CURED.
3. POSITION 2 GUIDE PINS AND INSTALL THE OIL PAN. SECURE THE PAN WITH
THE FOUR M8 BOLTS SHOWN ABOVE.
4. REMOVE THE GWIDE PINS AND INSTALL AND TORQUE THE EIGHTEEN M6 BOLTS,
BEGINNING AT HOLE " A " AND WORKING CLOCKWISE AROUND THE PAN.

A3759-B

FIG. 35 Oil Pan Installation

21-05-21 2300cc Four Cylinder Engine 21-05-21

OIL PUMP
Oil pump installation information is
shown in Fig. 36. Prime the oil pump SCREW AND WASHER
with engine oil when making final
installation.

SHAFT ASSY. OIL PUMP

INTERMEDIATE-6A618

A3760-B

FIG. 36 Oil Pump Installation —Typical

REAR BEARING CAP

CRANKSHAFT REAR OIL SEAL DIP SEALS IN ENGINE
OIL BEFORE INSTALLING
A split lip-type crankshaft rear oil
seal is used on this engine. Installation
information is given in Fig. 37.

MAIN BEARINGS REAR OIL SEAL

Selective-fit main bearings are used in
this engine. Number three journal is the
thrust bearing.
Main bearing installation information
is given in Fig. 38.
APPLY SEALER AS SHOWM
SEE NOTE BELOW
UPPER AND LOWER SEAL
ENDS TO BE FLUSH IN
SEALER NOTE: CLEAN THE AREA WHERE SEALEH
IS TO BE APPLIED BEFORE INSTALLING THE SEALS.
BLOCK ANDCAP
USE FORD SPOT REMOVER B7A-19521-A OR EQUIVALENT.
AFTER THE SEALS ARE IN PLACE, APPLY A 1/16 INCH
BEAD OF C3AZ-19562-A OR -B SEALER AS SHOWN
SEALER MUST NOT CONTACT SEALS.

FRONT OF ENGINE

LOCATING TAB

A3761-B

FIG. 37 Rear Oil Seal Installation

21-05-22 2300cc Four Cylinder Engine 21-05-22

REAR CAP - 6325

OIL- CRANKSHAFT JOURNALS

AND THRUST FACES- AFTER
INSTALLATION TO BLOCK

CAP REAR
INTMDT.-6327

ENTER CAP 6330

CRANKSHAFT-6303 REAR FACES OF THRUST

BEARINGS MUST BE FLUSH
NOTE: PRIOR TO FINAL TORQUE
-CAPS MUST BE SEATED PRIOR TO BOLT RUNDOWN OF BOLTS
- D O NOT ALLOW CRANKSHAFT TO ROTATE BEARINGS
-TORQUE ALL MAIN BEARING CAP BOLTS TO SPECIFICATION

CAP

14 3 JOURNAL
(THRUST BEARING)

PRESS PINS TO BOTTOM-3 PLACES- THRUST BEARING

PRIOR TO CRANKSHAFT INSTALLATION LOWER-6A339

THRUST BEARING
UPPER-6337

APPLY OIL-TO UPPER

BEARING THRUST
FACES IN BLOCK

SECTION A

VIEW FOR PCV BAFFLE INSTALLATION A3762-B

FIG. 38 Installing Crankshaft and Main Bearings

21-05-23 2300cc Four Cylinder Engine 21-05-23

Check crankshaft end play according
to the procedure given in Part 21-01,
under D i a g n o s i s and
Testing—Crankshaft End Play.
Fit replacement main bearings
according to the procedure given in Part
21-01 under Overhaul—Fitting Main or
C o n n e c t i n g Rod Bearings With
Plastigage.
CONNECTING ROD BEARINGS PISTONS AND CONNECTING
RODS
The connecting rod bearings are
selective-fit. Refer to procedures under Installation information on the
Overhaul — F i t t i n g Main And connecting rods and pistons is given in
Connecting Rods With Plastigage, Part Fig. 39.
21-01.
HAND START UNTIL FLUSH WITH
TOP OF BOLT, THEN TORQUE
IN 2 STEPS -AS DETAILED
IN SPECIFICATIONS

OIL ROD AND CAP BEARINGS

AFTER BEARING ASSEMBLY

OIL-ALL CRANKSHAFT
PIN JOURNALS

ROD CAP - 6210

PISTON AND R O D - 6 1 0 0

BLOCK FACE
OPTIONAL- OIL PISTON RINGS
PRIOR TO PISTON
INSTALLATION

OIL-COAT ALL CYLINDER BORE SURFACES

PRIOR TO INSTALLATION OF PISTON
AND ROD ASSEMBLY
SEGMENT GAPS TO BE APPROXIMATELY
80° AWAY FROM EXPANDER GAP AND
NOT IN AREA OF SKIRT

PISTON NOTCH TO FRONT

OF ENGINE AT INSTALLATION

<£ EXPANDER

C_ SEGMENT

INSTALL PISTON INTO BLOCK

WITH RING GAPS AS FOLLOWS
EXPANDER-TO FRONT OF PISTON
SEGMENT-TO REAR OF PISTON A3763-C

FIG. 39 Installing Pistons, Rings and Connecting Rods

21-05-24 2300cc Four Cylinder Engine 21-05-24

OIL FILTER FRONT OF ENGINE

Installation information for the oil

filter, oil pressure sender, water
temperature sender and the fuel pump 9278-01L SENDER-SEALING TYPE
are shown in Fig. 40.

10883-TEMP INDICATOR OR
10B843-TEMP SWITCH
SEALING TYPE

HAND TIGHTEN 1/2 TURN

AFTER GASKET CONTACT

APPLY CHASSIS GREASE

AS SHOWN PRIOR TO FUEL
PUMP INSTALLATION

A3771-A

FIG. 40 Installing Oil Filter, Sending Units and Fuel Pump

21-05-25 2300cc Four Cylinder Engine 21-05-25

DISASSEMBLY AND ASSEMBLY

CYLINDER HEAD
Information for disassembly and
assembly of the cylinder head is
contained in Figs. 19, 41 and 42.

(JA"« KEYS - 6518

RETAINER - 6 5 1 4

INSTALL SEAL AFTER VALVE

AND PRIOR TO SPRING INSTALLATION
-SEAL MUST BE BOTTOMED ON
VALVE GUIDE SPRING - 6513
ADJUSTER - 6C501

SEAL-6A517
NOTE: LASH ADJUSTERS MUST
NOT BE ALLOWED TO LEAK
OIL PRIOR TO, DURING, OR
AFTER INSTALLATION

(APPLY LUBRIPLATE Oct

EQUIVALENT TO VALVIE
SECTION OF STEMS AND GUIDES
INSTALLED SEAL BEFORE INSTALLING
VALVES)

NOTE: VALVE SPRING MUST

NOT BE COMPRESSED BEYOND INTAKE VALVE -6507
A HEIGHT OF 1.06 INCHES
DURING ASSEMBLY

EXHAUST V A L V E - 6 5 0 5

SEE
SPECIFICATION
SPRING SEAT MAINTAIN SPECIFIED
SPRING INSTALLED HEIGHT /AND
OR LOADBY VARYING THIS DIMENSION.

A3765 D

FIG. 41 Installing Valves, Springs, Seals, Retainers and Lash Adjusters

21-05-26 2300cc Four Cylinder Engine 21-05-26

CAM FOLLOWER-6564

DIP IN ENGINE OIL

PRIOR TO INSTALLATION

APPLY LUBRIPLATE TO VALVE

TIPS PRIOR TO ARM INSTALLATION

CYLINDER HEAD-6049

7
CAMSHAFT C_

TO BE INSTALLED WITH
GAP AWAY FROM CAMSHAFT C_

COMPLETELY DIP CAMSHAFT

IN ENGINE OIL PRIOR TO
INSTALLATION

CAMSHAFT-6250

SEAL-6700

RETAINING PLATE-6A222

FIG. 42 Installing Camshaft

21-05-27
When disassembling, mark the cam
followers, lash adjusters and valves so
that they can be installed in the original
positions.
If the cylinder head is being repaired,
remove the deposits from the combustion
chambers with a scraper and wire brush
before removing the valves.
If necessary to replace the cam
bearings, use the tool system shown in
Fig. 43.
CAMSHAFT
BEARING
REMOVAL
FIG. 43 Removing or Installing Camshaft Bearings—Typical
The assembled height of the valve
spring can be checked as shown in Fig.
44.
FIG. 44 Checking Valve Spring
Assembled Height
2300cc Four Cylinder Engine
Tool-71P-6250.A
OIL HOLES MUST
BE ALIGNED AT
TIME OF INSTALLATION
INSTALLATION
A3419-A
If the assembled height is greater than
specified, install the necessary 0.030 inch
thick spacer(s) between the cylinder head
spring pad and the valve spring to bring
the a s s e m b l e d height to t h e
recommended dimension. Do not install
spacers unless necessary. Use of spacers
in excess of recommendations will result
in overstressing the valve springs and
overloading the camshaft lobes. This
could lead to spring breakage and worn
cam lobes.
When assembling the cylinder head,
apply heavy SE oil to the valve stems,
cam bearings and like parts. Apply
Lubriplate or equivalent to the wiping
surfaces of the cam and cam followers.
OIL PUMP
Disassembly
1. Remove the oil inlet tube from the oil
pump and remove the gasket.
2. Remove the cover attaching screws,
then remove the cover. Remove the
inner rotor and shaft assembly, then
remove the outer race.
21 05-27
3. Drill a small hole and insert a self-
threading sheet metal screw of the
proper diameter into the oil pressure
relief valve chamber cap and pull the
cap out of the chamber. Remove the
spring and plunger.
Assembly
The oil pump assembly is shown in
Fig. 45.
1. Oil all parts thoroughly.
2. Install the oil pressure relief valve
plunger, spring and a new cap.
IDENTIFICATION
MARKS
A4093-A
FIG. 45 Oil Pump
3. Install the outer race and the inner
rotor and shaft assembly. Be sure the
dimple (identification mark) on the
outer race is facing outward and on
same side as identification mark on
rotor. The race rotor and shaft and
the outer race are serviced as an
assembly. One part should not be
replaced without replacing the other.
Install the cover and torque the
cover a t t a c h i n g s c r e w s to
specifications.
4. Position a new gasket and the oil inlet
tube on the oil pump and install the
attaching bolts.
 21-05-28 2300cc Four Cylinder Engine 21-05-28

PISTON AND CONNECTING ROD are used. Type I is shown in Fig. 4 . Type collar can be removed and re-installed as
Disassembly II in Fig. 48. necessary without damaging it.
1. Remove the bearing inserts from the Both lash adjusters are assembled Use the
hydraulic valve lifter
connecting rod and cap. with a simple crimped collar which snaps leakdown tester (Part 21-01) to fill the
2. Mark the piston and pins to assure lash
assembly with the same rod and into a groove on the outside body. This adjusters with test fluid.
installation in the same cylinders
from which they were removed.
3. Press the piston pin from the piston RETAINING RING
and connecting rod. Remove the
piston rings.
Assembly
Check the fit of a new piston in the
cylinder bore before assembling the
piston and pin to the connecting rod. FOLLOWER ARM
The piston pin bore of a connecting FULCRUM
rod and the diameter of the piston pin
must be within specifications.
1. Apply a light coat of engine oil, SE,
to all parts. Assemble the piston to the PLUNGER
connecting'rod with the boss on the
side of the connecting rod and the
arrow in the piston positioned as
PLUNGER RETURN
shown in Fig. 46. SPRING

. ARROW POINTING TOWARD

FRONT OF ENGINE

BODY
BOSS

A3767-C
NUMBER ON LEFT SIDE OF ROD FIG. 47 Type I Lash Adjuster
A3428B

FIG. 46 Correct Piston and Rod

Position

2. Start the piston pin in the piston and

RETAINING RING
connecting rod (this may require a
very light tap with a mallet). Press the
piston pin through the piston and FOLLOWER ARM
connecting rod until the pin is FULCRUM
centered in the piston.
3. Check the end gap and spacing (Fig.
39) of all piston rings. They must be METERING PLATE

within specifications.
4. Check the ring side clearance as
outlined in Part 21-01.
5. Be sure the bearing inserts and the PLUNGER
bearing bore in the connecting rod
and cap is clean. Foreign material
under the inserts will distort the
bearing and cause a failure. Install the
PLUNGER RETURN
bearing inserts in the connecting rod SPRING
and cap with the tangs fitting the slots
provided.
Make certain lock slots in cap are
on the same side of bore as the lock
slot in rod. Avoid nicking crank pin BODY
journals during rod installation.
HYDRAULIC LASH ADJUSTER
Two types of hydraulic lash adjusters FIG. 48 Type II Lash Adjuster
A3768-C
 T74P-6000-LB

NOTE: CRANKSHAF"
PULLEY REMOVER
ALSO REQUIRED

T74P-6700-B
T74P-6254-A

T74P-6015-A
T74P-7137-H . T74P-9510-A
2300cc MUSTANG A3769-B

FIG. 4 9 Special Tools—2300cc Engine

 2300cc 21-05-30

SPECIFICATIONS -1977
CAMSHAFT
GENERAL SPECIFICATIONS
LOBE LIFT
DISPLACEMENT 2.3L
Intake 0.2437
NUMBER OF CYLINDERS 4
Exhaust 0.2437
BORE AND STROKE .3.78 x 3.126
Allowahle Lobe Lift Loss 0.005 Max.
FIRINGORDER 1-3-4-2
THEORETICAL VALVE LIFT &• ZERO LASH
OIL PRESSURE (Hot @ 2000 RPM) 40-60
Intake 0.3997
DRIVE BELT TENSION © Exhaust 0.3.997
END PLAY 0.0010.007
CYLINDER HEAD AND VALVE TRAIN
Service Limit .0.009
COMBUSTION CHAMBER VOLUME (cc) . . . . 59.8-62.8 JOURNAL-TO-BEARING CLEARANCE 0.001-0.003
VALVE GUIDE BORE DIAMETER 0.3433-0.3443 Service Limit 0.006
VALVE SEATS JOURNAL DIAMETER
#1 1.7713 1.7720
Width - Intake
Width-Exhaust 0.070 0.090 #2 1.7713-1.7720
Angle 45° #3 1.7713-1.7720
Runout Limit (T.I.R. Max.) 0.0016 #4 1.7713-1.7720
VALVE ARRANGEMENT (Front to Rear) El El El El Runout Limit 0.005 Max. T.I.R.
VALVE LASH ADJUSTER BORE DIAMETER 0.8430-0.8449 Out-Of-Round Limit 0.0005 Max. T.I.R.
VALVE STEM-TO-GUIOE CLEARANCE FRONT BEARING LOCATION (3) 0.0000.010
Intake 0.0010-0.0027
0.0015 0.0032 CYLINDER BLOCK
Exhaust
Service Clearance 0.0055
HEAD GASKET SURFACE FLATNESS . 0.003 m any 6" - 0.006 overall.
VALVE HEAD DIAMETER
HEAD GASKET SURFACE FINISH (RMS) 60-150
Intake 1.73-1.74
CYLINDER BORE
Exhaust 1.49-1.51
Diameter 3.7795-3.7831
VALVE FACE RUNOUT LIMIT 0.002 Max.
Surface Finish (RMS) 18-38
VALVE FACE ANGLE 44°
Out-Of-Round Limit 0.0015
VALVE STEM DIAMETER (Std.)
Out-Of-Round Service Limit 0.005
Intake 0.3416-0.3423
Taper Service Limit 0.010
Exhaust 0.3411-0.3418
MAIN BEARING BORE DIAMETER 2.5902 2.5910
(0.003 Oversize)
DISTRIBUTOR SHAFT BEARING BORE DIAMETER . 0.5155 0.5170
Intake . . . . 0.3446-0.3453
Exhaust 0.3441-0.3448
(0.015 Oversize) CRANKSHAFT AND FLYWHEEL
Intake 0.3566 0.3573
Exhaust 0.3561 0.3568 MAIN BEARING JOURNAL DIAMETER 2.3990-2.3982'
(0.030 Oversize) Out-Of-Round Limit 0.0006 Max.
Intake 0.37160.3723 Taper Limit 0.0006 Per Inch
Exhaust 0.3711 0.3718 Journal Runout Limit 0.002 Max.
VALVE SPRINGS Surface Finish (RMS) 12 Max.
Compression Pressure (Lb. @ Spec. Length) . . 71-79 @ 1.56 Runout Service Limit 0.005
180-198 @ 1.16 THRUST BEARING JOURNAL
Free Length (Approximate) 1.82 Length 2.3990 2.3982
Assembled Height 1 1 7 / 3 2 - 1 19/32 CONNECTING ROD JOURNAL
Service Limit 10% Pressure Loss @ Spec. Length Diameter 2.0464-2.0472
Out-Of-Square Limit 5/64 (0.078) Out-Of-Round Limit 0.0006 Max.
ROCKER ARM (CAM FOLLOWER) Taper Limit 0.0006 Per Inch Max.
Ratio 1.64:1 Surface Finish (RMS) 12 Max.
VALVE TAPPET, LIFTER OR ADJUSTER MAIN BEARING THRUST FACE
Diameter (Std.) 0.8422 0.8427 Surface Finish (RMS) 35 Front/25 Rear (Max.)
Clearance To Bore 0.0007-0.0027 Runout Limit 0.001 Max.
Service Limit 0.005 FLYWHEEL CLUTCH FACE
Hydraulic Leakdown Rate @ 2-8 Seconds Runout Limit (T.I.R.) 0.005
Collapsed Tappet Gap - Allowable . . 0.035-0.055 @ Cam FLYWHEEL RING GEAR LATERAL RUNOUT (T.I.R.)
- Desired . . 0.0400.050 @ Cam Standard Transmission 0.025
Automatic Transmission 0.060
CRANKSHAFT FREE END PLAY 0.0040.008
Service Limit 0.012
A U X I L I A R Y SHAFT END PLAY 0.001 0.007
CONNECTING ROD BEARINGS
Clearance To Crankshaft - Desired 0.00080.0015
- Allowable 0.0008 0.0026
Bearing Wall Thickness (Std.) (4) 0.0619-0.0624
MAIN BEARINGS
Clearance To Crankshaft - Desired 0.00080.0015
- Allowable 0.0008 0.0026
Bearing Wall Thickness (Std.) (?) 0.0956-0.0951
A U X I L I A R Y SHAFT BEARINGS
Clearance To Shaft 0.00060.0026

CA1355-D1
21-05-31 2300cc Four Cylinder Engine 21-05-31

SPECIFICATIONS -1977
CONNECTING ROD, PISTON AND RINGS LUBRICATION SYSTEM

CONNECTING ROD OIL PUMP

Piston Pin Bore Diameter 0.9104-0.9112 Relief Valve Spring Tension (Lbs. @ Spec. Length) .. 15.2-17.2 @ 1.20
Crankshaft Bearing Bore Diameter 2.1720 2.1728 Drive Shaft-To-Housing Bearing Clearance .. . 0 . 0 1 5 0.0030
•Out-Of-Round Limit 0.0004 Relief Valve-To Bore Clearance . . . . 0.CD15-0.0Q30
Taper Limit 0.0004 Rotor Assembly End Clearance (Assembled) D.004 Max.
Length (Center-to-Center) 5.2031 5.2063 Outer Race-To-Housing Clearance . . . . . . . 1.001 0.013
Alignment (Bore-to-Bore Max. Dif.)
© OIL CAPACITY (Quarts U.S.) 4<7)
1 WIST 0.024
Bend 0.012 FUEL PUMP
Side Clearance (Assembled to Crank)
Standard 0.0035 0.0105 STATIC PRESSURE (P.S.I.):8 50 70
Service Limit 0.0150 MINIMUM VOLUME FLOWfg ^0) 1 Pint in 25 Seconds
PISTON ECCENTRIC TOTAL LIFT (Inches) !.304 0.326
Diameter (?)
Coded Red 3.7780 3.7786
TORQUE SPECIFICATIONS - Special Applications
Coded Blue 3.7792 3.7798
0.003 Oversize ..3.7804-3.7810 ITEM SIZE TOR1UE ;
Piston-ToBore Clearance 0.0014-0.0022
Pin Bore Diameter 0.9123 0.9126
Ring Groove Width AUXILIARY SHAFT GEAR BOLT M-10 28-40
Compression (Top) 0.080 0.081 AUXILIARY SHAFT THRUST PLATE BOLT M-6 6-9
Compression (Bottom) 0.080-0.081 BELT TENSIONER (TIMING) PIVOT BOLT M-10 28-40
Oil 1.1880 0.1890 BELTTENSIONER (TIMING) ADJUSTING BOLT M-8 14-2 I
PISTON PIN CAMSHAFT GEAR BOLT M-12 80-EO
Length 3.010 3.040 CAMSHAFT THRUST PLATE BOLT M-6 6-9
D iameter CARBURETOR-TO-SPACER STUD M-8 7.5-15
Standard 0.9119-0.9124 CARBURETOR SPACER TO-MANIFOLD BOLT M-8 10-1 1
0.001 Oversize 0.91300.9133 CONNECTING ROD NUT M-9 30 C 5
0.002 Oversize 0.9140-0.9143 CRANKSHAFT DAMPER BOLT M-14 100 120
Pm-To-Piston Clearance 0.0002-0.0004 CYLINDER HEAD BOLT M-12 80S ) J j )
Pm-To-Rod Clearance DECEL VALVE NUT 10-1 5
Interference Fit
DECEL VALVE TO INTAKE MANIFOLD ADAPTER 23 i 3
PISTON RINGS
DISTRIBUTOR CLAMP BOLT M-10 14-; i
Ring Width
Compression (Top) 0.077 0.078
DISTRIBUTOR VACUUM TUBE TO MANIFOLD ADAPTER 5-8
EXHAUST MAN. TO CYL. HEAD: BOLT, STUD OR NUT M 10 16 2 3
Compression (Bottom) 0.077-0.078
FLYWHEEL TO CRANKSHAFT BOLT M-10 54-111
Side Clearance
FUELPUMPTO CYLINDERBLOCK M-8 H;I
Compression (Top) 0.002-0.004
Compression (Bottom) 0.002 0.004
INTAKE MANIFOLD TO CYL. HEAD: BOLT OR NUT M-8 i4-:'i@
Oil Ring Snug Fit
MAIN BEARING CAPBOLT M-12 80-iO
OIL PRESSURE SENDING UNIT TO BLOCK 8-Hi
Service Limit 0.006
Ring Gap OILPUMPPICKUPTUBETO PUMP M-8 14-i'i
Compression (Top) 0.010 0.020
OIL PUMPTO BLOCK M-8 i4-:'i
Compression (Bottom) OIL PAN DRAIN PLUG TO PAN M-14 i5-:-5
0.010 0.020
Oil Ring (Steel Rail) 0.015-0.055
OIL PAN TO BLOCK M-6 6-8
M-8 8-Hl
OIL FILTER INSERTTO BLOCK 20 ;p5
OIL FILTER TO ENGINE @
ROCKER ARM TO COVER BOLT M-6 4-7
SPARK PLUG TO CYLINDER HEAD M-14 5-1(1
TEMPERATURE SENDING UNIT TO BLOCK 8-111
WATER JACKET DRAIN PLUG TO BLOCK 23-:!8
WATER PUMPTO BLOCK: BOLT M-8 14.M
EGR VALVE TO SPACER: BOLT M-8 14-:!1
EGRTUBETO EXHAUST MANIFOLD: CONNECTOR 9-1
EGR TUBE NUT 9-1 I
AUXILIARY SHAFT COVER BOLT M-6 6-9
WATER OUTLET CONNECTION BOLT M-8 i4-n
CYLINDER FRONT COVER BOLT M-6 6-9
INNER TIMING BELT COVER STUD M-8 14- M
OUTER TIMING BELT COVER BOLT M-6 69
ROCKER ARM COVER SHIELD BOLT M-10 28-10
THERMACTOR CHECK VALVE TO MANIFOLD 17-?0'
FUEL FILTERTO CARBURETOR 80-100 In. Lb.
21-05-32 2300cc Four Cylinder Engine 21-05-32

SPECIFICATIONS-1977
TORQUE SPECIFICATIONS - General Applications
Drive Belt Tension (Lbs.)

U.S. THREAD SIZES TORQUE Newly Installed Used

S i
" (A) Up to 10 Mm. Over 10 Min.
1/4-20 6-9
12 18 1/4" 50-80 40-80 (B) 40-60 (B)
5/16-24 14-20
3/8-16 22-32 Exc. 1/4" 120-160 90-160 (C) 75-120 (D)
3/8-24 27-38
7/16-14 (A) Read tension immediately after belt is installed, before it stretches or seats in pulley
40-55
7/16-20 grooves.
40-60
' /Z* 10 , 55-80 (B) If less than 40 pounds, readjust to 40-60 pounds.
(C) If less than 90 pounds, readjust to 90 120 pounds.
METRIC THREAD SIZES TORQUE (D) If less than 75 pounds, readjust to 90-120 pounds.
Time required for plunger to leak down 1/8" of travel with 50 ib. load and leakdown fluid
M-6 6-9 in lash adjuster.
M-8 14-21 Distance in inches that front bearing is installed below front face of bearing tower.
M-10 28-40 0.002 Undersize = Add 0.001 to Standard Thickness.
50-71 Pin bore and crank bearing bore must be parallel and in the same vertical plane within the
80-114 specified total difference when measured at the ends of an 8 " bar - 4 " on each side of rod
centerline.
PIPE THREAD SIZES TORQUE Measured at the piston pin bore centerline - 90° to the pin.
Add one quart with filter change.
1/8 5-8 On engine, temperature normal, curb idle, neutral.
1/4 12-18 Pump-to-tank return line pinched off, new fuel filter in line.
3/8 22 33 Smallest orifice =not less than 0.220" I. D.
1/2 25-35
(11s' Torque cylinder head bolts in sequence in two steps.
• All values are in ft.-lb. unless otherwise noted. • Step 1 - 50-60 ft.-lb.
• Oil threads with engine oil unless fasteners require sealers. • Step 2 - 80-90 ft.-lb.
(§) Torque manifold bolts in sequence in two steps:
• Step 1 - 5-7 ft.-lb.
• Step 2 - 14-21 ft.-lb.
* And then rotate into position.

CA1355-02
21-10-1 200 and 250 CID Six-Cylinder Engines 21-10-1

PART
200 and 250 CID Six-Cylinder Engines 21-10

SUBJECT PAGE SUBJECT PAGJE

DESCRIPTION REMOVAL AND INSTALLATION (Cont'd.)
Crankcase Ventilation System 10-2 Flywheel 10 10
Engine 10-2 Front Oil Seal 10 9
Exhaust Emission Control System 10-2 Hydraulic Valve Lifters 107
Main Bearings 10-11
ADJUSTMENTS Oil Filter 10-15
Hydraulic Valve Clearance 10-2 Oil Pan 10 11
Oil Pump 10-11
REMOVAL AND INSTALLATION Pistons and Connecting Rods 10-12
Camshaft 10-9 Valve Rocker Arm Cover and
Camshaft Bearing 10-15 Rocker Arm 10-5
Camshaft Rear Bearing Bore Plug 10-11 Valve Spring Retainer and Stem Seal 10-5
Clutch Pilot Bearing 10-10 Water Pump 10-7
Connecting Rod Bearings 10-12
Crankcase Ventilation System 10-5 DISASSEMBLY AND ASSEMBLY
Crankshaft 10-13 Cylinder Assembly 10-18
Crankshaft Rear Oil Seal 10-11 Cylinder Block 10-18
Cylinder Front Cover and Cylinder Head 10-16
Timing Chain 10-8 Oil Pump 10-17
Cylinder Head 10-6 Piston and Connecting Rod 10-17
Engine Assembly 10-3 Valve Lifter - Hydraulic 10-16
Engine Front Supports 10-4 Valve Rocker Arm Shaft Assembly 10-16
Engine Rear Support 10-5
Exhaust Manifold 10-7 SPECIFICATIONS 10-19

CA4293-A
21-10-2 200 and 250 CID Six-Cylinder Engines 21-10-2

DESCRIPTION
ENGINE
The 200 and 250 CID six cylinder
engines are in-line, overhead valve design
of lightweight cast iron construction.
Adjustment and repair procedures for
the two engines are basically the same.
A typical six cylinder engine is
shown in Fig. 1.
EMISSION CONTROL DEVICES
Operation, removal, installation and
required maintenance of the exhaust
emission control devices used on these
engines are covered in Group 29 and
Group 50 of this Manual.
CRANKCASE VENTILATION
SYSTEM
These engines are equipped with a
positive, closed-type ventilation system
re-cycling the crankcase vapors to the
intake manifold.

A2748G

FIG. 1 Typical In-Line Six-Cylinder Engine

With the crankshaft in the position compression stroke (1 revolution of

ADJUSTMENTS
HYDRAULIC VALVE CLEARANCE
A 0.060-inch shorter than standard
push rod and a 0.060-inch longer than
standard push rod are available for
s e r v i c e to p r o v i d e a m e a n s of
compensating for dimensional changes in
the valve mechanism. Refer to the Master
Parts List or the specifications for the
pertinent color code.
Valve stem to valve rocker arm
clearance should be within specifications
with the hydraulic lifter completely
collapsed. Repeated valve reconditioning
operations (valve and/or valve seat
refacing) will decrease the clearance to
the point that, if not compensated for, the
hydraulic valve lifter will cease to
function and the valve will be held open.
To determine whether a shorter or a
longer push rod is necessary, make the
following check:
1. Connect an auxiliary starter switch in
the starting circuit. Crank the engine
with the ignition switch OFF until the
No. 1 piston is on TDC after the
compression stroke.
designated in Steps 3 and 4, position the c r a n k s h a f t ) . By using the
the hydraulic lifter compressor tool procedure in Step 2, check the
on the rocker arm. Slowly apply following valves:
pressure to bleed down the hydraulic No. 2 Exhaust
lifter until the plunger is completely No. 3 Intake
bottomed (Fig. 2). Take care to avoid No. 4 Exhaust
excessive pressure that might bend No. 5 Intake
the push rod. Hold the lifter in this
position and check the available
Feeler Gauge Tool-6513-K
clearance between the rocker arm and
the valve stem tip with a feeler gauge.
If the c l e a r a n c e is less than
specified, install an under-size push
rod. If the clearance is greater than
specified, install an oversize push rod.
With the No. 1 piston on TDC after
the compression stroke, use the
procedure in Step 2 and check the
following valves:
No. 1 Intake
No. 1 Exhaust
No. 2 Intake
No. 3 Exhaust
No. 4 Intake
No. 5 Exhaust A3229-A
Now rotate the crankshaft until the
No. 6 piston is on TDC after the FIG. 2 Check Valve Clearance
21-10-3
No. 6 Intake
No. 6 Exhaust
5. When compressing the valve spring to
remove the push rods, be sure the
piston in the individual cylinder is
below TDC to avoid contact between
the valve and the piston. To replace
REMOVAL AND INSTALLATION
When installing nuts or bolts that
must be torqued, refer to the Specifi-
cation Section at the end of this
Part. Oil the threads with light-weight
engine oil. Do not oil threads that require
oil-resistant or water-resistant sealer.
Refer to Part 21-01 for cleaning and
inspection and engine test procedures.
ENGINE ASSEMBLY
If the engine is equipped with the
Thermactor system, remove or
disconnect parts that will interfere with
removal or installation of the engine.
Removal
1. Remove the hood.
2. Drain the cooling system and the
crankcase.
3. Disconnect the closed crankcase
ventilation hose. Remove the air
cleaner. Disconnect the battery
ground cable at the cylinder head and
at the battery. Disconnect the
radiator upper hose at the water
outlet housing and the radiator lower
hose at the water pump. On a vehicle
with automatic transmission
disconnect the transmission oil cooler
lines from the radiator.
4. Remove the radiator. Remove the
fan, spacer, belt and pulley.
5. Disconnect the heater hoses from the
water pump and cylinder block.
Disconnect the alternator wires from
the alternator, the starter cable from
the starter and the accelerator control
cable from the carburetor. On a
vehicle with air conditioning, remove
the compressor from the mounting
bracket, and position it out of the
way, leaving the refrigerant lines
attached.
6. Disconnect theflexiblefuel line at the
fuel pump line and plug the fuel line.
7. Disconnect the coil wires from the
coil. Disconnect the oil pressure and
the water temperature sending unit
wires from the sending units.
8. Remove the starter.
On a vehicle with a manual-shift
transmission, disconnect the clutch
retracting spring. Disconnect the
clutch equalizer shaft and arm
bracket at the underbody rail and
remove the arm bracket and equalizer
shaft.
200 and 250 CID Six-Cylinder Engines
a push rod, it will be necessary to
remove the valve rocker arm shaft
assembly. Upon replacement of a
valve push rod, valve rocker arm shaft
assembly or hydraulic valve lifter, the
engine should not be cranked or
rotated until the hydraulic lifters have
9. Raise the vehicle. Remove the
flywheel or converter housing upper
attaching bolts.
10. Disconnect the muffler inlet pipe at
the exhaust manifold. Loosen the
inlet pipe clamp and slide it off the
support bracket on the engine.
Disconnect the engine right and left
mounts at the underbody bracket.
Remove the flywheel or converter
housing cover.
On a vehicle with a manual-shift
transmission, remove the flywheel
housing lower attaching bolts.
On a vehicle with automatic
transmission, disconnect the
converter from theflywheel.Remove
the converter housing lower attaching
bolts.
11. Lower the vehicle. Support the
transmission and flywheel or
converter housing with a jack.
12. Attach the engine lifting hook (Fig.
3). Carefully lift the engine out of the
engine compartment. Place the engine
on a work stand (Fig. 4).
TOOI-T6OK-60OOA
FIG. 3 Engine Lifting Hook
Installation
1. If the clutch was removed, install as
detailed in Group 16. Install guide
pins in the flywheel or converter
housing bolt holes in the rear of the
engine.
2. Carefully lower the engine into the
engine compartment.
21-10-3
had an opportunity to leak clown to
their normal operating position. The
leak down rate can be accelerated by
using the tool shown in Fig. 2 on the
valve rocker arm and applying
pressure in a direction to collapse the
lifter.
3. Make sure the guide pins in the block
engage the holes in the flywheel
housing.
On a vehicle with automatic
transmission, start the converter pilot
into the crankshaft.
On a vehicle with a manual-shift
transmission, start the transmission
main drive gear into the clutch disc.
It may be necessary to adjust the
position of the transmission in
relation to the engine if the input shaft
will not enter the clutch disc If the
engine hangs up after the shaft enters,
turn the crankshaft slowly
(transmission in gear) until the shaft
splines mesh with the clutch disc
splines.
4. Remove the engine lifting hook.
Install the flywheel or converter
housing upper attaching bolts.
5. R e m o v e t h e j a c k from t h e
transmission. Raise the vehicle.
6. Remove the guide pin and install the
flywheel or converter housing lower
attaching bolts.
On a vehicle with automatic
transmission, attach the converter to
theflywheeland torque the attaching
nuts to specifications.
7. Install the flywheel or converter
housing dust cover.
On a vehicle with a manual-shift
transmission, install the clutch
equalizer shaft and arm bracket.
Connect the clutch retracting spring.
8. Install the engine left and right mount
to the underbody bracket.
9. Remove the plug from the fuel pump
line and connect theflexiblefuel line
to the fuel pump line. Using a new
gasket, install the exhaust manifold to
muffler inlet pipe with lockwashers
and nuts. Torque the nuts to
specifications. Position the inlet pipe
clamp on the support bracket on the
engine and tighten the clamp.
10. Lower the vehicle. Connect the oil
pressure and the engine temperature
sending unit wires. Connect the coil
wires. Connect the accelerator
control cable.
11. Install the starter motor. Connect the
starter cable. Connect the alternator
wires. Connect the heater hose at the
water pump and cylinder block.
Connect the battery ground cable.
21-10-4 200 and 250 CID Six-Cylinder Engines 21-10-4

12. Install the pulley, fan, and drive belt.
Adjust the drive belt tension. On a
vehicle with air conditioning, install
the compressor on the mounting
bracket, and adjust the belt tension to
specifications. Install the radiator.
Connect the radiator upper and lower
hoses. Fill and bleed the cooling
system. Fill the crankcase with the
proper grade and quantity of engine
oil.
13. Install and adjust the hood.
14. Operate the engine at fast idle and
check all g a s k e t s a n d hose
connections for leaks.
On a vehicle with automatic
transmission, perform a transmission
kickdown linkage adjustment (Part
24-60).
15. Install the air cleaner and connect the
positive closed-type crankcase
ventilation hose.
ENGINE FRONT SUPPORTS
The procedures given apply to either
a right or left installation.
The engine front supports are located
on each side of the cylinder block.
Whenever self-locking mounting bolts
and nuts are removed, they must be
Tool-T64L-6001-B
replaced with new self-locking bolts and
nuts.
Granada, Monarch, Maverick
and Comet 200 and 250 CID
Engines
Removal
1. Remove the insulator to support
bracket nuts and washers from both
insulators (Fig. 5).
2. Raise the engine with a jack and
wood block placed under the oil pan.
3. Remove the insulator-to-engine bolts
and washers and remove the
insulator.

A2842-A

FIG. 4 Engine Mounted on Work Stand—Typical

UPPER BRACKET -
6043 R.H.
6A069 L.H. 386242-S100
250 ENGINE ONLY 4REQ'D. LOWER
17-37 FT-LB BRACKET-
\ 6061 L.H.
INSULATOR - \ 6037 R.H. 382802-S2
6038 ASSY. 6 REQ'D.
2REQ'D. 20-37 FT-LB

UPPER BRACKET AND INSULATOR -

6C010 ASSY. R.H.
6C060 ASSY. L.H.

MAIN VIEW
VIEWY
383421-S2
LOWER BRACKET - 2 REQ'D.
6061 L.H. VIEWY
INSULATOR - 6068 REF.
6037 R.H. 250 ENG. ONLY
386242-S100 EXHAUST SYSTEM
200 ENG. ONLY
2 REQ'D. BRACKET- OTHERWISE SAME
17-32 FT-LB (FOR CATALYTIC AS VIEW Y
3 SPD. STD. TRANS.
SYSTEM ONLY)
FLOORSHIFTONLY

UPPER BRACKET
6043 R.H.
6A069 L.H.

ALL EXCEPT 386242-S100

6 REQ'D.
3-SPD. STD.
17-32 FT-LB
TRANS. FLOOR
SHIFT. 383421-S2
2 REQ'D.
INSULATOR
6038 ASSY. R
6B032 ASSY.
382400-S2
<*£* 2 REQ'D.
34977-S2 30-50 FT-LB
4 REQ'D
20-32 FT-LB
6K013
LOWER
ASSY.
BRACKET
6061 L.H. VIEWY
6037 R.H. 34978-S2 250 ENG.
2 REQ'D. ONLY
STAMPED 40-60 FT-LB
(GRANADA/MONARCH SHOWN -
LETTER " R "
MAVERICK/COMET SIMILAR) A4059-C

FIG. 5 Granada, Monarch, Maverick and Comet—Front and Rear Supports 200 and 250 CID Engines
21-10-5
Installation
1. Position the insulator assembly on the
engine and install the insulator- to-
engine bolts and washers finger-tight.
2. Lower the engine carefully to make
sure the insulator stud engages the
hole in the support bracket.
3. Install the insulator to support
bracket washer and nut on bolt engine
front mounts. Tighten the insulator
bolts and nuts to specification.
ENGINE REAR SUPPORT
The rear support is located at the
transmission extension housing (Fig. 5).
Whenever self-locking mounting bolts
and nuts are removed, they must be
replaced with new self-locking bolts and
nuts.
Granada, Monarch, Maverick
and Comet
Removal
1. On automatic transmission models,
support the engine with a jack and
wood block under the oil pan and
remove the rear insulator to
crossmember attaching nuts.
2. Remove the rear insulator to
transmission extension housing bolts
and lock washers.
3. On all models except those with floor
shift manual transmissions, raise the
transmission and remove the rear
insulator.
4. On floor shift manual transmission
models, support the transmission
with a floor jack and remove the
frame crossmember from the frame
and from the rear insulator; then
remove the rear insulator from the
transmission. Do not apply upward
pressure on the transmission with the
jack as damage to the transmission
shift lever console or mounting plate
will result.
Installation
1. Position the rear insulator on the
transmission extension housing.
2. On all models except those with floor
shift, install the rear insulator to
transmission extension housing bolts
and lock-washers. Torque the bolts to
specification. Lower the transmission.
3. Install the two insulator to
crossmember attaching nuts and
torque to specification.
4. On models with floor shift manual
transmission, position the rear
insulator to the transmission and
install and torque the attaching bolts.
5. Position the removable crossmember
to the frame and install the through
bolts. Remove the supporting jack,
install the nuts and washers attaching
the support to the crossmember and
torque the nuts to specification.
6. Remove the jack. Disconnect all
necessary vacuum components and
200 and 250 CID Six-Cylinder Engines
•ELBOW 382956-S
CRANKCASE CLOSURE
HOSE 6853
FRONT OF VEHICLE
FIG. 6 Closed Crankcase Ventilation System Components
lines for accessibility and identify
them for proper connection.
CRANKCASE VENTILATION
SYSTEM
The closed crankcase ventilation
system components are shown in Fig. 6.
Removal
1. Remove the inlet hose from the air
cleaner and the oil filler cap. Remove
the fresh air intake tube and the heat
shroud tube.
2. Remove the air cleaner and crank-
case vent hose.
3. Grasp the plastic "elbow" and PCV
valve assembly near the rocker arm
cover grommet and pull the regula-
tor valve from the rocker arm cover.
4. Remove the regulator valve from
the plastic "elbow" and remove the
vent hose from the hose fitting in
the carburetor spacer.
Installation
1. Install the vent hose on the fitting in
the carburetor spacer and the
regulator valve in the hose.
2. Insert the regulator valve into the
rocket arm cover mounting grommet.
3. Install the air cleaner.
4. Connect the inlet hose to the air
cleaner and the oil filler cap. Connect
the fresh air intake tube and the heat
shroud tube.
5. Operate the engine and check for
leaks.
21-10-5
CRANKCASE VEN"
HOSE 6A664
PCV VALVE
A3414-D
VALVE ROCKER A R M COVER
AND ROCKER ARM
Removal
1. Remove the air cleaner and the
crankcase ventilation system.
Remove the accelerator control cable
bracket.
2. Remove the valve rocker arm cover
and discard the gasket.
3. Remove the rocker arm shaft support
bolts by loosening the bolts two turns
at a time in sequence. Remove the
rocker arm shaft assembly (Fig. 7).
Remove the valve push rods. Make
sure the push rods are identified
before removal so they can be
returned to the same location when
they are installed.
A3165-A
FIG. 7 Valve Rocker Arm Shaft
Removal
Installation
1. Apply Lubriplate or equivalent to
both ends of the'push rods and to the
valve stem tip.
21-10-6
2. Install the valve push rods. Position
the valve rocker arm shaft assembly
on the cylinder head.
3. Install and tighten all valve rocker
arm support bolts, two turns at a time
in sequence, until the supports fully
contact the cylinder head. Torque the
bolts to specifications.
4. If any part which could affect the
valve clearance has been changed,
check the valve clearance following
the procedure outlined under
Hydraulic Valve Lifter Adjustment.
5. Clean the valve rocker arm cover and
cylinder head gasket surfaces. Install
the gasket in the cover making sure
that all tangs of the gasket are
engaged in the notches provided in
the cover. Connect all vacuum lines
and components using previous
identification for proper connection.
Tighten the cover attaching bolts in
two steps. First, torque the bolts to
specifications; then, retorque to the
same specifications two minutes after
initial tightening. Install the
accelerator control cable bracket.
6. Install the crankcase ventilation
system and the air cleaner.
VALVE SPRING, RETAINER AND
STEM SEAL
Broken valve springs or leaking valve
stem seals and retainer may be replaced
without removing the cylinder head
provided damage to the valve or valve
seat has not occurred.
Removal
1. Remove the air cleaner. Remove the
crankcase ventilation regulator valve
from the valve rocker arm cover.
Remove the valve rocker arm cover.
Remove the applicable spark plug.
2. Loosen the valve rocker arm shaft
support bolts two turns at a time, in
sequence, until the valve spring
pressure is relieved. Remove both
valve push rods of the cylinder to be
serviced.
3. Install an air line with an adapter in
the spark plug hole.
4. Tighten the attaching bolts just
enough to seat the rocker arm shaft
supports on the cylinder head. Push
the rocker arm to one side and secure
it in this position (Fig. 8). To move
the rocker arm on either end of the
shaft, it will be necessary to remove
the retaining pin and spring washer
and slide the rocker arm off the shaft.
5. Turn on the air supply. Air pressure
may turn the crankshaft until the
piston reaches the bottom of the
stroke.
Using the valve spring compression
tool shown in Fig. 8, compress the
valve and remove the valve spring
retainer locks, the sleeve, spring
retainer and the valve spring. If air
200 and 250 CID Six-Cylinder Engines
Air Line And Adapter Tool-T65P-6513
FIG. 8 Compressing Valve Spring—In
Chassis
pressure fails to hold the valve in the
closed position during this operation,
it can be presumed that the valve is
not seating or is damaged. If this
condition occurs, remove the cylinder
head for further inspection.
6. Remove the valve stem seal (Fig. 9).
If air pressure has forced the piston
to the bottom of the cylinder, any
removal of air pressure will allow the
valve(s) to fall into the cylinder. A
rubber band, tape or string wrapped
around the end of the valve stem will
prevent this condition and will still
allow enough travel to check the valve
for binds.
Air Line SEAL
FIG. 9 Removing Valve Stem Seal
Installation
1. Install a new valve stem seal. Position
the spring over the valve. Install the
spring retainer and sleeve. Compress
the valve spring and install the valve
spring retainer locks.
2. Apply Lubriplate or equivalent to
both ends of the push rod, the valve
and push rod ends of the rocker arm,
and the valve stem tip. Remove the
rocker arm shaft and install the push
rod(s), making sure the lower end of
the rod is positioned in the valve lifter
push rod cup.
3. Remove the wire securing the valve
rocker arm and slide the rocker arm
into position. If an end valve rocker
arm was removed, slide it into
position on the shaft and install the
spring washer and retainer pin. Turn
21-10-6
off the air and remove the air line and
adapter. Install the spark plug and
spark plug wire.
4. Install the rocker arm shaft by
following the instructions under
Rocker Arm Installation.
5. Clean the valve rocker arm cover and
cylinder head gasket surfaces. Install
a new gasket in the cover making sure
the gasket tangs are securely engaged
with the notches in the cover. Position
the cover on the head. Install and
tighten the cover attaching bolts in
two steps. First, torque the bolts to
specifications. Two minutes later,
torque the bolts to the same
specifications.
6. Insert the regulator valve (with the
vent hose attached) into the valve
rocker arm cover mounting grommet.
Install the air cleaner.
CYLINDER HEAD
Removal
1. Drain the cooling system. Remove
the air cleaner. Disconnect the
radiator upper hose at the engine.
2. Disconnect the muffler inlet pipe at
the exhaust manifold. Pull the muffler
inlet pipe down. Remove the gasket.
3. Disconnect the accelerator retracting
spring. Disconnect the accelerator
control cable at the carburetor.
4. Disconnect the transmission
kickdown rod. Disconnect the
accelerator linkage at the bellcrank
assembly.
5. Disconnect the fuel inlet line at the
fuel filter hose. Disconnect the
distributor vacuum lines. Disconnect
vacuum lines and components as
necessary for accessibility and
i d e n t i f y t h e m for p r o p e r
re-connection.
6. Disconnect the carburetor fuel inlet
line at the fuel pump. Remove the
lines as an assembly.
7. Disconnect the spark plug wires at the
spark plugs and the temperature
sending unit wire at the sending unit.
8. Remove the crankcase ventilation
system. Remove the accelerator
control cable bracket.
9. Remove the valve rocker arm cover.
10. Remove the valve rocker arm shaft
assembly. Remove the valve push
rods in sequence (Fig. 10).
A2224A
FIG. 10 Valve Push Rod Removal
11. Remove the remaining cylinder head
bolts and remove the cylinder head.
Do not pry between the cylinder head
21-10-7
and block as the gasket surfaces may
become damaged.
Installation
1. Clean the head and block gasket
surfaces. (Refer to Part 21-01 for
cleaning and inspection procedures).
If the cylinder head was removed for
a gasket change, check the flatness of
the cylinder head and block. Install
guide studs at each end of the cylinder
block (Fig. 11).
7 / 1 6 " - 1 4 x 6 " BOLT. CUT OFF HEAD, TAPER
•END AND SLOT FOR SCREWDRIVER.
A2790-A
FIG. 11 Cylinder Head Guide Studs
2. Position the cylinder head gasket over
the guide studs on the cylinder block.
3. Install a new gasket on the flange of
the muffler inlet pipe.
4. Lift the cylinder head over the guides
and slide it down carefully, connect
the muffler inlet pipe to the exhaust
manifold.
5. Install, but do not tighten two bolts
at opposite ends of the head to hold
the head and gasket in position.
Remove the guides and install the
remaining bolts.
6. The cylinder head bolts are tightened
in three progressive steps. Torque all
the bolts in sequence (Fig. 12) to
specifications. When cylinder head
bolts have been tightened following
this procedure, it is not necessary to
retorque the bolts after extended
operation. However, on cylinder
heads with composition gaskets, the
bolts may be checked and retorqued,
if desired. Tighten the exhaust
manifold flange attaching nuts to
specification.
A1369-A
FIG. 12 Cylinder Head Bolt Torque
Sequence
7. Apply Lubriplate or equivalent to
both ends of the push rods. Install the
push rods in the original bores,
positioning the lower end of the rods
into the tappet sockets. Apply
Lubriplate or equivalent to the valve
stem tips and to the rocker arm pads.
8. Install the valve rocker arm shaft
assembly following procedures under
200 and 250 CID Six-Cylinder Engines
Valve Rocker Arm Shaft Installation.
Check the valve c l e a r a n c e ,
following the procedure outlined
under Valve Clearance Adjustment.
9. Install the muffler inlet pipe lock
washers and attaching nuts. Torque
the nuts to specifications.
10. Connect the radiator upper hose at
the coolant outlet housing.
11. Position the distributor vacuum line
and the carburetor fuel inlet line on
the engine. Connect the fuel line at
the fuel filter using a new clamp, then
connect the distributor vacuum line at
the carburetor.
12. Connect the accelerator control cable
bracket.
13. Connect the accelerator control cable
retracting spring. Connect the
accelerator control cable at the
carburetor.
14. Connect the distributor vacuum line
at the distributor. Connect the
carburetor fuel inlet line at the fuel
p u m p . C o n n e c t all v a c u u m
components and lines using previous
identification for proper connection.
15. Connect the temperature sending unit
wire at the sending unit. Connect the
spark plug wires.
16. Fill and bleed the cooling system.
17. Install the crankcase ventilation
system.
18. Start the engine and check,for coolant
and oil leaks.
HYDRAULIC VALVE LIFTERS
Before replacing a hydraulic valve
lifter for noisy operation, be sure the
noise is not caused by improperly
adjusted valve clearance or by worn
rocker arms or push rods.
Removal
1. Remove the cylinder head and related
parts following the procedure under
Cylinder Head Removal.
2. Using a magnet, remove the valve
lifters (Fig. 13). Place the lifters in a
rack so they can be installed in the
original positions.
If the lifters are stuck in their bores
by excessive varnish or gum, it may
be necessary to use a plier-type or
claw-type tool (T70L-6500-A) to
remove the lifters. Rotate the lifter
back and forth to loosen any gum and
varnish which may have formed on
the lifter. Keep the assemblies intact
until they are to be cleaned. If the
valve lifters are to be tested or
disassembled and cleaned, follow the
procedures in Part 21-01. If a
hydraulic valve lifter has been
disassembled and cleaned, be sure to
fill it with test fluid before installing
211-10-7
Magnet A3135-A
FIG. 13 Removing Valve Lifter
it in the engine. New valve lifters
already contain test fluid.
Installation
1. Install new (or cleaned) hydraulic
valve lifters through the push rod
openings with a magnet (Fig 13).
2. Install the cylinder head and related
parts.
EXHAUST MANIFOLD
Removal
1. Remove the air cleaner and related
parts. Disconnect the muff er inlet
pipe from the exhaust manifold, and
remove the automatic choke hot air
tube.
2. Remove or disconnect the emission
components that interfere with the
removal of the exhaust manifold.
3. Bend the exhaust manifold attaching
bolt lock tabs back and remove the
bolts. Remove the exhaust manifold.
Installation
1. Clean the mating surfaces of the
exhaust manifold and cylinder head.
Scrape the gasket material from the
mounting flange of the exhaust
manifold and muffler inlet pipe.
2. Position the exhaust manifold on the
cylinder head and install the
attaching bolts and tab washers.
Torque the bolts and studs in
sequence shown in Fig. 14. Refer to
specifications.
3. Place a new gasket on the muffler
inlet pipe. Position the muffler inlet
pipe to the manifold. Install and
t o r q u e the a t t a c h i n g n u t s to
specifications. Install the auromatic
choke hot air tube.
4. Install or connect the emission
components previously disconnected.
5. Install the air cleaner and related
parts. Start the engine and check for
exhaust leaks.
WATER PUMP
Removal
1. Drain the cooling system. Remove
the air pump, power steering and air
conditioner drive belts, if so equipped.
2. Disconnect the radiator lower hose at
21-10-8
INSTRUCTIONS:
INSTALL 3/8-16 STUD & WASHER ASSEMBLY - HOLES NUMBERED 4 & 5 TORQUE TO 18-24 FT-LB.
3/8-16 X 2.62 BOLT - HOLES 3-6-7-8-TORQUE TO 18-24 FT-LB.
3/8-16 X 1.12 B O L T - HOLES 1-2-9-10-11 TORQUE TO 18-24 FT-LB FRONT
VIEW LOOKING AT RIGHT
SIDE OF ENGINE
FIG. 14 View Looking at Right Side of Engine
the water pump. Remove the drive
belt, fan, or fan and drive clutch, and
water pump pulley.
3. Disconnect the heater hose at the
water pump.
4. Remove the water pump.
Installation
1. If a new water pump is to be installed,
remove the heater hose fitting from
the old pump and install it on the new
pump. Clean the gasket surfaces on
the water pump and cylinder block.
The 250 CID six uses a one piece
gasket for the cylinder front cover
and water pump. Trim away the old
gasket at the edge of the cylinder
front cover. Use a water pump service
gasket to replace it.
2. Coat the new gasket on both sides
with water-resistant sealer and
position it on the cylinder block.
3. Position the water pump and install
the lockwashers and attaching bolts
(the alternator adjusting arm is
secured by one water pump bolt).
Torque the bolts to specifications.
4. Connect the radiator lower hose and
the heater hose to the water pump.
5. Install the water pump pulley and fan.
T o r q u e the bolts evenly and
alternately to specifications.
6. Install the air pump, power steering
and air conditioner drive belts, if so
equipped and adjust the tension to
specifications.
7. Fill and bleed the cooling system.
Operate the engine until normal
operating temperature is reached.
Check for leaks and check the coolant
level.
CYLINDER FRONT COVER AND
TIMING CHAIN
Removal
1. Drain- the cooling system and the
200 and 250 CID Six-Cylinder Engines
OF ENGINE
EXHAUST MANIFOLD (9430)
A4081-
crankcase. Disconnect the radiator
upper hose at the coolant outlet
housing and the radiator lower hose
at the water pump. On a vehicle with
automatic transmission, disconnect
the transmission oil cooler lines from
the radiator.
2. Remove the radiator. Remove the
drive belt, fan and pulley. On a
vehicle with air conditioning, remove
the condenser attaching bolts and
position the condenser forward. Do
not disconnect the refrigerant lines.
Remove the compressor drive belt. If
so equipped, remove the accessory
drive pulley. Using Tool T-58P-6316-
B, remove the crankshaft damper.
3. On a 200 CID engine, remove the
cylinder front cover attaching screws
from the cover and from the oil pan.
Pry the top of the front cover away
from the block slightly and, using a
thin bladed knife, cut the oil pan
gasket flush with the front face of the
cylinder block.
4. On a 250 CID engine, remove the oil
pan. Remove the cylinder front cover.
5. Clean any gasket material from the
surfaces.
6. R o t a t e t h e c r a n k s h a f t in a
counterclockwise direction (as viewed
from the front) to take up the slack
on the left side of the chain.
7. Check timing chain deflection
following the procedures given in Part
21-01. If the deflection exceeds 1/2
inch, replace the timing chain and
sprockets.
8. Crank the engine until the timing
marks are aligned as shown in Fig. 15.
Remove the camshaft sprocket
attaching bolt and washer. Slide both
sprockets and timing chain forward
and remove them as an assembly (Fig.
16).
21-10-8
A2791-B
FIG. 15 Aligning Timing Marks
A2792-B
FIG. 16 Timing Chain and Sprockets
Removal
Installation
1. Clean and inspect all parts before
installation. Oil the timing chain after
installing it on the camshaft and
crankshaft. Be sure the timing marks
on the sprockets are positioned as
shown in Fig. 15. Install the camshaft
sprocket attaching bolt and washer.
Torque the bolt to specifications.
2. Apply oil-resistant sealer to a new
cylinder front cover gasket and
position the gasket on the cylinder
front cover. Apply sealer to the
exposed area of the gasket. On a 200
CID engine, coat the gasket surface
of the oil pan with oil resistant sealer.
Cut and position the required
portions of a new gasket on the oil
pan. Apply sealer to the exposed areas
of the gasket, including the corners
where they contact the front cover
gasket. On a 250 CID engine, install
the timing chain snubber in the front
cover (Fig. 17).
3. Install the cylinder front cover using
the tool shown in Fig 18. On a 250
CID engine, no adjustment is needed
on the chain snubber (Fig. 17) as this
is automatically obtained during front
cover alignment. Torque the
attaching bolts to specifications.
21-10-9
CYLINDER FRONT
COVER
OIL SfcAL
TIMING CHAIN SNUBBER A 3222-A
FIG. 17 Timing Chain Snubber
Installation—250 CID Six
1K-6019-A
"A2809-A
FIG. 18 Aligning Cylinder Front
Cover
4. Lubricate the hub of the crankshaft
damper with Lubriplate or equivalent
to prevent damage to the seal during
installation or initial engine start.
Using Tool T52L6306-AEE, install
the crankshaft damper. Torque the
attaching bolt to specifications.
5. On a 250 CID engine, install the oil
pan and related parts, following the
i n s t r u c t i o n s u n d e r Oil Pan
Installation.
6. Install the fan, pulley and drive belt.
Adjust the drive belt.
7. Install the radiator. Connect the
radiator upper and lower hoses. Refill
the crankcase with the proper grade
and quantity of engine oil before
starting the engine.
8. Fill and bleed the cooling system.
9. Start the engine and check the
ignition timing. Operate the engine at
fast i d l e a n d c h e c k all h o s e
connections and gaskets for leaks.
FRONT OIL SEAL
Removal
1. Remove the cylinder front cover.
2. Drive out the oil seal with a pin
punch. Clean the recess in the cover.
Installation
1. Coat a new seal with grease and
install the seal. Drive the seal in until
it is fully seated in the recess (Fig. 19).
Check the seal after installation to be
sure the spring is properly positioned
in the seal.
200 and 250 CID Six-Cylinder Engines
2. Replace the cylinder front cover.
Tool-TS3L-200-A
OIL SEAL
A2808-A
FIG. 19 Crankshaft Front Oil Seal
Replacement
CAMSHAFT
The camshaft and related parts are
shown in Fig. 20.
6263 BEARINGS
\
CAMSHAFT REAR BEARING
BORE PLUG
6266
AND CAMSHAFT SPROCKET - 6256
FIG. 20 Camshaft and Related Parts
Removal
1. Drain the cooling system and the
crankcase. Remove the air cleaner.
2. Disconnect the radiator hoses from
the coolant outlet housing and the
water pump. Remove the radiator.
Remove the grille. On a vehicle with
air c o n d i t i o n i n g , r e m o v e t h e
condenser attaching bolts, and
position the condenser to one side. Do
not disconnect the condenser
refrigerant lines.
3. Disconnect the accelerator retracting
spring. Disconnect the accelerator
control cable from the carburetor.
4. Disconnect the fuel inlet line at the
fuel filter, and the distributor vacuum
line from the carburetor.
5. Disconnect the muffler inlet pipe
from the exhaust manifold. Pull the
muffler inlet pipe down. Remove the
gasket.
6. Disconnect the distributor vacuum
line from the distributor. Disconnect
the carburetor fuel inlet line from the
fuel pump. Remove the lines as an
assembly.
21-10-9
7. Disconnect the spark plug wires from
the spark plugs and the coil high
tension lead at the coil. Remove the
distributor cap and spark plug wires
as an assembly. Disconnect the
primary wires from the coil.
8. Disconnect the engine temperature
sending unit wire from the sending
unit. Disconnect the flexible fuel line
from the fuel pump line and plug the
line. Remove the distributor, the fuel
pump, and the oil filter.
9. Remove the crankcase vent hose,
regulator valve, valve rocker arm
cover and cylinder head by following
steps 8 thru 11 under Cylinder Head
Removal.
10. Using a magnet, remove t lie valve
lifters and keep them in order so that
they can be installed in their original
locations (Fig. 13). If the valve lifters
are stuck in the bores by excessive
varnish, etc., it may be necessary to
use a claw-type tool to remove the
lifters.
:?0326-S
THRUST
PLATE / WASHER
6269 L J- 6278
38406-S 371643-S
T I M I N G C H A I N
A2804-A
11. Loosen and remove the drive belt, fan
and pulley. Remove the crankshaft
damper using Tool T58P-6316-B.
12.Remove the oil level dipstick.
Remove the oil pan (250 CID only).
Remove the oil pump and inlet tube
assembly.
13. Remove the cylinder front cover and
gasket.
14. Push the camshaft toward the rear of
the engine. Install a dial indicator so
that the indicator point is on the
camshaft sprocket cap screw (Fig.
21). Zero the dial indicator. Position
a large screw driver between the
camshaft sprocket and the block. Pull
the camshaft forward and release it.
Compare the dial indicator reading
with specifications. If the end play is
excessive, replace the thrust plate.
15. Remove the dial indicator. Remove
the timing chain and sprockets as
detailed under Cylinder Front
Cover and Timing Chain Removal.
16. Remove the camshaft thrust plate.
Carefully remove the camshaft by
pulling it toward the fronr of the
21-10-10
engine. Use caution to avoid
damaging the journals and lobes.
TOOL-4201-C
A1374-B
FIG. 21 Checking Camshaft End Play
Installation
1. Clean the oil passage at the rear of the
cylinder block that feeds the rocker
arm shaft by blowing compressed air
into the opening in the block.
Camshaft lobes are to be coated with
Lubriplate or equivalent and the
journals lubricated with heavy oil SE
before installation. Carefully slide the
camshaft through the bearings.
2. Install the thrust plate with the oil
groove toward the rear of the engine
and torque the attaching bolts to
specifications. Replace the crankshaft
front oil seal.
3. Install the sprockets and timing
chain, cylinder front cover and
crankshaft damper as detailed under
Cylinder Front Cover and Timing
Chain Installation.
4. Clean the oil pump inlet tube screen,
oil pan, and block gasket surfaces.
Prime the oil pump by filling the inlet
opening with oil and rotate the pump
shaft until oil emerges from the outlet
opening. Install the pump inlet tube.
Install the oil pump and oil pan.
Install the oil level dipstick.
5. Install the fan, fan pulley and drive
belt. Adjust the belt tension. Install
the radiator and the grille.
6. Dip the base of the valve lifter body
in Lubriplate or equivalent. Tappets
or lifters and bores are to be
lubricated with heavy oil SE before
installation. Install the valve lifters in
their original bores.
7. Install the cylinder head, push rods
and the valve rocker arm shaft
assembly by following the procedure
under Cylinder Head Installation.
8. Using a new gasket, install the fuel
pump and connect the flexible fuel
line. Install the oil filter.
9. Position the No. 1 piston at TDC
after the compression stroke. Position
the distributor in the block with the
rotor at the No. 1firingposition and
200 and 250 CID Six-Cylinder Engines 21-10-10
the breaker points open. Install the removed only for flywheel
distributor hold-down clamp. replacement.
10. Connect the engine temperature
sending unit wire. Connect the coil CLUTCH PILOT BEARING
primary wire. Install the distributor Inspection procedures are outlined
cap. Connect the spark plug wires and under Flywheel Cleaning and Inspection
the coil high tension lead. in Part 21-01.
11. Install the carburetor fuel inlet line, Removal
using a new clamp on the filter tubing. 1. Remove the transmission, clutch
Connect the distributor vacuum line pressure plate, and disc following the
to the carburetor. procedures in Volume One, Group
12. On a vehicle with air conditioning, 16—Clutch.
position the condenser and install the 2. Using Tools T59L-100-B and
attaching bolts. Install the radiator T58L-101-A, remove the pilot
and connect the radiator upper and Bearing (Fig. 22) and adapter.
lower hoses.
13. Connect the accelerator control
cable retracting spring. Connect
the accelerator control cable at the
carburetor.
14. Fill the cooling system. Fill the
crankcase.
15. Start the engine and check and adjust
the ignition timing. Connect the
distributor vacuum line to the
distributor. Check for coolant and oil
leaks. Adjust the engine idle speed
and the idle fuel mixture.
Too/-T59L-700-B
FLYWHEEL A2837-A
Removal
1. On a manual-shift transmission, FIG. 22 Removing Clutch Pilot
remove the transmission, clutch Bearing
pressure plate and disc, following the Installation
procedures in Volume One, Group 1. A new clutch pilot bushing normally
16—Clutch. Do not drain the does not require lubrication.
transmission. However, due to long storage periods,
On a vehicle with an automatic it may lose some of the lubricant
t r a n s m i s s i o n , remove the pressed into the bushing in
transmission and converter housing manufacture. It is therefore
following the procedure in Volume recommended that the new bushing
One, G r o u p 17 — A u t o m a t i c be soaked in SAE-30 non-detergent
Transmission. Do not drain the type motor oil for a minimum of one-
transmission. half hour before installation. Do not
2. Refer to Part 21-01, Cleaning and lubricate with grease of any type.
Inspection, for flywheel face runout 2. Using Tool T65L-76OO-A, install the
checking procedure. Remove the pilot service bushing (Fig. 23).
flywheel attaching bolts and remove
the flywheel.
Installation
1. Clean and inspect all parts before
installation. Position the flywheel on
the crankshaft flange. Apply
oil-resistant sealer to the attaching
bolts. Install and torque the bolts in
sequence (across from each other)
to specifications.
2. On a manual-shift transmission,
install the clutch pressure plate, disc,
and the transmission following the
A2838-A
procedures in Volume One, Group
16—Clutch.
On a vehicle with automatic FIG. 23 Installing Clutch Pilot Service
transmission, install the converter Bushing
housing and transmission following
the procedure in Volume One, Group 3. Install the clutch pressure plate, disc,
17—Automatic Transmission. It is and the transmission following the
not necessary to adjust the procedure in Volume One, Group
transmission linkage when it has been 16—Clutch.
21-10-11
CAMSHAFT REAR BEARING BORE
PLUG
Removal
1. On a vehicle with a manual-shift
transmission, slide the transmission
to the rear and remove the clutch
pressure plate and disc following the
procedure in Volume One, Group
16—Clutch.
On a vehicle with automatic
t r a n s m i s s i o n , remove the
transmission and converter housing
following the procedure in Volume
O n e , G r o u p 17 — A u t o m a t i c
Transmission.
2. Remove the flywheel attaching bolts
and remove the flywheel and engine
rear cover plate.
3. Remove the plug as detailed in Part
21-01.
Installation
1. Install a new plug as detailed in Part
21-01.
2. Install the engine rear cover plate,
apply oil-resistant sealer to the
flywheel bolts and install the
flywheel.
On a vehicle with a manual-shift
transmission, install the clutch
pressure plate, disc, and transmission
following the procedure in Volume
One, Group 16—Clutch.
On a vehicle with automatic
transmission install the transmission
and converter housing following the
procedure in Volume One, Group
17—Automatic Transmission.
OIL PAN
Removal
1. Drain the crankcase
2. Remove the oil level dipstick and the
flywheel housing inspection cover.
3. Remove the oil pan and gasket.
4. Remove the oil pump inlet tube and
screen.
Installation
1. Clean the gasket surfaces of the block
and oil pan. Be sure to clean the seal
retainer grooves in the cylinder block
and oil pan. The oil pan has a two-
piece gasket. Coat the block surface
and the oil pan gasket surface with oil
resistant sealer. Position the oil pan
gaskets on the cylinder block (Fig.
25).
2. Position the oil pan front seal on the
cylinder front cover. Be sure the tabs
on the seal are over the oil pan gasket.
3. Position the oil pan rear seal on the
rear main bearing cap. Be sure the
tabs on the seal are over the oil pan
gasket.
4. Hold the oil pan in place against the
block and install a bolt, finger tight,
on each side of the oil pan. Install the
remaining bolts. Torque the bolts
from the center outward in each
direction to specifications.
200 and 250 CID Six-Cylinder Engines
Install the oil level dipstick. Fill the
crankcase with the proper grade and
quantity of engine oil. Operate the
engine and check for oil leaks.
A3169-A
FIG. 24 200 CID Six Oil Pump Inlet
Tube Installed
OIL PAN GASKET
FRONT SEAL A316&-A
FIG. 25 —200 CID Six Oil Pan
Gaskets and Seals Installed
OIL PUMP
Removal
1. Remove the oil pan and related parts
as outlined under Oil Pan Removal.
2. Remove the oil pump attaching bolts
and remove the oil pump, gasket, and
intermediate drive shaft.
21-10-11
Installation
1. Prime the oil pump by filling the inlet
port with engine oil. Rotate t!ie pump
shaft to distribute the oil within the
pump body.
2. Position the intermediate dr ive shaft
into the distributor socket.
3. Position a new gasket on the pump
housing. Insert the intermediate drive
shaft into the oil pump. Install the
pump and shaft as an assembly. Do
not attempt to force the pump into
position if it will not seat readily. The
drive shaft hex may be misaligned
with the distributor shaft. To align,
rotate the intermediate drive shaft
into a new position. Torque the oil
p u m p a t t a c h i n g s c r e w s to
specifications.
4. Install the oil pan and related parts as
outlined under Oil Pan Installation.
CRANKSHAFT REAR OIL SEAL
A split-lip type crankshaft rear oil
seal is used for replacement on all
engines. If replacement is necessary, this
type of seal must be used. The complete
seal can be replaced without removing
the crankshaft. Refer to Part 21-01 for
removal and installation procedures.
MAIN BEARINGS
Do not file or lap bearing caps or use
bearing shims to obtain the proper
bearing clearance.
Main bearings are available for
service in standard sizes and 0.001 and
0.002 inch undersize. Undersize bearings,
which are not selective fit, are available
for use on journals that have been
refinished.
Removal
1. Drain the crankcase. Remove: the oil
level dipstick. Remove the oil pan and
related parts.
2. Remove the oil pump inlet tube and
the oil pump.
3. Replace one bearing at a time, leaving
the other bearings securely fastened.
Remove the main bearing cap to
which new b e a r i n g s are to be
installed.
4. Insert the upper bearing removal tool
(Tool 6331) in the oil hole in the
crankshaft.
5. Rotate the crankshaft in the cirection
of engine rotation to force the bearing
out of the block.
Installation
1. Clean crankshaft journals. Inspect
journals and thrust faces (thrust
bearing) for nicks, burrs or bearing
pickup that would cause premature
bearing wear. When replacing
standard bearings with new bearings,
fit bearings to minimum specified
clearance. If the desired clearance
cannot be obtained with a standard
21-10-12
bearing, try one half of a 0.001 or
0.002 inch undersize in combination
with a standard bearing to obtain the
proper clearance. Be certain that
bearings and that the bearing bore in
the block or cap are clean. Foreign
material under a bearing insert can
cause bearing failure.
2. To install the upper main bearing,
place the plain end of the bearing over
the shaft on the locking tang side of
the block and partially install the
bearing so that Tool 6331 can be
inserted in the oil hole in the
crankshaft. With Tool 6331
positioned in the oil hole in the
crankshaft, rotate the crankshaft in
the opposite direction of engine
rotation until the bearing seats itself.
Remove the tool.
3. Install the cap bearing.
4. Select fit the bearings for proper
clearance following procedures under
Fitting Main and Connecting Rod
Bearings in Part 21-01.
5. If the rear main bearing is replaced,
replace the oil seal in the rear main
bearing cap as described under
Crankshaft Rear Oil Seal in Part
21-01.
6. After the bearing has been fitted,
apply a light coat of engine oil to the
journal and bearings, then install the
bearing cap. Torque the cap bolts to
specifications. Repeat the procedure
for the remaining bearings that
require replacement.
7. If the thrust bearing cap (No. 5 main
bearing) has been removed, install it
as follows:
Install the thrust bearing cap with
the bolts finger-tight. Pry the
crankshaft forward against the thrust
surface of the upper half of the
bearing (Fig. 26). Hold the crankshaft
forward and pry the thrust bearing
cap to the rear. This will align the
thrust surfaces of both halves of the
bearing. Retain the forward pressure
on the crankshaft. Torque the cap
bolts to specification.
8. Clean the oil pump inlet tube screen.
Prime the oil pump by filling the inlet
opening with oil and rotating the
HOLD
CRANKSHAFT?
FORWARD I •,
PRY CRANKSHAFT FORWARD
FIG. 26 Typical Thrust Bearing Alignment
200 and 250 CID Six-Cylinder Engines
pump shaft until oil emerges from the
outlet opening. Then install the oil
pump and the inlet tube, following
i n s t r u c t i o n s under Oil Pan
Installation.
9. Clean the gasket surfaces of the block
and oil pan. Be sure to clean the seal
grooves of the block and oil pan. The
oil pan has a two-piece gasket. Coat
the block side of the gasket with an
oil resistant sealer. Position the oil
pan gasket on the block, then install
. the oil pan and related parts following
i n s t r u c t i o n s u n d e r Oil Pan
Installation. Install the oil level
dipstick.
10. Fill the crankcase to the proper level
with the recommended engine oil.
Start the engine and check for oil
pressure. Operate the engine at fast
idle and check for oil leaks.
CONNECTING ROD BEARINGS
Removal
1. Follow steps 1 and 2 under Main
Bearing Replacement.
2. Turn the crankshaft until the
connecting rod to which new bearings
are to be fitted is down. Remove the
connecting rod cap. Remove the
bearing inserts from the rod and cap.
Installation
1. Be sure the bearing inserts and the
bearing bore in the connecting rod
and cap are clean. Foreign material
under the inserts will distort the
bearing and cause a failure.
2. Clean crankshaft journal. When
replacing standard bearings with new
bearings, fit the bearing to minimum
specified clearance.
3. Install the bearing inserts in the
connecting rod and cap with the tangs
fitted in the slots provided.
4. Pull the connecting rod assembly
down firmly on the crankshaft
journal.
5. Seledt fit the bearings for proper
clearance following procedures under
Fitting Main and Connecting Rod
Bearings in Part 21-01.
6. After bearing has been fitted, clean
and apply light coat of engine oil SE
to journal and bearings. Install
PRY CAP BACKWARD
21-10-12
connecting rod cap. Be sure
connecting rod bolt heads are
properly seated in connecting rod.
Torque nuts to specifications.
7. Repeat the procedure for the
remaining connecting rods that
require new bearings.
8. Install the oil pump assembly and oil
pan following the procedure under
Main Bearings.
PISTONS AND CONNECTING
RODS
Removal
1. Drain the cooling system and the
crankcase.
2. Refer to Cylinder Head Removal and
remove the cylinder head and related
parts.
3. Remove the oil pan and related parts.
Remove the oil pump inlet tube and
the oil pump.
4. Turn the crankshaft until the piston
to be removed is at the bottom of the
stroke, then place a cloth on the
piston head to collect the cuttings.
Remove any ridge and/or deposits
from the upper end of the cylinder
bores. Remove the cylinder ridge with
aridgecutter. Follow the instructions
furnished by the tool manufacturer.
Never cut into the ring travel area in
excess of 1/32 inch when removing
ridges.
5. Make sure all the connecting rod caps
are marked so that they can be
installed in the original positions.
Remove the connecting rod cap.
6. Push the connecting rod and piston
assembly out the top of the cylinder
with the handle end of a hammer.
Avoid damage to the crankpin or the
cylinder wall when removing the
piston and rod.
Installation
1. Clean the oil pump inlet tube screen,
and the oil pan and block gasket
surfaces.
2. Oil the piston rings, pistons and
cylinder walls with light engine oil.
3. Be sure to install the pistons in the
same cylinders from which they were
removed, or to which they were fitted.
The connecting rod and bearing caps
THRUST
BEARING
TIGHTEN CAP
21-10-13
are numbered from 1 to 6, beginning
at the front of the engine. The
numbers on the connecting rod and
bearing cap must be on the same side
when installed in the cylinder bore. If
a connecting rod is transferred from
one block or cylinder to another, new
bearings should be fitted and the
connecting rod should be numbered
to correspond with the new cylinder.
4. Make sure the ring gaps are properly
spaced around the circumference of
the piston (Fig. 27). Install a piston
ring compressor on the piston and
push the piston in with a hammer
handle until it is slightly below the top
of the cylinder (Fig. 28). Be sure to
guide the connecting rods to avoid
damaging the crankshaft journals.
Install the piston with the notch in the
dome of the piston toward the front
of the engine (Fig. 30).
OIL RING SPACER
OIL RING OIL RING
SEGMENT SEGMENT
COMPRESSION RING I COMPRESSION RING
FRONT OF ENGINE » A2811-A
FIG. 27 Piston Ring Gap Spacing
FRONT— P i . f o n R,n S
mpressor
NOTCH TO FRONT OF ENGINE
A2796-A
FIG. 28 Piston Installation
5. Check the clearance of each bearing,
following the p r o c e d u r e under
Connecting Rod Bearings.
6. After the bearings have been fitted,
apply a light coat of engine oil to the
journals and bearings.
7. Turn the crankshaft throw to the
bottom of the stroke, then push the
piston all the way down until the
connecting rod bearing seats on the
200 and 250 CID Six-Cylinder Engines
crankshaft j o u r n a l . Install the
connecting rod cap. Torque the nuts
to specifications.
8. After the piston and connecting rod
assemblies have been installed, check
the connecting rod side clearance on
each crankshaft journal (Fig. 29).
X 6.
A2806-A
FIG. 29 Typical Connecting Rod Side
Clearance
FRONT OF ENGINE
OIL SQUIRT HOLE
INDENTATION
NOTCH
A1392-A
FIG. 30 Typical Piston and
Connecting Rod Assembly
9. Prime the oil pump by filling the inlet
opening with the oil and rotating the
pump shaft until oil emerges from the
outlet opening. Install the oil pump
and the oil pump inlet tube. Install the
oil pan and related parts.
10. Install the cylinder head by following
the instructions under Cylinder Head
Installation.
11. Fill the crankcase with proper grade
of oil.
12. Start the engine and check for oil
pressure. Operate the engine at fast
idle and check for oil and coolant
leaks.
13. Check and adjust the ignition timing,
engine idle speed and the fuel
mixture.
14. Install the air cleaner.
CRANKSHAFT
Removal
The crankshaft and related parts are
shown in Fig. 31.
1. With engine removed from vehicle
and placed on a work stand, remove
the oil level dipstick.
2. Remove the accessory drive pulley (if
so equipped). Remove the crankshaft
damper attaching bolt and washer.
Remove the crankshaft vibration
damper using Tool T58P-6316-B.
3. Remove the cylinder front cover and
air conditioning idler pulley assembly
21-10-13
(if so equipped). Remove the cover
gasket.
4. Check the timing chain deflection;
then remove the timing chain and
sprockets as detailed under Cylinder
Front Cover and Timing Chain
Removal.
5. Invert the engine on the work stand.
Remove the flywheel. Remove the oil
pan and gasket. Remove the oil pump.
Make sure all bearing caps (main and
connecting rod) are marked so that
they can be installed in thei" original
locations. Turn the cranks tiaft until
the connecting rod from which the
cap is being removed i> down.
Remove the connecting rod cap. Push
the connecting rod and piston
assembly up in the cylinder. Repeat
for the remaining caps.
7. Remove the main bearing caps.
8. Carefully lift the crankshaft out of the
block so that the thrust bearing
surfaces are not damaged. Handle the
crankshaft with care to avoid possible
fracture or damage to the finished
surfaces.
Installation
1. Remove the rear journal oil seal from
the block and rear main bearing cap.
2. Remove the main bearing inserts
from the block and bearing caps.
3. Remove the connecting rod bearing
inserts from the connecting rods and
caps.
4. Clean the rear journal oil seal
grooves. Install a new rear journal oil
seal in the block and rear main
bearing cap.
5. Apply a thin coating of oil-resistant
sealer to the rear main bearing cap at
the rear of the top mating surface. Do
not apply sealer to the area forward
of the oil slinger groove.
6. If the crankshaft main bearing
journals have been refinished to a
definite undersize, install the correct
undersize bearings. Be sure the
bearing inserts and bearing bores are
clean. Foreign material under the
inserts will distort the bearing and
cause a failure.
7. Place the upper main bearing inserts
in position in the bores with the tang
fitting the slot provided.
8. Install the lower main beari ng inserts
in the bearing caps.
9. Carefully lower the crankshaft into
place. Be careful not to damage the
bearing surfaces.
10. Check the clearance of each main
bearing. Select fit the bearings for
proper clearance following
procedures under Fitting Main and
Connecting Rod Bearings in Part
21-01.
11. After the bearings have been fitted,
apply a light coat of engine oil to the
21-10-14
WASHER
6378
6700
FIG. 31 — 2 0 0 CID Six Crankshaft and Related Parts
journals and bearings. Install all the
bearing caps, except the thrust
bearing cap (No. 5 bearing). Be sure
that the main bearing caps are
installed in the original locations.
Torque the bearing cap bolts to
specifications.
12. Install the thrust bearing cap with the
bolts finger-tight.
13. Pry the crankshaft forward against
the thrust surface of the upper half of
the bearing (Fig. 26).
14. Hold the crankshaft forward and pry
the thrust bearing cap to the rear.
This will align the thrust surfaces of
both halves of the bearing.
15. Continue the forward pressure on
the crankshaft. Torque the cap
bolts to specifications.
16. Force the crankshaft toward the rear
of the engine.
17. Install a dial indicator so that the
contact point rests against the
crankshaft flange and the indicator
axis is parallel to the crankshaft axis
(Fig. 32).
18. Zero the dial indicator. Push the
crankshaft forward and note the
reading on the dial.
19. If the end play exceeds specifications,
replace the thrust bearing. If the end
play is less than the minimum limit,
inspect the thrust bearing faces for
scratches, burrs, nicks or dirt. If the
thrust faces are not damaged or dirty,
200 and 250 CtD Six-Cylinder Engines
RING GEAR
THRUST BEARING-6342
MAIN BEARING CAPS
BOLT-6345
Tool-T53L-200-A
OIL SEAL
A2808-A
FIG. 32 Crankshaft End Play
they probably were not aligned
properly. Install the thrust bearing
and align the faces following the
recommended procedure (steps 12,
13, 14 and 15). Check the end play
which should be within specifications.
20. Install new bearing inserts in the
connecting rods and caps. Check the
clearance of each bearing following
the procedure under Connecting Rod
Bearings.
21. If the bearing clearances are to
specifications, apply a light coat of
engine oil to the journals and
bearings.
21-10-14
CLUTCH PILOT BEARING
7600
BOLT
REAR SEAL
6701 (2)
A2230-E
22. Turn the crankshaft throw to the
bottom of the stroke. Push the piston
all the way down until the rod bearing
seats on the crankshaft journal.
23. Install the connecting rod cap.
Torque the nuts to specifications.
24. After the piston and connecting rod
assemblies have been installed, check
the connecting rod side clearance on
each connecting rod crankshaft
journal.
25. Turn the engine on the work stand so
that the front end is up. Install the
timing chain and sprockets, cylinder
front cover and crankshaft pulley or
damper, as detailed under Cylinder
Front Cover and Timing Chain
Installation.
26. Clean the oil pan, oil pump, and oil
pump screen.
27. Prime the oil pump byfillingthe inlet
opening with oil and rotating the
pump shaft until oil emerges from the
outlet opening. Install the oil pump
following steps 1, 2 and 3 under Oil
Pump Installation. Install the oil pan
following steps 2 thru 5 under Oil Pan
Installation.
28.Position the flywheel on the
crankshaft. Apply oil-resistant sealer
to theflywheelattaching bolts. Install
and torque the bolts to specifications.
On a flywheel for a manual-shift
transmission, locate the clutch disc
and install the pressure plate.
21-10-15
29. Turn the engine on the work stand so
that the engine is in the normal
position. Install the oil level dipstick.
Install the accessory drive pulley (if
so equipped). Install and adjust the
drive belt and accessory belts to
specifications.
30. Remove the engine from the work
stand and install it in the vehicle,
following engine installation
instructions.
CAMSHAFT BEARING
The camshaft bearings are available
pre-finished to size and require no
reaming for standard and 0.015 inch
undersize journal diameters.
Removal
1. Remove the engine following the
procedures under Engine Removal
and Installation. Place the engine on
a work stand and remove the flywheel
and the camshaft. Remove the rear
bearing bore plug.
2. Remove the camshaft bearings with
the tool shown in Fig. 33.
3. Select the proper size expanding collet
and back-up nut and assemble on the
e x p a n d i n g m a n d r e l . W i t h the
expanding collet collapsed, install the
collet assembly in the camshaft
bearing, and tighten the back-up nut
on the expanding mandrel until the
collet fits the camshaft bearing.
4. Assemble the puller screw and
extension (if necessary) as shown and
install on the expanding mandrel.
Wrap a cloth around the threads of
the puller screw to protect the front
bearing or journal. Tighten the
pulling nut against the thrust bearing
and pulling plate to remove the
camshaft bearing. Be sure to hold a
wrench on the end of the puller screw
to prevent it from turning.
5. Repeat the procedure for each
bearing. To remove the front bearing,
install the puller screw from the rear
of the cylinder block.
Installation
1. Position the new bearings at the
bearing bores, and press them in place
DISASSEMBLY AND ASSEMBLY
When installing nuts or bolts that
m u s t be t o r q u e d ( r e f e r to t h e
Specification at the end of this Part for
200 and 250 CID Six-Cylinder Engines
EXPANDING MANDREL
THRUST BEARING
DETAIL-8 '
PULLING NUT
DETAIL-5
PULLER SCREW PULLER SCREW EXTENSION
DETAIL-4
PULLING PLATE
FIG. 33 Typical Camshaft Bearing Replacement
with the tool shown in Fig. 33. Be
sure to center the pulling plate and
puller screw to avoid damage to the
bearing. Failure to use the correct
expanding collet can cause severe
bearing damage. Align the oil holes in
the bearings with the oil holes in the
cylinder block when the bearings are
installed. Be sure the front bearing is
installed below the front face of the
cylinder block to specifications. The
rear has two oil holes and must be
installed 24-3/4 inches from the face
of the camshaft thrust plate surface.
Check the oil passage that feeds the
rocker arm shaft for obstructions by
squirting oil into the opening in the
cylinder block and observing the flow
through the oil hole at the rear
camshaft bearing.
2. Install ,a new bearing bore plug as
detailed in Part 21-01.
3. Install the camshaft, crankshaft,
flywheel and related parts, following
the appropriate procedures. Do not
torque specifications), oil the threads
with light weight engine oil. Do not oil
threads that require oil-resistant or
21-10-15
DETAIL-1,-2 or -3
EXPANDING COLLET
DETAIL-!,-:: or -3
BACK-UP MUT
DETAIL-6or-7 CAMSHAFT BEARING ( ..OOSE )
Tool-T65L-62!iO-A
A2813-A
check connecting rod and main
bearing clearances as a part of
Camshaft Bearing Replacement.
Install the engine in the veh cle.
OIL FILTER
Removal
1. Place a drip pan under the filter.
Unscrew the filter from the adapter
fitting. Clean the adapter filter recess.
Installation
1. Add one quart of the proper :ype and
grade of oil to the crankcase. Coat the
gasket on the replacement filter with
oil. Position the filter on the adapter
fitting. Hand tighten the filter until
the gasket contacts the adapter face,
then advance it 1/2 turn.
2. Operate the engine at fast idle, and
check for oil leaks. If oil leaks are
evident, perform the necessary repairs
to correct the leakage. Chec < the oil
level and fill the c r a n k c a s e if
necessary.
water-resistant sealer. Refer to Part
21-01, for cleaning and inspection
procedures.
21-10-16
VALVE ROCKER ARM SHAFT
ASSEMBLY
Disassembly
1. Remove the pin and spring washer
from each end of the valve rocker arm
shaft.
2. Slide the valve rocker arms, springs,
and supports off the shaft. Be sure to
identify the parts.
3. If it is necessary to remove the plugs
from each end of the shaft, drill or
pierce the plug on one end. Use a steel
rod to knock out the plug on the
opposite end. Working from the open
end, knock out the remaining plug.
Assembly
1. All rocker arms and rocker arm shafts
are to be lubricated with heavy oil SE
before assembly.
2. If the plugs were removed from the
ends of the shaft, use a blunt tool or
large diameter pin punch and install
a plug, cup side out, in each end of the
shaft.
3. Install the spring washer and pin on
one end of the shaft.
4. Install the valve rocker a r m s ,
supports, and springs in the order
Shown in Figure 34. Be sure the oil
holes in the shaft are facing
downward. Complete the assembly by
installing the remaining spring
washer and pin.
SHAFT - 6563
SUPPORT BOLT HOLES
FIG. 34 Valve Rocker Arm Shaft Assembly
VALVE LIFTER—HYDRAULIC
Disassembly
Each valve lifter is a matched
assembly; therefore, the parts are not
interchangeable. Disassemble and
assemble each lifter carefully, keeping the
assemblies in proper sequence so they will
be installed in the original bores.
1. Grasp the lock ring with needle nose
pliers to release it from the groove. It
may be necessary to depress the
plunger to fully release the lock ring.
200 and 250 CID Six-Cylinder Engines
2. Remove the push rod cup, plunger
and spring.
3. Invert the plunger assembly and
remove the check valve retainer by
carefully prying up on it with a screw
driver. Remove the check valve and
spring. Refer to Part 21-01 for
Cleaning, Inspection and Testing
Procedures.
Assembly
A typical hydraulic valve lifter
assembly is shown in Fig. 35.
SPRING
VALVE DISC RETAINER
VALVE DISC
LOCK RING
LIFTER ASSEMBLY-6500 A1835-B
FIG. 35 Typical Valve Lifter Assembly
1. Place the plunger in the inverted
position on a clean work bench.
2. Place the check valve in position over
the oil hole on the bottom of the
PIN-372929-S
A3172-A
plunger. Set the check valve spring on
top of the check valve.
3. Position the check valve retainer over
the check valve and spring and push
the retainer down into place on the
plunger.
4. Place the plunger spring and then the
plunger (open end up) into the tappet
body.
5. Place the push rod seat in the plunger.
6. Depress the plunger and position the
closed end of the lock ring in the lifter
21-10-16
body groove. Release the plunger;
then depress it again to fully seat the
lock ring.
CYLINDER HEAD
Disassembly
1. R e m o v e d e p o s i t s f r o m t h e
combustion chambers and valve
heads with a scraper and a wire brush
before removing the valves. Be
careful not to scratch the cylinder
head gasket surfaces.
2. Compress the valve springs (Fig. 35).
Remove the valve retainer locks and
release the spring. If the valve locks
are stuck, place a piece of steel tubing
(3/4 inch OD, 1/2 inch ID and 3
inches long) over the end of the valve
stem squarely against the sleeve
surface. Tap the tube with a steel
hammer to disengage the locks.
3. Remove the sleeve, spring retainer,
stem seal, and valve. Discard the
valve stem seals. Identify all valve
parts. If the cylinder head is to be
replaced, remove the manifold
assembly.
Assembly
1. Clean, inspect and repair all parts
before assembly. If the cylinder head
is being replaced, install the manifold
assembly. Lubricate the valve guides
and valve stems with heavy engine oil
SE. Apply Lubriplate or equivalent to
the tips of the valve stems.
2. Install each valve (Fig. 37) in the
valve guide from which it was
removed or to which it was fitted.
Install a new stem seal on the valve.
3. Install the valve spring assembly over
the valve. Install the spring retainer
and sleeve.
4. Compress the spring and install the
retainer locks (Fig. 36).
Valve Spring Compressor
A2799-A
FIG. 36 Compressing Valve
Spring—On Bench
5. Measure the assembled height of the
valve spring from the surface of the
cylinder head spring pad to the
underside of the spring retainer with
dividers (Fig. 38).
6. Check the dividers against a scale. If
the assembled height is greater than
21-10-17 200 and 250 CID Six-Cylinder Engines 21-10-17
LOCKS-6518

SLEEVE-6517 installation in the same cylinders UPPER

from which they were removed. COMPRESSION
\ RING
RETAINER-6514.
3. Using an arbor press and the tool
shown in Fig. 39, press the piston pin
6148
from the piston and connecting rod.
VALVE SPRING-6513. Remove the piston rings.

Press Rar

OIL SEAL-6571

EXHAUST
VALVE
-6505

INTAKE
VALVE-6507

INSERT
TAPERED PILOT
A2800-B IN PISTON PIN
FOR PIN. REMOVAL
FIG. 37 Typical Valve Assembly INSERT THIS END
IN PISTON HOLE
FOR INSTALLATION

Adaptor Detail A-3

A2802-A
T68P-6I35-A
Cop Detail A-J
FIG. 40 Typical Piston, Connecting
Rod and Related Paris

SURFACE OF
SPRING PAD
UNDERSIDE OF
SPRING RETAINER
A2801-A
FIG. 38 Checking Valve Spring
Assembled Height
specifications, install the necessary
0.030 inch thick spacer(s) between the
cylinder head spring pad and the
valve spring to bring the assembled
h e i g h t to t h e r e c o m m e n d e d
dimension. Do not install spacers
unless necessary. Use of excess
spacers will result in overstressing the
valve springs and overloading the
camshaft lobes which would lead to
spring breakage and worn camshaft
lobes.
PISTON AND CONNECTING ROD
Disassembly
1. Remove the bearing inserts from the
connecting rod and cap.
2. Mark the pistons and pins to assure
assembly with the same rod and
A 2374-C
FIG. 39 Removing or Installing Piston
Pin
Assembly
The piston, connecting rod and
related parts are shown in Fig. 40. Check
the fit of a new piston in the cylinder bore
before assembling the piston and piston
pin to the connecting rod. Refer to Part
21-01 for fitting pistons procedure.
The piston pin bore of a connecting
rod and the diameter of the piston pin
must be within specifications. Refer to
specification at the end Section of this
part.
1. Apply a light coat of engine oil to all
parts. Assemble the piston to the
connecting rod with the oil squirt hole
in the connecting rod and the
indentation in the piston dome
positioned as shown in Fig. 30.
2. Start the piston pin in the piston and
connecting rod (this may require a
very light tap with a mallet). Using an
arbor press, press the piston pin
through the piston and connecting
rod until the pin is centered in the
piston (Fig. 39).
3. Check the end gap and spacing (Fig.
27) of all piston rings. They must be
within specifications.
4. F o l l o w t h e m a n u f a c t u r e r ' s
instructions (included with the piston
ring package) and install the piston
rings.
5. Check the ring side clearance of the
compression rings with a fee er gauge
inserted between the ring and the
lower land (Part 21-01). The gauge
should slide freely around t tie entire
ring circumference without binding.
Any wear that occurs will form a step
at the inner portion of the lower land.
If the lower lands have high steps, the
piston should be replaced.
6. Be sure the bearing inserts and the
bearing bore in the connecting rod
and cap are clean. Foreign material
under the inserts will distort the
bearing and cause a failure. Install the
bearing inserts in the connecting rod
and cap with the tangs fitting in the
slots provided.
OIL PUMP
Disassembly
1. Remove the oil inlet tube from the oil
pump and remove the gasket.
2. Remove the cover attaching screws,
and remove the cover. Remove the
inner rotor and shaft assembly, and
remove the outer race.
3. Drill a small hole, then insert a self-
threading sheet metal screw of the
proper diameter into the oil pressure
21-10-18 200 and 250 CID Six-Cylinder Engines
relief valve chamber cap and pull the 3. Install the outer race, and the inner
cap out of the chamber. Remove the rotor and shaft assembly. Be sure the
spring and plunger. identification mark on the rotor is on
the same side as the identification
Assembly mark on the outer race. The inner
The oil pump assembly is shown in rotor and shaft, and the outer race are
Fig. 41. serviced as an assembly. One part
6600
BODY
should not be replaced without
ASSEMBLY—I
replacing the other. Install the cover
and torque the cover attaching screws
to specification.
4. Position a new gasket and the oil inlet
tube on the oil pump and install the
attaching bolts.
5. Prime the oil pump byfillingthe inlet
port with oil. Rotate the pump shaft
until oil flows from the outlet port.
CYLINDER ASSEMBLY
Disassembly
1. Mount the old engine on a work
stand and remove all parts not
furnished with the new cylinder
A 280 3-B assembly, following the procedures
20426-S' given in the Removal and Installa-
FIG. 41 Oil Pump—Disassembled tion Section of this Part.
2. Remove the old cylinder assembly
from the work stand.
1. Clean, inspect and oil all parts Assembly
thoroughly. 1. Clean the gasket and seal surfaces of
2. Install the oil pressure relief valve all serviceable parts and assemblies.
plunger, spring, and a new cap. 2. Position the new cylinder assembly
21-10-18
on a work stand and transfer all
serviceable parts removed from the
old cylinder assembly, following the
procedures given in the Removal and
Installation Section of this Part.
3. Check all assembly clearances and
correct as necessary.
CYLINDER BLOCK
Before replacing a cylinder block,
determine if it is repairable. If so, make
the necessary repairs, following the
procedures given in Part 21-01.
Disassembly
1. Mount on a work stand and
completely disassemble the old
engine, following the procedures
given in the Removal and Installation
Section of this Part.
2. Remember to ridge-ream the cylinder
bores before removing piston
assemblies.
Assembly
1. Clean the gasket and seal surfaces of
all serviceable parts and assemblies.
2. Position the new cylinder block on
the work stand and transfer all
serviceable parts removed from the
old cylinder block, following the
instructions given in the Removal and
Installation Section of this Part.
3. Check all assembly clearances and
correct as necessary.
21-10-19 200 and 250 CID Six-Cylinder Engines 21-10-19

SPECIFICATIONS -1977
GENERAL SPECIFICATIONS CAMSHAFT

DISPLACEMENT 2OOCID/25OCID LOBE LIFT

NUMBEROF CYLINDERS 6 Intake 0.245
BORE AND STROKE 3.68x3.13 (200 CID) Exhaust 0.245
3.68 x 3.91 (250 CID) Allowable Lobe Lift Loss O.:O5Max.
FIRING ORDER 15-36 24 THEORETICAL VALVE LIFT@ZERO LASH
OIL PRESSURE (Hot @ 2000 RPM) 30 50 (200 CID) Intake 0.372
40 60 (250 CID) Exhaust 0.372
DRIVE BELT TENSION (0s END PLAY 0.C01 0.007
COMPRESSION PRESSURE (2 ) Service Limit 0.009
JOURNAL-TO-BEARING CLEARANCE 0.001-0.003
CYLINDER HEAD AND VALVE TRAIN Service Limit 0.006
CAMSHAFT GEAR BACKLASH 0.CD60.010
COMBUSTION CHAMBER VOLUME (cc) 57.25-60.25 JOURNAL DIAMETER
VALVE GUIOEBORE DIAMETER 0.31150.3125 # 1 1 80:5 1.8105
VALVE SEATS #2 1.80 = 5-1.8105
Width - Intake 0.060-0.080 #3 1.8035 1.8105
Width-'Exhaust 0.070 0.090 # 4 1.8055 1.8105
Angle 45° Runout Limit 0.008
Runout Limit (T.I.R. Max) 0.002 Out-Of-Round Limit 0.005 (M;K. T.I.R.)
VALVE ARRANGEMENT (Front to Rear) E 1 IE 1 EE1 El IE FRONT BEARING LOCATIONS 0.030 0.050
VALVE STEM TO GUIDE CLEARANCE
Intake 0.00080.0025 CYLINDER BLOCK
Exhaust 0.0010 0.0027
Service Clearance 0.0055
HEAD GASKET SURFACE FLATNESS d)
VALVE HEAD DIAMETER HEAD GASKET SURFACE FINISH (RMS) 60 150
Intake 1.760 1.742
CYLINDER BORE
Exhaust 1.381-1.399 3.6810 3.6848
Olameter
VALVE FACE RUNOUT LIMIT 0.002 Max
Surface Finish (RMS) 18-38
VALVE FACE ANGLE 44°
Out-Of-Round Limit 0.0015
VALVE STEM DIAMETER (Std.) Out-OfRound Service Limit 0.005
Intake 0.3100 0.3107
Taper Service Limit 0.010
Exhaust 0.3098 0.3105
TAPPET BORE DIAMETER 0.87E2 0.8767
(0.003 Oversize)
MAIN BEARING BORE DIAMETER .2.401 2 2.5020 (200 CID)
Intake 0.3130 0.3137
2.5902 2.5910 (250 CID)
Exhaust 0.31 28 0.3135
DISTRIBUTOR SHAFTBEARINGBOREDIAMETER 0.515.5-0.5170
(0.015 Oversi/e)
Intake 0.3250 0.3257
CRANKSHAFT AND FLYWHEEL
Exhaust 0.32480.3255
(0.030 Oversize)
MAIN BEARING JOURNAL DIAMETER .2.2482 2.2490 200 CID)
Intake 0.34000.3407
2.3982 2 3990 250 CID)
Exhaust 0.33980.3405
Out-Of-Round Limit 0.(1006 Max.
VALVE SPRINGS
Taper Limit O.OOOf Per Inch
Compression Pressure (Lb. @ Spec. Length) . . . 51-57 @ 1.59
Journal Runout Limit 0.002 Max.
142-158 @ 1.22
Surface Finish (RMS) .' 12 Max.
Free Length (Approximate) 1.79
Runout Service Limit 0.005
Assembled Height 1-9/16-1-19/32
THRUST BEARING JOURNAL
Service Limit 10% Pressure Loss @ Spec. Length
Length ...1.275-1.277 1200 CID)
Out-Of-Square Limit 5/64(0.078)
1.199-1.201 (250 CID)
ROCKER ARM
CONNECTING ROD JOURNAL
Shaft Diameter 0.7797 0.7807
Diameter 2.12:12-2.1240
Bore Diameter 0.7830-0.7845
Out-Of-Round Limit 0.0006 Max.
Ratio 1.52:1
Taper Limit OOOOC Per Inch
PUSH ROD RUNOUT (T.I.R. Max) 0.020
Surface Finish (RMS) 12 Max.
GASKET SURFACE FLATNESS ® MAIN BEARING THRUST FACE
Surface Finish (RMS) 60-150
Surface Finish (RMS) 35 Front 25 Rear
VALVE TAPPET, LIFTER OR ADJUSTER
Runout Limit C 001 Max.
Diameter (Std.) 0.8740-0.8745
FLYWHEEL CLUTCH FACE
Clearance To Bore 0.0007-0.0027
Service Lifnit Runout Limit (T.I.R.) 0.010
0.0005
Hydraulic Leakdown Rate 5-50 Seconds® FLYWHEEL RING GEAR LATERAL RUNOUT (T.I.R.)
Collapsed Tappet Gap - Allowable Standard Transmission 0.030
0.085 0.185 (200 CID)
0.0710.209 (250 CID) Automatic Transmission 0.060
Collapsed Tappet Gap -- Desired 0.110-0.160- (200 CID) CRANKSHAFT FREE END PLAY 0.0040.008
.0.096-0.184 (250 CID) Service Limit 0.012
CONNECTING ROD BEARINGS
Clearance To Crankshaft Oesired 0.00080.0015
- Allowable 0.0008-0.0026
Bearing Wall Thickness (Std.)(6) 0.05(i90.0574
MAIN BEARINGS
Clearance To Crankshaft - Oesired 0.0008 0.0015
-Allowable 0.00(18 0.0024
Bearing Wall Thickness (Std.)© 0.09!)4 0.0957

CA126SE
21-10-20 200 and 250 CID Six-Cylinder Engines 21-10-20

SPECIFICATIONS-1977
CONNECTING ROD, PISTON AND RINGS FUEL PUMP

STATIC PRESSURE (P.S.I.)(w) 5.0 7.0

CONNECTING ROD
MINIMUM VOLUME FL0W(U>) ( i 1 j . . . . 1 Pt. m 20 Sec.
Piston Pin Bore Diameter 0.91040.9112
ECCENTRIC TOTAL LIFT (Inches) 0 290 0.310
Crankshaft Bearing Bore Diameter 2.2390 2.2398
Out-Of-Round Limit 0.0004 Max.
Taper Limit 0.0004 Max. TORQUE SPECIFICATIONS
Length (Center-to-Center) 4.7135-4.7165(200 CID)
5.8785 5 8815 (250 CID) CAMSHAFT SPROCKET TO CAMSHAFT 35-45
Alignment (Bore-toBore Max. Dif.KT) CAMSHAFT THRUST PLATE TO BLOCK 12-18
Twist 0.024 CONNECTING ROD NUTS OR BOLTS 21-26
Bend 0012 CYLINDER FRONT COVER BOLTS 6-9
Side Clearance (Assembled to Crank) CYLINDER HEAD BOLTS &
Standard 0.0035-0.0105 DAMPER OR PULLEY TO CRANKSHAFT 85 100
Service Limit 0.0140 DISTRIBUTOR VACUUM CONTROL VALVE . 15-18
PISTON EGR VALVE TO CARBURETOR SPACER OR INT MANIFOLD .... 12 18
Diameter® FUEL PUMP TO CYLINDER BLOCK OR FRONT COVER 12-18
Coded Red 3.6784-3.6790 FLYWHEEL TO CRANKSHAFT 75 85
Coded Blue 3.6796 3.6802 MAIN BEARING CAP BOLTS 60-70
0.003 Oversize 3.6808 3.6814 MANIFOLD TO CYLINDER HEAD (Exhaust) 18 24
Piston-To-Bore Clearance 0.00130.0021 OIL FILTER INSERT TO CYLINDER BLOCK 10 15
Pin Bore Diameter
Ring Groove Width
0.9124 0.9127 OIL FILTER TO BLOCK OR ADAPTER
OIL INLET TUBE TO OIL PUMP
<§)
10-15
Compression (Top) 0.0800.081 OIL PAN DRAIN PLUG 15-25
Compression (Bottom) 0.080-0.081 OIL PAN TO CYLINDER BLOCK 7-9
Oil 0.188 0.189 OIL PUMP TO CYLINDER BLOCK 10-15
PISTON PIN PULLEY TO DAMPER (Bolt) 35 50
Length 3.010 3 040 ROCKER ARM SUPPORT SHAFT TO CYLINDER HEAD 30-35
Diameter SPARK PLUG TO CYLINDER HEAD 10-15
Standard 0.9119 0.9124 VALVE ROCKER ARM COVER 3-5
0.001 Oversize 0.9130 0.9133 ALTERNATOR BRACKET TO CYLINDER BLOCK (Bolt) 35-50
0.002 Oversize 0.9140 0.9143 ALTERNATOR ADJUSTING ARM TO CYLINDER BLOCK ...15-20 (200 CID)
Pm-To-Piston Clearance 0.0003-0.0005 35 50 (250 CID)
PinTo-Rod Clearance Interference Fit ALTERNATOR ADJUSTING ARM TO ALTERNATOR 24-40
PISTON RINGS THERMACTOR PUMP BRACKET TO CYLINDER BLOCK ...12-18 (200CID)
Ring Width 22-32 (250CID)
Compression (Top) 0.077-0.078 THERMACTOR PUMP PIVOT BOLT ...22-32 (200CIO)
Compression (Bottom) 0.0770.078 30-45 (250CIO)
Side Clearance THERMACTOR PUMP ADJUSTING ARM TO PUMP 12-18
Compression (Top) 0.0020.004 THERMACTOR PUMP ADJUSTING ARM TO CYLINDER BLOCK 20-28
Compression (Bottom) 0.0020.004 THERMACTOR PUMP PULLEY TO SHAFT . . . 130-118 In.-Lb.
Oil Ring Snug Fit POWER STEERING PUMP PULLEY TO DAMPER (Bolt) 35 50
Service Limit 0.006 FAN TO WATER PUMP HUB (Bolt) 12-18
Ring Gap CARBURETOR MOUNTING NUTS 12-15
Compression (Top) 0.0080.016 CARBURETOR SPACER TO INTAKE MANIFOLD 12-15
Compression (Bottom) 0.008 0.016 CARBURETOR MOUNTING STUD 15 Max.
Oil Ring (Steel Rail) 0.0150.055 FUEL FILTER TO CARBURETOR 80-100 In. Lb.

LUBRICATING SYSTEM

OIL PUMP
Relief Valve Spring Tension (Lbs. @ Spec. Length) 9.0-10.1 @ 1.078 (200 CID)
20.6-22.6 ^ 2 . 4 9 ( 2 5 0 CID)
Drive Shaft To-Housing Bearing Clearance 0.00150.0030
Relief Valve-To-Bore Clearance 0.00150.0030
Rotor Assembly End Clearance (Assembled) 0.004 Max.
Outer Race-To-Housing Clearance 0.001-0.013
OIL CAPACITY (Quarts U.S.) <9,
CA1265-E
21-10-21 200 and 250 CID Six-Cylinder Engines 21-10-21

SPECIFICATIONS -1977
TORQUE SPECIFICATIONS - General Applications
Drive Belt Tension (Lbs.)
U.S. THREAD SIZES TORQUE
Newly Installed Used
1/4-20 . . 6-9 s.« (A) Up to 10 Mm Over 10 Mm.
5/16-18 12-18
5/16-24 , 1/4" 50 80 40 80 (B) 40-60(8)
1420
3/8-16 . 22-32
Exc. 1/4" 120-160 90-160(0 75-120 (D)
3/8-24 . 27-38
7/16-14 40-55
Read tension immediately after belt is installed, before it stretches or seats in pulley
7/16-20 40-60
'^'grooves.
1/2-13 . . 55-80
(B) If less than 40 pounds, readjust to 40-60 pounds.
(C)lf less than 90 pounds, readjust to 90 120 pounds.
METRIC THREAD SIZES TORQUE
(D)lf less than 75 pounds, readjust to 90-120 pounds.

M-6. . To be within specifications, lowest cylinder (PSD must be within 75% of pressure (PSD of
. . . 6-9
highest cylinder. See Part 21-01.
M-8.. . 14-21
0.003 in any 6 inches; 0.006 overall.
M-10 . 28-40
Time required for plunger to leak down. 48" with 50 Ib. load and leakdown fluid in lifter.
M-12 . 50-71
Distance in inches that front edge of bearing is installed below front face of bloc*.
M-14 80-114
0.002 Undersize = Add 0 001 to Standard Thickness.
Pin bore and crank bearing bore must be parallel and in same vertical plane withr the
PIPE THREAD SIZES TORQUE specified ntal difference when measured at the ends of an 8" bar-4" on each side of rod
centerline.
.5-8
Measured at the pin bore centerline at 90° to the pin.
1/4 12-18
Add 1 quart with filter change.
3/8 22-33
On engine, normal temperature, curb idle, in neutral.
1/2 25-35
Inside diameter of smallest orifice not less than 0.220".
In sequence: Step 1 = 50 55; Step 2 = 60-65; Step 3 = 70-75.
• All values are in ft.-lb. unless otherwise noted.
1/2 turn after gasket contacts sealing surface - with oiled gasket.
• Oil threads with engine oil unless fasteners require sealers.
21-12-1 2800cc V-6 Engine 21-12-1

PART
2800 cc V-6 Engine 21-12
Pinto, Bobcat and Mustang

SUBJECT PAGE SUBJECT PAGE

DESCRIPTION REMOVAL AND INSTALLATION (Cont'd.)
Crankcase Ventilation System . . . 12-1 Front Oil Seal 12-11
Engine 12-1 Intake Manifold 12-8
Exhaust Emission Control System 12-1 Main Bearings 12-15
Oil Filter 12-18
ADJUSTMENTS Oil Pan 12-12
Valve Clearance 12-4 Oil Pump 12-13
Pistons and Connecting Rods 12-15
REMOVAL AND INSTALLATION Timing Gears 12-12
Camshaft 12-11 Valve Lifters 12-9
Camshaft Bearing 12-17 Valve Rocker Arm Cover and
Camshaft Rear Bearing Bore Plug 12-14 Rocker Arm 12-7
Clutch Pilot Bearings 12-13 Valve Spring Retainer and Stem Seal 12-7
Connecting Rod Bearings 12-15 Water Pump 12-10
Crankcase Ventilation System . . 12-7
Crankshaft 12-16 DISASSEMBLY AND ASSEMBLY
Cylinder Front Cover 12-10 Cylinder Assembly 12-20
Cylinder Head 12-9 Cylinder Block ^-20
Engine Assembly 12-5 Cylinder Head ^-19
Engine Front Supports 12-6 Oil Pump ^-19
Engine Rear Support 12-6 Pistons and Connecting Rods ^-19
Exhaust Manifold 12-8 Valve Rocker Arm Assembly 12-]$
Flywheel 12-14 SPECIFICATIONS 12-21

CA4286-A

DESCRIPTION
ENGINE
The compact Ford 60-degree V-6
engine (Figs. 1 and 2) is of modern light-
iron construction. It has precision-
molded cast iron crankshaft, supported
on four replaceable copper alloy bearings.
Camshaft and connecting rod bearings
are also replaceable. The connecting rods
are made of forged steel.
Except for the 60-degree block
inclination, it is similar to a V-8 in
construction and service accessibility.
EXHAUST EMISSION CONTROL
SYSTEM
Operation and required maintenance
of the exhaust emission control devices
used on this engine are covered in Groups
29 and 50 of this Manual.
CRANKCASE VENTILATION
SYSTEM
The engine is equipped with a
positive, closed-type crankcase
ventilation system re-cycling the
crankcase vapors to the intake manifold.
21-12-2 2800cc V-6 Engine 21-12-2

A3717-C

FIG. 1 2800cc V-6 Engine—With Thermactor and A/C—Left Front View

21-12-3 2800cc V-6 Engine 21-12-3

CM
CN

6
21-12-4
FIG. 3 V-6 Engine Full Pressure Lubrication System
ADJUSTMENTS
VALVE CLEARANCE
If some component of the valve train
is replaced, i.e., rocker arm, push rod,
camshaft, etc., it will be necessary to
make a valve lash adjustment before
starting the engine.
Cold Adjustment
1. Remove air cleaner assembly.
2. Disconnect negative battery cable
from battery.
3. Disconnect hose between thermactor
dump valve and check valve at check
valve.
4. Disconnect hose between thermactor
air pump and dump valve at dump
valve.
5. Disconnect thermactor dump valve
mounting bracket from engine and
remove thermactor dump valve,
2800cc V-6 Engine
mounting bracket and hose to check
valve.
Remove and discard both lifting eyes.
Remove alternator drive belt from
alternator and rotate alternator
outward toward fender.
8. Disconnect spark plug wires from
spark plugs and rocker arm covers.
9. Remove electric assist choke wire
from choke cap.
10. Remove wiring harnesses from
attaching brackets on rocker arm
covers as required and reposition to
facilitate rocker arm cover removal.
11. Remove PCV valve from rocker arm
cover.
12. Disconnect vacuum hose to exhaust
heat control valve at PVS.
21-12-4
A3541-A
13. Reposition vacuum hoses as required
to facilitate rocker arm cover
removal.
14. Remove rocker arm cover attaching
screws.
15. Remove rocker arm covers.
16. Torque rocker arm support bolts to
specification. Reconnect battery
cable.
17. Make sure transmission is in Neutral
(manual transmission), or in Park (P)
(automatic transmission), and that
parking brake is applied.
18.ADJUST VALVE LASH AS
FOLLOWS:
a. Place a finger on adjusting screw of
intake valve rocker arm for
cylinder No. 5. The slightest
21-12-5
motion of the rocker arm can be
detected in this way.
b. Using a remote starter button or
equivalent, "bump" the engine over
until the intake valve for cylinder
No. 5 just begins to open. The
camshaft is now in the correct
position to adjust the valves on No.
1 cylinder.
c. Adjust the No. 1 intake valve so
that a 0.016*' feeler has a light to
moderate drag and a 0.017" feeler
is very tight. (Turn adjusting screw
clockwise to decrease lash and
counterclockwise to increase lash).
See Fig. 4. Adjusting screws are
self-locking and will stay in set
position.
NOTE: Do not use step-type
"go/no-go" feeler gages.
CAUTION: When checking
lash, insert feeler between rocker
arm and valve tip at front (or rear)
edge of valve tip and move toward
opposite edge with a rearward (or
forward) motion that is parallel to
centerline of the crankshaft. Do not
insert feeler at outboard edge and
move inward toward carburetor
(perpendicular to the crank
centerline). This will produce an
erroneous "feel" that will result in
excessively tight valves.
REMOVAL AND INSTALLATION
ENGINE ASSEMBLY
Removal
Remove or disconnect Thermactor
system parts that will interfere with
removal or installation of the engine.
1. Disconnect the battery, drain the
cooling system and remove the hood.
2. Remove the air cleaner and intake
duct assembly.
3. Disconnect the upper and lower hoses
at the radiator.
4. Remove the fan shroud attaching
bolts and position the shroud over the
fan. Remove the radiator and shroud.
5. Remove the alternator and bracket.
Position the alternator out of the way.
Disconnect the alternator ground
wire from the cylinder block.
6. Disconnect the heater hoses at the
block and water pump.
7. Remove the ground wires from the
cylinder block.
8. Disconnect the fuel line at the fuel
pump. Plug the fuel tank line.
9. Disconnect the accelerator cable or
linkage at the carburetor and intake
manifold.
10. Disconnect the engine wire from the
ignition coil. Disconnect brake
booster line.
2800cc V-6 Engine
d. Using the same method, adjust the
No. 1 exhaust valve lash so that a
0.018" feeler has a light to
moderate drag and a 0.019" feeler
is very tight.
e. Adjust the remaining valves, in
firing order (1-4-2-5-3-6) by
positioning the cam according to
the following chart:
To adjust both valves
for cylinder JP 1 4 2 5 3 6
The intake valve just
be opening for
cylinder =tP 5 3 6 1 4 2
CA4094-A
19. Clean all gasket material from
cylinder heads and rocker arm cover
gasket surfaces.
20. Disconnect negative battery cable
from battery.
21. Reinstall rocker arm covers using
new gaskets and torque attaching
screws to specification.
22. Reposition vacuum hoses to their
original positions.
23. Reconnect vacuum hose from exhaust
heat control valve to PVS.
24. Reinstall PCV valve in rocker arm
cover.
11. Raise the vehicle and secure with
safety stands.
12. Disconnect the muffler inlet pipes at
the exhaust manifolds.
13. Disconnect the starter cable and
remove the starter.
14. Remove the engine front support
through bolts.
15.If equipped with a u t o m a t i c
transmission, remove the converter
inspection cover and disconnect the
flywheel from the converter.
Remove the downshift rod.
Remove the converter housing-to-
cylinder block bolts and the adapter
plate-to-converter housing bolt.
On vehicles equipped with a
manual transmission, remove the
clutch linkage.
16. Lower the vehicle.
17. Attach engine lifting sling, Tool No.
T53L-3OO-A and hoist to lifting
brackets at exhaust manifolds.
18.Position a j a c k u n d e r t h e
transmission.
19. Raise the engine slightly and carefully
pull it from the transmission.
Carefully lift the engine out of the
engine compartment so that the rear
cover plate is not bent or components
21-12-5
A3S42-B
FIG. 4 Adjusting Valve Lash
25. Replace wiring harnesses on rocker
arm covers.
26. Reinstall electric choke assist wire to
choke cap.
27. Reinstall spark plug wires on spark
plugs and attach to retaining clips on
rocker arm covers.
28. Reinstall alternator drive belt and
tighten to specification.
29. Reinstall thermactor components.
30. Reconnect battery cable.
31. Reinstall air cleaner assembly and
torque wing nut(s) to specification.
(15-20 in-lb.).
32. Start engine and check for oil and
vacuum leaks.
damaged. Install the engine on a work
stand.
Installation
If clutch pressure plate and disc have
been removed, install by following
procedures in Group 16.
1. Attach engine lifting sling (Tool No.
T53L-3OO-A) and hoist to lifting
brackets at exhaust manifolds.
Remove engine from work stand.
2. Lower the engine carefully into the
engine compartment. Make sure the
exhaust manifolds are properly
aligned with the muffler inlet pipes.
On a vehicle with a manual-shift
transmission, start the transmission
main shaft into the clutch disc. It may
be necessary to adjust the position of
the transmission in relation to the
engine if the input shaft will not enter
the clutch disc. If the engine hangs up
after the shaft enters, turn the
crankshaft slowly (transmission in
gear) until the shaft splines mesh with
the clutch disc splines. On a vehicle
with an automatic transmission, start
the converter pilot into the
crankshaft.
3. Install the clutch housing or
converter housing upper bolts,
21-12-6
making sure that the dowels in the
cylinder block engage the flywheel
housing. Remove the jack from under
the transmission.
4. Remove the lifting sling.
5. On automatic transmission equipped
vehicles, position the downshift rod
on the transmission and engine.
6. Raise the vehicle and secure with
safety stands.
7. On a vehicle with an automatic
t r a n s m i s s i o n , p o s i t i o n the
transmission linkage bracket and
install the remaining converter
housing bolts. Install the adapter
plate-to-converter housing bolt.
Install the converter-to-flywheel nuts
and install the inspection cover.
Connect the downshift rod on the
transmission.
On a vehicle with a manual
transmission, remove the pilot studs,
fthen install the clutch lower housing
bolts and connect the clutch linkage
to the cylinder block.
8. Install the starter and connect the
cable.
9. Connect the muffler inlet pipes at the
exhaust manifolds.
10. Install the engine front support
through bolts.
11. Lower the vehicle.
12. Install the ground wire. Connect the
ignition coil wires, then install the
water temperature sending unit and
oil pressure sending unit. Connect
brake booster line.
13. Install the accelerator linkage.
Connect the vacuum lines. Connect
the fuel tank line at the fuel pump.
14. Connect the ground wire at the
cylinder block. Connect the heater
hoses to the water pump and cylinder
block.
INSULATOR ASSY.
6C010R.H.
BRACKET -
6043 R.H.
INSULATOR ASSY. -
N602569-S100
(6 REQ'D.)
382802-S2
(2 REQ'D.
20-30 FT-LB
-6A069(L.H.)
FIG. 5 Engine Supports—Mustang with 2800cc V-6 Engine
2800cc V-6 Engine
15. Install the alternator and bracket.
Connect the alternator ground wire to
the cylinder block. Install the drive
belt and adjust the belt tension to
specifications.
16. Position the fan shroud over the fan.
Install the radiator and connect the
upper and lower hoses. Install the fan
shroud attaching bolts.
17. Fill and bleed the cooling system. Fill
the crankcase with the proper grade
and quantity of oil. Connect the
battery.
18. Operate the engine at fast idle until it
reaches normal operating
temperature and check all gaskets and
hose connections for leaks. Adjust
ignition timing and idle speed.
19. Install the air cleaner and intake duct.
Install and adjust the hood.
ENGINE FRONT
SUPPORTS—(FIGS. 5 AND 6)
The procedures given apply to either
a right or left installation.
Removal
1. Remove the fan shroud attaching
screws.
2. Support the engine using a wood
block and a jack placed under the oil
pan.
3. Remove the through-bolt and lock
nut attaching the insulator to the
insulator support bracket.
4. Remove the support bracket (between
front engine mount and frame side
rail) attaching bolts and locknuts.
5. Raise the engine sufficiently to
remove the support bracket from the
vehicle.
6. Remove the engine insulator
assembly to cylinder block attaching
6068 ASSY.
FOR AUTO &
MAN. 4-SPD.
56580-S2
2 REQ'D.
40-60 FT-LB
6A087 ASSY. R.H
\ —
6A088 ASSY. L.H.
57481 S2 ASSY
:: THESE BOLTS 4 REQ'D.
MUST BE INSERTED 35-50 FT-LB
AS SHOWN BOTH L.H.
AND R.H. SIDES
382802-S2
(4REQ'D.)
20-30 FT-LB
21-12-6
bolts and lockwashers. Remove the
engine mount assembly.
Installation
1. Position the engine mount to the
cylinder block. Install the bracket
bolts and torque to specifications.
2. Install the support bracket to the
frame side rail with attaching bolts
a n d l o c k n u t s . T o r q u e to
specifications.
3. Lower the engine until the engine
mount insulator lines up with the
support bracket to allow installation
of the through-bolt. Install the
through-bolt and locknut and torque
to specifications.
4. Remove the jack and wood block
from the engine oil pan.
5. Install the fan shroud attaching
screws and torque to specifications.
ENGINE REAR SUPPORT—(FIGS. 5
AND 6)
Removal
1. Place a block of wood and a jack
under the transmission to relieve the
weight from the s u p p o r t i n g
crossmember.
2. Remove the two (2) locknuts holding
the insulator to the crossmember.
3. Remove the two bolts and locknuts
attaching the crossmember to the
frame side rails, along with i:he two
bolts attaching the insulator to the
transmission.
4. Raise the transmission enough to
slide the crossmember and insulator
rearward.
5. Remove the crossmember and
insulator as an assembly.
Installation
1. Position the insulator to the
crossmember and loosely install the
QA-* 385540-S2
/ (4REQ'D.)
386040-S100
(2 REQ-D.)
L.H. SHOWN, R.H. SYMETRICALLY
OPPOSITE
T
57057-S2
4 REQ'D.
20-30 FT-LB
•NOTE: WHENEVER SELF-LOCKING BOLTS AND
NUTS ARE REMOVED, THEY MUST BE
REPLACED WITH NEW SELF-LOCKING
BOLTS AND NUTS.
A3725C
21-12-7 2800cc V-6 Engine 21-12-7

BOLT - 56753-S2
N602569-S100
ASSEMBLY
(6 REQ'D.)
35-60 FT-LB

NOTE: •
WHENEVER SELF-
LOCKING BOLTS 34670-S2
382802-S2
OR NUTS ARE RE- (2 REQ'D.)
(4 REQ'D.)
MOVED, THEY 30-45 FT-LB' AUTOMATIC 20-30 FT-LB
MUST BE REPLACED CRIMPED TRANSMISSION
WITH NEW SELF- MANUAL TRANSMISSION AFTER ASSEMBLY (SAME AS MANUAL
LOCKING BOLTS TO LOCK VIEW
TRANSMISSION VIEW X
AND NUTS. VIEWX A4069-C
EXCEPT AS SHOWN

FIG. 6 Engine Supports—Pinto and Bobcat with 2800cc V-6 Engine

two (2) attaching locknuts. Do not
tighten.
2. Slide the crossmember and insulator
into position under the transmission.
Loosely install the crossmember
attaching bolts and locknuts.
3. Lower the transmission and install
the insulator to the transmission
a t t a c h i n g b o l t s . T o r q u e to
specifications.
4. In sequence, torque the crossmember
bolts and then the engine mount-to-
crossmember attaching locknuts to
specifications.
5. Remove the jack and wood block
from under the transmission.
CRANKCASE VENTILATION
SYSTEM
Removal
1. Remove the inlet hose from the air
cleaner. Disconnect the carbon
canister hose.
2. Remove the air cleaner.
3. Remove the crankcase vent hose and
regulator valve from the rocker cover.
Installation
1. Install the vent hose and the regulator
valve in the valve cover.
2. Install the air cleaner.
3. Connect the inlet hose to the air
cleaner. Connect the carbon canister
hose.
4. Operate the engine and check for
leaks.
VALVE ROCKER A R M COVER
AND ROCKER A R M
Removal
Remove emission control equipment
as necessary to remove cover.
1. Disconnect spark plug wires from 7. Install parts removed to gain access
spark plugs and rocker arm cover, to rocker arm cover.
using the proper plier-type tool to 8. Coat inside of each spark plug boot
remove the wires from the plugs. with silicone lubricant, connect spark
2. Disconnect throttle linkage to plug wires and accelerator control
carburetor if it interferes with cable. Connect throttle return spring.
removal operation. 9. Start engine and run until normal
3. Remove rocker arm cover attaching temperature is reached.
screws. Tap rocker arm cover lightly 10. Run the engine at fast idle and check
with a plastic hammer to break gasket for oil leaks.
seal. Lift off rocker arm cover.
4. Remove rocker arm shaft stand VALVE SPRING, RETAINER AND
attaching bolts by loosening the bolts STEM SEAL
two turns at a time, in sequence. Lift Broken valve springs or leaking valve
off rocker arm and shaft assembly and stem seals and retainer may be replaced
oil baffle (Fig. 7). without removing the cylinder head
provided damage to the valve or valve
Installation seat has not occurred.
1. Loosen the valve lash adjusting
screws a few turns.
2. Apply SE-type engine oil to the
a s s e m b l y to p r o v i d e i n i t i a l
lubrication.
3. Install oil baffle and rocker arm shaft
assembly to the cylinder head and
guide adjusting screws on to push
rods (Fig. 7).
4. Install and tighten rocker arm stand
attaching bolts to specifications, two
turns at a time, in sequence.
5. Adjust valve lash to cold specified
setting.
6. Clean the valve rocker arm cover and
cylinder head gasket surfaces. Coat
one side of a new gasket with an oil-
resistant sealer and lay cemented side
of gasket on the cover. Install the
cover, making sure the gasket seats
evenly around the head. Tighten the
c o v e r a t t a c h i n g b o l t s to FIG. 7 Removing or Installing Rocker
specifications. Arm Assembly
21-12-8
Removal
1. Remove the air cleaner. Remove the
valve rocker arm cover. (Procedure
given under Rocker Arm Removal.)
Remove the applicable spark plug
wire and spark plug.
2. Remove the valve rocker arm shaft.
Remove both valve push rods of the
cylinder to be serviced. (Procedures
given under Cylinder Head
Removal.)
3. Install an air line with an adapter in
the spark plug hole.
4. Turn on the air supply. Air pressure
may turn the crankshaft until the
piston reaches the bottom of the
stroke. Using the valve spring
compression tool shown in Fig. 8,
compress the valve spring and remove
the valve spring retainer locks, spring
retainer and the valve spring. If air
pressure fails to hold the valve in the
closed position during this operation,
it can be presumed that the valve is
not seating or is damaged. If this
condition occurs, remove the cylinder
head for further inspection.
5. Remove the valve stem seal (Fig. 9).
If air pressure has forced the piston
to the bottom of the cylinder, any
removal of air pressure will allow the
valve(s) to fall into the cylinder. A
rubber band, tape or string wrapped
around the end of the valve stem will
prevent this condition and will still
allow enough travel to check the valve
for binds.
Installation
1. Install a new valve stem seal (Fig. 9).
Position the spring over the valve.
Install the spring retainer. Compress
the valve spring and install the valve
spring retainer locks.
2. Apply Lubriplate or equivalent to
both ends of the push rod, the valve
A3554-A
FIG. 8 Compressing Valve Spring-In
Chassis—Typical
2800cc V-6 Engine
A3299B
FIG. 9 Removing or Installing Valve
Stem Seal
tips and both ends of the rocker arms.
Install the push rod(s), making sure
the lower end of the rod is positioned
in the valve lifter push rod cup.
3. Turn off the air and remove the air
line and adapter. Install the spark
plug and spark plug wire.
4. Install the rocker arm shaft by
following the instructions under
Rocker Arm Installation.
5. Clean the valve cover and cylinder
head gasket surfaces. Coat one side of
a new gasket with an oil-resistant
sealer and lay the cemented side of the
gasket on the cover. Install the cover
making sure the gasket seats evenly
around the head. Tighten the cover
attaching bolts to specification.
6. Install the air cleaner.
7. Run the engine at fast idle and check
for oil leaks.
INTAKE MANIFOLD
Removal
1. Remove air cleaner. Disconnect
battery negative cable.
2. Disconnect throttle cable.
3. Drain coolant. Disconnect and
remove hose from water outlet to
radiator and bypass hose from intake
manifold to thermostat housing rear
cover.
4. Remove distributor cap and spark
plug wires as an assembly. Disconnect
distributor wire and distributor
vacuum line.
5. Observe and mark the location of the
distributor rotor and housing so
ignition timing can be maintained at
reassembly. Remove distributor hold-
down screw and clamp and lift out
distributor.
6. Remove fuel line and filter between
fuel pump and carburetor, rocker arm
covers, and EGR tube.
7. Remove intake manifold attaching
bolts and nuts. Tap manifold lightly
with a plastic mallet to break gasket
seal. Lift off manifold.
211-12-8
8. Remove all old gasket material and
sealing compound.
Installation
1. Apply sealing compound to the
joining surfaces. Place the intake
manifold gasket in position. Make
sure that the tab on the right bank
cylinder head gasket fits into the
cutout of the manifold gasket.
2. Apply sealing compound to the
attaching bolt bosses on the intake
manifold and position the intake
manifold. Tool T72C-6519 is required
to torque one of the intake manifold
bolts. Follow the torque sequence in
Fig. 10 and torque the bolts to
specifications.
3. Install distributor so that rotor and
housing are in same radial position
marked at removal.
4. Install distributor clarnp and
attaching bolt. Connect distributor
wire and vacuum line.
5. Install fuel line and filter between fuel
pump and carburetor and EGR tube.
Replace rocker arm cover gaskets,
and reinstall rocker arm valve covers
using the procedure given under
Rocker Arm Cover Installation.
6. Install distributor cap, coat the
inside of each spark plug wire
connector with silicone grease with
a small screwdriver, and install the
wires.
7. Install and adjust linkage.
8. Install air cleaner and air cleaner tube
at carburetor. Connect battery
negative cable.
9. Connect hoses from water outlet to
radiator and bypass hose from
thermostat housing rear cover to
intake manifold.
10. Refill the cooling system.
ll.Recheck ignition timing and reset
engine idle speed to specification.
12. Run engine at fast idle and check for
coolant and oil leaks.
EXHAUST MANIFOLD
Removal
1. Remove the carburetor air cleaner.
2. Remove the attaching nuts from the
exhaust manifold shroud (right side
only).
3. Disconnect the attaching nuts from
the muffler inlet pipe. Remove
thermactor components as necessary
to allow removal of exhaust
manifold(s).
4. Disconnect choke heat tubes at
carburetor.
5. Remove the manifold attach ing nuts.
6. Lift the manifold from the cylinder
head.
Installation
1. Position the manifold on the studs
and install and torque the attaching
bolts in sequence to specification (Fig.
11).
21-12-9 2800cc V-6 Engine 21-12-9

2. Install a new inlet pipe gasket. Install

and torque the inlet pipe attaching
nuts to specification.
3. Position the exhaust manifold shroud
on the manifold and install and
torque the attaching nuts to
specification (right side). Install
thermactor components that had been
removed.
4. Install the carburetor air cleaner.
Reinstall choke heat tube.
CYLINDER HEAD
Removal
1. Remove air cleaner from carburetor.
Disconnect negative battery cable.
Disconnect linkage. Drain coolant.
2. Remove distributor cap and wires as A3551-C
an assembly. Remove distributor
vacuum line, distributor, coolant FIG. 10 Intake Manifold Torque Sequence
outlet hose, coolant hose from
thermostat housing rear cover to
intake manifold, rocker arm covers, RIGHT SIDE
fuel line and filter, carburetor and
intake manifold.
3. Remove rocker arm shaft (by
loosening two bolts at a time—in
sequence) and oil baffles. Remove
push rods and keep in sequence for
proper assembly.
4. Remove exhaust manifold, following
procedure under Exhaust Manifold—
Removal.
5. Remove cylinder head attaching bolts
and lift off heads. Remove head 1 REQUIRED
gaskets.

Installation
1. Clean cylinder head, intake manifold,
valve rocker arm cover and cylinder
block gasket surfaces. Place cylinder
head gaskets in position on cylinder
block. (Gaskets are marked with the
words front and top for correct
positioning.) Left and right cylinder
head gaskets are different.
2. Install cylinder head assemblies on
cylinder block one at a time. Guide
carefully over positioning studs (Fig.
12). Tighten attaching bolts in
sequence shown in Fig. 13 to
specifications.
3. Install intake manifold. Be sure to use
sealing compound on gasket surfaces
and to position gasket correctly.
Torque attaching bolts in sequence
(Fig. 10).
4. Install exhaust manifold, following
procedures under Exhaust
Manifold—Installation»
5. Apply Lubriplate or equivalent
lubricant to both ends of the push
rods. Install valve push rods, oil
baffles and rocker arm and shaft
assemblies.
6. Install distributor hold-down bolt and
clamp.
5 REQUIRED
FIG. 11 Exhaust Manifold Torque Pattern—Pinto/Bobcat 2.8L Shown—
Mustang Same Pattern
7. Perform valve adjustment as
described under Adjustments.
8. Install rocker arm covers with new
gaskets.
9. Install carburetor and distributor cap
with spark plug wires. If necessary,
adjust linkage.
10. Install fuel line with filter and
vacuum line.
11. Install air cleaner and air cleaner tube
at carburetor. Connect battery
negative cable.
12. Refill and bleed cooling system.
13. Re-check ignition timing and check
idle speed.
14. Operate the engine at fast idle speed
and check for coolant and oil leaks.
A4083-A
VALVE LIFTERS
Removal
1. Remove the cylinder head and related
parts following the procedure under
Cylinder Head Removal.
2. Remove the valve lifters with a
magnet. Place them in a rack in
sequence. If the lifters are stuck in
bores, use plier-type Tool (T70P-
14151) to remove them (Fig. 14).
Rotate lifters back and forth to loosen
them from gum or varnish deposits.
Installation
1. Clean the valve lifters. Lifters and
bores are to be lubricated with heavy
oil SE before installation. Install the
lifters in their original bores with a
magnet (Fig. 14). Check any new
21-12-10
GUIDE STUDS
A 3552-A
FIG. 12 Cylinder Head Guide Studs
lifter for proper fit in bore to which
it is to be installed. See specifications.
2. Install the cylinder head and related
parts, following the procedures given
under Cylinder Head Installation.
WATER PUMP
Removal
1. Drain the coolant. Detach the
radiator lower hose and the heater
return hose from the water inlet
housing.
2. Loosen the alternator mounting bolts
and remove the belt. (With A/C,
remove alternator and bracket.)
3. Remove the fan and pulley.
4. Remove the water pump assembly
attaching bolts and remove water
pump assembly, water inlet housing
and thermostat from the front cover.
Installation
1. Remove all gasket material from the
sealing surfaces on front cover and
water pump assembly. Apply sealer to
both sides of the new gasket and place
the gasket on the water pump.
2. Position the water pump assembly to
the front cover with two bolts finger
tight. Remove all gasket material
from the water inlet housing sealing
surfaces. Apply sealer to both sides
of the new gasket and place the gasket
on the water inlet housing.
3. Install the thermostat and rubber
gasket. Position the water inlet
housing and by-pass flange to the
water pump and install the attaching
bolts. Torque all water pump
assembly a t t a c h i n g bolts to
specification. Note the different
length bolts.
4. Install fan and pulley. (With A/C,
install bracket and alternator.) Install
belt and a d j u s t t e n s i o n to
specification. Reconnect both hoses
to water inlet housing and tighten
hose clamps. Fill and vent cooling
system.
5. Start the engine and check for leaks.
CYLINDER FRONT COVER
Removal
1. Remove oil pan as described under
Oil Pan—Removal.
2. Drain the coolant. Remove the
radiator and any other parts to
provide necessary clearance.
2800cc V-6 Engine
FIG. 13 Cylinder Head Bolts Torque Sequence
3. Remove A/C compressor and
bracket, if equipped.
4. Remove alternator, thermactor pump
and drive belt(s). Remove water
pump and water lines.
5. Remove fan.
6. Remove the drive pulley from the
crankshaft.
7. Remove front cover retaining bolts. If
necessary, tap cover lightly with a
plastic hammer to break gasket seal.
Remove front cover. If front cover
plate gasket needs replacement,
remove two screws and remove plate
(Fig. 16). If necessary, remove guide
sleeves from cylinder block (Fig. 15).
Installation
1. Clean the mating surfaces of gasket
material. Apply sealing compound to
the gasket surfaces on the cylinder
block and back side of the front cover
plate. Position gasket and front cover
plate on cylinder block (Fig. 16).
Temporarily install four front cover
screws to position gasket and cover
MAGNET
A3556-A
FIG. 14 Removing or Installing Valve
Lifters—Typical
21-12-10
A3553-B
plate in place. Install and tighten two
cover plate attaching bolts (Fig. 17),
then remove four screws that were
temporarily installed.
2. If removed, fit new seal rings to the
guide sleeves and, with no sealer used,
insert the sleeves in the cylinder block
with the chamfered side of the sleeve
toward the front cover (Fig. 15).
3. Apply sealing compound to front
cover gasket surface. Place gasket in
position on front cover.
4. Place front cover on engine and start
all retaining screws two or three
turns. Center cover by inserting tool
in oil seal (Fig. 18).
5. Tighten front cover attaching screws
to specifications.
6. Install belt drive pulley and tighten
attaching bolt to specification
7. Install oil pan following Oil Pan
Installation procedure.
8. Install water pump, water hose, A/C
compressor, alternator, thermactor
pump and drive belt(s). Adjust drive
belt tension to specifications.
9. Fill the cooling system to the proper
level with the specified coolant.
10. Operate the engine at fast idle speed
and check for coolant and oil leaks.
A3557-A
FIG. 15 Removing or Installing Guide
Sleeves
 21-12-11
A3558-A
FIG. 16 Removing or Installing Front
Cover Plate
FRONT OIL SEAL
In-Chassis
Removal
1. Drain the coolant. Remove the
radiator and crankshaft pulley and
water pump drive belt. It is not
necessary to remove the front cover
for this operation.
2. Pull the front cover oil seal out with
the tools shown in Fig. 19.
Installation
1. Coat the new front cover oil seal with
Lubriplate or equivalent. Slide tool
and new oil seal onto the crankshaft.
Drive the oil seal in until the tool
abuts against the front cover (Fig. 20).
2. Replace crankshaft pulleys and bolt.
Torque bolt to specifications, then
replace radiator and drive belt.
Adjust belt tension to specification
using Tool T63L-8620-A.
3. Fill the cooling system to the proper
level with the specified coolant.
4. Operate the engine at fast idle speed
and check for coolant leaks.
Front Cover Removed
Removal
1. Support the front cover to prevent
damage while driving out seal.
2. Drive out seal from front cover with
the tool shown in Fig. 21.
A3559-A
FIG. 17 Torquing Front Cover Plate
Attaching Bolts
2800cc V-6 Engine 21-12-11
TOOL-T71P-7137-H
TOOL-T74P6019-A
A3595-B
FIG. 18 Aligning Front Cover FIG. 21 Removing Front Oil Seal—
Front Cover Removed
Installation
1. Support front cover to prevent alternator, thermactor pump, rocker
damage while installing seal. arm covers, fuel line and filter,
2. Coat the new front cover oil seal with carburetor, and intake manifold. Use
Lubriplate or equivalent. Install the the proper plier-type tool to remove
new seal in the front cover as shown the spark plug wire boots.
in Fig. 22. 3. Drain the crankcase. Refer to Rocker
Arm Removal and remove rocker
CAMSHAFT
arm and shaft assemblies. Lift out
The camshaft and related parts are
shown in Fig. 23. push rods and place in a marked rack
so they can be reinstalled in the same
Removal
1. Drain the coolant. Remove the location.
4. Remove oil pan, as described under
radiator, fan, spacer, water pump
pulley and drive belt. Oil Pan Removal.
5. Remove drive sprocket attaching bolt
2. Remove distributor cap with spark
plug wires as an assembly. Remove and slide sprocket off end of shaft.
6. Remove engine front cover and water
distributor vacuum line, distributor.
pump as an assembly.
7. Remove camshaft gear attaching bolt
and slide gear off camshaft.
8. Remove camshaft thrust plate and
screws.
9. Remove the valve lifters, following
Tool-1175-AB Valve Lifter Removal procedure.
10. Carefully pull the camshaft from the
block, avoiding any damage to the
camshaft bearings. Remove camshaft
gear key and spacer ring.
Installation
1. Oil the camshaft journals with heavy
v
Tool-T50T-100-A SE engine oil and apply Lubriplate or
orT59L-100-B equivalent lubricant to the cam lobes.
A3561-A 2. Install the camshaft in the block,
FIG. 19 Removing Front Oil Seal—In
carefully avoiding damage to the
Chassis bearing surfaces.
TOOLT74P 6700-A
TOOL-T71P-7137-H
A3562C A3596-B
FIG. 20 Installing Front Oil Seal—In FIG. 22 Installing Front Oil S e a l -
Chassis Front Cover Removed
21-12-12
3. Install the spacer ring with the
chamfered side toward the camshaft.
Insert camshaft key. Install thrust
plate so that it covers the main oil
gallery (Fig. 24). Torque attaching
screws to specifications.
4. Check the camshaft for the specified
end play. The spacer ring and thrust
plate are available in two thicknesses
to permit adjusting the end play.
5. Turn camshaft and crankshaft as
necessary to align timing marks as
shown in Fig. 27 and install camshaft
gear. Install attaching bolt and
washer and tighten to specifications.
6. Position the valve lifters in their
original locations, following Valve
Lifter Installation procedure.
7. Install engine front cover and water
pump as an assembly.
8. Install belt drive pulley and secure
with washer and attaching bolt.
Tighten bolt to specifications.
9. Install oil pan, as described under Oil
Pan Installation.
10. Apply Lubriplate or equivalent to
both ends of the push rods. Install
valve push rods in same location as
removed.
11. Install intake manifold, as described
under Intake Manifold Installation.
12. Install oil baffles and rocker arm and
shaft assemblies. Tighten rocker arm
stand bolts to specifications. Adjust
valves to specified cold setting.
13. Install water pump pulley, fan spacer,
fan, and drive belt. Adjust belt
tension to specifications. Install
carburetor, fuel line and filter,
alternator, thermactor pump,
distributor, distributor vacuum line,
and distributor cap and wires. Before
installing spark plug wires, coat
inside of each boot with silicone lube
using a small screwdriver. Install
the radiator. Fill the cooling system
to the proper level with the specified
coolant. Adjust ignition timing as
described in Group 29.
14. Install valve covers following Valve
Cover Installation procedures.
15. Run the engine and check the idle
speed.
16. Run the engine at fast idle speed and
check for coolant and oil leaks.
TIMING GEARS
Removal
1. Drain the cooling system and
crankcase. Remove oil pan and
radiator.
2. Remove the cylinder front cover and
water pump, drive belt, and camshaft
following the procedures in this
section.
3. Use the gear pullers as shown in Fig.
25 and remove the crankshaft gear.
Remove the key from the crankshaft.
2800cc V-6 Engine
CAMSHAFT
SPACE R-6278
REAR BEARING
BORE PLUG-6266
FIG. 23 Camshaft and Related Parts
Installation
1. Place the spacer and thrust plate on
the camshaft.
2. Install the key in the camshaft. Align
the keyway in the gear with the key,
then slide the gear onto the shaft,
making sure that it seats tight against
the spacer.
3. Check the camshaft end play. If not
within specifications, replace the
thrust plate.
4. Position the key in the crankshaft.
Align the keyway and install the gear,
using the tool shown in Fig. 26.
5. Install the cylinder front cover
following the procedures in this
section. Install the oil pan and
radiator.
6. Fill the cooling system and crankcase.
Start the engine and adjust the
ignition timing. Operate the engine at
fast idle and check all hose
connections and gaskets for leaks.
OIL PAN
Removal
1. Remove the oil level dipstick.
2. Remove the radiator pressure cap and
drain the cooling system. Disconnect
the radiator upper and lower hoses at
the radiator.
A3564-A
FIG. 24 Camshaft Thrust Plate
Installed
2112-12
CAMSHAFT SPROCK£ T-6256
THRUST PLATE-6279
SCREW-388379-GS
A3563-A
3. Remove the bolts attaching the fan
shroud to the radiator. Position the
shroud back over the fan. Disconnect
the battery ground cable at the
battery.
4. Raise the vehicle. Disconnect the
automatic transmission cooler lines (if
so equipped) at the radiator.
5. Disconnect the steering gear (and
power steering hoses, if equipped) and
position the gear out of the v/ay (see
Group 13).
6. Disconnect the sway bar at the ends
and rotate to allow clearance to
remove pan.
7. Drain the crankcase. Remove the
splash shield.
8. Remove the starter and disconnect
the electrical lead.
9. Remove the engine front support
nuts.
10. Raise the engine and place wood
blocks between the engine front
supports and chassis brackets.
11. Remove the oil pan attaching bolts
and remove the oil pan.
Installation
1. Clean the gasket surfaces of the block
and oil pan.
2. Coat both pieces of the oil pa i gasket
block surfaces with oil resistant
Tool T71P-7137 H
A3565-C
FIG. 25 Removing Crankshaft Gear
21-12-13
JF"* \ A3566-C
FIG. 26 Installing Crankshaft Gear
A3567-A
FIG. 27 Aligning Timing Marks
sealer. Position the oil pan gaskets on
the cylinder block (Fig. 28).
3. Position the oil pan front seal on the
cylinder cover. Make^ure the tabs on
the seal are over the oil pan gasket.
4. Place end seals in position, flush with
the cylinder block oil pan rail.
Position the oil pan rear seal on the
rear main bearing cap (Fig. 28). Be
sure the tabs on the seal are over the
oil pan gasket.
5. Position the oil pan on the cylinder
block. Install four bolts as shown in
Fig. 29, to secure the front and rear
of the oil pan. Install the remaining
bolts and torque to specification in the
sequence shown.
6. Reinstall the clutch cover (or
converter housing).
7. Raise the engine and remove the
wood blocks. Lower the engine and
install the engine support nuts.
Torque to specification.
8. Install the starter and reconnect the
electrical lead.
9. Install the splash shield.
10. Reconnect the sway bar. Install the
steering gear and power steering
2800cc V-6 Engine
FRONT S E A L « g f p i ^
U H H H M HX 7 ^
PAN GASKET
PAN GASKET » .M
Fesfly
ARROWS MUST POINT Jj^*~^ H R O D AND CAP
TOWARD FRONT m^•-^K1 NUMBERS ON
^—T LEFT SIDE
REAR MAIN j ^ f e ^ g j H
BEARING CAPfMSPiiLJa ^ i R E A R SEAL
HA..
FIG. 28 Oil Pan Gaskets and Seals
Installed
equipment disconnected following
procedures in Group 13.
11. Connect the automatic transmission
oil cooler lines at the radiator and
reconnect the radiator lower cooling
hose.
12. Lower the vehicle. Connect the
radiator upper hose. Position the
radiator shroud forward over the fan
and install the attaching bolts.
Maintain radial clearance shown in
Group 27.
13. Connect the battery ground cable. Fill
the cooling system following
instructions in Group 27.
14. Install the oil level dipstick andfillthe
crank case with the proper grade and
amount of engine oil. Start the engine
and check for oil or coolant leaks.
Correct as necessary.
OIL PUMP
Removal
1. Remove oil pan as described under
Oil Pan Removal.
©
INSTALL THESE BOLTS FIRST
FRONT OF ENGINE
©
24 23 22
FIG. 29 Oil Pan Installation and Bolt Torque Sequence
21-12-13
2. Remove bolt that attaches oil pick-up
screen to main bearing cap. Remove
oil pump attaching bolts (Fig. 30).
Lift off oil pump and withdraw oil
pump drive shaft.
Installation
1. Prime the oil pump by filling either
the inlet or outlet port with engine oil.
Rotate the pump shaft to distribute
the oil within the pump body.
2. Insert oil pump drive shaft into block
with the pointed end facing inward.
The pointed end is closest to the
pressed-on flange. Place oil pump in
position with new gasket and install
attaching screws. Tighten screws
securely. Clean and install the oil
pump inlet tube and screen assembly
with a new gasket. Torque the bolts
to specifications.
3. Install oil pan as described in this
Section.
4. Operate the engine at fast idle speed
and check for oil leaks.
CLUTCH PILOT BEARING
Inspection procedures are outlined in
Part 21-01.
Removal
1. Remove the transmission, clutch
pressure plate, and disc following the
procedures in Group 16—Clutch.
2. Using Tools T59L-1OO-B and T58L-
101-A, remove the pilot bearing (Fig.
31).
Installation
1. Using Tools T74P-7137-A and T74P-
7137-H install the pilot service
bearing, with the seal facing the
transmission (Fig. 32).
2. Install the clutch pressure plate and
disc, and the transmission following
the procedure in Group 16—Clutch.
10
21 20 19 18 A3721-A
 21-12-14
FIG. 30 Oil Pump and Inlet Tube
Installed
FLYWHEEL
Removal
1. On a manual-shift transmission,
remove the transmission, clutch
pressure plate and disc, following the
procedures in Group 16—Clutch.
On a vehicle with an automatic
t r a n s m i s s i o n , remove the
transmission and converter housing
following the procedure in Group
17—Automatic Transmission.
2. Refer to Part 21-01 forflywheelface
runout. Remove the flywheel
attaching bolts and remove the
flywheel.
Installation
1. Clean and inspect all parts before
installation. Position theflywheelon
the crankshaft flange. Apply oil-
resistant sealer to the attaching bolts.
Install and torque the bolts in
sequence across from each other to
specifications.
2. On a manual-shift transmission,
install the clutch pressure plate, disc,
and the transmission following the
procedures in Group 16—Clutch.
On a vehicle with automatic
transmission, install the converter
housing and transmission following
the procedure in Group 17 —
Automatic Transmission. It is not
Tool T58L-101-A
Tool T59L-100-B
A 3568-A
FIG. 31 Removing Clutch Pilot
Bearing
2800cc V-6 Engine
TOOLT-74P-7137A
9 T-74P-7137H
FIG. 32 Installing Clutch Pilot Bearing
necessary to adjust the transmission,
when it has been removed only for
flywheel removal.
CAMSHAFT REAR BEARING CORE
PLUG
Removal
1. On a vehicle with a manual-shift
transmission, slide the transmission
to the rear and remove the clutch
pressure plate and disc following the
procedure in Group 16—Clutch.
On a vehicle with automatic
t r a n s m i s s i o n , remove the
transmission and converter housing
following the procedure in Group
17—Automatic Transmission.
2. Remove the flywheel attaching bolts
and remove the flywheel and engine
rear cover plate.
3. Remove the core plug as detailed in
Part 21-01.
Installation
1. Install a new plug with the tool shown
in Fig. 33 using the procedure given
in Part 21-01.
2. Install the engine rear cover plate,
apply oil-resistant sealer to the
flywheel bolts and install the
Tool T72C-6266
A 3570-A
FIG. 33 Installing Camshaft Rear
Bearing Core Plug
21-12-14
flywheel. Torque the attaching bolts
to specifications.
On a vehicle with a manual-shift
transmission, install the clutch
pressure plate, disc, and transmission
following the procedure in Group
16—Clutch.
On a vehicle with automatic
transmission, install the transmission
and converter housing following the
procedure in Group 17—Automatic
Transmission.
CRANKSHAFT REAR OIL SEAL
Removal
1. Remove the transmission. Remove
clutch pressure plate and clutch disc,
if so equipped. Follow the procedures
given in Group 16.
2. Remove flywheel, flywheel housing
and rear plate.
3. Use an awl to punch two holes in the
crankshaft rear oil seal. Punch the
holes on opposite sides of the
crankshaft and just above the bearing
cap to cylinder block split line Install
a sheet metal screw in each hole (Fig.
34). Use two large screwdrivers or
small pry bars and pry against both
screws at the same time to remove the
crankshaft rear oil seal. It may be
necessary to place small blocks of
wood against the cylinder block to
provide a fulcrum point for the pry
bars. Use caution throughout this
procedure to avoid scratching or
otherwise damaging the crankshaft
oil seal surface.
4. Clean the oil seal recess in the
cylinder block and main bearing cap.
Inspect and clean the oil seal contact
surface on the crankshaft, following
the procedure in Part 21-01.
Installation
1. Coat the oil seal to cylinder block
surface of the oil seal with c 1. Coat
the seal contact surface of the oil seal
and crankshaft with Lubriplate or
equivalent. Start the seal in the recess
and install it with the tool as shown
in Fig. 35. Drive the seal into position
until it is firmly seated.
A3574-A
FIG. 34 Removing Crankshaft Rear
Oil Seal
21-12-15
A3575-B
FIG. 35 Installing Crankshaft Rear
Oil Seal
2. Install rear plate, flywheel housing,
and flywheel. Tighten flywheel bolts
to specifications.
3. Install clutch disc and clutch pressure
plate, if so equipped. Align clutch disc
before tightening pressure plate
attaching screws.
4. Install transmission.
M A I N BEARINGS
The main and connecting rod bearing
inserts are selective fit. Do not file or lap
bearing caps or use shims to obtain the
proper bearing clearance. Selective fit
main bearings are available for service in
standard and undersizes. Refer to the
parts catalog for the available sizes.
Undersize bearings which are not
selective fit, are available for use on
journals that have been refinished. (See
specifications.)
If the rear main bearing is to be
replaced, remove the engine and place it
in a work stand.
Removal
1. Drain the crankcase. Remove the oil
pan and oil pump.
2. Replace one bearing at a time, leaving
the other bearings securely fastened.
Remove the main bearing cap to
which new bearings are to be
installed.
3. Insert the upper bearing removal Tool
6331 in the journal oil hole.
4. Rotate the crankshaft slowly in the
direction of engine rotation to force
the bearing insert out of the block.
Installation
1. Clean each crankshaft journal before
installing the main bearing insert.
Inspect the journals for nicks, burrs
or bearing pick-up that would cause
premature bearing wear. Make sure
that the four thrust washers are in
place on the No. 3 main bearing.
2. To install the upper main bearing,
lubricate the bearing with heavy
engine oil SE then place the end of the
bearing over the shaft on the locking
tang side of the block and partially
2800cc V-6 Engine
install the bearing so that Tool 6331
can be inserted in the journal oil hole.
With Tool 6331 installed, rotate the
crankshaft slowly in the opposite
direction of engine rotation until the
bearing tang is seated. Remove the
bearing tool.
3. Select fit the bearing for proper
clearance following procedures under
Fitting Main and Connecting Rod
Bearings in Part 21-01.
4. Coat the bearing insert and journal
with heavy engine oil SE and install
the bearing cap. Tighten the cap bolt
to specification.
5. Install the remaining bearings in the
same manner. If servicing the rear
main bearing, apply sealer to the cap
as shown in Fig. 36. If necessary,
align the thrust bearing as shown in
Fig. 37.
6. Clean all oil pan gasket surfaces
thoroughly. Straighten the oil pan
f l a n g e if d e f o r m e d d u e to
overtorquing the bolts.
7. Clean oil pump inlet tube screen.
Prime pump by filling inlet opening
with oil while rotating shaft until oil
emerges from outlet opening. Install
pump and screen and t o r q u e
attaching bolts to specifications.
8. Coat the cylinder block oil pan
surfaces and oil pan gasket surface
with oil-resistant sealer.
9. Position the gaskets on the block. See
Fig. 38 for installation of the rear
main bearing cap wedge seals. Install
one end seal in the rear main bearing
cap and the other in the cylinder
block front cover. Be sure ends engage
oil pan side gaskets properly.
10. Position the oil pan and install the
attaching bolts. Torque the bolts to
specification.
11. Fill the crankcase to the correct level
with the specified oil. Start the engine
and check for leaks.
A3576-A
FIG. 36 Sealer Application to Rear
Main Bearing Cap
21-12-15
CONNECTING ROD BEARINGS
The connecting rod bearings are
selective fit. Refer to procedures under
Fitting Main and Connecting Rod
Bearing with Plastigage, Part 21-01.
Removal
1. Drain the crankcase. Remove the oil
pan and related parts.
2. Remove the oil pump.
3. Rotate the crankshaft until the
connecting rod in which the bearings
are to be fitted, is at the bottom.
4. Remove the bearing cap from the rod,
then remove the bearing inserts.
Installation
1. Make sure bearing inserts and bearing
bore in connecting rod and cap are
clean. Foreign material under inserts
or between rod and cap will distort
the bearing and cause premature
failure.
2. Clean the crankshaft journal.
3. Install the bearing inserts in the
connecting rod and cap with the tangs
fitted in the slots provided.
4. Pull the connecting rod assembly
down firmly on the crankshaft
journal.
5. Select fit the bearing following
procedures in Part 21-01.
6. After the bearing has been fitted,
clean and apply a light coat of engine
oil to the journal and bearings. Install
the connecting rod cap. Tighten the
nuts to specification.
7. Clean the oil pump inlet tube screen.
Prime the pump by filling the inlet
opening with oil while rotating the
shaft until oil emerges from the outlet
opening. Install the pump with a new
gasket and torque the attaching bolts
to specification.
8. Install the oil pan.
9. Fill the crankcase to the correct level
with the specified oil. Start the engine
and check for leaks.
PISTONS AND CONNECTING
RODS
Removal
1. Drain the cooling system and the
crankcase. Remove the intake
manifold, cylinder heads, oil pan and
oil pump, following the procedures in
this Section.
2. Remove any ridges and/or deposits
from the upper end of the cylinder
bores as follows:
Turn the crankshaft until the
piston to be removed is at the bottom
of its travel and place a cloth on the
piston head to collect the cuttings.
Remove any ridge and/or deposits
from the upper end of the cylinder
bores. Remove the cylinder ridge with
a ridge cutter. Follow the instructions
 21-12-16
A3577-A
FIG. 37 Aligning Thrust Bearing
furnished by the tool manufacturers.
Never cut into the ring travel area in
excess of 1/32 inch when removing
ridges.
3. Make sure all connecting rod caps are
marked so that they can be installed
in their original positions.
4. Turn the crankshaft until the
connecting rod being removed is
down.
5. Remove the connecting rod nuts and
cap.
6. Push the connecting rod and piston
assembly out the top of the cylinder
with the handle end of a hammer.
Avoid damage to the crankshaft
journal or the cylinder wall when
removing the piston and rod.
7. Remove the bearing inserts from the
connecting rod and cap.
8. Install the cap on the connecting rod
from which it was removed.
Installation
1. If new piston rings are to be installed,
remove the cylinder wall glaze.
Follow the instructions of the tool
manufacturer.
2. Oil the piston rings, pistons and
cylinder walls with light engine oil
(SE). Be sure to install the pistons in
WEDGE SEALS
A3578-A
FIG. 38 Replacing Rear Main Bearing
Cap Wedge Seals
2800cc V-6 Engine 21-12-16
the same cylinders from which they OIL RING SPACER
were removed or to which they were OIL RING ® OIL RING
SEGMENT SEGMENT
fitted. The connecting rod and
bearing caps are numbered from 1 to
3 in the right bank and from 4 to 6
in the left bank, beginning at the front
of the engine. The numbers on the
connecting rod and bearing cap must
be on the same side when installed in
the cylinder bore (Fig. 39). If a
connecting rod is ever transposed
from one block or cylinder to another,
new bearings should be fitted and the
connecting rod should be numbered
to correspond with the new cylinder
number.
3. Make sure the ring gaps are properly
spaced around the circumference of
the piston (Fig. 40).
FRONT OF ENGINE f A2811-A
FIG. 40 Piston Ring Gap Spacing
4. Install a piston ring compressor on
the piston and push the piston in with
11. Prime the oil pump by filling either
a hammer handle until it is slightly the inlet port or outlet port with
below the top of the cylinder (Fig. 41).
engine oil and rotating the pump shaft
Be sure to guide the connecting rods to distribute the oil within the
to avoid damaging the crankshaft
housing. Install the oil pump and the
journals. Install the piston with the oil pan.
indentation notch in the piston head
12. Install the cylinder heads following
toward the front of the engine (Fig. procedures under Cylinder Head
42).
Installation.
5. Check the clearance of each bearing 13. Install the intake manifold following
following the procedure under Fitting
procedures under Intake Manifold
Main and Connecting Rod Bearings Installation.
in Part 21-01.
14. Fill and bleed the cooling system. Fill
6. After the bearings have been fitted, the crankcase with the proper grade
apply a light coat of engine oil (SE)
and quantity of engine oil.
to the journals and bearings. 15. Start the engine and check and adjust
7. Turn the crankshaft throw to the
the ignition timing. Connect the
bottom of its stroke. Push the piston distributor vacuum hoses at the
all the way down until the connecting carburetor.
rod bearing seats on the crankshaft 16. Operate the engine at fast idle and
journal. check for oil and coolant leaks When
8. Install the connecting rod cap. the engine temperature has stabilized,
Tighten the nuts to specifications. adjust the engine idle speed and idle
9. After the piston and connecting rod fuel mixture.
assemblies have been installed, check 17. Install the air cleaner and intake duct
the side clearance between the assembly.
connecting rods on each crankshaft
journal (Fig. 43).
CRANKSHAFT
10. Disassemble, clean, and assemble the
oil pump. Clean the oil pump inlet Removal
tube screen and the oil pan and block The crankshaft and related parts are
gasket surfaces. shown in Fig. 44.
A3579-A
A3581-A
FIG. 39 Connecting Rod and Cap
Numbering FIG. 41 Installing Piston
21-12-17
RIGHT BANK
LEFT BANK
FRONT OF^
ENGINE
NUMBERED SIDE TO LEFT A3580-A
FIG. 42 Correct Piston and Rod
Positions
1. Remove engine from the vehicle and
place on a work stand.
2. Remove flywheel, flywheel housing
and rear plate.
3. Remove oil pan with engine in normal
upright position.
4. Remove components from front of
engine and front cover.
5. Invert engine and remove oil pump
and inlet tube assembly. Leave oil
pump drive shaft in position.
6. Make sure all main and connecting
bearing caps are marked so they can
be installed in their original locations.
7. If crankshaft is being replaced,
remove gear as shown in Fig. 25.
8. Remove connecting rod nuts and lift
off rod cap with bearing insert.
Carefully push piston and rod
assemblies down in cylinders.
9. Remove main bearing bolts and lift
off main bearing caps with inserts.
Discard rear oil seal.
10. Carefully lift crankshaft out of
cylinder block, being careful not to
damage the thrust bearing surfaces.
Remove bearing inserts from block
and identify for position if they are to
be re-used.
Installation
1. If crankshaft gear was removed,
install it as shown in Fig. 26.
2. Clean the bearing bores in the block
and caps and the bearing inserts on
both sides. Foreign material under the
Feeler Gouge
A 3594-A
FIG. 43 Checking Connecting Rod
Side Clearance
2800cc V-6 Engine
MAIN BEARING LINERS-6333
DAMPER & PULLEY
ASSEMBLY-6B321AA
SCREWS
MAIN BEARING CAP BOLT-6345
MAIN BEARING CAPS
* SERVICED IN 6010 BLOCK ASSY.
FIG. 44 Crankshaft and Related Parts
inserts or on the bearing surfaces may
distort the insert and cause bearing
failure.
3. Assemble main bearing inserts in
their correct location in bearing caps
and cylinder block. Check alignment
of oil holes in inserts with oil holes in
block. Apply a liberal coating of SE-
type engine oil to the bearing surfaces.
Carefully lower crankshaft into
position. Check gear timing marks for
correct positioning (Fig. 27).
4. Apply a thin even coating of sealing
compound to the rear sealing surface
of the rear main bearing cap as shown
in Fig. 36. Install main bearing caps
in their correct location. The arrows
on the front and center main bearing
caps must point to the front of the
engine.
5. Install and tighten all main bearing
bolts finger tight. Then tighten all
bolts, except for center thrust bearing,
in steps to specifications.
6. Align the thrust bearing surfaces by
forcing the crankshaft forward and
the thrust bearing cap rearward.
While holding in this position, tighten
the cap bolts to specifications (Fig.
37).
7. Coat the sealing lip of a new
crankshaft oil seal with SE-type
engine oil. Slide seal over end of
crankshaft and drive into position
(Fig. 33). Be sure the seal bottoms in
groove.
8. Using a flat tool such as a large blunt
end screwdriver, push the two wedge-
shaped seals between the cylinder
block and rear main bearing cap.
Position the seals with the round side
facing the main bearing cap (Fig. 38).
21-12-17
I FLYWHEEL ASSEMBLY-6375
6384 (RING GEAR)
BOLT-6379
MAIN BEARING LINERS
-6333
A3582-B
9. Pull connecting rods up one at a time
and install rod caps. Be sure to apply
a liberal coating of SE-type oil to the
bearing surfaces. Tighten cap nuts to
specifications.
10. Install oil pump and pick up tube as
an assembly.
11. Install front cover.
12. Install rear cover plate, flywheel
housing and flywheel. Tighten
flywheel bolts to specifications.
13. Install clutch disc and clutch pressure
plate, if so equipped.
14. Install oil pan as described under Oil
Pan—Installation. Be sure gaskets
and seals are installed as directed.
15. Install the front cover and previously
removed components.
16. Install the engine in the vehicle.
CAMSHAFT BEARING
The camshaft bearings are available
pre-finished to size and require no
reaming for standard and undersize
journal diameters.
Removal
1. Remove the engine from the vehicle
and place in a work stand. Remove
the flywheel and the camshaft.
Remove the rear bearing bore plug.
2. Remove the camshaft bearings with
the tools shown in Fig. 45.
3. Select the proper size expanding collet
and back-up nut and assemble on the
expanding mandrel. With the
expanding collet collapsed, install the
collet assembly in the camshaft
bearing. Tighten the back-up nut on
the expanding mandrel until the collet
fits the camshaft bearing.
4. Assemble the puller screw and
extension (if necessary) as shown and
install on the expanding mandrel.
21-12-18 2800cc V-6 Engine 21-12-18

Wrap a cloth around the threads of

the puller screw to protect the front
bearing or journal. Tighten the
pulling nut against the thrust bearing
and pulling plate to remove the
camshaft bearing. Be sure to hold a Tool T71P-6250A
wrench on the end of the puller screw
to prevent it from turning.
5. Repeat the procedure for each
bearing. To remove the front and rear
bearings, use the special adapter tube
Tool T72C-6250.
Installation
1. Position the new bearings at the
bearing bores, and press them in place
with the tools shown in Fig. 45. Be
sure to center the pulling plate and
puller screw to avoid damage to the
bearing. Failure to use the correct
expanding collet can cause severe
bearing damage. Align the oil holes in
the bearings with the oil holes in the
cylinder block when the bearings are A3585-B
installed. Check oil hole alignment of FIG. 45 Typical Camshaft Bearing Replacement
Nos. 2 and 3 bearings with a welding
rod or slightly smaller diameter than
the oil holes. Insert the rod into the
oil passage (Fig. 46). The rod will pass
into the camshaft bore when the holes
are properly aligned.
2. Install a new bearing bore plug.
3. Install the camshaft, flywheel and
related p a r t s , following the
appropriate procedures. Do not check
connecting rod and main bearing
clearances as a part of Camshaft
Bearing Replacement. Install the
engine in the vehicle.
OIL FILTER
Removal
1. Place a drip pan under the filter.
Unscrew the filter from the adapter
fitting. Clean thefilteradapter recess.
Installation
1. Coat the gasket on the replacement
filter with oil. Position the filter on
the adapter fitting. Hand tighten the
filter until the gasket contacts the
adapter face, then advance it 1/2
turn.
2. Operate the engine at fast idle, and
check for oil leaks. If oil leaks are
evident, perform the necessary repairs
to correct the leakage. Check the oil A3586-A
level and fill the crankcase to the
recommended level if necessary. FIG. 46 Checking Oil Hole Alignment—Nos. 2 and 3 Camshaft Bearings

DISASSEMBLY AND ASSEMBLY

When installing nuts or bolts that
must be torqued (refer to the
Specification at the end of this Part for
torque specifications), oil the threads
with light weight (SE) engine oil. Do not
oil threads that require oil-resistant or
water-resistant sealer. Refer to Part 21-
01 for cleaning and inspection
procedures.
VALVE ROCKER ARM ASSEMBLY
Refer to Fig. 47 for component parts.
Disassembly
1. Remove the spring washer and pin
from each end of the valve rocker arm
shaft.
2. Slide the rocker arms, springs and
rocker arm shaft supports off the
 21-12-19 2800cc V-6 Engine 21-12-19

shaft. Be sure to mark the parts for ROCKER ARM-6564

PIN-72034-S
re-assembly in the same locations.
3. If it is necessary to remove the plugs
from each end of the shaft, drill or
pierce the plug on one end. Use a steel
rod to knock out the plug on the PIN-72O34-S
SPRING WASHER
opposite end. Working from the open SUPPORT 6598
end, knock out the remaining plug. SPRING-6587 6531

SUPPORT-6531

1. The oil holes in the rocker arm shaft SUPPORT-6531

must point down when the shaft is
installed. This position of the shaft
can be recognized by a notch on the
front face of the shaft (Fig. 47).
2. If the plugs were removed from the
shaft, use a blunt tool and install a
plug, cup side out, in each end of the
shaft.
3. Install a spring washer and pin on one
end of the shaft, coat the rocker arm
shaft with heavy SE engine oil and
install the parts in the same sequence
they were removed.
4. Install the remaining spring washer
and pin.
5. Before installation on the engine, coat
the rocker arm pads with Lubriplate
or equivalent.
CYLINDER HEA6
Disassembly
1. Remove d e p o s i t s from the
combustion chambers and valve
heads with a scraper and a wire brush
before removing the valves. Be
careful not to scratch the cylinder
head gasket surfaces.
2. Compress the valve springs. Remove
the valve retainer locks and release
the springs.
3. Remove the spring retainer, stem seal,
and valve (Fig. 48). Discard the valve
stem seals. Identify all valve parts for
re-assembly. Remove the manifold
assembly and spark plugs.
Assembly
1. Clean, inspect and repair all parts
before assembly. Install the manifold
assembly and spark plugs. Torque the
spark plugs and manifold attaching
parts to specifications. Lubricate the
valve guides and valve stems with
engine oil. Apply Lubriplate or
equivalent to the tips of the valve
stems.
2. Install each valve in the valve guide
SPRING WASHER
6598
SHAFT-6563
FIG. 47 Rocker Arm Shaft Assembly
underside of the spring retainer with
dividers (Fig. 49).
6. Check the dividers against a scale. If
the assembled height is greater than
specifications, install the necessary
spacer(s) between the cylinder head
spring pad and the valve spring to
bring the assembled height to the
recommended dimension. Do not
install spacers unless necessary. Use
of excess spacers will result in
overstressing the valve springs and
overloading the camshaft lobes which
would lead to spring breakage and
worn camshaft lobes.
OIL PUMP
Disassembly
1. Remove oil pick-up tube and screen
assembly from pump housing.
2. Remove oil pump cover and lift out
two-piece rotor assembly (Fig. 50).
3. Drill a small hole in the center of
pressure relief valve plug. Thread an
appropriate size metal screw in the
hole and pull the plug from the
housing.
4. Remove pressure relief valve spring
and valve.
Assembly
1. Clean and inspect the oil pump
following procedures given in Part 21-
01. Apply SE-type engine oil to the
relief valve and relief valve spring.
LOCKS-6518
A3588-A
Insert relief valve and spring into
housing.
2. Install a new relief valve retaining
plug into the oil pump housing. Place
plug into housing until it bottoms.
The plug should be installed with its
flat side pointing out. With a round
drift of approximately 1/2 inch
diameter and a hammer, spread the
plug in the housing to prevent its
accidental removal.
3. Install inner and outer rotors and
shaft assembly in housing. Make sure
the dimple identification marks on the
outer rotor and inner rotor are on the
same side. Check the rotor end
clearance as described in Part 21-01.
4. Lubricate inner and outer rotors with
SE-type engine oil. Place oil pump
cover in position and tighten
attaching screws to specifications.
Check for free movement of rotor.
PISTON AND CONNECTING ROD
Disassembly
1. Remove the bearing inserts from the
connecting rod and cap.
2. Mark the pistons and pins to assure
assembly with the same rod and
installation in the same cylinders
from which they were removed.

from which it was removed or to

RETAINER-6514
which it was fitted. Install a new stem
seal on the valve. INTAKE VALVE
3. Install the valve spring assembly over 6507
the valve, close coils toward the \
cylinder head. Install the spring VALVE SPRING
retainer. 6513
OILSEAL-6571
4. Compress the spring and install the \
retainer locks (Fig. 48). EXHAUST VALVE
A3590-A
5. Measure the assembled height of the
valve spring from the surface of the A3589-A
FIG. 49 Checking Valve Spring
cylinder head spring pad to the FIG. 48 Valve Assemblies Assembled Height
21-12-20 2800cc V-6 Engine 21-12-20

DRIVER DETAIL A-7 UP3ER

BODY ASSEMBLY-6600 COMPRESSION
R MG

LOWER
ROTOR AND SHAFT COMPRESSION
ASSEMBLY-6608 RING
6148

BOLT
INSERT THIS END
PLATE-6616 ^ ^ FOR INSTALLATION
A3591 A
<*%
b 1*-REVERSIBLE LOCATOR
FIG. 50 Oil Pump Disassembled \ 1 DETAIL A-5

' * K ^ . N . INSERT THIS END

3. Using an arbor press and the tool A 1 FOR PIN REMOVAL
shown in Fig. 51 press the piston pin
from the piston and connecting rod.
Remove the piston rings. T72C-6U5

Assembly
The piston, connecting rod and Tool T68P-6135- A CONNECTING
ROD BEARINGS
related parts are shown in Fig. 52. Clean 6211
and inspect the piston and connecting rod
following procedures given in Part 21-01.
Check the fit of a new piston in the
NUT-6212
cylinder bore before assembling the 'CUP DETAIL A - l

piston and piston pin to the connecting A3593-B

rod.
The piston pin bore of a connecting
rod and the diameter of the piston pin
must be within specifications.
1. Apply a light coat of engine oil to all
parts. Assemble the piston and the
connecting rod as shown in Fig. 42.
2. Start the piston pin in the piston and
connecting rod (this may require a
very light tap with a mallet). Using an
arbor press, press the piston pin
through the piston and connecting
rod until the pin is centered in the
piston (Fig. 51).
3. Check the end gap and spacing of all
piston rings following instructions
given in Part 21-01. They must be
within specifications.
4. Follow the m a n u f a c t u r e r ' s
instructions (included with the piston
ring package) and install the piston
rings.
5. Check the ring side clearance of the
compression rings with a feeler gauge
inserted between the ring and the
lower land (Part 21-01). The gauge
should slide freely around the entire
ring circumference without binding.
Any wear that occurs will form a step
at the inner portion of the lower land.
If the lower lands have high steps, the
piston should be replaced.
A3592-A
FIG. 51 Removing or Installing Piston
Pin
6. Be sure the bearing inserts and the
bearing bore in the connecting rod
and cap are clean. Foreign material
under the inserts will distort the
bearing and cause a failure. Install the
bearing inserts in the connecting rod
and cap with the tangs fitting in the
slots provided.
CYLINDER ASSEMBLY
Disassembly
1. Mount the old engine in a work stand
and remove all parts not furnished
with the new cylinder assembly,
following the procedures given in the
Removal and Installation Section of
this Part.
2. Remove the old cylinder assembly
from the work stand.
Assembly
1. Clean the gasket and seal surfaces of
all serviceable parts and assemblies.
2. Position the new cylinder assembly in
a work stand and transfer all
serviceable parts removed from the
old cylinder assembly, following the
procedures given in the Removal and
Installation Section of this Part.
FIG. 52 Piston, Connecting Rod and
Related Parts
3. Check all assembly clearances and
correct as necessary.
CYLINDER BLOCK
Before replacing a cylinder block,
determine if it is repairable. If so. make
the necessary repairs, following the
procedures given in Part 21-01.
Disassembly
1. Completely disassemble the old
engine, following the procedures
given in the Removal and Installation
Section of this Part.
2. Remember toridge-reamthe cylinder
bores before removing piston
assemblies.
Assembly
1. Clean the cylinder block follow ing the
instructions given in Part 21-01.
Clean the gasket and seal surfaces of
all serviceable parts and assemblies.
2. Position the new cylinder block in a
work stand and install all serviceable
parts removed from the old cylinder
block, following the procedures; given
in the Removal and Installation
Section of this Part.
3. Check all assembly clearances and
correct as necessary.
21-12-21 2800cc V-6 Engine 21-12-21

SPECIFICATIONS-1977
GENERAL SPECIFICATIONS CAMSHAFT

LOBE LIFT
DISPLACEMENT . : : 2.8L(2800cc) 1ntdks 0.2555
NUMBER OF CYLINDERS 6 FvhaiKt .................. 0.2555
BORE ANDSTROKE 3 66x270 (.AlidUjl
0.005
FIRING ORDER 14 2 5 3-6 Allowable Lobe Lift Loss
OIL PRESSURE (Hot @ 2000 RPM) 40 60 THEORETICAL VALVE LIFT @ ZERO LASH
0.3730
DRIVE BELT TENSION Intake
(!) Exhsust 0.3730
COMPRESSION PRESSURE
® END PLAY 0.00080.004
CYLINDER HEAD AND VALVE TRAIN Service Limit 0.009
JOURNAL TO BEARING CLEARANCE 0.001 0.0026
Service Limit 0.006
COMBUSTION CHAMBER VOLUME (cc) 42.8-44.3 CAMSHAFT GEAR BACKLASH 0.0060.010
VALVE" GUIDE BORE DIAMETER 0 31740 3184
VALVE SEATS JOURNAL DIAMETER
Width - Intake 0.060 0.079 #1 1.6497 1.6505
Width - Exhaust 0.0600.079 #2 1.6347 1.6355
45° ff j 1.6197 1.6205
#4 1.6047 1.6055
Runout Limit (T. I. R. Max.) 0.0015
VALVE ARRANGEMENT (Front to Rear) Runout 0.005 Max. T. I. R.
L. H. = I - E - E - I - E - I
R. H. = IE IE El Out-Of-Round 0.0003 Max T. I. R.
GASKET SURFACE FLATNESS . . 0.003 in 6", 0.006" overall BEARING INSIDE DIAMETER
GASKET SURFACE FINISH (RMS) 60 150 #1 1.6515 1.6523
VALVE STEM-TO-GUIDE CLEARANCE 1.6365 1.6373
Intake 0.0008 0.0025 #3 1.6215 1.6223
Exhaust 0.0018 0.0035 1.6065 1.6073
Service Clearance 0.0055 FRONT BEARING LOCATION (4A 0.0400.060
VALVE HEAD DIAMETER
Intake 1.562 1.577 CYLINDER BLOCK

txnjiust 1.261 1.276

VALVE FACE RUNOUT LIMIT 0.002 Max. HEAD GASKET SURFACE FLATNESS (5)
VALVE FACE ANGLE 44° Finish (RMS) 60-150
VALVE STEM DIAMETER (Std) CRANKSHAFTTO REAR FACE OF BLOCK RUNOUT (T I.R.Max.) 0.005
' Intake 0.3159 0.3167 CYLINDER BORE
Exhaust 0.3149 0.3156 Diameter 3.6614 3.6630
(0.008 Oversiz* Surface Finish (RMS) 18 38
0.3239 0.3245 Out Of-Round 0.0015
Exhaust 0.3228 0.3235 Out-Of-Round Service Limit 0.005
(0.016 Oversize) Taper Service Limit 0.010
0.3318 0.3324 TAPER BORE DIAMETER 0.8750 0.8760
Exhaust 0 33070 3314 MAIN BEARING BORE DIAMETER 2.3866 2.3874
(0.032 Oversize) DISTRUBUTOR SHAFT BEARING BORE DIAMETER 0.45340.4549
IniaKB 0.3475 0.3481
Exhaust 0.3461 0.3468 CRANKSHAFT AND FLYWHEEL
VALVE SPRINGS
Compression Pressure (Lb. @ Spec. Length) 60.0 68.0 @ 1.585 MAIN BEARING JOURNAL DIAMETER 2.2433 2.2441
138.0 149.0 @ 1.222 Out Of-Round 0.0006
Free Length (Approximate) 1.91 Taper Limit 0.0006 per inch
Assembled Height 1 37/64-1 39/64 Journal Runout 0.002 Max.
Service Limit (3) Surface Finish (RMS) 12
Out Of Square 5/64 (0.078) Runout Service Limit : 0.005
ROCKER ARM THRUST BEARING JOURNAL
Shaft Diameter 0.7799 0.7811 Length 1.039 1.041
Bore Diameter 0.7830-0.7842 CONNECTINC ROD JOURNAL
Ratio . . . ' 1.46:1 Diameter 2.1252 2.1260
PUSH ROD RUNOUT (T. 1. R. Max.) 0.020 Out-Of-Round 0.0006
VALVE TAPPET, LIFTER OR ADJUSTER Taper Limit 0.0006 per inch
Diameter (Std) 0.8736-0.8741 Surface Finish (RMS) 12 Max.
Clearance To Bore 0.0009 0.0024 MAIN BEARING THRUST FACE
Service Limit 0.005 Surface Finish 20 Max.
VALVE LASH CLEARANCE (COLD) Runout (T. 1. R 0.001 Max.
Intake 0.014 FLYWHEEL CLUTCH FACE
Exhsust 0.016 Runout 0.005
FLYWHEEL RING GEAR LATERAL RUNOUT (T. 1. R.)
Standard Transmission 0.025
Automatic Transmission . • 0.060
CRANKSHAFT FREE END PLAY 0.0040.008
Service Limit 0.012
CONNECTING ROD BEARINGS
Clearance To Crankshaft - Desired 0.0006-0.0015
- Allowable 0.00050.0022
Bearing Wall Thickness (Std) (6) Red - 0.0548-0.0552
Blue - 0.0552 0.0556
MAIN BEARING
Clearance To Crankshaft - Desired 0.00080.0015
- Allowable 0.00050.0019
Bearing Wall Thickness (Std) (6) Red - 0.0707 0.0710
Blue - 0.07110.0714

CA1262F
21-12-22 2800cc V-6 Engine 21-12-22

SPECIFICATIONS-1977
CONNECTING ROD. PISTON AND RINGS TORQUE SPECIFICATIONS - SPECIAL APPLICATIONS

ITEM SIZE TORQU:

CONNECTING ROD
Piston Pin Bore Diameter . 0.94500.9452
Crankshaft Bearing Bore Diameter . 2.23702.2378 CAMSHAFT GEAR BOLT M-10 3036
Out-Of-Round 0.0004 CAMSHAFT THRUST PLATE BOLT M-8 12 15
Taper 0.0004 CARBURETOR TO SPACER (Stud) 3-5
Length {CentertoCenter) . 5.1386 5.1413 CARBURETOR ADAPTER TO MANIFOLD (STUD) 3-5
Alignment (BoretOBore Max. Diff.) (f) CARBURETOR TO SPACER (Nut) M-8 4 18
Twist 0.006 CONNECTING ROD NUT M-8 21-25
Bend 0.002 CRANKSHAFT DAMPER BOLT M 12 92-103
Side Clearance (Assembled to Crank) CRANKCASE VENT V A L V E 11-14
Standard 0.0040.011 CYLINDER HEAD BOLT M-12 65-80 (K)
Service Limit 0.014 DECEL V A L V E NUT 27-30
PISTON DECEL V A L V E TO MANIFOLD ADAPTER 3034
Diameter ( | ) DISTRIBUTOR CLAMP BOLT M-8 12-15
Coded Red . . 3.6605 3.6615 EGR TUBE FITTINGS 1520
0.020 Oversize 3.6802 3.6812 EGR V A L V E TO SPACER BOLT M-8 12 15
Piston-To-Bore Clearance . 0.00110.0019 EXHAUST MANIFOLD TO EGR TUBE (CONN.) 25 35
Pin Bore Diameter . 0.9450-0.9452 EXHAUST MAN. TO CYLINDER HEAD (Bolt/Stud) M-8 20-30
Ring Groove Width FLYWHEEL TO CRANKSHAFT (Bolt) M-10 47-51
Compression (Top) . 0.08030.0811 FRONT COVER TO CYLINDER BLOCK (Bolt) M-8 12-15
Compression (Bottom) . 0.11970.1205 FRONT PLATE TO CYLINDER BLOCK (Bolt) M-8 12-15
Oil . 0.15790.1587 FUEL PUMPTO CYLINDER BLOCK (Bolt) M-8 12-15
INTAKE MAN. TO CYLINDER BLOCK (Bolt/Nut) M-8 15-18 ( v i )
PISTON PIN
Length . 2.835 2.866 INTAKE MAN. TO CYLINDER BLOCK (Stud) M-8 10-12
Diameter MAIN BEARING CAP BOLT M-12 65-75
. 0.94460.9450 TIMING POINTER TO FRONT COVER (Bolt) M-6 57
Standard
Pin-To-Piston Clearance . 0.0003-0.0006 OIL PUMP PICK-UP TUBE TO PUMP (Bolt) M-6 7-9
Pin-To-Rod Clearance . Interference Fit OIL PUMP PICK-UP TUBE TO MAIN BEARING CAP(Bolt) M-8 12 15
PISTON RINGS OIL PUMP COVER (Bolt) M-6 79
Ring Width OIL PAN DRAIN PLUG M-14 15 20
Compression (Top) . . 0.0778 0.0783 OIL PAN TO CYLINDER BLOCK (Bolt) M-6 57
Compression (Bottom) . 0.1172 0.1177 OIL FILTER TO CYLINDER BLOCK (INSERT ) 10-15
Side Clearance OIL FILTER @
Compression (Top) . 0.0020 0.0033 ROCKER ARM COVER BOLT M-6 3-5
Compression (Bottom) . 0.0020-0.0033 ROCKER ARM SHAFT SUPPORT BOLT M-10 43-49
Oil Ring Snug Fit WATER JACKET DRAIN PLUG TO BLOCK 14-18
0.006 WATER OUTLET CONNECTION BOLT M-8 12-15
Service Limit
WATER PUMPTO CYLINDER BLOCK (Bolt) M-6 7-9
Ring Gap
. . . 0.015-0.023 WATER TEMPSENDING UNIT 7-11
Compression (Top)
Compression (Bottom) 0.015 0.023 SPARK PLUG TO CYLINDER HEAD 1015
Oil Ring (Steel Rail) 0.015 0.055 FUEL F I L T E R T O CARBURETOR 80 100 i - I b .
ALT MOUNTIN BRKT TO CYLINDER HEAD (Bolt) M-8 1825
LUBRICATING SYSTEM A L T M O U N T I N G B R K T T O CYLINDER BLOCK (Bolt) M-10 28-40
ALT PIVOT BOLT 45-60
OIL PUMP ALT ADJ ARM TO FRONT COVER (Bolt) M-12 50-71
Relief Valve Sorina Tension (Lbs. at Spec. Length) 13.6-14.7 @ 1.39 ALT ADJUSTING ARM TO ALTERNATOR 24-40
Drive Shaft-To-Housing Bearing Clearance . 0.0015 0.0030 CRANKSHAFT PULLEY TO DAMPER (Bolt) M-8 1825
Relief Valve-To-Bore Clearance . 0.0015 0.0030 FAN TO WATER PUMP HUB (Bolt) M-8 14-20
Rotor Assembly End Clearance (Assembled) . . . 0.004 Max. THERM PUMPMTG BRACKETTO CYLINDER BLOCK (Bolt) M-10 28-40
Outer Race-To-Housing Clearance . . . 0.0010.013 THERM PUMP MTG BRACKET TO CYLINDER HEAD (Bolt M-8 1825
OIL CAPACITY (Quarts U. S.) 4-1/2 (9) THERMACTOR PUMP ADJUSTING ARM TO PUMP (Bolt) 22 32
THERMACTORPUMPPIVOTBOLT 30-45
21-12-23 2800cc V-6 Engine 21-12-23

SPECIFICATIONS-1977
TORQUE SPECIFICATIONS - General Applications

U.S. THREAD SIZES TORQUE Drive Belt Tension (Lbs.)

Newly Installed Used
1/4-20 . .' 6-9 S.ze (A)
UptoiOMin. OveriOMin.
5/16-18 12 18
5/16-24 14-20 1/4" 50-80 40-80 (B) 40-60 (B)
3/8-16 22 32
3/8-24 27-38 Exc. 1/4" 120-160 90-160(0 75-120 (D)
7/16-14 40 55
7/16-20 40-60 (A) Read tension immediately after belt is installed, before it stretches or seats in pulley
1/2-13 55 80 grooves.
(B) If less than 40 pounds, readjust to 40 60 pounds.
TORQUE (C) If less than 90 pounds, readjust to 90 120 pounds.
METRIC THREAD SIZES
(D) If less than 75 pounds, readjust to 90-120 pounds.
6-9 PSI of lowest cylinder must be within 75% of highest (see part 21-01).
M-8 14-21 10% pressure loss @ specified Length.
M-10 28-40 Distance in inches that front edge of bearing is installed below front face of cyl. block.
M-12 . . 50-71 0.003 in any 6 inches - 0.006 overall.
M-14 80-114 0.002 undersize = add 0.001 to standard thickness.
Pin and crank bearing bore must be parallel and in same vertical plane within the
TORQUE specified total difference when measured at ends of an 8" bar, 4 " on each side of rod
PIPE THREAD SIZES
centerline.
1/8 . 5-8 Measured at the piston pin bore centerline at 90° to the pin.
1/4 12-18 Add 1/2 quart with filter change.
3/8 22 33 In Sequence: Step 1 = 29-40; Step 2 = 40-51; Step 3 = 65-80;
1/2 25-35 In Sequence: Step 1 = 3-6; Step 2 = 6 11; Step 3 = 11-15; Step 4 = 15-18. After engine
has been operating, retorque in sequence to 15-18 (hot).
• All values are in ft.-lb. unless otherwise noted 1/2 turn after gasket contacts sealing surface with oiled gasket.
• NOTE: Oil threads with engine oil unless the threads require oil.or water resistant sealer.
CA1262F
21-21-1 302 and 351W CID V-8 Engines 21-21-1

PART
302 and 351W CID V-8 Engines 21-21
Mustang, Maverick, Comet, Granada, Monarch, LTD I I , Cougar and Thunderbird

SUBJECT PAGE SUBJECT PAGE

DESCRIPTION
Crankcase Ventilation System . . . 21-1 Main Bearing 21-15
Engine 21-1 Oil Filter 21-19
Exhaust Emission Control System 21-1 Oil Pan 21-13
Oil Pump 21-14
REMOVAL AND INSTALLATION Pistons and Connecting Rods 21-16
Camshaft 21-12 Valve Lifter .21-9
Camshaft Bearings 21-18 Valve Rocker Arm Cover and
Camshaft Rear Bearing Bore Plug . 21-13 Rocker Arm .21-4
Clutch Pilot Bearing 21-13 Valve Spring, Retainer and Stem Seal .21-6
Connecting Rod Bearings 21-15 Water Pump 21-10
Crankcase Ventilation System . . . .21-5
Crankshaft 21-17 DISASSEMBLY AND ASSEMBLY
Crankshaft Rear Oil Seal 21-15 Cylinder Assembly 21-21
Cylinder Front Cover and Cylinder Block 21-21
Timing Chain 21-10 Cylinder Head 21-20
Cylinder Heads 21-9 Oil Pump 21-20
Engine Assembly 21-3 Pistons and Connecting Rods . . . 21-20
Engine Front Supports 21-4 Valve Lifter 21-19
Engine Rear Support 21-4
Exhaust Manifolds 21-10 SPECIFICATIONS 21-22
Flywheel 21-13
Front Oil Seal 21-12
Intake Manifold 21-7

CA4262-A

DESCRIPTION
ENGINE
The 302 and 351-W V-8 engines
(Figs. 1 and 2) have a piston displacement
of 302 and 351 cubic inches respectively.
EXHAUST EMISSION CONTROL
SYSTEM
Operation, removal, installation and
required maintenance of the exhaust
emission control devices used on these
engines are covered in Group 29 and
Group 50 of this Manual.
CRANKCASE VENTILATION
SYSTEM
The engine is equipped with a positive
closed-type crankcase ventilation system
re-cycling the crankcase vapors to the
intake manifold.
21-21-2 302 and 35IW CID V-8 Engines 21-21-2

A3287-B

FIG. 1 3/4 Right Front View—302-2V V-8

A2715-E

FIG. 2 3/4 Right Front View—351-W V8

21-21-3
REMOVAL AND INSTALLATION
When installing nuts or bolts that
must be torqued, oil the threads with
light weight engine oil. Do not oil threads
that require oil-resistant or water-
resistant sealer.
Refer to Part 21-01 for Cleaning and
Inspection and Engine test procedures.
ENGINE ASSEMBLY
The Engine Removal and Installation
procedures are for the engine only
without the transmission attached. If the
engine is equipped with the Thermactor
system, remove or disconnect parts that
will interfere with removal or installation
of the engine.
Removal
1. Drain the cooling system and the
crankcase.
2. Remove the hood. Disconnect the
battery and alternator ground cables
from the cylinder block.
3. Remove the air cleaner and intake
duct assembly.
4. Disconnect the radiator upper hose
from the coolant outlet housing and
the radiator lower hose at the water
pump.
On a vehicle with an automatic
transmission, disconnect the
transmission oil cooler lines from the
radiator.
Remcve the bolts attaching the fan
shroud to the radiator, if so equipped.
5. Remove the radiator. Remove the
fan, spacer, belt pulley and shroud.
6. Remove the alternator bolts and
position the alternator out of the way.
7. Disconnect the oil pressure sending
unit wire from the sending unit, and
the flexible fuel line at the fuel tank
line. Plug the fuel tank line.
8. Disconnect the accelerator cable from
the carburetor.
On a vehicle with an automatic
transmission disconnect the throttle
valve vacuum line from the intake
manifold. Disconnect the manual
shift ror' and disconnect the
retracting spiing at the shift rod stud.
Disconnect the transmission filler
tube bracket from the cylinder block.
On a vehicle with an air
conditioner, isolate and remove the
compressor as outlined in Group 36.
On a vehicle with power steering,
disconnect the power steering pump
bracket from the cylinder head.
Remove the drive belt. Position the
power steering pump out of the way
and in a position that will prevent the
fluid from draining out.
On a vehicle with power brakes,
disconnect the brake vacuum line
from the intake manifold.
302 and 351W CID V-8 Engines
9. Disconnect the heater hoses from the
water pump and intake manifold.
Disconnect the water temperature
sending unit wire from the sending
unit.
10. Remove the flywheel or converter
housing to engine upper bolts.
11. Disconnect the primary wire from the
ignition coil. Remove the wire
harness from the left rocker arm
cover and position the wires out of the
way. Disconnect the ground strap
from the block.
12. Raise the front of the vehicle.
Disconnect the starter cable from the
starter. Remove the starter.
13. Disconnect the muffler inlet pipes
from the exhaust manifolds.
Disconnect the engine support
insulators from the brackets on the
frame.
On a vehicle with a manual-shift
transmission, remove the bolts
attaching the clutch equalizer bar to
the frame rail and remove the
equalizer from the engine block.
Remove the remaining flywheel
housing to engine bolts.
On a vehicle with an automatic
transmission, disconnect transmission
cooler lines from retainer and remove
the converter housing inspection
cover. Disconnect the flywheel from
the converter. Secure the converter
assembly in the housing. Remove the
remaining converter housing to
engine bolts.
14. Lower the vehicle, and then support
the transmission. Attach the engine
lifting sling, Tool No. T53L-3OO-A
and hoist to lifting brackets on intake
manifolds.
15. Raise the engine slightly and carefully
pull it from the transmission.
Carefully lift the engine out of the
engine compartment (avoid bending
or damaging the rear cover plate or
other components). Install the engine
on a work stand.
Installation
1. Attach the engine lifting sling, Tool
No. T53L-3OO-A, and lifting brackets
to intake manifold. Hoist the engine
from the work stand.
2. Lower the engine carefully into the
engine compartment. Make sure the
exhaust manifolds are properly
aligned with the muffler inlet pipes.
On a vehicle with an automatic
transmission, start the converter pilot
into the crankshaft.
On a vehicle with a manual-shift
transmission, start the transmission
main drive shaft into the clutch disc.
21-21-3
It may be necessary to adjust the
position of the transmission in
relation to the engine if the input shaft
will not enter the clutch disc. If the
engine hangs up after the shaft enters,
turn the crankshaft slowly
(transmission in gear) until the shaft
splines mesh with the clutch disc
splines.
3. Install the flywheel or converter
housing upper bolts, making sure that
the dowels in the cylinder block
engage theflywheelhousing.
4. Install the engine support insulator to
bracket attaching nuts. Disconnect
the engine lifting sling and remove the
lifting brackets.
5. Raise the front of the vehicle.
Connect both muffler inlet pipes to
the exhaust manifolds. Torque the
nuts to specifications.
6. Install the starter and the starter
cable.
On a vehicle with a manual-shift
transmission, install the remaining
flywheel housing to engine bolts.
Position the clutch equalizer bar to
the engine block and install the
equalizer bar bracket on the frame
side rail.
On a vehicle with an automatic
transmission, remove the retainer
holding the converter in the housing.
Attach the converter to the
flywheel. Install the converter
housing inspection cover. Install the
remaining converter housing
attaching bolts.
7. Remove the support from the
transmission and lower the vehicle.
8. Connect the wiring harness to the left
valve rocker arm cover and connect
the coil wire.
9. Connect the water temperature
sending unit wire. Connect the heater
hose to the intake manifold.
10. Connect the bellcrank to the intake
manifold.
On a vehicle with an automatic
t r a n s m i s s i o n , connect the
transmission filler tube bracket.
Connect the manual shift rod and
connect the retracting spring.
Connect the throttle valve vacuum
line.
Connect the accelerator cable.
11. Remove the plug from the fuel tank
line and connect the fuel line and the
oil pressure sending unit wire.
12. Install the pulley, belt, spacer and fan.
13. Position the alternator and install the
alternator bolts. Connect the
alternator and the battery ground
cables. Adjust the belt tension to
specifications.
21-21-4
On a v e h i c l e with an air
conditioner, install the compressor as
outlined in Group 36.
On a vehicle with power steering,
install the drive belt and power
steering pump bracket. Install the
bracket attaching bolts. Adjust the
drive belt tension to specifications.
On a vehicle with power brakes,
connect the brake vacuum line.
14. Place the radiator shroud over the
fan, if so equipped. Install the
radiator. Connect the radiator upper
and lower hoses. On a vehicle with an
automatic transmission, connect the
transmission fluid cooler lines. Install
the shroud bolts if so equipped.
15. Connect the heater hose at the water
pump. Fill and bleed the cooling
system. Fill the crankcase with the
proper grade and quantity of oil.
16. Adjust the transmission throttle
linkage.
17. Operate the engine at fast idle and
check all gaskets and hose
connections for leaks.
18. Install the air cleaner and intake duct
assembly.
19. Install and adjust the hood.
ENGINE FRONT SUPPORTS
The front supports are located on
each side of the cylinder block (Figs. 3
thru 6). The procedures given apply to
either a right or left installation.
Whenever self-locking mounting bolts
arid nuts are removed, they must be
replaced with new self-locking bolts and
nuts. See (*) in Figs. 3—8.
Maverick, Comet Granada and
Monarch
Removal
1. Support the engine using a jack and
wood block placed under the oil pan.
2. Remove the nut and through bolt
attaching the insulator to the
insulator support bracket (Figs. 3 and
4).
3. Raise the engine slighly with the jack.
4. Remove the engine insulator
assembly to cylinder block attaching
SHIELD L.H
6C060 L.H. ASSY.
6C010R.H.
SIDE ONLY (SHOWN)
386069-S2
I9-S2 ,
I'D. \
2REO/D.
35-60 FT-LB\
FT-LB
NOTE: WASHER
MUST BE
INSERTED AS
SHOWN
383421-S2
2REO/D.
R.H. SIDE SHOWN
L.H. SIDE TYPICAL A4072-C
FIG. 3 Engine Front Supports—
Granada and Monarch
302 and 351W CID V-8 Engines
20-37 FT-LB
383232-S2
4REQ'D. \ 6061 L.H.
35-60 FT-LB \ 6037 R.H.
386454-S2
4REQ/D.
A3412D
FIG. 4 Engine Front Supports—
Comet and Maverick
bolts. Remove the engine insulator
assembly and the heat shield, if so
equipped.
Installation
1. Position the engine insulator
assembly and the heat shield, if so
equipped, to the cylinder block and
install the attaching lock bolts.
Torque the bolts to specifications.
2. Lower the engine into position, install
the engine insulator assembly to
insulator support bracket through
bolt and remove the jack and wood
block.
3. Install the engine insulator assembly
to insulator support bracket lock nut.
Torque the nut to specifications.
LTD II, Cougar, Thunderbird, and
Mustang
Removal
1. Remove the fan shroud attaching
screws.
2. From under the car support the
engine using a wood block and jack
placed under the oil pan.
3. Remove the nut and through bolt
attaching the insulator to the frame
crossmember (Figs. 5 and 6).
4. Raise engine enough to remove
insulator and heat shield (if so
equipped).
Installation
1. Position the insulator assembly and
heat shield, if so equipped, to the
engine block and torque the attaching
screws to specification.
2. Lower the engine until the through
bolt can be inserted through the
insulator and crossmember. Be sure
the locator boss on the insulator and
the locator hole in the crossmember
are properly aligned.
3. Install the through bolt nut and
torque to specification.
21-21-4
4. Remove the jack and wood block,
install the fan shroud attaching screw.
ENGINE REAR SUPPORT
The rear support is located at the
transmission extension housing (Figs. 7
and 8).
Whenever self-locking mounting
bolts and nuts are removed, they must be
replaced with new self-locking bolts and
nuts.
Removal
1. On LTD II, Cougar and Thunderbird
models, support the engine with a
jack and wood block under the oil pan
and remove the support insulator to
crossmember attaching nuts.
2. Remove the support insulator to
transmission extension housing bolts
and lockwashers.
3. On all models except those with floor
shift manual transmissions, raise the
transmission with a floor jack.
Remove the support insulator and
retainer.
4. Or\ floor shift manual transmission
models, support the transmission
with a floor jack and remove the
frame crossmember from the frame
and from the engine rear support;
then remove the rear support from the
transmission. Do not apply upward
pressure on the transmission with the
jack as damage to the transmission
shift lever console or mounting plate
will result.
Installation
1. Position the support insulator and
retainer on the transmission extension
housing.
2. On all models except those with floor
shift, install the support insulator to
transmission extension housing bolts
and lockwashers. Torque the bolts to
SHIELD-
6C050 - FOR 302
ENG. L.H. ONL
NO. 2
2REO/D.
DIRECTION CROSSMEMBER
OPTIONAL
A3232-G
FIG. 5 Engine Front Supports—LTD
II, Cougar and Thunderbird
21-21-5
382802-S2'
R.H.SIDE ONLY
20-30 FT-LB
6A088 ASSEMBLY
L.H. REF.
368041-S100
(2REQ'D.)
85-110 FT.-LB.
VIEW
L.H. SHOWN, R.H. SYMMETRICALLY
OPPOSITE
FIG. 6 Engine Supports — Mustang
s p e c i f i c a t i o n s . Lower the
transmission.
3. On models with floor shift manual
transmission, position the rear
support to the transmission and
install and torque the attaching bolts.
Position the removable crossmember
to the frame and install the through-
bolts. Remove the supporting jack,
install the n its and washers attaching
the support to the crossmember and
torque the nuts to specifications.
4. On LTD II, Cougar and Thunderbird
models, install the support insulator
to crossmember attaching nuts.
Tighten the nuts to specifications.
CRANKCASE VENTILATION
SYSTEM
The positive closed-type crankcase
ventilation system components are
shown in Fig. 9.
Removal
1. Remove the ventilation system air
intake hose from the air cleaner and
the right valve cover.
302 and 351W CID V-8 Engines 21 21-5
382802 -S2*
(2REQ'D.)
20-30 FT.-LB.
/
INSUL'vTOR -
091
386040-S100*
(2 REQ'D.)
85-110 FT.-LB
A4058-C
2. Remove the air cleaner and intake Removal
duct assembly. 1. To remove a valve rocker a m from
3. Disconnect the crankcase vent hose the right cylinder head, disconnect
from the carburetor spacer. the automatic choke heat chamber air
4. Pull the regulator valve out of the oil inlet hose from the inlet tube near the
filler cap in the left valve cover. right valve rocker arm cover, if so
equipped (302 only).
Installation
1. Insert the regulator valve into the oil
filler cap on the left valve cover.
2. Connect the vent hose to the regulator
valve; install the hose on the INSULATOR -
carburetor spacer. 6068 ASSY
3. Install the air cleaner and intake duct
assembly.
4. Install the ventilation system air
intake hose to the air cleaner and the
right valve cover fitting.
5. Start the engine and check for leaks.
VALVE ROCKER ARM COVER
AND ROCKER ARM
NO. 3 CROSSMEMBER REF
The valve rocker arm assembly FIG. 7 Engine Rear Supports—LTD II,
sequence is shown in Fig. 10. Cougar and Thunderbird
21-21*6
386242-S100
17-32 FT-LB (2 REQ'D.)
INSULATOR - 6 0 6 8
ALL EXCEPT
MANUAL
FLOOR SHIFT
FRONT OF CAR
A3413-D
FIG. 8 Engine Rear Supports—
Comet, Maverick, Granada
and Monarch
Remove the air cleaner and intake
duct assembly.
Remove the automatic choke heat
tube (302 only). Remove the
crankcase ventilation fresh air tube
from the valve rocker arm cover.
Disconnect the EGR vacuum
amplifier hoses.
2. Remove the Thermactor by-pass
valve and air supply hoses.
3. Disconnect the spark plug wires from
the spark plugs using Tool No. T68P-
6666-A. Do not pull on wire. Remove
the wires from the bracket on the
valve rocker arm cover(s) and
position the wires out of the way.
4. On a left side rocker arm cover,
remove the wire harness from the
CRANKCASE VENT
HOSE
FIG. 9 Typical Crankcase Ventilation System Components
302 and 351W CID V-8 Engines
retaining clips. Remove the valve
rocker arm cover attaching bolts and
remove the cover.
5. Remove the valve rocker arm stud
nut, fulcrum seat and rocker arm.
If removal of the rocker arm stud
is necessary, refer to the procedure
under Cylinder Head Repairs in Part
21-01.
Installation
All rocker arms and fulcrum seats are
to be lubricated with heavy engine oil SE
before installation.
1. Apply Lubriplate, or equivalent, to
the top of the valve stem and
underside of the fulcrum seats.
2. Inspect the stud nut for damage. The
chamfer on the nut should not be over
1/16-inch wide. A nut with a chamfer
larger than 1/16-inch can cause the
valves to be held open. (Refer to Part
21-01).
3. Rotate the crankshaft until the valve
lifter is on the cam base circle (all the
way down), and install the rocker
arm, fulcrum seat and stud nut.
4. Clean the valve rocker arm cover(s)
and the cylinder head gasket
surface(s). Position the valve rocker
cover gasket in each cover, making
sure that the tabs engage the notches
in the cover.
5. Position the cover(s) on the cylinder
head(s). Make sure the gasket seats
evenly all around the head. Install the
bolts and wire loom clips on left hand
cover. The cover is tightened in two
s t e p s . T o r q u e the b o l t s to
specifications. Two minutes later,
torque the bolts to the same
specifications. Install the EGR
vacuum amplifier hoses.
CRANKCASE VENT
TUBE EXTENSION HOSE
CRANKCASE VENT
TUBE HOSE -
6A664
CRANKCASE
VENT T U B E - 6 7 5 9
A4070 B
21-21-6
Install the crankcase ventilation
hoses in the covers. Install the
automatic choke heat tube and
connect the automatic choke heat
chamber air inlet hose at the air
cleaner.
6. Install the spark plug wires in the
bracket on the valve rocker arm
cover(s). Connect the spark plug
wires. Install the air cleaner and
intake duct assembly.
7. Install the Thermactor by-pass valve
and air supply hoses.
VALVE SPRING, RETAINER AND
STEM SEAL
Broken valve springs or damaged
valve stem seals and retainers may be
replaced without removing the cylinder
head, provided damage to the valve or
valve seat has not occurred.
Removal
1. Make sure the applicable piston is at
the top of its stroke to prevent
accidental dropping of the valve into
the cylinder. Remove the valve rocker
arm cover and the applicable spark
plug.
2. Install an air line with an adapter in
the spark plug hole and turn on the
air supply. Failure of the air pressure
to hold the valve(s) in the closed
position is an indication of valve seat
damage and necessitates removal of
the cylinder head.
3. Remove the valve rocker arm stud
nuts, fulcrum seats, valve rocker arms
and push rods from the applicable
cylinder. Remove the exhaust valve
stem caps.
4. Install the stud nut and position the
compressor tool as shown in Fig. 11.
A1634-O
FIG. 10 Valve Rocker Arm—302 and
351-W Engines
21-21-7
Tool-1
Air Line
or6513-HH
FIG. 11 Compressing Valve Spring—
In Chassis
Compress the valve spring and
remove the retainer locks, sleeve,
spring retainer and valve spring.
5. Remove and discard the valve stem
seal (Fig. 12).
6. If air pressure has forced the piston
to the bottom of the cylinder, any
removal of air pressure will allow the
valve(s) to fall into the cylinder. A
rubber band, tape or string wrapped
around the end of the valve stem will
prevent this condition and will still
allow enough travel to check the valve
for binds.
Installation
1. Inspect the valve stem for damage.
Rotate the valve and check the valve
stem tip for eccentric movement
during rotation. Move the valve up
and down through normal travel in
the valve guide and check the stem for
binds. If the valve has been damaged,
it will be necessary to remove the
cylinder head for repairs as outlined
in Part 21-01.
2. If the condition of the valve proved
satisfactory, apply heavy engine oil
SE to the valve stem and hold the
valve in the closed position. Apply the
air pressure within the cylinder.
3. Install a new valve stem seal (Fig. 12).
Place the spring in position over the
valve and install the valve spring
retainer and sleeve, if so equipped.
Compress the valve spring and install
the valve spring retainer locks.
Remove the compressor tool and stud
nut.
4. Turn off the air and remove the air
line and adapter. Install the spark
plug.
5. Apply Lubriplate or equivalent to
both ends of the push rod. Install the
push rod. Apply Lubriplate or
equivalent to the tip of the valve stem.
On exhaust valves, install the valve
stem cap.
6. Apply Lubriplate, or equivalent, to
the push rod socket, underside of the
fulcrum seat and the valve pad of the
302 and 351W CID V-8 Engines
FIG. 12 Removing or Installing Valve
Stem Seal
rocker arm; then install the valve
>ocker arms, fulcrum seats and stud
nuts.
7. Clean and install the rocker arm
cover.
If the right cover was removed
install the automatic choke heat tube
(302 only) and the crankcase
ventilation hose and fittings. Connect
the automatic choke heat chamber air
inlet hose (302 only).
8. Install the air cleaner and intake duct
assembly.
9. Install the valve rocker arm covers
and crankcase ventilation hoses, etc.
INTAKE MANIFOLD
The intake manifold assembly is
shown in Fig. 13.
Removal
1. Drain the cooling system. Disconnect
the automatic choke heat chamber air
inlet hose at the inlet tube near the
right valve rocker arm cover (302
MANIFOLD-TO-BLOCK
MANIFOLD-TO-HEAD GASKET
9441
MANIFOLD-TO-BLOCK FRONT SEAL'
9A42S
THERMOSTAT 8575
COOLANT OUTLET HOUSING"
8594
FIG. 13 Typical Intake Manifold Assembly
21-21-7
only). Remove the air cleaner,
crankcase ventilation hose and intake
duct assembly.
2. Disconnect the accelerator cable from
the c a r b u r e t o r . Remove the
accelerator cable bracket.
Disconnect vacuum lines, at the
intake manifold fitting.
3. Disconnect the high tension lead and
wires from the coil.
4. Remove Thermactor by-pass valve
and air supply hoses (302 only).
5. Disconnect the spark plug wires from
the spark plugs using Tool No T68P-
6666-A. Do not pull on the wire.
Remove the wires from the harness
brackets on the valve rocker arm
covers. Remove the distributor cap
and spark plug wire assembly.
Remove EGR vacuum amplifier at
rear of manifold.
6. Remove the carburetor fuel inlet line
and the automatic choke heat tube
(302 only).
7. Disconnect the distributor vacuum
hoses from the distributor. Remove
the distributor hold down bolt and
remove the distributor.
8. Disconnect the radiator upper hose
from the coolant outlet housing, and
the water temperature sending unit
wire at the sending unit. Disconnect
the hose from the intake manifold.
9. Loosen the clamp on the water pump
bypass hose at the coolant outlet
housing and slide the hose off the
outlet housing.
10. Disconnect the crankcase vent hose
assembly at the valve rocker arm
cover.
HEATER HOSE FITTING
MANIFOLD-TO-HEAD GASKET
9441
WATER TEMPERATURE
> SENDING UNIT
INTAKE MANIFOLD
9424
GASKET 8255
A1589-M
21-21-8
11. Disconnect EGR valve and vacuum
hoses from back-pressure transducer.
12. Remove the intake manifold and
carburetor as an assembly. It may be
necessary to pry the intake manifold
away from the cylinder head(s). Use
caution to avoid possible damage to
the gasket sealing surfaces. Remove
the intake manifold gaskets and seals.
13. If the manifold assembly is to be
disassembled, identify all vacuum
hoses before disconnecting them.
Remove the coolant outlet housing,
gasket and thermostat. Remove the
ignition coil, temperature sending
unit, carburetor, spacer and gaskets,
and EGR valve and back-pressure
transducer assembly, and gasket. On
351W remove the choke heat stove
cover and tube assembly.
Installation
1. If the intake manifold assembly was
disassembled, install the temperature
sending unit (threads coated with
electrical conductive sealer), ignition
coil carburetor, spacer and gaskets.
Install the EGR back-pressure
transducer and valve using a new
gasket. Position the thermostat in the
coolant outlet housing. Coat the
thermostat gasket with water-
resistant sealer and position it on the
coolant outlet housing. Install the
coolant outlet housing. Connect all
vacuum hoses.
2. Clean the mating surfaces of the
intake manifold, cylinder heads and
cylinder block. Use a solvent such as
lacquer thinner, chlorothane or tri-
chlor-ethylene. 'Apply a 1/8 inch bead
of silicone rubber sealer at the points
shown in Fig. 14.
3. Position new seals on the cylinder
block and new gaskets on the cylinder
heads with the gaskets interlocked
with the seal tabs. Be sure the holes
in the gaskets are aligned with the
holes in the cylinder heads.
Apply a 1/16 inch bead of the
above sealer to the outer end of each
intake manifold seal for the full width
of the seal (4 places). See Fig. 14.
NOTE: This sealer sets up in 15
minutes, so it is important that
assembly be completed promptly. Do
not drip any sealer into the engine
valley.
4. Using guide pins to ease installation,
carefully lower the intake manifold
into position on the cylinder block
and cylinder heads. After the intake
manifold is in place, run a finger
around the seal area to make sure the
seals are in place. If the seals are not
in place, remove the intake manifold
and position the seals.
302 and 351W CID V-8 Engines 21-21-8
TYPICAL SEALER APPLICATION AREAS FOR INTAKE MANIFOLD INSTALLATION
1/8" DIA. BEAD C3AZ-19526-A(OR B)
SEALER (4-JOINTS) INTAKE MANIFOLD GASKET
CYLINDER HEAD
INTAKE MANIFOLD
SEAL
SEAL MOUNTING SURFACE
OF CYLINDER BLOCK 1/16" DIA. BEAD C3AZ-19526-A(OR-B)
SEALER (4-SEAL ENDS)
A3715-B
FIG. 14 Typical RTV Sealer Installation-Intake Manifold
5. Be sure the holes in the manifold distributor vacuum hoses to the
gaskets and manifold are in distributor.
alignment. Remove guide pins. Install
15. Operate the engine at fast idle and
the intake manifold attaching bolts check all hose connections and
and nuts. Torque the intake manifold
gaskets for leaks. When engine
bolts in sequence (Fig. 15) to temperatures have stabilized adjust
specifications.
the engine idle speed and idle fuel
6. Install the water pump bypass hose on mixture. Retorque intake manifold
the coolant outlet housing. Slide the bolts to specifications.
clamp into position and tighten the
clamp. 16. Install the air cleaner and intake duct
7. Connect the radiator upper hose. assembly.
Connect the heater hose at the intake
manifold.
8. Install the carburetor fuel inlet line
and the automatic choke heat tubes.
9. Rotate the crankshaft damper until
the No. 1 piston is on TDC at the end
of the compression stroke. Position
the distributor in the block with the
rotor at the No. 1firingposition and
the points just open. Install the hold
down clamp.
10. Install the distributor cap. Position
the spark plug wires in the harness
brackets on the valve rocker arm
covers and connect the wires to the
spark plugs. Install Thermactor by-
pass valve and air supply hoses (302
only).
11. Connect the crankcase vent hose.
Connect the high tension lead and coil
wires.
12. Connect the accelerator cable and
accelerator cable bracket.
On a vehicle with an automatic
transmission, connect the
transmission vacuum line.
On a vehicle equipped with
vacuum-operated accessories,
connect any vacuum lines that were
disconnected from the intake
manifold during removal. A1658-F
13. Fill and bleed the cooling system.
14. Start the engine and check and adjust FIG. 15 Intake Manifold Bolts Torque
the ignition timing. Connect the Sequence
21-21-9
VALVE LIFTER
Before replacing a hydraulic valve
lifter for noisy operation, be sure the
noise is not caused by improper valve to
rocker arm clearance or by worn rocker
arms or push rods.
Removal
1. Remove the intake manifold and
related parts by following procedures
under Intake Manifold Removal.
2. Remove the crankcase ventilation
hoses and fittings from the valve
rocker arm covers.
3. Remove the valve rocker arm covers.
Loosen the valve rocker arm stud nuts
and rotate the rocker arms to the side.
4. Remove the valve push rods and
identify them so that they can be
installed in their original positions.
5. Using a magnet, remove the valve
lifters and place them in a rack so that
they can be installed in their original
bores (Fig. 16).
If the valve lifters cannot be
removed from their bores due to
excessive varnish, etc., it may be
necessary to use a plier-type tool
(T52T-65OO-DJD or 6500-D or
equivalent) or a claw type tool to
remove the lifters. Rotate the lifter
back and forth to loosen it from the
gum or varnish that may have formed
on the lifter.
If necessary to disassemble a lifter,
refer to Valve Lifter Disassembly and
Assembly.
Installation
Tappets or lifters and bores are to be
lubricated with heavy engine oil SE
before installation.
1. Clean outside of lifters and install in
the bores from which they were
removed. If a new lifter(s) is being
installed, check the new lifter(s) for a
free fit in the bore in which it is to be
installed. Lubricate the lifter(s) and
FIG. 16 Removing Valve Lifter
302 and 351W CID V-8 Engines
bore(s) with heavy engine oil SE
before inserting it in the bore.
2. Install the push rods in their original
position. Apply Lubriplate or
equivalent to the valve stem tips and
the push rod ends.
3. Lubricate the rocker arms and
fulcrum seats with heavy engine oil
SE. Position the rocker arms over the
push rods and install stud nuts.
Perform a valve clearance adjustment
as outlined under Valve Clearance
Adjustment—Hydraulic Valve
Lifters.
4. Install the valve rocker arm covers.
Install the crankcase ventilation
regulator valve in the valve rocker
arm cover.
5. Install the intake manifold and
related parts by following procedures
under Intake Manifold Installation.
CYLINDER HEADS
If a cylinder head is to be replaced,
follow the procedures under Cylinder
Head Disassembly and Assembly, and
transfer all valves, springs, spark plugs,
etc., to the new cylinder head. Clean and
inspect all parts, reface the valves (refer
to Part 21-01) and check all assembly
clearances before assembling the new or
used parts to the new cylinder head.
Removal
1. Remove the intake manifold and
carburetor as an assembly following
the procedure under Intake Manifold
Removal.
2. Remove the rocker arm cover(s).
If the left cylinder head is to be
removed on a vehicle with an air
conditioner, isolate and remove the
compressor as outlined in Group 36.
If the left cylinder head is to be
removed on a vehicle with power
steering, disconnect the power
steering pump bracket from the left
cylinder head and remove the drive
belt from the pump pulley. Position
the power steering pump out of the
way and in a position that will prevent
the oil from draining out.
3. If the right cylinder head is to be
removed, remove the alternator
mounting bracket bolt and spacer
from the right cylinder head
assembly.
4. Disconnect the exhaust manifold(s)
from the muffler inlet pipe(s).
5. Loosen the rocker arm stud nuts so
that the rocker arms can be rotated
to the side. Remove the push rods in
sequence (Fig. 18) so that they may
be installed in their original positions.
Remove the exhaust valve stem
caps.
6. Install the cylinder head holding
fixtures (Fig. 18).
21-21-9
AI593-C
FIG. 17 Removing Valve Push Rod
Remove the cylinder head
attaching bolts and lift the cylinder
head off the block. If required,
remove the exhaust manifolds to gain
access to the lower attaching bolts.
Remove and discard the cylinder
head gasket.
Installation
1. Clean the cylinder head, intake
manifold, valve rocker arm cover and
cylinder head gasket surfaces. If the
cylinder head was removed for a
cylinder head gasket replacement,
check the flatness of the cylinder head
and block gasket surfaces.
2. Position the new cylinder head gasket
over the cylinder dowels on the block.
Position the cylinder head on the
block and install the attaching bolts.
Remove the holding fixtures.
3. The cylinder head bolts are tightened
in three progressive steps. Torque all
the bolts in sequence (Fig. 19) to
specifications. When cylinder head
bolts have been tightened following
this procedure, it is not necessary to
retorque the bolts after extended
operation. However, the bolts may be
checked and retorqued if desired. If
removed, install the exhaust
manifolds and retorque the attaching
bolts to specification.
4. Clean the push rods in a suitable
solvent. Blow out the oil passage in
the push rod with compressed air.
Check the ends of the push rods for
nicks, grooves, roughness or excessive
wear. Visually check the push rods for
straightness or check push rod runout
with a dial indicator. If runout
exceeds the maximum limit at any
Too/-T62F-6085-A
A2853-A
FIG. 18 Cylinder Head Holding
Fixture—302 and 351W
21-21-10
FIG. 19 Cylinder Head Bolt Torque
Sequence
point, discard the rod. Do not attempt
to straighten push rods.
5. Apply Lubriplate or equivalent to
both ends of the push rods. Install the
push rods in their original positions.
Apply Lubriplate or equivalent to the
valve stem tips. Install the exhaust
valve stem caps.
6. Install the rocker arms. If all original
assembly components are installed, a
valve clearance adjustment is not
necessary. If any valve train
components are replaced, perform a
valve clearance adjustment as
outlined under Valve Clearance
Adjustment—Hydraulic Valve
Lifters (Part 21-01).
7. Connect the exhaust manifold(s) at
the muffler inlet pipe(s). Tighten the
nuts to specifications.
8. If the right cylinder head was
removed, install the alternator
attaching bracket on the right
cylinder head assembly. Install the
alternator. Adjust the drive belt
tension to specifications.
9. Clean the valve rocker arm cover(s).
Position the valve rocker cover gasket
in each cover, making sure that the
tabs engage the notches in the cover.
Install the valve rocker arm cover(s).
The valve rocker cover is tightened
in two steps. Tighten the bolts to
specifications. Two minutes later
r e t i g h t e n bolts to the same
specifications.
10. If the left cylinder head was removed
on a vehicle with an air conditioner,
install the compressor as outlined in
Group 36.
If the left cylinder head was
removed on a vehicle with power
steering, install the drive belt and
power steering pump bracket. Install
the bracket attaching bolts. Adjust
the drive belt to specifications.
11. Install the intake manifold and
related parts following the procedure
under Intake Manifold Installation.
EXHAUST MANIFOLDS
Removal
1. On a right exhaust manifold, remove
the air cleaner and intake duct
assembly. Disconnect the automatic
choke heat chamber air inlet hose
from the inlet tube near the right
valve rocker arm cover (302 only).
302 and 351W CID V-8 Engines
Remove the automatic choke heat
tube (302 only).
Remove the nuts or bolts retaining
the heat stove on the exhaust
manifold and remove the heat stove.
2. Disconnect the exhaust manifold
from the muffler inlet pipe. Remove
the attaching nuts and then remove
the spark plug wires, spark plugs and
heat shields.
3. Remove the attaching bolts and
washers and remove the exhaust
manifold.
Installation
1. Clean the mating surfaces of the
exhaust manifold and cylinder head.
Clean the mounting flange of the
exhaust manifold and muffler inlet
pipe.
2. Position the exhaust manifold on the
cylinder head and install the heat
shields and the attaching bolts and
washers. Working from the center to
the ends, torque the bolts to
specifications. Install the spark plugs
and spark plug wires. See Part 23-01
for special installation procedure.
3. Position the muffler inlet pipe to the
manifold. Install and torque the
attaching nuts to specifications.
4. Install the automatic choke heat tube
(302 only) and heat stove on the right
exhaust manifold. Install the air
cleaner and intake duct assembly.
5. Connect the automatic choke heat
chamber inlet hose (302 only).
6. Start the engine and check for exhaust
leaks.
WATER PUMP
Removal
1. Drain the cooling system.
On vehicles equipped with a fan
shroud, remove the shroud attaching
bolts and position the shroud over the
fan.
Remove the fan and spacer from
the water pump shaft. Remove the
shroud if so equipped.
2. Remove the air conditioner drive belt
and idler pulley bracket if so
equipped.
Remove the alternator drive belt.
Remove the power steering drive
belt and power steering pump, if so
equipped.
Remove all accessory brackets
which attach to the water pump.
Remove the water pump pulley.
3. Disconnect the radiator lower hose,
heater hose and water pump bypass
hose at the water pump.
4. Remove the bolts that attach the
pump to the cylinder front cover.
Remove the pump and gasket.
Discard the gasket.
21-21-10
Installation
1. Remove all gasket material from the
mounting surfaces of the cylinder
front cover and water pump.
2. Position a new gasket, coated on both
sides with sealer, on the cylinder front
cover; then install the pump.
3. Install the attaching bolts and torque
them to specifications.
4. Connect the radiator hose, heater
hose and water pump by-pass hose at
the water pump.
5. Install all the accessory brackets
which attach to the water pump.
Place the water pump pulley on the
water pump shaft.
6. Install the power steering pump and
drive belt if so equipped. Install the
alternator and drive belt. Install the
air conditioner idler pulley bracket
and drive belt if so equipped.
7. Position the fan shroud, if so
equipped, over the water pump pulley
and install the spacer or fan drive
clutch and fan. Install the shroud
attaching bolts.
Adjust the drive belts to the
specified belt tension.
8. Fill and bleed the cooling system.
Operate the engine until normal
operating temperatures have been
reached and check for leaks.
CYLINDER FRONT COVER AND
TIMING CHAIN
Removal
1. Refer to Water Pump Removal.
Perform all steps except removal of
the pump. Leave it attached to the
front cover.
2. Drain the crankcase.
3. Remove the crankshaft pulley from
the crankshaft vibration damper.
Remove the damper attaching screw
and washer. Install the puller on the
UNIVERSAL
PULLER
\
A3248-A
FIG. 20 Removing Crankshaft
Vibration Damper
 21-21-11
crankshaft vibration damper (Fig. 20)
and remove the vibration damper.
4. Disconnect the fuel pump outlet line
from the fuel pump. Remove the fuel
pump attaching bolts and lay the
pump to one side with theflexiblefuel
line still attached.
5. Remove the oil level dipstick.
6. Remove the oil pan to cylinder front
cover attaching bolts. Use a thin blade
knife to cut the oil pan gasket flush
with cylinder block face prior to
separating the cover from the cylinder
block. Remove the cylinder front
cover and water pump as an
assembly.
If a new cylinder front cover is to
be installed, remove the water pump
and dipstick tube from the old
cylinder front cover and install them
on the new cover.
7. Discard the cylinder front cover
gasket. Remove the crankshaft front
oil slinger.
8. Check the timing chain deflection
(refer to Part 21-01).
9. Crank the engine until the timing
marks on the sprockets are positioned
as shown in Fig. 21.
10. Remove the camshaft sprocket cap
screw, washers and fuel pump
eccentric. Slide both sprockets and
the timing chain forward, and remove
them as an assembly (Fig. 22).
Installation
1. Position the sprockets and timing
chain on the camshaft and crankshaft
simultaneously (Fig. 22). Be sure the
timing marks on the sprockets are
positioned as shown in Fig. 21.
TIMING MARKS A2731-A
FIG. 21 Aligning Timing Marks
302 and 351W CID V-8 Engines
A2732-A
FIG. 22 Removing or Installing Timing
Chain
2. Install the fuel pump eccentric,
washers and camshaft sprocket cap
screw. Torque the sprocket cap screw
to specifications. On 351W engines,
install the crankshaft front oil slinger
(Fig. 23).
3. Clean the cylinder front cover, oil pan
and the block gasket surfaces.
4. Install a new oil seal in the cylinder
front cover following the procedures
TWO PIECE DOWEL
FUEL PUMP ECCENTRIC
CRANKSHAFT FRONT OIL SLINGER A2733-B
FIG. 23 Fuel Pump Eccentric and
Front Oil Slinger Installed
21-21-11
under Front Oil Seal Removal and
Installation.
5. Lubricate the timing chain with
engine oil.
6. Coat the gasket surface of the oil pan
with sealer, cut and position the
required sections of a new gasket on
the oil pan, apply sealer at the
corners. Install pan seal as required.
Coat the gasket surfaces of the
block and cover with sealer, and
position a new gasket on the block.
7. Position the cylinder front cover on
the cylinder block. Use care when
installing the cover to avoid seal
d a m a g e or p o s s i b l e gasket
mislocation.
8. Install the cylinder front cover to seal
alignment tool into proper position.
9. It may be necessary to force the cover
downward to slightly compress the
pan gasket. This operation can be
facilitated by using a suitable tool at
the front cover attaching hole
locations.
10. Coat the threads of the attaching
screws with oil resistant sealer and
install the screws. While pushing in
on the alignment tool, tighten the oil
pan to cover attaching screws to
specifications (Fig. 24). Tighten the
cover to block attaching screws to
specifications. Remove the pilot.
11. Apply Lubriplate or equivalent to the
oil seal rubbing surface of the
vibration damper inner hub to
prevent damage to the seal. Apply a
white lead and oil mixture to the front
of the crankshaft for damper
installation.
12. Line up the crankshaft vibration
damper keyway with the key on the
crankshaft. Install the vibration
damper on the crankshaft (Fig. 25).
Install the cap screw and washer.
Tighten the screw to specifications.
Install the crankshaft pulley.
13. Install the fuel pump using a new
gasket. Connect the fuel pump outlet
line.
14. Install the oil level dipstick.
Too/-T6 7 P-60 7 9-8 or 6059-F
A1721-B
FIG. 24 Aligning Cylinder Front
Cover
21-21-12
Tool-T52L-6306-AEE or 6306-AJ
FIG. 25 Installing Crankshaft
Vibration Damper
15. Refer to Water Pump Installation.
Perform all the required steps except
installation of the pump.
16. Fill the crankcase with the proper
grade and quantity of engine oil.
17. Fill and bleed the cooling system.
18. Operate the engine at fast idle and
check for coolant and oil leaks. Check
and adjust the ignition timing.
FRONT OIL SEAL
Removal
1. Remove the cylinder front cover
following the procedure under
Cylinder Front Cover and Timing
Chain Removal.
2. Drive out the old seal with the pin
punch. Clean out the recess in the
cover.
Installation
1. Coat a new seal with grease, then
install the seal in the cover. Drive the
seal in until it is fully seated in the
recess (Fig. 26). Check the seal after
Tool-T53L-200-A Tool—
T58P-6700-B
or 6700-B
OIL SEAL
A2861-A
FIG. 26 Installing Crankshaft Front
Oil Seal
302 and 351W CID V-8 Engines
installation to be sure the spring is
properly positioned in the seal.
2. Replace the cylinder front cover
following the procedure under
Cylinder Front Cover and Timing
Chain Installation.
CAMSHAFT
The camshaft and related parts are
shown in Fig. 27.
Removal
1. Remove the cylinder front cover and
the timing chain following the
procedure under Cylinder Front
Cover and Timing Chain Removal.
2. Remove the intake manifold and
related parts by following procedures
under Intake Manifold Removal.
3. Remove the crankcase ventilation
valve and tubes from the valve rocker
arm covers. Remove the valve rocker
arm covers. Loosen the valve rocker
arm stud nuts and rotate the rocker
arms to the side.
4. Remove the valve push rods and
identify them so that they can be
installed in their original positions.
5. Remove the valve lifters following the
procedure under Valve Lifter
removal, and place them in a rack so
that they can be installed in their
original bores.
6. Remove the camshaft thrust plate.
Carefully remove the camshaft by
pulling toward the front of the engine.
Use caution to avoid damaging the
camshaft bearings.
Installation
1. Oil the camshaft journals with heavy
engine oil SE and apply Lubriplate or
equivalent to the lobes. Carefully slide
the camshaft through the bearings.
Install the camshaft thrust plate with
groove towards the cylinder block.
Check camshaft end play as shown in
Part 21-01.
TIMING CHAIN-6268 AND
CAMSHAFT SPROCKET-6256
TWO PIECE
FUEL PUMP ECCENTRIC-6287
FIG. 27 Camshaft and Related Parts
21-21-12
2. Lubricate the lifters and bores with
heavy engine oil SE. Install the valve
lifters in the bores from which they
were removed.
3. Apply Lubriplate or equivalent to
each end of the push rods and install
the push rods in their original
positions. Apply Lubriplate or
equivalent to the valve stem tips.
Lubricate the rocker arms and
fulcrum seats with heavy engine oil
SE. Position the rocker arms over the
push rods.
4. Install the intake manifold and
related parts by following procedures
under Intake Manifold Installation.
5. Connect the water temperature
sending unit and the engine ground
strap.
6. Connect the accelerator rod and
retracting spring.
7. Connect the heater hose at the intake
manifold. Position and connect the
fuel line.
8. Replace the crankshaft front oil seal
following procedures under Front Oil
Seal Removal and Installation. Install
the timing chain, cylinder front cover
and related p a r t s following
procedures under Cylinder Front
Cover and Timing Chain Installation.
9. On vehicles equipped with air
conditioning, install the air
conditioning condenser.
Position the fan shroud, if so
equipped, over the fan. Install the
radiator and connect the upper and
lower radiator hoses.
On a vehicle equipped with an
automatic transmission, connect the
transmission oil cooler lines.
Install the fan shroud attaching
screws if so equipped.
10. With No. 1 piston on TDC at the end
of the compression stroke, position
the distributor in the block with the
BEARINGS
CAMSHAFT
REAR BEARING
BORE PLUG
6266
A2863-B
 21-21-13
rotor at the No. 1 firing position and
the points just open. Install the hold
down clamp.
11. If any valve train components have
been replaced, perform a Valve
Clearance Adjustment as outlined
under Hydraulic Valve Lifters in Part
21-01.
12. Clean the valve rocker arm covers
and the cylinder head gasket surface.
Position the valve rocker cover gasket
in each cover, making sure that the
tabs engage the notches in the cover.
13. Position the covers on the cylinder
heads. Make sure the gasket seats
evenly all around the head. Install the
bolts. The cover is tightened in two
s t e p s . T o r q u e t h e b o l t s to
specifications. Two minutes later,
t o r q u e the bolts to the same
specifications.
14. Clean and install the crankcase
ventilation system.
15. Install the distributor cap. Position
the spark plug wires in the harness
brackets on the valve rocker arm
covers and connect the wires to the
plugs. See Part 23-01 for special
installation instructions. Connect the
high tension lead at the coil.
16. Fill and bleed the cooling system. Fill
the crankcase with the proper grade
and quantity of engine oil.
17. Start the engine and check and adjust
the ignition timing. Connect the
distributor vacuum line at the
carburetor.
18. Operate the engine at fast idle and
check all hose connections and
gaskets for leaks. When the engine
temperature has stabilized adjust the
engine idle speed and idle fuel
mixture. Retorque intake manifold
bolts and nuts.
19. Install the air cleaner and intake duct
assembly.
20. Connect the automatic choke heat
tube.
FLYWHEEL
Removal
1. On a vehicle with a manual-shift
transmission, remove the
transmission, clutch pressure plate
and disc following the procedures in
Group 16.
On a vehicle with automatic
transmission, remove the
transmission and converter housing
following the procedure in Group 17.
2. To check flywheel face runout or
replace flywheel ring gear for manual-
shift transmissions, refer to Part 21-
01.
3. Remove the flywheel attaching bolts
and remove the flywheel.
302 and 351W CID V-8 Engines
Installation
1. Coat the threads of the flywheel
attaching bolts with oil-resistant
sealer. Position the flywheel on the
crankshaft flange. Install and torque
the bolts in sequence across from each
other to specifications.
2. On a vehicle with a manual-shift
transmission, check the flywheel
runout, following the procedure in
Part 21-01 and install the clutch
p r e s s u r e p l a t e , disc and t h e
transmission following the
procedures in Group 16.
On a vehicle with an automatic
transmission, check the flywheel
runout, following the procedure in
Part 21 and install the transmission
and converter housing following the
procedure in Group 17.
CLUTCH PILOT BEARING
Removal
1. Remove the transmission, clutch
pressure plate and disc, following the
procedures in Group 16. It is not
necessary to remove the flywheel.
2. Remove the pilot bearing and adapter
as shown in Fig. 28.
Installation
1. Install the pilot service bearing as
shown in Fig. 29; using tool, install
new bearing and adapter so the
adapter is not cocked.
2. Install the clutch pressure plate, disc
and the transmission, following the
procedures in Group 16.
CAMSHAFT REAR BEARING BORE
PLUG
Removal
1. On a v e h i c l e with a m a n u a l
transmission, remove the
transmission, clutch pressure plate
and disc following the procedures in
Group 16.
On a vehicle with an automatic
transmission, remove the
transmission and converter housing
following the procedure in Group 17.
Too/—7581-707-/
or 7600-EZ"~~~
Tool-T59L-100-B
or 7600-E A2874-A1
FIG. 28 Removing Clutch Pilot
Bearing
21-21-13
Tool-7600-H
A3262-A
FIG. 29 Installing Clutch Pilot Bearing
2. Remove the flywheel attaching bolts
and remove theflywheel.Remove the
engine rear cover plate.
3. Remove the bore plug as detailed in
Part 21-01.
Installation
1. Install the bore plug as detailed in
Part 21-01.
2. Coat theflywheelattaching bolts with
oil-resistant sealer. Position the
engine rear cover plate on the cylinder
block dowels. Position the flywheel
on the crankshaft flange. Install and
torque the attaching bolts in sequence
a c r o s s from e a c h o t h e r to
specifications.
On a vehicle with a manual
transmission, install the clutch
p r e s s u r e p l a t e , disc and t h e
transmission following the
procedures in Group 16.
On a vehicle with an automatic
transmission, install the transmission
and converter housing following the
procedure in Group 17.
OIL PAN
Mustang
Removal
1. Disconnect battery cable.
2. Remove 4 bolts attaching fan shroud
to radiator and position shroud over
fan.
3. Raise vehicle on hoist.
4. Drain crankcase.
5. Remove the 4 attaching bolts and
remove the 2a crossmember.
6. Remove the attaching screw from flex
joint to release steering pinion shaft.
Remove 3 nuts and bolts attaching
steering gear to crossmember.
Remove 4 bolts attaching sway bar to
chassis and move sway bar down.
7. Disconnect battery cable from starter,
remove 2 starter attaching bolts and
remove starter.
21-21-14
8. Remove oil pan attaching bolts,
loosen oil pan from block and remove.
Installation
1. Clean oil pan gasket surface of
cylinder block. Clean and inspect oil
pan.
2. Position oil pan gasket and seals to
cylinder block using contact cement
(Fig. 30).
3. Position oil pan to engine and install
the attaching bolts.
4. Position sway bar to chassis and
install attaching bolts.
5. Position starter to clutch housing and
install attaching bolts. Connect
starter cable and tighten nut.
6. Position steering gear to steering
shaft, install 3 attaching bolts and
nuts at crossmember and torque to
specification. Install flex coupling to
steering gear stub shaft attaching bolt.
7. Position the 2a crossmember to the
vehicle and install the 4 attaching
bolts.
8. Lower the vehicle and fill the
crankcase with the specified engine
oil. Connect the battery cable to the
battery.
9. Position the shroud to the radiator
and install the 4 attaching bolts. Start
the engine and check for leaks.
REAR SEAL
FRONT SEAL
OIL PAN GASKET A2876 A
FIG. 30 Oil Pan Gaskets and Seals
Installed—302 and 351-W
Engines
302 and 351W CID V-8 Engines
LTD II, Cougar and Thunderbird
Removal
1. Remove the oil level dipstick.
Remove the bolts attaching the fan
shroud to the radiator. Position the
shroud over the fan.
2. Raise the vehicle.
3. Drain the crankcase.
4. Remove the stabilizer bar from the
chassis.
5. Remove the engine front support
through bolts.
6. Raise the engine and place wood
blocks between the engine front
supports and chassis brackets.
7. If equipped with an automatic
transmission, disconnect the oil
cooler lines at the radiator.
8. Remove the oil pan attaching bolts
and lower the oil pan onto the
crossmember.
9. Remove oil pump pickup tube and
screen from the oil pump. Rotate the
crankshaft for clearance and remove
the oil pan.
Installation
1. Clean the gasket surfaces of the block
and oil pan. The oil pan has a two-
piece gasket.
2. Clean the oil pump pick up tube and
screen.
3. Coat the block surface and the oil pan
gasket with sealer. Position the oil
pan gaskets on the cylinder block
(Fig. 33).
4. Position the oil pan front seal on the
cylinder front cover. Be sure the tabs
on the seal are over the oil pan gasket.
5. Position the oil pan rear seal on the
rear main bearing cap (Fig. 33). Be
sure the tabs on the seal are over the
oil pan gasket.
6. Position the oil pan on the
crossmember. Install a new gasket on
the oil pump and install the oil pump
pick up tube.
7. Position the oil pan against the block
and install a bolt, finger tight, on each
side of the block. Install the
remaining bolts. Tighten the bolts
from the center outward in each
direction to specifications.
8. If equipped with an automatic
transmission, connect the oil cooler
lines at the radiator.
9. Raise the engine and remove the
wood blocks from between the engine
supports and chassis brackets. Lower
the engine and install the engine
support through bolts. Tighten the
bolts to specifications.
10. Install the stabilizer bar to the chassis.
11. Lower the vehicle.
12. Install the fan shroud.
13. Install the oil level dipstick. Fill the
crankcase with the proper grade and
quantity of engine oil. Start the engine
and check for oil leaks.
21-21-14
Maverick, Comet Granada and
Monarch
Removal
1. Raise the vehicle and drain the
crankcase.
2. Remove the stabilizer bar from the
chassis.
3. Remove the engine front support
through bolts and remove the
supports. If so equipped, remove the
bolt and nut retaining the power
steering lines to the rear side of the
lower arm.
4. Remove the idler arm bracket
retaining bolts and pull the linkage
down and out of the way.
5. Remove the oil pan attaching bolts
and remove the pan.
6. Remove the oil pump pick-up tube
and screen assembly.
Installation
1. Clean the oil pan and inspect for
damage. Clean the oil pump pick-up
tube and screen.
2. Clean the gasket surfaces of the block
and oil pan. Position the oil pump
pick-up tube and screen with gasket.
Install the two bolts and torque to
specifications.
3. Coat the block surface and oil pan
gaskets with sealer. Position the oil
pan gaskets on the cylinder block
(Fig. 30).
4. Position the oil pan front seal on the
cylinder front cover. Be sure the tabs
on the seal are over the oil pan gasket.
5. Position the oil pan rear seal on the
rear main bearing cap (Fig. 30). Be
sure the tabs on the seal are over the
oil pan gasket.
6. Position the oil pan to the cylinder
block. Install the attaching bolts and
torque to specifications.
7. Position the idler arm bracket to the
chassis and install the attaching bolts.
Torque to specifications. Install the
power steering line bracket to the
lower control arm rear.
8. Position the engine supports to the
chassis side rails and install the
reattaching bolts. Torque to
specifications.
9. Install the stabilizer bar.
10. Lower the vehicle. Fill the crankcase.
Start the engine and check for oil
leaks.
OIL PUMP
Removal
1. Remove the oil pan and related parts
as outlined under Oil Pan Removal.
2. Remove the oil pump inlet tube and
screen assembly.
3. Remove the oil pump attaching bolts
and remove the oil pump and
intermediate drive shaft.
21-21-15
Installation
1. Prime the oil pump by filling either
the inlet or outlet port with engine oil.
Rotate the pump shaft to distribute
the oil within the pump body.
2. Position the intermediate drive shaft
into the distributor socket. With the
shaft firmly seated in the (distributor
socket, the stop on the shaft should
touch the roof of the crankcase.
Remove the shaft and position the
stop as necessary.
3. With the stop properly positioned,
insert the intermediate drive shaft
into the oil pump. Install the pump
and shaft as an assembly. Do not
attempt to force the pump into
position if it will not seat readily. The
drive shaft hex may be misaligned
with the distributor shaft. To align,
rotate the intermediate drive shaft
into a new position.
Torque the oil pump attaching
screws to specifications.
4. Clean and install the oil pump inlet
tube and screen assembly (Fig. 31).
5. Install the oil pan and related parts as
outlined under Oil Pan Installation.
CRANKSHAFT REAR OIL SEAL
A split-lip type crankshaft rear oil
seal is used for replacement on all
engines. If replacement is necessary, this
type of seal must be used. The complete
seal can be replaced without removing
the crankshaft. Refer to Crankshaft Rear
Oil Seal. Replacement in Part 21-01 for
replacement procedures.
MAIN BEARING
The main bearing inserts are selective
fit. Refer to procedures under Fitting
Main and Connecting Rod Bearings in
Part 21-01.
A3142-A
FIG. 31 Oil Pump and Inlet Tube
Installed
302 and 351W CID V-8 Engines
Removal
1. Drain the crankcase. Remove the oil
level dipstick. Remove the oil pan and
related parts.
2. Remove the oil pump inlet tube
assembly and the oil pump.
3. Replace one bearing at a time, leaving
the other bearings securely fastened.
Remove the main bearing cap to
which new bearings are to be
installed.
4. Insert the upper bearing removal Tool
(Tool 6331) in the oil hole in the
crankshaft.
5. Rotate the crankshaft in the direction
of the engine rotation to force the
bearing out of the block.
6. Clean the crankshaft journals.
Inspect the journals and thrust faces
(thrust bearing) for nicks, burrs or
bearing pick-up that would cause
premature bearing wear.
7. If the rear main bearing is being
replaced, remove and discard the rear
oil seal from the bearing cap.
8. Remove the block half of the rear oil
seal following the procedures given
under Crankshaft Rear Oil Seal
Removal in Part 21-01.
9. Repeat the above procedure (Steps 3
thru 8) for the remaining bearings to
be replaced.
Installation
1. If the rear main bearing is being
replaced clean the rear oil seal groove
in the block with a brush and the
recommended solvent (Part 21-01).
2. Install the block half of the rear oil
seal following the procedures given
under Crankshaft Rear Oil Seal
Installation in Part 21-01.
3. To install the upper main bearing,
place the plain end of the bearing over
the shaft on the locking tang side of
the block and partially install the
bearing so that Tool 6331 can be
inserted in the oil hole in the
crankshaft. With Tool 6331
positioned in the oil hole in the
crankshaft, rotate the crankshaft in
the opposite direction of engine
rotation until the bearing seats itself.
Remove the tool.
4. Replace the bearing in the cap.
5. Select fit the bearing for proper
clearance following procedures under
Fitting Main and Connecting Rod
Bearings in Part 21-01.
6. If the bearing is being replaced on
journal number 1, 2 or 4, apply a light
coat of engine oil to the journal and
bearings and install the bearing cap.
T i g h t e n t h e c a p b o l t s to
specifications.
7. If the rear main bearing is being
replaced, clean the oil seal groove in
the c a p , with a b r u s h and
recommended solvent (Part 21-01).
21-21-15
Remove the oil seal retaining pin
from the bearing cap, if so equipped.
The pin is not used with the split lip
seal.
8. Install the lower seal in the rear main
bearing cap with undercut side of seal
toward the FRONT of the engine;
allow the seal to p r o t r u d e
approximately 3/8 inch above the
parting surface to mate with the
upper seal when the cap is installed.
9. Refer to Crankshaft Rear Oil Seal
Installation for instructions on use of
sealer in installing the main bearing
cap. Lubricate the journal with
engine oil and install the rear main
bearing cap. Torque the cap bolts to
specifications.
10. If the thrust bearing cap (No 3 main
bearing) has been removed, install it
as follows:
Lubricate the journal with engine
oil and install the thrust bearing cap
with the bolts finger-tight. Fry the
crankshaft forward against the thrust
surface of the upper half of the
bearing (Fig. 32). Hold the crankshaft
cap to the rear. This will align the
thrust surfaces of both halves of the
bearing. Retain the forward pressure
on the crankshaft. Torque the cap
bolts to specifications.
11. Clean the oil pump inlet tube screen.
Prime by filling the inlet open ing with
oil and rotating the pump shaft until
oil emerges from the outlet opening.
Install the oil pump and the inlet tube
assembly.
12. Position the oil pan gaskets on the oil
pan. Position the oil pan front seal on
the cylinder front cover. Position the
oil pan rear seal on the rear main
bearing cap. Install the oil pan and
related parts. Install the oil level
dipstick.
13. Fill the crankcase. Start the engine
and check for oil pressure. Operate
the engine at fast idle and check for
oil leaks.
CONNECTING ROD BEARINGS
The connecting rod bearings are
selective fit. Refer to procedures under
Fitting Main and Connecting Rod
Bearings in Part 21-01.
Removal
1. Drain the crankcase. Remove the oil
level dipstick. Remove the oil pan and
related parts.
2. Remove the oil pump inlet tube
assembly and the oil pump.
3. Turn the crankshaft until the
connecting rod to which new bearings
are to be fitted is down. Remove the
connecting rod cap. Remove the
bearing inserts from the rod and cap.
21-21-16
FIG. 32 Aligning Thrust Bearing
Installation
1. Be sure the bearing inserts and the
bearing bore in the connecting rod
and cap are clean. Foreign material
under the inserts will distort the
bearing and cause a failure.
2. Clean the crankshaft journal.
3. Install the bearing inserts in the
connecting rod and cap with the tangs
fitting in the slots provided.
4. Pull the connecting rod assembly
down firmly on the crankshaft
journal.
5. Select fit the bearing following
procedures under Fitting Main and
Connecting Rod Bearings in Part 21-
01.
6. After the bearing has been fitted,
clean and apply a light coat of engine
oil to the journal and bearings. Install
the connecting rod cap. Tighten the
nuts to specifications.
7. Clean the oil pump inlet tube screen.
Prime the pump by filling the inlet
opening with oil and rotate the pump
shaft until oil emerges from the outlet
opening. Install the oil pump and the
inlet tube assembly.
8. Position the oil pan gaskets on the oil
pan. Position the oil pan front seal on
the cylinder front cover. Position the
oil pan rear seal on the rear main
bearing cap. Install the oil pan and
related parts. Install the oil level
dipstick.
9. Fill the crankcase. Start the engine
and check for oil pressure. Operate
the engine at fast idle and check for
oil leaks.
PISTONS AND CONNECTING
RODS
Removal
1. Drain the cooling system and the
crankcase. Remove the intake
manifold, cylinder heads, oil pan and
oil pump, following the procedures in
this Section.
302 and 351W CID V-8 Engines
2. Remove any ridges and/or deposits
from the upper end of the cylinder
bores as follows:
Turn the crankshaft until the
piston to be removed is at the bottom
of its travel and place a cloth on the
piston head to collect the cuttings.
Remove any ridge and/or deposits
from the upper end of the cylinder
bores. Remove the cylinder ridge with
aridgecutter. Follow the instructions
furnished by the tool manufacturers.
Never cut into the ring travel area in
excess of 1/32 inch when removing
ridges.
3. Make sure all connecting rod caps are
marked so that they can be installed
in their original positions.
4. Turn the crankshaft until the
connecting rod being removed is
down.
5. Remove the connecting rod nuts and
cap.
6. Push the connecting rod and piston
assembly out the top of the cylinder
with the handle end of a hammer.
Avoid damage to the crankshaft
OIL RING SPACER
30RE
PISTON
COMPRESSION RING COMPRESSION RING
FRONT OF ENGINE A7R11-A
FIG. 33 Piston Ring Spacing
21-21-16
HOLD CRANKSHAFT
FORWARD
journal or the cylinder wall when
removing the piston and rod.
7. Remove the bearing inserts from the
connecting rod and cap.
8. Install the cap on the connecting rod
from which it was removed.
Installation
1. If new piston rings are to be installed,
remove the cylinder wall glaze.
Follow the instructions of the tool
manufacturer.
2. Oil the piston rings, pistons and
cylinder walls with light engine oil.
Be sure to install the pistons in the
same cylinders from which they were
removed or to which they were fitted.
The connecting rod and bearing caps
are numbered from 1 to 4 in the right
bank and from 5 to 8 in the left bank,
beginning at the front of the engine.
The numbers on the connecting rod
and bearing cap must be on the same
side when installed in the cylinder
bore. If a connecting rod is ever
transposed from one block or cylinder
to another, new bearings should be
fitted and the connecting rod should
be numbered to correspond with the
new cylinder number.
3. Make sure the ring gaps are properly
spaced around the circumference of
the piston (Fig. 33).
••— FRONT — Piston Ring Compresso
NOTCH TO FRONT OF ENGINE ^A2870-A
FIG. 34 Installing Piston—Typical
21-21-17
15. Start the engine and check and adjust
16. Operate the engine at fast idle and
17. Install the air cleaner and intake duct
18. Connect the automatic choke heat
CRANKSHAFT
shown in Fig. 36.
A2871-A
FIG. 35 Checking Connecting Rod
Side Clearance
4. Install a piston ring compressor on
the piston and push the piston in with
a hammer handle until it is slightly
below the top of the cylinder (Fig. 34).
Be sure to guide the connecting rods
to avoid damaging the crankshaft
journals. Install the piston with the
indentation notch in the piston head
toward the front of the engine.
5. Check the clearance of each bearing
following the procedure under Fitting
Main and Connecting Rod Bearings
in Part 21-01.
6. After the bearings have been fitted,
apply a light coat of engine oil to the
journals and bearings.
7. Turn the crankshaft throw to the
bottom of its stroke. Push the piston
all the way down until the connecting
rod bearing seats on the crankshaft
journal.
8. Install the connecting rod cap.
Tighten the nuts to specifications.
9. After the piston and connecting rod
assemblies have been installed, check
the side clearance between the
connecting rods on each crankshaft
journal (Fig. 35).
10. Disassemble, clean, and assemble the
oil pump. Clean the oil pump inlet
tube screen and the oil pan and block
gasket surfaces.
11. Prime the oil pump by filling either
the inlet port or outlet port with
engine oil and rotating the pump shaft
to distribute the oil within the
housing. Install the oil pump and the
oil pan.
12. Install the cylinder heads following
procedures under Cylinder Head
Installation.
13. Install the intake manifold following
procedures under Intake Manifold
Installation.
14. Fill and bleed the cooling system. Fill
the crankcase with the proper grade
and quantity of engine oil.
302 and 351W CID V-8 Engines
the ignition timing. Connect the
distributor vacuum hoses at the
carburetor.
check for oil and coolant leaks. When
the engine temperature has stabilized
adjust the engine idle speed and idle
fuel mixture.
assembly.
chamber air inlet hose.
The crankshaft and related parts are
Removal
1. With engine removed from vehicle
and placed on a work stand,
disconnect the spark plug wires at the
spark plugs and remove the wires
from the ignition harness brackets on
the valve rocker arm covers.
Disconnect the coil to distributor
high tension lead at the coil. Remove
the distributor cap and spark plug
wire assembly. Remove the spark
plugs to allow easy rotation of the
crankshaft.
2. Remove the fuel pump and oil filter.
Slide the water pump by-pass hose
clamp toward the water pump.
M A I N BEARING INSERTS
CRANKSHAFT
6303 V
CRANKSHAFT SPROCKET KEY
6306^^ 372890
FRONT OIL SLINGER\ \
6310^ \ V
DAMPER
6316 or 6A329
PULLEY
6312
BOLT-
FIG. 36 Crankshaft and Related Parts
21-21-17
Remove the alternator and mounting
brackets.
3. Remove the crankshaft pulley from
the crankshaft vibration damper (if so
equipped). Remove the cap icrew and
washer from the end of the
crankshaft. Install the pulley on the
crankshaft vibration damper (Fig. 20)
and remove the damper.
4. Remove the cylinder front clover and
water pump as an assembly.
5. Remove the crankshaft front oil
slinger. Check the timing chain
Reflection, then remove the timing
chain and sprockets as detailed under
Cylinder Front Cover and Timing
Chain Removal.
6. Invert the engine on the work stand.
Remove the clutch pressure plate and
disc (manual-shift transmission).
Remove the flywheel and engine rear
cover plate. Remove the oil pan and
gasket. Remove the oil pump.
7. Make sure all bearing caps {main and
connecting rod) are marked so that
they can be installed in their original
locations.
Turn the crankshaft until the
connecting rod from which the cap is
being removed is down, and remove
the bearing cap. Push the connecting
rod and piston assembly up into the
cylinder. Repeat this procedure until
FLYWHEEL'
6375
MAIN BEARING
CAPS
A 2878-E
21-21-18
all the connecting rod bearing caps
are removed.
8. Remove the main bearing caps.
9. Carefully lift the crankshaft out of the
block so that the thrust bearing
surfaces are not damaged. Handle the
crankshaft with care to avoid possible
fracture or damage to the finished
surfaces.
To refinish journals, dress minor
imperfections, etc., refer to Part 21-01
for instructions.
Installation
1. Remove the rear journal oil seal from
the block and rear main bearing cap.
2. Remove the main bearing inserts
from the block and bearing caps.
3. Remove the connecting rod bearing
inserts from the connecting rods and
caps.
4. If the crankshaft main bearing
journals have been refinished to a
definite undersize, install the correct
undersize bearings. Be sure the
bearing inserts and bearing bores are
clean. Foreign material under the
inserts will distort the bearing and
cause a failure.
5. Place the upper main bearing inserts
in position in the bores with the tang
fitting in the slot provided.
6. Install the lower main bearing inserts
in the bearing caps.
7. Clean the rear journal oil seal groove
and the mating surfaces of the block
and rear main bearing cap. Remove
the oil seal retainer pin from the rear
main bearing seal groove, if so
equipped. The retainer pin is not used
with a split lip seal.
8. Dip the lip seal halves in clean engine
oil. Carefully install the seal halves in
the block and rear main bearing cap
with the undercut sides of the seal
toward the FRONT of the engine and
approximately 3/8 inch protruding
above the partial surface.
9. Carefully lower the crankshaft into
place. Be careful not to damage the
bearing surfaces.
10. Check the clearance of each main
bearing following the procedure
under Fitting Main and Connecting
Rod Bearings in Part 21-01.
11. After the bearings have been fitted,
apply a light coat of engine oil to the
journals and bearings. Install the rear
main bearing cap by following steps
7 thru 9 under Main Bearing
Installation. Install all the bearing
caps, except the thrust bearing cap
(No. 3 bearing). Be sure that the main
bearing caps are installed in their
original locations. Torque the bearing
cap bolts to specifications.
12. Install the thrust bearing cap with the
bolts finger-tight.
302 and 351W CID V-8 Engines
13. Pry the crankshaft forward against
the thrust surface of the upper half of
the bearing (Fig. 32).
14. Hold the crankshaft forward and pry
the thrust bearing cap to the rear.
This will align the thrust surfaces of
both halves of the bearing.
15. Retain the forward pressure on the
crankshaft. Tighten the cap bolts to
specifications.
16. Force the crankshaft toward the rear
of the engine.
17. Check the crankshaft end play (refer
to Part 21-01).
18. Install new bearing inserts in the
connecting rods and caps. Check the
clearance of each bearing following
the procedure under Fitting Main and
Connecting Rod Bearings in Part 21-
01.
19. After the connecting rod bearings
have been fitted, apply a light coat of
engine oil to the journals and
bearings.
20. Turn the crankshaft throw to the
bottom of its stroke. Push the piston
all the way down until the rod bearing
seats on the crankshaft journal.
21. Install the connecting rod cap.
Torque the nuts to specifications.
22. After the piston and connecting rod
assemblies have been installed, check
the side clearance between the
connecting rods and each connecting
rod crankshaft journal (Fig. 34).
23.Install the timing chain and
sprockets, cylinder front cover and
crankshaft pulley and adapter,
following Steps 1 thru 9 under
Cylinder Front Cover and Timing
Chain Installation.
THRUST BEARING
DETAIL-8
PULLING NUT
DETAIL -5
PULLER SCREW
DETAIL -4 PULLER SCREW EXTENSION I T , • r ^ c , z^rn 1
PULLING PLATE
FIG. 37 Camshaft Bearing Replacement
21-21-18
24. Coat the threads of the flywheel
attaching bolts with oil-resistant
sealer. Position the flywheel on the
crankshaft flange. Install and torque
the bolts to specifications.
On a flywheel for a manual-shift
transmission, use Tool 6392-N or
equivalent to align the clutch disc.
Install the pressure plate. Tighten the
attaching bolts.
25. Clean the oil pan, oil pump and oil
pump screen. Prime the oil pump by
filling either the inlet or outlet port
with engine oil and rotating the pump
shaft to distribute oil within the
housing. Install the oil pump and oil
pan by following the procedures
under Oil Pan and Oil Pump
Installation.
26. Install the oil filter, fuel pump and
connect the fuel lines. Install the
alternator, shield and mounting
bracket.
27. Install the spark plugs, distributor
cap and spark plug wires. Connect the
spark plug wires and high tension
lead. See Part 23-01 for special
installation instructions.
28. Install the engine in the vehicle.
CAMSHAFT BEARINGS
Removal
1. Remove the camshaft, flywheel and
crankshaft, following the appropriate
procedures in this Section. Push the
pistons to the top of the cylinders.
2. Remove the camshaft rear bearing
bore plug. Remove the camshaft
bearings (Fig. 37).
DETAIL-1,-2 or-3
EXPANDING COLLET
DETAIL-1,-2 or-3
BACK-UP NUT
CAMSHAFT BEARING (LOOSE)
DETAIL -6 or -7
Tool-T65L-6250-A
A2813-A
21-21-19
3. Select the proper size expanding collet
and back-up nut and assemble on the
expanding mandrel. With the
expanding collet collapsed, install the
collet assembly in the camshaft
bearing, and tighten the back-up nut
on the expanding mandrel until the
collet fits the camshaft bearing.
4. Assemble the puller screw and
extension (if necessary) as shown and
install on the expanding mandrel.
Wrap a cloth around the threads of
the puller screw to protect the front
bearing or journal. Tighten the
pulling nut against the thrust bearing
and pulling plate to remove the
camshaft bearing. Be sure to hold a
wrench on the end of the puller screw
to prevent it from turning.
5. Repeat the procedure for each
bearing. To remove the front bearing,
install the puller screw from the rear
of the cylinder block.
Installation
Camshaft bearings are available
prefinished to size for standard and
0.015-inch undersize journal diameters.
The bearings are not interchangeable
from one bore to another.
1. Position the new bearings at the
bearing bores with the oil holes
aligned, and press them in place with
the tool shown in Fig. 37. Be sure to
DISASSEMBLY AND ASSEMBLY
When installing nuts or bolts that
must be torqued (refer to Specifications),
oil the threads with light weight engine
oil. Do not oil threads that require oil-
resistant or water-resistant sealer.
Refer to Part 21-01 for Cleaning and
Inspection procedures.
VALVE LIFTER
The internal parts of each hydraulic
valve lifter assembly are matched sets.
Do not intermix the parts. Keep the
assemblies intact until they are to be
cleaned. Valve lifters should always be
tested after assembly; refer to the
cleaning, inspection and test procedures
covered in Part 21-01.
Disassemble and assemble each lifter
separately. Identify the lifter assemblies
so they can be installed in their original
bores.
1. Grasp the lock ring with needle nose
pliers to release it from the groove. It
may be necessary to depress the
plunger to fully release lock ring.
2. Remove the push rod cup, metering
valve (disc) plunger and spring.
302 and 351W CID V-8 Engines
center the pulling plate and puller
screw to avoid damage to the bearing.
Failure to use the correct expanding
collet can cause severe bearing
damage. Be sure the front bearing is
installed the specified distance below
the front face of the cylinder block
(Fig. 38). See Specifications.
2. Install the bore plug as detailed in
Part 21-01.
3. Install the camshaft, crankshaft,
flywheel and related parts, following
the appropriate procedures in this
Part, except do not check connecting
rod and main bearing clearances as a
p a r t of C a m s h a f t B e a r i n g
Replacement. Install the engine in the
vehicle.
INSTALL F )NT BEARING TO)'SPECI
SPECIFIED
^DIMENSION B :LOW FRONT FACE OF BLOCK
A2880-A
FIG. 38 Camshaft Front Bearing
Measurement
3. Remove the plunger assembly, the
check valve and the check valve
retainer and plunger spring. Carefully
remove the plunger spring, the check
valve retainer and, the check valve
disc from the plunger.
Assembly
Hydraulic lifter assembly is shown in
Fig. 40.
1. Place the plunger upside down on a
clean work bench.
PUSH ROD SOCKET
METERING VALVE
CHECK VALVE
CHECK VALVE SPRING
PLUNGER SPRING
LOCK RING
PLUNGER
CHECK VALVE
RETAINER
A2867-B
FIG. 40 Hydraulic Valve Lifter
Assembly
21-21-19
OIL FILTER
The oil filter assembly is shown in
Fig. 39.
Removal
1. Place a drip pan under the filter.
Unscrew the filter from the adapter
fitting and clean the adapter recess
and the filter gasket sealing surface.
Installation
1. Coat the gasket on a new filter with
oil. Place the new filter in position on
the adapter fitting. Hand tighten the
filter until the gasket contacts the
sealing surface, and then advance it
1/2 turn.
2. Operate the engine at fast idle, and
check for oil leaks. If oil leaks are
evident, perform the necessary repairs
to correct leakage. Check the oil level
and add oil as required to bring to
specified level.
FILTER ELEMENT
6731
ADAPTER FITTING
6890 A3704- B
FIG. 39 Cartridge-Type Oil Filter
2. Place the check valve (disc or ball
check) in position over the oil hole on
the bottom of the plunger. Set the
check valve spring on top of the check
valve {disc or ball check).
3. Position the check valve retainer over
the check valve and spring and push
the retainer down into place on the
plunger.
4. Place the plunger spring, and then the
plunger (open end up) into the lifter
body.
5. Position the metering valve (disc) in
the plunger, and then place the push
rod cup in the plunger.
6. Depress the plunger, and position the
closed end of the lock ring in the
groove of the lifter body. With the
plunger still depressed, position the
open ends of the lock ring in the
groove. Release the plunger, and then
depress it again to fully seat the lock
ring.
7. Use the hydraulic valve lifter
leakdown tester (Part 21-01) to fill the
lifters with test fluid.
21-21-20 302 and 351W CID V-8 Engines 21-21-20

CYLINDER HEAD SE. The valve tips are to have Lubriplate UNDERSIDE OF SPRING RETAINER

Disassembly or equivalent applied before installation.

1. Remove the exhaust valve stem caps.
2. Remove the exhaust manifolds (if
required) and the spark plugs.
3. Clean the carbon out of the cylinder
head combustion chambers before
removing the valves.
4. Compress the valve springs (Fig. 41).
Remove the spring retainer locks and
release the spring.
Valve Spring
Compressor
FIG. 41 Compressing Valve Spring
5. Remove the sleeve, spring retainer,
spring, stem seal and valve. Discard
the valve stem seals. Identify all valve
parts.
6. Clean, inspect and repair the cylinder
head as required, or transfer all usable
parts to a new cylinder head.
Assembly
All valves, valve stems and valve
guides are to be lubricated with heavy oil
LOCKS
OIL SEAL
6571
INTAKE
EXHAUST VALVE
VALVE
6506
6507
A 3307-A
FIG. 42.Valve Assembly—302-2V
and 351 -W engines
1. Install each valve (Fig. 42) in the port
from which it was removed or to
which it was fitted.
2. Install the valve stem seal and valve
spring over the valve and then install
the spring retainer (and rotator, on
351 exhaust valves). Compress the
spring and install the sleeve, if so
equipped, and retainer locks (Fig. 42).
3. Measure the assembled height of the
valve spring from the surface of the
cylinder head spring pad to the
underside of the spring retainer with
dividers (Fig. 43). Check the dividers SURFACE OF SPRING PAD A2857-A
against a scale. If the assembled
height is greater than specifications, FIG. 43 Valve Spring Assembled
install the necessary 0.030 inch thick Height
spacer(s) between the cylinder head
spring pad and tfre valve spring to
bring the assembled height to the PISTONS AND CONNECTING
recommended height. RODS
Do not install the spacers unless Disassembly
necessary. Use of spacers in excess of 1. Remove the bearing inserts from the
recommendations will result in connecting rod and cap.
overstressing the valve springs and 2. Mark the pistons to assure assembly
overloading the camshaft lobes which with the same rod and installation in
could lead to spring breakage and/or the same cylinders from which they
worn camshaft lobes. were removed.
4. Install the exhaust manifolds (if 3. Remove the piston rings. Using an
removed) and the spark plugs. Arbor Press and the tool shown in
Fig. 45, press the piston pin from the
OIL PUMP piston and connecting rod.
Disassembly
1. Remove the oil inlet tube from the oil
The piston, connecting rod and
pump and remove the gasket.
related parts are shown in Fig. 46. Check
2. Remove the cover attaching screws,
the fit of a new piston in the cylinder bore
then remove the cover. Remove the
before assembling the piston and piston
inner rotor and shaft assembly, then
pin to the connecting rod.
remove the outer race.
3. Drill a small hole and insert a self- The piston pin bore of a connecting
threading sheet metal screw of the rod and the diameter of the piston pin
proper diameter into the oil pressure must be within specifications. Refer to
relief valve chamber cap and pull the specification at end of this part.
cap out of the chamber. Remove the 1. Apply a light coat of engine oil to all
spring and plunger. parts. Assemble the piston to the
Assembly
The oil pump assembly is shown in
-6626
Fig. 44.
1. Oil all parts thoroughly.
2. Install the oil pressure relief valve
plunger, spring and a new cap.
3. Install the outer race and the inner *W4
rotor and shaft assembly. Be sure the
dimple (identification mark) on the
outer race is on same side as i " OIL RELIEF VALVE
/ ASSEMBLY
identification mark on rotor. The race INLET TUBE
rotor and shaft and the outer race are
ASSEMBLY
serviced as an assembly. One part 6622
should not be replaced without ROTOR AND SHAFT
replacing the other. ASSEMBLY
06O8
Install the cover and torque the
cover attaching screws to IDENTIFICATION MARKS
specifications. PLATE
4. Position a new gasket and the oil inlet 6616
A1643-F
tube on the oil pump and install the
attaching bolts. FIG. 44 Oil Pump Assembly
21-21-21 302 and 351W CID V-8 Engines 21-21-21

UPPER LOWER and cap with the tangs fitting in the

Press Ram COMPRESSION^. COMPRESSION slots provided.
RING | RING
CYLINDER ASSEMBLY
Disassembly
1. Mount the old engine in a work stand
61 OS and remove all parts not furnished
with the new cylinder assembly;
following the procedures given in the
Removal and Installation Section of
this Part.
2. Remove the 4 cylinder head locating
dowels and the block drain plugs.
3. Remove the old cylinder assembly
from the work stand.
INSERT
TAPERED PILOT
IN PISTON PIN 1. Clean the gasket and seal surfaces of
FOR PIN REMOVAL
all serviceable parts and assemblies.
INSERT THIS END
2. Position the new cylinder assembly in
IN PISTON HOLE a work stand and install the cylinder
FOR INSTALLATION
head locating dowels and bloc tc drain
plugs.
Adapter Detail A-3
3. Transfer all serviceable parts removed
from the old cylinder assembly,
T68P-6I35-A following the procedures given in the
Cup Detail A - l
Removal and Installation Section of
this Part.
4. Check all assembly clearances and
A3705-A A2872-A ' correct as necessary.

FIG. 45 Removing or Installing Piston
Pin
connecting rod with the cylinder
number side of the connecting rod and
the indentation notch in the piston
positioned as shown in Fig. 47.
On replacement connecting rods,
install the large chamfered side of the
connecting rod bearing bore towards
the crankshaft check; facing towards
front of engine on right bank rods,
and facing towards rear of engine on
left bank rods.
LEFT BANK
RIGHT BANK
NOTCH OR
ARROW TOWARD
FRONT OF ENGINE
NUMBERED SIDE OF ROD
FIG. 47 Correct Piston and Rod
Positions—302-2V and 3 5 1 -
W Engines
FIG. 46 Piston, Connecting Rod and
Related Parts
2. Start the piston pin in the piston and
connecting rod (this may require a
very light tap with a mallet). Using an
arbor press, press the piston pin
through the piston and connecting
rod until the pin is centered in the
piston (Fig. 45).
3. Check the end gap of all piston rings
(Part 21-01). It must be within
specifications. Follow the instructions
contained on the piston ring package
and install the piston rings.
4. Check the ring side clearance of the
compression rings with a feeler gauge
inserted between the ring and its
lower land (Part 21-01). The gauge
should slide freely around the entire
ring circumference without binding.
Any wear that occurs will form a step
at the inner portion of the lower land.
If the lower lands have high steps, the
piston should be replaced.
5. Be sure the bearing inserts and the
A3706-B bearing bore in the connecting rod
and cap are clean. Foreign material
under the inserts will distort the
bearing and cause a failure. Install the
bearing inserts in the connecting rod
CYLINDER BLOCK
Before replacing a cylinder block,
determine if it is repairable. If sc, make
necessary repairs, following the
procedures given in Part 21-01.
Disassembly
1. Completely disassemble the old
engine, following the procedures
given in the Removal and Installation
Section of this Part.
2. Remember to ridge-ream the cylinder
b o r e s before r e m o v i n g p i s t o n
assemblies.
3. Remove the cylinder head locating
dowels and the block drain plugs.
Assembly
1. Clean the gasket and seal surfaces of
all serviceable parts and assemblies.
2. Position the new cylinder block in a
work stand and install the cylinder
head locating dowels and the block
drain plugs.
3. Transfer all serviceable parts re moved
from the old cylinder block, following
the procedures given in the Removal
and Installation Section of this Part.
4. Check all assembly clearances and
correct as necessary.
21-21-22 302 and 351W CID V-8 Engines 21-21-22

SPECIFICATIONS-1977
GENERAL SPECIFICATIONS CAMSHAFT

LOBE LIFT
DISPLACEMENT 302CID/351 CID
Intake 0.2373 (302 CID)
NUMBER OF CYLINDERS 8
0.2600(351 CID)
BORE AND STROKE 4 . 0 0 x 3 . 0 0 (302 CID)
Exhaust 0.2474 (302 CID)
4 . 0 0 x 3 . 5 0 (351 CID)
0.2600 (351 CID)
FIRING ORDER 15-4-2-6-3-7 8 (302 CID)
Allowable Lobe Lift Loss 0.005 Max.
1 3 7 2-6 5-4-8 (351 CID)
THEORETICAL V A L V E LIFT @ ZERO LASH
OIL PRESSURE (Hot @ 2000 RPM) 40-65
Intake 0.3823 (302 CID)
DRIVE BELTTENSION • © 0.4186(351 CID)
Exhaust 0.3884 (302 CID)
CYLINDER HEAD AND VALVE TRAIN
0.4186(351 CID)
COMBUSTION CHAMBER VOLUME (cc) 67.5-70.5 END PLAY 0 0010.007
V A L V E GUIDE BORE DIAMETER 0.3433-0.3443 Service Limit 0.009
V A L V E SEATS JOURNAL TO BEARING CLEARANCE 0.001 0.003
Width - Intake 0 060-0 080 Service Limit 0.006
Width - Exhaust 0.060-0.080 CAMSHAFT GEAR BACKLASH 0.006-0.010
Angle 45° JOURNAL DIAMETER
Runout Limit (T I R Max} 0 002 # 1 , . 2.0805 2.0815
V A L V E ARRANGEMENT (Front to Rear) (L. H.) E-l-E-l-E-l E l #2 .2.0655-2.0665
(R. H.) I-EI-E-I E-l-E # 3 2 0505-2 0515
V A L V E STEM TO GUIDE CLEARANCE #4 2.0355 2.0365
Intake .. 0 0010 0 0027 #5 2.0205 2.0215
Exhaust 0 0 0 1 5 0 0032 Runout Limit '. 0.005 Max. T. 1. R.
Service Clearance 0.0055 Out-Of-Round Limit 0.0005 Max. T. 1. R
V A L V E HEAD DIAMETER BEARING INSIDE DIAMETER
Intake 1.773 1.791 #1 2.0825 2.0835
Exhaust 1.442 1.460 (302 CID) #2 2.0675-2.0685
1.468 1.453 (351 CID) #3 2.0525-2.0535
V A L V E FACE RUNOUT LIMIT 0.002 Max. #4 2.0375-2.0385
V A L V E FACE ANGLE .44° #5 2.0225 2.0235
V A L V E STEM DIAMETER (Std) FRONT BEARING LOCATION (3) 0.005-0.020
Intake 0.34160.3423
Exhaust 0 3411-0 3418 CYLINDER BLOCK
(0.003 Oversize)
'intake 0.34460.3453 HEAD GASKET SURFACE FLATNESS ®
Exhaust 0 3441-0 344ft HEAD GASKET SURFACE FINISH (RMS) 60-150
(0.015 Oversize) CYLINDER BORE
Intake 0.35660.3575 Diameter . . . 4.0004-4.0052 (302 CID)
Exhaust 0 3561-0 3568 4.0000-4.0048(351 CID)
0.030 Oversize Surface Finish (RMS) 18-38
Intake 0.3716-0.3723 Out-Of-Round Limit 0.0015
Exhaust 0 3711-0 3718 0ut-Of-Rniinri ^prv/irp ! imit 0 005
VALVE SPRINGS
uui \j\ nuuiiu JCI vnc uniiu • 0.010
Taper Sfirvtce Limit
Compression Pressure (Lb @ Spec. Length) TAPPET BORE DIAMETER 0.87520.8767
Intake 76-84 @ 1.69 (302 CID) MAIN BEARING BORE DIAMETER . . . 2.4412 2.4420 (302 CID)
190-2109 1.31 (302 CID) 3.1922-3.1930 (351 CID)
71-79 @ 1.79 (351 CID) DISTRIBUTOR SHAFT BEARING BORE DIAMETER . . . . . . 0.4525-0.4541 (302 CID)
190-210 @ 1.34 (351 CID) 0.5155 0.5171 (351 CID)
Exhaust 76-84 @ 1.60 (302 CID)
190-210 @ 1.20 (302 CIO)
76-84 @ 1.60 (351 CID)
190 210@ 1.20 (351 CID)
Free Length (Approximate)
Intake 1 94 (302 CID)
2.06(351 CID)
Exhaust 1 87 (302 CID)
1.87(351 CID)
Assembled Height
Intake 1-21/32-1-23/32 (302 CID)
1-49/64-1-13/16 (351 CID)
Exhaust 1-19/32-1-5/8 (302 CID)
1-19/32-1-5/8 (351 CID)
Service Limit . . . . 10% Pressure Loss @ Spec. Length
Out-Of-Square Limit . . 5/64 (0.078) 302 CIO/351 CID
ROCKER ARM
Stud Bore Diameter 0 37800 3795
Ratio 1 611
PUSH ROD RUNOUT (T. 1. R. Max) 0.015
V A L V E TAPPET, LIFTER OR ADJUSTER
Diameter (Std) 0.8740-0.8745
Clearance To Bore 0.0007-0.0027
! Service Limit 0.005
' Hydraulic Leakdown Rate 5-50 Seconds®
Collapsed Tappet Gap — Allowable 0 071-0 193
Collapsed Tappet Gap - Desired • 0.096-0.168

CA1308D
21-21-23 302 and 351W CID V-8 Engines 21-21-23

SPECIFICATIONS -1977
CRANKSHAFT AND FLYWHEEL CONNECTING ROD. PISTON AND RINGS

MAIN BEARING JOURNAL DIAMETER 2.2482 2.2490 (302 CID)

2.9994-3.0002 (351 CIO) CONNECTING ROD
Out-Of-Round Limit 0 0006 Max . Piston Pin Bore Diameter 0.9096D.9112
Taper Limit 0.0006 Max. Crankshaft Bearing Bore Diameter 2.2390 2.2398 {3C ? CID)
Journal Runout Limit 0.002 Max. 2.4265 2.9273 (35 1 CID)
Surface Finish (RMS) 12 Max. Out-Of-Round Limit 0.004 Max.
Runout Service Limit 0.005 Taper Limit 0.004 Max.
THRUST BEARING JOURNAL Lenth (Center-to-Center) 5.0885-5.0915(30:! CID)
Lei.gth 1.137-1.139 5.9545 5.9575 (35 i CID)
CONNECTING RODJOURNAL Alignment (Bore-to-Bore Max Diff) (6)
Diameter 2 1228-2 1236(302 CID) Twist 0.024
2.3103-2.3111 (351 CID) Bend 0.012
OutOf-Round Limit 0.0006 Side Clearance (Assembled to Crank)
Taper Limit 0.0006 per inch Max. Standard 0.01(1 0.020
Surface Finish (RMS) 12 Max. Service Limit 0.023
MAIN BEARING THRUST FACE PISTON
Surface Finish (RMS) 35 Front/25 Rear Diameter (T)
Runout Limit Coded Red 3.9984 3.9990 (3C2 CID)
0.001 Max.
3.9978 3.9984 ( 3 M CID
FLYWHEEL CLUTCH FACE
Coded Blue 3.9996-4.0002 (312 CID)
Runout Limit (T. I. R.) 0.010
3.9990-3.9996 (3£ 1 CID)
FLYWHEEL RING GEAR LATERAL RUNOUT (T. I. R.)
0.003 Oversize 4.0008-4.0014 (3C2 CID)
Standard Transmission 0.030
4.0002-4.0008 (3E1 CID)
Automatic Transmission 0.060
Coded Yellow 4.0020-4.0026(30;! CID)
CRANKSHAFT FREE END PLAY 0 004-0 008
0.012 4.0014-4.0020 (35 1 CID)
Service Limit
Piston-To-Bore Clearance ; . 0.0018 :.0026
CRANKSHAFT RUNOUT TO REAR FACE OF BLOCK (T. I. R. Max.) 0.005
Pin Bore Diameter 0 9122 0.9127 (3C:! CID)
CONNECTING ROD BEARINGS
Clearance To Crankshaft - Desired 0.9124 0.9127 (35 i CID)
0 0008-0 0015
Ring Groove Width
- Allowable 0.00070.0024 (302 CID)
0 00080 0025 (351 CID) Compression (Top) 0.080 0.091
Bearing Wall Thickness (Std) ( f ) 0.05720.0577 Compression (Bottom) 0.080 0.091
MAIN BEARINGS Oil 0.188 0.189
Clearance To Crankshaft - Desired . . No. 1 = 0.0001-0.0015 (302 CID) PISTON PIN
All others 0.0005 0.0015 (302 CID) Length 3.010 3.040
0.00080.0015 (351 CIO) Diameter
- Allowable . No. 1 = 0.0001-0.0020 (302 CID) Standard 0.9119-C.9124
Others 0.0005-0 0024 (302 CID) 0 001 Oversize 0.9130-:.9133
0.0008-0.0026 (351 CID) 0.002 Oversize 0.9140-:.9143
Bearing Wall Thickness (Std) (§) . . No. 1 = 0.0961-0.0966 (302 CID) Pin-To-Piston Clearance 0.0002-0.0004(30:'CID)
All others 0.0957-0.0962 (302 CID) 0.00030.0005(35 CID)
0.0957-0.0960 (351 CID) Pin-To-Rod Clearance Jnterfere'ce Fit
PISTON RINGS
Ring Width
Compression (Top) 0.07} 0.078
Compression (Bottom) 0.077 0.078
Side Clearance
Compression (Top) 0.002 0.004
Compression (Bottom) 0.005 0.004
Oil Ring Snug Fit
Service Limit 0.006
Ring Gap
Compression (Top) 0.01C 0.020
Compression (Bottom) 0.01C 0.020
Oil Ring (Steel Rail) ///, 0.0U 0.055
21-21-24 302 and 351W CID V-8 Engines 21-21-24

SPECIFICATIONS-1977
LUBRICATION SYSTEM TORQUE SPECIFICATIONS - SPECIAL APPLICATIONS

CAMSHAFT SPROCKET TO CAMSHAFT 40-45

OIL PUMP
CAMSHAFT THRUST PLAT TO BLOCK 9 12
Relief Valve Spring Tension (Lbs at Spec. Length) 10.6-12.2 @ 1.704 (302 CID)
18.2-20.2 @ 2.49 (351 CID) CONNECTING ROD NUTS OR BOLTS 19-24 (302 CID)
0.0015-0.0030 40-45(351 CIO)
Drive Shaft-To-Housing Bearing Clearance
. . .0.00150.0030 CYLINDER FRONT COVER BOLTS , . 12-18
Relief Valve-To-Bore Clearance
0.004 Max. CYLINDER HEAD BOLTS (302 (rj) >
Rotor Assembly End Clearance (Assembled)
0.001-0.013 (351 <% )
Outer Race-To-Housing Clearance
4 O? DAMPER OR PULLEY TO CRANKSHAFT 70-90
OIL CAPACITY (Quarts U. S.)
DISTRIBUTOR VACUUM CONTROL V A L V E 15-18
FUEL EGR V A L V E TO CARBURETOR SPACER OR INT MANIFOLD . 12-18
FUEL PUMP TO CYLINDER BLOCK OR FRONT COVER 19-27
STATIC PRESSURE (P. S. I . ) ® . . . .. 6.0 8.0 FLYWHEEL TO CRANKSHAFT 75-85
MINIMUM VOLUME FLOW ( 9 Y Q o ) 1 pt./20 sec. MAIN BEARING CAP BOLTS 60 70 (302 CID)
ECCENTRIC TOTAL LIFT (Inches) . . 0 690 0 710 95-105I351CIO)
MANIFOLD TO CYLINDER HEAD (Intake) . . . . 23 25 (vs)
MANIFOLD TO CYLINDER HEAD (Exhaust) 18-24
OIL FILTER INSERTTO CYLINDER BLOCK 20
OIL FILTER TO BLOCK OR ADAPTER
OILINLETTUBETOOILPUMP 10-15
OIL PAN DRAIN PLUG 15-25
OIL PAN TO CYLINDER BLOCK 5/16 11-13/1/4 = 7-9
O I L P U M P T O CYLINDER BLOCK 22 32
PULLEY TO DAMPER (Bolt) 35-
ROCKER ARM STUD NUT • • 17-23 _
ROCKER ARM STUD OR BOLT TO CYLINDER HEAD Press Fit
SPARK PLUG TO CYLINDER HEAD 10-15
V A L V E ROCKER ARM COVER 3-5
ALTERNATOR BRACKET TO CYLINDER BLOCK (Bolt) 12-18
ALTERNATOR PIVOT BOLT 45-57
ALTERNATOR ADJUSTING ARM TO CYLINDER BLOCK 15-20
THERMACTOR PUMP BRACKET TO CYLINDER BLOCK 12-18
THERMACTOR PUMP PIVOT BOLT 22-32
THERMACTOR PUMP ADJUSTING ARM TO PUMP 22 32
THERMACTOR PUMP ADJUSTING ARM TO CYLINDER BLOCK 12-18
THERMACTOR PUMP TO SHAFT 130 180 In. Lb.
POWER STEERING PUMP PULLEY TO DAMPER (Bolt) 35-50
FAN TO WATER PUMP HUB (Bolt) 12-18
CARBURETOR MOUNTING NUTS 12-15
CARBURETOR MOUNTING STUD 15 Max.
FUEL FILTER TO CARBURETOR • 80-100 In. Lb.
ALTERNATOR ADJUSTING ARM TO ALTERNATOR 24-40
21-21-25 302 and 351W CID V-8 Engines 21-21-25

SPECIFICATIONS -1977
TORQUE SPECIFICATIONS - General Application |

U.S. THREAD SIZES TORQUE

1/4-20 6-9
5/16-18 12-18
5/16-24 14-20
3/8-16 22 32
3/8-24 27 38
7/16-14 40-55
7/16-20 • 40-60
1/2-13 55-80

METRIC THREAD SIZES TORQUE

M-6 6-9
IVrO 14-21
M-10 28-40
IVI-12 50 71
M-14 80-114

PIPE THREAD SIZES TORQUE

1/8 5-8
1/4 12-18
3/8 22-33
1/2 25-35

o All values are in ft-lb. unless otherwise noted

o Oil threads with engine oil unless fasteners require sealers.

CA1308O 1
21-22-1 351M and 400 CID V-8 Engines 21-22-1

PART
351M and 400 CID V-8 Engines 21-22
LTD II, Cougar, Thunderbird, Lincoln Continental, Continental Mark V

SUBJECT PAGE SUBJECT PAGE

DESCRIPTION REMOVAL AND INSTALLATION (Cont'd.)
Crankcase Ventilation System 22-1 Flywheel 22-12
Engine 22-1 Front Oil Seal 22-10
Exhaust Emission Control System 22-1 Intake Manifold 22-6
ADJUSTMENTS Main Bearing 22-13
Valve Clearance - Oil Filter 22-17
Hydraulic Valve Lifters 22-2 Oil Pan 22-12
REMOVAL AND INSTALLATION Oil Pump 22-12
Camshaft 22-11 Pistons and Connecting Rods 22-14
Camshaft Bearing 22-16 Valve Lifter 22-8
Camshaft Rear Bearing Bore Plug 22-12 Valve Rocker Arm Cover and
Connecting Rod Bearings 22-14 Rocker Arm 22-5
Crankcase Ventilation System 22-5 Valve Spring, Retainer and Stem Seal 22-6
Crankshaft 22-15 Water Pump 22-9
Crankshaft Rear Oil Seal 22-13 DISASSEMBLY AND ASSEMBLY
Cylinder Front Cover Plate Cylinder Assembly 22-19
and Timing Chain 22-9 Cylinder Block 22-19
Cylinder Heads 22-8 Cylinder Head 22-18
Engine 22-3 Oil Pump 22-19
Engine Front Supports 22-4 Pistons and Connecting Rods 22-19
Engine Rear Support 22-4 Valve Lifter 22-18
Exhaust Manifold 22-8 SPECIFICATIONS 22-21
CA4287-A

DESCRIPTION
ENGINE
The 351-M and 400 CID V-8 engines
are basically of the same design and
structure. Except for a revised crankshaft
damper, the differences between the 2
engines is internal and consists of the
following: the 351M engine has a shorter
stroke, accomplished by using a revised
crankshaft and a piston with an increased
compression height (piston pin to top of
piston). The 351M also uses a revised
camshaft for proper valve timing. Both
the 351M and 400 CID V-8 engines are
equipped with a thermactor air injection
system for reduced engine emissions (Fig.
1).
EXHAUST EMISSION CONTROL
SYSTEM
Operation, removal, installation and
required maintenance of the exhaust
emission control devices used on these
engines are covered in Group 29 and
Group 50 of this Manual.
CRANKCASE VENTILATION
SYSTEM
The engine is equipped with a positive
closed-type crankcase ventilation system
re-cycling the crankcase vapors to the
intake manifold.
21-22-2
FIG. 1 Right Front View—351-M and 400 Engines (Typical)
ADJUSTMENTS
VALVE CLEARANCE—HYDRAULIC
VALVE LIFTERS
The valve arrangement on the left
bank is E-I-E-I-E-I-E-I and on the right
bank is I-E-I-E-I-E-I-E.
The 0.060 inch shorter push rod or a
0.060 inch longer push rod are available
for service to provide a means of
compensating for dimensional changes in
the valve mechanism. Refer to the Master
Parts List or the specification for the
pertinent color code.
Valve stem to valve rocker arm
clearance should be within specification
with the hydraulic lifter completely
collapsed. Repeated valve reconditioning
operations (valve a n d / o r valve seat
refacing) will decrease the clearance to
the point that if not compensated for, the
hydraulic valve lifter will cease to
function and the valve will be held open.
To determine whether a shorter or a
longer push rod is necessary, make the
following check:
1. D i s c o n n e c t t h e b r o w n lead (I
terminal) and the red and blue lead (S
terminal) at the starter relay.
Install an auxiliary starter switch
between the battery and S terminals
of the Starter relay. Crank the engine
with the ignition switch OFF until the
351M and 400 CID V-8 Engines 21-22-2
A4071-B
No. 1 piston is on TDC on the 5. After these valves have been checked,
compression stroke. rotate the crankshaft to POSITION
2. With the crankshaft in the positions 3 in Fig. 3 and check the following
designated in Steps 3, 4 and 5, valves:
p o s i t i o n t h e h y d r a u l i c lifter No. 2 Intake No. 4 Exhaust
compressor tool on the rocker arm. No. 5 Intake No. 5 Exhaust
Slowly apply pressure to bleed down No. 6 Intake No. 8 Exhaust
the hydraulic lifter until the plunger
is completely bottomed (Fig. 2). Hold
the lifter in this position and check
the available clearance between the
rocker arm and the valve stem tip 777P-6573-A
with a feeler gauge.
If the c l e a r a n c e is less than
specification, install an undersize
push rod. If the clearance is greater
than specification, install an oversize
push rod.
3. With the No. 1 piston on TDC at the
end of the compression stroke,
POSITION 1 in Fig. 3, check the
following valves:
No. 1 Intake No. 1 Exhaust
No. 4 Intake No. 3 Exhaust
No. 8 Intake No. 7 Exhaust
4. After these valves have been checked,
rotate the crankshaft to POSITION
2 in Fig. 3, and check the following
valves: IA3235-B
No. 3 Intake No. 2 Exhaust
No. 7 Intake No. 6 Exhaust FIG. 2 Checking Valve Clearance
21-22-3
With No. 1 at TDC at end of compression stroke
make a chalk mark at points 2 and 3 approximately
90 degrees apart.
FIG. 3 Position of Crankshaft for Checking Valve Clearance and Installing Rocker Arms
REMOVAL AND INSTALLATION
When installing nuts or bolts that
must be torqued (see Specifications), oil
the threads with light weight engine oil.
Do not oil threads that require oil-
resistant or water-resistant sealer.
ENGINE
Removal
Remove or disconnect Thermactor
system parts that will interfere with
removal or installation of the engine.
1. Disconnect the battery, drain the
cooling system and remove the hood.
2. Remove the air cleaner and intake
duct assembly.
3. Disconnect the radiator upper hose at
the engine and the lower hose at the
radiator. Disconnect the oil cooler
lines at the radiator.
4. Remove the fan shroud attaching
bolts and position the shroud over the
fan. Remove the radiator and shroud.
5. Remove the fan and spacer.
6. On vehicles equipped with air
conditioning, loosen the idler pulley
and remove the drive belt.
7. Loosen the alternator and remove the
drive belt.
8. Loosen and remove the power
steering pump drive belt.
9. Remove the water pump pulley.
10. Remove the power steering pump
brackets and position the pump out of
the way in an upright position to
prevent fluid loss.
11.On vehicles equipped with air
conditioning, isolate and remove the
compressor as outlined in Group 36.
12. Remove the alternator and bracket.
Position the alternator out of the way.
Disconnect the alternator ground
wire from the cylinder block.
13. Disconnect the heater hoses at the
block and water pump.
351M and 400 CID V-8 Engines
POSITION 1 - No. 1 at TDC at en
POSITION 2 - Rotate the crank
POSITION 3 - Rotate the crank
14. Remove the ground wires from the
cylinder block and right cylinder
head.
15. Disconnect the fuel line at the fuel
pump. Plug the fuel tank line.
Disconnect the vacuum lines at the
rear of the intake m a n i f o l d .
Disconnect vacuum control valve
hoses and wires on engines so
equipped.
16. Disconnect the accelerator cable or
linkage at the carburetor and intake
manifold. Disconnect transmission
downshift linkage, if so equipped.
17. Disconnect the engine wire harness at
the ignition coil, water temperature
sending unit and oil pressure sending
unit. Remove the wire harness from
the hold down clips.
18. Raise the vehicle and secure with
safety stands.
19. Disconnect the exhaust system at the
exhaust manifolds and remove the
exhaust heat control valve (if so
equipped) or the exhaust manifold-to-
pipe spacer.
20. Disconnect the starter cable and
remove the starter.
21. Remove the engine front support
through bolts and the starter cable
clamp at the engine right front
support.
22. Remove the converter inspection
cover and disconnect the flexplate
from the converter. Remove the
downshift rod.
Remove the four converter lower
housing-to-engine block bolts and the
adapter plate-to-converter housing
bolt.
23. Lower the vehicle.
24. Remove the two converter housing
upper bolts.
21-22-3
pression stroke.
ees (one half
•POSITION 1 .
revolution) clock
degrees (three
quarter revolution from
POSITION 2.
A3234-C
25. Attach engine lifting sling (Tool No.
T53L-3OO-A), and hoist, to lifting
brackets at exhaust manifolds.
26.Position a jack under the
transmission.
27. Raise the engine slightly and carefully
pull it from the transmission.
Carefully lift the engine out of the
engine compartment so that the rear
cover plate is not bent or components
damaged. Install the engine on a work
stand.
Installation
1. Attach engine lifting sling, Tool No.
T53L-3OO-A, and hoist to lifting
brackets at exhaust manifolds.
Remove engine from work stand.
2. Lower the engine carefully into the
engine compartment.
Start the converter pilot into the
crankshaft.
3. Install the converter housing upper
bolts, making sure that the dowels in
the cylinder block engage the flywheel
housing. Remove the jack from under
the transmission.
4. Remove the lifting sling.
5. Position the downshift rod on the
transmission and engine.
6. Raise the vehicle and secure with
safety stands.
7. Position the transmission linkage
bracket and install the remaining
converter housing bolts. Install the
adapter plate-to-converter housing
bolts. Install the converter-to-
flywheel nuts and install the
inspection cover. Connect the
downshift rod to the transmission.
8. Install the starter and connect the
cable.
9. Install the exhaust heat control valve
(if so equipped) or manifold-to-pipe
21-22-4
spacer and connect the exhaust
system to the exhaust manifolds.
10. Install the engine front support
through bolts and install the starter
cable clamp at the engine right front
support.
11. Lower the vehicle.
12. Connect the ground wire at the right
cylinder head. Install the engine wire
harness and connect it to the ignition
coil, then install the water
temperature sending unit and oil
pressure sending unit.
13. Install the accelerator linkage and
connect the downshift rod.
14. Connect the vacuum lines at the rear
of the intake manifold. Connect the
fuel tank line at the fuel pump"
15. Connect the ground wire to the right
front of cylinder block. Connect the
heater hoses to the water pump and
cylinder block.
16. Install the alternator and bracket.
Connect the alternator ground wire to
the cylinder block.
17. On a vehicle with air conditioning,
install the air conditioning
compressor and brackets as outlined
in Group 36.
18. Install the power steering pump and
brackets. Install all parts of the
Thermactor System that were
disconnected and/or removed.
19. Install the water pump pulley, fan and
spacer. Install the drive belts on their
respective pulleys and adjust the belt
tension to specification.
20. Position the fan shroud over the fan.
Install the radiator and connect the
radiator upper and lower hoses.
Install the fan shroud attaching bolts.
21. Fill and bleed the cooling system. Fill
the crankcase with the proper grade
and quantity of oil. Adjust the
transmission downshift linkage.
Connect the battery.
22. Operate the engine at fast idle until it
reaches normal operating
temperature and check all gaskets and
hose connections for leaks. Adjust
ignition timing and idle speed.
23. Install the air cleaner and intake duct.
Install and adjust the hood.
ENGINE FRONT SUPPORTS
Whenever self-locking mounting
bolts and nuts are removed, they must be
replaced with new self-locking bolts and
nuts. (Marked * in Figs. 4, 5 and 6).
The front supports are located on
each side of the cylinder block (Figs. 4,
5 and 6). The procedures given apply to
either a right or left installation.
Removal
1. Remove the fan shroud attaching
bolts. On Ford, Lincoln Continental
and Mercury 400 CID, remove the
transmission oil cooler inlet and
351M and 400 CID V-8 Engines 21-22-4
outlet lines from the retaining bracket Removal
on the block. 1. Support the transmission with a floor
2. Remove the through bolt and lock nut jack to remove weight from the
attaching the insulator to the supporting crossmember.
insulator support bracket (No. 2 2. Remove the nuts attaching the
crossmember on LTD II, Cougar, i n s u l a t o r a s s e m b l y to the
Thunderbird and Continental Mark crossmember.
V). On Ford and Mercury 400 CID,
remove the nut and through bolt on 38E.759-S2'
the opposite mount to prevent 383232-S2* X"
35-60 FT-LB
distortion of the insulator.
3. Raise the engine slightly with a jack
and a wood block placed under the oil SSY.
pan.
4. Remove the engine insulator
assembly to cylinder block attaching
bolts. Remove the engine insulator
assembly and heat shield, if so
equipped.
Installation
1. Position the engine insulator
assembly and heat shield, if so
equipped, to the cylinder block and
install the attaching bolts. Tighten the 385637-S2
bolts to specification. DIRECTION OF BOLT OPTIONAL
2. Lower the engine into position, install A :37OO-B
the engine insulator assembly to the
support bracket (No. 2 crossmember FIG. 5 Engine Front Support—?
on LTD II, Cougar, Thunderbird and and Mercury
Continental Mark V). Install the
through bolt and remove the jack and 6C010 ASSY. R.H. 385849-S?
6C060 ASSY. L.H. 2 REQD
wood block. 383232-S2 40-55 FT. LB.
6 REQD. DIRECTION OF
3. Install the engine insulator assembly. 35-60 FT. LB. BOLTOFDONAL
Tighten the nut to specification. On
Ford and Mercury 400 CID, install
the transmission oil cooler lines in the
retaining bracket on the cylinder
6C050SHIELD
block.
4. Install the fan shroud attaching bolts. .© (EXCEPT CALIFORNIA)
NO. 2 CROSSMEMBER
ENGINE REAR SUPPORT
The rear support is located at the
transmission extension housing (Figs. 7,
8 and 9). Whenever self-locking
mounting bolts and nuts are removed, 382400-S2
2 REQD.
they must be replaced with new self- 35-50 FT. LB
FOR L.H. SID1-:
locking bolts and nuts. (Marked * in Figs. R.H. SHOWN L.H.
SIMILAR ONLY
7, 8 and 9.) A4288-A
FIG. 6 Engine Front Support—L ncoln
Continental
INSULATOR ASSEMBLY
6C060 L.H.
6C010
383232-S2* INSULATOR -
6068 ASSY.
385849-S2
NO. 3 CROSSMEMBER REF
FIG. 4 Engine Front Supports—LTD
II, Cougar, Thunderbird and FIG. 7 Engine Rear Support—LTD
Continental Mark V Cougar and Thunderbird
21-22-5
3. Remove or loosen the bolts attaching
the supporting crossmember for
repositioning or removal as necessary
to remove the insulator assembly.
4. Remove the bolts and washers that
attach the engine rear insulator to the
transmission.
5. Remove the insulator assembly.
Installation
1. Position the engine rear insulator
assembly in place beneath the
transmission. Install the attaching
bolts and washers and torque to
specification.
2. Position the supporting crossmember.
Install/tighten the bolts to proper
torque specification.
3. Install the nuts attaching the
i n s u l a t o r a s s e m b l y to the
crossmember.
4. Remove the floor jack.
CRANKCASE VENTILATION
SYSTEM
The crankcase ventilation system
components are shown in Fig. 10.
386454-S2
25-40 FT-LB
(DIRECTION OF
BOLT OPTIONAL)
A3138C
FIG. 8 Engine Rear Support—Ford
and Mercury
\ 382400-S2
2REQ'D.
NO. 3 CROSSMEMBER 30-50 FT-LB
A4289-A
FIG. 9 Engine Rear Support—Lincoln
Continental and Continental
Mark V
351M and 400 CID V-8 Engines
Removal
1. Remove the ventilation system air
intake hose from the air cleaner.
2. Remove the crankcase vent hose from
the regulator valve located in oil fill
cap.
3. Remove the air cleaner and intake
duct assembly.
4. Disconnect the crankcase vent hose
from the carburetor.
5. Pull the regulator valve out of the oil
fill cap.
6. Remove the crankcase ventilation
filter from the air cleaner body.
1. Install the crankcase ventilation filter
in the air cleaner body.
2. Insert the PCV valve into the oil fill
cap mounting grommet.
3. Connect the vent hose to the
carburetor.
4. Install the air cleaner and intake duct
assembly.
5. Install the ventilation system air
intake hose to the air cleaner and the
regulator valve.
6. Start the engine and check for leaks.
VALVE ROCKER ARM COVER
AND ROCKER ARM
The valve rocker arm is shown in Fig.
11.
CRANKCASE VENT
HOSE
FIG. 10 Typical Crankcase Ventilation System Components
21-22-5
Removal
1. Remove the air cleaner and intake
duct assembly. Remove appropriate
crankcase ventilation hose(s) at the
valve rocker arm cover(s).
2. Disconnect the spark plug wires from
the spark plugs by grasping, twisting
and pulling the molded cap only with
the proper tool. Remove the wires
from the bracket on the valve rocker
arm cover(s) and position the wires
out of the way.
3. Remove the valve rocker arm
cover(s).
4. Remove the valve rocker arm bolt, oil
deflector, fulcrum seat and rocker
arm.
Installation
All rocker arms and fulcrum seats are
to be lubricated with heavy engine oil SE
before installation.
1. Apply Lubriplate or equivalent to the
top of the valve stem. Lubricate the
rocker arm and fulcrum seat with
heavy engine oil SE.
2. Position the No. 1 piston on TDC at
the end of the compression stroke,
POSITION 1 in Fig. 3, and install the
rocker arm, fulcrum seat, oil
deflector, and fulcrum bolts on the
following valves:
CRANKCASE VENT
TUBE EXTENSION HOSE
CRANKCASE VENT
TUBE HOSE -
6A664
PCV VALVE -
6A666
CRANKCASE
VENT TUBE - 6759
A4070-B
21-22-6
No. 1 Intake No. 1 Exhaust
No. 4 Intake No. 3 Exhaust
No. 8 Intake No. 7 Exhaust
Position the crankshaft in
POSITION 2 in Fig. 3 and install the
rocker arm, fulcrum seat, oil deflector
and fulcrum bolts on the following
valves:
No. 3 Intake No. 2 Exhaust
No. 7 Intake No. 6 Exhaust
Position the crankshaft in
POSITION 3 in Fig. 3 and install the
rocker arm, fulcrum seat, oil deflector
and fulcrum bolts on the following
valves:
No. 2 Intake No. 4 Exhaust
No. 5 Intake No. 5 Exhaust
No. 6 Intake No. 8 Exhaust
Be sure that the fulcrum seat base
is seated in its slot on the cylinder
head before tightening the fulcrum
bolts. Tighten the fulcrum bolt to
specification. Check the valve
clearance following the procedures
under Valve Clearance Adjustment.
3. Clean the valve rocker arm cover(s)
and the cylinder head gasket
surface(s). Apply oil-resistant sealer
to one side of new cover gasket(s).
Lay the cemented side of the gasket(s)
in place in the cover(s).
4. Position the cover(s) on the cylinder
head(s). Make sure the gasket seats
evenly all around the head. Install the
bolts. The cover is tightened in two
s t e p s . T i g h t e n the b o l t s to
specification. Two minutes later,
tighten the bolts to the same
specification.
R e c o n n e c t the c r a n k c a s e
ventilation hose(s).
Install the air cleaner and intake
duct assembly.
5. Install the spark plug wires in the
bracket on the valve rocker arm
cover(s). Connect the spark plug
wires. See Part 23-01 for special
installation instructions.
6. Start the engine and check for leaks.
VALVE SPRING, RETAINER AND
STEM SEAL
Broken valve springs or damaged
valve stem seals and retainers may be
replaced without removing the cylinder
head, provided damage to the valve or
valve seat has not occurred.
Removal
1. Remove the required rocker arm(s)
following the instructions given in
Rocker Arm Removal.
2. Install an air line with an adapter in
the spark plug hole and turn on the
air supply.
3. Install the compressor tool as shown
in Fig. 12. Compress the valve spring
and remove the retainer locks, spring
retainer and valve spring.
351M and 400 CID V-8 Engines
4. Remove and discard the valve stem
seal (Fig. 13).
5. If air pressure has forced the piston
to the bottom of the cylinder, any
removal of air pressure will allow the
valve(s) to fall into the cylinder. A
rubber band, tape or string wrapped
around the end of the valve stem will
prevent this condition and will still
allow enough travel to check the valve
for binds.
Installation
1. Inspect the valve stem for damage.
Rotate the valve and check the valve
stem tip for eccentric movement
during rotation. Move the valve up
and down through normal travel in
the valve guide and check the stem for
binds. If the valve has been damaged,
it will be necessary to remove the
cylinder head for repairs as outlined
in Part 21-01.
2. If the condition of the valve proved
satisfactory, hold the valve in the
closed position and apply the air
pressure within the cylinder.
3. Lubricate the valve stem with heavy
engine oil SE.
4. Install a new valve stem seal (Fig. 13).
Place the spring in position over the
valve and install the valve spring
retainer. Compress the valve spring
and install the valve spring retainer
locks. Remove the compressor tool
and stud nut. Turn off the air and
remove the air line adapter.
5. Lubricate and install the push rod.
Apply Lubriplate or equivalent to the
tip of the valve stem.
FULCRUM
BOLT-6A529
OIL DEFLECTOR
FULCRUM
SEAT-6A528
A3236-B
FIG. 11 Rocker Arm and Related
Parts
21-22-6
6. Install the required rocker arm(s)
following the instructions given in
Rocker Arm Installation.
7. Check the rocker arm to valve stem
clearance and install the related parts
as outlined in Valve Rocker Arm
Cover and Rocker Arm Installation.
INTAKE MANIFOLD
A typical intake manifold assembly is
shown in Fig. 14.
Removal
1. Remove the air cleaner and intake
duct. On Ford and Mercury vehicles,
with Frigidaire A/C compressor,
isolate and remove the compressor,
following procedure in Group 36.
2. Disconnect the high tension lead and
wires from the coil. Disconnect the
engine wire harness and position it
out of the way.
3. Disconnect the spark plug wires from
the spark plugs by grasping, twisting
and pulling the molded cap only. (Use
Tool T75P-6666-A.) Remove the
wires from the harness brackets on
the valve rocker arm covers. Remove
the distributor cap and spark plug
wire assembly. Remove the
Thermactor by-pass valve and hose
from the check valve.
A3245-A
FIG. 12 Compressing Valve Spring, in
Chassis
A3246-A
FIG. 13 Removing or Installing Valve
Stem Seal
21-22-7
4. Remove the carburetor fuel inlet line.
5. Remove the heater hoses from the
retainers and position the hoses out of
the way.
6. Remove the ignition coil, vacuum
solenoid valve, and bracket.
7. Disconnect the crankcase emission
hose at the left rocker arm cover.
8. Disconnect the vacuum lines from the
intake manifold.
9. Disconnect the distributor vacuum
hoses from the distributor. Remove
the distributor hold down bolt and
clamp and remove the distributor.
Block the distributor hole with a rag
to prevent entry of foreign material
into the crankcase.
10. Disconnect the accelerator linkage
and position out of the way.
11. Remove the carburetor.
12. Remove the manifold attaching bolts.
Remove the manifold. Remove and
discard the intake manifold gasket
and seals.
13. If the manifold assembly is to be
disassembled, disconnect vacuum
hoses.
Installation
1. Clean the mating surfaces of the
intake manifold, cylinder heads and
cylinder block. Use a solvent such as
lacquer thinner, chlorothane or tri-
chlor-ethylene. Apply a 1/8 inch bead
of silicone rubber sealer at the points
shown in Fig. 15. Caution: Do not
apply sealer to waffle section of end
seals as the sealer will rupture the
seal material.
2. Position new seals on the cylinder
block and press the seal locating
extensions into the holes in the mating
surface.
3. Apply a 1/16 inch bead of the above
sealer to the outer end of each intake
manifold seal for the full width of the
seal (4 places). See Fig. 15. Caution:
Do not apply sealer to waffle section
of end seals as the sealer will rupture
the seal material. NOTE: This sealer
sets up in 15 minutes, so it is
i m p o r t a n t t h a t assembly be
completed promptly. Do not drip any
sealer into the engine valley. Position
the intake manifold gasket onto the
block and cylinder heads with the
alignment notches under the dowels
on the cylinder heads. Be sure the
holes in the gasket are aligned with
the holes in the cylinder head.
4. Carefully lower the intake manifold
into position on the cylinder block
and cylinder heads.
5. Be sure the holes in the manifold
gaskets and manifold are in
alignment. Install the intake manifold
attaching bolts. Tighten the intake
manifold bolts in three steps (Fig. 16).
351M and 400 CID V-8 Engines 21-22-7
Tighten all bolts in sequence to
specification.
After completing the remaining CHOKE HEATER
ASSEMBLY
assembly steps, operate the engine
until it reaches normal operating
temperature then re-tighten the
manifold bolts in sequence to
specification.
6. Install the carburetor and gasket.
7. Rotate the crankshaft damper until
the No. 1 piston is on TDC at the end
of the compression stroke. Position
the distributor in the block with the
rotor at the No. 1 firing position and
the points just open. Install the hold
down clamp.
8. Install the accelerator linkage. INTAKE MANIFOLD
GASKET-9441
9. Install the vacuum solenoid valve and
the ignition coil.
10. Connect the vacuum lines at the
manifold. Install the Thermactor by-
pass air supply hose.
11. Position the engine wire harness
under the hold down clips on the left
rocker arm cover and connect the
wires at the ignition coil, water
temperature sending unit and throttle
solenoid.
12. Connect the crankcase emission line
at the left hand rocker arm cover. A3238-C
FIG. 14 Intake Manifold Assembly
TYPICAL SEALER APPLICATION AREAS FOR INTAKE MANIFOLD INSTALLATION
SEAL MOUNTING SURFACE
X
CYLINDER HEAD
OF CYLINDER BLOCK
INTAKE MANIFOLD SEAL
1/8" DIA. BEAD C3AZ-19526-A(OR-B)
SEALER (4-JOINTS)
1/16" DIA. BEAD C3AZ-19526-AIOR-B)
SEALER (4-SEAL ENDS)
A3716-B
FIG. 15 Typical RTV Sealer Installation-Intake Manifold—351-M and 400
Engines
FRONT
OF
ENGINE
© .©(5)®.© Q A3237-A
FIG. 16 Intake Manifold Torque Sequence
21-22-8
13. Install the heater hoses in the
retainers.
14. Connect the fuel pump to carburetor
fuel line at the carburetor.
15. Install the distributor cap. Position
the spark plug wires in the harness
brackets on the valve rocker arm
covers and connect the wires to the
spark plugs. See Part 23-01 for special
installation instructions. On Ford and
Mercury vehicles equipped with
Frigidaire A/C compressor, install
compressor following procedure in
Group 36.
16. Start the engine and check for leaks.
Adjust the ignition timing and
connect the distributor vacuum lines.
17.When engine temperature has
stabilized, adjust idle mixture and
speed. Retorque the intake manifold
to specification.
18. Install the air cleaner and re-check
idle speed.
VALVE LIFTER
Before replacing a hydraulic valve
lifter for noisy operation, be sure the
noise is not caused by improperly
adjusted valve clearance (collapsed
tappet clearance) or by worn rocker arms
or push rods.
The following procedure applies to
the removal of one or all valve lifters.
NOTE: Since not all pushrod holes are
large enough to permit the removal of the
associated lifter, it may be necessary to
remove the adjacent rocker arm and
pushrod and use that pushrod hole for
access.
Removal
1. Remove the valve rocker arm covers.
2. Remove the valve necessary rocker
arm(s) push rod(s) and identify them
so that they can be installed in their
original positions.
3. Using tool T70P-14151, remove the
valve lifter(s) and place them in a rack
so that they can be installed in their
original bores (Fig. 17). If removing
lifter through adjacent lifter hole, use
a small light to aid in transferring
lifter into position for lifting out with
T70P-14151 Tool.
4. Instructions for disassembling and
assembling the lifters are given in
Valve Lifter—Disassembly and
Assembly.
Installation
Tappets or lifters and bores are to be
lubricated with heavy engine oil SE
before installation.
1. Clean the external surfaces of the
valve lifters and install in the bores
from which they were removed. If a
new lifter(s) is being installed, check
the new lifter(s) for a free fit in the
bore in which it is to be installed.
Lubricate the lifter(s) and bore(s)
351/$ and 400 CID V-8 Engines
with heavy engine oil SE before
inserting it in the bore.
2. Install the push rods in their original
position. Apply Lubriplate or
equivalent to the valve stem tips.
3. Install the rocker arm(s) following the
instructions given in Rocker Arm
Installation.
4. Check the rocker arm to valve stem
tip clearance (collapsed tappet
clearance), and install the related
parts as outlined in Valve Rocker
Arm Cover and Rocker Arm
Installation.
EXHAUST MANIFOLD
Removal
1. If a right exhaust manifold is being
removed, remove the air cleaner,
intake duct and heat stove. If a left-
hand exhaust manifold is being
removed, first remove the oil filter.
2. On vehicles equipped with a column
selector and automatic transmission,
disconnect the selector lever cross
shaft for clearance.
3. Disconnect the muffler inlet pipe or
catalytic converter at the exhaust
manifold. Remove the spark plug heat
shields.
4. Remove the exhaust manifold
attaching bolts and remove the
manifold.
Installation
1. Clean the mating surfaces of the
exhaust manifold and cylinder head.
Clean the mounting flange of the
exhaust manifold and muffler inlet
pipe or catalytic converter.
2. Apply graphite grease to the mating
surface of the exhaust manifold.
3. Position the exhaust manifold on the
head and install the attaching bolts. •'*
Working from the center to the endfc,
tighten the bolts to specification.^
Install the spark plug heat shields.
4. Install the spacer between the inlet
pipe and the exhaust manifold.
5. Connect the muffler inlet pipe or
catalytic converter at the exhaust
manifold. Tighten the attaching nuts
to specification.
6. If a left exhaust manifold is being
installed, install the oil filter.
On a vehicle with an automatic
transmission and column selector,
connect the selector cross shaft at the
chassis and cylinder block.
7. If a right exhaust manifold is being
replaced, install the air cleaner heat
stove. Install the air cleaner and
intake duct.
8. Start the engine and check for exhaust
leaks.
CYLINDER HEADS
If a cylinder head is to be replaced,
follow the procedures under Cylinder
21-22-8
S&A3456B
FIG. 17 Removing Hydraulic Valve
Lifter
Head Disassembly and Assembly, and
transfer all valves, springs, spark plugs,
etc., to the new cylinder head. Clean and
inspect all parts, reface the valves (refer
to Part 21-01) and check all assembly
clearances before assembling the new or
used parts to the new cylinder head.
Removal
1. Remove the intake manifold and
carburetor as an assembly following
the procedure under Intake Manifold
Removal.
2. Remove the rocker arm cover(s).
If the left cylinder head is to be
removed on a vehicle with an air
conditioner, isolate and remove the
compressor as outlined in Group 36.
If the left cylinder head is to be
removed, disconnect the power
steering pump bracket from the left
cylinder head and remove the drive
belt from the pump pulley. Position
the power steering pump out of the
way and in a position that will prevent
the oil from draining out.
3. If the right cylinder head is to be
removed, remove the alternator
mounting bracket through bolt and
air cleaner inlet duct from the right
cylinder head assembly. Remove the
ground wire at the rear of the cylinder
head.
4. Disconnect the exhaust manifold(s)
from the muffler inlet pipe(s) or
catalytic converter(s).
5. Remove the rocker arm bolts, oil
deflectors, rocker arms, and push
rods in sequence (Fig. 18) so thai: they
may be installed in their original
positions.
6. Remove the cylinder head attaching
bolts and lift the cylinder head off the
block. Remove and discard the
cylinder head gasket.
21-22-9
Installation
1. Clean the cylinder head, intake
manifold, valve rocker arm cover and
cylinder head gasket surfaces. If the
cylinder head was removed for a
cylinder head gasket replacement,
check theflatnessof the cylinder head
and block gasket surfaces.
2. Position the new cylinder head gasket
over the cylinder dowels on the block.
Position the cylinder head on the
block and install the attaching bolts.
3. The cylinder head bolts are tightened
in three progressive steps. Tighten all
the bolts in sequence (Fig. 19) to 50
ft-lbs, then to 60 ft-lbs and finally to
specification. When cylinder head
bolts have been tightened following
this procedure, it is not necessary to
retorque the bolts after extended
operation. However, the bolts may be
checked and retorqued if desired.
4. Clean the push rods in a suitable
solvent. Blow out the oil passage in
the push rod with compressed air.
Check the ends of the push rods for
nicks, grooves, roughness or excessive
wear. Visually check the push rods for
straightness or check push rod runout
with a dial indicator. If runout
exceeds the maximum limit at any
point, discard the rod. Do not attempt
to straighten push rods.
5. Lubricate and install the push rods in
their original positions. Apply
Lubriplate or equivalent to the valve
stem tips.
6. Lubricate and install the rocker arms
following procedures under Valve
Rocker Arm Installation.
7. Connect the exhaust manifold(s) at
the muffler inlet pipe(s) or catalytic
converter(s). Tighten the nuts to
specification.
8. If the right cylinder head was
removed, install the alternator
mounting bracket through bolt and
air cleaner inlet duct on the right
cylinder head assembly. Connect the
ground wire at the rear of the cylinder
head. Adjust the drive belt tension to
specification.
9. Apply sealer to the rocker cover and
cover gasket to hold gasket in place.
Position gasket on cover aligning the
holes in cover and gasket. Install the
valve rocker arm cover(s).
If the left cylinder head was
removed on a vehicle with an air
conditioner, install the compressor as
outlined in Group 36.
If the left cylinder head was
removed, install the drive belt and
power steering pump bracket. Install
the bracket attaching bolts. Adjust
the drive belt to specification.
351M and 400 CID V-8 Engines 21-22-9
10. Install the intake manifold and 11. Connect the battery cable. Fill and
related parts following the procedure bleed the cooling system. Operate the
under Intake Manifold Installation. engine until normal operating
temperature has been reached and
WATER PUMP check for leaks.
Removal
1. Drain the cooling system and CYLINDER FRONT COVER PLATE
disconnect the battery. AND TIMING CHAIN
2. Remove the fan shroud attaching
bolts and position the shroud Removal
1. Refer to Water Pump Removal.
rearward.
3. Remove the fan and spacer from the Perform Steps 1 thru 9, but leave the
water pump attached to the front
water pump shaft.
4. Remove the air conditioner cover plate.
2. Remove the heater hose and lower
compressor drive belt lower idler
pulley and compressor mount to radiator hose from the water pump.
3. Remove the crankshaft pulley from
water pump bracket, if so equipped.
5. Loosen the alternator and remove the the crankshaft vibration damper.
Remove the vibration damper
drive belt.
6. Loosen the power steering pump and attaching screw. Install the puller on
the crankshaft vibration damper (Fig.
remove the drive belt.
7. Remove the water pump pulley. 20) and remove the vibration damper.
8. Remove the alternator bracket from
water pump and position it out of the
way.
9. Remove the power steering pump
bracket from the water pump and
position it out of the way.
10. Remove the heater hose from the
water pump.
11. Disconnect the radiator lower hose at
the water pump.
12. Remove the water pump attaching
bolts and remove the water pump.
Installation
1. Remove all gasket material from the
mounting surfaces of the cylinder
front cover and water pump. On Ford FIG. 18 Removing Valve Push Rod
and Mercury vehicles with Frigidaire
A/C compressors, remove all gasket
material from the water pump spacer.
2. Position a new gasket, coated on both
sides with sealer, on the cylinder front
cover (on spacer for Ford and
Mercury vehicles with A / C A3241-A
compressor); then install the pump. FIG. 19 Cylinder Head Bolt Torque
Coat the threads of the attaching Sequence
screws with oil-resistant sealer and
install the screws. Tighten the
attaching screws to specification. \
3. Install the air conditioner compressor UNIVERSAL
,r J£ :?"&'
PULLER
to water pump bracket and lower A
idler pulley, if so equipped.
4. Position the alternator bracket and \
power steering pump bracket on the
water pump and install the bracket
bolts.
5. Position the water pump pulley on the
water pump shaft and install the drive
belts.
6. Place the fan shroud over the pulley
and install the fan and spacer.
7. Install the fan shroud attaching bolts.
8. Adjust the drive belts to specification.
9. Connect the radiator lower hose at
the water pump. A3248-A
10. Connect the heater hose at the water FIG. 20 Removing Crankshaft
pump. Vibration Damper
21-22-10
4. Remove the timing pointer.
5. Remove the bolts attaching the front
cover plate and water pump to the
cylinder block. Remove the front
cover plate and water pump assembly.
6. Disconnect the fuel pump outlet line
from the fuel pump. Remove the fuel
pump attaching bolt and nut and lay
the pump to one side with the flexible
fuel line still attached.
7. Discard the cylinder front cover plate
gasket and oil pan seal.
8. Check the timing chain deflection
(refer to Part 21-01).
9. Crank the engine until the timing
marks on the sprockets are positioned
as shown in Fig. 21.
10. Remove the camshaft sprocket cap
screw, washer and two piece fuel
pump eccentric. Slide both sprockets
and the timing chain forward, and
remove them as an assembly (Fig. 22).
Installation
1. Position the sprockets and timing
chain on the camshaft and crankshaft
(Fig. 23). Be sure the timing marks on
the sprockets are positioned as shown
in Fig. 21.
2. Install the two-piece fuel pump
eccentric, washers and camshaft
sprocket cap screw (Fig. 23). Torque
the s p r o c k e t cap screw to
specification. Be sure the outer
eccentric sleeve rotates freely.
3. Coat a new fuel pump gasket with oil-
resistant sealer and position the fuel
pump and gasket on the cylinder
block with pump arm resting on the
eccentric outer sleeve. Install the
pump attaching bolt and nut and
tighten to specification. Connect the
fuel pump outlet line.
4. Remove the front crankshaft seal
from the cylinder front cover plate
with the tool shown in Fig. 24. Clean
the cylinder front cover plate and the
engine block gasket surfaces.
5. Coat the gasket surfaces of the block
and cover with sealer, and position a
new gasket on the cylinder block
alignment dowels.
6. Position the cylinder front cover plate
and water pump assembly on the
cylinder block alignment dowels.
7. Coat the threads of the attaching bolts
with oil-resistant sealer and install the
timing pointer and attaching bolts.
Torque the bolts to specification.
8. Install the front crankshaft seal into
the cylinder front cover plate with the
tool shown in Fig. 25.
9. Apply Lubriplate or equivalent to the
oil seal rubbing surface of the
vibration damper inner hub to
prevent damage to the seal. Apply a
white lead and oil mixture to the front
of the crankshaft for damper
installation.
351M and 400 CID V-8 Engines 21-22-10
10. Line up the crankshaft vibration 4. Remove the crankshaft pulley from
damper keyway with the key on the the vibration damper. Remove the
crankshaft. Install the vibration damper attaching screw and washer.
damper on the crankshaft using Tool Install the puller on the crankshaft
T52L-63O6-AEE (or 6306-AJ) (Fig. vibration dampef (Fig. 20) and
26). Install the cap screw and washer. remove the vibration damper.
T i g h t e n t h e cap s c r e w to 5. Place the front seal removing tool
specification. Install the crankshaft onto the front cover plate over the
pulley. front seal as shown in Fig. 24. Tighten
11. Connect the heater hose and the the two through bolts to force the seal
radiator lower hose at the water puller under the seal flange.
pump.
12. Refer to Water Pump Installation and
complete Steps 3 thru 11 to install the
necessary parts, fill and bleed the
cooling system, etc.
13. Raise the vehicle. Remove the oil pan
and install new gaskets and seals
following procedures under Oil Pan
Removal and Installation.
14. Lower the vehicle.
15. Fill the crankcase with the proper
grade and quantity of engine oil. Fill
and bleed the cooling system.
16. Connect the battery. Operate the
engine until normal operating
temperature has been reached and
check for leaks.
FRONT OIL SEAL
Removal
1. Remove the bolts attaching the fan
shroud to the radiator.
2. Remove the fan and spacer bolts from
the water pump shaft. Remove the
fan, spacer and shroud.
3. Loosen the alternator, power steering,
Thermactor and air conditioner drive
belts, if so equipped. Remove the FIG. 22 Removing or Installing Timing
drive belts. Chain
TWO PIECE FUEL
PUMP ECCENTRIC
TIMING MARKS DOWEL
A3250-A A3252-B
FIG. 21 Aligning Timing Marks FIG. 23 Fuel Pump Eccentric Installed
21-22-11
6. Alternately tighten the four puller
bolts a half turn at a time as shown
in Fig. 24 to pull the oil seal from the
front cover.
Installation
1. Coat a new front cover plate oil seal
with Lubriplate or equivalent and
place it onto the front oil seal
alignment and installation sleeve as
shown in Fig. 25. Place the sleeve and
seal onto the end of the crankshaft
and push it toward the engine until
the seal starts into the front cover.
2. Place the installation screw, washer
and nut onto the end of the
crankshaft. Thread the screw into the
crankshaft. Tighten the nut against
the washer and installation sleeve to
force the seal into the front cover
plate. Remove the installation tool
from the crankshaft.
3. Apply Lubriplate or equivalent to the
oil seal rubbing surface of the
vibration damper inner hub to
prevent damage to the seal. Apply a
white lead and oil mixture to the front
of the crankshaft for damper
installation.
4. Line up the crankshaft vibration
damper keyway with the key on the
crankshaft. Install the vibration
damper on the crankshaft (Fig. 26).
Install the cap screw and washer.
Torque the screw to specification.
Install the crankshaft pulley.
5. Install the alternator, power steering
p u m p , T h e r m a c t o r and air
conditioner belts, if so equipped.
6. Position the fan shroud over the water
pump pulley. Install the fan and
spacer. Install the fan shroud
attaching screws.
7. Adjust the drive belts to specification.
CAMSHAFT
The camshaft and related parts are
shown in Fig. 27.
Removal
1. Drain the cooling system. Disconnect
the upper and lower radiator hoses at
the radiator. Disconnect the oil cooler
lines at the radiator. If equipped with
air conditioning, remove the
condenser.
2. Remove the cylinder front cover
plate, fuel pump and the timing chain
following the procedure under the
Cylinder Front Cover Plate and
Timing Chain Removal.
3. Remove the intake manifold
following the procedure under Intake
Manifold Removal.
4. Remove the valve rocker arm covers.
Loosen the valve rocker arm fulcrum
bolts and rotate the rocker arms to the
side.
5. Remove the valve push rods and
identify them so that they can be
351M and 400 CID V-8 Engines 21-22-11
installed in their original positions. radiator shroud attaching bolts.
6. Using the tool shown in Fig. 17, 14. Raise the vehicle. Remove the oil pan
remove the valve lifters and place and install new gaskets and seals
them in a rack so that they can be following procedures under Oil Pan
installed in their original bores. Removal and Installation.
Rotate the lifter back and forth to Lower the vehicle. On vehicles so
loosen it from the gum or varnish that equipped, install the fan shroud
may have formed at the lifters. attaching bolts.
7. Be sure the Number 1 piston is in the 15. Fill and bleed the cooling system. Fill
TDC position. Remove the camshaft the crankcase with the proper grade
thrust plate. Carefully remove the and quantity of engine oil.
camshaft by pulling toward the front
of the engine. Use caution to avoid
damaging the camshaft bearings.
Installation
Camshaft lobes are to be coated with
Lubriplate or equivalent and the journals
lubricated with heavy engine oil SE
before installation.
1. Oil the camshaft journal and apply
Lubriplate or equivalent to the lobes.
Carefully slide the camshaft through
the bearings. Install the camshaft
thrust plate onto the cylinder block.
Install the timing sprockets and
timing chain. Check camshaft end
play as shown in Part 21-01.
2. Install the valve lifters in the bores
from which they were removed.
3. Install fuel pumps cylinder front
cover plate and related parts
following steps 1 thru 13 under
Cylinder Front Cover Plate and
Timing Chain Installation.
4. Adjust the drive belts to specification.
5. Install the push rods in their original
positions.
6. Install the rocker arms following the
procedure given in Rocker Arm
Installation.
7. Install the rocker arm covers
following the procedure given in
Rocker Arm Cover Installation.
8. Install the intake manifold,
distributor and related parts by FIG. 24 Removing Crankshaft Front
following procedures under Intake Seal
Manifold Installation.
T70P-6B070-A
9. Connect the accelerator cable and
retracting spring. Connect the
transmission downshift rod if so
equipped. Install the vacuum lines
that were disconnected from the
intake manifold during removal.
10. Clean and install the crankcase
ventilation system.
11. Install the distributor cap. Position
the spark plug wires in the harness
brackets on the valve rocker arm
covers and connect the wires to the
plugs. Connect the high tension lead
at the coil.
12. If equipped with air conditioning,
install the condensor.
13. Place the radiator shroud over the
fan. Install the radiator and connect
the hoses. Connect the transmission
oil cooler lines at the radiator. On FIG. 25 Installing Front Crankshaft
vehicles so equipped, install the Seal
21-22-12
16. Start the engine and check and adjust
the ignition timing. Connect the
distributor vacuum lines.
17. Operate the engine at fast idle and
check all hose connections and
gaskets for leaks. When the engine
temperature has stabilized adjust the
engine idle speed and idle fuel
mixture.
18. Install the air cleaner and intake duct
assembly.
FLYWHEEL
Removal
1. Remove the transmission and
converter housing following the
procedure in Group 17.
2. To check ring gear for lateral run-out,
refer to Part 21-01.
3. Remove the flywheel attaching bolts
and remove the flywheel.
Installation
1. Coat the threads of the flywheel
attaching bolts with oil-resistant
sealer. Position the flywheel on the
crankshaft flange. Install and torque
the bolts in sequence across from each
other to specification.
2. Check the flywheel lateral runout,
following the procedure in Part 21-01,
and install the transmission and
converter housing following the
procedure in Group 17.
CAMSHAFT REAR BEARING BORE
PLUG
Removal
1. Remove the transmission and
converter housing following the
procedure in Group 17.
2. Remove the flywheel attaching bolts
and remove the flywheel. Remove the
engine rear cover plate.
3. Remove the core plug as detailed in
Part 21-01.
Installation
1. Using Tool T70P-6011-A, install the
core plug as outlined in Part 21-01.
2. Coat theflywheelattaching bolts with
oil-resistant sealer. Position the
engine rea * cover plate on the cylinder
block dowtis. Position the flywheel
on the crankshaft flange. Install and
torque the attaching bolts in sequence
a c r o s s from each o t h e r to
specification.
Install the transmission and
converter housing following the
procedure in Group 17.
OIL PAN
Removal
1. Remove the oil level dipstick.
2. Remove the fan shroud attaching
bolts and position the fan shroud over
the fan.
3. Raise the vehicle.
351M and 400 CID V-8 Engines 21-22-12
4. Drain the crankcase. 8. Install the sway bar to chassis
5. Disconnect the starter cable and attaching bolts (except Ford and
remove the starter. Mercury).
6. Remove the sway bar attaching bolts 9. Install the starter and connect the
from the chassis and lower the sway starter cable.
bar for clearance (except Ford and 10. Lower the vehicle.
Mercury). 11. Install the fan shroud attaching bolts.
7. Remove the engine front support 12. Install the oil level dipstick. Fill the
through bolts. crankcase with the proper grade and
8. Raise the engine and place wood quantity of engine oil. Start the engine
blocks between the engine supports and operate at idle speed until it
and chassis brackets. reaches normal operating
9. Remove the oil pan attaching bolts. temperature. Check for oil leaks.
10. If equipped with an automatic
transmission, position the oil cooler OIL PUMP
lines out of the way. Removal
11. Remove the oil pan. 1. Remove the oil pan and related parts
Installation as outlined under Oil Pan Removal.
1. Clean the gasket surfaces of the block 2. Remove the oil pump attaching bolts
and oil pan. The oil pan has a two- and remove the oil pump with pick up
piece gasket. tube and screen, gasket and
2. Clean the oil pump pick-up tube and intermediate drive shaft.
screen. Installation
3. Coat the block surface and the oil pan 1. Clean and install the oil pump inlet
gasket with sealer. Position the oil tube and screen assembly (Fig. 29).
pan gaskets on the cylinder block
(Fig. 28). Tool-T52L-6306-AEE or 6306-AJ
4. Position the oil pan front seal on the
cylinder front cover plate. Be sure the
tabs on the seal are over the oil pan
gasket.
5. Position the oil pan rear seal on the
rear main bearing cap (Fig. 28). Be
sure the tabs on the seal are over the
oil pan gasket.
6. Position the oil pan against the block
and install a bolt, finger tight, on each
side of the block. Install the
remaining bolts. Tighten the bolts
from the center outward in each
direction to specification.
7. Raise the engine and remove the
wocd blocks from between the engine
supports and chassis brackets. Lower A2862-B
the engine and install the engine
support through bolts. Tighten the FIG. 26 Installing Crankshaft
bolts to specification. Vibration Damper
BEARINGS
6263-
THRUST
PLATE
6269
TIMING CHAIN - 6268 AND
CAMSHAFT SPROCKET - 6256
CAMSHAFT
REAR BEARING
BORE PLUG
6266
CAMSHAFT
6250
BOLT
TWO PIECE FUEL
PUMP ECCENTRIC -6287
A3253-A
FIG. 27 Camshaft and Related Parts
21-22-13
2. Prime the oil pump by filling either
the inlet or outlet port with engine oil.
Rotate the pump shaft to distribute
the oil within the pump body.
3. Position the intermediate drive shaft
into the distributor socket. With the
shaft firmly seated in the distributor
socket, the stop on the shaft should
touch the roof of the crankcase.
Remove the shaft and position the
stop as necessary.
4. With the stop properly positioned,
insert the intermediate drive shaft
into the oil pump. Install the pump
and shaft as an assembly.
Do not attempt to force the pump
into position if it will not seat readily.
The drive shaft hex may be
misaligned with the distributor shaft.
To align, rotate the intermediate
drive shaft into a new position.
Tighten the oil pump attaching
screws to specification. Be sure the oil
pick up screen is parallel with the oil
pan mounting surface.
5. Install the oil pan and related parts as
outlined under Oil Pan Installation.
CRANKSHAFT REAR OIL SEAL
A split-lip type crankshaft rear oil
seal is used for replacement on all
engines. If replacement is necessary, this
type of seal must be used. The complete
seal can be replaced without removing
the crankshaft. Refer to Part 21-01 for
removal and installation procedures.
MAIN BEARING
Main bearing inserts are selective
fits. Do not file or lap bearing caps or use
bearing shims to obtain proper clearance.
Selective fit bearings are available for
service in standard size, 0.001 and 0.002
inch undersize. Undersize bearings
(0.010, 0.020, 0.030 and 0.040 inch)
which are not selective fit, are available
for use on crankshaft journals that have
been refinished.
Removal
1. Drain the crankcase. Remove the oil
level dipstick. Remove the oil pan and
related parts.
2. Remove the oil pump and inlet tube
assembly.
3. Replace one bearing at a time, leaving
the other bearings securely fastened.
Remove the main bearing cap to
which new bearings are to be
installed.
351M and 400 CID V-8 Engines 21-22-13
4. Insert the upper bearing removal tool toward the FRONT of the engine,
(Tool 6331) in the oil hole in the allow the seal to p r o t r u d e
crankshaft. approximately 3/8 inch above the
5. Rotate the crankshaft in the direction parting surface to mate with the
of the engine rotation to force the upper seal when the cap is installed.
bearing out of the block. 9. Refer to Part 21-01 for special
6. If the rear main bearing is being instructions in applying sealer to the
replaced, remove and discard the rear rear main bearing cap. Lubricate the
oil seal from the bearing cap. journal with engine oil and install the
Loosen all main bearing bolts, rear main bearing cap. Tighten the
thereby lowering the crankshaft cap bolts to specification.
slightly but not to exceed 1/32 inch.
Remove the block half of the rear oil FRONT SEAL
seal. Use a seal removal tool or install
a small metal screw in one end of the
seal, and pull on the screw to remove
the seal. Be careful not to burr the
crankshaft seal nibbing surface.
Installation
1. If the rear main bearing is being
replaced, clean the rear oil seal groove
in the block with a brush and solvent.
Carefully install the upper seal
(split lip type) into its groove with the
undercut side of the seal toward the
FRONT of the engine by rotating it
on the seal journal of the crankshaft
until approximately 3/8 inch
protrudes below the parting surface.
Be sure no rubber has been shaved
from the outside diameter of the seal
by the bottom edge of the groove.
Tighten the bolts on main bearings 1,
2, 3 and 4, thereby raising the
crankshaft to its original position.
Torque the bolts to specification.
2. Clean the crankshaft journals.
Inspect the journals and thrust faces
(thrust bearing) for nicks, burrs or
bearing pick-up that would cause
premature bearing wear.
3. To install the upper main bearing, REAR SEAL A3263-A -
place the plain end of the bearing over
the shaft on the locking tang side of FIG. 28 Oil Pan Gasket and Seals
the block and partially install the Installed—Typical
bearing so that Tool 6331 can be
inserted in the oil hole in the
crankshaft. With Tool 6331
positioned in the oil hole in the
crankshaft, rotate the crankshaft in
the opposite direction of engine
rotation until the bearing seats itself.
Remove the tool.
4. Replace the cap bearing.
5. Select fit the bearing for proper
clearance following procedures under
Fitting Main and Connecting Rod
Bearings in Part 21-01.
6. If the bearing is being replaced on
journal number 1,2 or 4, apply a light
coat of engine oil to the journal and
bearings and install the bearing cap.
Tighten the cap bolts to specification.
7. If the rear main bearing is being
replaced, clean the oil seal groove
A 3264-B
with a brush and solvent.
8. Install the lower seal in the rear main FIG. 29 Oil Pump and Inlet Tube
bearing cap with undercut side of seal Installed
21-22-14
10. If the thrust bearing cap (No. 3 main
bearing) has been removed, install it
as follows:
Lubricate the journal with engine
oil and install the thrust bearing cap
with the bolts finger tight. Pry the
crankshaft forward against the thrust
surface of the upper half of the
bearing. Hold the crankshaft cap to
the rear. This will align the thrust
surfaces of both halves of the bearing.
Retain the forward pressure on the
crankshaft. Torque the cap bolts to
specification.
11. Clean the oil pump inlet tube screen.
Prime the pump by filling the inlet
opening with oil and rotate the pump
shaft until oil emerges from the outlet
opening. Install the oil pump and the
inlet tube assembly.
12. Position the oil pan gaskets on the oil
pan. Position the oil pan front seal on
the cylinder front cover. Position the
oil pan rear seal on the rear main
bearing cap. Install the oil pan and
related parts. Install the oil level
dipstick.
13. Fill the crankcase with proper grade
of oil. Start the engine and check for
oil pressure. Operate the engine at fast
idle and check for oil leaks.
CONNECTING ROD BEARINGS
The connecting rod bearings are
selective fit. Refer to procedures under
Fitting Main and Connecting Rod
Bearings in Part 21-01.
Removal
1. Drain the crankcase oil. Remove the
oil level dipstick. Remove the oil pan
and related parts.
2. Remove the oil pump and inlet tube
assembly.
3. Turn the crankshaft until the
connecting rod to which new bearings
are to be fitted is down. Remove the
connecting rod cap. Remove the
bearing inserts from the rod and cap.
Installation
1. Be sure the bearing inserts and the
bearing bore in the connecting rod
and cap are clean. Foreign material
under the inserts will distort the
bearing and cause a failure.
2. Clean the crankshaft journal.
3. Install the bearing inserts in the
connecting rod and cap with the tangs
fitting in the slots provided.
4. Pull the connecting rod assembly
down firmly on the crankshaft
journal.
5. Select fit the bearing following
procedures under Fitting Main and
Connecting Rod Bearings in Part 21-
01.
6. After the bearing has been fitted,
clean and apply a light coat of engine
351M and 400 CID V-8 Engines 21-22-14
oil to the journal and bearings. Install Be sure to install the pistons in the
the connecting rod cap. Torque to same cylinders from which they were
specification. removed or to which they were fitted.
7. Clean the oil pump inlet tube screen. The connecting rod and bearing caps
Prime byfillingthe inlet opening with are numbered from 1 to 4 in the right
oil and rotate the pump shaft until oil bank and from 5 to 8 in the left bank,
emerges from the outlet opening. beginning at the front of the engine.
Install the oil pump and the inlet tube The numbers on the connecting rod
assembly. and bearing cap must be on the same
8. Position the oil pan gaskets on the oil side when installed in the cylinder
pan. Position the oil pan front seal on bore. If a connecting rod iis ever
the cylinder front cover plate. transposed from one block or cylinder
Position the oil pan rear seal on the to another, new bearings should be
rear main bearing cap. Install the oil fitted and the connecting rod should
pan and related parts. Install the oil be numbered to correspond with the
level dipstick. new cylinder number.
9. Fill the crankcase. Start the engine 3. Make sure the ring gaps are properly
and check for oil pressure. Operate spaced around the circumference of
the engine at fast idle and check for the piston (Fig. 30).
oil leaks. 4. Install a piston ring compressor on
PISTONS AND CONNECTING the piston and push the piston in with
RODS a hammer handle until it is slightly
Removal below the top of the cylinder (Fig. 31).
1. Drain the cooling system and the Be sure to guide the connecting rods
crankcase. Remove the intake to avoid damaging the crankshaft
manifold, cylinder heads, oil pan and journals. Install the piston with the
oil pump, following the procedures in arrow on the piston head toward the
this section. front of the engine (Fig. 32).
2. Remove any ridges and/or deposits 5. Check the clearance of each bearing
from the upper end of the cylinder following the procedure under Fitting
bores as follows: Main and Connecting Rod Bearings
Turn the crankshaft until the in Part 21-01.
piston to be removed is at the bottom OIL RING SPACER
of its travel and place a cloth on the OIL RING ® OIL RING
piston head to collect the cuttings. SEGMENT __-J<__ SEGMENT
Remove any ridge and/or deposits
from the upper end of the cylinder
bores. Remove the cylinderridgewith
aridgecutter. Follow the instructions
furnished by the tool manufacturers.
Never cut into the ring travel area in
excess of 1/32 inch when removing
3. Make sure all connecting rod caps are
marked so that they can be installed
in their original positions.
4. Turn the crankshaft until the
connecting rod being removed is
down.
COMPRESSION RING COMPRESSION RING
5. Remove the connecting rod nuts and
FRONT OF ENGINE A2811-4
cap.
6. Push the connecting rod and piston
FIG. 30 Piston Ring Spacing
assembly out the top of the cylinder
with the handle end of a hammer.
Avoid damage to the crankshaft
journal or the cylinder wall when
removing the piston and rod.
7. Remove the bearing inserts from the
connecting rod and cap.
8. Install the cap on the connecting rod
from which it was removed.
Installation
1. If new piston rings are to be installed,
remove the cylinder wall glaze.
Follow the instructions of the tool
manufacturer. A3257 D
2. Oil the piston rings, pistons and
cylinder walls with light engine oil. FIG. 31 Installing Piston
21-22-15
6. After the bearings have been fitted,
apply a light coat of engine oil to the
journals and bearings.
7. Turn the crankshaft throw to the
bottom of its stroke. Push the piston
all the way down until the connecting
rod bearing seats on the crankshaft
journal.
8. Install the connecting rod cap and
b e a r i n g . T o r q u e the n u t s to
specification.
9. After the piston and connecting rod
assemblies have been installed, check
the side clearance between the
connecting rods on each crankshaft
journal (Fig. 33).
10. Disassemble, clean and assemble the
oil pump. Clean the oil pump inlet
tube screen and the oil pan and block
gasket surfaces.
11. Prime the oil pump by filling either
the inlet port or outlet port with
engine oil and rotating the pump shaft
to distribute the oil within the
housing. Install the oil pump and the
oil pan.
12. Install the cylinder heads following
procedures under Cylinder Head
Installation.
13. Install the intake manifold following
procedures under Intake Manifold
Installation.
14. Fill and bleed the cooling system. Fill
the crankcase with the proper grade
and quantity of engine oil.
15. Start the engine and check and adjust
the ignition timing. Connect the
distributor vacuum hoses at the
distributor.
16. Operate the engine at fast idle until it
reaches normal operating
temperature and check for oil and
coolant leaks. When the engine
temperature has stabilized adjust the
engine idle speed and idle fuel
mixture.
17. Install the air cleaner and intake duct
assembly.
CRANKSHAFT
The crankshaft and related parts are
shown in Fig. 34.
Removal
1. With engine removed from vehicle
and placed on a work s t a n d ,
disconnect the spark plug wires at the
spark plugs and remove the wires
from the ignition harness brackets on
the valve rocker arm covers.
Disconnect the coil-to-distributor cap
and spark plug wire assembly.
Remove the spark plugs to allow easy
rotation of the crankshaft.
2. Disconnect the fuel pump outlet line
at the pump. Remove the fuel pump
from the cylinder block. Remove the
alternator and mounting brackets.
3. Remove the crankshaft pulley from
the crankshaft vibration damper.
351M and 400 CID V-8 Engines 21-22-15
Remove the cap screw and washer of the seal toward the FRONT of the
from the end of the crankshaft. Install engine.
the puller on the crankshaft vibration 9. Carefully lower the crankshaft into
damper (Fig. 20) and remove the place. Be careful not to damage the
damper. bearing surface.
4. Remove tne timing pointer. Remove 10. Check the clearance of each main
the water pump and cylinder front bearing following the procedure
cover plate as an assembly. Discard under Fitting Main and Connecting
the gasket. Rod Bearings in Part 21-01.
5. Check the timing chain deflection 11. After the bearings have been fitted,
(Refer to Part 21-01). Remove the apply sealer to the rear main bearing
camshaft sprocket cap screw, washer cap, following the instructions given
and two piece fuel pump eccentric. in Part 21-01 for use of silicone rubber
Slide both sprockets and the timing sealer in this area.
chain forward and remove them as an 12. Apply heavy engine oil SE to the
assembly (Fig. 22). journals and bearings.
6. Invert the engine on the work stand. 13. Install the rear main bearing cap with
Remove the flywheel and engine rear the rear surface flush or slightly ahead
cover plate. Remove the oil pan and of the rear of the cylinder block.
gasket. Remove the oil pump. Install all bearing caps, except the
7. Make sure all bearing caps (main and thrust bearing cap (No. 3 bearing). Be
connecting rod) are marked so that sure that the main bearing caps are
they can be installed in their original installed in their original locations.
locations. Torque the bearing cap bolts to
Turn the crankshaft until the specification.
connecting rod from which the cap is 14. Install the thrust bearing cap with the
being removed is down, and remove bolts finger tight.
the bearing cap. Push the connecting
rod and piston assembly up into the
cylinder. Repeat this procedure until
RIGHT BANK LEFT BANK
all the connecting rod bearing caps NOTCH OR
are removed. ARROW TOWARD
FRONT OF ENGINE } y>^_.
8. Remove the main bearing caps.
9. Carefully lift the crankshaft out of the
block so that the thrust bearing
surfaces are not damaged. Handle the
crankshaft with care to avoid possible
fracture or damage to the finished
surfaces. To refinish journals, dress
minor imperfections, etc., refer to
Part 21-01.
Installation NUMBERED SIDE OF ROD A3706-B
1. Remove the rear journal oil seal from
the block and rear main bearing cap. FIG. 32 Correct Piston and Rod
2. Remove the main bearing inserts Positions—351-C and 400
from the block and bearing caps. CID
3. Clean the rear journal oil seal groove
and the mating surfaces of the block
and rear main bearing cap.
4. Remove the connecting rod bearing
inserts from the connecting rods and
caps.
5. If the crankshaft main bearing
journals have been refinished to a
definite undersize, install the correct
undersize bearings. Be sure the
bearing inserts and bearing bores are
clean. Foreign material under the
inserts will distort the bearing and
cause a failure.
6. Place the upper main bearing inserts
in position in the bores with the tang
fitting in the slot provided.
7. Install the lower main bearing inserts
in the bearing caps.
2 56-A
8. Dip the lip seal halves in clean engine
oil. Install the lip seals in the bearing FIG. 33 Checking Connecting Rod
cap and block with the undercut side Side Clearance
21-22-16 351M and 400 CID V-8 Engines 21-22-16

15. Pry the crankshaft forward against CAMSHAFT BEARING Wrap a cloth around the threads of
the thrust surface of the upper half of Camshaft bearings are available the puller screw to protect t/ie front
the bearing (Fig. 35). prefinished to size for standard and 0.015 bearing or journal. Tigh:en the
16. Hold the crankshaft forward and pry inch undersize journal diameters. The pulling nut against the thrust bearing
the thrust bearing cap to the rear. bearings are not interchangeable from and pulling plate to remove the
This will align the thrust surfaces of one bore to another. camshaft bearing. Be sure to hold a
both halves of the bearing. Removal wrench on the end of the puller screw
17. Retain the forward pressure on the 1. Remove the engine from the vehicle. to prevent it from turning.
crankshaft. Tighten the cap bolts to Remove the camshaft, flywheel and 5. Repeat the procedure for each
specification. crankshaft, following the appropriate bearing. To remove the front bearing,
18. Force the crankshaft toward the rear procedures in this part. Push the install the puller screw from the rear
of the engine. pistons to the top of the cylinders. of the cylinder block.
19. Check the crankshaft end play (Refer 2. Remove the camshaft rear bearing
to Part 21-01). bore plug. Remove the camshaft Installation
2O.Install the timing chain and bearings (Fig. 36). 1. Position the new bearings at the
sprockets, cylinder front cover plate 3. Select the proper size expanding collet bearing bores with the oil holes
and fuel pump, following steps 1 thru and back-up nut and assemble on the aligned, and press them in phice with
8 under Cylinder Front Cover Plate expanding mandrel. With the the tool shown in Fig. 36. Be sure to
and Timing Chain Installation. expanding collet collapsed, install the center the pulling plate and puller
21. Install the engine rear cover plate collet assembly in the camshaft screw to avoid damage to the bearing.
onto the alignment dowels at the rear bearing, and tighten the back-up nut Failure to use the correct expanding
of the cylinder block. on the expanding mandrel until the collet can cause severe bearing
22. Coat the threads of the flywheel collet fits the camshaft bearing. damage. Be sure the front bearing is
attaching bolts with oil-resistant 4. Assemble the puller screw and installed the specified distance below
sealer. Position the flywheel on the extension (if necessary) as shown and the front face of the cylinder block
crankshaft flange. Install and tighten install on the expanding mandrel. (Fig. 37).
the bolts to specification.
23. Install new bearing inserts in the
MAIN BEARING INSERTS
connecting rods and caps. Check the
clearance of each bearing following
the procedures under Fitting Main
and Connecting Rod Bearings in Part OIL SEAL
21-01.
24. After the connecting rod bearings
have been fitted, apply a light coat of
engine oil to the journals and
bearings.
25. Turn the crankshaft throw to the
bottom of its stroke. Push the piston
all the way down until the rod bearing
seats on the crankshaft journal.
26. Install the connecting rod cap.
Torque the nuts to specification. CRANKSHAFT SPROCKET
6306
27. After the piston and connecting rod
assemblies have been installed, check
the side clearance between the
connecting rods on each connecting
rod crankshaft journal (Fig. 33).
28. Clean the oil pan, oil pump and oil
pump screen. Prime the oil pump by
filling either the inlet or outlet port
with engine oil and rotating the pump
shaft to distribute oil within the
housing. Install the oil pump and oil
pan by following the procedures
under Oil Pan and Oil Pump
Installation.
29. Install the front oil seal, vibration
damper and crankshaft pulley,
following Steps 10 thru 12 under
Cylinder Front Cover Plate and
Timing Chain Installation.
30. Install the spark plugs, distributor /
cap and spark plug wires. Refer to BOLT
MAIN BEARING CAF >
Part 23-01 for special installation
instructions. Connect the spark plug A3266-O
wires and high tension lead.
31. Install the engine in the vehicle. FIG. 34 Crankshaft and Related Parts
21-22-17 351M and 400 CID V-8 Engines 21-22-17

HOLD PRY CAP

PRY FORWARD CRANKSHAFT HOLD CRANKSHAFT
BACKWARD
FORWARD FORWARD

THRUST BEARING THRUST BEARING I! f .

THRUST BEARING

PRY CRANKSHAFT FORWAR PRY CAP BACKWARD

FIG. 35 Aligning Thrust Bearing

DETAIL-1,-2 or-3
EXPANDING COLLET

DETAIL -1,-2. or -3
EXPANDING MANDREL BACK-UP NUT

DETAIL-8
PULLING NUT
INSTALL FRONT BEARING TO SPECIFIED
DIMENSION BELOW FRONT FACE OF BLOCKi

FIG. 3 7 Camshaft Front Bearing

Measurement

FILTER ELEMENT
/ 673?

DETAIL-5 CAMSHAFT BEARING (LOOSE)

PULLER SCREW
DETAIL-4
PULLING PLATE
Tool-T65L.625Q.A ADAPTER FITTING'
6890 A3704- B
A 2813-A

FIG. 36 Camshaft Bearing Replacement FIG. 38 Oil Filter Installation

Install the core plug as detailed in
Part 21-01.
Install the camshaft, crankshaft,
flywheel and related parts, following
the appropriate procedures in this
section except do not check
connecting and main bearing
clearances as a part of Camshaft
Bearing Replacement. Install the
engine in the vehicle.
OIL FILTER
The oil filter assembly is shown in
Fig. 38.
Removal
Place a drip pan under the filter.
Unscrew the filter from the adapter
fitting and clean the adapter recess.
Installation
1. Coat the gasket on a new filter with
oil. Place the new filter in position on
the adapter fitting. Hand tighten the
filter until the gasket contacts the
sealing surface, and then advance
it 1/2 turn.
2. Operate the engine at fast idle, and
check for oil leaks. If oil leaks are
evident, perform the necessary repairs
to correct leakage. Check the oil level
and fill the crankcase if necessary.
21-22-18
DISASSEMBLY AND ASSEMBLY
When installing nuts or bolts that
must be t o r q u e d (refer to t o r q u e
specification), oil the threads with light
weight engine oil. Do not oil threads that
require oil-resistant or water-resistant
sealer. Refer to Part 21-01, for cleaning
and inspection procedures.
CYLINDER HEAD
Disassembly
1. Remove the exhaust manifolds, the
spark plugs and spark plug wire
shields.
2. Clean the carbon out of the cylinder
head combustion chambers before
removing the valves.
3. Compress the valve springs (Fig. 39).
Remove the spring retainer locks and
release the spring.
4. Remove the spring retainer, spring
and stem seal. Discard the valve stem
seals. Remove any burrs from the
valve stem with tool T70P-6505-A as
shown in Fig. 40 to prevent damage
to the valve guide bore. Remove the
valve. Identify all valve parts.
5. Clean, inspect and repair the cylinder
head as required, or transfer all usable
parts to a new cylinder head.
Assembly
All valves, valve stems and valve
guides are to be lubricated with heavy
engine oil SE. The valve tips are to have
Lubriplate or equivalent applied. The
l u b r i c a n t is to be applied before
installation.
1. Clean the spring retainer lock grooves
on the valves to remove any loose
material left by the valve stem
deburring tool.
2. Lubricate the valve guide and valve
stem with heavy engine oil SE.
3. Install each valve (Fig. 41) in the port
from which it was removed or to
which it was fitted. Install a new stem
seal on the valve.
4. Install the valve spring over the valve,
and then install the spring retainer.
Compress the spring and install the
retainer locks (Fig. 41).
5. Measure the assembled height of the
valve spring from the surface of the
cylinder head spring pad to the
underside of the spring retainer with
dividers (Fig. 42). Check the dividers
against a scale. If the assembled
height is greater than specification,
install the necessary 0.030 inch thick
spacer(s) between the cylinder head
spring pad and the valve spring to
bring the assembled height to the
recommended height. Do not install
the spacers unless necessary. Use of
spacers in excess of recommendations
351M and 400 CID V-8 Engines 21-22-18
will result in overstressing the valve 7. Use the h y d r a u l i c valve ifter
springs and over-loading the camshaft leakdown tester (Part 21-01) to fill the
lobes which could lead to spring lifters with test fluid.
breakage and/or worn camshaft
lobes.
6. Install the exhaust manifolds and the
spark plugs.
VALVE LIFTER
The internal parts of each hydraulic
valve lifter assembly are matched sets.
Do not intermix the parts. Keep the
assemblies intact until they are to be
cleaned.
Valve lifters should always be tested
after assembly; refer to the procedures
covered in Part 21-01 for cleaning,
inspection and testing.
FIG. 39 Compressing Valve Spring
Disassembly
Disassemble and assemble each lifter
separately. Identify the lifter assemblies
so they can be installed in their original
bores.
1. Grasp the lock ring with needle nose
pliers to release it from the groove. It
may be necessary to depress the J70P-6505-A
plunger to fully release lock ring.
2. Remove the push rod cup, metering
valve (disc), plunger and spring.
3. Remove the plunger assembly, the
check valve and the check valve
retainer and plunger spring. Carefully
A3247-A
remove the plunger spring, the check
valve retainer and, the check valve FIG. 40 Removing Valve Stem Burrs
disc from the plunger.
Assembly
Hydraulic lifter assembly is shown in
Fig. 43.
1. Place the plunger upside down on a
clean work bench.
2. Place the check valve (disc or ball
check) in position over the oil hole on
the bottom of the plunger. Set the
check valve spring on top of the check
valve (disc or ball check).
3. Position the check valve retainer over
the check valve and spring and push
the retainer down in to place on the
plunger.
4. Place the plunger spring, and then the
plunger (open end up) into the lifter
body.
5. Position the metering valve (disc) in
the plunger, and then place the push
rod cup in the plunger.
6. Depress the plunger, and position the
closed end of the lock ring in'the
groove of the lifter body. With the
plunger still depressed, position the
open ends of the lock ring in the
groove. Release the plunger, and then <v3243-D
depress it again to fully seat the lock
ring. FIG. 41 Valve and Related Parts
21-22-19
OIL PUMP
Disassembly
1. Remove the oil inlet tube from the oil
pump.
2. Remove the cover attaching screws,
then remove the cover. Remove the
inner rotor and shaft assembly, then
remove the outer race.
3. Remove the cotter key. Drill a small
hole and insert a self-threading sheet
metal screw of the proper diameter
into the oil pressure relief valve
chamber cap and pull the cap out of
the chamber. Remove the spring and
plunger.
Assembly
The oil pump assembly is shown in
Fig. 44.
1. Oil all parts thoroughly.
2. Install the oil pressure relief valve
plunger, spring, a new cap and the
cotter key. • compression rings with a feeler gauge
3. Install the outer race and the inner
rotor and shaft assembly. Be sure the
dimple (identification mark) on the
outer race is on same side as
identification mark on rotor. The race
rotor and shaft and the outer race are
serviced as an assembly. One part
should not be replaced without
replacing the other.
Install the cover and tighten the
c o v e r a t t a c h i n g s c r e w s to
specification.
4. Install the oil inlet tube and screen
assembly on the oil pump.
5. Prime the pump by filling either the
inlet or outlet port with engine oil.
Rotate the pump shaft to distribute
the oil within the pump body.
PISTON AND CONNECTING ROD
1. Remove the bearing inserts from the
connecting rod and cap.
2. Mark the pistons to assure assembly
with the same rod and installation in
the same cylinders from which they
were removed.
3. Remove the piston rings. Using an
arbor press and the tool shown in Fig.
45, press the piston pin from the
piston and connecting rod.
Assembly
The piston connecting rod and related
parts are shown in Fig. 46. Check the fit
of a new piston in the cylinder bore
before assembling the piston and piston
pin to the connecting rod.
The piston pin bore of a connecting
rod and the diameter of the piston pin
must be within specification.
1. Apply a light coat of engine oil to all
parts. Assemble the piston to the'
connecting rod with the cylinder
number side of the connecting rod
and the arrow on the piston
351M and 400 CID V-8 Engines 21-22-19
positioned as shown in Fig. 32. On following the installation procedures
replacement connecting rods, install given in the Removal and Installation
the large-chamfered side of the section of this Part.
connecting rod bearing bore towards 4. Check all assembly clearances and
the crankshaft cheek; facing towards correct as necessary.
front of engine on right bank rods,
and facing towards rear of engine on CYLINDER BLOCK (6010)
left bank rods. Before replacing a cylinder block,
2. Start the piston pin in the piston and determine if it is repairable. If so, make
connecting rod (this may require a the necessary repairs, following the
very light tap with a mallet). Using an procedures given in Part 21-01.
arbor press and the tool shown in Fig.
45, press the piston pin through the
piston and connecting rod until the
pin is centered in the piston.
3. Check the end gap of all piston rings
(Part 21-01). It must be within
specification. Follow the instructions
contained on the piston ring package
and install the piston rings.
4. Check the ring side clearance of the
inserted between the ring and its
lower land (Part 21-01). The gauge
should slide freely around the entire
ring circumference without binding.
Any wear that occurs will form a step
at the inner portion of the lower land. FIG. 42 Valve Spring Assembled
If the lower lands have high steps, the Height
piston should be replaced.
5. Be sure the bearing inserts, the
bearing bore and the mating surfaces PUSH ROD SOCKET
/ METERING VALVE
on the connecting rod and cap are CHECK VALVE
clean. Foreign material under the
inserts will distort the bearing and CHECK VALVE SPRING
cause a failure. Install the bearing
PLUNGER SPRING
inserts in the connecting rod and cap
with the tangs fitting in the slots LOCK RING BODY
provided.
CYLINDER ASSEMBLY (6009) PLUNGER
Disassembly CHECK VALVE
1. Remove the intake manifold, cylinder RETAINER
A2867-B
heads, front cover (with water pump
attached), thermostat and housing, oil
pressure and temperature sending FIG. 43 Hydraulic Valve Lifter
units, fuel pump,flywheel,oil pan, oil Assembly
pump and associated attaching parts
from the old engine, using the GASKET-6659
procedures given in the Removal and
Q|L REL|EF VALVE 6A616
ASSEMBLY
Installation section of this Part.
2. Remove the dipstick tube, oil filter 6670
adapter and fuel pump retaining stud
from the old block. Remove fasteners
and components not received with the
replacement cylinder block.
Assembly
1. Clean the gasket and seal surfaces of
all parts and assemblies.
2. Position the replacement cylinder IDENTIFICATION
assembly in a work stand. Install the MARKS
cylinder block drain plugs, cylinder
head locating dowels, front and rear
cover plate locating dowels, dipstick PLATE
tube, oil filter adapter and fuel pump 6616
retaining stud. 3493-A
3. Transfer all serviceable parts removed
from the old cylinder assembly, FIG. 44 Oil Pump Assembly
21-22-20 351M and 400 CID V-8 Engines 21-22-20

Disassembly
1. Disassemble the engine completely, Press Ram
UPPER
COMPRESSION
following the various procedures RING
given in the Removal and Installation
section of this Part. Remember to
remove any ridge or carbon deposit
from the upper end of the cylinder
bores before removing pistons.
2. Remove the temperature and oil
pressure sending units from the old
block, dipstick tube, oil filter adapter
and fuel pump retaining stud.
3. Remove the old cylinder block from
the work stand.
Assembly
1. Install the replacement cylinder block
on the work stand. Install the INSERT
TAPERED PILOT
temperature and oil pressure sending IN PISTON PIN
units, dipstick tube, oil filter adapter FOR PIN REMOVAL

and fuel pump retaining stud.

Remove fasteners and components INSERT THIS END
IN PISTON HOLE
not received with the replacement FOR INSTALLATION
cylinder block.
2. Clean all the gasket and seal surfaces Adapter Detail A-3
of all parts and assemblies before
installing on the replacement cylinder T68P-6I35-A
block. Cup D e t a i l A - l
3. Transfer all serviceable parts removed
from the old cylinder block to the
replacement unit, using the
A3705-A \3259-A
procedures given in the Removal and
Installation section of this Part.
FIG. 45 Removing or Installing Piston FIG. 46 Piston, Connecting Rod and
4. Check all assembly clearances and Related Parts
Pin
correct as necessary.
21-22-21 351M and 400 CID V-8 Engines 21-22-21

SPECIFICATIONS-1977
GENERAL SPECIFICATIONS CAMSHAFT

LOBE LIFT
DISPLACEMENT • • 351 CtD/400 CID
Intake 0.235 (351 CID)
NUMBER OF CYLINDERS 8
0.2474 (400CID)
BORE ANDSTROKE 4.00x3.50(351 CID)
Exhaust 0 285 (351 CID)
4.00x4.00 (400 CIO)
0.2500 (400 CID)
FIRING ORDER 13 7 2 6 5 4 8
Allowable Lobe Lift Loss 0.005 Max.
OIL PRESSURE (Hot @ 2000 RPM) 50-75
THEORETICAL VALVE LIFT ©ZERO LASH
DRIVE BELT TENSION © Intake 0 4065 (351 CID)
0.4280 (400 CIO)
CYLINDER HEAD AND VALVE TRAIN
Exhaust 0 4065 (351 CIO)
0.4325 (400 CIO)
COMBUSTION CHAMBER VOLUME (cc) 76.9-79.9
END PLAY 0 001-0 006
VALVET3UIDE BORE DIAMETER . . . . 0.3433-0.3443
Service Limit 0 009
VALVE SEATS
0.060-0 080 JOURNAL TO-BEARING CLEARANCE 0.0010.003
Width - Intake
Service Limit 0.006
Width - Exhaust 0.060 0.080
CAMSHAFT GEAR BACKLASH 0.0060.010
Angle 45°
Runout Limit (T. 1. R. Max.) 0.002 JOURNAL DIAMETER
#1 2.1238-2.1248
V A L V E ARRANGEMENT (Front to Rear) . (LH) EIEI-EI-E 1
(RH) IE IE IE IE H 2 2.0655-2.0665

V A L V E STEM-TO-GUIDE CLEARANCE
# 3 2 0505-2 0515

Intake . . 0.00100.0027 2.0355-2.0365

Exhaust ... 0.001500032 #5 2.0205-2.0215
Service Clearance 0.0055 Runout Limit . . : 0.005
VALVE HEAD DIAMETER Out-Of-Round Limit 0.0005
Intake 2.032 2.050 CAMSHAFT BEARING INSIDE DIAMETER
#1 2.1258-2.1268
Exhaust ... 1.6635 1.6495
V A L V E FACE RUNOUT LIMIT 0.002 Max. #2 2.0675 2.0685
VALVE FACE ANGLE 44° #3 2.05252.0535
V A L V E STEM DIAMETERIStdl #4 2.03752.0385
Intake 0.34160.3423 #5 2.02252.0235
0.3411 0.3418 FRONT BEARING LOCATION (?) 0.0050.020
Exhaust
(0.003 Oversize)
Intake 0.34460.3453 CYLINDER BLOCK
Exhaust 0.3441-0.3448
(0.015 Oversize) HEAD GASKET SURFACE FLATNESS ©
Intake . . . 0.35660.3575 HEAD GASKET SURFACE FINISH (RMS) 60-150
Exhaust 0.3561 0.3568 CYLINDER BORE
(0.030 Oversize) Diameter 4.0000-4.0048
Intake 0.37160.3723 Surface Finish (RMS) 18-38
Exhaust 0.3711 0.3718 OutOf-Round Limit 0.0015
VALVE SPRINGS Out-Of-Round Service Limit 0.005
Compression Pressure (Lb. @ Spec. Length) 76-84 @ 1.82 Taper Service Limit 0.010
215-237 @ 1.39 TAPPET BORE DIAMETER 0.87520.8767
Free Length (Approximate) 2.06 MAIN BEARING BORE DIAMETER 3.1922 3.1930
As Assembled Height . 113/16—1 27/37 DISTRIBUTOR SHAFT BEARING BORE DIAMETER 0.5160-0.5175
Service Limit ®
OutOfSquare Limit 5/64 (0.078)
ROCKER ARM
Ratio 1.64:1
PUSH ROD RUNOUT (T. I. R. Max.) 0.015
VALVE TAPPET, LIFTER OR ADJUSTER
Diameter (Std) ... 0.8740-0.8745
Clearance To Bore 0.00070.0027
Service Limit 0.005
Hydraulic Leakdown Rate . . . 5 50 Seconds (5)
Collapsed Tappet Gap - Allowable 0.1000.200
- Desired 0.125 0.175
21-22-22 351M and 400 CID V-8 Engines 21-22-22

SPECIFICATIONS-1977
CRANKSHAFT AND FLYWHEEL CONNECTING ROD. PISTON AND RINGS (Continued)

Ring Groove Width

MAINBEARINGJOURNALDIAMETER 2.9994 3.0002
Compression (Top) 0.08(1 0.081
Out-Of Round Limit 0.0006 Max.
Compression (Bottom) 0.080-0.081
Taper Limit 0.0006 Max.
Oil 0.1811-0.189
Journal Runout Limit 0.002 Max.
PISTON PIN
Surface Finish (RMS) 12 Max.
Length 3.1E0-3.170
Runout Service Limit 0.005
Diameter
THRUST BEARING JOURNAL
Standard 0.974J o_9754
Length 1.137-1.139
0.001 Oversize :• . . . 0.976: 0.9760
CONNECTING ROD JOURNAL
0.002 Oversize 0.977C 0.9773
Diameter 2.3103 2.3111
Pin To-Piston Clearance O.OOO: 0.0005
Out Of Round Limit 0.0006 Max.
Pin To-Rod Clearance Interfeu nee Fit
Taper Lunit 0.0006 Max.
PISTON RINGS
Surface Finish (RMS) 12 Max.
Ring Width
MAIN BEARING THRUST FACE
Compression (Top) 0.0"'7-0.078
Surface Finish 25 Front/20 Rear
Runout Limit 0.001 Max.
Compression (Bottom) ; 0.077-8.(pf£
Side Clearance
FLYWHEEL RING GEAR LATERAL RUNOUT (T. I. R.)
Compression (Top) 0.002 0.OO4- -•
Automatic Transmis$ion 0.060
Compression (Bottom) 0.002 0.004
CRANKSHAFT FREE END PLAY 0.004-0.008
Oil Ring Snug Fit
Service Limit 0.012
Service Limit 0.006
CONNECTING ROD BEARINGS
Ring Gap
Clearance To Crankshaft - Desired 0.00080.0015
Compression (Top) 0.0 10 0.020
- Allowable 0.0008-0.0025
Compression (Bottom) 0.010 0.020
Bearing Wall Thickness (Std) (6) 0.0622-0.0625
Oil Ring (Steel Rail) 0.015-0.055
MAIN BEARINGS
Clearance To Crankshaft - Desired 0.0008-0.0015
- Allowable 0,0008-0.0026 LUBRICATING SYSTEM
Bearing Wall Thickness (Std.) © 0.0955-0.0960
OIL PUMP
CONNECTING ROD, PISTON AND RINGS Relief Valve Spring Tension (Lbs. at Spec Length) 20.6-22.6(?>2.49
Drive Shaft-To-Housing Bearing Clearance 0.00'5 0.0030
CONNECTING ROD Relief Valve-To-Bore Clearance 0.0' 5 0.0030
Piston Pin Bore Diameter ,.... 0.97260.9742 Rotor Assembly End Clearance (Assembled) 0 D04 Max.
Cranshaft Bearing Bore Diameter 2.4361 2.4369 Outer Race-To-Housing Clearance 0.(131-0.013
Out-OfRound Limit 0.0004 Max. OIL CAPACITY (Quarts U.S.) 4 (9)
Taper Limit 0.0004 Max.
Length (Center-to-Center) 6.5785 6.5815 FUEL PUMP
Alignment (Bore-to-Bore Max. Diff.) (z)
Twist 0.024
STATIC PRESSURE (P. S. 1.) ® . 6.0-8.0(351 CID/40: 2V CID)
Bend 0.024
6.7 8.7 (40('4VCID)
Side Clearance (Assembled to Crank)
MINIMUM VOLUME FLOW (io)(ri)(i2) 1 Pint in 2 ! Seconds
Standard 0.010-0.020
ECCENTRIC TOTAL LIFT (Inches) . .' O.I5O2-O.622
Service Limit 0.023
PISTON
Diameter (§)
Coded Red 3.9982 3.9988
Coded Blue 3.9994-4.0000
0.003 Oversize 4.0006-4.0012
Coded Yellow . . 4.0018-4.0024 (400 only)
Piston-to-Bore Clearance 0.0014-0.0022
Pin Bore Diameter 0.97540.9757
21-22-23 351M and 400 CID V-8 Engines 21-22-23

SPECIFICATIONS-1977
TORQUE SPECIFICATIONS PIPE THREAD SIZES TORQUE
CAMSHAFT SPROCKET TO CAMSHAFT 40-45
1/8 .. 5-8
CAMSHAFT THRUST PLATE TO BLOCK 912
1/4 • • 12-18
CONNECTING ROD NUTS OR BOLTS 40-45
3/8 . 22 33
CYLINDER FRONT COVER BOLTS 12-18
1/2 •• 25-35
CYLINDER HEAD BOLTS @
DAMPER OR PULLEY TO CRANKSHAFT 70-90
o All values are in ft.-lb. unless otherwise noted
DISTRIBUTOR VACUUM CONTROL VALVE 10 15
o Oil threads with engine oil unless fasteners require sealers.
EGR TO CARBURETOR SPACER OR INT MANIFOLD 12 18
FUEL PUMP TO CYLINDER BLOCK OR FRONT COVER Nut = 14-20
Bolt = 10-15
FLYWHEEL TO CRANKSHAFT 75-85
MAIN BEARING CAP BOLTS 95-105
MANIFOLD T O t Y L I N D E R HEAD (Intake) 3/8 • 22-32
5/16=19-25
MANIFOLD TO CYLINDERHEAD (Exhaust) 18-24
OIL FILTER INSERT TO CYLINDER BLOCK : 20-30
OIL FILTER TO BLOCK OR ADAPTER ®
OIL PAN DRAIN PLUG 15 25
OIL PAN TO CYLINDER BLOCK 5/16 = 11-13
1/4 = 7-9
PULLEY TO DAMPER (Bolt) 35-50
ROCKER ARM STUD OR BOLTTO CYLINDER HEAD 18-25
SPARK PLUG TO CYLINDER HEAD 10-15
VALVE ROCKER ARM COVER 3-5
ALTERNATOR BRACKET TO CYLINDER BLOCK (Bolt) 15-20
ALTERNATOR PIVOT BOLT 45-57
ALTERNATOR ADJUSTING ARM TO CYLINDER BLOCK 15-20 Drive Belt Tension (Lbs.)
ALTERNATOR ADJUSTING ARM TO ALTERNATOR 240
Newly Installed Used
THERMACTOR PUMP BRACKET TO CYLINDER BLOCK 15-20 S,ze (A)
THERMACTOR PUMP PIVOT BOLT 35-45 UptoiOMin. Over 10 Mm.
THERMACTOR PUMP ADJUSTING ARM TO PUMP 22-32 1/4" 50-80 40-80 (B) 40-60 (B)
THERMACTOR PUMP ADJUSTING ARM TO CYLINDER BLOCK 15-20
THERMACTOfl PUMP PULLEY TO SHAFT 130 180 In. Lb. Exc. 1/4" 120-160 90-160(0 75-120 (D)
POWER STEERING PUMP PULLEY TO DAMPER (Bolt) 35-50
FAN TO WATER PUMP HUP (Bolt) 12-18 (A) Read tension immediately after belt is installed, before it stretches or seats in pulley
CARBURETOR MOUNTING NUTS 12-15 grooves.
CARBURETOR MOUNTING STUD 4-7 (B) If less than 40 pounds, readjust to 40-60 pounds.
( 0 If less than 90 pounds, readjust to 90-120 pounds.
TORQUE SPECIFICATIONS - General Applications (D) If less than 75 pounds, readjust to 90-120 pounds.
10% pressure loss at specified length.
U.S. THREAD SIZES TORQUE
Time required to leak down 1/16" with 50 lb. load and lifter filled with leakdown fluid.
1/4-20 . Distance Front edge of bearing is installed below front face of block.
5/16 18 12-18 0.003 in any 6 inches - 0.006 overall.
5/16 24 1420 For 0.002 Undersize, add .001 to Standard Thickness.
3/8 16 22 32 Pin bore and crank bearing bore must be parallel and in same vertical plane within the
3/8-24 27-38 specified total difference when measured at the ends of an 8 " bar - 4 " on each side of
7/16-14 40-55 rod centerline.
7/16-20 40-60 Measured at the piston pin bore centerline @ 90° to the pin.
1/2 13 . 55-80 Add 1 quart with filter change
On engine, normal temperature, curb idle, transmission in neutral.
METRIC THREAD SIZES TORQUE No orifice in test circuit smaller than 0.220" I. D. .-,• YA\
With new filter; pump to tank return line pinched off.
M-6 6-9 Torque in sequence: Step 1 = 75; Step 2 = 95-105.
M-8 14-21 1/2 turn after contacting sealing surface with oiled gasket.
M-10 28-40
M-12 50 71 CA1309E 3
M-14 80 114
21-24-1 460 CID V-8 Engines 21-24-1

PART
460 CID V-8 Engines 21-24
Ford, Mercury, Lincoln Continental and Continental Mark V

SUBJECT PAGE SUBJECT PAGE

DESCRIPTION REMOVAL AND INSTALLATION (Cont'd.)

Crankcase Ventilation System 24-2 Main Bearing 24-14
Engine 24-2 Oil Filter 24-18
Exhaust Emission Control System 24-2 Oil Pan 24-13
Oil Pump 24-14
REMOVAL AND INSTALLATION Pistons and Connecting Rods 24-16
Camshaft 24-12 Valve Lifter .24-8
Camshaft Bearings 24-18 Valve Rocker Arm Cover and
Camshaft Rear Bearing Bore Plug 24-13 Rocker Arm 24-5
Connecting Rod Bearing 24-15 Valve Spring Retainer and
Crankcase Ventilation System 24-5, Stem Seal 24-6
Crankshaft 24-16 Water Pump 24-9
Crankshaft Rear Oil Seal 24-14
Cylinder Front Cover and DISASSEMBLY AND ASSEMBLY
Timing Chain 24-10 Cylinder Assembly 24-20
Cylinder Heads 24-8 Cylinder Block 24-20
Engine 24-2 Cylinder Head 24-19
Engine Front Supports 24-3 Oil Pump 24-20
Engine Rear Support 24-4 Piston and Connecting Rod 24-10
Exhaust Manifolds 24-9 Valve Lifter 24-10
Flywheel 24-13
Front Oil Seal 24-11 SPECIFICATIONS 24-21
Intake Manifold 24-6

CIM4036-A
21-24-2
DESCRIPTION
ENGINE
The 460 V-8 engine (Fig. 1) is a
lightweight cast iron design.
EXHAUST EMISSION CONTROL
SYSTEM
Operation, removal, installation and
required maintenance of the exhaust
emission control devices used on this
engine are covered in Group 29 and
Group 50 of this Manual.
CRANKCASE VENTILATION
SYSTEM
The 460 V-8 engines have a positive
closed-type crankcase ventilation system
recycling the crankcase vapors to the
intake manifold.
REMOVAL AND INSTALLATION
When installing nuts or bolts that
must be torqued (refer to torque
specifications), oil the threads with light-
weight engine oil. Do not oil threads that
require oil-resistant or water-resistant
sealer.
Refer to Part 21-01 for Cleaning,
Inspection and Test procedures.
ENGINE
The engine removal and installation
procedures are for the engine, without
the transmission attached. Remove or
disconnect Thermactor parts that will
interfere with removal or installation of
the engine.
Removal
1. Raise the hood and mask the edges of
the hood, fenders and cowl to protect
the paint. Place fender covers on
fenders.
2. Remove the hood.
3. Drain the cooling system at the
radiator and the cylinder block.
4. Disconnect the ground cable from the
battery. Remove the air cleaner and
intake duct assembly. Cover the
carburetor air horn with a clean cloth.
460 CID V-8 Engines
FIG. 1 3/4 Left Front View-460 CID Engine
5. Disconnect the radiator upper and
lower hoses at the engine. Disconnect
the transmission oil cooler lines at the
radiator.
6. Remove the fan shroud attaching
bolts.
7. Remove the cooling fan-to-water
pump hub attaching bolts. Remove
the cooling fan and the shroud.
8. Remove the radiator upper support
and the radiator.
9. If equipped with air conditioning,
purge the system of freon. Remove
the clamp bolt at the air conditioner
muffler support if so equipped and
position the refrigerant lines out of
the way.
Loosen the compressor adjustment
and remove the drive belt. Remove
the compressor support bracket-to-
water pump bolt. Remove the
compressor-to-mounting bracket
bolts. Remove the power steering
pump and position it to one side.
Disconnect the compressor clutch
wire and remove the compressor.
Remove the compressor mounting
bracket and idler pulley.
21-24-2
A2976-C
10. Disconnect the fuel inlet line at the
fuel pump. Plug or cap the line to
prevent fuel loss. Disconnect the fuel
return line.
11. Loosen the alternator adjusting arm
and mounting bolts. Remove the
drive belts and water pump pulley.
Remove the alternator and mounting
brackets and position out of way,
leaving the wires connected.
12. Disconnect the ground cable at the
right front corner of cylinder block.
Disconnect the heater hoses. Remove
the transmission fluid filler tube
attaching bolt from the right valve
rocker arm cover, and position the
transmission filler tube out of the
way.
13. Disconnect all vacuum lines at the
rear of intake manifold.
14. Disconnect the speed control at
carburetor if so equipped. Disconnect
the accelerator cable and secure out
of way.
15. Disconnect the engine wiring harness
at the multi-connector on dash.
21-24-3
16.Raise the vehicle on a hoist.
Disconnect the inlet pipes at exhaust
manifolds.
17. Disconnect the starter cable from
starter solenoid or starter. Remove
starter attaching bolts and remove
starter by moving starter assembly
forward, rotating it to turn solenoid
outward, then removing it toward
rear of vehicle.
18. Remove access cover from converter
housing. Remove the flywheel to
converter attaching nuts, rotating the
flywheel as necessary. Remove the
converter-to-engine lower rear cover
plate attaching bolts.
19. Remove the nuts attaching the front
support insulators to the underbody
crossmember.
20. Hold the transmission in position
with a support tool.
21. Lower the vehicle on hoist. Remove
converter housing to cylinder block
upper attaching bolts (left side).
Disconnect the coil wire, and remove
the coil and bracket assembly from
the intake manifold.
22. Attach an engine lifting sling, Tool
No. T53L-3OO-A, hoist and lifting
brackets to intake manifolds.
Carefully remove engine from the
vehicle. Install the engine on a work
stand and remove the lifting sling.
Installation
1. Attach engine lifting sling, Tool No.
T53L-3OO-A, hoist and lifting
brackets to intake manifolds. Remove
engine from work stand.
2. Carefully lower engine into vehicle.
With engine supported by lifting
sling, align converter-to-flywheel
mounting studs with flywheel.
Position the engine support insulator
heat shields, then lower the engine,
guiding the front support insulator
studs into holes in underbody
crossmember.
3. Install the converter housing- to-
cylinder block upper attaching bolts
and torque to specification. Remove
the transmission support. Position the
hoist out of the way and remove
lifting sling.
4. Raise the vehicle on a hoist and install
the front support insulator stud nuts.
Torque them to specification. Install
the converter housing-to-engine rear
cover plate lower attaching bolts and
torque them to specification.
5. Install the nuts on converter-to-
flywheel mounting studs and torque
nuts to specification. Install converter
access plate.
6. Install the starter and connect starter
cable.
7. With gaskets in place on inlet pipes,
guide pipe ends into exhaust manifold
460 CID V-8 Engines
flanges. Install nuts on flange studs
and torque to specifications.
8. Lower the vehicle and connect
accelerator cable. Connect engine
wiring harness at multi-connector at
dash.
9. Connect all vacuum lines at rear of
intake manifold. Connect speed
control chain, if so equipped, to
carburetor linkage.
10.Connect h e a t e r h o s e s . Set
transmission filler tube in position
and tighten bolt at right valve rocker
arm cover to secure tube.
11. Connect ground wire to right front
corner of cylinder block. Install
alternator and mounting brackets.
12. If equipped with air conditioning,
install the compressor upper
mounting bracket to left cylinder
head. Position the air conditioner
muffler bracket and power steering
reservoir or pump on studs in left
cylinder head. Install compressor to
upper mounting bracket and attach
compressor support bracket to water
pump. Connect compressor clutch
wire bullet connector.
13. Connect the fuel inlet line and fuel
return line to the fuel pump. Install
the coil to intake manifold and
connect wires.
14. If equipped with air conditioning,
connect the service valves to
compressor and install air conditioner
muffler.
15. Set radiator in position and install the
radiator upper support. Install the
radiator upper and lower hoses.
Connect the oil cooler lines to
radiator.
16. Fit the water pump pulley in position.
Install all drive belts.
17. Place fan assembly inside radiator
shroud and position the shroud.
Install fan assembly to water pump
hub and torque bolts to specification.
Install the shroud attaching bolts.
18. Fill the crankcase, cooling system and
power steering reservoir to the correct
level with specified lubricants. Adjust
the tension of drive belts to
specification.
19. Connect the distributor and vacuum
lines. Install the air cleaner and intake
duct, crankcase ventilation system air
supply hose and oil filler cap.
20. Connect the battery. Start the engine
and check for leaks.
21. When engine temperature stabilizes,
adjust the ignition timing, engine idle
speed and mixture, and transmission
linkage, as required.
22. If equipped with air conditioning,
recharge the system
23. Install the hood. Remove the masking
tape and fender covers.
21-24-3
ENGINE FRONT SUPPORTS
Front supports (Figs. 2 through 4) are
located on each side of the cylinder block.
Following procedures apply to either
support.
Ford and Mercury
Removal
1. Block rear wheels and set parking
brake. Raise front of vehicle with a
floor jack and install safety stands.
2. Place a jack under the front area of
the oil pan. Position a wood block
between the jack and pan. Raise the
jack just enough to support the
engine.
3. Remove the nut and through bolt that
attaches the front support insulator to
the lower support bracket (Fig. 2).
385758-S2
DIRECTION OF
BOLT OPTIONAL
6043 ASSY. R.H.
6A069 ASSY. L.H
385637-S2
8 REQ'D.
25-40 FT-LB
DIRECTION OF
BOLT OPTIONAL
A;?979G
FIG. 2 Engine Front Support Ford
and Mercury
4. Remove the bolts attaching support
insulator and heat shield to the
cylinder block. Replace the insulator
on one side before proceeding to other
support insulator.
Installation
1. Position the support insulator and the
heat shield to cylinder block (Fig. 2).
Install and torque the attaching bolts
to specifications.
2. Lower the engine, guiding front
support insulator through bolt holes
into alignment with support bracket
and install the through bolt. Remove
the floor jack and wood block.
T o r q u e t h e t h r o u g h bolt to
specifications.
3. Raise the front of the vehicle and
remove the safety stands. Lower the
vehicle.
4. Remove the rear wheel blocks and
release the parking brake.
21-24-4
Lincoln Continental
Removal
1. Block rear wheels and set parking
brake. Raise front of vehicle and
install safety stands.
2. Remove through bolts and nuts
which attach insulator assembly to
number 2 crossmember.
SHIELD 6C050
(LEFT SIDE ONLY)
385849-S2
NO. 2
35-50 FT-LB CROSSMEMBER REF.
•NOTE: WHENEVER SELF-LOCKING
BOLTS AND NUTS ARE RE-
MOVED, THEY MUST BE RE-
PLACED WITH NEW SELF-
LOCKING BOLTS AND NUTS. A3281-D
FIG. 3 Engine Front Support-Lincoln
Continental
3. Place a wood block on a jack under
the front end of the oil pan. Raise the
engine high enough (approximately 1-
1/2 inches) to provide clearance to
remove the support and not damage
the radiator.
4. Remove the bolts that attach the
support bracket to the cylinder block
(Fig. 3).
5. Remove the bracket-to-insulator
attaching bolt and separate the units.
Installation
1. Position the support bracket on the
support insulator (Fig. 3) and install
and torque the attaching nut to
specifications.
2. Install insulator and bracket assembly
to engine block with three attaching
bolts and torque to specification.
3. Lower the engine.
4. Install and torque the through bolt
attaching insulator to the number 2
crossmember.
LTD II, Cougar, Thunderbird and
Continental Mark V
Removal
1. Remove the fan shroud attaching
screws.
2. Remove the through bolt and nut
attaching the insulator to the frame
crossmember.
3. Raise the engine using a floor jack
and block of wood under the oil pan.
4. Remove the insulator to upper
bracket attaching nuts (Fig. 4).
5. If required, the upper bracket can
now be removed by removal of the
460 CID V-8 Engines
UPPER BRACKET ASSEMBLY
(6A069-L.H.)
(6043-RiH.)
HEAT SHIELD ASSEMBLY
(6D037 L.H.)
(6D036 R.H.)
THROUGH BOLT
DIRECTION OF BOLT
OPTIONAL
FIG. 4 Engine Front Support-Continental Mark V
three screws holding the bracket to
the cylinder block. Whenever self-
locking mounting bolts and nuts are
removed, they must be replaced with
new self-locking bolts and nuts.
Installation
1. Position the upper bracket to the
cylinder block, install the three
attaching screws and torque to
specification.
2. Position the heat shield and insulator
on the upper bracket studs and over
the frame crossmember. Install the
two attaching nuts and torque to
specification.
3. Lower the engine until the locator
stud in the insulator engages the
l o c a t o r h o l e in t h e frame
crossmember.
4. Install the through bolt and locking
nut. Torque the locking nut to
specification.
5. Remove jack and wood block. Install
fan shroud attaching screws and
torque to specification.
ENGINE REAR SUPPORT
Ford and Mercury
Removal
1. Remove the insulator assembly to
crossmember attaching bolt(s) and
nut(s) (Fig. 5).
2. Raise the transmission with a jack to
obtain clearance at the transmission
extension housing. Then, remove the
retainer and insulator assembly
mounting bolts and washers. Remove
the insulator assembly and the
retainer.
Installation
1. Position the insulator assembly and
retainer; then install the mounting
bolts and lock washers. Torque the
bolts to specification.
21-24-4
SUPPORT INSULATOR ASSEMBLY
(6B032 L.H.)
(6038 R.H.)
382400-S2*
35-50 FT-LB
•NOTE:
WHENEVER SELF-LOCKING
BOLTS AND NUTS ARE RE-
MOVED, THEY MUST BE RE-
PLACED WITH NEW SELF-
LOCKING BOLTS AND NUTS.
#2 CROSSMEMBER A3499-E
INSULATOR
INSULATOR RETAINER
6054
FRAMEX
CROSSMEMBER
"*3T38-C
FIG. 5 Engine Rear Support Ford and
Mercury
2. Lower the transmission. Install the
insulator assembly to crossmember
attaching bolt(s) and nut(s). Torque
them to specification.
Continental Mark V
Removal
1. Remove the insulator assembly to
crossmember attaching nuts (Fig. 6).
2. Raise the transmission with a jack to
obtain clearance and remove the
insulator to extension housing
attaching bolts and remove the
insulator assembly.
Installation
1. Position the insulator assembly and
install the insulator to extension
h o u s i n g b o l t s . T o r q u e to
specification.
2. Lower the transmission so that the
insulator studs and locators are
properly seated on the crossmember
and install the attaching nuts. Torque
to specification.
 21-24-5
CRANKCASE VENTILATION
SYSTEM
Removal
1. Remove ventilation system air intake
hose from air cleaner. Remove the
hose, elbow and grommet from the
left rocker arm cover.
2. Remove air cleaner and intake duct
assembly.
3. Disconnect the inlet vent hose and
tube from the carburetor.
Unlock the oil filler cap from the
left rocker arm cover and remove the
inlet hose and oil filler cap as an
assembly.
4. Pull regulator valve out of mounting
grommet in right valve rocker arm
cover.
Installation
1. Install the oil filler cap. Insert the
regulator (PCV) valve into the right
rocker arm cover grommet.
2. Position the inlet vent hose and tube
and connect to carburetor and
regulator valve.
3. Install air cleaner and intake duct
assembly.
4. Install ventilation system air intake
hose and elbow to air cleaner and oil
filler cap.
VALVE ROCKER ARM COVER
AND ROCKER ARM
The valve rocker arm and attaching
parts are shown in Fig. 7.
Removal
1. Remove the air cleaner and intake
duct assembly.
If a right cylinder head rocker arm
is to be removed, remove the
crankcase ventilation regulator valve
from the valve rocker arm cover.
2. Disconnect the spark plug wires from
the spark plugs by grasping, twisting
and pulling the moulded cap only
with Tool T74P-6666-A. Remove the
With No. 1 at TDC at end of compression stroke
make a chalk mark at points 2 and 3 approximately
90 degrees apart.
FIG. 8 Position of Crankshaft for Installing Valve Rocker Arms
460 CID V-8 Engines 21-24-5
wires from the bracket on the valve 4. Position the cover(s) on the cylinder
rocker arm cover(s) and position the head(s). Make sure the gasket seats
wires out of the way. evenly all around the head. Install the
3. Remove the valve rocker arm bolts. The cover is tightened in two
cover(s).
4. Remove the valve rocker arm bolt, oil 386242S100*
deflector, fulcrum seat and rocker 20-30 FT-LB
arm. REAR SUPPORT
INSULATOR
Installation 6B002 ASSEMBLY
1. Apply Lubriplate or equivalent to the
top of the valve stems, the rocker arm
and fulcrum seats.
2. Position the No. 1 piston on TDC at
the end of the compression stroke in #3 CROSSMEMBER
position 1 in Fig. 8 and install the
rocker arm, fulcrum seat, oil deflector
and bolt on the following valves:
No. 1 Intake No. 1 Exhaust INSULATOR - 6 A 0 6 1
No. 7 Intake No. 5 Exhaust SPACER -386510-S2
No. 8 Intake No. 4 Exhaust "382802-S2
Position the crankshaft in position 20-35 FT-LB
2 in Fig. 9 and install the rocker arm, •NOTE: WHENEVER SELF-LOCKING
fulcrum seat, oil deflector and bolt on BOLTS AND NUTS ARE RE-
MOVED, THEY MUST BE RE-
the following valves: PLACED WITH SELF-LOCKING
No. 4 Intake No. 2 Exhaust BOLTS AND NUTS.
A2980-F
No. 5 Intake No. 6 Exhaust FIG. 6 Engine Rear Support-
Position the crankshaft in position Continental Mark V
3 in Fig. 9 and install the rocker arm,
fulcrum seat, oil deflector and bolt on
the following valves:
No. 2 Intake No. 3 Exhaust
No. 3 Intake No. 7 Exhaust
No. 6 Intake No. 8 Exhaust
Be sure that the fulcrum seat base
is inserted in its slot on the cylinder
head before tightening the fulcrum
bolts. Tighten the fulcrum bolt to
specification. Check the valve
clearance following the procedures in
Part 21-01 under Valve Clearance
Adjustment.
3. Clean the valve rocker arm cover(s)
and the cylinder head gasket
surface(s). Position the new gasket in
the cover, making sure that the gasket
tangs are secured in the notches in the A3236-B
cover. FIG. 7 Rocker Arm and Attaching
Parts
POSITION 1 - No. 1 at TDC at end of compression stroke.
POSITION 2 - Rotate the crankshaft 180 degrees (one -alf
revolution) clockwise from POSITION 1 .
POSITION 3 - Rotate the crankshaft 270 degrees (three
quarter revolution) clockwise from
POSITION 2.
A32:i4-C
21-24-6
s t e p s . T i g h t e n the bolts to
specification. Two minutes later,
tighten the bolts to the same
specification.
If the right cover was removed,
install the crankcase ventilation
regulator valve.
Install the air cleaner and intake
duct assembly.
5. Install the spark plug wires in the
bracket on the valve rocker arm
cover(s). Connect the spark plug
wires. See Part 23-01 for special
installation instructions.
6. Start the engine and check for leaks.
VALVE SPRING, RETAINER AND
STEM SEAL
Broken valve springs or defective
valve stem seals or retainers may be
replaced without removing the cylinder
head if valve or valve seat is not damaged.
Removal
1. If defective spring, retainer, or seal is
on right side of engine, remove air
cleaner and intake duct assembly.
Remove crankcase ventilation system
regulator valve and hose from right
valve rocker arm cover.
If spring, retainer, or seal to be
removed is on left side of engine,
remove oil filler cap and ventilation
hose from left valve rocker arm cover
and position out of way.
2. Remove valve rocker arm cover(s)
and applicable spark plug(s).
3. Remove valve rocker arm bolts, oil
deflectors, fulcrum seats, rocker
arms, and push rods from affected
cylinders).
4. Install air line with adapter in spark
plug hole. Turn on air supply to hold
valves closed.
5. Install Tool T70P-6049-A (Fig. 9)
and compress valve spring. Remove
retainer locks, spring retainer, and
spring. Remove and discard valve
stem seal (Fig. 10). If air pressure
fails to hold valve in closed position,
valve damage affecting sealing is
indicated. Remove and inspect
cylinder head assembly.
6. Wrap rubber band, tape or string
around end of valve stem to prevent
valve from dropping into cylinder
when air pressure in cylinder is shut
off if piston is at bottom of cylinder.
Shut off air pressure.
7. Inspect valve stem for damage.
Rotate valve, checking tip for
eccentric movement. Move valve up
and down through normal travel in
valve guide and check for binding. If
valve is damaged, cylinder head must
be removed for repairs.
460 CID V-8 Engines 21-24-6
Installation control valve and tag for proper
1. If valve proves satisfactory, hold installation. Remove distributor and
valve closed and turn on air pressure vacuum lines as an assembly.
in cylinder. 7. Disconnect accelerator linkage at
2. Lubricate the valve stems with heavy carburetor. Remove speed control
engine oil SE. Install new valve stem linkage bracket, if so equipped, from
seal (Fig. 11). Set spring and retainer intake manifold and disconnect it
over valve stem. Compress valve from the carburetor. Remove bolts
spring (Fig. 10) and install retainer holding accelerator cable bracket and
locks. Release spring and remove tool position cable out of way.
and stud nut. 8. Disconnect fuel line at carburetor.
3. Shut off air pressure and remove air 9. Disconnect wiring harness at coil
line and adapter. Install spark plug. terminals, engine temperature
4. Apply Lubriplate (or equivalent) to sending unit, oil pressure sending
tip of valve stem and each end of push unit, and other connections as
rod. Install push rod. Be sure lower necessary. Disengage wiring harness
end of push rod is seated in valve from three clips at left valve rocker
lifter. arm cover bolts, and position wiring
5. Lubricate fulcrum seats and sockets harness out of way.
with Lubriplate or equivalent. 10. Remove coil and bracket assembly.
6. Lubricate the push rod socket, Remove the Thermactor air supply
fulcrum seat and the valve pad of the tubes and check valve from the rear
rocker arm with heavy engine oil SE. of the cylinder heads.
7. Install the rocker arms using the 11. Remove attaching bolts and nuts and
procedure and sequence given under remove intake manifold and
Rocker Arm Installation. carburetor as an assembly (Fig. 11).
8. Clean gasket material from rocker If necessary to pry manifold away
arm cover and cylinder head and from cylinder heads, do not damage
install the rocker arm cover, using a gasket sealing surfaces.
new gasket.
If the right cover was removed,
install the crankcase ventilation
regulator valve.
9. Install the spark plug and connect the
spark plug wires. See Part 23-01 for
special installation instructions.
10. Install the air cleaner and intake duct
assembly.
11. Connect the automatic choke heat
chamber air inlet hose.
INTAKE MANIFOLD
Removal
1. Drain cooling system. Remove air
cleaner and intake duct assembly.
2. Disconnect radiator upper hose at
engine.
3. Disconnect heater hoses at intake
manifold and water pump, and
position out of way. Loosen water FIG. 9 Compressing Valve Spring—In
pump by-pass hose clamp at intake Chassis
manifold.
4. Disconnect positive crankcase
ventilation valve and hose at right
valve rocker arm cover. Disconnect
all vacuum lines at rear of intake
manifold and tag for proper
installation.
5. Disconnect wires at spark plugs by
twisting and pulling moulded caps
with Tool T74P-6666-A (see Part 23-
01). Remove wires from brackets on
valve rocker arm covers. Disconnect
coil high tension lead at coil and
remove distributor cap and wires as A3246-A
an assembly.
6. Disconnect all distributor vacuum FIG. 10 Removing or Installing Valve
lines at carburetor and vacuum Stem Seal
21-24-7 460 CID V-8 Engines 21-24-7

A2986-B
FIG. 11 Removing or Installing Intake
Manifold
12. Remove and discard intake manifold
gaskets and seals. (See Fig. 13.)
13.If manifold is to be further
disassembled (Fig. 14), remove
coolant outlet housing, gasket, and
thermostat. Remove automatic choke
heat tubes, vacuum hoses, carburetor,
spacer, EGR valve and gaskets.
Remove the thermostatic choke
heater tube. Remove engine
temperature sending unit. Discard all
gaskets.
Remove all gasket material from the
machined surfaces of the manifold. Clean
the manifold in a suitable solvent and dry
it with compressed air.
Inspect the manifold for cracks,
manifold seal for the full width of the
seal (Fig. 12).
NOTE: This sealer sets up within
15 minutes after application, so
assembly should proceed promptly.
Carefully lower intake manifold into
position over four (4) studs in ends of
cylinder heads. When intake manifold
is in place, run finger around seal area
to be sure seals are in place. If seals
have shifted, remove manifold and
reposition seals.
Install attaching bolts and nuts snugly
to manifold. Torque bolts and nuts in
sequence (Fig. 15) to specification to
CYLINDER
HEAD
C3A2-19526-A (OR -B) SEALER
APPROXIMATELY .12 BEAD
CYLINDER BLOCK
compress gaskets and seals Then
repeat sequence, torquing bolts and
nuts to same specification.
7. Install water pump by-pass hose to
intake manifold fitting.
8. Connect radiator upper hose to
coolant outlet housing.
9. Rotate crankshaft damper until No.
1 piston is at TDC at end of
compression stroke. Position
distributor in block with rotor at No.
1 firing position. Install hold-down
clamp.
10. Connect heater hose at intake
manifold and water pump.
C3AZ-19526-A (OR -B) SEALER
PRESS FIRMLY
INTO BLOCK
INTAKE MANIFOLD SEAL
A4073-A

damaged gasket surfaces, or other FIG. 12 Sealing Intake Manifold with RTV Sealer
damage that would make it unfit for
service. Replace all studs that are VALLEY COVER AND
stripped or otherwise damaged. Remove GASKET ASSEMBLY -
9D440
all filings and foreign matter that may
have entered the manifold as a result of
repairs.
Installation
1. If intake manifold assembly was
disassembled, install coolant outlet
housing, new gasket, and thermostat.
Install carburetor, EGR valve spacer,
new gaskets, automatic choke heat
tubes and thermostatic choke heater
tube. Coat threads with electrical
conductive sealer and install water INTAKE MANIF DLD
SEAL - 9 A 4 2 5
temperature sending unit.
2. Clean mating surfaces of intake
manifold, cylinder heads, and
cylinder block. Use a solvent such as
lacquer thinner, chlorothane, tri-
chlor-ethylene or similar degreasing
agent.
INTAKE MANIFOLD
3. Apply a 1/8 inch diameter bead of SEAL - 9 A 4 2 5
silicone rubber sealer in and along the
joint, the full width of the cylinder
block seal mounting surface (4
corners) as shown in Fig. 12.
4. Install the cylinder head to manifold
FRONT OF ENGINE
gaskets and valley baffle assembly
(Fig. 13), and the front and rear
intake manifold to cylinder block
seals. Apply a 1/16 inch bead of sealer
at the outer end of each intake FIG. 13 Installing Intake Manifold Gaskets and End Seals
21-24-8
11.Connect p o s i t i v e c r a n k c a s e
ventilation valve and hose to right
valve rocker arm c o v e r and
carburetor.
12. Connect fuel line to carburetor.
13. Install coil and bracket assembly to
intake manifold.
14. Fit wiring harness into two (2) clips
on left valve rocker arm cover and
connect to all terminals.
15. Position accelerator cable bracket on
manifold. Attach speed control
linkage bracket to intake manifold, if
so equipped. Install attaching bolts
and connect linkage to carburetor.
16. Connect the vacuum lines to their
respective ports on the intake
manifold. Install Thermactor air
supply tubes and check valve to rear
of cylinder heads.
17. Secure distributor cap to distributor.
Connect spark plug wires to spark
plugs and fit wires into brackets on
valve rocker arm covers. Connect coil
high tension lead to coil and attach
connector to coil terminals.
18. Fill the cooling system.
19. Fill the power steering reservoir.
20. Start engine. Check and adjust
ignition timing. Connect distributor
vacuum lines to their respective parts.
21. Operate engine at fast idle and check
for coolant and power steering fluid
leaks. Bleed power steering system
and refill reservoir as necessary.
Recheck coolant level and refill as
necessary.
22. Allow engine to reach normal
operating temperature, then retorque
the manifold attaching nuts and bolts
to specification.
23. Check and adjust carburetor (Group
24 and Group 29) as required. Install
air cleaner and intake duct assembly.
VALVE LIFTER
The following procedure is applicable
for removing one or all of the valve lifters.
Before replacing a hydraulic valve lifter
for noisy operation, be sure the noise is
not caused by improper valve clearance
or by worn rocker arms and/or push
rods.
Removal
1. Remove intake manifold and
carburetor as an assembly, following
instructions under Intake Manifold.
2. Remove the valve rocker arm covers.
Loosen the rocker arm bolts and turn
rocker arms to one side.
3. Remove the push rods in sequence.
4. Remove the valve lifters with a
magnet. Place them in a rack in
sequence. If the lifters are stuck in
bores, use plier-type Tool (T70P-
14151) to remove them. Rotate lifter
back and forth to loosen them from
gum or varnish deposits.
460 CID V-8 Engines 21-24-8
COOLANT OUTLET
HOUSING-8594
r
WATFR TEMPERATURE
SENDING UNIT-10884
A2944E
FIG. 14 Intake Manifold Disassembled
Refer to Part 21-01 for cleaning,
inspection and testing procedure. If
necessary to disassemble lifter(s), refer to
Valve Lifter Disassembly and Assembly
in this Part.
Installation
1. Clean the outside of valve lifters.
Lifters and bores are to be lubricated
with heavy oil SE before installation.
Install the lifters in their original
bores. Check any new lifter for free fit
in bore to which it is to be installed.
2. Install push rods in original positions.
Apply Lubriplate or equivalent to
valve stem tips and push rod ends.
3. Position the rocker arms over the
push rods and tighten the bolts
following the procedure under Valve A2932 B
Rocker Arm Installation. Adjust
valve clearance. FIG. 15 Intake Manifold Torque
4. Clean gasket material from rocker Sequence
arms and cylinder head and install
valve rocker arm covers. 3. Loosen air conditioning compressor
5. I n s t a l l i n t a k e m a n i f o l d and drive belt, if so equipped.
carburetor, following the instructions 4. Loosen alternator attaching bolts and
under Intake Manifold. remove bolt attaching alternator and
air pump bracket to right cylinder
CYLINDER HEADS head.
Removal 5. If equipped with air conditioning
1. Remove intake manifold and purge the system of freon. Remove
carburetor as an assembly, following nuts attaching compressor support
procedure under Intake Manifold bracket to water pump. Remove bolts
Removal. attaching compressor to upper
2. Disconnect muffler inlet pipe at mounting bracket and remove
exhaust manifold. compressor. Remove compressor
21-24-9
upper mounting bracket from
cylinder head.
If not e q u i p p e d with air
conditioning, remove bolts attaching
power steering reservoir bracket to
left cylinder head. Position reservoir
and bracket out of way.
6. Remove valve rocker arm covers.
Remove rocker arm bolts, rocker
arms, oil deflectors, fulcrums and
push rods in sequence (Fig. 16) so
they can be installed in their original
positions.
FIG. 16 Removing Valve Push Rod
7. Remove cylinder head attaching
bolts. Lift cylinder heads and exhaust
manifolds as assemblies from cylinder
block with a hoist. If necessary to
loosen cylinder head gasket seal, pry
at forward corners of cylinder heads
against casting bosses provided on
cylinder block. Do not damage
machined surfaces of head or block.
Discard cylinder head gasket.
8. If disassembly or machining of
cylinder head is required, remove
exhaust manifold.
Installation
1. Clean cylinder head, intake manifold,
valve rocker arm cover, and cylinder
block gasket surfaces. If cylinder head
was removed for cylinder head gasket
replacement, check flatness of
cylinder head and block gasket
surfaces. If exhaust manifold was
removed, coat cylinder head and
manifold port areas with film of
graphite grease and install manifold
to cylinder head.
2. Place two (2) long cylinder head
attaching bolts in two rear lower bolt
holes of left cylinder head. Place a
long cylinder head attaching bolt in
rear lower bolt hole of right cylinder
head. Use rubber bands to retain bolts
in position until cylinder heads are
installed.
3. Position new cylinder head gaskets on
block over dowels. Do not apply
sealer to head gasket surfaces. Place
cylinder heads on block, guiding
460 CID V-8 Engines
exhaust manifold studs into inlet pipe
connections. Install remaining
attaching bolts (longer bolts in lower
row of bolt holes). Tighten all
cylinder head attaching bolts in
sequence (Fig. 17) to specification.
When this procedure is used, it is
not necessary to retorque bolts
after extended operation.
FIG. 17 Cylinder Head Bolt Torque
Sequence
4. Clean and inspect push rods, one at
a time. Clean the oil passage in the
push rods with a suitable solvent, and
blow out with compressed air.
5. Install push rods in original positions.
Apply Lubriplate or equivalent to
valve stem tips and push rod ends.
6. Lubricate and install the rocker arms
following the procedure under Valve
Rocker Arm installation. Be sure
lower ends of push rods remain seated
in valve lifters.
7. Torque catalyst or muffler inlet pipe
stud nuts to specification.
8. Install intake manifold and
carburetor assembly, following
procedure under Intake Manifold
Installation.
9. If valve train components were
changed, perform valve clearance
adjustment, as detailed under Valve
Clearance adjustment (Part 21-01).
10. If equipped with air conditioning,
install compressor upper mounting
bracket to left cylinder head. Attach
compressor to upper mounting
bracket. Attach power steering
reservoir and compressor mounting
bracket to left cylinder head and
water pump. Connect hoses to
compressor.
If not e q u i p p e d with air
conditioning, attach power steering
reservoir bracket to left cylinder head.
11. Apply oil-resistant sealer to one side
of new valve rocker arm cover
gaskets. Lay cemented side of gaskets
in place in covers. Install covers.
12. Install bolt attaching alternator and
air pump bracket to right cylinder
head. Adjust alternator and air pump
drive belt tension to specification and
tighten attaching bolts.
13. If equipped with air conditioning,
adjust compressor drive belt tension
to specification and tighten attaching
bolts.
21-24-9
14. Fill radiator and power steering
reservoir, as necessary.
15. Start engine and check for leaks.
16. Check and adjust carburetor idle
speed and mixture (Group 24 and
Group 29) as required.
17. If equipped with air conditioning,
evacuate and charge system with
refrigerant (Group 36).
EXHAUST MANIFOLDS
Removal
1. If removing right exhaust manifold,
remove air cleaner and intake duct
assembly.
2. Disconnect exhaust manifold(s) at
catalyst or muffler inlet pipe( i).
3. Remove attaching bolts and washers,
and remove exhaust manifold(s) and
spark plug wire heat shields.
Inspect the cylinder head joining
flanges of the exhaust manifold(s) for
evidence of exhaust gas leaks.
Inspect the manifold(s) for cracks,
damaged gasket surfaces, or other
defects that would make them unfit
for service.
Installation
1. Clean mating surfaces of exhaust
manifold(s) and cylinder head(s).
Clean mounting flange of manifold(s)
catalyst and inlet pipe(s). Apply light
film of graphite grease to exhaust
manifold(s).
2. Position spark plug wire heat shields
and exhaust manifold(s) on cylinder
head(s). Install attaching bolts and
washers, starting at fourth bolt hole
from front of each manifold. Position
lifting bracket under bolts at third
exhaust port from front of engme. On
right exhaust manifold, install
shoulder stud(s) for air intake heat
shroud at first and sixth bolt holes
from front of manifold (Fig. 18).
Torque bolts to specification, working
from center of manifold to both ends.
3. Place new gasket(s) on resonator or
muffler inlet pipe(s). Position inlet
pipe(s) to manifold(s). Install
attaching nuts and torque to
specification.
4. Install air cleaner and intake duct
assembly, if removed.
5. Start engine and check for exhaust
leaks.
WATER PUMP
Removal
1. Drain cooling system and remove the
fan shroud attaching bolts.
2. Remove bolts attaching fan assembly
to water pump and remove shroud
and fan.
3. Loosen the power steering pump
attaching bolts.
4. If vehicle is equipped with air
conditioning, loosen compressor
21-24-10
attaching bolts. Remove the
compressor and power steering pump
drive belts.
5. Loosen the alternator pivot bolt.
Remove the two attaching bolts and
spacer. Remove the belt, then rotate
the bracket out of the way. Remove
the Thermactor air pump pulley and
air pump pivot bolt. Remove the air
pump adjusting bracket at the pump.
Remove the upper bracket attaching
bolt and swing bracket out of way.
6. Remove the three air conditioning
compressor attaching bolts and
secure the compressor to the left
fender brace.
7. Remove the power steering pump
attaching bolts and position the pump
to one side.
8. Remove the air conditioner bracket
attaching bolts and remove the
bracket.
9. Disconnect the radiator lower hose
and the heater hose from the water
pump.
10. Loosen the by-pass hose clamp at the
pump.
11. Remove remaining water pump
attaching bolts and remove water
pump from cylinder front cover.
Remove cover plate from water
pump. Discard gaskets.
Installation
1. Remove any gasket material from
water pump, cylinder front cover and
pump cover.
2. Position new gaskets coated on both
sides with water-resistant sealer.
3. Position water pump on cylinder
front cover and install only those
bolts not used to attach compressor
bracket (if installed) and alternator
bracket to water pump. Torque bolts
to specification. Install the
Thermactor parts removed or
loosened in Step 5 of Removal.
4. Connect radiator lower hose, heater
return hose, and by-pass hose to water
pump.
5. Position the air conditioner
compressor bracket and install and
torque the attaching bolts, stud and
nuts.
6. Secure the compressor to the bracket.
7. Position the power steering pump
bracket and install the three attaching
bolts and the nut.
8. Rotate the alternator bracket into
position and install the two attaching
bolts and spacer. Adjust the belt
tension and torque the attaching bolts
to specification.
9. Place the water pump pulley on the
pump. Position the power steering
and compressor drive belts on their
respective pulleys.
10. Lower the fan and radiator shroud
into position. Install the fan attaching
460 CID V-8 Engines
HEAT SHROUD
FIG. 18 Right Exhaust Manifold Installation
bolts and the shroud attaching bolts.
Torque the bolts to specification.
11. Adjust the power steering, alternator
and compressor and air pump belt
tension. Torque the compressor
attaching bolts to specification.
12. Fill the cooling system.
13. Start the engine and check for leaks.
CYLINDER FRONT COVER AND
TIMING CHAIN
Removal
Cylinder front cover oil seal
replacement is recommended whenever
the cover has been removed.
1. Drain cooling system and crankcase.
2. Remove screws attaching radiator
shroud to radiator. Remove bolts
attaching fan to water pump hub.
Remove fan and radiator shroud.
3. Disconnect radiator upper and lower
hoses at engine. Disconnect oil cooler
lines at radiator.
4. Remove radiator upper support and
remove radiator.
5. Loosen alternator and air pump
attaching bolts to relieve tension on
drive belt. If equipped with air
conditioning, loosen compressor idler
pulley. Remove drive belts and water
pump pulley.
6. Remove bolts attaching compressor
support, water pump and compressor,
and remove compressor support (if so
equipped).
7. Remove the crankshaft pulley from
the vibration damper.
8. Remove bolt and washer attaching
crankshaft damper. Remove
crankshaft damper with a puller (Fig.
19). Remove Woodruff key from
crankshaft.
9. Loosen by-pass hose at water pump.
Disconnect heater return tube at
water pump.
10. Disconnect and plug fuel inlet line at
fuel pump. Disconnect fuel line to
21-24-10
HEAT SHROUD
A2945-C
UNIVERSAL
PULLER
\
A3248-A
FIG. 19 Removing Crankshaft
Vibration Damper
carburetor at fuel pump. Remove fuel
pump.
11. Remove bolts attaching cylinder front
cover to cylinder block. Using a thin
blade knife, cut the oil pan seal flush
with cylinder block face prior to
separating the cover from the cylinder
block. Remove cylinder front cover
and water pump as an assembly.
Discard cylinder front cover gasket
and oil pan seal.
12. If new cylinder front cover is to be
installed, remove water pump and
install it and a new gasket on the new
front cover.
13. Check timing chain deflection by
rotating the crankshaft in a
counterclockwise direction to take up
the slack on the left side of the chain.
(All directions are as viewed from the
front of the engine.)
Establish a reference point on the
block and measure from this point to
the left side of the chain as shown in
Fig. 20.
21-24-11
Rotate the crankshaft in the
opposite direction to take up the slack
on the right side of the chain. Force
the left side of the chain out with the
fingers and measure the distance
between the reference point and the
chain. The deflection is the difference
between the two measurements.
If t h e d e f l e c t i o n exceeds
specification, replace the timing chain
and sprockets.
14. If the timing chain and sprocket are
to be removed, crank the engine until
timing marks on sprockets are as
shown in Fig. 21.
15. Remove camshaft sprocket cap screw,
washer, and two piece fuel pump
eccentric. Slide timing chain and
sprockets forward, and remove as an
assembly (Fig. 22).
Refer to Part 21-01 for cleaning
and inspection procedures.
Installation
1. Assemble the timing chain and
sprockets so sprocket timing marks
point directly toward each other as
shown in Fig. 21. Install the chain and
sprockets as an assembly to
crankshaft and camshaft. Verify
proper alignment of timing marks
after installation.
2. Install the fuel pump eccentric,
camshaft sprocket cap screw and
washer. Torque cap screw to
specification. Lubricate timing chain
with engine oil.
3. Coat the gasket surface of the oil pan
with sealer. Cut and position the
required sections of a new seal on the
oil pan. Apply sealer at the corners.
4. Coat the gasket surfaces of the block
and cover with sealer, and position a
new gasket on the block.
5. Position the cylinder front cover on
the cylinder block. Use care when
installing the cover to avoid seal
damage or possible mislocation.
6. Install the cylinder front cover to seal
alignment tool into proper position. It
may be necessary to force the cover
downward to slightly compress the
pan seal. This operation can be made
easier by using a suitable tool at the
attaching bolt hole locations.
7. Coat the threads of the attaching bolts
with oil-resistant sealer and install the
screws.
8. While pushing in on the alignment
tool (Fig. 23), torque the oil pan to
cover attaching bolts to specification.
Torque the cover to cylinder block
attaching screws. Remove alignment
tool.
9. Apply white lead and oil mixture to
front of crankshaft for damper
installation.
460 CID V-8 Engines 21-24-11
REFERENCE _ _ _ ^ _ _
POINT P j y J B B P A2952-E
c o
FIG. 20 Timing Chain Deflection
lO.Position crankshaft damper
Woodruff key and install crankshaft
damper (Fig. 24). Install damper
attaching screw and washer.
11. Install the crankshaft pulley.
12. Coat new fuel pump gasket with oil- FIG. 21 Aligning Timing Marks
resistant sealer and place on fuel
pump. Install fuel pump.
Connect fuel lines to fuel pump.
13. Install compressor support bracket to
compressor and water pump, if so
equipped.
14. Install water pump pulley and all
drive belts.
15. Position radiator to lower support,
position upper support to radiator,
and install attaching bolts. Connect
radiator upper and lower hoses at
engine. Connect oil cooler lines.
16. Place fan assembly inside radiator
shroud and set in position in vehicle.
Position the fan on the water pump
and install and torque the attaching
U . AI'954-A
bolts. Install screws attaching shroud
to radiator. FIG. 22 Removing or Installing Timing
Chain
17. Adjust belt tensions to specification.
Tighten alternator and air pump
attaching bolts and compressor idler
pulley, if so equipped, to specification.
18. Fill and bleed the cooling system. Fill
the crankcase to the correct level with
the recommended oil.
19. Run engine at fast idle and check for
coolant and oil leaks. Adjust ignition
timing.
FRONT OIL SEAL
Removal
Replacement of the front oil seal is
recommended whenever the cylinder
front cover is removed. TOOL-T61P-6019-B
1. Drive out the old seal with a pin or (6059- F)
punch. Clean the seal recess in the FIG. 23 Aligning Cylinder Front
cylinder front cover. Cover
21-24-12 460 CID V-8 Engines 21-24-12

Installation
1. Coat a new seal with grease. Install
the seal with Tool T68P-6700-A (Fig.
25). After installation, be sure seal
spring remains in proper position.
CAMSHAFT
The camshaft and related parts are
shown in Fig. 26.
Removal -T64T-6306-A
1. Remove timing chain and sprockets,
following procedure under Cylinder :
A2957-A Tool-T68P-6700-A .->" A2955-A
Front Cover and Timing Chain.
Check timing chain deflection before FIG. 24 Installing Crankshaft FIG. 25 Installing Front Oil Seal
removal.
Vibration Damper
2. Remove the intake manifold and
carburetor as an assembly, following
the instructions under Intake
Manifold.
6263-
3. Remove valve rocker arm covers. BEARING
Back off all rocker arm bolts, turn
rocker arms sideways, and remove the
push rods in sequence (Fig. 16).
4. Remove the valve lifters with a
magnet and place them in a rack in
sequence. If the lifters are stuck in
bores, use Tool (T70P-14151) to
remove them. Rotate the lifter back
and forth to loosen it from gum or
CAMSHAFT-6250
varnish deposits.
5. Remove the bolts attaching the air
conditioning condenser to the chassis,
if so equipped, and carefully move the
condenser to rest on the left fender.
Secure it in this position.
6. Remove the grille.
7. Remove the camshaft thrust plate
attaching bolts, and carefully remove THRUST PLATE-6269
the camshaft from the front of engine.
Do not damage the camshaft
bearings. TIMING CHAIN AND SPROCKET
Refer to Part 21-01 for cleaning 6268 6256
and inspection procedures.
Refer to Part 21-01 for repair
procedure. • TWO PIECE
FUEL PUMP ECCENTRIC-6287
Installation A2959-B
1. Oil the camshaft journals and apply
Lubriplate or equivalent to the cam FIG. 26 Camshaft and Related Parts
lobes. Carefully slide camshaft into
position. 6. Lubricate the lifters and lifter bores over push rods and tighten bolts
2. Install camshaft thrust plate. Check with heavy oil SE before installing following the procedure under Valve
camshaft end play, following them. Lubricate the push rod ends Rocker Arm Installation. Check
procedure in Part 21-01. If end play with Lubriplate or equivalent. Install valve clearance, as shown in Part 21-
is excessive, replace the camshaft the valve lifters and push rods in their 01.
thrust plate. original position.
3. Install timing chain, sprockets, and 7. Install intake manifold and 10. Clean the valve rocker arm covers
cylinder front cover as detailed under carburetor, following the procedure and cylinder head gasket surfaces.
Cylinder Front Cover and Timing under Intake Manifold. Apply oil-resistant sealer to one side
Chain. 8. Rotate the crankshaft damper until of the new cover gaskets. Lay the
4. Position the radiator in the vehicle No. 1 piston is at TDC at the end of cemented side of gaskets in place in
and install the radiator upper support compression stroke. Position the the covers.
to secure radiator. Connect the distributor in the block with the rotor 11. Position the covers on the cylinder
radiator lower hose and oil cooler at No. 1firingposition and points just heads and make sure that gaskets seat
lines. starting to open. Install the hold evenly. Install cover attaching bolts
5. Install the grille center support and down clamp. and torque to specification. Two
air conditioning condenser, if so 9. Apply Lubriplate or equivalent to minutes later, torque bolts to same
equipped. valve stem tips. Position rocker arms specification.
21-24-13
12. Connect the radiator upper hose.
Connect heater hose at intake
manifold and at water pump.
13. Connect the fuel line to carburetor.
14. Install the coil and bracket assembly
to intake manifold.
15. Install the accelerator linkage. Install
the speed control linkage, if so
equipped.
16. Engage engine wiring harness in clips
on left cylinder head and connect all
wire terminals. Connect engine
vacuum lines to their original outlets
on the fitting at rear of the intake
manifold. Connect positive crankcase
ventilation valve and hose to right
valve rocker arm cover.
17. Install the distributor cap and
connect the coil and spark plug wires.
See Part 23-01 for special installation
instructions.
18. Place the water pump pulley and
drive belts in position. Place the fan
assembly in the radiator shroud and
set in position. Position the fan
assembly to water pump hub and
install and torque the attaching
screws to specification. Install screws
attaching shroud to the radiator.
19. Adjust the tension of drive belts to
specifications and tighten attaching
screws.
20. Fill and bleed the cooling system and
power steering reservoir. Run engine
at fast idle and check for leaks.
21. Adjust the ignition timing and
connect distributor vacuum line.
22. Check and adjust the carburetor idle
speed and mixture as required after
engine temperature has stabilized.
Adjust transmission linkage, if
necessary. Install the air cleaner and
intake duct.
FLYWHEEL
Removal
1. Remove the transmission from
vehicle. Remove the mounting bolts
and remove flywheel from the
crankshaft.
Refer to Part 21-01, for inspection.
Installation
1. Install flywheel on crankshaft. Install
the mounting bolts and torque to
specifications.
2. Check flywheel runout (Fig. 27) and
ring gear runout following procedure
in Part 21-01.
3. Install transmission assembly in
vehicle.
CAMSHAFT REAR BEARING BORE
PLUG
Removal
1. Remove the transmission from the
vehicle as detailed in Group 17.
460 CID V-8 Engines
2. Remove flywheel and engine rear
cover plate, following procedure
under Flywheel Removal.
3. Replace the plug as detailed in Part
21-01.
Installation
1. Install the engine rear cover plate and
flywheel, following procedure under
Flywheel Installation.
2. Install the transmission as detailed in
Group 17.
OIL PAN
Continental Mark V
Removal
1. Disconnect the battery ground cable.
Disconnect the two transmission oil
cooler lines from the radiator.
2. Remove the radiator shroud
attaching bolts and position the
shroud over the fan.
3. Raise the vehicle on a hoist.
4. Drain the crankcase, then remove the
oil filter.
5. Remove end attachments of front
stabilizer bar and rotate ends of bar
down to raise center of bar.
6. Support the engine with a jack, then
remove the bolt that attaches each
engine support to insulator.
7. Remove the bolt that attaches the
transmission oil cooler line bracket to
the cylinder block.
8. Remove the two starter motor
attaching bolts.
9. Raise the engine high enough to
remove the engine support insulator
attaching bolts, then remove the right
insulator and heat shield. Position a
wood block 3 inches high between
each engine support bracket and
exhaust manifold. Lower the engine
to allow the blocks to support the
engine.
10. Remove the converter housing to
cylinder block support attaching bolts
and remove the brackets.
11. Remove the oil pan attaching bolts
and lower the pan to the No. 2
crossmember.
12. Move the transmission oil cooler lines
upward, then remove the pan.
Refer to Part 21-01 for cleaning
and inspection procedures. Check the
gasket surface for damage caused by
over-torqued bolts. Straighten the
surface as required to restore original
flatness.
Installation
1. Clean the gasket surfaces of the block
and oil pan. Coat the block gasket
surface and oil pan gasket surface
with oil-resistant sealer. Position the
oil pan gaskets on the cylinder block.
2. Position the oil pan front seal on the
cylinder front cover. Be sure that the
21-24-13
TOOL-4201-C
A 2966 A
FIG. 27 Checking Flywheel Runout
tabs on the seal are over the oil pan
gasket.
3. Position the oil pan rear sea) on the
rear main bearing cap. Be sure that
the tabs on the seals are over the oil
pan gasket.
4. Hold the oil pan in place agai nst the
block and install a bolt, fingertight, on
each side of the pan. Install the
remaining bolts. Torque the bolts
from the center outward in each
direction to specification.
5. Install the converter housing to
cylinder block supports and torque
the attaching bolts to specification.
6. Tighten the starting motor attaching
bolts to specification.
7. Raise the engine and remove the two
wood support blocks.
8. Install the engine support insulator
and heat shield on the right side of the
engine and torque the attaching bolts
to specification.
9. Lower the engine into place and
install and torque the engine support
bolts to specification.
10.Rotate front stabilizer bar into
position and attach ends to lower
control arms.
11. Clean the oil filter sealing surface and
install the filter.
12. Secure the transmission oil coder line
retaining bracket to the cylinder
block with the attaching bolt.
13. Lower the vehicle to the floor.
14. Position the radiator shroud and
install the attaching bolts.
15. Connect the transmission oil cooler
lines to the radiator.
16. Fill the crankcase to the proper level
with the recommended oil.
17. Fill the power steering reservoir to the
correct level with the specified
lubricant.
18. Connect the battery ground cable.
Start the engine and check for leaks
and correct as required.
21-24-14
Lincoln Continental
Removal
1. Disconnect the battery ground cable.
Disconnect the radiator shroud from
the radiator.
2. Raise the vehicle on a hoist and drain
the crankcase.
3. Remove the starter attaching bolts.
4. Place a floor jack under front of oil
pan, with a block of wood between
jack and pan. Raise the jack just high
enough to remove weight of engine
from the front supports. Remove the
through bolt from each support.
Remove the two forward bolts from
the right engine support insulator.
Loosen the rear bolt, then pivot the
insulator upward to gain access to the
converter support bracket attaching
bolts.
5. Install a one inch wood block under
each engine support bracket, then
remove the jack.
6. Remove the end attachments of the
front stabilizer bar and rotate ends of
bar down to raise the center of bar.
Remove the oil filter.
7. Remove the oil pan attaching bolts,
then remove the oil pan.
Refer to Part 21-01 for cleaning
and inspection procedures. Check the
gasket surface for damage caused by
over-torqued bolts. Straighten the
surface as required to restore original
flatness.
Installation
1. Clean the gasket surfaces of the block
and oil pan. Coat the block gasket
surface and oil pan gasket surface
with oil-resistant sealer. Position the
oil pan gaskets on the cylinder block.
2. Position the oil pan front seal on the
cylinder front cover. Be sure that the
tabs on the seal are over the oil pan
gasket.
3. Position the oil pan rear seal on the
rear main bearing cap. Be sure that
the tabs on the seal are over the oil
pan gasket.
4. Hold the oil pan in place against the
block and install a bolt,fingertight,on
each side of the pan. Install the
remaining bolts. Torque the bolts
from the center outward in each
direction to specification.
5. Clean the oil filter seal surface and
install the oil filter.
6. Rotate the front stabilizer bar into
position and attach the ends to lower
control arms.
7. Install and tighten the starter
attaching bolts.
8. Raise the engine slightly with a floor
jack and wood block against forward
edge of oil pan. Remove the wood
blocks from under the front support
insulators. Install the two insulator
460 CID V-8 Engines
attaching bolts on the right insulator.
T i g h t e n the t h r e e b o l t s to
specification. Lower the engine as
required to install the through bolts.
Torque the nuts and bolts to
specification.
9. Lower the vehicle on a hoist and
attach shroud to radiator. Connect
the battery ground cable.
10. Fill crankcase to proper level with the
specified oil. Start the engine and
check for leaks.
Ford and Mercury
Removal
1. Disconnect the battery ground cable.
Disconnect the radiator shroud from
the radiator, and position it over the
fan.
2. Raise the vehicle on a hoist and drain
the crankcase.
3. Remove the sway bar attaching bolts.
Remove the two bolts and bushings
that attach the sway bar to the lower
arms. Move the sway bar forward on
the struts.
4. Remove the through bolt from each
engine support. Placefloorjack under
the front edge of the oil pan, with
block of wood between jack and oil
pan. Raise the engine just enough to
insert 1-1/4 inch blocks of wood
between the insulators and brackets.
Remove the floor jack.
5. Remove the oil filter.
6. Remove the oil pan attaching bolts
and remove the pan. It may be
necessary to rotate the crankshaft to
provide clearance between the pan
and c r a n k s h a f t t h r o w s or
counterweights.
7. Refer to Part 21-01 for cleaning and
inspection procedures. Check the
gasket surface for damage caused by
over-torqued bolts. Straighten the
surface as required to restore original
flatness.
Installation
1. Clean the gasket surfaces of the block
and oil pan. Coat the block gasket
surface and the oil pan gasket surface
with oil-resistant sealer. Position the
oil pan gaskets on the cylinder block.
2. Position the oil pan front seal on the
cylinder front cover. Be sure that the
tabs on the seal are over the pan
gasket.
3. Position the oil pan rear seal on the
rear main bearing cap. Be sure that
the tabs on the seal are over the oil
pan gasket.
4. Hold the oil pan in place against the
block and install a bolt,fingertight,on
each side of the oil pan. Install the
remaining bolts. Torque the bolts
from the center outward in each
direction to specification.
21-24-14
5. Move the stabilizer bar into position
and install the attaching bolts. Rotate
the stabilizer bar into position and
attach the ends to the lower control
arms.
6. Clean the oil filter seal surface and
install a new oil filter.
7. Raise the engine slightly with a floor
jack and wood block against the
forward edge of the oil pan. Remove
the wood spacers from under the
front support insulators. Lower the
engine as required to install the
insulator through bolts. Remove the
jack, then torque the nuts to
specification.
8. Lower the vehicle on a hoist and
attach shroud to radiator. Connect
the battery ground cable.
9. Fill the crankcase to the proper level
with the recommended oil. Start the
engine and check for leaks.
OIL PUMP
Removal
1. Remove the oil pan, following the
procedure under Oil Pan Removal.
2. Remove the oil pump mounting bolts,
and remove the pump from the
cylinder block.
Installation
1. Prime the oil pump byfillingthe inlet
port with engine oil. Rotate the pump
shaft to distribute oil within the pump
body.
2. Install the distributor intermediate
shaft in the oil pump rotor shaft.
3. Insert the intermediate shaft into the
distributor shaft hex bore. Make
certain that the intermediate shaft is
properly seated. Do not force the
pump into position if it will not seat
readily. The intermediate shaft hex
may be misaligned with distributor
shaft. To a l i g n , r o t a t e the
intermediate shaft until it can be
seated. Secure the oil pump to
cylinder block and torque the screws
to specifications.
4. Install the oil pan and related parts,
following procedure under Oil Pan
Installation.
CRANKSHAFT REAR OIL SEAL
A split-lip type crankshaft rear oil
seal is used for replacement on all
engines. If replacement is necessary,
this type of seal must be used. The
complete seal can be replaced without
removing the crankshaft. Refer to
Part 21-01 for removal and installation
procedures.
MAIN BEARING
Main and connecting rod bearing
inserts are selective fits.
Selective fit bearings are available for
service in standard size, 0.001 and 0.002
 21-24-15 460 CID V-8 Engines
inch undersize. Undersize bearings, locking tang side of block and
(0.010, 0.020, 0.030 and 0.040 inch) partially install bearing so Tool 6331
which are not selective fit, are available can be inserted in oil hole in
for use on crankshaft journals that have crankshaft (Fig. 29). With Tool 6331
been refinished. in oil hole, rotate the crankshaft in the
Removal opposite direction of engine rotation
1. Drain the crankcase. Remove the oil until the bearing seats itself. Remove
level dipstick. Remove the oil pan and the tool.
related parts, following the procedure 2. Fit the main bearings as detailed in
under Oil Pan Removal. Part 21-01 under Fitting Bearings
2. Remove the oil pump. with Plastigage.
3. Replace one bearing at a time, leaving 3. After the bearing has been fitted,
other bearings securely fastened. apply light coat of engine oil to
Remove the main bearing cap to journal and bearings. Install the
which new bearings are to be bearing cap. Torque the cap bolts to
installed. specification.
4. Insert the upper bearing removal tool 4. Repeat the procedure for remaining
(Tool 6331) in oil hole in crankshaft bearings that require replacement.
(Fig. 28). 5. If the rear main bearing is to be
5. Rotate the crankshaft in the direction replaced, remove the rear main
of engine rotation to force bearing out bearing cap. Remove and discard the
of block. rear oil seal.
6. Clean the crankshaft journals. 6. Clean rear journal oil seal groove and
Inspect journals and thrust faces mating surfaces of block and rear
(thrust bearing) for nicks, burrs or main bearing cap.
bearing pickup that would cause 7. Install the new seal.
premature bearing wear. 8. Refer to Part 21-01 for procedure
Installation used in sealing the rear main bearing
1. To install upper main bearing, place cap. After sealing, install the rear
plain end of bearing over shaft on main bearing cap and torque cap bolts
to specification.
9. If thrust bearing cap (No. 3 main
bearing) has been removed, install as
follows:
Install the thrust bearing cap with
bolts finger-tight. Pry the crankshaft
forward against the thrust surface of
upper half of bearing (Fig. 29). Hold
the crankshaft forward and pry thrust
bearing cap to rear. This aligns thrust
surfaces of both halves of bearing.
Retain forward pressure on
crankshaft. Torque cap bolts to
Tool-6331-E I BEARING INSERT
specification.
CRANKSHAFT JOURNAL A2962-A
10. Clean the oil pump inlet tube screen.
PIG. 28 Removing or Installing Upper Prime the oil pump byfillingthe inlet
Main Bearing Insert opening with oil and rotate the pump
1. PRY CRANKSHAFT
FORWARD AND HOLD
2. PRY CAP REARWARD
FIG. 29 Aligning Thrust Bearing
21-24-15
shaft until oil emerges from the outlet
opening. Install the oil pump
following procedure under 0:1 Pump
Installation.
11.Install the oil pan, following
procedure under Oil Pan Installation.
12. Fill the crankcase to the proper level
with the recommended oil. Start the
engine and check for oil pressure.
Operate the engine at fast idle and
check for oil leaks.
CONNECTING ROD BEARING
Removal
1. Follow steps 1 and 2 under Main
Bearing Removal.
2. Turn the crankshaft until connecting
rod to which new bearings a re to be
fitted is down. Remove t h e
connecting rod cap. Remove the
bearing inserts from rod and cap.
3. Be sure the bearing inserts and
bearing bore in connecting rod and
cap are clean. Foreign material under
inserts will distort bearing and cause
a failure.
4. Clean the crankshaft journal When
replacing standard bearings with new
bearings, it is good practice tofitthe
bearing to minimum specified
clearance.
Installation
1. Fit connecting rod bearings as
detailed in Part 21-01 under Fitting
Bearings with Plastigage.
2. Install the bearing inserts in the
connecting rod and cap with tangs in
the slots provided.
3. Pull the connecting rod assembly
down firmly on the crankshaft
journal.
4. Apply a light coat of engine oil to the
journal and bearings. Install the
connecting rod cap. Be sure the
connecting rod bolt heads are
properly seated in the connecting rod.
Torque the nuts to specification.
3. TORQUE CAP ESOLTS
WHILE HOLDING
CRANKSHAFT t:0RWARD
A2964-A
21-24-16
5. Repeat the procedure for the
remaining connecting rods that
require new bearings.
6. To complete installation, follow
instructions under Main Bearing
Installation.
Refer to Part 21-01 for cleaning
and inspection procedures.
PISTONS AND CONNECTING
RODS
1. Drain the cooling system and
crankcase. Remove the intake
manifold, cylinder heads, oil pan and
oil pump, following procedures in this
section.
2. Remove any ridge and/or deposits
from upper end of cylinder bores as
follows:
Turn the crankshaft until the
piston to be removed is at bottom of
its travel. Place a cloth on top of the
piston to collect cuttings. Remove any
ridge and/or deposits from the upper
end of the cylinder bore. Remove the
cylinder ridge with a ridge cutter.
Follow instructions furnished by tool
manufacturer. Never cut into ring
travel area in excess of 1/32 inch
when removing ridges. Repeat the
procedure at the remaining cylinders.
3. Make sure that all connecting rod
caps are marked so they can be
installed in their original positions.
4. Turn the crankshaft until the
connecting rod being removed is
down.
5. Remove the connecting rod nuts and
cap.
6. Push the connecting rod and piston
assembly out through the top of the
cylinder with the handle end of a
hammer. Avoid damage to the
crankshaft journal or cylinder wall
when removing the piston and rod.
7. Remove the bearing inserts from the
connecting rod and cap.
8. Install the cap on the connecting rod
from which it was removed.
Installation
1. If new piston rings are to be installed,
remove the cylinder wall glaze.
Follow instructions as detailed in Part
21-01.
2. Oil the piston rings, pistons and
cylinder walls with light engine oil.
Be sure to install pistons in the same
cylinders from which they were
removed or to which they were fitted.
Connecting rod and bearing caps are
numbered from 1 to 4 in the right
bank, and 5 to 8 in the left bank,
beginning at the front of engine.
Numbers on the connecting rod and
bearing cap must be on the same side
when installed in the cylinder bore. If
a connecting rod is ever transposed
460 CID V-8 Engines
from one block or cylinder to another,
new bearings should be fitted and the
connecting rod should be numbered to
correspond with the new cylinder
number.
3. Make sure that ring gaps are properly
spaced around circumference or
piston (Fig. 30).
OIL RING SPACER
OIL RING (A > OIL RING
SEGMENT t^-_ SEGMENT
COMPRESSION RING
COMPRESSION RING
FRONT OF ENGINE A2811-A
FIG. 30 Piston Ring Spacing
4. Install piston ring compressor on
piston and push in with hammer
handle until it is slightly below top of
cylinder (Fig. 31). Be sure to guide
connecting rods while tapping them
into position to avoid damaging
crankshaft journals. Install piston
with indentation notch in piston head
toward front of engine.
A2965-A
FIG. 31 Installing Piston Assembly
5. Check clearance of each bearing,
following procedure under Fitting
Connecting Rod Bearings, Part 21-
01.
6. After the bearings have been fitted,
apply a light coat of engine oil to the
journals and bearings.
7. Turn the crankshaft throw to the
bottom of the stroke. Push the piston
all the way down until the connecting
rod bearings seat on the crankshaft
journal.
21-24-16
8. Install the connecting rod cap. Be
sure connecting rod bolt heads are
properly seated in the connecting rod.
Torque the nuts to specifications.
9. After the piston and connecting rod
assemblies have been installed, check
the side clearance between the
connecting rods on each crankshaft
journal.
10. Disassemble, clean and assemble the
oil pump. Clean the oil pump inlet
tube screen, and oil pan and the block
gasket surfaces.
11. Prime the oil pump by filling the inlet
port with engine oil and rotating the
pump shaft to distribute oil within the
housing. Install the oil pump. Install
the oil pan, following the procedure
under Oil Pan Installation.
12. Install the cylinder heads, following
instructions under Cylinder Head
Installation.
13. Install the intake manifold, following
instructions under Intake Manifold
Installation.
14. Fill and bleed the cooling system. Fill
the crankcase to the correct level with
the specified engine oil.
15. Start the engine and adjust the
ignition timing. Connect the
distributor vacuum line.
16. Operate the engine at fast idle and
check for oil and coolant leaks. With
the engine temperatures stabilized,
adjust the engine curb idle speed and
mixture.
17. Install the air cleaner and intake duct
assembly.
CRANKSHAFT
To perform the following operation,
it is necessary to remove the engine and
install it on a work stand.
Crankshaft and related parts are
shown in Fig. 32.
Removal
1. Disconnect the wires from the spark
plugs. Remove the spark plugs to
allow easy rotation of crankshaft.
2. Remove the fuel pump and the oil
filter. Slide water pump by-pass hose
clamp toward the water pump.
3. Remove the crankshaft pulley from
the vibration damper.
4. Remove the cap screw and washer
from the end of the crankshaft. Install
a puller on the crankshaft vibration
damper (Fig. 19) and remove damper.
Remove Woodruff key.
5. Remove the cylinder front cover and
water pump as an assembly. Check
the timing chain deflection. Remove
the timing chain and sprockets as
detailed in Cylinder Front Cover and
Timing Chain Removal.
6. Invert the engine on a work stand.
Remove the flywheel and the engine
21-24-17
PULLEY-6312
FIG. 32 Crankshaft and Related Parts
rear cover plate. Remove the oil pan
and gasket. Remove the oil pump.
7. Make sure that all bearing caps (main
and connecting rod) are marked so
they can be installed in their original
locations.
Turn the crankshaft until the
connecting rod from which cap is
being removed is down, then remove
the bearing cap. Push the connecting
rod and piston assembly up out of the
cylinder. Repeat this procedure until
all connecting rod bearing caps are
removed.
8. Remove the main bearing caps.
9. Carefully lift the crankshaft out of the
block so thrust bearing surfaces are
not damaged. Handle the crankshaft
with care to avoid possible fracture or
damage to finished surfaces.
Refer Part 21-01 for cleaning and
inspection procedures. Clean the
crankshaft damper.
To refinish journals, dress minor
imperfections, etc., refer to Part 21-
01.
Installation
1. Remove the rear journal oil seal from
block and rear main bearing cap.
2. Remove the main bearing inserts
from the block and bearing caps.
3. Remove the connecting rod bearing
inserts from the connecting rods and
460 CID V-8 Engines
MAIN BEARING INSERTS
6333
4. If the crankshaft main bearing
journals have been refinished to a
definite undersize, install the correct
undersize bearing. Be sure that
bearing inserts and bearing bores are
clean. Foreign material under inserts
will distort the bearing and cause
failure.
5. Place the upper main bearing inserts
in the bores with tang in slot.
6. Install lower main bearing inserts in
bearing caps.
7. Clean the rear journal oil seal groove
and mating surfaces of the block and
rear main bearing cap.
8. Install a new rear main bearing oil
seal in the block and cap as detailed
in Part 21-01.
9. Carefully lower the crankshaft into
place. Be careful not to damage
bearing surfaces.
10. Check the clearance of each main
bearing as detailed in Part 21-01.
11. After bearings have been fitted, apply
light coat of engine oil to journals and
bearings. Install a new seal in the rear
main bearing cap and install the rear
main bearing cap. Install all bearing
caps except thrust bearing cap (No. 3
bearing). Be sure that main bearing
caps are installed in original
locations. Torque the bearing cap
bolts to specification.
12. Install the thrust bearing cap with
bolts fingertight.
21-24-17
FLYWHEEL-6375
REAR BEARING
CAP JOURNAL
SEAL-6701
REAR BEARING
CAP JOURNAL
S:AL-6701
" • >
MAIN BEARING CAPS
A2970-D
13. Pry the crankshaft forward against
thrust surface of upper half of bearing
(Fig. 29).
14. Hold crankshaft forward and pry
thrust bearing cap to rear. This aligns
thrust surfaces of both halves of
bearing.
15. Retain forward pressure on the
crankshaft. Tighten cap bolts to
specifications.
16. Force the crankshaft toward the rear
of engine.
17. Check the crankshaft end play (refer
to Part 21-01).
18. Install new bearing inserts in the
connecting rods and caps. Check
clearance of each bearing, following
procedure detailed in Part 21-01,
Fitting Bearings with Plastigage.
19. After the connecting rod bearings
have been fitted, apply light coat of
engine oil to journals and bearings.
20. Turn the crankshaft throw to bottom
of its stroke. Push the piston all the
way down until rod bearing seats on
the crankshaft journal.
21. Install the connecting rod cap. Be
sure that connecting rod bolt heads
are properly seated in connecting rod.
Torque nuts to specifications.
22. After piston and connecting rod
assemblies have been installed, check
side clearance between connecting
rods on each c o n n e c t i n g rod
crankshaft journal.
21-24-18
23. Install timing chain and sprockets,
cylinder front cover, and crankshaft
damper as detailed in Cylinder Front
Cover and Timing Chain Installation.
24. Install the engine rear cover plate.
Coat flywheel attaching bolt threads
with oil-resistant sealer. Position
flywheel on crankshaft flange. Install
and torque the bolts to specifications.
25. Clean the oil pan, oil pump and oil
pump screen. Prime the oil pump by
filling inlet port with engine oil and
rotating pump shaft to distribute oil
within housing. Install oil pump and
oil pan by following procedures under
Oil Pan and Oil Pump Installation.
26. Install the oil filter and fuel pump,
and connect the fuel lines.
27. Install the spark plugs and connect
the spark plug wires.
28. Install the engine in vehicle.
CAMSHAFT BEARINGS
Camshaft bearings are available
prefinished to size for standard and
undersize journal diameters.
Removal
1. Remove the camshaft, flywheel, and
crankshaft, following the appropriate
procedures in this part. Push pistons
to top of cylinders.
2. Remove the camshaft rear bearing
bore plug as detailed in Part 21-01.
Remove camshaft bearings (Fig. 33).
Installation
1. Select the proper size expanding collet
and back-up nut and assemble on
expanding mandrel. With the
expanding collet collapsed, install the
collet in the camshaft bearing, and
tighten back-up nut on expanding
mandrel until collet fits camshaft
bearing.
2. Assemble the puller screw and
extension (if necessary) as shown in
Fig. 35 and install on expanding
mandrel. Wrap a cloth around
threads of the puller screw to protect
the front bearing or journal. Tighten
pulling nut against the thrust bearing
and pulling plate to remove camshaft
bearing. Hold a wrench on the end of
puller screw to prevent it from
turning.
3. Repeat the procedure for each
bearing. To remove the front bearing,
install puller screw from rear of
cylinder block.
4. Position new bearings at bearing
bores, and press in place with the tool
460 CID V-8 Engines 21-24-18
DETAIL-1,-2 or -3
EXPANDING COLLET
DETAIL-l,-2or -3
THRUST BEARING
BACK-UP NUT
DETAIL
PULLING NUT
DETAIL-5
CAMSHAFT BEARING (LOOSE)
PULLER SCREW DETAIL-6 or -7
DETAIL-4 PULLER SCREW EXTENSION
PULLING PLATE Tool-T65L.625Q.A |
A2813-A
FIG. 33 Replacing Camshaft Bearing
shown in Fig. 33. Be sure to center the
pulling plate and puller screw to avoid
bearing damage. Failure to use
correct expanding collet can cause
severe bearing damage. Align oil
holes in bearings with oil holes in
cylinder block before pressing them
into block. Be sure front bearing is
installed specified distance below
front face of cylinder block (Fig. 34).
5. Install the core plug as detailed in
Part 21-01.
6. Install the camshaft, crankshaft, A2972-A
flywheel and related parts, following
appropriate procedures in this part, FIG. 34 Measuring Depth of
except do not check connecting rod Camshaft Front Bearing
and main bearing clearances.
FILTER ELEMENT
OIL FILTER / 6731
Removal
The oil filter assembly is shown in
Fig. 35.
1. Place a drip pan under the filter.
Unscrew the filter from the adapter ADAPTER FITTING
6890 A3704- B
fitting and clean the adapter recess.
Clean the oil filter gasket surface. FIG. 35 Oil Filter
Installation 2. Operate the engine at fast idle and
1. Coat the gasket on a new filter with check for oil leaks. If oil leaks are
oil. Place a new filter on the adapter evident, perform the necessary repairs
fitting. Hand tighten the filter until to correct the leakage. Check the oil
the gasket contacts the sealing surface level and fill the crankcase to the
then tighten 1/2 turn more. correct level.
21-24-19 460 CID V-8 Engines 21-24-19

DISASSEMBLY AND ASSEMBLY

When installing nuts or bolts that 2. Clean carbon from combustion PUSH ROD SOCKET
METERING VALVE
must be torqued, refer to Specifications. chambers before removing valves. CHECK VALVE
Oil the threads with light engine oil. Do 3. Compress valve springs (Fig. 37).
not oil threads that require oil-resistant Remove spring retainer locks and CHECK VAL\/E SPRING
or water-resistant sealer. release springs. Remove retainers, PLUNGER SPRING
springs, stem seals, and valves.
VALVE LIFTER Discard stem seals. BODY

Each lifter is a matched assembly. If Clean and inspect cylinder head(s)

parts of one are intermixed with those of
another, improper valve operation may
result. Disassemble and assemble each
lifter separately. Valve lifters should be
tested after assembly as described in Part
21-01. Keep the lifter assemblies in
proper sequence so they can be installed
in their original bores.
Disassembly
Hydraulic valve lifter assembly is
and related components, using PLUNGER
pertinent procedures in Part 21-01.
Refer to Part 21-01 for repair CHECK VALVE
RETAINER
procedures for cylinder heads and A2867-B
valves.
Assembly
Lubricate all valves, valve stems and FIG. 36 Hydraulic Valve Lifter
valve guides with heavy oil SE. The valve
tips are to have Lubriplate or equivalent VALVE SPRING
applied. The lubricant is to be applied COMPRESSOR

shown in Fig. 36. before installation.

1. Grasp the lock ring with needle nose
pliers to release it from the groove. It
may be necessary to depress the
plunger to fully release lock ring.
2. Remove the push rod cup, metering
valve (disc), plunger and spring.
3. Remove the plunger assembly and the
plunger spring. Carefully remove the
plunger spring, check valve retainer
spring, check valve retainer and check
valve disc from the plunger.
Refer to Part 21-01 for cleaning
and inspection procedures.
Assembly
1. Place the plunger upside down on a
clean work bench.
2. Place the check valve (disc or ball
check) in position over the oil hole on
the bottom of the plunger. Set the
check valve spring on top of the check
valve (disc or ball check).
3. Position the check valve retainer over
the check valve and spring then push
the retainer down into place on the
plunger.
4. Place the plunger spring and the
plunger (open end up) into lifter body.
5. Position the metering valve (disc) in
the plunger, and place push rod seat
in the plunger.
6. Depress the plunger and position the
1. Install each valve in port from which
it was removed or to which it was
fitted. Install new stem seal on each
valve.
2. Set valve spring and retainer over
valve stem. Compress spring (Fig. 37)
and install retainer locks.
3. With dividers, measure assembled
height of valve spring from surface of
spring pad on cylinder head to
underside of spring retainer (Fig. 38).
Check dividers with accurate scale. If
assembled height exceeds
specification, install spacer(s) below
s p r i n g to r e d u c e height to A 3145-A
recommended dimension. Reducing
assembled height below specification FIG. 37 Compressing Valve Spring—
can cause spring breakage and rapid On Bench
wear of cam lobe.
4. Coat the fulcrum seats and sockets
with Lubriplate or equivalent, Make
certain that the rocker arm bolts are
in serviceable condition before
installing them. Install rocker arms,
fulcrum seats, oil deflectors and bolts
as detailed under Valve Rocker Arm
Installation.
5. Install exhaust manifolds and spark
plugs. Refer to Part 21-01 for cleaning
and inspection procedures.
PISTON AND CONNECTING ROD
A3244-A

closed end of lock ring in the groove Disassembly

of the lifter body. With the plunger
still depressed, position the open ends
of lock ring in the groove. Release the
plunger, and then depress it again to
fully seat the lock ring.
7. Use a hydraulic valve lifter leak-down
tester to fill the lifter with test fluid.
CYLINDER HEAD
Disassembly
1. Remove rocker arm bolts, oil
deflectors, fulcrum seats and rocker
arms. Remove exhaust manifolds and
spark plugs.
1. Remove the bearing inserts from the
connecting rod and cap.
2. Mark the pistons to assure assembly
with same rod and installation in the
same cylinders from which they were
removed.
3. Using an arbor press and tool shown
in Fig. 39, press the piston pin from
the piston and connecting rod.
Remove the piston rings.
Refer to Part 21-01 for cleaning
and inspection procedures.
Refer to Part 21-01 for repair
procedures.
FIG. 38 Measuring Valve Spring
Assembled Height
Assembly
Check the fit of a new piston in the
cylinder bore before assembling piston
and piston pin to connecting rod. Piston
pin bore of connecting rod and diameter
of piston pin must be within specification.
1. Apply a light coat of engine oil to all
parts. Assemble the piston to the
connecting rod with the cylinder
number side of the connecting rod
and indentation notch in piston
positioned as shown in Fig. 40.
21-24-20 460 CID V-8 Engines 21-24-20

2. Start the piston pin in the piston and Press Ram RIGHT BANK LEFT BANK
the connecting rod. Using an arbor NOTCH TOWARD
press, press the piston pin through the FRONT OF ENGINE
piston and connecting rod until the
end of pin is 1/16-inch to 1/8-inch
below chamfer of the pin bore in the
piston.
3. Check the end gap of all piston rings.
End gap must be within specification.
Follow the instructions contained on
piston ring package and install the
piston rings.
4. Check the ring side clearance of NUMBERED SIDE OF ROD A2975-C
compression rings with a feeler gauge
inserted between the ring and the FIG. 40 Correct Piston and Rod
INSERT
lower land. Feeler gauge should slide TAPERED PILOT Positions
freely around the ring circumference IN PISTON PIN
without binding. Any wear will form FOR PIN REMOVAL
a step at the inner portion of the lower INSERT THIS END
IN PISTON HOLE
land. If the lower lands have high FOR INSTALLATION
steps, replace the piston.
5. Be sure the bearing inserts and Adaptor Detail A-2
bearing bore in the connecting rod
and cap are clean. Foreign material Tool-T6SL.6135-C
under the inserts will distort the Cup Detail A-7

bearing and cause failure. Install

bearing inserts in connecting rod and
cap with tangs fitting in slots
provided.
A 2967-B
OIL PUMP A2969-A

FIG. 39 Removing or Installing Piston FIG. 41 Removing Oil Pump Relief

1. Remove the four screws and washers
securing the oil pump cover to the oil
pump.
2. Remove the oil pump outer rotor and
rotor shaft assembly from the oil
pump housing.
3. Remove the cotter pin that secures
the relief valve plug in the oil pump
housing. To remove the plug, drill a
small hole and insert a self-tapping
screw in the relief valve plug. Use
pliers to remove plug from oil pump
housing (Fig. 41). Use care to prevent
the loss of the relief valve spring.
4. Remove the spring and relief valve
from the oil pump housing.
Refer to Part 21-01 for cleaning
and inspection procedures.
Assembly
1. Install the relief valve, spring and the
relief valve plug in the oil pump
housing. Press the plug inward until
it seats; then, install the cotter pin.
2. Install the outer rotor and rotor shaft
in the housing. Be sure that the
identification mark on the outer rotor
is on the same s i d e as the
identification mark on the inner
rotor. These parts are matched sets
and should only be replaced as an
assembly. Fill the housing with engine
oil for priming purposes.
Pin—Typical
CYLINDER ASSEMBLY
Disassembly
1. Mount the old engine in a work stand
and remove all the parts not furnished
with the new cylinder assembly,
following the procedures given in the
Removal and Installation Section of
this Part.
2. Remove the 4 cylinder head locating
dowels and the block drain plugs.
3. Remove the old cylinder assembly
from the work stand.
Assembly
1. Clean the gasket and seal surfaces of
all serviceable parts and assemblies.
2. Position the new cylinder assembly in
a work stand and install the cylinder
head locating dowels and block drain
plugs.
3. Transfer all serviceable parts removed
from the old cylinder assembly,
following the procedures given in the
Removal and Installation Section of
this Part.
4. Check all assembly clearances and
correct as necessary.
CYLINDER BLOCK
Before replacing a cylinder block,
determine if it is repairable. If so, make
Valve Plug
the necessary repairs, following the
procedures given in Part 21-01.
Disassembly
1. Mount the old engine in a work stand
and completely disassemble it,
following the procedures given in the
Removal and Installation Section of
this Part.
2. Remember to ridge-ream the cylinder
bores before removing piston
assemblies.
3. Remove the cylinder head locating
dowels and the block drain plugs.
Assembly
1. Clean the gasket and seal surfaces of
all serviceable parts and assemblies.
2. Position the new cylinder block in a
work stand and install the cylinder
head locating dowels and the block
drain plugs.
3. Transfer all serviceable parts removed
from the old cylinder block, following
the procedures given in the Removal
and Installation Section of this Part.
4. Check all assembly clearances and
correct as necessary.
21-24-21 460 CID V-8 Engines 21-24-21

SPECIFICATIONS-1977
GENERAL SPECIFICATIONS CAMSHAFT

LOBE LIFT
DISPLACEMENT, . , 460 CID Intake 0.253
NUMBER OF CYLINDERS/TYPE V8-DHV 0.278
Exhaust
BORE AND STROKE . . . . . . . . . . . 4 3 6 x 3.85 Allowable Lobe Lift Loss 0D05 Max.
FIRING ORDER ........... 15426378
THEORETICAL VALVE LIFT @ ZERO LASH
OIL PRESSURE (Hot @ 2000 RPM) 40-65 0.437
Intake
DRIVE BELT TENSION ....: ® Exhaust 0.481
COMPRESSION PRESSURE
® END PLAY 0.001-0.006
Service Limit 0.009
CYLINDER HEAD AND V A L V E TRAIN J O U R N A L T O BEARING CLEARANCE 0.001 0.003
Service Limit 0.006
COMBUSTION CHAMBER VOLUME (cc) 94.7 97.7
JOURNAL DIAMETER
VALVE GUIDE BORE DIAMETER ' ' ' ' ' " " ' 0.3433 0.3443
#1 2.12:8 2.1248
VALVE SEATS
#2 2.12:8 2.1248
Width - Intake 0.060 0.080
#3 2,1218 2.1248
W'dth - Exhaust 0.060 0.080
#4 2.1238 2.1248
Angle 45°
#5 2.12:8-2.1248
Runout Limit (T. I. R.Max.) 0.002
Runout Limit (T. 1. R. Max.) 0.005
VALVE ARRANGEMENT (Front to Rear) (RH) E-l-E-l-E -I-E-I
Out-Of-Round Limit (T. 1. R. Max.) 0.0005
(LH) I E I E 1 E l E
VALVE STEM-TO-GUIDE CLEARANCE BEARING INSIDE DIAMETER (ALL) 2 12f.8 2.1268
Intake 0.0010 0.0027 FRONT BEARING LOCATION (§) 0 1)40-0.060

Exhaust 0.00100.0027
Service Clearance 0.0055 CYLINOER BLOCK
VALVE HEAD DIAMETER
Intake 2.075 2.090 HEAD GASKET SURFACE FLATNESS ©
HEAD GASKET SURFACE FINISH (RMS) 60-150
Exhaust • 1.646-1.661
VALVE FACE RUNOUT LIMIT 0.002 Max. CYLINDER BORE
VALVE FACE ANGLE 44° Diameter 4.3600-4.3636
Surface (RMS) 18-38
V A L V E STEM DIAMETER (Std)
0.34160.3423 Out-Of-Round Limit 0.0015
Intake
0.3416-0.3423 Out-Of-Round Service Limit 0.005
Exhaust
Taper Service Limit 0.010
(0.003 Oversize)
0.34460.3453 TAPPET BORE DIAMETER 0.87S20.8767
Intake
0.3446-0.3453 MAIN BEARING BORE DIAMETER 3.19 ?2 3.1930
Exhaust
DISTRIBUTOR SHAFT BEARING BORE DIAMETER 0.51-0-0.5175
(0.015 Oversize)
Intake 0.3566-0.3573
0.35660.3573 CRANKSHAFT AND FLYWHEEL
Exhaust
(0,030 Oversize) 2.99H4 3.0002
MAIN BEARING JOURNAL DIAMETER
Intake 0.3716 0.3723
Out OfRound Limit 0.(1006 Max.
Exhaust 0.3716 0.3723
Taper Limit : 0.0001! per inch
VALVE SPRINGS 0.(102 Max.
Journal Runout Limit
Compression Pressure (Lb. @ Spec. Length) 76 84 @ 1.81
Runout Wear Limit 0.005
218-240 @ 1.33
Surface Finish (RMS) 12 Max.
Free Length (Approximate) 2.07
1-51/64-1-53/64 THRUST BEARING JOURNAL
Assembled Height
Length 2.«1 124-1.126
Service Limit
OutOf-Square Limit 5/64
®
(0.078)
CONNECTING ROD JOURNAL
Diameter 2.49 32 2.5000
ROCKER ARM
Runout Service Limit 0 )006 Max.
Ratio 1.73:1
0.015 Taper Limit 0.0006 Max.
PUSH ROD RUNOUT (T. I. R. Max.)
Surface Finish (RMS) 12 Max.
VALVE TAPPET, LIFTER OR ADJUSTER
0.8740 0.8745 MAIN 8EARING THRUST FACE
Diameter (Std)
Clearance To Bore 0.0007 0.0027 Surface Finish (RMS) 25 F r o t / 2 3 Rear
Service Limit Runout Limit (I 001 Max.
0.005
Hydraulic Leakdown Rate 5-50 Seconds © FLYWHEEL RING GEAR LATERAL RUNOUT (T. 1 R.)
Automatic Transmission 0.060
Collapsed Tappet Gap - Allowable 0.075 0.175
0.1000.150 CRANKSHAFT FREE END PLAY 0 )04-0.008
- Desired
Service Limit 0.012
CONNECTING ROD BEARINGS
Clearance To Crankshaft - Desired 0.0(080.0015
- Allowable 0.0C 08-0.0026
Bearing Wall Thickness (Std) 0 0.07 56 0.0761
MAIN BEARINGS
Clearance To Crankshaft - Desired 0.00)8-0.0015
- Allowable No. 1 = 0.0004-0.0021
All others = 0.0008-0.0026
Bearing Wall Thickness (Std) @ . . No. 1 (Upper) = 0.09500.0965
All others = 0.0f 35-0.0960
21-24-22 460 CID V-8 Engines 21-24-22

SPECIFICATIONS-1977
CONNECTING ROD, PISTON AND RINGS TORQUE SPECIFICATIONS - SPECIAL APPLICATION

CONNECTING ROD CAMSHAFT SPROCKET TO CAMSHAFT '40-45

Piston Pin Bore Diameter 1.0386 1.0393 CAMSHAFT THRUST PLATE TO BLOCK 9-12
Crankshaft Bearing Bore Diameter 2.6530 2.6522 CONNECTING ROD NUTS OR BOLTS 40-45
Out-OfRound Limit 0.0004 Max. CYLINDER FRONT COVER BOLTS 12-18
Taper Limit 0.0004 Max. CYLINDER HEAD BOLTS @
Length (Centerto-Center) 6.6035 6.6065 DAMPER OR PULLEY TO CRANKSHAFT 70-90
Alignment (Bore-to-Bore Max. Diff.) (8) DISTRIBUTOR VACUUM CONTROL VALVE 15 18
Twist • • • • • • 0.024 EGR VALVE TO CARBURETOR SPACER OR INT MANIFOLD . 12.18
Bend 0.012 FUEL PUMP TO CYLINDER BLOCK OR FRONT COVER 19-27
Side Clearance (Assembled to Crank) FLYWHEEL TO CRANKSHAFT 75-85
Standard 0.010 0.020 MAIN BEARING CAP BOLTS 95-105
Service Limit 0.023 MANIFOLD TO CYLINDER HEAD (Intake) 22-32 ®
PISTON MANIFOLD TO CYLINDER HEAD (Exhaust) 28-33
Diameter V9 OIL FILTER INSERT TO CYLINDER BLOCK 20-30
Coded Red 4.3585-4.3591 OIL FILTER TO BLOCK OR ADAPTER
Coded Blue 4.3597-4.3603 OIL INLET TUBE TO OIL PUMP ©
Press Fit
0.003 Oversize 4.3609 4.3615 OIL PAN DRAIN PLUG 15-25
Piston-ToBore Clearance • 0.00140.0022 OIL PAN TO CYLINDER BLOCK 5/16 = 9 11/1/4 = 7-9
Pin Bore Diameter 1.0402 1.0405 OIL PUMP TO CYLINDER BLOCK 22-32
Ring Groove Width PULLEY TO DAMPER (Bolt) 35-50
Compression (Top) 0.0805 0.0815 ROCKER ARM STUD OR BOLT TO CYLINDER HEAD 18-25
Compression (Bottom) 0.0805 0 0815 SPARK PLUG TO CYLINDER HEAD 10-15
Oil 0.188-0.189 VALVE ROCKER ARM COVER 5-6
PISTON PIN ALTERNATOR BRACKET TO CYLINDER BLOCK (Bolt) 35-50
Length 3.290 3.320 ALTERNATOR PIVOT BOLT 45-57
Diameter ALTERNATOR ADJUSTING ARM TO CYLINDER BLOCK 35-50
Standard 1.0398 1.0403 ALTERNATOR ADJUSTING ARM TO ALTERNATOR 24-40
0.001 Oversize 1.0410 1.0413 THERMACTOR PUMP BRACKET TO CYLINDER BLOCK . 35-50
Pin-To-Piston Clearance 0.00020.0004 THERMACTOR PUMP PIVOT BOLT 25-35
PinTo-Rod Clearance Interference Fit THERMACTOR PUMP ADJUSTING ARM TO PUMP 22-32
PISTON RINGS THERMACTOR PUMP ADJUSTING ARM TO CYLINDER BLOCK 29-37
Ring Width THERMACTOR PUMP PULLEY TO SHAFT 130-180 In-Lb
Compression (Top) 0.077-0.078 POWER STEERING PUMP PULLEY TO DAMPER (Bolt) 35-50
Compression (Bottom) 0.077 0.078 FAN TO WATER PUMP HUB (Bolt) 12-18
Side Clearance OIL COOLER/FILTER ADAPTER TO CYLINDER BLOCK 40-50
Compression (Top) 0.0025-0.0045 CARBURETOR MOUNTING NUTS 12 15
Compression (Bottom) 0.00250.0045 CARBURETOR MOUNTING STUD 15 Max
Service Limit 0.006 FUEL FILTER TO CARBURETOR 29-31
Oil Ring Snug Fit
Ring Gap TORQUE SPECIFICATIONS - Gemral Applications
Compression (Top) 0.0100.020 U.S. THREAD SIZES TORQUE
Compression (Bottom) 0.010-0.020
Oil Ring (Steel Rail) 0.015 0.055 1/4-20 6-9
5/16-18 12-18
LUBRICATING SYSTEM 5/16 18 14-20
3/8-16 22-32
OIL PUMP 3/8-24 27-38
Relief Valve Spring Tension (Lbs. at Spec. Length) 20.6-22.6 @ 2.49 7/16-14 40-55
Drive Shaft-To-Housing Bearing Clearance 0.0015-0.0030 7/16-20 40-60
Relief ValveTo-Bore Clearnace 0.0015-0.0030 55-80
1/213
Rotor Assembly End Clearance (Assembled) 0.004 Max.
Outer RaceRo-Housing Clearance 0.001 0.013
OIL CAPACITY (Quarts U. S.) 4®
FUEL PUMP

STATIC PRESSURE (P. S. I.) <£) 5.7-7.7

MINIMUM VOLUME FLOW ( j j ) @ 1 pt./20 sec
ECCENTRIC TOTAL LIFT (Inches; 0.890-0.910

CA1310E
21-24-23 460 CID V-8 Engines 21-24-23

SPECIFICATIONS-1977
METRIC THREAD SIZES TORQUE
Drive Belt Tension (Lbs.)
•VI* 0 6-9 Used
Newly Installed
M-8 14-21 Size (A)
M-10 28-40 UptoiOMin. Over 10 Min.
IV1" 1 t , , 50-71
1/4" 50-80 40-80 (B) 40-60 (B)
80-114
Exc. 1/4" 120-160 90-160(0 75-120 (D)
PIPE THREAD SIZES TORQUE
(A) Read tension immediately after belt is installed, before it stretches or seats n pulley
1/8 5-8 grooves.
1/4 12-18 (B) If less than 40 pounds, readjust to 40-60 pounds.
3/8 22-33 (C) If less than 90 pounds, readjust to 90-120 pounds.
1/2 25-35 (D) If less than 75 pounds, readjust to 90-120 pounds.
• All values are in ft.-lb. unless otherwise noted. (2) PSI If lowest cylinder must be 75% of highest.
• Oil threads with engine oil unless fasteners require sealers. (3) 10% Pressure loss @ specified length.
(4) To leak down 1/16", with 50 Ib. load and tappet filled with leakdown fluid.
(5) Distance front edge of bearing is below front face of block.
6 0.003 in any 6 inches; 0.006 overall.
7 For 0.002 Undersize, add 0.001 to standard.
(8) Pin and crank bearing bore must be parallel and in same vertical plane within the specified
total difference when measured at ends of an 8" bar, 4 " on each side of rod centerline.
(9) Measured at piston pin bore centerline; at 90° to the pin.
(g) Add 1 quart when changing filter.
(fl) With new filter in line and pump-to-tank return line pinched off.
(g) No orifice in test circuit smaller than 0.220" I. D.
@ Torque in sequence: Step 1 = 70-80; Step 2 - 100=110; Step 3 = 130-140.
<g) Retorque to specification after engine is hot.
<15) 1/2 turn after oiled gasket contacts sealing surface.

CA1310E 1
21-27-1 460 CID Police Interceptor Engine 21-27-1

PART
460 CID Police Interceptor Engine 21-27

SUBJECT PAGE SUBJECT PAGE

GENERAL INFORMATION 27-1 REMOVAL AND INSTALLATION (Cont'd.)
REMOVAL AND INSTALLATION Oil Filter Adapter , 27-2
Crankcase Oil Cooler 27-2
Oil Filter 27-2 SPECIFICATIONS 27-3

CN4045-A

GENERAL INFORMATION
The 460 CID Police Interceptor
Engine is basically the same as 460 CID procedures are common to both engines 1) used with all 460 C I D P o l i c e
engine covered in Part 21-24. All service except for the crankcase oil cooler (Fig. Interceptor Engine installations.

WATER OUTLET NIPPLE

18D266

WATER INLET
18D265

NOTE: USE TWO WRENCHES

TO TORQUE SWIVEL NUTS.
(BOTH ENDS) TO SPECIFICATION.

OIL COOLER OUTLET HOSF

8B451

I TORQUE TO SPECIFICATION \ TOP END

OIL FILTER INLET

WATER HOSE CLIP OIL FILTER ADAPTER
377494 •. Si 00 6881

WATER PUMP

WATER HOSE BRACKET

6B870
NOT USED W/AIR CONDITIONER ALIGN BLUE
ALIGN RED PAINT STRIPES PAINT STRIPES^-

TO OIL COOLER

OIL COOLER INLET HOSE

8N039
A3699-B

FIG. 1 Crankcase Oil Cooler Installation— Ford/Mercury With A/C

21-27-2
REMOVAL AND INSTALLATION
CRANKCASE OIL COOLER
Removal
1. Drain the cooling system.
2. Disconnect the water coolant lines
from the oil cooler (Fig. 1).
3. Disconnect the oil cooler inlet and
outlet hoses.
4. Remove the one nut and one
capscrew that attaches the front
support to the front strap.
5. Remove the two nuts that attach the
oil cooler to the rear strap.
6. Remove the two screws that attach
the front support bracket to the oil
cooler and remove the bracket.
Installation
1. Install the front support bracket on
the oil cooler with the top end as
shown in Fig. 1 to fit the contour of
the fender apron.
2. Position the oil cooler on the fender
apron and install the three attaching
nuts and one bolt.
3. Connect the oil inlet hose to the rear
of the cooler and torque it to
specification. Connect the oil outlet
hose to the front of the cooler and
torque it to specifications. Use two
wrenches when tightening. Be careful
460 CID Police Interceptor Engine
not to bend the hoses in a tight radius.
The teflon liner in the hose could be
crimped or twisted causing an oil leak
or obstruction if bent too sharply.
4. Connect the water inlet hose to the
upper fitting on the oil cooler and the
outlet hose to the lower fitting.
Tighten the hose clamps.
5. Fill the cooling system with the
specified coolant.
6. Check the oil level and fill to the
proper level with the specified oil.
7. Start the engine and bleed the cooling
system. Check for oil and coolant
leaks.
OIL FILTER
The oil filter is removed and installed
as detailed in Part 21-24.
OIL FILTER ADAPTER
Removal
1. Remove the oil filter.
2. Disconnect the oil cooler inlet and
outlet hoses from the oil filter adapter
(Fig. 1).
21-27-2
3. Remove the oil filter adapter
attaching bolt and gasket. Remove
the adapter and mounting gasket
from the cylinder block.
Installation
1. Clean all old gasket material from the
cylinder block.
2. Position a new mounting gasket with
the rib in the horizontal position and
the rib of the adapter in the vertical
position (Fig. 1).
3. Install a new gasket and the adapter
attaching bolt. Tighten the attaching
bolt to specification.
4. Connect the oil cooler inlet hose and
the outlet hose to the adapter making
sure that the paint mark on each hose
is matched with that on the adapter
and that they are in alignment.
5. Install a new oil filter element.
6. Fill the crankcase to the correct level
with the specified oil.
7. Start the engine and check for oil
leaks.
8. Recheck oil level after running and
add oil as necessary to obtain correct
level.
21-27-3 460 CID Police Interceptor Engine 21-27-3

SPECIFICATIONS-1977
GENERAL SPECIFICATIONS CAMSHAFT

LOBE LIFT
DISPLACEMENT (C. 1. D.) 460 CID Intake 0.289
NUMBER OF CYLINDERS TYPE V8-DHV
Exhaust 0.289
BOREANDSTROKE 4.36 x 3.85
Allowable Lobe Lift Loss 0.005 Max.
FiRING ORDER 15426378
THEORETICAL VALVE LIFT (9> ZERO LASH
OIL PRESSURE (Hot & 2000 RPM) 40 65
Intake 0.437 0.505
DRIVE BELT TENSION
COMPRESSION PRESSURE d) Exhaust 0.481 0.505
& END PLAY
Service Limit
0.001 0.006
0.009
CYLINDER HEAD AND VALVE TRAIN JOURNAL TO BEARING CLEARANCE 0.001 0.003
Service Limit 0.006
COMBUSTION CHAMBER VOLUME (cc) 94/97.7
JOURNAL DIAMETER
VALVE GUIDE BORE DIAMETER 0.3433 0.3443
#1 2.1238 2.1248
VALVE SEATS PI 2.1238 2.1248
Width - Intake 0.060 0.080
#3 2.1238 2.1248
Width - Exhaust 0.060 0.080
#4 2.1238 2.1248
Angle 45°
#5 2.1238 2.1248
Runout Limit (T. 1. R. Max.) 0.002
Runout Limit (T. 1. R.Max.) 0.005
VALVE ARRANGEMENT (Front to Rear) (RH) E l E l E l E l
Out Of Round Limit (T. 1. R. Max.) 0.0005
(LH) I E 1 E l - E l E
BEARING INS.IDE DIAMETER (ALL) 2.1258 2.1268
VALVE STEM To GUIDE CLEARANCE
FRONT BEARING LOCATION (§) . . . 0.040 0.060
Intake 0.00100.0027
Exhaust 0.0010 0.0027
CYLINDER BLOCK
Service Clearance 0.0055
VALVE HEAD DIAMETER
Intake 2 075 2.090
HEAD GASKET SURFACE FLATNESS ®
HEAD GASKET SURFACE FINISH (RMS) , 60-150
Exhaust 1.646 1.661 CYLINDER BORE
VALVE FACE RUNOUT LIMIT 0.002 Max Diameter 4.3600 4.3636
VALVE FACEANGLF 44° 18-38
Surface Finish (RMS)
VALVE STEM DIAMETER (Std) Out-Of Round Limit 00015
Intake 0.3416-0.3423 Out-Of-Round Service Limit 0.005
Exhaust 0 3416 0.3423 Taper Service Limit 0.010
(0.003 Oversize) TAPPET BORE DIAMETER 0 8752 08767
Intake 0.34460.3453 3 1922 3.1930
MAIN BEARING BORE DIAMETER
Exhaust 0.34460.3453 DISTRIBUTOR SHAFT BEARING BORE DIAMETER 0.51600.5175
(0.015 Oversize)
Intake 0356603573 CRANKSHAFT AND FLYWHEEL
Exhaust 0.3566 0.3573
10.030 Oversize) MAIN BEARING JOURNAL DIAMETER 2.9994 3.0002
Intake 0.37160.3723 Out-Of-Round Limit 0.0006 Max.
Exhaust 0.37160.3723 Taper Limit 0.0006 per inch
VALVE SPRINGS Journal Runout Limit 0.002 Max.
Compression Pressure (Lb. @ Spec. Length) . .. 87 97 @ 1.82/300 330 @ 1.32 Runout Service Limit 0.005
Free Length (Approximate) 2.07 Surface Finish (RMS) 12 Max.
Assembled Height 1 51/64-1 53/64
THRUST BEARING JOURNAL
Service Limit
(D Length 1.124 1.126
Out O< Square Limit 5/64 (0.078)
CONNECTING ROD JOURNAL
ROCKER ARM
Diameter 2.4992 2.5000
Ratm 1.73:1
Out Of Round Limit . 0.0006 Max.
PUSH ROD RUNOUT (T. 1. R Max ) 0.015
Taper Limit 0.0006 Max.
VALVE TAPPET. LIFTER OR ADJUSTER
Surface Finish (RMS) 12 Max.
Diameter (Std 1 0.8740 0.8745
MAIN BEARING THRUST FACE
Clearance To Bore 0 0007 0.0027
Surface Finish (RMS) 25 Front/23 Rear
Service Limit 0.005
Runout Limit 0.001 Max.
Hydraulic LeJkdown Rate 5-50 Seconds (4)
FLYWHEEL RING GEAR LATERAL RUNOUT (T 1. R.)
Collapsed Tappet Gap Allowable 0.075-0.175
Automatic Transmission 0060
Desired 0 100 0.150
CRANKSHAFT FREE END PLAY 0.004 0.008
Service Limit 0.012
CONNECTING ROD BEARINGS
Clearance To Cranshaft -Desired 0.0008 0.0015
-Allowable 0.0008 0.0028
Bearing Wall Thickness (Std) (?) 0.0756 0.0761
MAIN BEARINGS
Clearance To Crankshaft - Desired 0.0008 0.0015
-Allowable . . . No. 1 = 0.0004 0 0022
All others = 0.0009 0.0027
Bearing Wall Thickness (Std) (7) No 1 (Upper) = 0.09600.0965
All others = 0.0935 0 0960

CA1311 C
21-27-4 460 CID Police Interceptor Engine 21-27-4

SPECIFICATIONS-1977
CONNECTING ROD. PISTON AND RINGS FUEL PUMP

CONNECTING ROD STATIC PRESSURE (P. S. 1.) v11y 5.0-7.0

Piston Pin Bore Oiameter . 1.0386 1.0393 MINIMUM VOLUME FLOW ( i y ( i 2 ) 1 pint i 20 Sec
Crankshaft Bearing Bore Diameter 2.6530 2.6522 ECCENTRIC TOTAL LIFT (Inches). Of )0 0910
OutOf Round Limit 0.0004 Max.
Taper Limit 0.0004 Max.
TORQUE SPECIFICATIONS -SPECIAL APPLICATION
Length (CentertoCenter) 6.6035 6.6065
Alignment (Bore to Bore Max Dtft.) (8) CAMSHAFT SPROCKET TO CAMSHAFT 40-45
Twist 0.024 CAMSHAFT THRUST PLATE TO BLOCK 9 12
Bend 0.012 CONNECTING ROD NUTS OR BOLTS 40-45
Side Clearance (Assembled to Crank) CYLINDER FRONT COVER BOLTS 12-18
Standard 0.010 0.020 CYLINDER HEAD BOLTS VJ3)
Service Limit 0.023 DAMPER OR PULLEY TO CRANKSHAFT . . 70-90
PISTON DISTRIBUTOR VACUUM CONTROL VALVE 15 18
Diameter [9) EGR VALVE TO CARBURETOR SPACER OR INT MANIFOLD 12-18
Coded Red 4.3585 4.3591 FUEL PUMPTO CYLINDER BLOCK OR FRONT COVER 19-27
Coded Blue 4.3597 4.3603 FLYWHEEL TO CRANKSHAFT 75 85
0.003 Oversize 4.3609 4.3615 MAIN BEARING CAP BOLTS 95-105
Piston To-Bore Clearance 0.0022 0.0032 MANIFOLD TO CYLINDER HEAD (Intake) . . . : i 32 ^
Pin Bore Diameter 1.0402 1 0405 28-33
MANIFOLD TO CYLINDER HEAD (Exhaust)
Ring Groove Width OIL FILTER INSERTTO CYLINDER BLOCK 45-55
Compression (Top) 0.08050.0815
Compression (Bottom) 0.08050.0815
OIL FILTER TO BLOCK OR ADAPTER
OIL INLET TUBE TO OIL PUMP ©
Press Fit
Oil 0.188 0 189
OIL PAN DRAIN.PLUG 15 25
PISTON PIN OIL PAN TO CYLINDER BLOCK . . . 5/16 = 9 11
Length 3.290 3.320 • /4 = 7-9
Diamet.ir
OIL PUMPTO CYLINDER BLOCK 22 32
Standard 1.0398 1.0403 PULLEY TO DAMPER (Bolt) 35.5O
0.001 Oversize 1.0401 1.0413 ROCKER ARM STUD OR BOLT TO CYLINDER HEAD 18 25
Pin-To-Piston Clearance 0.00020.0004 5 10
SPARK PLUG TO CYLINDER HEAD
Pin-To-Rod Clearance Interference Fit 5-6
VALVE ROCKER ARM COVER
PISTON RINGS
ALTERNATOR TO CYLINDER BLOCK (Bolt) 35-50
Ring Width
ALTERNATOR PIVOT BOLT 45-57
Compression (Top) 0.077 0.078 ALTERNATOR ADJUSTING ARM TO CYLINDER BLOCK 35-50
Compression (Bottom) 0.077 0.078 ALTERNATOR ADJUSTING ARM TO ALTERNATOR 24-40
Side Clearance THERMACTOR PUMP BRACKET TO CYLINDER BLOCK 35 50
Compression (Top) 0.0025 0.0045 THERMACTOR PUMP PIVOT BOLT 25 35
Compression (Bottom) 0.0025 0.0045 THERMACTOR PUMP ADJUSTING ARM TO PUMP 22-32
Service Limit 0.006 THERMACTOR PUMP ADJUSTING ARM TO CYLINDER BLOCK 22 32
Oil Ring Snug Fit THERMACTOR PUMP PULLEY TO SHAFT . 130 180 m Ib.
Ring Gap POWER STEERING PUMP PULLEY TO OAMPER (Bolt) 35-50
Compression (Top) 0.0100.020 FAN TO WATER PUMP HUB (Bolt) 12 18
Compression (Bottom) 0 0100.020 OIL COOLER/FILTER ADAPTER TO CYLINDER BLOCK 40-50
Oil Ring (Steel Rail) 0.015 0.055 CARBURETOR MOUNTING NUTS 12 15
CARBURETOR MOUNTING STUD 15 Max.
LUBRICATION SYSTEM FUEL FILTER TO CARBURETOR 29-31

i OIL PUMP TORQUE SPECIFICATIONS - General Applications

Relief Valve Spring Tension (Lbs. at Spec Length) . . . 20.6-22.6 @ 2.49
Drive Shaft-To Housing Bearing Clearance 0 0015 0.0030 U.S. THREAD SIZES TORQUE
Relief Valve To Bore Clearance 0 0015 0.0030
Rotor Assembly End Clearance (Assembled) 0.004 Max. 1/4-20 6-9
Outer Race To Housing Clearance 0.001 0.013 5/16-18 12-18
OIL CAPACITY (Quarts U S ) 6 'icy 5/16-24 14 20
3/8-16 22 32
3/8-24 27 38
7/16-14 . 40-55
21-27-5 460 CID Police Interceptor Engine 21-27-5

SPECIFICATIONS-1977
US THREAD SIZES (Continued) TORQUE
Drive Belt Tension (Lbs.)
7 16 20 40 60
Newly Installed Used
1 2 13 55 80 Si
» (A) Up to lOMin. OveriOMin.

METRIC THREAD SIZES TORQUE 1/4" 50-80 40-80 (B) 40-60 (B)

M-6 6-9 Exc. 1/4" 120-160 90-160(0 75-120(0)

M 8 14-21
M 10 28 40 (A) Read tension immediately after belt is installed, before it stretches or seats in pulley
M-12 ,. . . . 50-71 grooves.
M 14 80 114 (B) If less than 40 pounds, readjust to 40-60 pounds.
(C) If less than 90 pounds, readjust to 90 120 pounds.
PIPE THREAD SIZES TORQUE (D) If less than 75 pounds, readjust to 90 120 pounds.
PSI of lowest cylinder must be 75% of highest.
18 5-8
10% pressure loss & specified length
1 4 . 12 18
To leak down 1/16", with 50 Ib. load and tappet tilled with leakdown fluid.
3 8 ....'.'.'.' 22 33
Distance front edge of bearing is below front face of block.
1? 25 35
0.003 in any 6 inches; 0.006 overall.
For 0.002 Undersize, add 0.001 to Standard
o All values in m ft.-lb. unless otherwise noted,
Pin and crank bearing bore must be parallel and in same vertical plane within the
o Oil threads with engine oi! unless fasteners require sealers.
specified total difference when measured at ends of an 8 " bar, 4 " on each side of rod
centerline.
Measured at piston pin bore centerline; at 90° to the pin.
Add 1 quart when changing filter, and 3/4 quart for oil cooler.
With new filter in line and pump-to tank return line pinched off.
No orifice in test circuit is smaller than 0.220 I. D.
Torque in Sequence: Step 1 = 70-80, Step 2 = 100 110; Step 3 = 130 140.
Retorque to Specification after engine is hot.
1/2 turn after oiler gasket contacts sealing surface.

CA1311C
23-00-1 Ignition System 23-00-1

GROUP
IGNITION SYSTEM
(12000)

PART
General Ignition 23-01
All Models

SUBJECT PAGE SUBJECT PAGE

GENERAL INFORMATION REMOVAL AND INSTALLATION (Cont'd.)
Centrifugal Advance 01-3 Fixed Base Plate 01-6
Circuit Operation 01-3 Distributor - 4- and 6-Cylinder Engines 01-8
Distributor 01-2 Magnetic Pickup Assembly 01-8
Vacuum Advance 01-3 Vacuum Advance Unit 01-8
Replacing Spark Plugs 01-9
ADJUSTMENTS 014 Spark Plug Boot Replacement - All Engines . . . 01-9
Spark Plug Wires - Secondary
TESTING (High Tension) Wires 01-8
Functional Checks 014
Distributor Advance and Retard Check 014 CLEANING AND INSPECTION
Distributor Dual Diaphragm Check . . . 014 Coil 01-11
Ignition Timing 01-4 Distributor 01-11
Distributor Cap 01-11
REMOVAL AND INSTALLATION Spark Plugs 01-11
Connecting To Coil Connector For Secondary Wiring 01-8
Tachometer - All Engines 01-9 Ignition Resistor Wire 01-11
Distributor, Rotor and Cap 01-9
Distributor - 8-Cylinder Engines . 014 SPECIFICATIONS 01-13
Magnetic Pickup Assembly 01-6
Vacuum Advance Unit 01-6 SPECIAL TOOLS 01-14

CB3519-A

GENERAL INFORMATION
For 1977, all California passenger
cars except those with the 2.3L four-
cylinder engine will be equipped with
the new high energy "Dura Spark I"
ignition system. The California 2.3 L
and all engines in the other 49 states
and Canada will be equipped with the
"Dura Spark II" ignition system.
Dura Spark I features special vehicle
primary wiring, a new design coil, an
all-new electronic control module, a
new distributor cap and adapter, new
high energy secondary wiring and
special wide-gap spark plugs. In opera-
tion, it senses current flow through
the coil, adjusting "dwell" for maxi-
mum spark intensity. Thus, coil "on"
time is adjusted for best efficiency
related to engine RPM. If the module
senses that the ignition switch is ON
and the distributor is not turning, it
will automatically turn the coil current
OFF after about one second. To re-
establish the module cycle, turn the
key to START or to OFF and then to
ON again.
Dura Spark II is basically a 1976
solid state ignition system with two
major differences: the ballast resistor
value has been changed from 1.35 to 1.10
ohms to boost coil current and energy
output, and the system now uses the
23-01-2 General Ignition Service 23-01-2

new Dura Spark I rotor, distributor
cap and adapter, ignition secondary
wires and wide-gap spark plugs to take
advantage of the higher energy
produced.
Both systems use the same distribu-
tor (Fig. 1) arid both control modules
have the same exterior appearance
(Fig. 2).
VACUUM ADVANCE LINK
MAGNETIC PICKUP
ASSEMBLY
DISTRIBUTOR
HOUSING
It is important to note that the
Dura Spark II amplifier module and
coil are "on" when the ignition switch
is "on". Because of this, the ignition
system will generate a spark when the
key is turned "off". This feature may
be used as a diagnostic tool, to verify
continuity of circuit, coil and ignition
switch. Certain other service actions
VACUUM ADVANCE/
RETARD ASSEMBLY
such as removing the distributor cap
with the ignition switch ' o n " may
also cause the system to fire. For this
reason, the ignition switch should remain
"off during any underhood operations
unless the intent is to start the vehicle
engine, or to perform a specific test that
requires the ignition switch to be "on".
This procedure will prevent the
possibility of inadvertent engine rotation
caused by triggering of tht: ignition
system during servicing.
Dura Spark I systems automatically
shut down when the system senses no
distributor rotation within one second.

ADVANCE PLATE
DISTRIBUTOR
SLEEVE T h e a r m a t u r e t u r n s with t h e
distributor shaft, causing fluct aations in
the magnetic field generated by the
pickup coil assembly. These fluctuations
cause the amplifier to turn the ignition
coil current off and on, generating high
tension spark needed to fire the spark
plugs. The distributor is equipped with a
new high energy cap and adapter
(Fig. 3).

ARMATURE

FIXED BASE PLATE

SYSTEM GROUND

B3505-B

ADAPTER
CLIP
FIG. 1 Distributor - V-8 Shown - Others Similar
\ DISTRIBUTOR
~\BODY

B3520-A

FIG. 3 Typical Dura-Spark Distributor

All distributors are equipped with

both vacuum and centrifugal spark
advance control units. The vacuum
advance unit governs ignition timing
according to engine load, while the
centrifugal advance unit governs ignition
B3777-B timing according to engine speed (rpm).
FIG. 2 Typical Dura Spark Module
23-01-3 General Ignition Service 23-01-3

A dual diaphragm vacuum advance unit
is used on some engines to provide
additional ignition timing retard during
engine closed throttle operation. This
occurs both at curb idle and during
engine coast-down with closed throttle.
Retarding the timing during these
periods helps control engine emissions.
The distributor on four or six cylinder
engines rotates in a clockwise direction.
To advance timing; rotate the distributor
counterclockwise. The distributor on V-8
engines rotates counterclockwise. To
advance timing, rotate the distributor
clockwise.
CENTRIFUGAL ADVANCE
The distributor advance units operate
independently, with vacuum advance
operating the base plate assembly and
centrifugal advance operating the
position of the armature in relation to the
distributor shaft. The centrifugal advance
assembly, located below the base plate,
has centrifugal weights that move inward
or outward with changes in engine
speed.
As engine speed increases, the weights
move the sleeve and plate assembly ahead
of the distributor shaft, thus advancing
the position of the armature. The rate of
advance is controlled by calibrated
springs.
VACUUM ADVANCE
The dual diaphragm unit consists of
two diaphragms that operate from two
independent sources of vacuum (Fig. 4).
The outer (primary) diaphragm operates
from carburetor venturi vacuum to
provide timing advance during normal
off-idle driving conditions. This
diaphragm is connected to the distributor
magnetic pickup coil assembly by the
vacuum advance link.
The inner (secondary) diaphragm
operates from intake manifold vacuum
and acts to retard ignition timing. This
retard diaphragm is connected to the
outer diaphragm by means of a sliding
linkage. Since intake manifold vacuum is
stronger than carburetor venturi vacuum
during closed throttle operation, the
secondary diaphragm will retard the
spark during these periods. In all other
phases, the larger primary diaphragm
operates from venturi vacuum and pulls
the base plate against distributor
rotation, advancing the spark timing.
On some A/C applications, a fast-
idle compensator applies intake mani-
fold vacuum to the primary side of
the diaphragm during hot engine
conditions, acting to increase engine
idle speed as an aid to cooling.
Return springs in both the advance
and retard portions center the
diaphragms when vacuum drops.
Vacuum modulators installed in the
vacuum supply lines from the carburetor
and intake manifold will vary the
operation of the advance and retard
diaphragms. These modulators are
covered in Group 29 and Group 50.
CIRCUIT OPERATION
The Dura Spark System consists of
a primary (low voltage) and a second-
ary (high voltage) circuit (Fig. 5).
The primary circuit consists of the:
1. Battery.
2. Ignition Switch.
3. Primary Circuit Resistance Wire (in
Dura Spark II).
4. Primary Windings of the Ignition
Coil.
5. Magnetic pickup assembly.
6. Amplifier Module.
The secondary circuit consists of
the:
1. Secondary windings of the ignition
coil.
2. Distributor rotor.
3. Distributor cap.
4. High tension (spark plug) wires.
5. Spark plugs.
With the ignition switch "on", the
primary circuit is on and the ignition coil
is energized. When the armature
"spokes" approach the magnetic pickup
coil assembly, they induce a voltage
which tells the amplifier to turn the coil
primary current off. A timing circuit in
the amplifier module will turn the
current on again after the coil field has
collapsed. When the current is "on", it
flows from the battery through the
ignition switch, the primary windings of
the ignition coil, and through the
amplifier module circuits to ground.

AMOUNT OF TRAVEL FOR RETARD DIAPHRAGM-

PLATE RESTING 0° RETARD

RETARD DIAPHRAGM AT FULL RETARD-

PLATE RESTING ON STOP

MANIFOLD
ADVANCE DIAPHRAGM IN VACUUM
FULL ADVANCE POSITION
CONNECTION

FULL VACUUM RETARD

CARBURETOR CONNECTION

ADVANCE SPRING

ADVANCE DIAPHRAGM

DISTRIBUTOR BASE

VACUUM ADVANCE AND RETARD DIAPHRAGMS AT REST

FIG. 4 Dual Diaphragm Vacuum Advance Mechanism

23-01-4
When the current is off, the magnetic
field built up in the ignition coil is
CONNECTOR
PRIMARY CIRCUIT
•••••• SECONDARY CIRCUIT
ADJUSTMENTS
TESTING
For testing and system diagnosis,
refer to Part 29-02.
FUNCTIONAL CHECKS
Distributor Advance and Retard
Check
Check the initial ignition timing,
centrifugal advance, vacuum advance,
and vacuum retard (dual-diaphragm
distributor), following the procedure
under Ignition Timing.
Distributor Dual Diaphragm Test
1. To check vacuum a d v a n c e ,
disconnect the vacuum lines from
both the outer and inner diaphragms.
Plug the lines removed from the
inner and outer diaphragm.
2. Using a tachometer, increase the idle
speed by setting on thefirststep of the
fast idle cam.
3. Using a timing light, observe the
ignition timing setting.
4. Connect carburetor vacuum to the
outer diaphragm. Timing should
REMOVAL AND INSTALLATION
DISTRIBUTOR—8 CYLINDER
ENGINES
General Ignition Service
allowed to collapse, inducing a high
voltage into the secondary windings of
DURA SPARK CAP
SPARK PLUG
V^
DISTRIBUTOR
B3741-B
No adjustments are to be made to the
ignition system except initial engine
timing and spark plug gap (Part 50-29).
advance slowly as vacuum equalizes
through the SDV. Adjust if needed.
5. To check vacuum retard, readjust the
engine idle speed to 550-600 rpm.
6. Using a timing light observe the spark
timing.
7. Remove the plug from the manifold
vacuum line and connect the line to
the inner diaphragm.
8. T h e t i m i n g s h o u l d r e t a r d
immediately. Replace the dual
diaphragm unit if either of the
diaphragms are leaking.
IGNITION TIMING
All engines are equipped with con-
ventional ignition timing and engines
sold in California are also equipped
with the new "monolithic" timing
features. The conventional system
employs degree numbers on the crank-
shaft vibration damper, a timing
pointer near the damper, and an index
mark on both the distributor rotor
and distributor body.
The "monolithic" system employs a
Removal
1. Remove the air cleaner. Disconnect
23-01-4
the coil. High voltage is produced each
time the field is thus built up and
collapsed.
The high voltage flows through the
coil high tension lead to the distributor
cap where the rotor distributes it to one
of the spark plug terminals in the
distributor cap. This process is repeated
for every power stroke of the engine.
Ignition system troubles a:-e caused
by a failure in the primary and/or the
secondary circuit; incorrect ignition
timing; or incorrect distributor advance.
Circuit failures may be caused Dy shorts,
corroded or dirty terminals, loose
connections, defective wire insulation,
cracked distributor cap or rotor,
defective pick-up coil assembly or
amplifier module, or fouled spark plugs.
If an engine starting.or operating
trouble is attributed to the ignition
system, start the engine if possible and
verify the complaint. On engines that will
not start, be sure there is gasoline in the
fuel tank and that fuel is reaching the
carburetor. Then locate the ignition
system problem by an oscilloscope
test, spark intensity test, or by means
of the ohmmeter test procedure.
timing receptacle designed to accept an
electronic probe (Fig. 6) that is connected
to digital read-out equipment. Thus, the
timing is determined electronically. The
receptacle is located at the front of all
engines except the 23OOcc four cylinder
which has a boss for monolithic timing
in the left rear of the cylinder block.
To check and adjust timing, follow
the procedures outlined in Groups 50 and
29.
TIMING f'OINTER
MONOLITHIC "IMING
PROBE RECEF TACLE
(EXCEPT 230C CC
FOUR CYLINDER)
I335OO-A
FIG. 6 Typical Timing Pointer and
Probe Receptacle
the distributor wiring connector from
the vehicle wiring harness.
 CYLINDER NUMBERING AND CYLINDER NUMBERING AND CYLINDER NUMBERING AND CYLINDER NUMBERING AND
DISTRIBUTOR LOCATION DISTRIBUTOR LOCATION DISTRIBUTOR LOCATION DISTRIBUTOR LOCATION

DISTRIBUTOR

DISTRIBUTOR

DISTRIBUTOR

FRONT FRONT FRONT

DISTRIBUTOR

FIRING ORDER AND POSITION FIRING ORDER AND ROTATION FIRING ORDER AND ROTATION FIRING ORDER AND ROTATION

POSITION OF
CAP ATTACHING CLOCKWISE COUNTERCLOCKWISE
SCREWS

FRONT FRONT CLOCKWISE FRONT FRONT

FIRING ORDER
FIRING ORDER - 1-3-4-2 FIRING ORDER - 1-4-2-5-3-6 FIRING ORDER - 1-5-3-6-2-4 3 5 1 . 4 0 0 - 1-3-7-2-6-5-4-8
3 0 2 , 4 6 0 - 1-5-4-2-6-3-7-8

VIEW 351M/400 W/FRIGIDAIRE A/C

FROM LEFT SIDE OF E N G I N E -
VIEW ALL OTHERS /
FRONT FROM RIGHT SIDE. / FRONT
FRONT FRONT TIMING / •
POINTER^ W
TIMING BTDC TDC
TIMING I < ^
POINTER i. I BTDC
POINTER ATDC
TDC BTDC TDC BTDC
\IUC

T / J \

1" " I " " I " " I " " I

TC 10 20 30
TC 3 6 9 12
10
\ /
(— \

^TIMING
ROTATION ROTATION ROTATION
ROTATION ^ ^ A MARK

CRANKSHAFT TIMING MARKS CRANKSHAFT TIMING MARKS CRANKSHAFT TIMING MARKS CRANKSHAFT TIMING MARKS

2.3L4-CYLINDER 2.8LV6 200/250 C.I.D. IN-LINE SIX CYLINDER 302/351/400/460 C.I.D. V-8
B3435-G

FIG. 7 Engine Timing and Cylinder Firing Order

23-01-6
2. Disconnect the vacuum advance lines
at the distributor. Remove the
distributor cap and place it and wires
to one side.
3. Scribe a mark on the distributor body
and the cylinder block indicating the
position of the rotor in the distributor
and the distributor in the block. These
marks will be used as guides when
installing the distributor.
4. Remove the distributor hold-down
bolt and clamp. Lift the distributor
out of the block. Do not rotate the
engine while the distributor is out of
the block, or it will be necessary to
time the engine.
Installation
1. If the crankshaft was rotated while
the distributor was removed from the
engine, it will be necessary to time the
engine as follows: R o t a t e the
crankshaft until No. 1 piston is on
TDC after the compression stroke.
Align the correct initial timing mark
on the timing pointer with the timing
pointer on the crankshaft damper.
Position the distributor in the block
with one of the armature segments as
shown in Fig. 8, and the rotor at
number one firing position.
M a k e s u r e the oil pump
intermediate shaft properly engages
the distributor shaft. It may be
necessary to crank the engine with
the starter, after the distributor drive
gear is partially engaged, in order to
engage the oil pump intermediate
shaft. Install, but do not tighten, the
retaining clamp and bolt. Rotate the
distributor to advance the timing to
a point where the armature tooth is
aligned properly. Tighten the clamp.
2. If the crankshaft has not been moved
position the distributor in the block
STATOR TOOTH MUST BE PERFECTLY
ALIGNED WITH STATOR
ROTOR
FIG. 8 Static Timing Position—8-Cylinder Engine Distributor
General Ignition Service
with the rotor aligned with the mark
previously scribed on the distributor
body and the marks on the distributor
body and cylinder block in alignment.
3. Install the distributor cap and wires.
4. Connect the distributor wiring
connector to the vehicle harness.
5. Check the ignition timing with a
t i m i n g l i g h t a n d a d j u s t to
specifications. NOTE: Due to the
higher coil charging currents inher-
ent in the new Dura Spark system,
it may be necessary to use a timing
light specifically designed for this
type system. Existing inductive
pickup type lights might also work
satisfactorily if an insulated stand-
off such as a piece of split vacuum
hose is first put around the plug
wire. Connect the vacuum line(s),
and check the advance with the
timing light when the engine is
accelerated.
6. Install the air cleaner.
MAGNETIC PICKUP ASSEMBLY
Removal
1. Remove the distributor cap, rotor
and adapter, and disconnect the
distributor harness plug (Fig. 9).
2. Using a small gear puller or two
screwdrivers, lift or pry the armature
from the advance plate sleeve.
Remove the roll pin.
3. Remove the large wire retaining clip
from the base plate annular groove.
4. Remove the snap ring that secures the
vacuum advance link to the pickup
assembly.
5. R e m o v e t h e m a g n e t i c p i c k u p
assembly ground screw and lift the
assembly from the distributor.
6. Lift the vacuum advance arm off the
post on the pickup assembly and
move it out against the distributor
housing.
EACH 1/2 TOOTH ERROR IS
EQUAL TO 7-3/4 ENGINE
DEGREES TIMING ERROR
ARMATURE
23-01-6
Installation
1. Place the new pickup assembly in
position over the fixed base plate and
slide the wiring in position through
the slot in the side of the distributor
housing.
2. Install the fine wire snap ring securing
the pickup assembly to the fixed base
plate.
3. Position the vacuum advance arm
over the post on the pickuj: assembly
and install the snap ring.
4. Install the grounding screw through
the tab on the wiring harne-s and into
the fixed base plate.
5. Install the armature on the advance
plate sleeve, making sure ttie roll pin
is engaged in the matching slots.
6. Install the distributor adapter, rotor
and cap.
7. Connect the distributor wiring plug to
the vehicle harness.
VACUUM ADVANCE UNIT—DUAL
DIAPHRAGM
Refer to Fig. 9 for proper relationship
of internal parts.
Removal
1. Remove the cap, rotor and adapter.
2. Disconnect the vacuum lines.
3. Remove the spring clip that secures
the diaphragm link to the movable
advance plate.
4. Remove the diaphragm unit attaching
screws and carefully remove the unit
by tilting downward to disengage the
link from the post on the movable
advance plate.
Installation
1. Position the diaphragm unit on the
distributor and hook the diaphragm
link in position.
2. Install the spring clip that secures the
diaphragm link to the movable
advance plate. Install the d laphragm
unit attaching screws.
3. Connect the vacuum lines.
4. Install the rotor, adapter and dis-
tributor cap.
FIXED BASE PLATE
Removal
1. Remove the distributor cap, adapter
and rotor.
2. R e m o v e the v a c u u m a d v a n c e
diaphragm unit.
3. R e m o v e the m a g n e t i c p i c k u p
assembly.
4. Remove the remaining attaching
screw from the fixed base plate and
lift it out of the distributor.
NOTE: Do not remove sleeve and
plate assembly, weights or weight
springs.
Installation
1. Position fixed base plate in distributor
and install first attaching sjrew.
23-01-7 General Ignition Service 23-01-7

ROLL PIN

ARMATURE

MAGNETIC PICKUP ASSEMBLY

(STATOR ASSEMBLY)

SYSTEM GROUND

WIRING HARNESS
CONNECTION

B3508-A

FIG. 9 Typical Dura Spark Distributor — Disassembled

23-01-8
2. Install pick-up assembly and wiring.
3. Install vacuum advance unit,
4. Install the distributor adapter, rotor
and cap.
DISTRIBUTOR—4 AND 6
CYLINDER ENGINE
Removal
1. Remove the air cleaner assembly on
V-6 engines. On 4-cylinder and
6-cylinder in-line engines, remove one
thermactor pump mounting bolt, and
the drive belt; then, swing the pump
to one side to allow access to the
distributor. It may also be necessary
to disconnect the Thermactor air
filter and lines.
2. Using a remote starter switch or
rotating the engine by hand, position
the proper timing mark on the engine
crankshaft damper with the timing
pointer.
3. Remove the distributor cap and check
to see that the rotor and armature are
lined up with the index mark on the
top of the magnetic pickup (Fig. 10),
and the marks on the side of the
distributor body.
4. Disconnect the vacuum hose(s) from
the distributor. Disconnect the
ignition lead from the wiring harness.
5. Remove the distributor hold-down
bolt and remove the distributor from
the block. The hex shaft that drives
the oil pump may stick in the
distributor shaft and be withdrawn
from the pump.
Installation
1. Make sure the engine is still aligned
with the proper timing marks. Align
the distributor rotor with the marks
on the distributor and the armature
with the marks on the top of the
magnetic pickup (Fig. 10). If the oil
pump drive shaft was withdrawn with
the distributor, coat one end with
heavy grease, insert that end into the
hex hole in the distributor shaft and
position the distributor into the
cylinder block. Make sure the oil
pump drive shaft is fully seated in the
pump, and that the distributor rotor
and body are in the proper position.
2. Install the distributor hold-down bolt
and bracket.
3. Install the vacuum hose(s) and
connect the ignition wire to the wiring
harness.
4. Install the rotor, adapter and dis-
tributor cap.
5. Install the thermactor belt on four
and in-line 6-cylinder engines, and
adjust belt tension to specification.
Connect all Thermactor hoses and the
filter.
6. Check engine timing as covered in
Part 29-02 or 50-29 under Ignition
Timing.
General Ignition Service
STATOR
TOOTH MUST BE PERFECTLY
ROTOR ALIGNED WITH TIMING MARKS
i EACH 1/2 TOOTH EFIROR IS
TIMING POSITION - 6-CYLINDER SHOWN
FIG. 10 Static Timing Position—6-Cylinder Shown—4-Cylinder Similar
MAGNETIC PICKUP ASSEMBLY
Removal
1. Remove the distributor cap, adapter
and rotor and disconnect the dis-
tributor harness plug.
2. Using a small gear puller or two
screwdrivers, lift or pry the armature
from the advance plate sleeve.
Remove the roll pin.
3. Remove the snap ring, washer and
wave washer that secure the pickup
assembly to the lower plate.
4. Remove the magnetic pickup
assembly ground screw and lift the
assembly from the distributor.
Installation
1. Place the pickup assembly in position
over thefixedbase plate and insert the
pickup assembly post into the vacuum
advance arm.
2. Slide the wiring grommet into the slot
at the edge of the lower plate and
install the ground screw. Install the
washers and snap ring to secure the
pickup assembly to the lower plate.
3. Install the armature on the advance
plate sleeve, making sure the roll pin
is engaged in the matching slots.
4. Install the distributor rotor, adapter
and cap and connect the distributor
wiring plug to the vehicle harness.
VACUUM ADVANCE UNIT
Removal
1. Remove the distributor cap, rotor
and adapter.
2. Disconnect the vacuum line(s).
3. Remove the diaphragm unit attaching
screws and carefully remove the unit
by tilting downward to disengage the
link from the advance plate.
23-01-8
EQUAL TO 7-3/4 ENGINE
DEGREES TIMING ERROR
ARMATURE
B3739-B
Installation
1. Hook the diaphragm link in position
and position the diaphragm unit on
the distributor.
2. Install the diaphragm unit attaching
screws.
3. Connect the vacuum line(s).
4. Install the adapter, rotor ,;nd dis-
tributor cap.
SPARK PLUG WIRES
Secondary (High Tension) Wires
The secondary wires include trie wires
connecting the distributor cap to the
spark plugs and the wire connecting the
center terminal of the distributor cap to
the center terminal of the ignition coil.
These wires are the radio resistance-
type which filter out the high frequency
electrical impulses that are the source of
ignition noise interference.
Check ignition wire resistance
through the distributor cap. To check the
secondary wire resistance, turn the
ignition switch "off" and then remove the
distributor cap. It is important 1 hat the
ignition system be "off to prevent
inadvertant engine rotation due to firing
of the ignition system.
Do not, under any circumstance,
puncture an ignition cable when checking
resistance. Do not use a commercial
probing device, but measure resistance
only from the ends of the wire or the wire
terminals inside the distributor cap.
If the resistance of a wire exceeds
5,000 ohms per inch, it should be
completely removed from the distributor
cap and the resistance measured directly
from the wire ends. If the resistance still
exceeds 5,000 ohms per inch, the wire
should be replaced.
23-01-9
When removing wires from spark
plugs, use Tool T74P-6666-A or
equivalent. (Fig. 11.) Grasp and twist the
molded cap back and forth on the plug
insulator to free cap. Use the special tool
to pull the cap from the plug. Do not pull
on the wire directly, or it may become
separated from the connector inside the
cap.
Whenever a high tension wire is
removed for any reason from a spark
plug, coil or distributor terminal hous-
ing, silicone grease must be applied to
the boot before it is reconnected.
Using a small clean tool, coat the
entire interior surface of the boot with
Ford silicone greaseD7AE-19A331-AA
or equivalent.
TOOL T74P-6666-A
TWIST & PULL
B3496-A
FIG. 11 Removing Wires from Spark
Plugs
Installation
1. Insert each wire on the proper
terminal of the distributor cap. Be
sure the wires are forced all the
way down over their terminals.
The No. 1 terminal is identified on
the cap. Install the wires starting
with No. 1. Each spark plug wire
is numbered for 1977. Cylinders
are numbered 1-2-3-4-5-6 on all
inline 6-cylinder engines and from
front to rear; right bank 1-2-3-4,
left bank 5-6-7-8 on all V-8 engines.
V-6 engines are numbered from
front to rear; right bank 1-2-3, left
bank 4-5-6. Four-cylinder engines
are numbered from front to rear,
1-2-3-4.
2. Remove the wire retaining brackets
from the old spark plug wire set and
install them on the new set in the
same relative position. Install the
wires in the brackets on the valve
rocket arm covers (V-8 and V-6).
3. Connect the wires to the proper spark
plugs. Install the coil high tension
lead. Be sure the No. 7 spark plug
wire is positioned in the bracket.
Notice that the wires are positioned
in this bracket in a special order from
front to rear (7-5-6-8). This applies to
all V-8 engines except the 351 engine.
The wires for the 351 V-8 should be
positioned in the bracket from front
General Ignition Service
to rear (5-7-8-6). Arranging the wires
in this manner will prevent cylinder
cross-fire.
B1391-D
FIG. 12 Checking and Setting Spark
Plug Gap
DISTRIBUTOR ROTOR AND CAP
When installing a new distributor
cap or rotor, coat the brass rotor
electrode surfaces on all sides out-
board of the plastic, including the
outer edge, with D7AE-19A331-AA
silicone grease (or equivalent Dow
Corning No. I l l or General Electric
G-627 compounds) to approximately
1/8" thickness. Do not reapply or
attempt to remove any silicone coating
from the distributor cap electrodes.
As this compound ages, it has the
appearance of being a contaminant of
the cap and rotor electrodes. This
condition is normal and causes no
performance loss.
REPLACING SPARK PLUGS
Removal
1. Remove the wire from each spark
plug by grasping the molded boot
with Tool T74P-6666-A (Fig. 11).
Twist the boot until it loosens and
then pull it off the spark plug. Do not
pull on the wire, as ihfc connection
may become damaged.
2. Any wire damaged must be replaced.
Each original spark plug wire is
numbered for the cylinder to which it
is designed. If wires are not
numbered, each wire should be
numbered as to the plug from which
it was removed.
3. Clean the area around each spark
plug port with compressed air.
4. Using the proper size spark plug
socket remove the spark plugs.
Installation
1. Check the gap on each new spark plug
and set to specification, if necessary
(Fig. 12).
2. Install each spark plug and torque to
specification.
3. Coat the inside of each spark plug
boot with silicone grease D7AE-
19A331-AA or equivalent, using a
small screwdriver blade. Connect
each spark plug wire to the plug
from which it was re moved. Be
sure each wire is fully depressed
on each plug and molded boot is
firmly in place.
23-01-9
CONNECTING TO NEW COIL
CONNECTOR FOR TACHOMETER
TEST—ALL VEHICLES
The ignition coil connector allows
a tachometer test lead with an alligator-
type clip to be connected to the DEC
(Distributor Electronic Control) ter-
minal without removing the connector
(Fig. 13).
COIL CONNECTOR
TO "DEC" TERMINAL
(DISTRIBUTOR ELEC-
TRONIC CONTROL)
MUELLER 60 SERIES
ALLIGATOR CLIP
TACHOMETER TEST LEAD B3516-A
FIG. 13 Attaching Tachometer Lead
to Coil Connector
When engine rpm must be checked,
install the tachometer alligator clip into
the "TACH TEST" cavity as shown. If
the coil connector must be removed,
grasp the wires and pull horizontally
until it disconnects from the terminals.
SPARK PLUG BOOT
REPLACEMENT—ALL ENGINES
When it is necessary to replace only
the boot on a particular spark plug wire,
proceed as follows:
1. Cut off the old boot. Apply sili-
cone lubricant D7AE-19A331-AA
or equivalent to that area of the
old wire that will contact the new
boot.
2. Position the new boot onto Tool
P73-192-1 as shown in Fig 14.
3. Position the tool onto the wire
terminal and slide the boot onto the
wire. Remove the tool from the end
of the wire terminal.
B3514A
FIG. 14 Installing Spark Plug Wire
Boot on Wire
 General Ignition Service 23-01-10
23-01-10

CLEANING AND INSPECTION

GAP BRIDGED CARBON FOULED

IDENTIFIED BY DEPOSIT IDENTIFIED BY WET BLACK DEP- IDENTIFIED BY BLACK,

BUILD-UP CLOSING GAP OSITS ON THE INSULATOR SHELL
BETWEEN ELECTRODES. BORE ELECTRODES CAUSED BY
CAUSED BY OIL OR EXCESSIVE OIL ENTERING COMBUS-
CARBON FOULING. REPLACE TION CHAMBER THROUGH WORN
PLUG, OR, IF DEPOSITS ARE RINGS AND PISTONS, EXCESSIVE
NOT EXCESSIVE, THE PLUG CLEARANCE BETWEEN VALVE
CAN BE CLEANED. GUIDES AND STEMS, OR WORN OR
LOOSE BEARINGS. REPLACE THE
PLUG. IF ENGINE IS NOT REPAIRED,
USE A HOTTER PLUG.
DRY FLUFFY CARBON
DEPOSITS ON INSULATOR
TIPS, EXPOSED SHELL
SURFACES AND ELECTRODES.
CAUSED BY TOO COLD A
PLUG, WEAK IGNITION, DIRTY
AIR CLEANER, DEFECTIVE FUEL
PUMP, TOO RICH A FUEL
MIXTURE, IMPROPERLY
OPERATING HEAT RISER
OR EXCESSIVE IDLING.
CAN BE CLEANED.

WORN NORMAL LEAD FOULED

IDENTIFIED BY SEVERELY IDENTIFIED BY LIGHT TAN OR IDENTIFIED BY DARK

ERODED OR WORN ELECTRODES.
CAUSED BY NORMAL WEAR.
SHOULD BE REPLACED
GRAY DEPOSITS ON THE GRAY, BLACK, YELLOW
FIRING TIP. OR TAN DEPOSITS OR A
FUSED GLAZED COATING
ON THE INSULATOR TIP.
CAUSED BY HIGHLY
LEADED GASOLINE.
REPLACE THE PLUG.

PRE-IGNITION OVERHEATING FUSED SPOT DEPOSIT

IDENTIFIED BY MELTED IDENTIFIED BY A WHITE OR LIGHT IDENTIFIED BY MELTED

ELECTRODES AND POSSIBLY
BLISTERED INSULATOR.
METALLIC DEPOSITS ON
INSULATOR INDICATE ENGINE
DAMAGE.
CAUSED BY WRONG TYPE
OF FUEL, INCORRECT IGNITION
TIMING OR ADVANCE, TOO HOT
A PLUG, BURNT VALVES OR
ENGINE OVERHEATING.
REPLACE THE PLUG.
GRAY INSULATOR WITH SMALL OR SPOTTY DEPOSITS
BLACK OR GRAY BROWN SPOTS RESEMBLING BUBBLES
AND WITH BLUISH-BURNT APPEAR- OR BLISTERS.
ANCE OF ELECTRODES, CAUSED CAUSED BY SUDDEN
BY ENGINE OVERHEATING. WRONG ACCELERATION. CAN BE
TYPE OF FUEL, LOOSE SPARK CLEANED IF NOT EXCESSIVE.
PLUGS, TOO HOT A PLUG, LOW OTHERWISE REPLACE PLUG.
FUEL PUMP PRESSURE OR INCOR-
RECT IGNITION TIMING. REPLACE
THE PLUG.
B3235-B

FIG. 15 Spark Plug Inspection

23-01-11 General Ignition Service 23-01-11

SPARK PLUGS Distributor Cap replace it (refer to Spark Plug Boot

Examine the firing ends of the spark
plugs, noting the type of deposits and the
degree of electrode erosion. Refer to Fig.
15 for the various types of spark plug
fouling and their causes.
Clean the plugs on a sand blast
cleaner, following the manufacturer's
instructions. Do not prolong the use of
the abrasive blast as it will erode the
insulator and electrodes.
Examine the plug carefully for
cracked or broken insulators, badly
pitted electrodes, and other signs of
failure. Replace as required.
DISTRIBUTOR
Inspect distributor components to see
that all snap rings are in place, and that
the magnetic pickup assembly moves
freely on the fixed base plate. Blow
assembly clean with compressed air.
Make sure no filings or metal chips
adhere to pickup magnet face.
Clean the distributor cap with a soft
bristle brush and mild cleaning solvent or
mineral spirits. Dry the cap with
compressed air. Inspect the cap for
cracks, burned contacts, broken carbon
button, carbon tracks or dirt or corrosion
in the sockets. Replace the cap if it is
damaged.
Rotor
Clean the rotor with a soft bristle
brush and mild cleaning solvent or
mineral spirits. Dry the rotor with
compressed air. Inspect the rotor for
breaks, cracks, carbon tracks or burns.
Replace the rotor if it is corroded or
damaged.
Secondary Wiring
Without removing from the engine,
inspect the secondary wires for visable
damage such as cuts, pinches, cracks or
torn boots. Do not remove wires from
distributor cap. Replace wires that are
damaged. If spark plug boot is damaged,
Replacement—All Engines, in this Part).
Coil
Wipe the coil with a damp cloth and
check for any cracks or other defects.
IGNITION RESISTOR WIRE
(Vehicles equipped with Dura
Spark II)
The special ignition resistance wire
must be of a specified length and
diameter to reduce the operating voltage
of the ignition system. Due to its special
resistance, under no circumstances
should it be replaced by any other wire
other than the correct service resistor
wire. When a new resistor wire is
installed, the old one should be isolated
from the system.
Note: Although the 1977 Lincoln
Continental system is shown, all other
systems are similar in operation and
repair. The only difference will be in
the disconnect points in the 14401

FUSE AND CIRCUIT BREAKER PANEL

(PART OF 14401 WIRING HARNESS)

14290
FUSE AND CIRCUIT BREAKER PANEL RETAINER WIRING HARNESS
AND 14401 HARNESS CONNECTOR
ASSEMBLY

RETAINER-CONNECTOR ASSEMBLY-
TO-DASH TABS (4)

14398
RETAINING SCREW WIRING HARNESS

FIG. 16 Disconnecting 14389 Wiring From Fuse Block — Typical

K2421-B
 23-01-12
wiring harness. See the latest service
information for other vehicles not
contained in this manual.
Lincoln Continental
The procedure which follows should
be used when making a replacement
of a damaged ignition resistor wire
(part of 14401 wiring harness). The
resistor wire is fed from a circuit weld
in the harness approximately 3" from
the connector to the ignition switch
on the steering column, and is routed
to the connector on the back of the
fuse panel which connects with the
14389 engine compartment wiring
harness on the left side of the dash
panel.
1. Disconnect the battery cable.
2. In the engine compartment, dis-
connect the 14389 wiring connec-
tor from the 14401 wiring and fuse
panel (on the left side of the dash
panel). See Fig. 16
3. To facilitate easier access to the
fuse panel and the ignition switch
connection, remove the lower trim
panel and disconnect the steering
column from the instrument paneL
4. Inside the car, detach the 14401
wiring connector that mates with
the 14398 wiring connector from
the back of the fuse panel.
5. Drop or pull the connector detached
from the fuse panel below the
instrument panel to facilitate the
removal of the damaged resistor
wire from the connector.
UNLOCKING WIRE TERMINAL FROM RETA.NER-CONNECTOR ASSEMBLY
FIG. 17 Removing Female Terminal From Fuse Block Connector
General Ignition Service
6. Locate the No. 16A red-light green
stripe wire in the connector and
retract the terminal retaining tab
with a small screwdriver or a large
paper clip. Now pull the female
terminal from the connector (Fig.
7. Cut the damaged resistor wire as
close to the harness as possible and
insulate the exposed ends with
C1AZ-19627-A electrical tape or
equivalent.
8. Now locate the ignition switch
connector and about 3 inches from
the connector unwrap the tape
covering and expose the circuits
welded into the harness.
9. Cut the damaged No. 16A (red-
light green stripe) wire from the
14401 harness at the weld. Approx-
imately iy2" from the connector,
cut the 16 gage red-light green wire,
strip about 3/8" of insulation from
each cut end and install a C5AZ-
14294-B bullet connector to each
end. Re-connect the circuit by
plugging both bullet connectors
into a B6A-14487-A double con-
nector (Fig. 18),
10. Install one end of a new -12250-
resistor wire into the remaining
opening in the double connector.
Re-wrap the exposed welded cir-
cuits previously exposed in the
14401 harness using appropriate
plastic tape.
11. Route the new resistance wire to
the connector behind the fuse panel
and tape it to the harness.
INSTALLING WIRE TERMINAL TO
RETAINER-CONNECTOR ASSEMBLY
CAUTION: Do not fold, loop or
overlap the resistor wire onto itself
under the harness covering.
12. Cut a 4" piece of No. 16 gage wire
(B6A-14296-C) from bulk stock,
strip 3/8" of insulation from each
end. Install a D2OB-14474-CB fe-
male terminal on one end and a
C5AZ-14294-B bullet terminal on
the other end (Fig. 18).
13.Install the female terminal into the
vacated cavity of the fuse panel
connector, where the damaged 16A
circuit was removed (Fig. 17). Push
the terminal firmly into place until
the locking tab snaps into place.
14. Connect the free end of the new
resistor wire to the free end of the
jumper, using a B7A-14487-A single
connector (Fig. 18).
15. Reassemble the connector to the
back of the fuse panel and connect
it with the 14389 wiring harness at
the dash panel.
16. Reconnect the battery cable to the
battery.
17. Start the vehicle and see if the
engine will continue runn ing when
the lock cylinder is released to the
RUN position. If not, check for
proper voltage at the ignition coil
IGN terminal. Voltage should be
about 6.4 volts, or resistance to
ground should read from 1.05-1 15
ohms at 75°F. The new resistor
allows for a slightly highe: current
to the coil.
K2591-A
 23-01-13 General Ignition Service 23-01-13

RETAINER-CONNECTOR
ASSEMBLY
CUT AND INSULATE
D20B-14474-CB NO. 16 CIRCUIT
FEMALE-SNAP.
ON TERMINAL

FABRICATED
JUMPER WIRE

D7AB-12250-AA
RESISTOR WIRE

B6A-14487-A
DOUBLE CONNECTOR

B3743-A
FIG. 18 New Resistor Wire Installation — Lincoln Continental Shown, Others Similar

SPECIFICATIONS
DISTRIBUTOR GENERAL INFORMATION ©

Rotor Air Distributor Gear Rotor Air Distributor Gear

Gap Voltage Shaft End Location Gap Voltage Shaft End Location
Engine Play ©
Drop (Max.) ® Engine Drop (Max.) Play (2) ®
2.3L 0.022-0.033 2.220-2.230 351 0.024-0.035 4.031-4.038
7.5KV
2.8L 0.022-0.033 2.655-2.660 400 0.024-0.035 4.031-4.038
200 7.5KV 0.022-0.033 2.510-2.515 460 0.024-0.035 4.031-4.038
250 0.022-0.033 2.510-2.515 460 PI 0.024-0.035 4.031-4.038
302 0.024-0.035 4.031-4.038
0 Refer to specification booklet for performance specifications. (2) Measured with distributor removed.
(3) Distance from bottom of mounting flange to bottom of gear.

Coil Primary Circuit Resistor Coil Primary Circuit Resistor

Primary Resistance Secondary Resistance 7,000-13,000

(Ohms) 1.0-2.0 Resistance (Ohms) (Ohms 1.30-1.40(75°)

CB3742C

Distributor Identification PART NUMBER PREFIX

PART NUMBER SUFFIX
The distributor identification number
is stamped on the distributor housing.
The basic part number for distributors is
12127. To procure replacement parts,
refer to the part number prefix and suffix
stamped on the distributor housing,
identifying the particular distributor. If
the Master Parts Catalog lists a change DATE CODE MANUFACTURER
date relating to the part needed, it may
also be necessary to refer to the date code
stamped on the distributor body. B3401-A

FIG. 19 Distributor Identification

23-01-14 General Ignition Service 23-01-14

SPECIAL TOOLS

Tool Description Tool No. Tool Description Tool No.

Spark Plug Boot Replacing Tool P73-192-1 Spark Plug Wire Removing Tool T74P-6666-A

Ignition Oscilloscopes ARE-27-55or Timing Light Snap-On MT-212, Sun PLT-61

ARE-881 orSunSX-239

CB1098-E
24-01-1 Fuel System 24-01-1

GROUP
FUEL SYSTEM
(9500)
PART TITLE PART NO. PART TITLE PART NO.

Air Cleaner - Dry Type 24-41 General Fuel System Service 24-01
Air Cleaner Duct System 24-42 Motorcraft Model 5200 2-V Carburetor 24-10
Carter Model YFA 1-V Carburetor 24-06 Motorcraft Model 4350 4-V Carburetor 24-26
Fuel Filters 24-51 Motorcraft Model 2150 2-V Carburetor 24-25
Fuel Pump - Mechanical 24-30 Motorcraft Model 2700 VV Carburetor 24-27
Fuel Tank, Fuel Lines and Evaporative Throttle Linkage 24-60
Emission System 24-50
CV2260-A

PART
General Fuel System Service 24-01

SUBJECT PAGE SUBJECT PAGE

DESCRIPTION CLEANING AND INSPECTION

Decel Valve 01-1 Air Cleaner 01-2
Fuel System 01-1 Carburetor 01-2
Fuel Pump 01-2
TESTING AND ADJUSTMENT 01-2

CV2261-A

DESCRIPTION
FUEL SYSTEM
Ford Motor Company vehicles
manufactured for domestic sale are
equipped with a variety of emission
control systems. Modification or
adjustment of these systems so as to
render them inoperative constitutes a
violation of federal law.
This Part of the shop manual will
cover those test and adjustment
procedures related directly to
carburetors. Other emission systems
related to the fuel system, but not directly
to the carburetor, will be covered in
Group 29 or in Volume 5, Part 50-29.
Carburetor Identification
A carburetor identification tag is
attached to each carburetor, usually
under one of the fuel bowl cover
attaching screws. The basic part number
for carburetors is 9510. To procure
replacement parts, it is necessary to
supply the proper prefix and suffix. In
some instances, the design change code
(Fig. 1) must also be supplied. Always
refer to the master parts list for parts
usage and interchangeability before
replacing a carburetor or any of its
component parts.
DECEL VALVE
A decel (deceleration) valve is
installed on some vehicles. The valve
provides fuel system enrichment during
closed throttle engine deceleration for
purposes of emission reduction. A typical
decel valve is shown in Figure 2.
Testing, problem diagnosis,
maintenance and replacement of decel
valves is covered in Part 50-29 and in
Group 29.
24-01-2
PART NO. PREFIX
INDICATES NEW
DESIGN
ASSEMBLY CODE-YEAR,
MONTH AND DAY
FIG. 1 Typical Carburetor
Identification Tag
TESTING AND ADJUSTMENT
All adjustments affect engine
emissions and should be performed by
competent personnel using specified
equipment. Refer to Part 50-29 of
CLEANING AND INSPECTION
AIR CLEANER
Refer to Volume 5 for the
recommended air cleaner assembly
maintenance mileage interval. Cleaning
the air cleaner or crankcase ventilation
filter elements is not recommended. They
should be replaced at the specified
mileage intervals. Clean the air cleaner
body and the cover with a solvent or
compressed air. Wipe the air cleaner
body and cover dry if a solvent is used.
Inspect the air cleaner body and cover for
distortion or damage at the gasket mating
surfaces. Replace the cover or body if
they are damaged beyond repair. Hold
the filter in front of a light and carefully
inspect it for any splits or cracks. If the
filter is split or cracked, replace it.
CARBURETOR
Dirt, gum, water or carbon
contamination in the carburetor or the
exterior moving parts of the carburetor
are often responsible for unsatisfactory
performance. Efficient carburetion
depends upon careful cleaning and
inspection.
The cleaning and inspection of those
parts not included in the carburetor
overhaul repair kit are covered here. All
gaskets and parts included in the repair
kit should be installed when the
carburetor is assembled and the old
gaskets and parts should be discarded.
Wash all the carburetor parts (except
the accelerating pump diaphragm, the
General Fuel System Service
PART NO. SUFFIX
V129O-F
FIG. 2 Typical Decel Valve
Volume 5 before performing critical fuel
system adjustments.
Refer to each carburetor section for
specific adjustment points for individual
enrichment valve, the choke pulldown
diaphragm, and the anti-stall dashpot
assembly) in clean commercial
carburetor cleaning solvent. If a
commercial solvent is not available,
lacquer thinner or denatured alcohol may
be used.
Rinse the parts in kerosene to remove
all traces of the cleaning solvent, then dry
them with compressed air. Wipe all parts
that can not be immersed in solvent with
a clean, soft, dry cloth. Be sure all dirt,
gum, carbon, and other foreign matter
are removed from all parts.
Force compressed air through all
passages of the carburetor. Do not use a
wire brush to clean any parts, or a drill
or wire to clean out any openings or
passages in the carburetor. A drill or wire
may enlarge the hole or passage,
changing the calibration of the
carburetor.
Check the choke shaft for grooves,
wear and excessive looseness or binding.
Inspect the choke plate for nicked edges
and for ease of operation, and free it if
necessary. Make sure all carbon and
foreign material has been removed from
the automatic choke housing and the
piston. Check the operation of the choke
piston in the choke housing to make
certain it has free movement.
Check the throttle shafts in the bores
for excessive looseness or binding and
24-01-2
A4082A
carburetors. Refer to Groups 29 and 50
for test and adjustment procedures for
decel valves, EGR valves, PVS switches
and all other emission control systems
equipment.
check the throttle plates for burrs which
prevent proper closure. Inspect the main
body, throttle body, air horn, nozzle bars
and booster venturi assemblies, choke
housing and thermostatic spring housing,
enrichment valve cover and accelerating
pump cover for cracks.
Check metallic float(s) for leaks by
holding them under water that has been
heated to just below the boiling point.
Bubbles will appear if there is a leak.
Shake the float to check for the entry of
fuel or water. If a float leaks, replace it.
Replace the float if the arm needle
contact surface is grooved. If the floats
are serviceable, polish the needle contact
surface of the arm with crocus clcth or
steel wool. Replace thefloatshafts if they
are worn. Replace all screws and nuts
that have stripped threads. Replace all
distorted or broken springs.
Inspect all gasket mating surfaces for
nicks and burrs. Repair or replace any
parts that have a damaged gasket su rface.
FUEL PUMP
Clean the exterior of the fuel pump
with a cloth. Inspect the fuel pump for
cracks or damage. Inspect the mounting
flange for distortion. Inspect the rocker
arm and pin for wear, cracks or damage.
Replace the pump if any of these
conditions are noted.
24-06-1 Model YFA 1-V Carburetor 24-06-1

PART
Model YFA 1-V Carburetor 24-06
All Six-Cylinder In-Line Engines

SUBJECT PAGE SUBJECT PAGE

DESCRIPTION ADJUSTMENTS (Cont'd.)
Carburetor Assembly 06-1 Metering Rod Adjustment 06-4

ADJUSTMENTS REMOVAL AND INSTALLATION

Anti-Stall Dashpot 06-3 Air Horn to Main Body Gasket . . 06-5
Automatic Thermostatic Spring Carburetor Assembly 06-5
Housing 06-3 Float or Needle Valve 06-5
Choke Plate Pulldown 06-3 Main Metering Jet, Low-Speed Jet,
Dechoke Adjustment 06-3 Metering Rod and Accelerator
Fast Idle Adjustment 06-3 Pump 06-6
Fast Idle Cam Setting 06-4
Float Drop Adjustment 06-4 DISASSEMBLY AND ASSEMBLY
Float Level Adjustment 06-4 Carburetor Assembly 06-6

CA4243-A

DESCRIPTION
CARBURETOR ASSEMBLY
INTERNAL FUEL
The Carter Model YFA 1-V BOWL VENT
carburetor is made up of three main
assemblies: the air horn, the main body
and throttle body (Figs. 1, 2 and 3).
CHOKE COLD AIR
The air horn, which serves as the AUTOMATIC PICK-UP CONNECTION
main body cover, contains the choke CHOKE
plate, an internal vent for the fuel bowl,
automatic choke thermostatic control
and electric assist choke (if equipped),
fuel inlet fitting, inlet needle and seat and
the float and lever assembly. The anti-
stall dashpot or solenoid throttle
positioner is attached to the air horn by
means of a bracket. The Model YFA
carburetor has a choke hot air inlet
adapter and some models are equipped
with a external mechanical bowl vent for
improved control of evaporative
emissions.
The Model YFA Carburetors used on
some in-line six-cylinder engines are
equipped with solenoid throttle
positioners (Fig. 1). The solenoid reduces
"dieseling" or after-running by allowing THROTTLE
the throttle plate to close further than the SOLENOID POSITIONER
THROTTLE LEVER (TSP) SOME MODELS
normal curb idle position when the
ignition is turned off. V2136-A
The main body contains the
accelerator pump assembly, metering FIG. 1 Model YFA 1-V Carburetor—Rear View
24-06-2 Model YFA 1-V Carburetor 24-06-2

rod, main metering jet, low-speed jet,
accelerator pump check ball and weight,
and the main discharge nozzle.
The throttle body contains the
throttle plate, throttle shaft and lever and
idle mixture adjusting screw with a
plastic limiter cap.
The engine speed is regulated and
controlled by the proportion of fuel and
air delivered to the cylinders for all
engine operating conditions. Operation is
based on the principle of pressure
differences.
Air is drawn into the carburetor air
horn by manifold vacuum. As the air
passes through the carburetor on the way
to enter the cylinders, low pressure is
created at the fuel discharge outlets of the
CHOKE PLATE
carburetor. The fuel bowl is vented to the
carburetor air horn. The higher air
pressure exerted on the fuel in the bowl
forces the fuel to travel up through the
fuel discharge channels and out into the
air stream passing through the
carburetor. The fuel and air is mixed at
this point and distributed into the engine
cylinders for combustion.

FUEL INLET

MECHANICAL CHOKE HOT AIR

FUEL BOWL VENT INLET ADAPTER

VENTURI VACUUM
CONNECTION

FUEL BOWL
ANTI-STALL
DASHPOT (SOME MODELS)

FIG. 2 Model YFA 1-V Carburetor-Left Front View

V2050-A

FIG. 3 YFA 1-V Carburetor Equipped with Solenoid—Rear View

24-06-3
ADJUSTMENTS
Most carburetor adjustments are
factory set, and based on guidelines
determined for reduced engine emission.
In order to adjust:
Automatic Choke
Idle Speeds
Fuel Mixture
you must refer to Engine Emission
Control System Part 29-01 of this
Volume or Part 50-29 of Volume 5.
Adjustment points for the YFA 1-V
Carburetor are shown in Figs. 1, 2, 3 and
4.
FAST IDLE ADJUSTMENT
Make certain the curb idle speed and
mixture are adjusted to specification
before attempting to set the fast idle
1. With the e n g i n e o p e r a t i n g
temperature normalized (hot), EGR
vacuum disconnected and a jumper
line (if required) to the distributor, air
cleaner removed and the tachometer
attached, manually rotate the fast idle
cam until the fast idle adjusting screw
rests on the kickdown step of the cam
as shown in Fig. 5.
ANTI-STALL DASHPOT
1. With the engine idle speed and
mixture properly adjusted, and the
engine at n o r m a l o p e r a t i n g
temperature, loosen the anti-stall
dashpot lock nut.
2. Hold the throttle in the curb idle
position and depress the dashpot
plunger with a screwdriver blade.
Measure the clearance between the
AUTOMATIC
CHOKE
THROTTLE SOLENOID
POSITIONER
(TSP) ADJ.
IDLE FUEL MIXTURE
POSITIONER
TSP OFF
IDLE SPEED ADJUSTMENT
ADJUSTMENT SCREW
V2039-A
FIG. 4 Carburetor Adjustments—
Model YFA 1-V
Model YFA 1-V Carburetor
FAST IDLE SPEED
ADJUSTING SCREW
FIG. 5 Fast Idle Adjusting Screw
throttle lever and the plunger tip.
Turn the anti-stall dashpot in a
direction to provide the specified
clearance between the tip of the
plunger and the throttle lever.
Tighten the locknut to secure the
adjustment.
AUTOMATIC THERMOSTATIC
SPRING HOUSING
The automatic choke has an
adjustment to control its reaction to
engine temperature. By loosening the
retaining screws that attach the
thermostatic spring housing to the choke
housing, the spring housing can be turned
to alter the adjustment. Refer to the
engine emissions decal for the proper
setting.
1. Remove the air cleaner assembly from
the carburetor.
2. Loosen the thermostatic spring
housing retaining screws. Set the
spring housing to the specified index
mark and tighten the retaining
screws.
3. If other carburetor adjustments are
not required, install the air cleaner
assembly on the carburetor.
DECHOKE ADJUSTMENT
1. Remove the air cleaner assembly.
2. Hold the throttle plate fully open and
close the choke plate as far as possible
without forcing it. Use a drill of the
proper diameter to check the
clearance between the lower edge of
the choke plate and air horn (Fig. 6).
24-06-3
FAST IDLE CAM
V2138-A
3. If the clearance is not within
specification, adjust by bending the
arm on the choke trip lever of the
throttle lever. Bending the arm
downward will decrease the
clearance, and bending it upward will
increase the clearance. Always
recheck the clearance after making
any adjustment.
CHOKE PLATE PULLDOWN
1. Remove the air cleaner assembly,
then remove the choke thermostatic
spring housing, gasket and heat baffle
from the carburetor.
2. Bend a 0.026 in. diameter wire gauge
at a 90 degree angle approximately
1/8-inch from one end. Insert the
bent end of the gauge between the
choke piston slot and the right
hand slot in the choke housing.
Rotate the choke piston lever
counterclockwise until the gauge is
snug in the piston slot (Fig. 7).
3. Exert a light pressure on the choke
piston lever to hold the gauge in place,
then use a drill with a diameter equal
to the specified pulldown clearance
between the lower edge of the choke
plate and the carburetor bore to check
clearance (Fig. 7).
4. To adjust the choke plate pulldown
clearance, bend the choke piston lever
between the choke shaft and piston
link as required to obtain the specified
setting. When bending the lever, be
careful not to distort the piston link.
5. Install the heat baffle, choke gasket
choke thermostatic spring housing
24-06-4 Model YFA 1-V Carburetor 24-06-4

and gasket. Set the housing to

specifications.
FAST IDLE CAM SETTING
1. Position the fast idle screw on the
kickdown step of the fast idle cam
against the shoulder of the high step
(Fig. 5).
2. Adjust by bending the choke plate DRILL
connecting rod to obtain the specified GAUGE
clearance between lower edge of the
choke plate and the carburetor bore.
METERING ROD ADJUSTMENT
1. Remove the carburetor air horn and
gasket from the carburetor.
2. Back out the idle speed adjusting
screw until the throttle plate is closed
tight in the throttle bore.
3. Press down on the end of the pump
diaphragm shaft until the assembly
bottoms.
4. To adjust the metering rod, hold the
diaphragm assembly as in Step 3,
then, turn the rod adjustment screw
counterclockwise (Fig. 8) until the
metering rod just bottoms in the body
casting.
5. Turn the metering rod adjustment
screw in (clockwise) one additional THROTTLE LEVER
(OPEN POSITION)
turn for the final adjustment. MAKE DECHOKE
6. Install the carburetor air horn with a ADJUSTMENT HERE
new gasket on the carburetor. V2 139-B

FLOAT LEVEL ADJUSTMENT

The dryfloatfuel level adjustment is FIG. 6 Choke Plate Clearance Adjustment
a final float or fuel level adjustment.
1. Remove the carburetor air horn and
gasket from the carburetor. Refer to
Air Horn to Main Body Gasket
Replacement for the proper
procedure.
2. Fabricate a float level gauge (Fig. 9) DRILL GAUGE
to the specified float level dimension.
3. Invert the air horn assembly, and BEND PISTON LINK
check the clearance from the float HERETO CONSTRUCTION OF TYPICAL
ADJUST WIRE GAUGE.
indentation on the top of the float to
the bottom of the air horn with the CHOKE
float level gauge (gasket removed) PISTON
LEVER
(Fig. 9). Hold the air horn at eye level
when gauging thefloatlevel. The float
arm (lever) should be resting on the
needle pin. Do not load the needle
when adjusting the float. Bend the
float arm as necessary to adjust the
float level (clearance). Do not bend
the tab at the end of the float arm. It
prevents the fuel inlet needle from
becoming disengaged. .026" WIRE
4. Install the carburetor air horn and a
new gasket on the carburetor. Refer
to Carburetor Air Horn to Main
Body Gasket Replacement for the .026"
proper procedure. WIRE
GAUGE
FLOAT DROP ADJUSTMENT
1. Remove the carburetor air horn and V1452-B
gasket from the carburetor. Refer to
Air Horn to Main Body Gasket FIG. 7 Pull down Clearance Adjustment—Model YFA 1-V
24-06-5
Replacement for the proper
procedure.
2. Fabricate a float drop gauge to the
specified dimension.
3. Hold the airhorn upright and let the
float hang free. Measure the
maximum clearance from the top of
the float to the bottom of the air horn
(gasket removed) with the float drop
gauge. Hold the air horn at eye level
when gauging the dimension.
4. To adjust, bend the tab (Fig. 9) at the
end of the float arm to obtain the
specified setting.
5. Install the carburetor air horn and a
new gasket on the carburetor as
described in this Part.
REMOVAL AND INSTALLATION
AIR HORN TO M A I N BODY
GASKET
Removal
1. Remove the air cleaner.
2. Disconnect the choke heat tube at the
carburetor air horn. Disconnect the
fuel inlet line at the carburetor.
Disconnect the choke clean air hose
at the carburetor. Disconnect the
external vent hose (if equipped).
3. Disconnect the solenoid wire at the
connector (if equipped). Disconnect
the electric choke wire at the
connector (if equipped).
4. Remove the clip retaining the link
joining the choke shaft lever to the
fast idle cam and remove the link.
5. Remove the air horn assembly
attaching screws, dashpot and
bracket assembly or solenoid throttle
positioner and air horn gasket.
Discard the gasket.
Installation
1. Install a new air horn to main body
gasket. Make sure all holes in the new
gasket have been properly punched
and that no foreign material has
adhered to the gasket. Install the air
horn assembly, solenoid throttle
positioner and air horn attaching
screws. Position the link joining the
fast idle cam to the choke shaft lever
and retain in place with a wire clip.
2. Connect the fuel inlet line, choke heat
tube and choke clean air hose and
external vent hose (if equipped) to
the carburetor air horn.
3. Connect the solenoid wire and electric
choke wire (if equipped).
4. Install the air cleaner. Start the
engine, check for fuel leaks and run
Model YFA 1-V Carburetor
ROD ACTION CAUSED
BY SCREW ACTING AS
PIVOT POINT FOR LEVER
SCREW RETAINING METERING
SPRING R<
1 V1445-E
FIG. 8 Metering Rod Adjustment
it until normal operating temperature
is reached. Install the air cleaner
Adjust the idle fuel mixture and idle
speed.
FLOAT OR NEEDLE VALVE
Removal
1. Remove the carburetor air horn and
gasket. Follow instructions under Air
Horn to Main Body Gasket
Replacement.
2. Hold the air horn assembly bottom
side up, and remove the float pin and
float and lever assembly. Turn the air
horn assembly over and catch the
needle pin, spring and needle.
3. Remove the needle seat, inlet screen
and gasket.
Installation
1. Replace the float if the needle pin
contact surface is grooved. If the float
is serviceable, polish the needle pin
contact surface with crocus cloth or
steel wool. Replace the float pin if it
is worn.
2. Install the needle seat, gasket and
inlet screen in the air horn. With the
air horn inverted, install the needle,
pin spring, needle pin, float and lever
assembly and float pin (Fig. 13).
3. A d j u s t t h e f l o a t level to
specifications.
4. Install the carburetor air horn and
gasket.
CARBURETOR ASSEMBLY
Removal
Flooding, stumble on acceleration
and other performance complaints are in
many instances, caused by the presence
of dirt, water or other foreign matter in
24-06-5
TAB (LOW FUEL LEVEL)
FLOAT ARM
FLOAT
V2079-A
FIG. 9 Fuel Level Float Adjustment
the carburetor. To aid in diagnosing the
cause of complaint, the carburetor should
be carefully removed from the engine
without removing the fuel from the bowl.
The contents of the bowl may then be
examined for contamination as the
carburetor is disassembled.
1. Remove the air cleaner.
2. Remove the throttle cable or rod from
the throttle lever. Disconnect the
distributor vacuum line, in-line fuel
filter and the choke heat tube at the
carburetor.
3. Disconnect the solenoid wire at the
connector (if equipped). Disconnect
the electric choke wire at the
connector (if equipped).
4. Disconnect the choke clean air hose
from the air horn.
5. Remove the carburetor retaining
nuts; then remove the carburetor.
Remove the carburetor mounting
gasket, spacer (if equipped) and lower
gasket, from the intake manifold.
Installation
1. Clean the gasket mounting surfaces of
the spacer and carburetor. Place^the
spacer between two new gaskets and
position the spacer and gaskets on the
intake manifold. Position the
carburetor on the spacer and gasket
and secure it with the attaching nuts.
To prevent leakage, distortion or
damage to the carburetor body flange,
snug the nuts; then, alternately
tighten each nut in a crisscross
pattern to the specified torque.
2. Connect the in-line fuel filter, throttle
cable, choke heat tube, distributor
vacuum line and EGR vacuum line.
24-06-6
3. Connect the choke clean air hose to
the air horn. Connect the solenoid
wire and electric choke wire (if
equipped).
4. Install the air cleaner.
5. Adjust the engine idle speed, the idle
fuel mixture and anti-stall dashpot (if
so equipped).
M A I N METERING JET, LOW-
SPEED JET, METERING ROD AND
ACCELERATOR PUMP
Removal
1. Remove the carburetor from the
engine as described in this Part.
2. Remove the carburetor air horn and
gasket by following the instructions
under Air Horn to Main Body Gasket
Replacement.
3. Turn the main body casting upside
down and catch the accelerating
pump check ball and weight.
4. Loosen the throttle shaft arm screw,
and remove the arm and the pump
connector link.
5. Remove the accelerator pump
diaphragm housing screws. Remove
the accelerator pump discharge tube.
Lift out the pump diaphragm
assembly, the pump lifter link, the
anti-rock plate, the metering rod as a
unit (Figs. 10 and 11).
6. Disengage the metering rod arm
spring from the metering rod, and
remove the metering rod from the
metering rod arm assembly. Note the
location of any washers shimming
either spring for proper reassembly.
Compress the upper pump spring,
and remove the spring retainer.
Remove the pump spring, the
metering rod arm assembly, the anti-
rock plate and the pump lifter link
from the pump diaphragm shaft.
Compress the pump diaphragm
spring. Remove the pump diaphragm
spring retainer, spring and pump
diaphragm assembly from the pump
DISASSEMBLY AND ASSEMBLY
Refer to Part 24-01 for Cleaning and
Inspection procedures.
CARBURETOR ASSEMBLY
Disassembly
Use a separate container for the
component parts of the various
assemblies to facilitate cleaning,
inspection and assembly.
The following is a step-by-step
sequence of operations for completely
overhauling the carburetor; however,
certain components of the carburetor
may be serviced without a disassembly of
the entire unit.
Model YFA 1-V Carburetor
PUMP DIAPHRAGM
METERING ROD
V1448-D
FIG. 10 Accelerating Pump and Lifter
Link Assembly
diaphragm housing assembly (Fig.
10).
7. With the proper size jet tool or
screwdriver, remove the low speed jet
and the main metering jet (Fig. 13).
Installation
1. With the proper size jet tool (or
screwdriver) install the low speed jet
and the main metering jet (Fig. 13).
2. Install the pump diaphragm in the
pump diaphragm housing. Position
the pump diaphragm spring on the
diaphragm shaft and housing
assembly. Install the spring shim
washers (if equipped) in the proper
locations. Install the spring retainer.
Install the pump lifter link, the anti-
rock plate, metering rod arm and
spring assembly and the upper pump
spring on the diaphragm shaft.
Depress the spring and install the
upper pump spring retainer.
3. Install the metering rod on the
metering rod arm and place the
looped end of the metering rod arm
spring on the metering rod as shown
in Fig. 10. Align the pump diaphragm
1. Remove the choke retaining screws
and h o u s i n g r e t a i n e r s , the
thermostatic spring housing
assembly, spring housing gasket,
spring housing baffle plate and fast
idle link.
2. Remove the air horn assembly
attaching screws, dashpot or solenoid
bracket assembly, air horn assembly,
and air horn gasket (Fig. 13).
3. Hold the air horn assembly bottom
side up and remove the float pin and
float and lever assembly. Turn the air
24-06-6
ACCELERATOR
PUMP NOZZLE
PUMP CHECK
BALL AND WEIGHT
DIAPHRAGM
HOUSING SCREW
PUMP
DIAPHRAGM
AND HOUSING
ASSEMBLY
METERING
ROD
V2051-B
FIG. 11 Pump Diaphragm and
Housing Installation
with the diaphragm housing; make
sure holes are aligned. Install the
housing attaching screws to keep the
diaphragm and housing aligned.
Install the accelerator pump
discharge tube.
4. Install the throttle shaft arm and link
to the end of the throttle sh aft.
5. Adjust metering rod as described in
this Part. .
6. Install the carburetor air horn and
gasket as described under Air Horn
to Main Body Gasket Replacement.
7. Install the carburetor on the engine as
described in this Part.
horn assembly over and cntch the
needle pin, spring and needle.
4. Remove the needle seat and gasket.
5. Remove the air cleaner bracket.
Remove the choke plate attaching
screws. File the staked ends, if
necessary, and use new screws upon
reassembly. Remove the choke plate
from the air horn assembly; remove
the choke link lever and attaching
screw. Rotate the choke shaft and
piston assembly counterclockwise
until the choke piston is out of the
choke piston cylinder (Fig. 12).
24-4)6-7
Remove the assembly from the air
horn. Remove the piston pin and
piston from the choke piston lever
and link assembly.
6. Turn main body casting upside down
and catch the accelerating pump
check ball and weight.
7. Loosen the throttle shaft arm screw,
and remove the arm and pump
connector link.
8. Remove the fast idle cam and
shoulder screw.
9. Remove the accelerating pump
diaphragm housing screws. Lift out
the pump diaphragm assembly, the
pump lifter link, the metering rod as
a unit.
10. Disengage the metering rod arm
spring from the metering rod, and
remove the metering rod from the
metering rod arm assembly. Note the
location of any washers shimming
either spring for proper reassembly.
Compress the upper pump spring,
and remove the spring retainer.
Remove the upper spring, the
metering rod arm assembly and the
pump lifter link from the pump
diaphragm shaft. Compress the pump
diaphragm spring, and remove the
pump diaphragm spring retainer,
spring, and pump diaphragm
assembly from the pump diaphragm
housing assembly.
11. With the proper size jet tool or
screwdriver, remove the main
metering rod jet and the low speed jet
(Figs. 11 and 13).
12. Remove the retaining screws and
separate the throttle body flange
assembly from the main body casting.
Remove the body flange gasket.
13. Remove the throttle plate retaining
screws. File the staked ends, if
necessary, and use new screws upon
assembly. Slide the throttle shaft and
lever assembly out of the throttle
body flange assembly. Note the
location of the ends of the torsion
spring on the throttle shaft for proper
reassembly. When removing the idle
CHOKE PISTON LEVER
CHOKE PISTON A N D LINK ASSEMBLY
CYLINDER
CHOKE PISTON
PIN
V1454-C
FIG. 12 Automatic Choke Piston
Removal or Installation
Model YFA 1-V Carburetor
mixture limiter cap be sure to note the
position of the tab. After removing
the limiter cap count the number of
turns to lightly seat the needle. This
information will be used in
reassembly.
Assembly
1. Install the throttle shaft and lever
assembly with torsion throttle return
spring and bushing (Figs. 13 and 14)
in the throttle body flange. Position
the throttle plate on the throttle shaft
with the notch in the plate aligned
with the slotted idle port (Fig. 14) in
the throttle body flange. Install the
throttle plate attaching screws snug,
but not tight. Move the shaft back and
forth and rotate it to be sure the
throttle plate does not bind in the
flange bore. It is necessary that the
throttle plate should close tight in the
bore therefore the idle speed screw
should be backed out sufficiently to
insure it does not contact the throttle
stop. Reposition the plate, if
necessary. Tighten the screws and
stake (or peen) the screws in place.
Install the idle mixture screw the
same number of turns out from lightly
seated. Install the limiter cap in the
same position as removed.
2. Place a new body flange gasket and
the main body casting on the throttle
body flange. Install the attaching
screws and tighten them evenly.
3. With the proper size jet tool (or
screwdriver) install the low speed jet
and the main metering rod jet (Figs.
11 and 13).
4. Install the pump diaphragm in the
pump diaphragm housing (Fig. 11).
Position the pump diaphragm spring
on the diaphragm shaft and housing
assembly. Install the spring shim
washers in the proper locations.
Install the spring retainer. Install the
pump lifter link, metering rod arm
and spring assembly, and upper pump
spring on the diaphragm shaft.
Depress the spring and install the
upper pump spring retainer.
5. Install the metering rod on the
metering rod arm and place the
looped end of the metering rod arm
spring on the metering rod as shown
in Fig. 10. Align the pump diaphragm
with the diaphragm housing; make
sure the holes are aligned. Install the
housing attaching screws to keep the
diaphragm and housing aligned.
6. Align the pump housing, pump lifter
link, metering rod and baffle plate
with the main body casting. Be sure
the vacuum passage in the diaphragm
24-06-7
housing is aligned with the vacuum
passage in the main body. Install the
assembly in the main body casting
being careful to engage the pump
lifter link with the main body, and to
insert the metering rod in the main
metering rod jet. Install the pump
housing attaching screws snug, but
not tight. Push down on the
diaphragm shaft to compress the
diaphragm, and tighten the attaching
screws. Adjust the metering rod,
following the procedure under
Metering Rod Adjustment.
7. Install the fast idle cam and shoulder
screw. Install the throttle shaft arm
and pump connector link on the
throttle shaft and pump lifter link
(Fig. 14). Tighten the lock screw.
8. Assemble the choke piston and pin to
the choke piston lever and link
assembly. Install the choke shaft
assembly in the air horn and position
the piston as shown in Fig. 12.
9. Align the piston with the cylinder and
rotate the shaft assembly clockwise
until the piston pin is inside the piston
cylinder.
10. Position the choke plate on the choke
shaft and install the screws snug.
Check the choke plate movement to
be sure it isn't binding. Tighten the
screws and peen or stake them to
prevent loosening. Install the choke
link lever and tighten the attaching
screw.
11. Install the needle seat and gasket in
the air horn. With the air horn
inverted, install the needle, pin spring,
needle pin, float and lever assembly,
and float pin. Adjust thefloatlevel to
specifications.
12. Place the pump check ball and weight
in the main body casting (Fig. 11).
Position a new air horn gasket, the air
horn assembly, and the dashpot or
solenoid bracket on the main body.
Install and tighten the attaching
screws.
13. Install the thermostatic coil housing,
gasket and baffle plate, identification
mark facing outward, with the gasket
between the baffle and coil housing.
Be sure the thermostatic spring
engages the choke lever tang and is
not stopped by a retaining tab on the
baffle plate (if equipped). Install the
retainers and housing screws. Set the
coil housing index to specifications
and tighten the screws.
14. Install the air cleaner bracket. Install
the fast idle link.
24-06-8 Model YFA 1-V Carburetor 24-06-8

SCREWS

AIR CLEANER BRACKET

SCREW

ANTI-STALL DASHPOT
AIR HORN
CHOKE PLATE ASSEMBLY

FAST IDLE CHOKE LEVER

AIR HORN ASSEMBLY
COIL HOUSING BAFFLE PLATE

COIL HOUSING GASKET

ELECTRIC ASSIST
CHOKE CAP

CHOKE PISTON LEVER

AIR HORN GASKET AND SHAFT ASSEMBLY
PISTON PIN
CHOKE PISTON

NEEDLE PIN
SPRING, SEAT AND UPPER PUMP SPRING
GASKET ASSEMBLY RETAINER
METERING ROD ARM ASSEMBLY
COIL HOUSING RETAINER \
METERING ROD UPPER PUMP SPRING 9D598 \
ARM SPRING
ATTACHING SCREW
FLOAT PIN ANTI-ROCK PLATE

FLOAT AND LEVER PUMP LIFTER LINK

ASSEMBLY
PUMP DIAPHRAGM SPRING RETAINER

PUMP DIAPHRAGM SPRING

METERING ROD JET DIAPHRAGM HOUSING ATTACHING SCRIiW

PUMP CHECK WEIGHT

PUMP DIAPHRAGM HOUSING ASSEMB.Y

PUMP CHECK BALL
MAIN BODY CASTING
SCREW PUMP DIAPHRAGM
ASSEMBLY
Yf^ BODY FLANGE
\fi ATTACHING SCREW

THROTTLE SHAFT ARM BODY FLANGE

GASKET

SCREW

PUMP CONNECTOR LINK SOLENOIC "OFF"

OR CURB
FAST IDLE IDLE SPEED SCREW
BODY FLANGE *-f| ADJUSTING SCREW
ATTACHING SCREW Q

FAST IDLE
CAM LINK

SPRING

IDLE FUEL THROTTLE SHAFT AND

-MIXTURE ADJUSTING LEVER ASSEMBLY
SCREW AND SPRING

ALUMINUM THROTTLE
BODY FLANGE ASSEMBLY

V1129-M

FIG. 13 Model YFA 1-V Carburetor Assembly

24-06-9 Model YFA 1-V Carburetor 24-06-9

THROTTLE SHAFT
AND LEVER ASSEMBLY

SLOTTED
IDLE PORT
NOTCH

THROTTLE PLATE V1453-A

FIG. 14 Throttle Plate and Shaft Arm

Installation
24-10-1 Model 5200 2-V Carburetor 24-10-1

PART
Model 5200 2-V Carburetor 24-10
2.3L Engine: Pinto, Bobcat and Mustang

SUBJECT PAGE SUBJECT PAGE

DESCRIPTION ADJUSTMENTS (Cont'd.)

General ,10-1 Fast Idle Cam Clearance 10-3
Altitude Compensation 10-2 Secondary Throttle Stop Screw . 10-4

ADJUSTMENTS DISASSEMBLY AND ASSEMBLY

Choke Plate Vacuum Pulldown .10-3 Disassembly 10-5
Dry Float Setting .10-4 Assembly 10-8
CV2262-A

CAM LATCH

INDEX NOTCH
DESCRIPTION
BIMETAL SPRING
GENERAL

The Motorcraft Model 5200 2-V

carburetor is a two stage, two venturi
carburetor. The primary venturi is
smaller than the secondary venturi. The
secondary system is operated by
mechanical linkage.
The primary stage includes a curb idle
system, accelerator pump system, idle
transfer system, main metering system BIMETAL ASSEMBL
and power enrichment system.
The secondary side includes a transfer
system, main metering system and power CHOKE HOUSING'
system. Both the primary and secondary y-1912-B
systems draw fuel from a common fuel FIG. 1 Fast Idle Cam Latch
bowl.
The Model 5200 2-V is equipped
with an automatic choke featuring an
electric heater assist. This provides for
choke pull-off in a short time after
engine start. Testing and adjustment
information for the choke is contained
in Part 29-01 of this volume.
Fast Idle Cam Latch (Fig. 1) is
provided to hold the fast idle cam in the
high position (fast idle) until the choke
heats up and the bimetal latch "B" backs
off and allows the latch pin and fast idle
cam to rotate to the normal run position.
(TSP)
An overcenter spring is also provided to SOLENOID "OFF
assist in closing the choke plate for initial IDLE SPEED
starting of a cold engine in high ambient ADJUSTING SCREW

temperatures. After initial choke

(TSP)
pull-down occurs, the overcenter spring SOLENOID "ON
has little or no effect on choke operation. (CURB) IDLE SPEED SOLENOID
ADJUSTING SCREW ELECTRICAL
Three new throttle positioners CONNECTION
(TSP) are used on the 1977 carbure- /1911-B
tors (Fig. 2). The solenoids operate
when ignition switch is on. FIG. 2 Model 5200 2-V Carburetor With Solenoid Throttle Positioner
24-10-2 Model 5200 2-V Carburetor 24-10-2

The vacuum kickers are actuated

when air conditioning units are turned
on, by vacuum switched through a
vacuum solenoid valve. This provides
higher idle speed when the air condi-
tioner compressor is operating.
The carburetor is provided with a
drilled passage to connect the EGR
valve.

ALTITUDE
E.G.R. VALVE COMPENSATION
CONNECTION ASSEMBLY V2263-A

V1969-C
FIG. 4 Model 5200 Carburetor with Altitude Compensation
FIG. 3 E.G.R. Valve Connection

ALTITUDE COMPENSATION
Some model 5200 carburetors in-
stalled on vehicles sold in high altitude
areas are equipped with altitude com-
pensation. This is a two-position man-
ual system that uses the carburetor's
supplemental metering system when
the driver places the instrument panel
control in the "sea level" position,
and the normal fuel metering system
when the driver places the control in
the "altitude" position (Fig. 4).

ADJUSTMENTS
Most carburetor adjustments are
factory set, and based on guidelines
determined for reduced engine emission.
In order to adjust:
Automatic Choke and Electric Assist
Idle Speeds
Fuel Mixture
Idle CO
you must refer to Engine Emission
Control Systems Part 29-02 of this
Volume or Part 50-29 of Volume 5.
Adjustment points for the Motorcraft
5200 2-V carburetor are shown in Figs.
2, 5 and 6.

IDLE MIXTURE
ADJUSTMENT CURB IDLE (TSP
OFF) ADJUSTMENT

V2134B

FIG. 5 Curb Idle Speed and Mixture Adjustments

24-10-3 Model 5200 2-V Carburetor 24-10-3

CHOKE PLATE VACUUM

PULLDOWN
1. Remove the three hex head screws
and the ring retaining the choke
thermostatic spring cover.
2. Remove choke electric assist as-
sembly. Remove latch plate assem-
bly. CAUTION: Choke plate must
be closed in air horn when re-
installing the electric assist with
latch.
3. Set the fast idle cam on the top step.
4. Using a screwdriver, pu«h the
diaphragm stem back against its stop
(Fig. 8). Place a specified gage rod or
drill between the lower edge of the
choke plate and the air horn wall.
FAST IDLE SPEED 5. Remove the slack from the choke
ADJUSTING SCREW
linkage by attaching a rubber :>and to
V2135-B the choke operating lever as shown in
Fig. 9.
6. To adjust the choke plate-to-air horn
FIG. 6 Fast Idle Speed Adjustment clearance, turn the vacuum
diaphragm adjusting screw in or out
FAST IDLE CAM CLEARANCE as required (Fig. 9).
1. Insert a specified inch drill between
the lower edge of the choke plate and
the air horn wall.
2. With the fast idle screw held on the
bottom step of the fast idle cam,
against the top step, measure the
clearance between the tang of the
choke lever and the arm on the fast
idle cam (Fig. 7). The tang and arm
should be in light contact. Bend choke
lever tang up or down as required.

DRILL OR !
GAUGE ROD

CHOKE TANG

CHECK
CLEARANCE
HERE FIG. 8 Measuring Choke Plate Pulldown
FAST IDLE CAM V1705-B

FIG. 7 Fast Idle Cam Clearance

24-10-4 Model 5200 2-V Carburetor 24-10-4

DRY FLOAT SETTING

With the bowl cover held in an
inverted position and the float tang
resting lightly on the spring loaded fuel
VACUUM DIAPHRAGM
inlet needle, measure the clearance
between the edge of thefloatand the bowl
3&* cover (Fig. 10). To adjust the clearance,
bend the float tang up or down as
required (Fig. 11). Do not scratch or
damage the tang.
Adjust both floats equally.

FLOAT LEVEL FLUA I UK UP

ADJUSTING ADJUSTING
TANG TANG

420-A

V1712-B

FIG. 11 Float Adjustment

FIG. 9 Adjusting Choke Plate Pulldown

SECONDARY THROTTLE STOP

SCREW
FLOAT
1. Back off the secondary throttle stop
DRILL OR
GAUGE ROD
screw until the secondary throttle
plate seats in its bore.
2. Turn the screw in until it touches the
tab on the secondary throttle lever.
3. Turn the screw in an additional 1/4
turn for a 2300 cc 4-cylinder en-
gine (Fig. 12).

V1418C

FIG. 10 Dry Float Setting

24-10-5 Model 5200 2-V Carburetor 24-10-5

SECONDARY
THROTTLE
STOP
ADJUSTING
SCREW

V1708-B

FIG. 12 Secondary Throttle Stop Adjustment

DISASSEMBLY AND ASSEMBLY

DISASSEMBLY
Refer to Fig. 13 for the disassembled
view of the carburetor.
24-10-6 Model 5200 2-V Carburetor 24-10-6

AIR HORN

FUEL
INLET

CHOKE PLATES
AIR CLEANER
STUD

CHOKE SHAFT
AND LEVER

SOLENOID
THROTTLE
POSITIONER
ASSEMBLY

SECONDARY
OPERATING
RETURN SPRING

FAST IDLE
ADJUSTING
SCREW THROTTLE
RETURN
SPRING

THERMOSTATIC
HOUSING

THROTTLE SOLENOID
POSITIONER " O F F "
ADJUSTING SCREW

DIAPHRAGM
COVER ADJUSTING
SCREW

FIG. 13 Model 5200 Carburetor Disassembled

24-10-7
Bowl Cover
1. Remove the bowl cover screws and
lockwashers.
2. Remove the retainer clips from the
choke rod and carefully remove the
bowl cover (Fig. \4)- Remove the
choke rod seal.
3. Remove the float hinge pin, float and
inlet needle.
4. Remove the inlet needle seat and
gasket.
5. Remove the three enrichment valve
vacuum diaphragm screws, washers
and diaphragm.
BOWL COVER
V1709-A
FIG. 14 Removing Bowl Cover
Automatic Choke
1. Remove the choke thermostatic
spring housing retaining ring
attaching screws. Remove the ring,
housing and electric heater assembly.
2. Remove the choke housing assembly
screws. Note that the long screw goes
in the long leg of the assembly. Slip
the housing away from the main body
and disengage the fast idle rod.
Remove the O-ring from the vacuum
passage (Fig. 15).
3. Remove the choke shaft nut and
lockwasher, choke lever and fast idle
cam.
4. Remove the fast idle lever attaching
screw, fast idle lever and spacer.
Remove the screw and spring from
the lever.
5. Remove the choke diaphragm cover
screws and cover, return spring,
diaphragm and rod assembly.
Accelerator Pump
1. Remove the four pump cover screws
and pump cover assembly. Remove
the pump diaphragm assembly and
pump return spring.
2. Remove the pump discharge screw
assembly and pump discharge nozzle
and two gaskets. Remove the two
pump discharge check balls (Fig. 13).
Model 5200 2-V Carburetor
VACUUM
DIAPHRAGM
"O"RING
OKE LEVER
FAST IDL
ADJUSTING SCREW V1710-A
FIG. 15 Removing Automatic Choke
FIG. 16 Removing Main Well Tubes
Main Body
1. Remove the primary high speed bleed
and main well tube (Fig. 17).
2. Remove the secondary high speed
bleed and main well tube. Note the
size of the air bleed plugs and main
well tubes so they may be installed in
the correct position.
3. Remove the primary and secondary
main metering jets. Note the different
size jets so they may be installed in
the correct position. (Fig 17).
24-10-7
4. Remove the power valve and gasket.
Remove the primary and secondary
idle jet retainers and idle jets located
on the sides of the carburetor body
(Fig. 17).
5. Turn the idle limiter cap i:i to the
stop. Remove the idle limiter cap.
Count the turns required to lightly
seat the idle adjustment needle.
Count to the nearest 1/16 turn.
Remove the idle needle and spring.
6. Remove the secondary operating
lever return spring.
7. Remove the primary throttle lever
nut and lock tab. Remove the primary
lever and flat washer. Remove the
secondary operating lever assembly
and lever bushing.
V1711-B
. Remove the idle adjusting lever
spring and shaft washer. Note how
the primary throttle return spring is
hooked over the idle adjusting lever
and the carburetor body.
9. Remove the idle speed screw an*i
spring from the idle adjusting lever.
10. Remove the secondary throttle lever
nut, lockwasher, flat washer and
secondary throttle lever. Remove the
secondary idle adjusting screw.
 24-10-8
SECONDARY VENTURI
AAAIN BODY
IDLE JET RETAINER
IDLE JET
M A I N JET
FIG. 17 Main Metering Jets and Idle Jets
ASSEMBLY
Main Body
1. Install the secondary idle adjusting
screw, secondary throttle lever, flat
washer, lockwasher and nut.
2. Install the idle speed screw and spring
in the idle adjusting lever.
3. Install the washer, primary throttle
return spring and idle adjusting lever
and lever bushing. Install the
secondary operating lever assembly
(Fig. 13).
4. Install the flat washer and primary
throttle lever. Install the lockwasher
and nut. Attach the secondary
operating lever return spring.
5. Install the idle mixture adjusting
needle and spring. Turn it in until it
lightly bottoms. Back out the screw
the exact number of turns recorded at
disassembly. Install a new limiter cap
on the idle mixture needle with the
stop tab on the cap against the lean
side of the stop on the carburetor
body.
6. Install the idle jet and retainer
assemblies on each side of the
carburetor body. Check carefully for
Model 5200 2-V Carburetor
PRIMARY VENTURI
FUEL BOWL
IDLE JET RETAINER
M A I N WELL TUBE
M A I N WELL TUBE PLUG
V1427-C
the correct primary and secondary
sizes (Fig. 17).
7. Install the power valve gasket and
power valve.
8. Install the primary and secondary
main jets. Be sure the correct sizes are
installed.
9. Install the primary and secondary
main well tubes and high speed
bleeds. Be sure the correct sizes are
installed.
Accelerator Pump Assembly
1. Install the pump discharge check
balls (2) screw. Install the pump
discharge nozzle with a gasket on top
and bottom. Install the pump
discharge screw.
2. Install the pump return spring and
pump diaphragm assembly. Start the
four pump cover screws. Hold the
pump operating lever partially open
to align the diaphragm gasket.
Tighten the four cover screws evenly.
Automatic Choke
1. Install the diaphragm adjusting
screw. Initially adjust the screw so
that the threads are flush with the
inside of the cover.
2. Install the choke diaphragm and rod
24-10-8
assembly. Install the diaphragm
return spring and cover. Install the
cover screws and lock-washers.
3. Install the fast idle adjusting screw
and spring to the fast idle arm. Install
the flat spacer, fast idle arm and
attaching screw.
4. Install the choke shaft into the
housing and position the fast idle cam
on the housing post.
5. Install the choke lever, lockwasher
and nut.
6. Install the O-ring on the vacuum
passage. Install the fast idle rod with
the end with one tab in the fast idle
adjusting lever and the end with two
tabs in the primary throttle lever.
7. Position the choke housing against
the main carburetor body and install
the long attaching screw in the long
leg of the housing. Install the other
screws.
8. Adjust choke plate pulldown,
referring to ADJUSTMENT Section.
9. Install the latch plate and electric
choke heater, thermostatic housing,
retaining ring and attaching screws.
Be sure choke plate is in full closed
position before installing the choke
electric assist heater element. Index
the housing and tighten the screws.
Bowl Cover
1. Install the inlet needle seat and
gasket.
2. Install the power valve vacuum
diaphragm. Depress the spring and
install the screws and washers finger
tight. Hold the stem so that the
diaphragm is horizontal and tighten
the screws evenly.
3. Install the float needle clip on the
float tab and position the float and
needle. Install the float shaft.
4. Hold the bowl cover in an inverted
position and adjust the dry float
setting (Fig. 10).
5. Hold the cover in its normal position
and adjust the float drop (Fig. 11).
6. Install the choke rod seal and seal
plug. Install the choke rod through
the seal and hook it into the choke
lever. Install the retaining clip.
7. Install the bowl cover gasket.
8. Install the choke link into the choke
lever. Install the retaining clip.
9. Install the five bowl screws and
torque them evenly.
10. Install the throttle positioner (if
equipped).
24-25-1 Model 2150 2-V Carburetor 24-25-1

PART
Model 2150 2-V Carburetor 24-25
2.8L, 302 C.I.D. (Except California), 351W, 351M and 400 C.I.D. Engines

SUBJECT PAGE SUBJECT PAGE

DESCRIPTION 25-1 REMOVAL AND INSTALLATION (Cont'd.)
Air Horn to Main Body Gasket 25-6
DIAGNOSIS AND TESTING 25-4 Carburetor Assembly 25-6
Choke Pulldown Diaphragm Assembly 25-7
ADJUSTMENTS Float, Needle Valve and Seat, Inlet
Accelerating Pump Stroke Adjustment 25-4 Screen or Main Jets 25-6
Choke Plate Pulldown and Fast Idle
Cam Clearance 25-4 MAJOR REPAIR OPERATIONS
Fuel Level (Float) Adjustment - Dry 25-5 Disassembly 25-7
Fuel Level (Float) Adjustment - Wet 25-5 Assembly 25-9

REMOVAL AND INSTALLATION

Accelerator Pump Diaphragm and/or
Elastomer Valve 25-6

DESCRIPTION
The Motorcraft Model 2150 2-V
carburetor (Figs. 1, 2 and 3) has two main
assemblies; the air horn and the main
body.
Some are equipped with altitude
compensation, designed to provide
improved high altitude emission control
and driveability (Figs. 1 and 2). Intake air
entering the bypass intake is metered into
the airflowjust above the throttle plates,
thus making for a leaner air/fuel mixture
needed at higher altitude. Air flow is
controlled by a valve activated by an
aneroid attached to the rear of the
carburetor main body.
To provide improved high altitude
cold engine starts, those carburetors
equipped with altitude compensation are
also equipped with a choke in the bypass
air intake, linked to the main choke plate.
The air horn assembly, which serves
as the main body cover, contains the
choke plate and the fuel bowl vent valve.
It also contains the pullover
enrichment system, which provides
additional fuel flow at high air flow
through the air horn (Fig. 1). Fuel is
drawn through metering orifices from the
fuel bowl and into the air flow through
bleeds in the upper body air horn.
The throttle plate, the accelerating
pump assembly, the enrichment valve
assembly, the fuel bowl and the
mechanical high speed bleed system are
in the main body. The automatic choke
housing and choke pulldown diaphragm
are attached to the main body.
Each bore contains a main and
booster venturi, main fuel discharge,
accelerating pump discharge, idle fuel
discharge and throttle plate.
The booster venturi contains high
speed bleed orifices, along with a
mechanical high speed bleed control
system. This system consists of a
mechanical lift rod that actuates reverse-
tapered "ballbat" metering rods in the
CA4235-A
high speed bleed orifices. This allows
control of fuel/air mixture to the booster
Venturis for more precise high speed
operation and improved low-speed
response.
The Model 2150 2-V also uses the
electric assist automatic choke system.
This system consists of a choke cap,
thermostatic spring, bimetallic
temperature sensing disc (switch), and a
ceramic heater powered from the stator
tap of the alternator (Fig. 4).
Voltage is constantly supplied to the
temperature sensing switch as long as the
engine is running. The system is
grounded through a strip connected to
the carburetor body. At temperatures
above approximately 80°-110°F., the
temperature sensing switch closes, and
current is supplied to the heater. As the
heater warms, it causes the thermostatic
spring to pull the choke plate open.
Testing and adjustment of electric
assist choke is covered in Part 29-02 of
this Volume.
24-25-2 Model 2150 2-V Carburetor 24-25-2

MECHANICAL FUEL BOWL ALTITUDE

VENT VALVE COMPENSATION
CHOKE

BYPASS
CHOKE
LINK

ACCELERATOR PUMP
LEVER SOLENOID OFF (TSP OFF>
IDLE SPEED ADJUSTING V1885-C
SCREW

FIG. 1 Model 2150 2-V Carburetor—Left Front 3/4 View (With Altitude
Compensation)

FAST IDLE CAM

ADJUSTING SCREW

ANEROID
ASSEMBLY CHOKE THERMOSTATIC
SPRING HOUSING
CHOKE DIAPHRAGM FAST IDLE SPEED
ASSEMBLY ADJUSTING SCREW
V1884C

FIG. 2 Model 2150 Carburetor—-Right Rear 3/4 View (With Altitude

Compensation)
24-25-3 Model 2150 2-V Carburetor 24-25-3

CHOKE CLEAN (COLD)

AIR TUBE
MECHANICAL HIGH SPEED
BLEED CAM CHOKE HEAT
TUBE CONNECTION
THROTTLE LEVER

SOLENOID-DASHPOT
THROTTLE POSITIONER

AUTOMATIC CHOKE
ENRICHMENT THROTTLE IDLE MIXTURE HOUSING
VALVE COVER EJS* ™ ^

V1886-B

FIG. 3 Model 2150 2-V Carburetor - Bottom View

(w/o Altitude Compensation)

POSITIVE TEMPERATURE
COEFFICIENT (PTC) CERAMIC
HEATER

TEMPERATURE
SENSITIVE
BIMETALLIC DISC

QUICK-DISCONNECT
TERMINAL

GROUND STRAP

V1595-B

FIG. 4 Electric Assist Choke—Typical

24-25-4
DIAGNOSIS AND TESTING
Refer to the Engine Diagnosis in Part
29-02 of this Volume for all diagnosis and
testing.
ADJUSTMENTS
Most carburetor adjustments are set
at assembly, based on guidelines
established for reduced engine emission
and acceptable driveability.
For adjustment procedures for:
Automatic Choke
Idle Speeds
Idle Fuel Mixture
Idle CO
you must refer to Group 29 or 50.
Adjustment points for these items are
shown in Figs. 5 thru 8.
LIMITER STOPS V1887-B
FIG. 5 Idle Fuel Mixture Adjusting
Screw Limiters and Stops
ACCELERATING PUMP STROKE
ADJUSTMENT
The accelerating pump stroke has
been factory set for a particular engine
application and should not be readjusted.
If the stroke has been changed from
the specified hole, reset to specification
by following these procedures (Fig. 9):
SOLENOID "OFF" IDLE-
SPEED ADJUSTING SCREW
V1679B
FIG. 6 Idle Speed Adjustments—
Vehicles Equipped With
Throttle Solenoid Positioner
(TSP)
Model 2150 2-V Carburetor
ADJUST SOLENOID V1888-A
FIG. 7 Idle Speed Adjustments—
Vehicles Equipped With
Solenoid Dashpot Throttle
Positioner (TSP) or Through-
Adjust Solenoid
FAST IDLE CAM
FAST IDLE SPEED
ADJUSTING SCREW
V1889-B
FIG. 8 Fast Idle Speed Adjustment-
Typical
1. To release the rod from the retaining
clip, lift upward on the portion of the
clip that snaps over the shaft and then
disengage the rod.
2. Position the clip over the specified
hole in the overtravel lever and insert
the operating rod through the clip and
the overtravel lever. Snap the end of
the clip over the rod to secure.
CHOKE PLATE PULLDOWN AND
FAST IDLE CAM CLEARANCE
Choke Plate Pulldown
The Model 2150 2-V carburetor is
equipped with a remotely-mounted
choke pulldown diaphragm assembly.
Vacuum is metered to the diaphragm
through internal passages in the
carburetor, through a connecting
24-25-4
external tube. As the vacuum bleeds
through the orifices in the carburetor, the
choke diaphragm pulls the choke plate to
the pulldown position (Fig. 10).
To check choke pulldown, proceed as
follows:
1. Set throttle on fast idle cam top step.
2. Note index position of choke
bimetallic cap. Loosen retaining
screws and rotate cap 90 degrees in
the rich (closing) direction (Fig. 11).
3. Activate choke plate pulldown motor
by applying vacuum to external
vacuum tube or by manually forcing
pulldown control diaphragm link in
the direction of applied vacuum (Fig.
10).
4. Measure vertical hard gage clearance
between bottom edge of choke plate
and center of carburetor air horn wall
nearest fuel bowl (Fig. 10).
Pulldown setting should be within
specification for minimum choke
plate opening. Refer to Car
Specifications book for specified
opening.
If choke plate pulldown is found to
be out of specification, reset by
adjusting diaphragm stop on end of
choke pulldown diaphragm.
Loctite 290 was applied to the
threads of the pulldown adjusting
screw during manufacturing to
prevent the screw from backing due
to vibration. DO NOT attempt to
turn the screw without first heating
the immediate area enough to loosen
the Loctite. Heat the area with an
electric soldering gun while applying
torque to the screw until the Loctite
FIG. 9 Accelerating Pump Stroke
Adjustment
24-25-5
CONNECT HAND
VACUUM PUMP
FIG. 10 Adjusting Choke Plate Pulldown
softens and the screw can be easily
turned.
After pulldown check is completed,
reset choke b i m e t a l l i c cap to
recommended index position as
specified in Car Specifications Book
or on Engine Tune-up decal. Check
and r e s e t fast idle speed to
specification if necessary.
NOTE: To adjust fast idle cam
clearance or other choke functions,
refer to Part 2 9 - 0 2 of t h i s
Supplement.
V1681A
FIG. 11 Automatic Choke
Thermostatic Spring Housing
Adjustment
Model 2150 2-V Carburetor
MEASURE CLEARANCE
BOTTOM EDGE OF CHOKE
VALVE TO WALL OF AIR HORN
FUEL LEVEL (FLOAT)
ADJUSTMENT—DRY
The dry float adjustment is a
preliminary fuel level adjustment only.
The final adjustment (Fuel Level Float
Adjustment—Wet) must be made after
the carburetor is mounted on the engine.
With the air horn removed, the float
raised and the fuel inlet needle seated,
check the distance between the top
surface of the main body (gasket
removed) and the top surface of the float
B2590-A
FIG. 12 Fuel Level (Float)
Adjustment—Dry
24-25-5
FIG. 13 Fuel Level (Float)
Adjustment—Wet
for conformance to specification. Depress
the float tab to seat the fuel inlet needle.
Take the measurement near the center of
the float at a point 1/8 inch frorr the free
end of the float.
If the cardboard float gauge is used,
place the gauge in the corner of the
enlarged end section of the fuel bowl (Fig.
12). The gauge should touch tie float
near the end, but not on the end radius.
If necessary, bend the tab on the float
to bring the setting within the specified
limits. This should provide the proper
preliminary fuel level setting.
FUEL LEVEL (FLOAT)
ADJUSTMENT—WET
1. Operate the engine to normalize
engine temperatures, and place the
vehicle on a flat surface as near level
as possible. Stop the engine.
2. Remove the carburetor air cleaner
assembly if not previously removed.
3. Remove the air horn attachin g screws
and the carburetor identification tag.
Temporarily leave the air horn and
gasket in position on the carburetor
main body and start the engine. Let
the engine idle for a few minutes, then
remove the air horn and gasket to
provide access to the float assembly.
4. While the engine is idling, use a
standard depth scale to measure the
vertical distance from the top
machined surface of the carburetor
main body to the level of th s fuel in
the fuel bowl (Fig. 13).
The measurement must be made at
least 1/4 inch away from any vertical
surface to assure an accurate reading,
because the surface of the fuel is
concave (higher at the edges than in
the center). Care must be exercised to
measure the fuel level at the point of
contact with the gauge. Refer to the
24-25-6
specifications for the correct fuel level
(wet) setting.
5. If any adjustment is required, stop the
engine to minimize the hazard of fire
due to fuel spray when the float
setting is disturbed. To adjust the fuel
level, bend the float tab (contacting
the fuel inlet valve) upward in relation
to the original position to raise the
fuel level, and downward to lower it.
Each time an adjustment is made
to the float tab to alter the fuel level,
REMOVAL AND INSTALLATION
CARBURETOR ASSEMBLY
Removal
Flooding, stumble on acceleration
and other performance complaints are in
many instances, caused by the presence
of dirt, water, or other foreign matter in
the carburetor. To aid in diagnosing the
cause of complaint, the carburetor should
be carefully removed from the engine
without removing the fuel from the bowl.
The contents of the bowl may then be
examined for contamination as the
carburetor is disassembled.
1. Remove the air cleaner.
2. Remove the throttle cable from the
throttle lever. Disconnect all vacuum
lines, emission hoses, the fuel line and
the choke heat tube at the carburetor.
3. Remove the carburetor retaining
nuts; then remove the carburetor.
Remove the carburetor mounting
gasket, spacer (if equipped) and lower
gasket from the intake manifold.
Installation
1. Clean the gasket mounting surfaces of
the spacer and carburetor. Place the
spacer between two new gaskets and
position the spacer and gaskets on the
intake manifold. Position the
carburetor on the spacer and gasket.
Position and connect the choke heat
tube. Take care to avoid damage to
the tube nut.
2. Install the spark and EGR vacuum
lines before bolting carburetor in
place. Secure the carburetor with the
attaching nuts. To prevent leakage,
distortion or damage to the
carburetor bodyflange,snug the nuts;
then, alternately tighten each nut in
a criss-cross pattern to the specified
torque.
3. Connect the fuel line, throttle cable,
and all emission lines and vacuum
lines removed. Observe color coded
vacuum line connections on
carburetor.
4. Adjust the engine idle speeds, fuel
mixture, and check and adjust the
accelerator stroke if necessary. (Make
Model 2150 2-V Carburetor
the air horn must be re-installed, and
the engine started and permitted to
idle for a few minutes to stabilize the
fuel level. Remove the air horn and
gasket and check the fuel level after
each adjustment until the specified
level is obtained.
6. Install a new air horn gasket, the air
horn a s s e m b l y , c a r b u r e t o r
identification tag and the attaching
screws. Be sure the plastic dust seal
on the choke operating rod is
sure the rod is set in the specified
hole.)
AIR HORN TO M A I N BODY
GASKET
Removal
1. Remove the air cleaner. Remove the
air cleaner anchor screw.
2. Disconnect the automatic choke clean
air tube at the carburetor.
3. Remove the automatic choke plate
operating rod to choke lever retainer.
4. Remove the air horn attaching screws
and lock washers, and the carburetor
identification tag. Remove the air
horn gasket.
Installation
1. Install a new air horn to main body
gasket. Make sure all holes in the new
gasket have been properly punched
and that no foreign material has
adhered to the gasket.
2. Position the air horn on the main
body and gasket so that the choke
plate operating rod fits into the
opening in the choke housing lever.
Install the choke plate rod retainer.
Be sure the plastic dust shield on the
choke operating rod is properly
positioned and does not cause the rod
to bind.
3. Install the air horn attaching screws
and lock w a s h e r s and t h e
identification tag. Install the air
cleaner anchor screw, and tighten to
the specified torque.
4. Connect the automatic choke clean
air tube to the carburetor.
5. Adjust the idle fuel mixture and idle
speed as outlined in Part 29-02.
6. Install the carburetor air cleaner
assembly.
FLOAT, NEEDLE VALVE AND
SEAT, INLET SCREEN OR M A I N
JETS
Removal
1. Remove the carburetor air horn to
main body gasket by following the
24-25-6
positioned correctly and does not
cause the rod to bind. Tighten the
screws. Install the air cleaner anchor
stud and tighten to the specified
torque.
7. Check the idle fuel mixture, idle speed
adjustments and the carburetor
throttle positioner adjustment (if so
equipped). Adjust the carburetor as
required.
8. Install the air cleaner.
procedure under Air Horn to Main
Body Gasket Replacement.
2. With the use of a screwdriver, pry the
float shaft retainer from the fuel inlet
seat. Remove the float, float shaft
retainer and fuel inlet needle
assembly.
3. If required, remove the fuel inlet
needle seat, filter screen, baffle and
main jets with a jet wrench. Be sure
the correct (specified) jets are
installed.
Installation
1. If required, install the fuel inlet filter
in the inlet valve seat bore. Install the
valve seat, baffle and gasket. Install
the fuel inlet needle valve.
2. Slide the float shaft into the float
lever. Position the float shaft retainer
on the float shaft.
3. Insert the float assembly into the fuel
bowl and hook the float lever tab
under the fuel inlet needle clip. Insert
the float shaft into the guides at the
sides of the fuel bowl.
4. With the use of the screwdriver,
position thefloatshaft retainer on the
groove of the fuel inlet needle seat.
5. Refer to Float Adjustment—Dry,
and perform a dry float fuel level
adjustment on the float.
6. Install the carburetor air horn and
gasket and related parts. Refer to Air
Horn to Main Body Gasket
Replacement.
7. Refer to Fuel Level F l o a t
Adjustment—Wet, and perform the
wet fuel level adjustment procedures.
8. Adjust the idle fuel mixture and
engine idle speed.
ACCELERATOR PUMP
DIAPHRAGM AND/OR
ELASTOMER VALVE
Removal
1. Remove the carburetor air horn to
main body gasket following the
procedure under Air Horn to Main
Body Gasket Replacement.
24-25-7
2. Remove the accelerator pump
operating rod retainer. To release the
rod from the retaining clip, lift
upward on the portion of the clip that
snaps over the shaft and then
disengage the rod. Remove the rod.
Remove the accelerator pump cover,
diaphragm assembly and spring.
3. If inspection proves it necessary to
remove the Elastomer valve, grasp it
firmly and pull it out. If the
Elastomer valve tip broke off during
removal, be sure to remove the tip
from the fuel bowl. An Elastomer
valve must be replaced whenever it is
removed from the main body. See Fig.
19 and 22.
Installation
1. If the Elastomer valve was removed,
lubricate the tip of a new valve and
insert the tip into the accelerator
pump cavity. Using needle-nosed
pliers, reach into the fuel bowl and
grasp the valve tip. Pull the valve in
until it seats, and cut off the tip
forward of the retainer shoulder.
Remove the tip from the bowl.
2. Position the new accelerator pump
diaphragm assembly to the cover and
place the cover and diaphragm
assembly in position on the return
spring and main body. The large end
of the spring must face the Elastomer
valve. Install the cover screws
fingertight. Push the accelerator
pump plunger the full length of travel
and tighten the cover screws.
3. Position the accelerator pump
operating rod in the hole in the pump
operating arm.
MAJOR REPAIR OPERATIONS
DISASSEMBLY
To facilitate working on the
carburetor, and to prevent damage to the
throttle plates, install carburetor legs on
the base. If legs are unavailable, install
four (4) bolts (about 2-1/4 inches long of
the correct diameter) and eight (8) nuts
on the carburetor base.
Use a separate container for the
component parts of the various
assemblies to facilitate cleaning,
inspection and assembly.
The following is a step-by-step
sequence of operations for completely
overhauling the carburetor. However
certain components of the carburetor
may be serviced without a complete
diassembly of the entire unit. For a
complete carburetor overhaul, follow all
of the steps. To partially overhaul a
carburetor or to install a new gasket kit,
follow only the applicable steps.
Model 2150 2-V Carburetor
LINK
FIG. 14 Choke Pulldown Diaphragm Assembly
4. Adjust the accelerator pump stroke to
specification by installing the
accelerator pump rod in the proper
hole in the overtravel lever. Position
the rod retainer over the proper hole
and insert the end of the rod through
the hole in the retainer. Snap the end
of the retainer over the rod.
5. Install the carburetor air horn and
gasket. Refer to the Air Horn to Main
Body Gasket Replacement.
CHOKE PULLDOWN DIAPHRAGM
ASSEMBLY
Removal
1. Remove the air cleaner.
2. Disconnect the choke pulldown link
by removing the rod retainer and
pulling the rod out of the diaphragm
link slot (Fig. 14)
Air Horn
1. Remove the air cleaner anchor screw.
2. Remove the automatic choke control
rod retainer.
3. Remove the air horn attaching
screws, lock washers and the
carburetor identification tag. Remove
the air horn and air horn gasket.
4. Remove the choke control rod by
loosening the screw that secures the
choke shaft lever to the choke shaft.
Remove the rod from the air horn.
Slide the plastic dust seal out of the
air horn.
5. If it is necessary to remove the choke
plate, remove the staking marks on
the choke plate attaching screws and
remove the screws. Remove the choke
plate by sliding it out of the shaft from
the top of the air horn. Remove any
burrs around screw holes prior to
removing chokeshaft. If equipped
24-25-7
POSITIVE CLOSURE
SPRING
V1894-B
3. Remove the two (2) attaching screws
from the bracket, disconnect the
vacuum supply tube and remove the
pulldown diaphragm.
Installation
1. Position the choke pulldown
diaphragm mounting bracket against
the main body casting and install the
two (2) attaching screws.
2. Connect the vacuum supply tube to
the correct vacuum base tube
connection.
3. Insert the choke pulldown control rod
through the slot in the diaphnigm link
and install the retainer clip over the
end of the rod, in the slot.
4. Perform the automatic choke
pulldown and fast idle cam
adjustments as described in Part 29-
02 of this manual.
5. Install the air cleaner assembly.
with altitude compensation, rotate
the main choke shaft and disconnect
the connecting link. Slide the choke
shaft out of the air horn.
6. Remove the staking marks on the
bypass air choke plate attaching
screws (if used) and remove the
screws. Slide the choke shaft from the
air horn.
Choke Pulldown Diaphragm
Assembly
Follow procedures given under
Removal and Installation.
Automatic Choke
1. Remove the fast idle cam retainer
(Fig. 15).
2. Remove the thermostatk: choke
spring housing retaining screws and
remove the clamp, housing and
gasket.
24-25-8
RETAINER
FAST IDLE
SCREW
V1683-A
FIG. 15 Fast Idle Cam and Fast Idle
Lever—2.8L Shown, Others
Similar
3. Remove the choke housing assembly
retaining screws. If the air horn was
not previously removed, remove the
choke control rod retainer. Remove
the choke housing assembly, gasket
and the fast idle cam and rod from the
fast idle cam lever.
4. Remove the choke lever retaining
screw and washer. Disconnect the
choke control rod from the choke
lever. Remove the choke lever and
fast idle cam lever from the choke
housing.
Main Body
1. With the use of a screwdriver, pry the
float shaft retainer from the fuel inlet
seat (Figs. 16 and 17). Remove the
float,floatshaft retainer and fuel inlet
needle assembly. Remove the retainer
and float shaft from the float lever.
2. Remove the fuel inlet needle, seat,
filter screen, and the main jets with
a jet wrench.
3. Remove the booster venturi screw
(accelerator pump discharge), booster
FLOAT HINGEk
FUEL INLET NEEDLE
FLOAT
GUIDE
FIG. 16 Float Assembly
Model 2150 2-V Carburetor
V1685-B
FIG. 17 Removing or Installing Float
Shaft Retainer
venturi and metering rod assembly
and gasket. Invert the main body and
let the accelerating pump discharge
w e i g h t ( n o t used in some
applications) and ball fall into the
hand.
4. Remove the accelerator pump
operating rod from the overtravel
lever and the retainer. To release the
operating rod from the overtravel
lever retainer, press upward on that
part of the retainer that snaps over the
rod. Disengage the rod from the
retainer and from the overtravel lever.
Remove the rod and retainer.
5. Remove the accelerator pump cover
attaching screws. Remove the
accelerator pump cover, diaphragm
assembly and spring (Fig. 18).
6. If it is necessary to remove the
Elastomer valve, grasp it firmly and
pull it out. If the Elastomer valve tip
broke off during removal, be sure to
remove the tip from the fuel bowl. An
Elastomer valve must be replaced
whenever it has been removed from
the carubretor.
7. Invert the main body and remove the
enrichment valve cover and the
gasket. Remove the enrichment valve
with a box wrench or socket wrench
ELASTOMER
VALVE-9576
RETURN SPRING
-93545
DIAPHRAGM
-93559
VI296-E
FIG. 18 Accelerating Pump Assembly
24-25-8
8-Point
Socket Wrench
FIG. 19 Removing or Installing
Enrichment Valve
(Fig. 19). Remove the enrichment
valve gasket. Discard the gasket.
8. Remove the idle fuel mixture
adjusting screws (needles) and the
springs. Remove the limiters from the
adjusting screws.
9. If necessary, remove the nut and
washer securing the fast idle adjusting
lever assembly to the throttle shaft,
and remove the lever assembly. If
necessary, remove the idle screw and
the spring from the fast idle adjusting
lever.
10. Remove the anti-stall dashpot or
solenoid (if so equipped).
11. Remove the four (4) screws that
attach the aneroid assembly to the
main body (if altitude compensated)
and remove the assembly.
12. If it is necessary to remove the
throttle plates, lightly scribe the
throttle plates along the throttle shaft,
and mark each plate and its
corresponding bore with a number or
letter for proper installation (Fig. 20).
13. Slide the throttle shaft out of the main
body, making sure you catch the
mechanical high speed bleed actuator
located on the throttle shaft between
the throttle plates.
Clean and inspect the carburetor
component parts according to
procedures outlined in Part 29-02 and
24-01 of this Manual.
HIGH SPEED BLEED CAM
SCRIBE LINES AND
IDENTIFICATION MARKS V1896 A
FIG. 20 Scribing Throttle Plates
24-25-9
ASSEMBLY
Make sure all holes in new gaskets
have been properly punched, and that no
foreign material has adhered to the
gaskets. Make sure the accelerator pump
diaphragm is not torn or cut. The Model
2150 2-V c a r b u r e t o r is shown
disassembled in Fig. 21.
Main Body
1. Slide the throttle shaft assembly into
the main body until it begins to enter
the high speed bleed cam slot in the
body.
2. Holding the cam by the edge of the
point, hold it in the slot and rotate the
throttle shaft until it will pass through
the cam. Rotate the shaft clockwise
until the throttle lever clears the boss
for the TSP "Off" idle speed screw.
Continue inserting the shaft into
proper position, rotating as necessary
to properly position cam.
3. Refer to the lines scribed on the
throttle plates and install the throttle
plates in their proper location with
the screws snug, but not tight. Always
use new screws when installing
throttle plates.
4. Close the throttle plates. Invert the
main body, and hold it up to the light.
Little or no light should show
between the throttle plates and the
throttle bores. Tap the plates lightly
with a screwdriver handle to seat
them. Hold the throttle plates closed
and tighten and stake the attaching
screws. Stake hardened screws by
crimping exposed threads with
diagonal cutters.
5. If necessary, install the fast idle screw
spring and the screw on the fast idle
adjusting lever.
6. Position the aneroid assembly to the
main body (if altitude compensated)
and attach with four (4) screws.
7. Install the anti-stall dashpot,
solenoid, or solenoid-dashpot if
equipped.
8. Place the fast idle adjusting lever
assembly on the throttle shaft and
install the retaining washer and nut
(Fig. 21).
9. If the Elastomer valve was removed,
lubricate the tip of a new Elastomer
valve and insert the tip into the
accelerator pump cavity center hole.
Using a pair of needle-nosed pliers,
reach into the fuel bowl and grasp the
valve tip. Pull the valve in until it
seats in the pump cavity wall and cut
off the tip forward of the retaining
shoulder. Remove the tip from the
bowl.
lO.Install the a c c e l e r a t o r pump
diaphragm return spring on the boss
in the chamber (Fig. 18). Insert the
diaphragm assembly in the cover and
Model 2150 2-V Carburetor
place the cover and diaphragm
assembly into position on the main
body. Install the cover screws.
11. Insert the accelerator pump operating
rod into the hole in the accelerator
pump actuating lever. Position the
accelerator pump operating rod
retainer over the specified hole in the
over-travel lever. Insert the operating
rod through the retainer and the hole
in the overtravel lever and snap the
retainer down over the rod.
12. Invert the main body. Install the
enrichment valve and new gasket with
a wrench (Fig. 19). Tighten the valve
securely.
13. Install the idle mixture adjusting
screws (needles) and springs (Fig. 21).
Turn the needles in gently with the
fingers until they just touch the seat,
then back them off 1-1/2 turns for a
preliminary idle fuel mixture
adjustment. Do not install the idle
mixture limiters at this time. Install
the enrichment valve cover and new
gasket. The coyer must be installed
with the limiter stops on the cover in
position to provide a positive stop for
the tabs on the idle mixture adjusting
screws limiters.
14. Install the main jets and the fuel inlet
seat, filter screen, baffle and new
gasket. Be sure the correct jets are
installed.
15. Install the fuel inlet needle assembly
in the fuel inlet seat.
16. Slide the float shaft into the float lever
(Fig. 16). Position the float shaft
retainer on the float shaft.
17. Insert the float assembly into the fuel
bowl and hook the float lever tab
under the fuel inlet needle assembly.
Insert the float shaft into its guides at
the sides of the fuel bowl.
18. With a screwdriver, position the float
shaft retainer in the groove on the fuel
inlet needle seat (Fig. 17). Check the
float setting.
19. Drop the accelerator pump discharge
ball and weight (if removed during
disassembly) into the passage in the
main body.
20. Position the new booster assembly
gasket and the booster venturi
assembly in the main body. Install the
accelerator pump discharge screw.
Tighten the screw.
Automatic Choke
1. Position the fast idle cam lever on the
thermostatic choke shaft and lever
assembly. The bottom of the fast idle
cam lever adjusting screw must rest
against the tang on the choke lever.
Insert the choke lever into the rear of
the choke housing. Position the choke
lever so that the hole in the lever is
to the left side of the choke housing.
24-25-9
2. Install the fast idle cam rod on the fast
idle cam lever. Place the fast idle cam
on the fast idle cam rod and install the
retainer. Place the choke housing
vacuum pick-up port to main body
gasket on the choke housing llange.
3. Position the choke housing on the
main body and at the same time,
install the fast idle cam on the hub on
the main body. Position the gasket,
and install the choke housing
attaching screws. Install the fast idle
cam retainer. Install the thennostatic
spring housing.
Choke Pulldown Diaphragm
Assembly
Refer to procedure under Removal
and Installation.
Air Horn
Refer to Fig. 21 for the correct
location of the parts.
1. If removed, position the bypass air
choke plate shaft through the air
horn, then install the bypass choke
plate. Before tightening the mounting
screws, check for proper fit and shaft
rotation.
2. If the main choke plate shaft was
removed, position the shaft in the air
horn. Rotate the main choke plate
shaft and connect the bypass choke
link. Install the choke plate rod on the
end of the main choke shaft.
3. If the choke plate was removed, insert
the choke plate into the choke plate
shaft. Install the choke plate screws
snug, but not tight. Check for proper
plate fit, binding in the air horn and
free rotation of the shaft by moving
the plate from the closed position to
the open position. If necessary,
remove the choke plate and grind or
file the plate edge where it is binding
or scraping on the air horn wall. If the
choke plate and shaft moves freely,
tighten the choke plate screws while
holding the choke in the fully closed
position.
4. Position the fuel bowl gasket and the
choke rod plastic seal on the main
body. Position the air horn on the
main body and gasket so that the
choke plate rod fits through the seal
and the opening in the main body.
5. Insert the end of the choke plate rod
into the automatic choke lever. Install
the air horn attaching screws and the
carburetor identification tag. Tighten
the attaching screws. Install the
choke plate rod retainer. Install the
air cleaner anchor screw. Tighten the
air cleaner anchor screw to the
specified torque.
Perform all automatic choke
adjustments and other carburetor
functions as required to meet
specifications. See Group 29 for
adjustments not covered in this Part.
24-25-10 Model 2150 2-V Carburetor 24-25-10

HIGH-SPEED BLEED
METERING ROD YOKE
AND LIFT ROD
BOOSTER
VENTURI
SCREW

WEIGHT
(SOME APPLICATIONS)
ACCELERATING PUMP
DISCHARGE BALL CHECK NOZZLE BAR, HIGH-SPEED
BLEED AND BOOSTER
VENTURI ASSEMBLY

IDLE KICKDOWN
SPRING MIXTURE ADJUSTMENT
IDLE NEEDLE SCREW
LIMITER v \
CAP
RETAINER
ACCELERATING
PUMP DIAPHRAGM •OcW*
ACCELERATING
PUMP COVER

VENT VALVE
ACTUATING
LEVER

UPPER BODY

ACCELERATING PUMP
OVER-TRAVEL SPRING

THROTTLE SOLENOID
POSITIONER
(SOLENOID-DASHPOT)

CHOKE CLEAN
AIR TUBE

FLOAT SHAFT
SHAFT RETAINER
SOLENOID OFF FUEL INLET NEEDLE
IDLE (HOT ENGINE)
SPEED ADJUSTING FUEL INLET NEEDLE SEAT
SCREW SHIELD
FILTER SCREEN

V1897 D

FIG. 21 Model 2150 2-V Carburetor—Disassembled View

24-26-1 Model 4350 4-V Carburetor 24-26-1

PART
Model 4350 4-V Carburetor 24-26
460 C.I.D. V-8 Only

SUBJECT PAGE SUBJECT PAGE

DESCRIPTION ADJUSTMENTS (Cont'd.)

Delayed Choke Pulldown and Fast Idle
Mechanical Fuel Bowl Vent Valve 26-5
Top Step Pulloff 26-2
Vacuum Piston and Metering
General 26-1
Rods Adjustment 26-9
High Altitude Compensation 26-3

ADJUSTMENTS REMOVAL AND INSTALLATION 26-11

Accelerator Pump Adjustment 26-4
Automatic Choke Functions 26-5 MAJOR REPAIR OPERATIONS
Fuel Inlet System Adjustment 26-7 Disassembly . . . . 26-12
High Altitude Compensation System 26-9 Assembly . . . . 26-13
CA4292-A

DESCRIPTION
GENERAL
'INTERNAL" FUEL BOWL VENTS
The Motorcraft Model 4350 4-V
carburetor (Figs. 1, 2 and 3) has three
main assemblies; the upper body, the
main body and the throttle body. DELAYED CHOKE CHOKE PLATE
PULLDOWN DIAPHRAGM
The upper body, which serves as the
MECHANICAL FUEl
main body cover, contains the choke BOWL VENT VALV-
plate, booster venturi assembly, the
secondary air valve, accelerating pump SOLENOID ThPOTTLE
plunger, mechanical fuel bowl vent valve POSITIOf.ER
and fuel inlet and float system.
The main body contains the fuel bowl
and primary fuel metering system
vacuum piston and rods.

EGR CONNECTION

IDLE MIXTURE SPARK

t ^THROTTLE ADJUSTMENT SCREWS PORT
AT BODY

V1914-A

V1915-B
FIG. 1 Model 4350 4-V Carburetor-
Main Assemblies FIG. 2 Model 4350 4-V Carburetor—Front View
24-26-2
The throttle body contains both
primary and secondary throttle plates.
Primary throttle operation is from the
accelerator linkage. Secondary throttle
operation is accomplished by mechanical
linkage from the primary throttle lever.
A lockout tang coupled to the automatic
choke linkage prevents operation until
the choke is fully off. The secondary
throttle shaft is split and loosely coupled
in the center to allow tighter secondary
throttle plate seating in the bores (Fig. 4).
PCV CONNECTION
HOT IDLE
COMPENSATOR
FIG. 3 Model 4350 4-V Carburetor—Top View Without Altitude Compensation
FIG. 4 Split Secondary Throttle Shaft
Model 4350 4-V Carburetor
P r i m a r y f u e l m e t e r i n g is
accomplished by tapered metering rods
that are raised or lowered according to
engine vacuum, limited by mechanical
system that is positioned according to
throttle plate opening (Figs. 5 and 30). A
lever on the acceleration pump operating
shaft moves upward as the throttle is
opened.
Under high engine vacuum
conditions, the vacuum piston pulls the
metering rods down into the main jets.
VENTURI VACUUM -
SOME APPLICATIONS
SECONDARY
AIR VALVE
CHOKE PLATE
V1916-C
V1917-A
24-26-2
causing a lean mixture to be delivered.
Under acceleration, when engine vacuum
is lowered, an internal spring causes the
piston to rise. This puts the narrower part
of the metering rod in the jet, causing a
larger fuel opening and enriching the fuel
mixture.
Fuel inlet to t h e fuel bowl is
controlled by a twin pontoon type float
(or two floats on police models) hinged
to the upper body of the carburetor. The
acceleration pump is piston type. The
linkage and operating rod are part of the
upper body, and the piston is suspended
into the pump well in the fuel bowl.
The automatic choke system consists
of a standard bimetallic thermostatic
choke mechanism. Also, an electric assist
is used when underhood temperatures are
above 60°F. This system operates to
assure full choke opening within a
predetermined time of engine start.
The electric assist choke system
consists of a choke cap, thermostatic
spring, bimetallic temperature sensing
disc (switch), and ceramic Positive
Temperature Coefficient (PTC) heater
(Fig. 6).
The choke is powered from the stator
tap of the alternator, providing voltage to
the system as long as the engine is
running. The system is grounded through
a g r o u n d s t r a p c o n n e c t e d to t h e
carburetor body.
At temperatures below approximately
60°F., the switch is open and no current
is supplied to the ceramic heater located
within the thermostatic spring. Normal
thermostatic choking action then occurs.
At temperatures above approximately
60°F., the temperature sensing switch
closes and current is supplied to the PTC
ceramic heater. As the heater warms, it
causes the thermostatic spring to pull the
choke plate open within 70 seconds.
For test and adjustment information,
refer to this Part and to Part 50-29.
DELAYED CHOKE PULLDOWN
AND FAST IDLE TOP STEP
PULLOFF
The Motorcraft 4350 4-V carburetor
is equipped with a unique, vacuum-
V1918-A
FIG. 5 Metering Rod Primary
Metering System
24-26-3 Model 4350 4-V Carburetor 24-26-3

operated delayed choke pulldown POSITIVE TEMPERATURE

diaphragm. This system operates in COEFFICIENT (PTC) CERAMIC
HEATER
addition to the usual pulldown system
found in the Model 4300 carburetor.
The remotely-mounted delayed choke
pulldown diaphragm assembly is TEMPERATURE
connected to the automatic choke linkage SENSITIVE
BIMETALLIC DISC
by an override linkage (Fig. 7).
When the engine is first started, the
piston inside the choke housing pulls the
choke plate slightly open (initial choke
pulldown). This is accomplished with
engine vacuum through internal passages
in the carburetor. At the same time,
vacuum bleeds to the delayed choke
pulldown diaphragm. When the delayed
pulldown diaphragm is fully retracted
(about 6-18 seconds after engine start) it
opens the choke to the delayed pulldown
setting. At the same time, linkage pulls QUICK-DISCONNECT
the fast idle screw from the top step of TERMINAL

the fast idle cam to the kickdown step.

GROUND STRAP
HIGH ALTITUDE COMPENSATION
V1595-B
Some Carburetors Built for High
Altitude Operation
Some Motorcraft Model 4350 4-V FIG. 6 Electric Assist Choke—Model 4350 4-V Carburetor
carburetors are equipped with altitude
compensation, designed to provide
improved high-altitude emission control
and driveability (Fig. 8).
Intake air entering the by-pass intake
is metered into the air flow below the
primary, thus making for a leaner
mixture needed at higher altitudes. Air
flow is controlled by a valve activated by
an aneroid attached to the rear of the
carburetor main body housing.
To provide improved high-altitude
cold engine starts, the bypass intake is
equipped with a choke plate linked to the
main choke system.

CHOKE DELAYED
PULLDOWN
DIAPHRAGM

DIAPHRAGM
STOP SCREW FILTER CAP
V1919-B

FIG. 7 Delayed Choke Pulldown and Fast Idle Top Step Pulloff Diaphragm
24-26-4 Model 4350 4-V Carburetor 24-26-4

BYPASS (COMPENSATION)
CHOKE PLATE LINK,
BYPASS (COMPENSATION)
CHOKE PLATE

BYPASS INTAKE

ANEROID
HOUSING

POPPET METERING
VALVE HOUSING

V2049-B

FIG. 8 Motorcraft Model 4350 4-V Carburetor With Altitude Compensation

(Cutaway View)

ADJUSTMENT
Most carburetor adjustments are set
at assembly, based on guidelines
established for reduced engine emission
and acceptable driveability.
Adjustments not covered in this Part
will be found in Part 29-02 or Part 50-29.
Adjustment points for all carburetor
adjustments are shown in Figs. 8 thru 22.
deliver the proper amount of fuel for the
engine on which it is installed, and a
capacity adjustment which should only
be made if the operating arm is replaced.
This setting should not be changed from
the specified adjustment (Fig. 12).
The control rod that operates the
accelerator pump also operates the
limiter that controls the height of the
main metering rod piston (Fig. 13).
Do not turn the vacuum piston limiter
lever adjusting nut in order to adjust the
stroke of the accelerator pump. This
adjustment is set at the factory and
changing it could affect drivability of the
vehicle.

ACCELERATOR PUMP
ADJUSTMENT
The accelerator pump has only two
adjustments, a piston-to-shaft pin
position which is set at the factory to
TSP "OFF"
IDLE SPEED
4350 ADJ. SCREW
IDLE FUEL MIXTURE
ADJUSTMENT SCREWS
AND LIMITER CAPS

THROTTLE
SOLENOID LEVER

THROTTLE POSITIONER
ADJUSTMENT (EITHER END)
(TSP " O N " CURB IDLE) V1921-A
V1920-B

FIG. 9 Idle Fuel Mixture Adjusting FIG. 10 Idle Speed Adjustment Points -Vehicles With Solenoid Throttle
Screws, Limiters and Stops Positioner
24-26-5
Remove the upper body assembly and
invert it (see Removal and Installation).
Disconnect the accelerator pump
from the operating arm by holding
downward on the spring and sliding the
arm out of the pump shaft slot.
1. Disassemble the spring and nylon
keeper that retains the adjustment pin
(Fig. 12). If the pin is not in the
specified hole, remove it, reposition
the shaft to the correct hole in the
piston assembly and reinstall the pin.
2. Slide the nylon retainer over the pin
and position the spring on the shaft.
Compress the spring on the shaft and'
install the pump on the pump arm.
If the nylon pump arm is damaged
during disassembly or assembly, follow
this procedure to replace and adjust the
arm. The throttle plates, shafts and lever
must be installed to specification to
properly adjust the replacement pump
arm.
1. Remove the screw retaining the
mechanical fuel bowl vent rod bracket
and remove the bracket and rod.
2. Remove the two expansion plugs (one
aluminum, one brass) from the air
horn over the accelerator pump arm.
This will give access to the arm
adjusting screw and gauge pin hole.
These access plugs can be removed by
penetrating with a sharp drift and
prying out.
3. Remove the upper body assembly
from the main body.
4. Remove the vacuum piston limiter
lever and nylon accelerator pump arm
from the accelerator pump lever and
shaft assembly (Fig. 38). Also remove
the accelerator pump adjusting screw
(5/64 in. alien wrench) from the old
nylon pump arm.
5. Install the accelerator pump
adjusting screw in the new nylon
pump arm. Position the screw so that
one full thread of the point end of the
screw is exposed below the pump arm.
6. Install the nylon accelerator pump
lever and shaft assembly using an "E"
clip (Fig. 38).
7. Install upper body to main body and
install accelerator pump rod into the
proper hole in the throttle pump
lever.
8. Position the accelerator pump gage
pin thru the accelerator pump gage
access hole so that it will rest on top
of the accelerator pump stem (Fig.
39).
9. With the throttle lever at the idle
position, measure the distance from
the top of the gage pin to the upper
body casting surface using a depth
scale and note the measurement.
10. Rotate throttle lever to wide open
throttle position (W.O.T) and again
measure the distance from top of the
Model 4350 4-V Carburetor 24-26-5
FAST IDLE CAM ADJ
SCREW
CHOKE CAP
INDEX MARK
DELAYED PULLDOWN
DIAPHRAGM LINK ROD V1923B
FIG. 1 1 Automatic CLoke Adjustments
gage pin to the upper body casting lever (Fig. 14), then t u r n the
surface. The difference between the a d j u s t i n g s c r e w one (1) t u r n
two measurements at idle and W.O.T. clockwise.
should be 5/16 inch (.312). If the 2. Turn the engine off and observe that
difference is not 5/16 in., turn the the vent operating linkage pushes
accelerator pump adjustment screw down on the vent valve stem.
c l o c k w i s e to i n c r e a s e and
counterclockwise to decrease the AUTOMATIC CHOKE FUNCTIONS
reading. Recheck reading using the Initial Choke Pulldown
same procedure.
11. Install new access hole plugs. When the engine is first started, the
choke plate is pulled to an initial
12. Install the mechanical bowl vent rod,
bracket and retaining screw. pulldown position by a small piston in the
choke housing, operated by engine
NOTE: Do not attempt to adjust
the accelerator pump with the nylon vacuum. To adjust initial choke plate
pulldown, follow this procedure:
nut on the vacuum piston limiter
lever.
PUMP SHAFT
MECHANICAL FUEL BOWL VENT
VALVE
The vent valve is designed to be open
to the carbon canister when the engine is
off and closed when the engine is
operating. Adjust the valve with the
carburetor installed on the vehicle.
1. With the engine at CURB IDLE PIN
RETAi SIER
speed, and the solenoid throttle
positioner (if equipped) in the
PUMP PISTON V1925-B
retracted (de-energized) position,
adjust the vent valve so that the
adjustment screw just touches the FIG. 12 Setting Accelerator Pump
drive tab on the accelerator pump Stroke
24-26-6
1. Remove the choke thermostatic
spring housing assembly.
2. Open throttle about half-throttle and
position the fast idle adjusting screw
on the high step of the fast idle cam.
3. Bend a 0.036 inch diameter wire
gauge at a 90 degree angle
approximately 1/8 inch from its end.
Insert the bent end of the gauge
between the choke piston slot and the
upper edge of theright-handslot in
the choke housing (Fig. 15).
4. Rotate the choke thermostat lever
counterclockwise until the gauge is
snug in the piston slot. Hold the gauge
in position with light force on the
lever and move the top of the choke
rod away from the carburetor while
moving the bottom of the rod toward
carburetor to remove end play from
linkage.
5. Using a drill gauge or equivalent,
check initial choke pulldown
clearance by placing the gauge against
the inner wall of the choke air horn
on t h e d o w n s t r e a m side at
approximately the longitudinal
centerline of the carburetor and check
clearance from wall to edge of choke
plate.
6. If the measured clearance is not
within specification, adjust clearance
by turning the hex head lock screw on
the choke plate shaft in a clockwise
direction three (3) full turns. (Note:
Lock screw is left-hand threaded).
Pry choke lever from shaft to loosen
taper lock. Choke lever should rotate
freely on choke shaft.
7. Hold the drill gauge with diameter
equal to specified pulldown clearance
between the lower edge of the choke
plate and air horn wall, maintaining
light closing force on choke plate.
8. With choke piston snug against the
0.036 inch wire gauge, the top of the
choke rod held away from the
carburetor while moving the bottom
of the rod toward the carburetor to
remove end play from linkage, and
the choke plate held against the drill
gauge, tighten the hex head screw on
the choke shaft.
9. Using the .036 inch gauge in the
vacuum slot, above the top of the
piston, hold the piston in the full
down position. Now rotate the
thermostatic spring lever back and
forth to check for binding.
10. Reinstall the gasket and choke
thermostatic spring housing
assembly.
Delayed Choke Pulldown
The Model 4350 4-V carburetor is
equipped with a vacuum-diaphragm
operated delayed choke pulldown that
opens the choke to a wider setting
approximately 6-18 seconds after engine
Model 4350 4-V Carburetor
ACCELERATOR PUMP
OPERATING LEVER 9529
ACCELERATOR PUMP CAPACITY
f ADJUSTING SCREW
VACUUM PISTON LIMITER
ACCELERATOR PUMP
LEVER ADJ. - 9564
ASSY. - 9E528
FIG. 13 Throttle-To-Accelerator Pump Linkage
startup. To check and adjust, follow this
procedure:
1. With throttle set on fast idle cam,
note position of index marks on cap
of choke bimetallic cap. Loosen
retaining screws and rotate cap 90
degrees in the closing (rich) direction.
2. Disconnect the vacuum supply hose
from the port on the delayed choke
pulldown diaphragm assembly. Place
a piece of tape over the purge hole
after removing the filter cap and
connect a vacuum source of at least
14-18 in. Hg to the port (Fig. 16).
3. Measure hard gage pulldown
dimension at lower edge of choke
plate, in center of air horn, using
gauge of specified diameter (see
Group 29). Adjust by turning stop
screw on delayed choke pulldown
diaphragm.
4. After pulldown is properly set,
remove external vacuum source,
reconnect tube to carburetor port and
reset choke thermostatic cap to
specified index setting. When using a
hand vacuum pump, cover purge hole
(Fig. 7).
Fast Idle Top Step Pulloff
As the delayed choke pulldown
diaphragm operates, additional linkage
pulls the fast idle lever and screw from
the top step of the fast idle cam to the
second step, reducing cold engine idle
speed (Fig 17).
To check the operation of the fast idle
top step pulloff linkage, operate the
delayed pulldown diaphragm manually
or by connecting an external vacuum
source of 14-18 in. Hg to the vacuum
port. Place hand over holes in filter cap.
Position the fast idle speed screw on the
top step of the fast idle cam with the
24-26-6
THROTTLE
LEVER AND
SHAFT ASSY
9581
ACCELERATOR PUMP
LINK-9B542
ADJUST
V1926-C
FIG. 14 Adjusting Mechanical Fuel
Bowl Vent Valve
choke plate closed. (Rotate choke
thermostatic cap if necessary to close
choke plate.) Observe the fast idle speed
adjusting screw drops to second
(kickdown) step of cam as delayed choke
pulldown diaphragm is operated.
Fast Idle Cam Clearance
1. Loosen the attaching screws and
rotate the spring housing to align the
center index mark on the choke
housing with the index mark on the
spring housing. Rotate the spring
housing an additional 90 degrees
counterclockwise and tighten the
attaching screws.
2. Position the fast idle speed, adjusting
screw end on the kickdown (center)
step of the fast idle cam. Close the
choke plate as far as it will go. Check
the clearance between the lower edge
of the choke plate and the air horn
wall. Turn the fast idle cam adjusting
screw inward to increase the
clearance or outward to decrease the
clearance. Make sure the fast idle
speed adjusting screw stays at the
kickdown step of the fast idle cam
during the adjustment.
 24-26-7 Model 4350 4-V Carburetor 24-26-7

3. Loosen the attaching screws, set the

DRILL GAUGE OF SPECIFIED
thermostatic choke housing to the CLEARANCE SIZE TAPER-LOCK CHOKE SHAFT
specified index mark and tighten the SCREW (LEFT HAND THREAD)
attaching screws.
4. If the choke plate clearance and fast
idle cam linkage adjustment was
performed with the carburetor on the
engine, adjust the engine idle speed
and fuel mixture.
Dechoke Clearance
1. Open the throttle plate to the wide
open position and hold.
2. Rotate the choke plate toward the
closed position until the pawl on the
fast idle speed lever contacts the fast
idle cam.
3. Check the clearance between the
lower edge of the choke plate and the
air horn wall (Fig. 18).
4. Adjust the clearance to specification
by bending the pawl on the fast idle
speed lever forward to increase or
backward to decrease the clearance.
FUEL INLET SYSTEM
ADJUSTMENTS
Checking Fuel Level With Bubble
APPLY LIGHT PRESSURIE
Type Fuel Level Gauge (Before TO CHOKE LEVER
Carburetor Disassembly)
1. Make sure vehicle is level. FAST IDLE ADJUSTMENT SCREW
V1967-B
2. Remove the air cleaner assembly.
3. Start the engine and allow to run FIG. 15 Checking and Adjusting Initial Choke Plate Pulldown
briefly, u n t i l t h e fuel level is
stabilized.
*4. Insert the Fuel Level Gauge T72L-
9550-B into the carburetor fuel bowl
vent on the throttle lever side as
shown in Fig. 19. Rest the gauge pad
on the other vent.
5. Using the fuel primer, syphon fuel
into the sight tube and allow the fuel
to reach a level.
6. Note where the fuel level falls on the
gauge. If the fuel level is within the
specified band, adjustment is not
required. If the fuel level is not
correct, adjust as follows.
Float Setting (With Fabricated
Gauge and Bending Tools)
To simplify parallel setting of the dual
pontoons, first refer to Fig. 19 for the
construction of an adjustable float gauge
and a float tab bending tool.
NOTE: When adjusting float(s),
always use the float tab bending tool. If
a tool such as needle nose pliers is used,
the tab could be scratched or otherwise
marred, resulting in a sticking float.
R e f e r to M A J O R R E P A I R
OPERATIONS for disassembly of the
Model 4350 4V carburetor. Pay
particular attention to instructions for
s c r i b i n g r e f e r e n c e l i n e s on the ATTACH VACUUM
accelerator pump operating arm shaft PUMP
and the carburetor air horn casting. This
relationship must be maintained when VTJ27-A
disassembling and assembling the
carburetor. FIG. 16 Choke Plate Delayed Pulldown Adjustment
24-26-8 Model 4350 4-V Carburetor
1. Adjust gauge to the specified height.
2. Insert gauge into the air horn
outboard holes (Fig. 21).
3. Check the clearance and alignment of
the pontoons to the gauge. Both
pontoons should just touch the gauge
for the proper setting. Align the
pontoons if necessary on passenger
models by slightly twisting the
pontoons.
If it is necessary to adjust the float
clearance, bend the primary needle
V1928-A tab downward to raise the float and
upward to lower the float. On police
FIG. 17 Fast Idle Top Step Pulloff models, it is necessary to set each float
Linkage independently.
To bend the tabs with the float
bending tool, the procedure is as
follows:
To Raise the Float, insert the open
DRILL OR GAUGE OF
SPECIFIED SIZE J*0
end of the bending tool to the RIGHT
side of the float lever tab and between
the needle and float hinge. Raise the
float lever off the needle and bend the
tab downward. To lower the Float,
insert the open end of the bending tool
to the LEFT side of the float lever tab,
between the needle and float hinge.
Support the float lever and bend the
tab upward.
Float Setting (With Gauge
Supplied in Rebuilding Kit)
1. With the air horn removed from the
FIG. 18 Checking Dechoke Clearance carburetor and inverted, check the
FUEL BOWL VENT
FIG. 19 Checking Fuel Level
24-26-8
clearance of the pontoon floats to the
gauge (Fig. 22).
2. If necessary, adjust the alignment and
height of the floats as outlined under
adjustments for fabricated gauge and
tool.
Auxiliary (Supplemental) Fuel
Inlet Valve Setting
With the float gauge installed to
maintain the specified setting, invert the
upper body. Check the auxiliary valve
clearance (Fig. 23). If it is necessary to
adjust the auxiliary valve and float tab to
the specified clearance, use the bending
tool shown in Fig. 20.
Fuel Inlet Needle Drop Limiter
Adjustment
All model 4350 4V carburetors except
Police Interceptor models are equipped
with a new fuel inlet needle drop limiter
for 1977. The limiter (Fig. 24) controls
fuel inlet during stops and turns to help
prevent engine stalling and must be
installed and adjusted correctly. Im-
proper adjustment can result in engine
stalling or fuel starvation. Adjust the
limiter as follows:
1. After adjusting float level, remove the
float hinge pin, float(s) and inlet
needle.
2. Re-install the fuel inlet needle drop
limiter and the hinge pin, with the
foot of the limiter behind the tang on
FUEL LEVEL
V1535B
 24-26-9
the vacuum piston limiter lever (Fig
25).
Rotate the vacuum piston limiter
lever and shaft assembly until the new
scribe marks made during
disassembly line up (Fig. 26). Hold in
place with heavy duty tape.
Invert the upper body and check the
clearance between the needle drop
limiter tab and the fuel inlet seat with
5/8"
ADJUST BOTH NUTS TO FLOAT
HEIGHT SPECIFICATIONS
FIG. 20 Float Gauge and Bending Tool Details
FLOATS SHOULD JUST
CONTACT GAGE
BEND TAB TO RAISE OR LOWER FLOAT
INSTALL FLOAT PIN
FROM THIS SIDE
FIG. 21 Float Setting—Fabricated Gauge (Passenger Carburetor Shown—Police
Carburetor Similar)
Model 4350 4-V Carburetor
a feeler gauge (Fig. 27). If not .005
inch, first loosen the holding tape and
rotate the vacuum piston limiter lever
away from the needle drop limiter and
then adjust for proper clearance by
carefully bending the long "foot" on
the needle drop limiter. Re-index the
vacuum piston limiter lever and
recheck the clearance.
When clearance is to specification,
NO. 12 32 x 2 SCREWS (2 REQ'D.)
NO. 12 NUTS (6 REQ'D.)
BENDING TOOL - 1/16" DIAMETER
SPRING STEEL WIRE OR WELDING
ROD 8" LONG
3/8"
B2859D
SET GAGE TO
SPECIFICATIONS
(BOTH SIDES)
V1151-E
24-26-9
remove hinge pin and needle drop
limiter. Re-install inlet needle, float(s)
and inlet needle drop limiter. Make
sure foot of needle drop limiter is
behind tab of vacuum piston limiter
lever.
VACUUM PISTON AND
METERING RODS ADJUSTMENT
There are no " d r i v e a b i l i t y "
adjustments to be made to the main fuel
metering system. The metering rod
setting is unique to each carburetor and
is set during manufacture with "flow
box" test equipment to a critical air/fuel
ratio at a given part throttle opening.
This setting cannot be determined in
service«
HIGH ALTITUDE COMPENSATION
SYSTEM
No adjustment of the high altitude
system is permitted. To clean the poppet-
type metering valve (See Maintenance
Schedule for interval) remove the three
screws that attach the aneroid bellows
housing to the valve and remove the
housing. Spray Ford Carburetor Choke
Cleaner C9AZ-19A501-B or equivalent
directly on the poppet valve and stem/
guide area. Check to see that valve moves
freely by depressing and releasing.
Repeat if valve is sticking. Reinstall
housing and tighten screws.
FIG. 22 Float Setting—Rebuilding Kit
Gauge
AUXILIARY
VALVfi
CLEAF ANCE
FLOAT
V1 I52-C
FIG. 23 Auxiliary (Supplemental
MH
vdve Setting
24-26-10 Model 4350 4-V Carburetor 24-26-10

FIG. 24 Fuel Inlet Needle Drop Limiter

V2053-A

FIG. 25 Limiter Installed For Adjusting

24-26-11 Model 4350 4-V Carburetor 24-26-11

V2054-A

FIG. 26 Aligning Disassembly Scribe Marks

FIG. 27 Checking Needle Drop Limiter Clearance

REMOVAL AND INSTALLATION

Removal
Flooding, stumble on acceleration
and other performance complaints are in
many instances caused by foreign matter
in the carburetor. To aid in diagnosing
the cause of complaint, the carburetor
should be carefully removed from the
engine without removing the fuel from
the bowl. The contents of the bowl can
then be examined for contamination as
the carburetor is disassembled.
1. Remove the air cleaner assembly.
2. Disconnect the throttle cable from the
throttle lever. Disconnect and remove
transmission kickdown linkage.
Disconnect all fuel, vacuum arid heat
lines from the carburetor.
Disconnect the choke clean (cold) air
pick-up connecting tube frcm the
carburetor air horn.
4. Remove the carburetor attaching nuts
and the carburetor.
24-26-12
5. Remove the carburetor spacer, if
equipped, the carburetor and spacer
gasket from the intake manifold.
Installation
1. Clean the gasket surfaces of the
spacer and carburetor. Place the
spacer between two new gaskets and
position the spacer and gaskets on the
intake manifold.
MAJOR REPAIR OPERATIONS
DISASSEMBLY
The mechanical portion of the fuel
metering system maintains a direct
relationship between the fuel flow
through the main jets (metering rod and
vacuum piston rod height) and throttle
plate position.
This relationship is established during
manufacturing and should not be
changed.
To maintain the relationship during
carburetor disassembly and assembly,
follow this procedure:
1. Before disassembly, scribe a line on
both the pump operating lever and
the carburetor air horn casting, with
the throttle set at fast idle position
(with the fast idle screw on the top
step of the fast idle cam). See Fig. 28.
DO NOT USE THE LINES
ALREADY SCRIBED ON THE
LEVER AND HOUSING. THEY
ARE FOR MANUFACTURING
REFERENCE ONLY.
2. Now the throttle link to the vacuum
piston limiter lever can be removed by
unscrewing the nylon adjusting nut.
To facilitate working on the
carburetor, and to prevent damage to
the throttle plates, install carburetor
legs on the base. If legs are
unavailable, install four 5/16 x 2-1/2
inch bolts and 8 nuts; install nuts on
the bolts, above and below the
carburetor base.
Use a separate container for the
component parts of the various
assemblies to facilitate cleaning,
inspection, and assembly. Refer to
Part 24-01 for cleaning and
inspection.
The following is a step-by-step
sequence of operations for completely
overhauling the carburetor. However,
certain components of the carburetor
may be serviced without a complete
disassembly of the entire unit.
Air Horn
1. Remove the fuel inlet line from the
fuel filter.
2. Remove the choke clean air pick up
connecting tube from the air horn.
3. Remove the choke control rod
retainer from the automatic choke
lever. Separate the rod from the lever.
Model 4350 4-V Carburetor
2. Position the carburetor on the spacer
and gaskets and connect the choke
heat tube. BE VERY CAREFUL
NOT TO CROSSTHREAD THE
TUBE NUT. Position and snug the
attaching nuts and washers.
Alternately torque the carburetor
attaching nuts to specification,
working in a criss-cross pattern.
4. Remove the air cleaner assembly
anchor screw and remove the air horn
to fuel bowl attaching screws.
5. Remove accelerator pump drive rod
at the throttle lever.
6. Lift the air horn off the main body.
7. Invert the air horn, pull the float pivot
pin and remove the float(s) and float
drop limiter.
8. Using the proper tool, remove the
main and auxiliary (supplemental)
fuel inlet valve seats and gaskets.
9. Remove the secondary air valve lever
pivot pin and the rod from the
damper piston assembly and air valve
plate, then remove the air valve
damper piston rod and spring.
10. If it is necessary to remove the
secondary air valve plates or shaft
proceed as follows: Do not perform
this operation with carburetor on
engine, as parts may fall through to
intake manifold. Remove the C-clip
from the secondary air valve plate
link from the damper lever. Remove
the link from the damper lever. Then
remove the air valve plate retaining
screws. Slide the shaft out of the body.
Note that there are spacers used at
either end of the shaft. Lift the air
valve plate and attached metering
rods out of the carburetor (Fig. 29).
11. If necessary to remove choke plate,
first remove the staking marks on the
choke plate attaching screws and
remove the screws. If the tips of the
screws are flared excessively, file the
flared portion to prevent damage to
the threads in the shaft. If equipped
with altitude compensation,
disconnect the compensation choke
plate control link. Remove the choke
plate, then slide the shaft and lever
out of the air horn. The choke lever
is attached to the shaft with a left
hand thread screw.
12. Disengage the operating arm from the
accelerator pump piston. Remove the
clip from accelerator pump operating
shaft and remove both the vacuum
limiter lever and accelerator pump
arm. Slide the shaft out of the air horn
casting.
13. Remove the hex-head screw that
attaches the mechanical fuel bowl
24-26-12
3. Connect the throttle cable and all
lines.
4. Adjust engine idle speeds, fuel
mixture and throttle positioner, if
equipped. Refer to Part 29-02 or
50-02 for procedures.
vent valve operating rod retainer.
Remove the retainer and operating
rod (see Fig. 30).
14. Remove the C-clip that retains the
spring on the shaft. Remove the
spring and plunger assembly.
Main Body
1. Turn the main body upside down and
catch the accelerator pump discharge
needle and ball, (Fig. 31).
2. Turn the body right side up again and
depress the metering rod hanger and
check the gap between the bottom
edge of the metering rod hanger and
the top of the vacuum cylinder (Fig.
32). Record the dimension for
reference during assembly. With a
pair of needle-nosed pliers, remove
the vacuum piston stop (nylon) from
the channel in the main body casting.
3. Remove the main metering vacuum
piston and fuel metering rods as an
assembly. DO NOT DISTURB
S E T T I N G OF P I S T O N
ADJUSTMENT SCREW OR
METERING ROD ADJUSTMENT
SCREWS.
4. With the appropriate screwdriver,
unscrew the vacuum piston cylinder
and remove the cylinder, the return
spring and guide pin (Fig. 32).
5. Remove the main metering jets from
the fuel bowl with a jet tool.
FIG. 28 Scribing New Index Line
Before Removal of Air Horn
Assembly
24-26-13 Model 4350 4-V Carburetor 24-26-13

6. Remove the four (4) altitude

compensation aneroid assembly AIR VALVE PLATE
attaching screws and remove the
assembly from the carburetor body
7. If e q u i p p e d with a l t i t u d e
compensation, you will now be able
METERING ROD WELLS
to remove the two (2) hot idle
compensator attaching screws
through the aneroid poppet valve hole
and remove the compensator. If not
equipped with altitude compensation,
you must remove the cup plug that is
inserted in this hole before removing
the hot idle compensator mounting
screws and compensator. METERING RODS

Throttle Body
Do not remove the idle mixture
limiter caps or the mixture screws from
the throttle body.
1. Remove the throttle body, to main
body screws from the bottom of the
throttle body (Fig. 33) and separate
the two castings.
2. Remove the choke housing cover
s c r e w s , c o v e r , g a s k e t and
thermostatic spring.
3. Remove the choke piston lever
retaining screw, then remove the
piston assembly.
4. Remove the retainers from the
secondary throttle lever to primary
throttle connecting link, then remove
the link.
5. If it is necessary to remove the
throttle plates or shafts from the
throttle body, remove the staking
marks on the throttle plate attaching
screws. Remove the screws and the
plates. Discard the screws.
6. The secondary throttle shaft is of two-
piece design, and is removed in
halves. Pull each half out of the
throttle shaft bores after the plates are
removed.
7. Remove the screw from the primary
throttle shaft, remove the fast idle
lever and adjusting screw. Slide the
shaft assembly out of the primary
throttle shaft bore.
8. Slide the p imary return spring off the
throttle shaft assembly.
9. If it is necessary to remove the fast
idle cam or bushing, carefully press
the bushing out of the choke housing
and bushing column. The column may
bend out of alignment or break
without proper support to the column
d u r i n g b u s h i n g r e m o v a l or
installation. Make sure all holes in
the new gaskets have been properly
punched and that no foreign material
has adhered to the gaskets. Gasket
surfaces must be clean and flat and
free of nicks or burrs. The carburetor
assembly is shown in Fig. 34.
FIG. 29 Removing Air Valve Plate
ASSEMBLY
Throttle Body
1. If the throttle plates and shafts have
beem removed, slide the primary
throttle return spring on the primary
throttle shaft (one-piece shaft) and
slide the shaft into the primary shaft
bores (mixture needles side of body).
2. Position the primary throttle plates
(smaller diameter) in the primary
bores with ground flat edges of the
plate facing toward the idle mixture
needles. Install the plate attaching
screws snug but not tight.
3. Rotate the throttle shaft to the closed
position and tap the plate lightly with
the end of a screw driver handle or
similar tool, so that the plates are
properly and fully seated in the
throttle bores (when viewed with a
light behind the plates, little or no
light should be observed). Tighten the
throttle plate screws.
4. Install the secondary throttle lock out
lever.
5. Install the fast idle speed lever and
adjusting screw.
6. Engage the throttle plate return
spring tang in the recess provided in
the throttle body casting. Make sure
spring operates in a closing direction.
7. Install return springs on each half of
the secondary throttle plate shaft,
with the hook positioned over the
V1931-A
VENT VALVE
VI932-A
FIG. 30 Mechanical Fuel Bowl Vent
Valve—Removal and
Installation
lever and the straight tang on the
inboard end of the shaft. Insert the
shafts into their bores until the tang
on the return spring engages the
appropriate boss. Rotate the hnlves of
the shaft in opposite directions until
the center key indexes.
8. Position the secondary throttle plates
in the bores with the embossed letter
"A" on the plates facing upward and
toward the rear of the carburetor.
Install the new attaching screws
snugly but not tight. Position and
check as with the primary throttle
plates. Make sure return springs
operate in a closed direction.
24-26-14
9. If the fast idle cam and bushing were
removed, insert the automatic choke
shaft bushing through the choke
housing. Position the fast idle cam
between the choke housing and
bushing column. Slide the bushing
through the fast idle cam. Press the
bushing in the choke housing and into
the column. Clean the bushing with
a 1/4-inch reamer.
10. Insert the automatic choke shaft and
lever in the bushing.
11. Position the automatic choke piston
in the choke cylinder and the lever on
the automatic chokeshaft. Install the
attaching screw and lock washer.
12. Position the hot idle compensator into
the bypass air intake and secure with
two mounting screws through the
altitude compensation poppet valve
opening.
13. Insert the secondary throttle to
primary throttle connecting rod into
the throttle levers and install
retainers.
Main Body To Throttle Body
1. Position the main body on a working
surface with the fuel bowl down. If
equipped with altitude compensation,
position gasket and aneroid assembly
to main carburetor body and attach
with four (4) screws. If not equipped
with altitude compensation, seal the
poppet valve hole in the casting with
a 1-1/8 inch cup plug and an
appropriate driver tool.
2. Position the main body to throttle
body gasket on the main body.
3. Position the throttle body on the main
body and install the attaching screws.
4. Invert the main body and the throttle
body so the fuel bowl is upward.
5. With the appropriate jet wrench d*r
screwdriver, install main jets in the
fuel bowl.
6. Install the vacuum piston cylinder
and gasket assembly into the main
body. Place the spring over the guide
pin so that it sits in the retaining
groove and position the pin and
spring in the bottom of the vacuum
piston cylinder. Slide the vacuum
piston over the spring.
7. Carefully position the metering piston
and metering rods into the cylinder
and main metering jets. Push the
piston and metering rods to the full
downward position and install the
nylon piston stop in the channel in the
main body casting.
8. If the metering rod adjustment has
been disturbed, manually depress the
metering rod hanger. Using a small
screwdriver no wider than 3/32 inch,
carefully turn the vacuum piston
adjusting screw (Fig. 37) and the
metering rod adjusting screws,
counterclockwise until the metering
Model 4350 4-V Carburetor
rod hanger is fully seated against the
vacuum cylinder top face.
NOTE: If you do not have a
suitable 3/32 inch wide screwdriver,
make one byflatteninga heavy paper
clip and then filing to the correct
dimensions (Fig. 36).
9. Holding tbe metering rod hanger
lightly in the full downward position,
turn each metering rod adjusting
screw clockwise until the metering
rod hanger just starts to rise. (The
metering rods are now set in the
proper relationship with the vacuum
piston.)
lO.Now turn the vacuum piston
adjusting screw clockwise until the
clearance between the bottom of the
metering rod hanger and the top edge
of the vacuum piston cylinder
(recorded during disassembly) is
achieved (Fig. 37).
11. Install the choke-to-throttle lockout
lever.
12. Place the accelerator pump discharge
check ball and weight in position in
the body.
Air Horn
1. Install the accelerator pump
operating shaft into the bore in the
upper body casting. Assemble the
vacuum piston limiter lever and
accelerator pump operating arm to
the end of the shaft and secure with
a clip (Fig. 38).
NOTE: If a new accelerator pump
operating arm is being installed, refer
to Adjustments for proper sequence
of operations.
2. Install the accelerator pump on the
arm. Install the vent valve plunger,
spring and clip.
MAIN JETS V-1933-B
FIG. 31 Main Body Components—Air
Horn Removed
24-26-14
3. If the choke plate and shaft were
removed, slide the choke shaft
through the holes in the air horn.
Install the choke shaft lever on the
end of the shaft on the automatic
choke side. If equipped with altitude
compensation, position compensation
choke plate link to compensation
choke plate and main choke plate.
The lever and shaft are tapered and
the attaching screw has a left hand
thread. Insert the choke plate into the
slot in the choke shaft and install the
plate attaching screws snug but not
tight.
4. Close the choke plate and gently tap
the plate with the end of a screwdriver
or a similar tool to properly position
the plate in the air horn.
© HOLD HANGER
DOWN
(5) MEASURE
VACUUM PISTON CLEARANCE
ADJUSTING SCREW SET AT
FACTORY
V2047-A
FIG. 32 Measuring Vacuum Piston
Setting Before Disassembly
THROTTLE BODY TO
MAIN BODY ATTACHING CHOKE HOUSING
SCREWS (6 REQUIRED)
SECONDARY THROTTLE
SHAFT & LEVERS
PRIMARY THROTTLE
SHAFT & LEVERS V1934-A
FIG. 33 Throttle Body Bottom View
24-26-15 Model 4350 4-V Carburetor 24-26-15

SCREW
C-CLIP ALTITUDE COMP
VENT VALVE RETAINER f
CHOKE PLATE LINK
ADJUSTING
SCREW SCREW
AIR
VALVE CHOKE PLATE
LINK

ALTITUDE COMP
CHOKE PLATE *"
SCREW LEVER

SCREW CHOKE PLATE

SHAFT
AIR VALVE UPPER BODY
SHAFT
VACUUM PISTON
LI MITER LEVER

ACCELERATOR PUMP ARM

ACCELERATOR PUMP
SPRING RETAINER
ACCELERATOR PUMP
LEVER AND ROD
PUMP SPRING
FUEL BOWL
ACCELERATOR VENT VALVE
PUMP LINK PUMP SHAFT

RETAINER
AIR VALVE DAMPER
PISTON AND ROD METERING RODS
FLOAT AND & YOKE
FUEL INLET VALVE LEVER
AND SEAT ASSEMBLY MAIN JETS
(EXCEPT POLICE)

FLOAT
HOT DROP
IDLE VACUUM PISTON
ALTITUDE ACCEL-PUMP LIMITER
COMPENSATOR
COMPENSATION INLET NEEDLE SPRING
ASSEMBLY
VALVE

VACUUM PISTON
CYLINDER
PRIMARY
THROTTLE PLATES GASKET

PRIMARY THROTTLE SHAFT THROTTLE

AND LEVER ASSEMBLY AUXILIARY
LEVER

AUTOMATIC CHOKE
SHAFT AND LEVER

CAM ADJUSTING SCREW

FAST IDLE CAM
SECONDARY THROTTLE
SHAFT AND LEVER (L.H.) CAP

CHOKE CONTROL ROD

SECONDARY
THROTTLE
PLATES
PISTON AND LEVER ASSEMBLY
CHOKE
THERMOSTATIO
THROTTLE BODY CAP
AND CHOKE CHOKE HEAT
HOUSING CONNECTION
THROTTLE
STOP LEVER

1
/
RETURN / FAST IDLE SPEED
CHOKE DELAYED PULLDOWN ADJUSTING SCREW
AND FAST IDLE TOP STEP SPRING /
PULLOFF DIAPHRAGM SECONDARY THROTTLE
ASSEMBLY SHAFT AND LEVER (R.H.)

FIG. 34 Model 4350 4-V Carburetor With Altitude Compensation—Disassembled View

24-26-16 Model 4350 4-V Carburetor 24-26-16

SCREW
RETAINER
C-CLIP VENT VALVE
ADJUSTING SCREW
DAMPER SCREW
AIR LINK CHOKE PLATE
VALVE \ \ .
LINK \ \

V
AIR VALVE
PLATE LEVER

CHOKE PLATE
SHAFT
AIR VALVE
SHAFT VACUUM PISTON
LIMITER LEVER
SPACER
ACCELERATOR PUMP ARM

ACCELERATOR PUMP
SPRING RETAINER
ACCELERATOR PUMP
PUMP SPRING
LEVER AND ROD
BOWL VENT
VALVE
ACCELERATOR PUMP SHAFT
PUMP LINK \ ^ /

AIR VALVE DAMPER

PISTON AND ROD METERING RODS
& YOKE
FUEL INLET VALVE
AND SEAT

GASKET
HOT IDLE
COMPENSATOR

VACUUM PISTON
CYLINDER
PRIMARY
THROTTLE PLATES

-YZfr^^ THROTTLE
PRIMARY THROTTLE SHAFT Srfr"* " AUXILIARY
AND LEVER ASSEMBLY

/ AUTOMATIC CHOKE
SHAFT AND LEVER
CAM ADJUSTING SCREW
FAST IDLE CAM
SECONDARY THROTTLE
SHAFT AND LEVER (L.H.) CAP

CHOKE CONTROL ROD

SECONDARY
THROTTLE
PLATES
IDLE PISTON AND LEVER ASSEMBLY
SPEED
SCREW CHOKE
THERMOSTATIC
THROTTLE BODY CAP
AND CHOKE RETAINER
HOUSING CHOKE HEAT
CONNECTION SCREW
THROTTLE
STOP LEVER
PULLOFF
LINKAGE
FAST IDLE SPEED
CHOKE DELAYED PULLDOWN ADJUSTING SCREW
AND FAST IDLE TOP STEP SECONDARY THROTTLE
PULLOFF DIAPHRAGM SHAFT AND LEVER (R.H.)
ASSEMBLY V1935-D

FIG. 35 Model 4350 4-V Carburetor Without Altitude Compensation (Police Model)—Disassembled View
24-26-17
T i g h t e n and stake the plate
attaching screws.
5. If the air valve plate and shaft were
removed, slide the shaft through the
holes on the secondary side of the air
horn and with the slotted end of the
shaft in the air valve spring chamber.
6. Install the secondary metering rods in
the keyed slots on the air valve plate.
Do not attempt to remove or install
the secondary air valve plate and
metering rods with the carburetor
installed on the engine, as the shaft
s p a c e r ( s ) , metering rods and
attaching screws can fall into the
intake manifold. Lower the air valve
plate into position while guiding the
metering rods into the air valve wells.
Then slide the air valve shaft and
spacer(s) into position and install the
air valve plate to the shaft.
7. Close the air valve plate and lightly
tap the plate with end of a screwdriver
or similar tool to properly position it
in the air horn.
T i g h t e n and s t a k e the plate
attaching screws. Be sure the plate
and shaft turns freely after assembly.
8. Install fuel inlet needle seat and
gasket, using proper tool. Insert fuel
inlet needle into the fuel inlet needle
seat.
9. Install the supplementary fuel inlet
valve and gasket.
10. Position float and lever assembly
between hinge post and over fuel inlet
valves.
11. Insert the float hinge pin through the
post and float lever. The pin must be
inserted from the accelerator pump
plunger side for self-retention.
12. Position return spring over air valve
damper rod. Insert assembly through
upper body and insert cranked end of
damper rod into inner arm hole in
damper link.
13. Position damper link (bell crank) over
post on upper body and install split
pin shaft.
14. Insert cranked end of air valve link
through tang on air valve plate and
position other end throughout board
end t h r o u g h remaining hole in
damper link (bell crank). Install C-
clip over end of air valve link.
15. Insert the accelerating pump bleed
disc into the pump bleed cavity.
16. Set the float level.
17. Position the mechanical vent valve
operating lever in the cast slots and
install the retainer and screw.
Model 4350 4-V Carburetor 24-26-17
Upper Body To Main Body
1. Position the main body to upper body
gasket on the main body.
2. Carefully position the upper body
assembly over the main body. Guide SCREW DRIVER
the accelerator pump plunger and the
secondary throttle dashpot piston
into their chambers as the upper body VACUUM
PISTON
is gently lowered into position. ADJUSTING
3. Install the other upper body attaching SCREW
o
screws.
4. Position the throttle levers so that the
fast idle screw is positioned on the
high step of the fast idle cam. Insert
the key end of the accelerator pump
link into the keyed hole in the / VI959-A
primary throttle lever.
5. Insert the threaded end of the FIG. 37 Preliminary Vacuum Piston
accelerator pump link through the Adjustment
hole in the accelerator pump lever
and install the nut (nylon) so that the
index marks made during disassembly
line up. The nut is self-locking. -
6. Insert the choke control rod end into
the automatic choke lever. With long VACUUM PISTON LIMITER
SHAFT
nose pliers, install the retaining clip.
7. Install the choke cover gasket so that
round hole lines up with the air inlet
hole in the casting.
8. Install the choke thermostatic spring
housing and retainer. Set the cap to
the 90 degree rich position.
9. Check the fast idle cam clearance.
10. Reset the choke cap to specifications.
11. Remove the carburetor legs or bolts ACCELERATOR
from the throttle body. PUMP OPERATING ARM
VI'336-B
Note: Adjust mechanical fuel bowl
vent valve after carburetor is reinstalled
on vehicle. (See ADJUSTMENT.) FIG. 38 Assembling Components to
Vacuum Piston Limiter Lever
Shaft
GAGE ADJUST
PIN dF /
V2056A
A4291 A
FIG. 36 Fabricating Special 3/32 FIG. 39 Adjusting Accelerator Pump
inch Wide Screwdriver Nylon Arm
24-27-1 Motorcraft Model 2700 VV Carburetor 24-27-1

Motorcraft Model PART

2700 W Carburetor 24-27

SUBJECT PAGE SUBJECT PAGE

GENERAL INFORMATION 27-1 ADJUSTMENTS (Cont'd.)

OPERATION Fast Idle Speed 27-8
Accelerator Pump System 27-4 Float Drop 27-8
Cold Enrichment System 27-2 Fuel Level 27-8
Control Vacuum 27-2 High Cam Speed Positioner (H.C.S.P.) 27-9
Control Vacuum Regulator (CVR) 27-4 Idle Trim 27-9
Cranking Enrichment System 27-3 Internal Vent 27-8
External Vent System 27-4 Venturi Valve Limiter 27-8
Fast Idle Cam 27-3 DISASSEMBLY AND ASSEMBLY
Fuel Inlet System 27-2 Assembly
Idle Trim System 27-4 Main Body 27-18
Main Metering System 27-2 Throttle Body 27-18
Venturi Valve Limiter 27-3 Upper Body 27-18
ADJUSTMENTS Disassembly
Cold Enrichment Metering Rod 27-7 Main Body 27-16
Control Vacuum j 27-7 Throttle Body 27-16
Control Vacuum Regulator (CVR) 27-9 Upper Body 27-14
Curb Idle Speed 27-7 SPECIFICATIONS 27-20
Fast Idle Cam 27-8 SPECIAL TOOLS 27-21
CV2059-A

GENERAL INFORMATION
The Motorcraft Model 2700 VV
(variable venturi) carburetor is able to
vary the area of its venturi according to
engine speed and load, making it different
from all other Motorcraft carburetors,
which have fixed area venturi. The 2700
VV uses a dual-element venturi valve that
moves in and out of the air flowing into
the two throats of the carburetor (Figs.
1 and 2).
The venturi valve is controlled by
engine vacuum and throttle position, and
is connected to two main metering rods
which control fuel flow. In operation, air
speed through the carburetor is fairly
constant, making for more even air/fuel
mixtures throughout the engine
operating range. In a fixed venturi
carburetor, air flow speed varies
according to throttle opening and engine
speed. In order to work with the
changing flow speed, supplementary
systems such as an independent idle
system, enrich-valve system and choke
plate are needed. In the Motorcraft 2700 V2060 A
VV c a r b u r e t o r , none of these
supplementary systems are needed. FIG. 1 Motorcraft Model 2700 VV Carburetor—3/4 Front View
24-27-2 Motorcraft Model 2700 VV Carburetor 24-27-2

V2061-A

FIG. 2 Motorcraft Model 2700 VV Carburetor—3/4 Rear View

OPERATION
FUEL INLET SYSTEM
The fuel inlet system is a suspended valve is controlled by two forces: a spring body, main body and the diaphragm
float type, similar to the Motorcraft 4350 that acts to close the valve, and control housing. The diaphragm is connected to
4V, except that it has a single float. On vacuum that acts to open the valve. Both the venturi valve.
some applications, an in-line fuel filter is these forces are present in the control When the engine is running, an
used, while others use an integralfilterat vacuum diaphragm assembly (Fig. 5). increase in throttle plate opening will
the fuel inlet. The float and lever Control vacuum is the vacuum below normally increase the control vacuum.
assembly controls fuel inlet through a the venturi valve and above the throttle When the vacuum signal increases, the
single inlet valve and seat assembly (Fig. plates, and is routed to the control control vacuum diaphragm pulls in
3). vacuum diaphragm through the upper against the spring and opens the venturi
The needle valve riding on the float
lever reacts to changes in fuel level,
admitting enough fuel to replace that
used.
MAIN METERING SYSTEM
The pressure drop caused by airflow
past the fuel discharge nozzles causes
solid fuel to flow from the fuel bowl, up
the main well tubes, through the main
metering jets and into the venturi (Fig.
4).
The fuel flow rate is controlled by
tapered metering rods inserted into the
main metering jets and linked to the
venturi valve. Small torsion springs are
used to position the metering rods against
the top of the main metering jet orifices GASKET
for more precise fuel flow control. A
change in throttle plate opening or engine
load causes a change in venturi valve and FUEL FILTER
metering rod position, providing fuel FITTING
flow in proportion to air flow.
CONTROL VACUUM
v;:062A
During normal warm-engine
operation, the position of the venturi FIG. 3 Fuel Inlet System
24-27-3 Motorcraft Model 2700 VV Carburetor 24-27-3

valve and the main metering jets. Since Fuel flow is metered by a metering vacuum and determine the position of the
the venturi valve is not linked directly to rod suspended from the upper body venturi valve. Manifold vacuum applied
the throttle shaft, the control vacuum through a jet located in the bottom of the to the diaphragm causes the venturi
and spring can select the precise fuel/air fuel bowl (Fig. 8). The metering rod opening to be slightly larger than normal
ratio for all speed and load conditions height is regulated by the choke bimetal (hot engine) to prevent engine loading at
except wide open throttle (WOT). and the fuel is channeled through the idle due to an overrich fuel mixture.
same passage as the cranking enrichment Under acceleration, the venturi valve
VENTURI VALVE LIMITER fuel. assumes the normal position providing a
At wide open throttle, under some After a cold start (below 95°F) the richer mixture for good cold driveaway.
load conditions, the control vacuum will control vacuum regulator (CVR)
not be strong enough to override the restricts part of the normal control FAST IDLE CAM
venturi valve diaphragm spring pressure vacuum to the venturi valve operating A conventional fast idle cam controls
and open the valve fully. In this case, the diaphragm. This restriction allows engine speed during the cold enrichment
valve is opened by the venturi valve manifold vacuum to override the control cycle. An unique feature of the fast idle
limiter lever on the throttle shaft (Fig. 6).
VENTURI VALVE
On some engine applications, an
additional spring operates the venturi
valve limiter lever, providing venturi
valve control during heavy part-throttle
acceleration.
CRANKING ENRICHMENT
SYSTEM
The cranking enrichment system
provides fuel for cold engine starting
(below 75°F.) when the ignition key is in
the START position. It consists of a
normally closed valve connected to a
solenoid mounted at the front of the
carburetor. Fuel inlet to this valve is
controlled by a bimetallic valve that is
closed above 75° (Fig. 7).
The volume of fuel flowing in the
system is controlled by the position of the
solenoid valve and the position of the
bimetallic valve. Some carburetors also
have a small bypass restrictor located in
the bottom of the fuel bowl which allows
fuel to flow even if the bimetallic valve V2063A
is closed, to aid in hot engine starting. FIG. 4 Main Metering System
When the ignition switch is in the
START position, the cranking
enrichment solenoid is energized, CVR ROD
allowing fuel to flow in the cranking
enrichment system if the ambient
temperature is below 75° and the
cranking fuel control valve is open. Fuel
flows from the fuel bowl through the CONTROL
VACUUM
cranking fuel control valve (bimetal), DIAPHRAGM
through the cranking enrichment
solenoid valve, to the discharge points
below the venturi valve. When the engine
starts, and the key is released to the RUN
position, the cranking enirchment
solenoid is de-energized and the valve SCREW
closes. Fuel for cold driveaway is
controlled by the main metering system
and the cold enrichment system.
SPRING

COLD ENRICHMENT SYSTEM r V i l FUEL

STEM CONNECTED TO VENTURI VALVE
The cold enrichment system utilizes Y7M AIR
a conventional exhaust heated bimetal I j CONTROL VACUUM
coil type choke system to regulate the 1 I MANIFOLD VACUUM (WEAK)
flow of fuel and the positioning of both H I MANIFOLD VACUUM (STRONG)
the venturi valve and the fast idle cam for V2064A
cold engine operation. FIG. 5 Control Vacuum Circuit
24-27-4 Motorcraft Model 2700 VV Carburetor 24-27-4

cam mechanism is a vacuum operated the piston upward and allows the pump and opens or closes the internal vent in
high cam speed positioner (HCSP). cavity to refill. response to throttle position. The internal
Under cold start conditions, a lever is A bypass system built into the main vent is closed at the idle position with the
inserted between the fast idle cam and body allows some of the fuel to be engine off.
fast idle lever to provide increased diverted through a calibrated restrictor
throttle plate opening for starting (Fig. back into the fuel bowl. The size of this EXTERNAL VENT SYSTEM
9). When the engine starts, manifold restrictor (some carburetors may not The external vent system is used to
vacuum is applied to the (HCSP) have one) is determined by the amount relieve fuel bowl pressure caused by fuel
diaphragm and the lever is retracted, of fuel required for a particular engine. vapor formed in the fuel bowl during hot
, after the first throttle movement, and Another unique feature of this engine conditions (Fig. 13).
remains retracted as long as the engine is carburetor is the positive seal internal When fuel vapor pressure builds up
running. This lowers the fast idle speed vent. A rubber coated disc type valve is in the fuel bowl, the external vent check
for all cold drive modes. mounted on the accelerator pump piston valve is lifted from its seat, allowing the
CONTROL VACUUM REGULATOR
When the engine warms up and the
choke bimetal unwraps, the CVR rises,
opens the restricted port in the control
vacuum circuit and allows the control of
the venturi valve to return to normal as
described under main metering system
(Fig. 10). As the CVR rises the cold
enrichment rod is lowered until it is WOT STOP
seated in its jet shutting off the cold
enrichment fuel.
IDLE TRIM SYSTEM
This carburetor does not have a
conventional idle system since the idle
fuel is controlled through the main
metering jets. However a system is
provided to trim the fuel flow at idle (Fig.
11). The idle trim fuel is pulled, by
manifold vacuum, from the main
metering chamber, flows through an
independent channel and is discharged
THROTTLE
through a timed port below the trailing SPRING SHAFT
edge of each throttle plate. The flow of
this fuel is controlled by tapered screws 72065-A

which bypass air into the trim channels.

There is an idle fuel trim channel for FIG. 6 Venturi Valve Limiter
each bore. CRANKING VACUUM
CRANKING
FUEL CONTROL
ACCELERATOR PUMP SYSTEM VALVE
The accelerator pump system is a
positive displacement, piston type similar
to the model 4350 carburetor. It consists
of a piston assembly that is activated by
an overtraveling spring system mounted
on the throttle shaft (Fig. 12).
The pump cavity, located in the
bottom of the fuel bowl, fills from the top
and the floating cup acts as an inlet check
valve.
As the throttle is opened, and the
pump piston is driven downward, 75° AMBIENT
pressure developed in the cavity seals the POSITION

cup against the piston causing the fuel to

flow. An anti-syphon check ball and
weight, located in the up channel are
unseated and fuel is delivered through the
pump discharge nozzles in the Venturis.
£ 1 3 FUEL
When the fuel supply in the pump
AIR
channel is exhausted, the check ball and PLUNGER OPEN ONLY
weight return to the seated position to MANIFOLD VACUUM (STRONG) WHEN CRANKING
prevent syphoning during high speed VZ226 A
operation. When the throttle returns to
the idle position, the return spring forces FIG. 7 Cranking Enrichment System
24-27-5 Motorcraft Model 2700 VV Carburetor 24-27-5

fuel vapor to be vented to a carbon of these fuel vapors in this manner that could arise if the vapor remained
canister that is part of the vehicle's prevents hot engine starting problems trapped in the carburetor,
evaporative emission system. Disposing

I 1 MANIFOLD VACUUM (WEAK)

tm MANIFOLD VACUUM (STRONG)
C D CONTROL VACUUM VENTURIVALVES CONTROL VACUUM
EZ3FUEL REGULATOR
CZ3AIR

COLD ENRICHMENT
ROD

ENGINE COLO
V2227A

FIG. 8 Cold Enrichment System

COLD START CRANKING

HCSP
DIAPHRAGM

| MANIFOLD VACUUM (STRONG)

V2228-A

FIG. 9 Fast Idle Cam and HCSP Operation

24-27-6 Motorcraft Model 2700 VV Carburetor 24-27-6

1 1 MANIFOLD VACUUM (WEAK)

VENTURIVALVES
• I MANIFOLD VACUUM (STRONG) CONTROL VACUUM
rrr\ CONTROL VACUUM REGULATOR
E3
VZPPi A I R

COLD ENRICHMENT
ROD

ENGINE HOT

V2229A

FIG. 10 Control Vacuum Regulator (CVR)

V2230A

FIG. 11 Idle Trim System

24-27-7
FIG. 12 Accelerator Pump System
FIG. 13 External Vent System
ADJUSTMENTS
Before making any adjustments with
the engine running, set the vehicle
parking brake and/or block the wheels.
If the vehicle has a vacuum parking brake
release, disconnect the line to the parking
brake control and plug the line.
Conduct all engine running tests with
the engine at normal operating
temperature (radiator upper hose hot to
touch).
CURB IDLE SPEED
Curb idle speed is adjusted in
conventional manner, depending on the
throttle positioner used (Fig. 14). Refer
to the engine emission control decal for
curb idle speed specification.
Motorcraft Model 2700 VV Carburetor
LINK INTERNAL
VENT VALVE PUMP DISCHARGE
NOZZLE
BYPASS RESTRICTOR RETURN SPRING
CHECK VALVE
VALVE SEAT
COLD ENRICHMENT METERING
ROD
1. Remove the choke cap.
2. Install the stator cap (Tool T77L-
9848-A) as a weight to seat the cold
enrichment rod (Fig. 15).
3. Install a dial indicator (Tool 4201-C)
or equivalent with the tip on the top
surface of the enrichment rod and
adjust the dial to zero. Raise the
weight slightly and release to make
sure the zero repeats.
4. Remove the stator cap and reinstall
it at the index position, the dial
indicator should read to specification.
If the rod height is not to specification
turn the adjusting nut clockwise to
24-27-7
PUMP CHECK
BALL AND
WEIGHT
V2231A
V2232-A
increase or counterclockwise to
decrease height.
Reinstall the choke cap at the
specified setting.
CONTROL VACUUM
1. Install a tachometer.
2. Start the engine and set the idle to
specification.
3. Using an alien wrench turn the
venturi valve diaphragm adjusting
screw clockwise until the valve is
firmly closed (Fig. 16).
4. Connect a vacuum gauge (T77L-
9510-A or equivalent) to the vacuum
tap on the venturi valve cover.
 24-27-8 Motorcraft Model 2700 VV Carburetor
SOLA-DASH
THRU ADJUST
DASHPOT
PLUNGER DEPRESSED
SOLA-DASH
BRACKET - ADJUST
FIG. 14 Curb Idle Speed Adjustment
5. With the engine at curb idle, use an
alien wrench to turn the venturi
bypass adjusting screw to reach the
specified vacuum setting.
NOTE: It may be necessary to reset
the idle speed while making the
adjustment.
6. Turn the venturi valve diaphragm
adjusting screw counterclockwise
until the vacuum drops to the
specified setting.
NOTE: It is necessary to cycle the
throttle during this adjustment to get
the vacuum to drop.
7. Check and/or reset the curb idle.
INTERNAL VENT
1. Set the c u r b idle speed to
specification.
2. Place a. 010" feeler gauge between the
accelerator pump stem and the pump
operating link. (Fig. 17).
3. Turn the nylon adjusting nut until
there is just a slight drag when the
gauge is removed.
SOLENOID
BRACKET ADJUST
SOLENOID
THRU ADJUST
NOTE: This adjustment must be
checked and/or set whenever the curb
idle speed is adjusted.
FAST IDLE SPEED
1. With the engine idling at normal
operating temperature, place the fast
idle lever on the specified step of the
fast idle cam (Fig. 18).
NOTE: EGR disconnected and
vacuum line plugged.
2. Make sure the high cam speed
positioner lever is disengeged.
3. Turn the fast idle adjusting screw
clockwise to increase speed and
counterclockwise to decrease speed.
FAST IDLE CAM
1- Remove the choke cap.
2. Place the fast idle lever in the corner
of the specified step of the fast idle
cam (counting the highest step as the
first) with the high cam speed
positioner retracted (Fig. 19).
24-27-8
3. Hold the throttle lightly closed with
a rubber band to maintain cam
position.
NOTE: This step is not required if
the adjustment is done on the vehicle.
4. Install the stator cap (T77L-9848-A)
and rotate clockwise until lever
contacts the adjusting screw
5. Turn the fast idle cam adjusting screw
until the index mark on the stator cap
lines up with the specified notch on
the choke casting.
6. Remove the stator cap and reinstall
the choke cap to specified setting.
FUEL LEVEL
1. Remove the upper body assembly.
Remove the upper body gasket and
install a new gasket before making the
adjustment.
2. Fabricate a gauge to the specified
dimension (Fig. 20).
3. With the upper body inverted, place
the fuel level gauge on the cast surface
of the upper body (NOT ON THE
GASKET) and measure the vertical
distance from the cast surface of the
upper body and the bottom of the
float.
4. To adjust, bend the float operating
lever away from the fuel inlet needle
to decrease the setting and toward the
needle to increase the setting,
5. Check and/or adjust the float drop.
NOTE: The float pontoon must be
parallel with the gasket.
FLOAT DROP
1. Fabricate a gauge to the specified
dimension.
2. With the upper body assembly held in
the "upright position, place the gauge
against the cast surface of the upper
body (NOT ON THE GASKET) and
measure the vertical distance between
the cast surface of the upper body and
the bottom of the float (Fig. 21).
3. To adjust, bend the stop tab on the
float lever away from the hinge pin to
increase the setting and toward the
hinge pin to decrease the set ring.
4. Reinstall the upper body assembly.
VENTURI VALVE LIMITER
1. Remove the carburetor.
2. Remove the venturi valve cover and
roller bearings.
3. Remove the expansion plug located at
the rear of the main body on the
throttle side of the carburetor
(CENTER PUNCH TILL LOOSE).
4. Using an alien wrench, remove the
venturi valve wide open throttle stop
screw (Fig. 22).
5. Block the throttle plates wide open.
6. Apply light closing pressure on the
venturi valve and check the gap
24-27-9 Motorcraft Model 2700 VV Carburetor 24-27-9

between the valve and the air horn ADJUSTING NUT DIAL INDICATOR
wall (if not to specification it must be TOOL-4201-C
adjusted).
7. Manually move the venturi valve to
the wide open position and insert an
alien wrench into the hole from which
the stop screw was removed. Turn the
limiter adjusting screw clockwise to
i n c r e a s e the gap and
counterclockwise to decrease.
8. Remove the alien wrench and apply
light closing pressure to the valve.
Recheck the gap.
9. Reinstall the venturi valve wide open
stop screw and turn clockwise until it
contacts the valve.
10. Push the venturi valve to the wide
open position and check the gap
between the valve and the air horn
wall.
11. Turn the stop screw until the gap is
to specification.
12. Install a new expansion plug in the
access hole.
13. Reinstall the venturi valve cover and
roller bearings.
14. Reinstall the carburetor.
CONTROL VACUUM REGULATOR
(CVR) ADJUSTMENT V2235-A
NOTE: The cold enrichment metering
rod adjustment must be checked and/or FIG. 15 Cold Enrichment Metering Rod Adjustment
set before making this adjustment.
1. Rotate the choke cap 180 degrees
clockwise (rich) from index and cycle
the throttle to set the fast idle speed 1/8"
cam.
2. Press lightly on the CVR rod. If there
is any down travel, the rod is not
seated and must be adjusted. If there
VENTURIBYPASS
is no down travel, turn the adjusting ADJ. SCREW
screw counterclockwise until there is
some down travel and proceed with
the adjustment.
3. Turn the CVR rod clockwise until the
adjusting nut just begins to rise.
4. Again, press lightly on the CVR
rod—if any springback can be seen
the rod is not fully seated. Turn the
adjusting screw clockwise in 1/4 turn V.V. DIAPHRAGM
increments until no springback can be ADJ. SCREW
seen.
5. Reset the choke cap to the specified
setting.
HIGH CAM SPEED POSITIONER
(H.CS.P.)
V2236A
1. Place the high cam speed positioner
(H.CS.P.) in the corner of the FIG. 16 Control Vacuum Adjustment
specified cam step (counting the
highest step as the first). See Fig. 24. rotate counterclockwise 1/2 to 1 1/2 2. Use an alien wrench. Turn the air
2. Place the fast idle lever in the corner turns until the vacuum port and adjusting screw clockwise to enrichen
of the H.CS.P. diaphragm hole line up. and counterclockwise to lean out.
3. Hold throttle closed firmly to 5. Install the diaphragm cover.
maintain Steps 1 and 2.
4. Remove diaphragm cover and adjust IDLE TRIM
diaphragm assembly clockwise until 1. Remove the air cleaner cover only
lightly bottomed on casting, then (Fig. 25).
24-27-10 Motorcraft Model 2700 VV Carburetor 24-27-10

V2237A

FIG. 17 Internal Vent Adjustment

FIG. 18 Fast Idle Speed Adjustment

24-27-11 Motorcraft Model 2700 VV Carburetor 24-27-11

STATOR CAP -
T77L-9848-A

V2239-A

FIG. 19 Setting Fast Idle Cam

V2240-A

FIG. 20 Fuel Level Adjustment

24-27-12 Motorcraft Model 2700 VV Carburetor 24-27-12

V2241-A

FIG. 21 Float Drop Adjustment

FABRICATE

5/32"
LIMITER
ADJUSTMENT
V2242A

FIG. 22 Venturi Valve Limiter Adjustment

24-27-13 Motorcraft Model 2700 VV Carburetor 24-27-13

3/32"

CVR ROD
ADJUSTING NUT

V2243A

FIG. 23 Control Vacuum Regulator (CVR) Adjustment

VACUUM PORT AND

DIAPHRAGM HOLE
MUST BE LINED UP.

V2244A

FIG. 24 High Cam Speed Positioner (H.C.S.P.) Adjustment

24-27-14
FIG. 25 Idle Trim Adjustment
DISASSEMBLY AND ASSEMBLY
To facilitate working on the
carburetor and prevent damage to the
throttle plates, the carburetor should be
placed on a carburetor stand. If a proper
stand is not available use four (4) bolts
5/16x2-1/2 inch as legs. Install nuts on
the bolts above and below the throttle
body.
The following is a step-by-step
sequence of operations for completely
overhauling the carburetor. However,
most components may be serviced
without a complete disassembly of the
unit. To replace individual components
of the carburetor follow only the
applicable steps.
NOTE: Use a separate container for
the component parts of each sub-
assembly to insure proper assembly. See
Figs. 26, 27 and 28 for a disassembled
view of the major sub-assemblies.
Numbers in parenthesis refer to the parts
indicated on the disassembled views.
DISASSEMBLY
Upper Body (Fig. 26)
1. Remove the fuel inlet fitting, fuel
filter, gasket and spring. (1, 2, 3, 4)
2. Remove the E rings on the accelerator
pump rod and the choke control rod
and disengage the rods. (5, 6, 7)
Motorcraft Model 2700 VV Carburetor
3/32'
3. Remove the air cleaner stud. (Not
Shown)
4. Remove the seven screws retaining
the upper body assembly, remove the
upper body and place it inverted on
a clean work surface. (8, 8A). Note
position of 2 long screws for re-
assembly.
5. Remove the float hinge pin and the
float assembly. (10,11)
6. Remove the float bowl gasket. (12)
7. Remove the fuel inlet valve, seat and
gasket. (13, 14, 15)
Remove the accelerator pump rod
and the dust seal. (6, 16)
9. Remove the accelerator pump link
retaining pin and the link. (17, 18)
10. Remove the accelerator pump swivel
and adjusting nut (19, 20)
11. Remove the choke control rod.
Remove the dust seal by lifting the
retainer carefully and sliding the seal
out. (7, 16)
12. Remove the E ring on the choke hinge
pin and slide the pin out of the
casting. (5, 21)
13. Remove the cold enrichment rod
adjusting nut, lever, adjusting swivel,
control vacuum regulator, and
adjusting nut as an assembly (Fig.
24-27-14
V2245-A
27); disassemble as required. (20,
22,23,24,25)
14. Slide the cold enrichment rod out of
the upper body casting. (26)
15. Remove the venturi valve cover plate
screws, the plate and the roller
bearings. (27, 28, 29)
16. Remove the venturi air bypass screw.
(30)
17. Using special Tool T77P-9928-A,
press the tapered plugs out of the
venturi valve pivot pins. (31) See Fig.
28.
18. Push the venturi pivot pins out and
slide the venturi valve to the rear until
it is free of the casting. (32, 3;l)
19. Remove the venturi valve pivot pin
bushings. (34)
20. Remove the metering rod pivot pins
(on the outboard sides of the venturi
valve), the metering rods and the
springs. (35, 36, 37)
NOTE: Identify the rods,
"throttle" or "choke" side, for proper
assembly.
CAUTION: Always block the
venturi valve wide open when working
on the jets.
21. Using the jet plug removal Tool
(T77L-9533-B) remove the cup plugs
24-27-15 Motorcraft Model 2700 VV Carburetor 24-27-15

UPPER BODY

1. FUEL INLET FITTING. 17. PIN-.12X.69

2. FUEL INLET FITTING GASKET. 18. ACCELERATOR PUMP LINK. 33. VENTURI VALVE.
3. FUEL FILTER. 19. ACCELERATOR PUMP SWIVEL. 34. VENTURI VALVE PIVOT PIN BUSHING.
4. FUEL FILTER SPRING. 20. NUT-NYLON. 35. METERING ROD PIVOT PIN.
5. 1/8 RETAINING E-RING. 21. CHOKE HINGE PIN. 36. METERING ROD.
6. ACCELERATOR PUMP ROD. 22. COLD ENRICHMENT ROD LEVER. 37. METERING ROD SPRING.
7. CHOKE CONTROL ROD. 23. COLD ENRICHMENT ROD SWIVEL. 38. CUP PLUG.
8. SCREW (2). 8-32 X .88 24. CONTROL VACUUM REGULATOR ADJUSTING NUT. 39. MAIN METERING JET ASSEMBLY.
8A. SCREW (5) 8-32 X .75 25. CONTROL VACUUM REGULATOR. 40. " O " RING.
9. UPPER BODY 26. COLD ENRICHMENT ROD. 41. ACCELERATOR PUMP RETURN SPRING.
10. FLOAT HINGE PIN. 27. SCREW (2) 8-32 X .75 42. ACCELERATOR PUMP CUP.
11. FLOAT ASSEMBLY. 28. VENTURI VALVE COVER PLATE. 43. ACCELERATOR PUMP PLUNGER.
12. FLOAT BOWL GASKET. 29. ROLLER BEARING. 44. INTERNAL VENT VALVE.
13. FUEL INLET VALVE. 30. VENTURI AIR BYPASS SCREW. 45. 3/16 RETAINING E-RING.
14. FUEL INLET SEAT. 31. VENTURI VALVE PIVOT PLUG. 46. IDLE TRIM SCREW.
15. FUEL INLET SEAT GASKET. 32. VENTURI VALVE PIVOT PIN. 47. VENTURI VALVE LIMITER ADJUSTING SCREW.
16. DUST SEAL. 33. VENTURI VALVE. 48. PIPE PLUG.

V2247-A

FIG. 26 Upper Body

 24-27-16

Main Body (Fig. 31)

FIG. 27 Removing Cold Enrichment Rod Assembly and CVR Assembly
VENTURIVALVE
MOUNTING BRACKET
"REMOVE" SCREW
PLUG PIN
V2248-A
FIG. 28 Pressing Out Tapered Pins
FIG. 29 Removing Cup Plugs
recessed in the upper body casting
(38)
NOTE: The main metering jet
setting is an important factor in the
overall carburetor calibration. For
this reason the following steps must
be carefully followed:
V2246A
TOOL T77L-9533-A
V2250-A
FIG. 30 Removing Main Jets
22. Using the special jet wrench (T77L-
9533-A) turn each main metering jet
clockwise counting the number of
turns, until they bottom in the
casting. Record the number of turns
to the nearest 1/4 turn.
23. T u r n t h e j e t a s s e m b l y
counterclockwise to remove. Remove
" O " rings and identify the jets,
"throttle" or "choke" side, for proper
assembly. (39, 40)
24. Remove the accelerator pump
plunger assemble and disassemble as
required. (41, 42, 43, 44, 45)
25. Remove the idle trim screws. (46)
26. Remove the venturi valve limiter
adjusting screw from the throttle side
of the venturi valve. (47)
27. Remove the 1/8" pipe plug in the fuel
inlet boss if required for cleaning (48)
1. Remove the cranking enrichment
solenoid and remove the " ( ) " ring
seal. (1, 2)
2. Remove the venturi valve diaphragm
cover retaining screws, cover, spring
guide and spring. (3, 4, 5, 6) (Tap
lightly to loosen the cover, do not pry)
3. Carefully loosen the diaphragm and
slide it out of the main body. (7)
4. Remove the venturi valve diaphragm
adjusting screw. (9)
5. Remove the venturi valve wide open
stop screw (Note: center punch the
access hole cover plug until loose).
(10, 11)
6. Remove the cranking fuel control
assembly from the bottom of the fuel
bowl. (12)
CAUTION: This part should not
be removed unless there is evidence
of physical damage. If control is
damaged, bend the bi-metal enough to
expose the discharge port and use the
jet plug removal Tool (T77L-9533-B)
to extract the control assembly (Fig.
32).
7. Place the carburetor inverted on a
clean surface (hold your hand in
position to catch the accelerator
pump check ball and weight while
turning the carburetor over). (13, 14)
8. Remove the five screws retaining the
throttle body and remove the throttle
body and gasket. (15)
9. Remove the choke heat shield screw
and the shield. (16, 17)
Throttle Body (Fig. 33)
1. Remove the throttle return control
device sol-a-dash, solenoid, dashpot
and bracket (Disengage the kickdown
return spring). (1, 2, 3, 4, 5, 37, 38)
2. Remove the choke thermostatic
housing screws, retainer ring,
housing, and gasket. (6, 7, 8, S)
3. Remove the choke thermostatk: lever
screw and lever. (10, 11)
4. Slide the choke shaft and lever
assembly out of the casting and
remove the fast idle cam. (12, 13, 35,
5. R e m o v e t h e high cam speed
positioner assembly. (14)
6. R e m o v e t h e high cam speed
positioner cover screws, cover and
return spring. (15, 16, 17) '
7. R e m o v e t h e high cam speed
positioner diaphragm and rod
(disassemble if necessary). (18, 19)
8. The choke housing bushing is pressed
into the casting and staked in place.
Should replacement be required, it
will have to be carefully pressed out.
While pressing the casting must be
supported to prevent damage. (20)
CAUTION: Before pressing, file
or grind off the staked areas.
24-27-17 Motorcraft Model 2700 VV Carburetor 24-27-17

MAIN BODY

1. CRANKING ENRICHMENT SOLENOID. 10. WIDE OPEN STOP SCREW.

2. " 0 " RING SEAL. 11. PLUG EXPANSION.
3. SCREW. (4) 8-32 X .56 12. CRANKING FUEL CONTROL ASSEMBLY.
4. VENTURI VALVE DIAPHRAGM COVER. 13. ACCELERATOR PUMP CHECK BALL.
5. VENTURI VALVE DIAPHRAGM SPRING GUIDE. 14. ACCELERATOR PUMP CHECK BALL WEIGHT.
6. VENTURI VALVE DIAPHRAGM SPRING. 15. THROTTLE BODY GASKET.
7. VENTURI VALVE DIAPHRAGM ASSEMBLY. 16. SCREW. 6-32 X..38
8. MAIN BODY. 17. CHOKE HEAT SHIELD.
9. VENTURI VALVE ADJUSTING SCREW.

V2251-A

FIG. 31 Main Body

24-27-18 Motorcraft Model 2700 VV Carburetor
9. Remove the choke heat tube fitting.
(21)
10. Remove the curb idle adjusting screw
(T.S.P. Off). (22)
11. Remove the throttle shaft retaining
nut, the fast idle adjusting lever, the
fast idle lever and the fast idle
adjusting screw. (23, 24, 25, 26)
12. If necessary to remove the throttle
plates lightly scribe a line along the
shaft and mark the plates T or C for
throttle or choke side to insure proper
assembly.
CAUTION: The throttle plate
screws are staked at assembly, the
staked ends should be filed before
removal. The old screws should be
discarded.
Remove the throttle plate screws
and the plates. (27, 28)
13. In order to remove the throttle shaft
assembly it is necessary to drive the
limiter lever stop pin down until it is
flush with the shaft. (29)
14. Slide the throttle shaft assembly out
of the casting and remove the
transmission kickdown adjusting
screw if necessary. (29, 30)
15. Remove the venturi valve limiter
lever, bushing, and spring (if
equipped), disassemble if necessary.
(32, 33, 34)
ASSEMBLY
Throttle Body (Fig. 33)
NOTE: Before installing, carefully
support the throttle shaft assembly and
drive the venturi valve limiter stop pin
out of the shaft. (Discard the pin.)
1. Place the venturi valve limiter
assembly in the throttle body and
slide the throttle shaft into place. (30,
31, 32, 33, 34)
2. Place the throttle plates in the proper
position, note the scribed marks,
and turn the new screws in until they
are snug but not tight. With the
throttle closed, tap the plates lightly
to insure proper centering and tighten
the screws. Stake the screws carefully.
(27, 28)
3. Drive the new venturi valve limiter
stop pin into the shaft. Leave
approximately 1/8 inch exposed. (29)
4. Install the fast idle lever, the fast idle
adjusting lever, the throttle shaft
retaining nut, and the fast idle
adjusting screw. (23, 24, 25, 26)
5. Install the curb idle adjusting screw
(T.S.P Off). (22)
6. If the bushing was removed, it must
be carefully pressed into the housing
and staked in place. The casting must
be carefully supported while pressing
and staking.
7. Install the cam speed positioner
assembly and the fast idle cam (13,14,
36).
FIG. 32 Removing Cranking Fuel Control Assembly
8. Slide the high cam speed positioner
diaphragm and rod into position and
engage the rod. (18, 19)
9. Slide the choke shaft and lever
assembly into the casting and install
the choke thermostatic lever and
screw. (10, 11, 12)
NOTE: Refer to the adjustment
section and adjust the high cam speed
positioner diaphragm before
installing the cover.
10. Install the high cau speed positioner
diaphragm spring, cover and screws.
(15, 16, 17)
11. Install the choke thermostatic gasket,
housing, retainer and attaching
screws. (6, 1% 8, 9)
12. Install the throttle return control
device and bracket. (1, 2, 3, 4, 5)
13. Install the choke heat tube fitting.
(21)
Main Body (Fig. 31)
1. Position the throttle body gasket on
the main body and assemble the main
body to the throttle body. (15)
2. Drop the accelerator pump check ball
and weight into the pump discharge
channel. (13, 14)
3. If the cranking fuel control has been
removed install a new assembly. Place
the control assembly on its cavity and
tap lightly using a brass drift and
small hammer alternating from side
to side until it is firmly seated. (12)
4. Do not install the venturi valve wide
open stop screw and plug at this time.
They should be installed after
complete assembly. (10, 11) (Refer to
the venturi valve limiter adjustment.)
5. Slide the venturi valve diaphragm
into the main body. (7)
6. Install the venturi valve diaphragm
spring, spring guide, cover and
retaining screws. (3, 4, 5, 6)
24-27-18
V2252-/
7. Install the venturi valve diaphragm
adjusting screw. (9) The final
adjustment of the screw is made on
the vehicle.
8. Place the cranking enrichment
solenoid "O"ringseal on the solenoid
and install the assembly. (1, 2)
NOTE: " O " rings should be
lubricated with a mild solution of
soapy water before installation.
9. Install the choke heat shield and
attaching screw. (16, 17)
Upper Body (Fig. 26)
1. Install the 1/8 inch pipe plug in the
fuel inlet boss. (48)
2. Install the venturi valve limiter screw
in the venturi valve. (47)
3. Install the idle trim screws. (46)
4. Install the "O" ring seals on the main
metering jets. (40)
NOTE: "O" ring seals should be
lubricated with a mild solution of
soapy water before installation.
5. Using the special jet wrench (T77L-
9533-A) turn each main metering jet
clockwise until it is seated in the
casting. Then turn each jet
counterclockwise the number of turns
recorded during disassembly. (39)
6. Using the special jet plug driver
(T77L-9533-C) install the jet plugs.
Tap lightly until the tool bottoms on
the face of the casting. (38) See Fig.
35.
7. Install metering rods, the metering
rod springs and the metering rod
pivot pins on the venturi valve. (35,
36, 37)
8. Install the venturi valve, carefully
guide the metering rods into the main
metering jets. (33) Press down on the
metering rods. If the springs are
properly assembled they will spring
back.
24-27-19 Motorcraft Model 2700 VV Carburetor 24-27-19

THROTTLE BODY

1. THROTTLE RETURN CONTROL DEVICE. 21. CHOKE HEAT TUBE FITTING.

2. THROTTLE RETURN CONTROL DEVICE BRACKET. 22. CURB IDLE ADJUSTING SCREW (TSP OFF).
3. MOUNTING SCREW. 10-32 X .50 23. RETAINING NUT. 10-32
4. ADJUSTING SCREW (TSP ON) 24. FAST IDLE ADJUSTING LEVER.
5. ADJUSTING SCREW SPRING. 25. FAST IDLE LEVER.
6. SCREW (3). 8-32 X.50 26. FAST IDLE ADJUSTING SCREW.
7. CHOKE THERMOSTATIC HOUSING RETAINER. 27. THROTTLE PLATE SCREWS (4).
8. CHOKE THERMOSTATIC HOUSING. 28. THROTTLE PLATES.
9. CHOKE THERMOSTATIC HOUSING GASKET. 29. VENTURI VALVE LIMITER STOP PIN.
10. SCREW. 6-32 X .50 30. THROTTLE SHAFT ASSEMBLY.
11. CHOKE THERMOSTATIC LEVER. 31. TRANSMISSION KICKDOWN ADJUSTING SCREW.
12. CHOKE LEVER AND SHAFT ASSEMBLY. 32. VENTURI VALVE LIMITER LEVER.
13. FAST IDLE CAM. 33. VENTURI VALVE LIMITER BUSHING.
14. HIGH CAM SPEED POSITIONER ASSEMBLY. 34. VENTURI VALVE LIMITER SPRING.
15. SCREW (2). 8-32 X .75 35. THROTTLE BODY.
16. HIGH CAM SPEED POSITIONER DIAPHRAGM COVER. 36. FAST IDLE CAM ADJUSTING SCREW.
17. HIGH CAM SPEED POSITIONER DIAPHRAGM SPRING. 37. TRANSMISSION KICKDOWN LEVER RETURN SPRING.
18. HIGH CAM SPEED POSITIONER DIAPHRAGM ASSEMBLY. 38. 3/16 RETAINING E-RING.
19. HIGH CAM SPEED POSITIONER ROD. 39. SCREW (5) 8-32 X .75
20. CHOKE HOUSING BUSHING.
V2253-A

FIG. 33 Throttle Body

24-27-20 Motorcraft Model 2700 VV Carburetor 24-27-20

9. Install the venturi valve pivot pin
bushings and the pivot pins. (32, 34)
10. Carefully press the tapered plugs into
the venturi valve pivot pins with
Special Tool T77P-9928-A (Fig. 31).
11. Install the venturi air bypass screw.
Turn clockwise four turns to provide
clearance for installing the cover
plate. (30)
12. Install the venturi valve cover plate
roller bearings, the plate and
attaching screws. (27, 28, 29)
13. Insert the accelerator pump swivel
and adjusting nut into the pump
link. (19, 20)
14. Install the accelerator pump link and
the retaining pin. (17, 18)
15.Install the a c c e l e r a t o r pump
operating rod and the dust seal. (6,
16)
16. Install the fuel inlet valve seat gasket,
the seat and the valve. (13, 14, 15)
17. Install the float bowl gasket. (12)
18. Install the float assembly and the float
hinge pin. (10, 11)
19. Assemble the accelerator pump
return spring, cup, plunger, internal
vent valve and retainer. Place the
pump piston assembly in position in
the hole in the upper body. (41, 42,
43, 44, 45)
20. Assemble the upper body to the main
body. Hold the pump piston assembly
with your finger and guide it into the
pump cavity in the main body. (8, 8A)
CAUTION. Make sure that the
venturi valve diaphragm stem engages
the venturi valve.
21. Install the fuel filter spring, the filter,
the inlet fitting gasket and the inlet
fitting. (1, 2, 3, 4)
22. Install the air cleaner stud. (Not
Shown)
23. Install the choke control rod dust seal
and tap gently to straighten the
retainer. (16)
24. Slide the cold enrichment rod into the
upper body. (26)
25. Assemble the cold enrichment rod
adjusting nut, lever, adjusting swivel,
the control vacuum regulator and
adjusting nut. Install the assembly.
(20, 22, 23, 24, 25)
26. Install the choke hinge pin and the
"E" ring. (5, 21)
27. Install the choke control rod. For
final adjustment, see cold enrichment
rod and control vacuum regulator
adjustment. (7)
28.Engage the accelerator pump
operating rod and the choke control
rod and install the "E" ring retainers.
(5, 6, 7)
29. Install the wide open stop screw
(omitted when assembling the main
body) and follow the venturi valve
limiter adjusting procedure. (Main
Body 10, 11)

"REPLACE" SC:!EW
V2254-A
V V:!256-A
V2255-A
FIG. 34 Positioning Stop Pin For
Throttle Shaft Removal FIG. 35 Installing Main Jet Plugs FIG. 36 Installing Tapered Plug:,

SPECIFICATONS

Mustang. Mustang,
Granada/Monarch, Pinto and Granada/Monarch, Pinto and
Item Maverick/Comet Bobcat Item Maverick/Comet Bobcat

Throttle Bore Diameter 1-9/16 1-9/16 Pump System

Venturi Diameter Variable Variable Internal Vent .010 .010
Fuel Inlet System Pump Weight Material Aluminum Aluminum
Float Setting (Dry) ± 1 / 3 2 1-3/64 1-3/64 Choke System
Float Drop ± 1 / 3 2 1-15/32 1-15/32 Bimetal Identification 7-40 MF 7-85 MF
Main Metering System Cap Setting Index Index
Metering Rod Identification 144 Fast Idle Cam Set 1NR@ 3rd Step 4NR@2nd Step
156
Venturi Valve Limiter 61/64 Cam Identification 4 Step 2 Step
13/32
Wide Open Throttle Stop 1 inch Cold Enrichment Rod Setting .125±.OO5 .125+.005
3/4
Control Vacuum (in. H2O) 5.0 Cold Enrichment Rod Identification 7 5
5.0
Spring Preload Vacuum (in. H2O) 4.7 4.7

CV2257-A
24-27-21 Motorcraft Model 2700 W Carburetor 24-27-21

SPECIAL TOOLS

Description Number

Pivot Pin Remover and Installer T77L-9928-A

Choke Adjustment Tool (Stator Cap) T77L-9848-A
Vacuum Test Tool T77L-9510-A
Jet Plug Remover T77L-9533-B
Jet Plug Installer T77L-9533-C
Metering Jet Adjustment Tool T77L-9533-A

CV2258-A
24-30-1
Fuel Pump—Mechanical
SUBJECT
DESCRIPTION
TESTING
Capacity (Volume) Test
Pressure Test
DESCRIPTION
A single a c t i o n fuel pump
(mechanically operated) is standard
equipment for all vehicle models.
The fuel pump on the 6-cylinder
engine is mounted on the lower left center
of the engine cylinder block.
On all V-8 engines, the fuel pump is
mounted on the left-side of the cylinder
front cover. On the Pinto, Bobcat and
TESTING
Incorrect fuel pump pressure and low
volume (capacity offlowrate) are the two
most likely fuel pump troubles that will
affect engine performance. Low pressure
will cause a lean mixture and fuel
starvation at high speeds. Excessive
p r e s s u r e will cause high fuel
consumption and carburetor flooding.
Low volume will cause fuel starvation at
high speeds.
To determine that the fuel pump is in
safisfactory operating condition, tests for
both fuel pump pressure and fuel pump
capacity (volume) should be performed.
The tests are performed with the fuel
pump installed on the engine and the
engine at normal operating temperature
and at idle speed. Before the tests, make
sure the replaceable fuel filter has been
changed within the recommended
maintenance mileage interval. When in
doubt, install a new filter.
PRESSURE TEST
Refer to Fuel System Specifications at
the end of this Part and note the fuel
pump pressure and capacity (volume)
specifications.
Fuel Pump—Mechanical
All Models
PAGE SUBJECT
30-1 REMOVAL AND INSTALLATION
SPECIFICATIONS
30-1
30-1
Mustang engines the fuel pump is
mounted on the left-front of the engine.
The pump is actuated by an eccentric on
the auxiliary shaft on the 2300 cc 4-
cylinder engines, and on the camshaft on
2800 cc V-6 engines.
A separate fuel filter is used on all
engines. The filter is of one piece
1. Remove the air cleaner assembly.
Disconnect the fuel inlet line or the
fuel filter at the carburetor. Use care
to prevent combustion from fuel
spillage.
2. Connect a pressure gauge, a restrictor
and a flexible hose (Fig. 2) between
the fuel filter and the carburetor.
3. Position the flexible hose and the
restrictor so the fuel can be
discharged into a suitable, graduated
container (Fig. 2).
4. Before taking a pressure reading,
operate the engine at the specified idle
rpm and vent the system into the
container by opening the hose
restrictor momentarily.
5. Close the hose restrictor, allow the
pressure to stabilize, and note the
reading.
If the pump pressure is not within
specifications, and the fuel lines and
filter are in satisfactory condition, the
pump should be replaced.
24-30-1
PART
24-30
PAGE
30-3
30-4
CA4244 A
construction and does not contain a
cleanable filter element.
All passenger car engines are
equipped with a disposal-type fuel pump
(Fig. 1).
These pumps have no serviceable
parts, and must be replaced if out of
specification.
If the pump pressure is within
specifications, perform the test for
fuel capacity (volume).
CAPACITY (VOLUME) TEST
With the fuel pump pressure within
specifications, test the capacity (volume)
as follows:
1. Operate the engine at the specified
idle rpm.
2. Open the hose restrictor and allow the
fuel to discharge into the graduated
container (Fig. 2) for the specified
time; then, close the restrictor. At
least one pint of fuel should have been
discharged within the specified time
limit. If the pump volume is below
specifications, repeat the test using an
auxiliary fuel supply and a new fuel
filter. If the pump volume meets
specifications while using the
auxiliary fuel supply, check for a
restriction in the fuel supply from the
tank and for improper tank
ventilation.
 Fuel Pump—Mechanical 24-30-2
24-30-2

200/250 CID
SIX CYLINDER 460 CID V-8 302, 351W CID V-8

2.3L FOUR 351-M/400CID 2.8 L V-6

V-8
V1937-D

FIG. 1 Typical Mechanical Fuel Pumps

24-30-3
Fuel Outlet Hose
Fuel Container
FIG. 2 Typical Fuel Pump Pressure and Capacity Test Equipment
REMOVAL AND INSTALLATION
NOTE: Before removing or installing
fuel pump, rotate engine so that low point
of fuel pump cam lobe is against pump
arm. This position can be determined by
rotating the engine with the pump held
loosely in position until tension is
removed from arm.
Removal
1. Disconnect the inlet line and the
outlet line at the fuel pump.
2. Remove the fuel pump attaching bolts
and remove the pump and the gasket.
Discard the gasket.
Fuel Pump—Mechanical
Hose Restricto
Pressure Gauge
Installation
1. Remove all the gasket material from
the mounting pad and pump. Apply
oil-resistant sealer to both sides of a
new gasket. Position the new gasket
on the pump flange and hold the
p u m p in p o s i t i o n against t h e
mounting pad. Make sure the rocker
arm or rod is riding on the camshaft
or intermediate shaft eccentric.
24-30-3
2. Press the pump tight against the pad,
install the attaching bolts and
a l t e r n a t e l y t o r q u e them to
specifications.
3. Connect the fuel inlet line or hose (use
a new clamp on the hose) and the
outlet line. If a hose is used at the fuel
pump connection, crimp the retaining
clamp securely.
4. Operate the engine and check for fuel
leaks.
24-30-4 Fuel Pump—Mechanical 24-30-4

SPECIFICATIONS
FUEL PUMP—MECHANICAL

FUEL PUMP-MECHANICAL
Engine Static Pressure Min. Volume Flow Eccentric Total Lift
C.I.D. (PSD® (Inches)
©©
2.3L 5.0 - 7.0 0 1 Pt. in 25 Sec. .304 - .326
2.8L 3.0 - 6.0 1 Pt. in 25 Sec. .193-.213
250 5.0 - 7.0 1 Pt. in 20 Sec. .290-.310
302 6.0 - 8.0 1 Pt. in 20 Sec. .690-.710
351W 6.0 - 8.0 1 Pt. in 20 Sec. .690-.710
351M 6.0 - 8.0 1 Pt. in 20 Sec. .602 - .622
400 (2V) 6.0 - 8.0 1 Pt. in 20 Sec. .602 - .622
400 (4V) 6.7 - 8.7 1 Pt. in 20 Sec. .602 - .622
460 5.7 - 7.7 1 Pt. in 20 Sec. .890-.910
460 P.I. 5.0 - 7.0 1 Pt. in 20 Sec. .890-.910

(?) On engine, with temperatures normalized and at normal curb idle speed, transmission in
neutral.
(7) With the pump-to-tank fuel return line pinched off, and a new fuel filter installed in fuel
line.
(T) Inside diameter of smallest passage in test flow circuit must not be smaller than 0.220".
CV1274-D
24-41-1 Air Cleaner - Dry Type 24-41-1

PART
Air Cleaner—Dry Type 24-41
SUBJECT PAGE SUBJECT PAGE
DESCRIPTION 41-1 REMOVAL AND INSTALLATION (Cont'd.)
REMOVAL AND INSTALLATION Replacing Crankcase Ventilation
Replacing Air Filter Element... 41-1 Filter in Air Cleaner 41-2
SPECIFICATIONS 41-2
CA4245-A

DESCRIPTION WING NUT

TEMPERATURE
SENSOR COVER
All car engines are equipped with dry
type air cleaners with replaceable filter
elements and replaceable crankcase
ventilation system filter element. The air FILTER ELEMENT
cleaner body is mounted on the TVS VALVE (SOME MODELS)
carburetor body and secured with a wing COLD WEATHER MODULATOR ^

nut (or nuts) or bolts. To prevent FRONT OF VEH CLE

inadvertantly dropping dirt into the
carburetor, always remove the air filter
DUCT AND VALVE ASSEMBLY
body before removing the filter element
(Fig. 1). AMBIENT
VACUUM MOTOR

TEMPERATURE
SENSOR
(CATALYST
VEHICLES)

FROM CANNISTER
PURGE SOURCE

FROM CRANKCASE
CLOSURE HOLE

HEAT SHROUD
AND RISER TUBE
(HOT AIR PICKUP) VI899-B

FIG. 1 Typical Air Cleaner—V-8 Engine

REMOVAL AND INSTALLATION

REPLACING AIR FILTER ELEMENT
Removal
Refer to Part 50-29, Emissions
Systems Maintenance Schedule for
frequency of filter inspection and/or
replacement.
1. Remove the wing nut(s) attaching the
air cleaner body to the carburetor air
horn stud(s). Disconnect the
crankcase ventilation system hose at
the air cleaner body. Disconnect the
evaporative emission control system
hose at the air cleaner body.
Disconnect the zip tube clip.
Disconnect the catalyst switch by
removing the retaining clip on
vehicles so equipped. Disconnect the
vacuum lines from the TVS valve
a n d / o r CWM (cold weather
modulator), if equipped.
NOTE: Where the catalyst switch
is pop-riveted to the air cleaner tray,
disconnect the switch by separating
the connectors. Disconnect the
vacuum supply hose for the air
cleaner valve.
NOTE: When removing the 2.3L
engine air cleaner, disconnect the
vacuum hoses from the air cleaner
vacuum motor and the intake
manifold (or the tee connection above
the manifold). The air cleaner, with
the two vacuum hoses connected, can
then be removed and reinstalled as an
assembly. Before reinstalling the air
cleaner assembly, make sure the two
vacuum hoses under the air cleaner
are fully engaged and tight on their
respective fittings.
2. Remove the air cleaner cover and
filter element. To prevent din from
entering the carburetor, always
remove the air cleaner body from the
carburetor before removing the air
cleaner element.
3. Replace the air cleaner gasket if it is
badly worn or damaged.
Inspection
Visually inspect the element fo- dust
on the clean air side, the slightesi hole,
or damaged end seals. Place a light on the
inside and look through the filter it the
light. Any hole in the element, even the
smallest, is cause to replace the filter.
24-41-2
Also, check the element for charred
(burned) or brittle spots that could fail
under engine operating vibration and
cause a hole. Discoloration only, caused
by b a c k f i r e , is not a cause for
replacement.
Installation
1. Install a new air cleaner mounting
gasket on the carburetor, if necessary.
2. Wipe all inside surfaces of the air
cleaner body before installing filter
element.
3. Install the air cleaner body on the
carburetor. Make sure the air intake
duct and hot air intake tube are
properly aligned. Connect zip tube
and vacuum hose for duct valve.
4. Connect the catalyst switch or
connect the vacuum lines to the TVS
and/or CWM switch (if equipped).
5. Place the air cleaner filter element in
the cleaner body. Make sure the
element is properly seated.
6. Install the cover and tighten the wing
nut(s) or bolt(s) to the specified
torque.
NOTE: On those air cleaners
having two attaching wing nuts, it is
necessary to recheck the torque on
SPECIFICATIONS
TORQUE SPECIFICATIONS - AIR CLEANER WING NUTS OR BOLTS
FASTENER COMPOSITION
STEEL
PLASTIC
Air Cleaner — Dry Type 24-41-2
the first wing nut after tightening the 2. Connect oil filler cap to air cleaner
second. closure hose at filter retainer clip.
7. Connect the crankcase ventilation 3. Install air cleaner cover and secure
system hose to the air cleaner body. with wing nut(s) or bolt(s), and
Connect the evaporative emission torque air cleaner nut to specification.
control system hose. NOTE: On air cleaners having two
Replacing Crankcase Ventilation attaching wing nuts, it is necessary to
Filter in Air Cleaner recheck the torque on the first wing
The crankcase ventilation system air nut tightened after tightening the
filter is shown in Fig. 2. second.
Removal
1. Disconnect the oil filter cap to air
cleaner closure hose at the air cleaner
FILTER PACK.
by unsnapping the elbow from the
retainer clip. FILTER RETAINER
2. Remove the air cleaner body cover.
3. Remove the crankcase ventilation
filter retainer clip and remove the
filter retainer from the air cleaner
body.
4. Remove the filter pack from the
retainer, clean out the retainer and
install a new filter pack.
V1408B
Installation
1. Position crankcase ventilation filter
assembly in air cleaner body and FIG. 2 Crankcase Ventilation System
install retainer clip. Filter
TORQUE (IN-LB)
15-25
... . 25-35
CV2046-B
24-42-1
Air Cleaner Duct Systems
SUBJECT
DESCRIPTION
TESTING
Appendix " A "
Auxiliary Air Inlet Valve
DESCRIPTION
All vehicles except 2.8L V-6 engine
applications have a fresh air inlet tube
leading to the air cleaner to allow
ambient air to enter the system (Fig. 1).
To determine whether the system is
functioning properly, perform the tests
detailed in this Part.
TESTING
DUCT AND VALVE ASSEMBLY—
VACUUM OPERATED
NOTE: For air cleaner systems with
a vacuum system delay valve, see Part 29-
01. On vehicles with a cold weather
modulator o: vacuum delay valve, by-
pass these valves by connecting the 3/16
inch (ID) vacuum line from the sensor
directly to the 1/4 inch (ID) vacuum
motor line with a reducer.
CAUTION: DO NOT IMMERSE
ANY PART OF THE VACUUM
OPERATED DUCT AND VALVE
ASSEMBLY IN WATER. If the sensor
switch vacuum bleed opens, water will be
introduced into the vacuum system. This
can p e r m a n e n t l y d a m a g e the
temperature sensor switch.
1. Remove necessary items to see duct
door. Remove the air cleaner cover.
Air Cleaner Duct Systems 24-42-1
PART
24-42
All Models
PAGE SUBJECT PAGE
42-1 TESTING (Cont'd.)
Duct and Valve Assembly -
Vacuum Operated 42-1
42-3 REMOVAL AND INSTALLATION
42-2 Duct and Valve Assembly -
Vacuum Operated 42-3
CA4246-A
AIR CLEANER
ASSEMBLY
DUCT AND VALVE ASSEMBLY
HEAT SHROUD
AND RISER TUBE
(HOT AIR PICKUP)
V1938-A
FIG. 1 Fresh Air Inlet—Typical
2. Check to see that the duct valve door from a small can of R-12 refrigerant
is in the open (Heat OFF—no and a ZRE-6271 can adapter or
vacuum) position when the engine is equivalent.
not running (Fig. 2). If the duct valve CAUTION: DO NOT COOL
door is closed, check for binding and THE TEMPERATURE SENSOR
sticking. Repair and/or replace as WHILE THE E N G I N E IS
necessary. R U N N I N G . IF R-12
3. Place a magnetic base temperature REFRIGERANT IS DRAWN
indicator Tool T75L-9601-A as near INTO THE CARBURETOR
as possible to the temperature sensor WHILE THE E N G I N E IS
on the air inlet side. On aluminum air RUNNING, POISONOUS
cleaners, use a piece of tape to hold PHOSGENE GAS WILL BE
the temperature indicator in place. EXHAUSTED INTO THE TEST
4. Start the engine. With a cold engine AREA. CONDUCT THIS
and an ambient temperature below PROCEDURE ONLY IN A WELL
75°F, the duct and valve door should VENTILATED AREA.
be in the closed or FULL HEAT Restart the engine. If the duct valve
position. If the door is closed, proceed door is closed, proceed to Step 5. If
to Step 5. If the duct valve door is not door is open during idle, check related
closed, turn off the engine. Cool the vacuum system per Appendix "A"
temperature sensor to a temperature (24-42). Repair or replace as
below 75°F by spraying with liquid necessary.
24-42-2 Air Cleaner Duct Systems 24-42-2

5. Reinstall the air cleaner cover

without installing the wing nut(s). Bl-METAL SWITCH

6. With the engine running, observe the

duct door. When the duct door starts
to open, remove the air cleaner cover
and note the temperature reading of
the temperature indicator. It should FULL FRESH AIR
be within the following specifications:
For sensors color-coded with a
brown stripe: temperature should not
exceed 90°F.
For sensors color-coded with a
black or pink stripe: temperature
should not exceed 100°F.
For sensors color-coded with a blue FULL HEAT
\
or yellow stripe: temperature should
not exceed 115°F. TO VACUUM SOURCE TO DUCT VALVE
MOTOR OR CWM
a. If the temperatures are greater than V1231-D
those specified, replace the sensor.
b. If the duct door does not start to FIG. 2 Vacuum-Operated Duct and Valve Assembly
open within 5 minutes, remove the
air cleaner cover and note the
temperature. If the temperature is
less than those specified above, the
temperature is insufficient to
operate the duct door. Reinstall the
air cleaner cover without installing
the wing nut(s) and run engine
until the specified temperature is
reached. If the duct door has not
started to open by then, replace the
sensor
Turn off the engine. Remove all test
instruments and check to insure that
no extraneous dirt or sand is on the
air cleaner tray or cover on the inside AUXILIARY AIR INLET VALVE AND
VACUUM MOTOR ASSEMBLY
of the air cleaner element. If dirt is
apparent, the assembly should be
cleaned per the maintenance
procedure. Reinstall the system
components and torque the wing
nut(s) to specification.
7. Cold Weather Modulator (Only on
Applicable Models).
a. Cool the cold weather modulator to
40°F or less. The modulator can be
cooled by spraying with liquid R-12
refrigerant and a ZRE-6271 can
adapter or equivalent. Allow
sufficient time for the modulator
temperature to stabilize and the B3169-B
modulator valve to close.
CAUTION: DO NOT COOL FIG. 3 Air Cleaner With Auxiliary Air Inlet Valve and Vacuum Motor
THE COLD WEATHER
MODULATOR WHILE THE modulator and the vacuum gauge. AUXILIARY AIR INLET VALVE
ENGINE IS RUNNING. IF R-12 Using an external vacuum source, In addition to checking the duct and
REFRIGERANT IS DRAWN apply a minimum of 16 inches Hg. valve assembly, the vacuum motor that
INTO THE CARBURETOR to the vacuum motor side of the is attached to the air cleaner should be
WHILE THE ENGINE IS m o d u l a t o r and t r a p . The checked for functional operation.
RUNNING, POISONOUS modulator must hold at least 5 1. Start the engine, observe the vacuum
PHOSGENE GAS WILL BE inches Hg vacuum for 30 seconds, motor plate. It should be fully closed
EXHAUSTED INTO THE TEST otherwise, replace the modulator, (Fig. 3).
AREA. CONDUCT THIS c. Warm the modulator to 70°F or 2. Disconnect the vacuum hose at the
PROCEDURE ONLY IN A above. The modulator should not vacuum motor. The plate should be
WELL VENTILATED AREA. hold vacuum at or above this in the full-open position.
b. A 24-inch length of 1/4-inch ID temperature. If the modulator does 3. If the positions as described, are not
vacuum hose should be used not function as indicated, it must be obtained, check for interference and
between the cold weather replaced. alignment of plate and motor rod and
24-42-3
vacuum from the hose at the vacuum
motor (minimum of 10 inches Hg).
If vacuum is not available, check
the hose and connection for leaks.
4. If the vacuum motor plate still
remains in one position, remove the
vacuum motor from the air cleaner,
connect it to another vacuum source
to confirm that vacuum motor is not
operating. If the motor rod does not
move when vacuum is applied, the
motor should be replaced.
5. Reassemble the motor to the air
cleaner and repeat Steps 1 and 2.
REMOVAL AND INSTALLATION
DUCT AND VALVE ASSEMBLY-
VACUUM OPERATED
Removal
1. Disconnect the vacuum hose at the
vacuum motor.
2. Remove the hex head cap screws that
secure the air intake duct and valve
assembly to the air cleaner.
Air Cleaner Duct Systems
APPENDIX " A "
Vacuum Motor Test
1. Check the duct valve door for sticking
or binding condition by depressing
with fingers and allowing the internal
vacuum motor spring to return the
door to the normal position. Correct
any sticking or binding condition
before proceeding with test.
2. Disconnect the vacuum hose from the
vacuum motor connector tube.
3. Connect an external vacuum source
of 16 inches Hg to the vacuum motor.
3. Remove the duct and valve assembly
from the engine.
Installation
1. Position the duct and valve assembly
24-42-3
If duct valve door remains open,
replace vacuum motor. If door closes,
proceed to Step 4.
4. Using an external vacuum source,
apply a minimum of 16 inches Hg
vacuum and trap. The vacuum motor
should remain closed for 60 seconds.
If not, replace the vacuum motor
assembly.
FOR OTHER AIR CLEANER
AND DUCT SYSTEM-RELATED
TESTS AND ADJUSTMENTS,
SEE PART 29-02, PROCEDURE
SSD-9.
to the air cleaner and heat stove tube.
Install the attaching cap screws.
2. Connect the vacuum line at the
vacuum motor.
24-50-1
Fuel Tanks and
SUBJECT
DESCRIPTION AND OPERATION
Auxiliary Fuel Tanks
Double Locking Fuel Cap
Fuel Tanks and Fillers
Fuel Vapor Emission Control System
REMOVAL AND INSTALLATION
Auxiliary Fuel Tanks
DESCRIPTION AND OPERATION
FUEL TANKS AND FILLERS
All vehicles are equipped with a
restricted fuel filler neck that allows only
a non-leaded fuel nozzle to be inserted
(Fig. 1).
The restrictor consists of a narrow
opening in the filler covered by a spring
steel trap door. The smaller non-leaded
fuel nozzle will fit through the narrow
opening and push the trap door aside,
allowing normal filling. If the nozzle for
leaded fuel is inserted, however, it does
not fit through the narrow opening. The
trap door being closed causes a fuel back-
up, and automatic nozzle shutoff.
The restricted fuel filler is serviced as
an assembly, and cannot be repaired.
Tank capacity is limited by the filler
control-tube or the position at which the
filler tube enters the tank, depending on
model. Duringfilling,fuel vapors and air
are vented through the filler neck or
control tube. When the fuel covers the
filler control tube or filler heck, a dead
air space is created in the top of the tank.
This will cause a backup in thefillerneck
and cause automatic shutoff.
DOUBLE LOCKING FUEL CAP
A double set of locking tangs or tabs
are used on the pressure/vacuum fuel
cap. These tangs require a two stage
removal/installation procedure and
provide for escape of any residual
pressure in the system during cap
removal. This system is also used with the
optional locking-type fuel cap. Whenever
a fuel cap is replaced, it should be
replaced with the proper pressure relief
double locking cap to prevent possible
system malfunction (Fig. 1).
Fuel Tanks and Lines
All Models
PAGE SUBJECT
REMOVAL AND INSTALLATION (Cont'd.)
50-4 Fuel Cap
50-1
50-1 MAJOR REPAIR OPERATIONS
50-1 Auxiliary Fuel Tanks
Fuel Line
50-4 Fuel Tanks
FUEL VAPOR EMISSION
CONTROL SYSTEM
As a part of the fuel system, all
passenger cars are equipped with fuel
evaporative emission control systems to
meet federal requirements in effect at the
time of production.
System control and operation are
accomplished through four separate basic
functions in the system which are:
a. Fill Control Vent System
b. Tank Vapor Vent and Storage
System
c. Pressure and Vacuum Relief
System (fuel cap)
d. Fuel Vapor Return System
Fill Control Vent System
Fill limiting is accomplished through
fill neck configuration and/or internal
vent lines within the fill neck and tank.
The vent system is designed to permit an
approximate 10-12 percent tank volume
air space when the tank is filled to
capacity. This air space provides for
thermal expansion of fuel as well as being
an aid to the in-tank vapor vent system.
Vapor Vent System
In-Tank Venting
This system provides a vapor space
above the gasoline surface in the fuel
tank. This area is sufficient to permit
adequate breathing space for the tank
vapor separator assembly under all static
and most dynamic c o n d i t i o n s .
Horizontally mounted tanks accomplish
this by a raised mounting section for the
vapor separator assembly that is centrally
located on the upper surface of the tank.
Vertically mounted tanks use a centrally
24-50-1
PART
24-50
PAGE
50-4
50-5
50-5
50-5
CN4041-A
mounted vapor separator assembly on
the uppermost surface of the fuel tank.
Tank Vapor Separator (Orifice)
Assembly
All fuel tank vapor separators make
use of a small orifice that tends to allow
only vapor and not fuel to pass into the
line running forward to the vapor storage
canister. This assembly mounts directly
to the fuel tank using the same type
cam lock ring as the fuel sending unit.
Fuel vapors trapped in the sealed fuel
tank are vented through the orificed
vapor separator assembly in the top of the
tank. The vapors leave the separator
assembly through a single vapor line and
continue to the carbon canister in the
engine compartment for storage, until
such time as they are purged to the engine
by means of a tube connected to the air
cleaner.
In vehicles equipped with fuel/vapor
return lines, vapor generated in the fuel
supply line by high engine compartment
temperatures is continuously vented back
to the fuel tank. This action prevents
engine surging from unwanted fuel
enrichment and assists in hydrocarbon
emission control.
Carbon Canister
Fuel tank vapor separated by the
orificed vapor separator is stored in a
carbon-filled canister located in the
engine compartment (Fig. 2).
Pressure and Vacuum Relief
System
Sealed Fill Cap
Thefillcap is a sealed cap with a built
in pressure-vacuum relief valve. Fuel*
24-50-2 Fuel Tanks and Lines 24-50-2

VIEW

FUEL CAP ASSEMBLY (9030)

TWO STAGE REMOVAL
FUEL FILLER PIPE (9034)
WITH RESTRICTED OPENING

PIN RIVET SPECIAL UNLEADED FUEL NOZZLE

IN POSITION FITS THROUGH RESTRICTED
FILL PIPE AS SHOWN

ELLIPTICAL SHAPED
OPENING

SECTION A
V2115-B

FIG. 1 Restricted Fuel Tank Filler Opening and Double Locking Fuel Cap

system vacuum relief is provided after
negative 0 to 1/4 psi and pressure relief
from 3/4 to 1.8 PSI. Under normal
operating conditions, the fill cap operates
as a check valve, allowing air to enter the
tank as gasoline is used, while preventing
vapors from escaping the tank through
the cap.
Fuel Vapor Return System
A fuel vapor return system has been
added to certain engines to reduce the
amount of fuel vapor entering the
carburetor (Figs. 3 and 4).
The system consists of a vapor return
line from the fuel pump to the fuel return
outlet of the fuel sender.

RETURN LINE

TO CARBURETOR

387289
TO FUEL TANK
VAPOR LINE

FUEL LINE
V 618-A
CANISTER V1617-C

FIG. 4 Fuel Return Line Connections

FIG. 2 Typical Canister FIG. 3 Supply Line Vapor Separator At Sender Unit
24-50-3 Fuel Tanks and Lines 24-50-3

LINE TO
MAIN TANK.
VENT
CONNECTOR

V1939-D

FIG. 5 Fuel and Vapor Emission Control System—Mustang with 302 CID V-8 or Optional Installation of Auxiliary Fuel
Tank
24-50-4
DIAGNOSIS
Physical damage, leaks, and missing
items are the major answers to diagnosis
problems for emission system
AUXILIARY FUEL TANKS
On all Mustang II equipped with the
302 CID V-8 engine, a separate auxiliary
fuel tank is required (see Fig. 5).
Ford, Mercury and Lincoln
Continental sedans and Ford and
Mercury station wagons are available
with an optional auxiliary fuel tank (Figs.
5 through 8). Mustang vehicles with 2.3
and 2.8 liter engines also offer auxiliary
fuel tanks as an option. Auxiliary fuel
tank locations are dependent on car line
or body type. Ford, Mercury and Lincoln
Continental sedan auxiliary fuel tanks are
located in the luggage compartment to
the left of the spare tire well (Fig. 6),
whereas station wagon auxiliary tanks
are located behind the left rear trim panel
in the cargo area (Fig. 7). The auxiliary
tank is located in the left rear wheelhouse
behind the tire and a metal splash shield.
REMOVAL AND INSTALLATION
All component parts of the standard
fuel system are serviced by a simple nut,
bolt, or screw part removal and
installation. Refer to individual systems
drawings for specific part references.
FUEL CAP
To remove the fuel cap:
1. Rotate the cap approximately one-
third turn counterclockwise to allow
the first set of tabs to clear the slots
inside the filler pipe.
2. Pull upward on the cap and continue
turning counterclockwise on the cap
until the second set of tabs is free and
the cap can be removed.
To install the fuel cap:
1. Place the cap on the filler pipe and
turn clockwise until fully seated. Be
sure the second set of tabs is engaged.
AUXILIARY FUEL TANK
NOTE: Removal and installation
procedures described here may also be
required when removing and installing
main fuel tanks associated with these
auxiliary tanks. Connecting hoses and
tubes will require following some of the
steps, if only for removal and installation
of common parts.
Mustang vehicles will require care
during auxiliary tank removal to ensure
Fuel Tanks and Line:
malfunctions. Fill cap damage or
contamination that renders the pressure-
vacuum valve inoperative may result in
Component parts required with
Mustang auxiliary fuel tanks include an
upper filler pipe with rubber seal, lower
filler pipe with hose connection between
the auxiliary tank and main tank, a vapor
separator, fill vent tube connector (in
main and auxiliary tanks and connected
by vent pipe and section of hose) and a
restraining strap and hose clamps to
complete the system between the fill
opening and the main tank. The fuel/
vapor separator is connected to the
carbon cannister. The fill vent tube
connector is attached to another
connector in the main tank. A unique
retaining strap is also used on Mustang
auxiliary tanks. When the bolt is torqued
to 25-35 ft-lbs, the strap is properly
positioned and becomes "bottomed out"
on the outer wheel housing (Fig. 6).
that the fuel level in the main tank is
below the auxiliary fill pipe connection
before it is disconnected. The main tank
should be drained below the fill pipe by
disconnecting the fuel sending unit hose
at the point where it connects to the fuel
line leading to the fuel pump.
Mustang (See Figs. 5 and 6)
Removal
1. Siphon or pump out the auxiliary fuel
tank.
2. Remove the four screws holding the
filler tube to the body sheet metal at
the fill opening. Remove the filler
tube.
3. Inside the left rear wheelhousing,
remove the three bolts holding the
inner splash panel that covers the
auxiliary fuel tank. Remove the panel.
4. Disconnect the hose between the
main tank fuel sending unit and the
fuel line at the fuel line. Drain a
sufficient quantity of fuel to drop the
main tank level below the auxiliary
tank fill pipe connection.
5. Loosen the two clamps that hold the
rubber hose located on the filler tube
between the auxiliary and main tank.
6. Carefully slide the rubber hose off the
auxiliary tank and downward on the
metal pipe attached to the main fuel
24-50-4
deformation of the tank. Care should
always be exercised to be sure that a
proper fill cap (in working order) is used.
VENT HOSE
V2116-C
FIG. 6 Auxiliary Fuel Tank Vent
Connector (Mustang with 302
CID Engine)
tank. It may be necessary to put a
drain can under the rubber hose
during this operation to catch any
gasoline that might be left in the
auxiliary tank.
7. Remove the screw holding the
auxiliary fuel tank retaining st rap and
remove the strap.
8. Lower the tank until the clamp
holding the boot to the fill tube neck
of the auxiliary tank can be loosened
and the rubber boot removed.
9. Continue to lower the tank until the
vapor separator and fill vent tube
connector can be disengaged from the
top of the tank.
10. Remove the auxiliary tank from the
vehicle.
Installation
1. Install the vapor separator and fill
vent tube connector, then thefilltube
neck rubber boot using clamp
38O153-S8. Be sure to correctly align
the locating notch in the boot with the
locating rib on the tank filler neck.
Tighten the boot clamp and position
the tank in the fender well.
2. Raise the tank sufficiently to install
the rubber boot to the lip of the filler
tube opening in the quarter panel.
24-50-5 Fuel Tanks and Lines 24-50-5

3. Attach the tank retaining strap and
loosely install the strap attaching
screw.
4. Slide the rubber hose connecting the
main and auxiliary tanks into position
over the auxiliary tank outlet neck.
Tighten the hose clamps and the tank
retaining strap screw. Attach the hose
from the fuel sending unit (on the
main tank) to the fuel line using a new
hose clamp.
5. Install the fuel filler tube into the
auxiliary tank and attach the tube
flange to the body sheet metal with
the four attaching screws.
This removal/installation procedure
will also be used in conjunction with
removal/installation of the main fuel
tank either in part or in its entirety to
enable draining of the main tank for
servicing.

MAJOR REPAIR OPERATIONS

FUEL TANKS
Fuel emission type fuel tanks do not
require special repair procedures and
may be steam-cleaned and/or repaired
using standard procedures. After
steaming, allow to thoroughly air dry.
The orificed vapor separator assembly
should be replaced, if found to be
damaged or inoperative.
AUXILIARY FUEL TANKS
Maintenance and repair consists of
replacement of defective or damaged
parts and cleaning. Repairs to the
auxiliary tank are not possible inasmuch
as the material used for construction is
high density polyethylene. This material
is also used for the protective cover on
Ford/Mercury and Lincoln Continental
vehicles which makes it subject to the
same repair procedure as the tank. Tanks
or protective covers that are damaged
should be replaced. Cleaning of a tank is
accomplished using a detergent solu-
tion to thoroughly flush the tank and
clean water rinsing until all detergent
is removed. The tank must be com-
pletely dry prior to re-installing in the
system.
AUXILIARY FUEL TANKS MUST
NOT BE STEAM CLEANED OR
EXPOSED TO EXTREME HEAT OF
ANY KIND.
-TO FUEL PUMP
FIG. 7 Fuel Supply Tube Assembly
FUEL LINES
Repair
With the exception of the pump-to-
carburetor fuel supply tubes used in fuel/
vapor return systems (Fig. 7) the various
fuel lines are not serviced as assemblies.
They must be cut, squared and formed
out of rolls of fuel system service tubing
and hose material available at
dealerships.
A damaged section of tubing longer
than 12 inches can be cut out of the
existing line and replaced by a
comparable service tubing section,
spliced into the line by means of
connecting hoses and retaining clamps. A
damaged section of tubing snorter than FLOAT
12 inches can be cut out of the line and
replaced by a length of service hose and SPRING
two retaining clamps.
All replacement hoses must be cut to TYPICAL SECTION
a length that will assure proper clamp VAPOR SEPARATOR VALVE WITH
FLOAT VALVE AND INTERNAL SPRING
retention beyond the flared ends of the
V1780-D
connecting tubing.
Removal
1. Drain the fuel from the tank.
2. Disconnect the line at the fuel gauge
sender unit and the fuel pump. FIG. 8 Vapor Separators
Remove the lines from the holding section to be replaced. Allow extra
clips along the underbody. Remove length for flaring the ends of the
all damaged hose sections and tube tubing. Square the ends of the cut
sections. tubing with a file.
Installation 2. Ream the inside edges of the cut
1. Cut a new section of tubing to tubing with the reamer blade on the
approximately the same length as the tube cutter. Be sure metal chips are
removed from inside the tube(s).
Double flare the ends of the cut
tubing, as required.
3. Bend the tube section to conform to
the contour of the original tube. Cut
an ample length of hose to form a
TO CARBURETOR coupling between the flared ends of
the fuel lines. Connect the hose
couplings to the tubing and install the
retaining clamps.
4. Position the lines in the underbody
clips and tighten the clips. Connect
the line to the fuel gauge sender unit
V1621-C
and the fuel pump. Fill the tank and
check for leaks.
 9A228 REF. 9291 REF.
9291 REF.

55914-S36M 383369-S2
380882-S100
2REQ'D.

• 55914-S36M
\
381138-S080A

FUEL SENDER ASSY. REF 55914-S36M

9G291 REF.
9N041 ASSY. REF.
ESE-M2C96-B, SAE-10W30 ENGINE OIL 55914-S36M
MAY BE USED ON 9034 AND/OR 9072
AS AN ASSEMBLY AID. NO OTHER FUEL TANK
MATERIAL MAY BE USED. ASSY. - 9002 HOSE MUST LIE WITHIN VALVE VAPOR
FUEL TANK DEPRESSION ASSY. - 9B593
9 0 3 0 - CAP-FUEL

9034

381136-S040A r^£g?
i !
CARBON CANISTER *
VIEWY

Q
ALL EXCEPT CALIFORNIA BOBCAT
J Q_
FUEL RETURN

9034 ASSY 381136-S040A'

CARBON CANISTER-
VAPOR LINE -9A228
: 9B058ASSY.
REF.

€
/ ^ --—" (2.3L) -N800173-S100
N800152-S100 ' .,"
9002 ASSY. REF.
20-30 FT-LB
SAME AS VIEW X EXCEPT AS SHOWN
FOR CALIFORNIA BOBCAT ONLY
\ VIEW IN CIRCLE P
9092 ASSY. R.H. SIDE ONLY
• INSTALL HOSE ONTO TUBE .62 MIN. CLAMP 384029-S2
9A228 REF.
MUST BE ON HOSE AND FLUSH TO 1/8" FROM
END OF HOSE WHERE APPLICABLE. 9002 ASSY. REF.
55914 REF.
* INSTALL HOSE TO SECOND BEAD OF TUBE
CLAMP MUST BE ON HOSE AND FLUSH TO 1/8"
FROM END OF HOSE WHERE APPLICABLE.
2 REQ'D.
BRAKE REL. V 55914-S36M
STRAP ASSY.
REF. - 9 0 9 2
ESE-M2C96-B, SAE-10W30 ENGINE OIL MAY BE
USED AS AN ASSEMBLY AID FOR ASSEMBLY INSTALLATION MARKED 3 PLACES O

MAY BE USED. V2118-C

FIG. 9 Fuel and Vapor Emission Control Systems—Pinto/Bobcat Sedan

 9G291 REF.
9A228 REF.
N602568-S51M ASSY
FUEL PUMP REF. 9A084 REF.
384029-S2
38720-S2
385766-S2 9G291 REF. 381136-S080A
Q 2 REQ'D. 9B337 REF. 384029-S.2 55914-S36M
55914-S36M
381136-S015A 55914-S36M 383369-S2
385766-S32
| 2 REQ'D. 9A228 REF.
381136-S080A

I 9291 REF
383369-S2
'9G291 REF. 384029-S2
81136-S120A
'9A084 REF.
381138-S080A 380882-S100
381138-S015A

o ESE-M2C96-B, SAE 10W30 ENGINE OIL

I MAY BE USED ON 9034 AND/OR 9072

AS AN ASSEMBLY AID. NO OTHER
MATERIAL MAY BE USED.
Q
7T
Q
Q.
9A228 REF.

INSTALL HOSE ONTO TUBE .62 MIN. CLAMP

MUST BE ON HOSE AND FLUSH TO 1/8"
FROM END OF HOSE WHERE APPLICABLE.
INSTALL HOSE TO SECOND BEAD OF TUBE.
55914-S36M
CLAMP MUST BE ON HOSE AND FLUSH TO 1/8"
FROM END OF HOSE WHERE APPLICABLE.
383369-S2 9B007-SHIELD
ESE-M2C96-B, SAE-10W30 ENGINE OIL
MAY BE USED AS AN ASSEMBLY AID FOR 9092 ASSY. REF. 55914-S36M
ASSEMBLY OF HOSES ON TUBES. NO K>
OTHER MATERIAL MAY BE USED. I VIEWZ I

N4031-B
 ALL EXCEPT A/C AND
C3 TRANS
386918-S2
9A228 REF
55914-S36M \
384029-S2 9G291 REF
383369-S2
9A084 FUEL TUBE RR 55914-S36M

9291 REF
OIL COOLER LINES REF
OIL COOLER LINES REF 40927-S2
FOR A/C AND C3 383369-S2 9A228 REF
TRANS. ONLY 1 REQD.X

381138-S080A
VALVE ASSY. VAPOR 9B593
FUEL PUMP REF
ESB-M3G56-A100W

VIEW 2
9A084 REF

383369-S2-*-.
2 REQD.

55914-S36M
5 REQD.
9B337
FUEL RETURN VAPOR LINE
LINE 9A228

VAPOR LINE
9A228
\J //'9B291
TUBE-TANK \ / / RETURN TUBE
TO PUMP
9A084
TUBE-FUEL SHIELD
VAPOR 9B007
ESE-M2C96-B, SAE-10W-30 ENGINE OIL
9G291
MAY BE USED ON 9034 AND/OR 9072
AS AN ASSEMBLY AID. NO OTHER
MATERIAL MAY BE USED.

372223-S2 9A084 REF.

VIEW Z
* INSTALL HOSE ONTO TUBE .62 MIN. CLAMP SECTION C-C
MUST BE ON HOSE AND FLUSH TO 1/8" TYPICAL 2 PLACES
381136-S080A
FROM END OF HOSE WHERE APPLICABLE.
385766-S32 9092 ASSY. R.H.
• INSTALL HOSE TO SECOND BEAD OF TUBE. 2 REQD. PIPE ASSY. - FUEL FILTER
9034 9N041 ASSY. L.H.
CLAMP MUST BE ON HOSE AND FLUSH TO 1/8"
FROM END OF HOSE WHERE APPLICABLE.
N800152-S100
9N041 STRAP ASSY 20 30 LB. P T .
AS AN ASSEMBLY AID FOR ASSEMBLY OF HOSES ON
TUBES. "NO OTHER MATERIAL MAY BE USED. V2119-C

FIG. 11 Fuel and Vapor Emissions Control Systems—Mustang W / 2 . 3 L Engine

 9A228 REF.
380882-S100
2 REQD.

55914-S36M

SECTION A - A

9092 STRAP ASSY.

ESE-M2C96-B, SAE-10W-30 ENGINE OIL

MAY BE USED ON 9034 AND/OR 9072
AS AN ASSEMBLY AID. NO OTHER
MATERIAL MAY MAY BE USED.

•fr INSTALL HOSE ONTO TUBE .62 MIN. CLAMP

MUST BE ON HOSE AND FLUSH TO 1/8"
381138-S080A
FROM END OF HOSE WHERE APPLICABLE.
9034 9092 ASSY. R.H.
• INSTALL HOSE TO SECOND BEAD OF TUBE.
9N041 STRAP ASSY.
PIPE ASSY.- -S100
N800173-S100 4/ I 9N041ASSY. L.H.
CLAMP MUST BE ON HOSE AND FLUSH TO 1/8" FUE:LFILTER
FROM END OF HOSE WHERE APPLICABLE.

ESE-M2C96-B, SAE-10W-30 ENGINE OIL | VIEW 2 \

MAY BE USED AS AN ASSEMBLY AID FOR N800152-S100
ASSEMBLY OF HOSES ON TUBES. NO TYPICAL 2 PLACES 20-30 LB. FT.
OTHER MATERIAL MAY BE USED.
V2120-C
FIG. 12 Fuel and Vapor Emission Control Systems—Mustang W / 2 . 8 L Engine
 55914-S36M
381138-S140A 9A228 REF.

55914-S36M

ESE-M2C96B, SAE-10W-30 ENGINE 376656-S100 9B593 ASSY

OIL MAY BE USED AS AN ASSEMBLY 2 REQD.
AID FOR ASSEMBLY OF HOSES
ON TUBES. NO OTHER MATERIAL
MAY BE USED.

+ INSTALL HOSE ONTO TUBE .62 MIN. CLAMP

MUST BE ON HOSE AND FLUSH TO 1/8" FROM
END OF HOSF WHERE APPLICABLE.

• INSTALL HOSE TO SECOND BEAD OF TUBE.

CLAMP MUST BE ON HOSE AND FLUSH TO 1/8"
FROM END OF HOSE WHERE APPLICABLE.

• ESE-M2C69-B, SAE-10W-30 ENGINE OIL

MAY BE USED ON 9041 AND/OR 9072 55914-S36M
AS AN ASSEMBLY AID. NO OTHER 380882-S100
MATERIAL MAY BE USED. SECTION A - A 2 REQD.
9N041 386911-S 384237-S100

55914-S36M 381 123-S043A 15.20~|N. LB. 25-35 FT. LBS. V2121-C

FIG. 13 Fuel and Vapor Emission Control Systems—Mustang W / 3 0 2 CID V-8 Engine
 MEMBER-SHOCK 381136-S210A
ABSORBER MOUNTING

9B593 REF.

N80O173-S10O
2 REQD.

45341-S36
SECOND NUT 386939-S2 385427-S2 VIEWR
FUEL RELEASE DEFORMATION OF CLIP
PERMISSIBLE WHEN NUT 9064 REF.
IS FULLY TORQUED. 385733 REF. HOSE MUST LIE WITHIN FUEL
TANK DEPRESSION AND NOTCH IN N800152-S100
BRAKE TUBE REF. FUEL TANK SUPPORT AFTER ASSY. 2 REQD.
20-30 LB. FT.

BRAKE TUBE REF.

385427 REF 9002 ASSY. REF.

VIEW Z

9A228 REF \

55981 REF

TYPICAL INSTALLATION
9 PLACES MARKED ft
BRAKE RELEASE

BACK PANEL
REF.
381138 REF
386940-S2 FUEL FILLER PIPE
9034 ASSY.

CARBON CANISTER
G.P.D. RELEASE
ESE-M2C96-B, SAE-10W-30
381138-S150A 380882-S100 ENGINE OIL MAY BE USED ON
2 REQD. 9034 AND OR 9072 AS AN
ASSEMBLY AID. NO OTHER
MATERIAL MAY BE USED.
200/250 ENGINES 381138-S065A
9291 REF.

VIEW V

* INSTALL HOSE TO SECOND BEAD OF TUBE.

CLAMP MUST BE ON HOSE AND FLUSH
TO 1/8" FROM END OF HOSE WHERE APPLICABLE.

• INSTALL HOSE ONTO TUBE .62 MIN.

CLAMP MUST BE ON HOSE AND FLUSH 381138-S180A
TO 1/8" FROM END OF HOSE WHERE APPLICABLE. 9291 REF.
381138 REF
ESE-M2C96-B SAE-10W-30 ENGINE OIL MAY 383369-S2 CLIP
BE USED AS AN ASSEMBLY AID FOR HOLES 55981-S36M SCREW 9002 ASSY. REF.
ON TUBES. NO OTHER MATERIAL MAY BE USED.
TYPICAL INSTALLATION APPROX. 3.40
7 PLACES MARKED if
V2123C

FIG. 14 Fuel and Vapor Emission Control Systems—Maverick and Comet

 MEMBER SHOCK 9A068
384029 REF. ABSORBER MOUNTING 2 REQ'D.
381136-S210A 9B593 REF. CENTER ON TANK TOP AND
TAPE IN POSITION SHOWN.

VALVE ASSY. - VAPOR

- 9B593

N800173-S100
CARBON 2 REQ'D.
CANISTER
REF.

A < 55980-S36
REF.
VIEW U HOSE MUST LIE WITHIN FUEL
TANK DEPRESSION AND NOTCH IN
9291 OR9A084REF FUEL TANK SUPPORT AFTER ASSY.
384029-S2 ESB-M3G56-A
4REQ'D.

TYPICAL INSTALLATION 9002 ASSY. REF. N800152-S100

11 PLACES MARKED 2 REQ'D.
380882-S100 VIEWX 20-30 FT-LB
2 REQ'D.

VAPOR LINE FUEL CAP ASSY

- 9A 228 55981-S36M -9030
5 REQ'D. W/APPR. GROUP

TYPICAL INSTALLATION BACK PANEL REF.

10 PLACES MARKED •
I 9B176-DECAL
FOR CANADIAN
USE ONLY

ESE-M2C96-B. SAE-10W30 ENGINE OIL

382119-S100 MAY BE USED ON 9034 AND/OR 9072
FOR 351WENG. ONLY AS AN ASSEMBLY AID. NO OTHER
380882-S100 MATERIAL MAY BE USED. FUEL CAP -
2 REQ'D. - FOR 302 ENG. 9030 ASSY.
1 REQ'D. - FOR 351W ENG. GRANADA

9291 - FUEL LINE VIEWZ

(302/351 ENGINES)
9002 ASSY. REF.

TUBE-TANK TO
PUMP - 9A084
* INSTALL HOSE TO SECOND BEAD OF TUBE.
CLAMP MUST BE ON HOSE AND FLUSH TO 380882-S100
1/8" FROM END OF HOSE WHERE APPLICABLE. 2 REQ'D. WIRE HARNESS
(200/250 ENGINES) REF.
INSTALL HOSE ONTO TUBE .62 MIN. CLAMP
MUST BE ON HOSE AND FLUSH TO 1/8" FROM
END OF HOSE WHERE APPLICABLE. VIEWV

ESE-M2C96-B. SAE 10W30 ENGINE OIL MAY

ASSEMBLY OF HOSES ON TUBES. NO OTHER

MATERIAL MAY BE USED. V2124-C
FIG. 15 Fuel and Vapor Emission Control Systems—Monarch and Granada
 BRAKE LINE REF. FUEL TANK 228 REF.
NO. 2 CROSSMEMBER REF. SUPPORT REF.
384243 REF. 381136-S26DAB
228 REF.
9291 REF.

#385265 REF. 384029 R E F . * 381877 REF.

#381877 R*EF. 381877 REF.*
INSTALLATION - INSTALLATION BRAKE SYSTEM RELEASE
VIEWW 2 PLACES MARKED * 2 PLACES MARKED if
9291 REF/
11381140-S11
386148-S32 381877-S2 ASSY.
REF.
387474-S2 382119-S1 UNDERBODY
2 REQ'D. REF.
BRAKE LINE REF.
9275 ASSY. REF. 9092 ASSY.
9A228 REF. 9291 REF. REF.
IDENTIFICATION CODE - COLOR ORANGE
THIS RIB AREA FOR THUNDERBIRD
9291 REF. INSTALLATION - 9 PLACES MARKEDO INSTALLATION - 5 PLACES MARKED if
(351 CALIFORNIA REFERENCE ONLY)
FUEL LINE TO VIEWZ
380882-S100
CARS. REF.
382119-S100
FOR 302 ENG. - LTD II & COUGAR ONLY
VIEWV

VIEWZ
VIEWX
384766 REF

BRAKE SYSTEM RELEASE a

- 3 PLACES MARKED#
384372-S
381136-S140A

6528630
9092 REF.

INSTALL TUBE INTO 9002 ASSY. REF.

384766 CLIPS. THEN
11 HOSE MUST BE INSTALLED ASSEMBLE CLIP MARKED
VIEWU
WITH SMOOTH BENDS AND FIRST AND CLIP MARKED
NO KINKS SECOND. ASSEMBLE
REMAINING CLIPS.
ESE-M2C96-B, SAE-10W30 ENGINE - V E N T TUBE
9034 ASSY.
OIL MAY BE USED AS AN ASSEMBLY
FUEL FILLER
AID FOR ASSEMBLY OF HOSES ON TUBES.
PIPE
NO OTHER MATERIAL MAY BE USED.
SE-M2C96-B, SAE-10W-30
D INSTALL HOSE TO SECOND BEAD OF TUBE ENGINE OIL MAY BE USED ON
CLAMP MUST BE ON HOSE & FLUSH TO 1/8" 9034 AND/OR 9072 AS AN
FROM END OF HOSE WHERE APPLICABLE. 381877 REF. ASSEMBLY AID, NO OTHER
• INSTALL HOSE ONTO TUBE .62 MIN. CLAMP MATERIAL MAY BE USED.
MUST BE ON HOSE & FLUSH TO 1/8" FROM
BRAKE TUBE REF VIEWX
END OF HOSE WHERE APPLICABLE

INSTALLATION MARKED
V2125-G

FIG. 16 Fuel and Vapor Emission Control Systems—LTD II, Cougar and Thunderbird
 9 0 3 0 - FUEL CAP 381877 REF. BRAKE TUBE REF.
FUEL CAP ASSY.

384029-S2
FUEL PUMP REF 384243 REF.
9A228 REF.
TYPICAL INSTALLATION

382119-S 100 2 PLACES MARKED

2 REQ'D.
381877-S2

INSTALLATION - 3 PLACES MARKED *

387474-S2
^ S C R E W -
9291 REF.
i? 381877 REF

BRAKE TUBE REF.- / —-^BRAKE REL.

INSTALLATION MARKED T 9A228 REF

AFTER TIGHTENING
FUEL TANK
ASSY. - 9002

3843 72-S
INSTALL TUBE INTO
381136-S140A 384766 CLIPS. THEN
VAPOR LINE ASSEMBLE CLIP MARKED
- 9A228 FIRST AND CLIP MARKED •
SECOND. ASSEMBLE
REMAINING CLIPS
9B593 MUST BOTTOM OUT 9291 REF.
ON GROMMET IN 9002 387474-S2
AFTER ASSY.
INSTALLATION - 2 PLACES MARKED £
VALVE-VAPOR ASSY
- 9B593 385467-S32B

NO. 2 CROSSMEMBER REF

9275 ASSY. REF.

N800151-S100
a
B HOSE MUST BE INSTALLED WITH
SMOOTH BENDS AND NO KINKS. 387474 REF.
384029 REF.
ESE-M2C96-B, SAE 10W30 ENGINE OIL BRAKE LINE REF 382119-S 100
MAY BE USED AS AN ASSEMBLY AID 381877-S2 2 REQ'D.
FOR ASSEMBLY OF HOSES ON TUBES. 384766 -
NO OTHER MATERIAL MAY BE USED. BRAKE
RELEASE ' 9291 REF.
• INSTALL HOSE TO SECOND BEAD OF TUBE •»— N800152-S100
CLAMP MUST BE ON HOSE & FLUSH TO 1/8" 20-30 FT-LB
387474-S2
FROM END OF HOSE WHERE APPLICABLE.

• INSTALL HOSE ONTO TUBE .62 MIN. CLAMP INSTALLATION - 2 PLACES MARKED
MUST BE ON HOSE & FLUSH TO 1/8" FROM INSTALLATION-
Ei\JD OF HOSE vVriERE APFLiCABLc t> PLAUtS M
3 PLACES MARKED •
V2126-C

FIG. 17 Fuel and Vapor Emission Control Systems—LTD II and Cougar Wagons
 FUEL TANK UNDERBODY ESE-M2C96-B, SAE-10-30
NO. 2 CROSSMEMBER REF. ENGINE OIL MAY BE USED ON
SUPPORT REF. •>T*"*REF.
,9034 AND/OR 9072 AS AN FUEL FILLER PIPE
ASSEMBLY AID, NO OTHER ASSY. - 9034
MATERIAL MAY BE USED

387474 REF

9291 REF. 9076 REF.

B.E.O. REL.

WOOD GRAIN MUST

BRAKE TUBE REF MATCH PATTERN OF
WOOD GRAIN ON
QUARTER PANEL
INSTALLATION MARKED • WHEN CAP IS
FUEL SYSTEM RELEASE - 5 PLACES MARKED * / INSTALLED.
y 381877 REF BRAKE RELEASE-1 PLACE MARKED A ''

384243 REF 4.00" TO 4.10" DIA.

BRAKE TUBE REF. 381136-S140A

9002 TANK ASSY.
BRAKE SYSTEM - 2 PLACES MARKED - FUEL
.045 TRANSPARENT WOOD
BRAKE LINE REF. MAX. GRAIN VINYL
9291 R^EF. | p | T V ( N Y L F L U S H T 0 045" FROM EDGE OF
9291 T U B E - T A N K FLANGE, TRIM IF NECESSARY.
TO PUMP
FOR SQUIRE MODELS WITH TRANSPARENT
INSTALL TUBE INTO WOOD GRAIN VINYL PANELS.
384766 CLIPS, THEN
ASSEMBLE CLIP MARKED
FIRST AND CLIP MARKED VALVE ASSY.-
SECOND. ASSEMBLE 384766 REF.
VAPOR - 98593
REMAINING CLIPS 9002 ASSY. REF
BRAKE SYSTEM - 3 PLACES MARKED •
381877-S2
TYPICAL INSTALLATION FUEL LINE TO
4 PLACES MARKED * CARB. REF.

HOSE MUST BE INSTALLED WITH SMOOTH

380882-S100 9324 HOSE -
BENDS AND NO KINKS.
FUEL FRONT
ESE-M2C96-B, SAE-10W30 ENGINE 381140-S110A
VIEW V
OIL MAY BE USED AS AN ASSEMBLY FOR 302 ENG
AID FOR ASSEMBLY OF HOSES ON
TUBES. NO OTHER MATERIAL MAY
BE USED.
N800173-S100
VIEW V 2REQ'D.
INSTALL HOSE TO SECOND BEAD OF TUBE.
CLAMP MUST BE ON HOSE & FLUSH TO 1/8" FOR 351 & 400 ENG
FROM END OF HOSE WHERE APPLICABLE.
INSTALL HOSE ON TO TUBE .62 MIN. CLAMP N800152-S100 STRAP ASSY. - FUEL
MUST BE ON HOSE & FLUSH TO 1/8" FROM 2REQ'D. TANK - 9092
END OF HOSE WHERE APPLICABLE. INSTALLATION - 6 PLACES MARKED O 20-30 FT-LB 2REQ'D. V2127-C

FIG. 18 Fuel and Vapor Emission Control Systems—Ranchero

 9002 ASSY. REF.
*REF
REF. 381136-S290A

387474 REF.
386021 REF.
MERC. ONLY WITH
REAR DISC BRAKES
.50 CLEARANCE
BETWEEN FUEL
HOSE AND ENGINE
OIL COOLER OR
FITTING.

9030
CAP ASSY.-
FUEL

55914 REF.
4 REQD.
B.E.O. RELEASE

9034 FUEL FILLER PIPE ASSY.

+.50 MIN. CLEARANCE - HOSES 386021 REF. ESE-M2C96-B, SAE-10W-30 ENG. OIL MAY BE
TO STABILIZER BAR. 460 MERC. USED ON 9034 AND/OR 9072 AS AN ASSEMBLY
• INSTALL HOSE TO SECOND BEAD OF TUBE. ONLY WITH AID. NO OTHER MATERIAL MAY BE USED.
CLAMP MUST BE ON HOSE AND FLUSH TO 1/8" REAR DISC
BRAKES I
FROM END OF HOSE WHERE APPLICABLE. <&* N800152-S100
ESE-M2C96-B,SAE-10W-30 ENGINE VIEW Z UNDERBODY REF.
2 REQD.
OIL MAY BE USED AS AN ASSEMBLY 20-30 FT. LB.
384790 REF. 9064 ASSY. REF. VIEW Y
AID FOR ASSEMBLY OF HOSES
400 4V, 460 AND 460 Pl- MEMBER FUEL

s
ON TUBES. NO OTHER MATERIAL
5 PLACES M A R K E D * TANK SUPPORT
MAY BE USED.
VIEW S
• I N S T A L L HOSE ONTO TUBE .62 MIN. CLAMP
MUST BE ON HOSE AMD F i l i a l I TO MV," r n n r . i
END OF HOSE WHERE APPLICABLE. V2128-C

FIG. 19 Fuel and Vapor Emission Control Systems—Ford/Mercury Sedans

a*
 381877-S2 *REF.
385467 REF.

387474 REF.
BRAKE RELEASE
384029-S2
386021 REF.
MERC. ONLY WITH
REAR DISC BRAKES

9B337 REF.

387474 REF.
386021 REF. I «**"

SL

i
f
387474 REF.
BRAKE
386021 REF.
MERC. ONLY WITH
REAR DISC BRAKES
6528630 REF.

• INSTALL HOSE TO SECOND BEAD OF TUBE.

CLAMP MUST BE ON HOSE AND FLUSH TO 1/8"
9034
FUEL FILLER
FROM END OF HOSE WHERE APPLICABLE.
PIPE ASSY.
ESE-M2C96-B.SAE-10W-30 ENGINE
OIL MAY BE USED AS AN ASSEMBLY OF HOSES ESE-M2C96-B, SAE-10W-30 ENG. OIL MAY BE
USED ON 9034 AND/OR 9072 AS AN ASSEMBLY
AID FOR ASSEMBLY OF HOSES ON TUBES
AID. NO OTHER MATERIAL MAY BE USED.
NO OTHER MATERIAL MAY BE USED.

INSTALL HOSE ONTO TUBE .62 MM. CLAMP

MUST BE ON HOSE AND FLUSH TO 1/8" FROM
END OF HOSE WHERE APPLICABLE.
V2129-C

FIG. 20 Fuel and Vapor Emission Control Systems — Ford/Mercury Wagon

 FUEL PUMP REF.
FUEL TANK
9A228 REF. SUPPORT REF.
FUEL LINE TO
CARB. REF.

CANISTER ASSY. REF

382119-S100 ESB-M3G56-A
*?-*• 2 REQD. 9B593 VALVE ASSY.-VAPOR

381136-S100A

9A228 REF
9002
TANK ASSY.
FUEL
,] FUEL LINE TO
FRAME REF ' REF.

UNDERBODY REF.

9092 STRAP ASSY.

COLOR ORANGE THIS RIB IviEW Z

384790 REF. BRAKE TUBE REF

9002 ASSY. REF.

TYPICAL INSTALLATION
4 PLACES MARKED
9049-
t VENT TUBE
9030 CAP ASSY.-FUEL

ESE-M2C96-B, SAE-10W-30
ENGINE OIL MAY BE USED ON
9034 AND/OR 9072 AS AN
ASSEMBLY AID, NO OTHER
MATERIAL MAY BE USED

FUEL TANK SUPPORT

REF.

FUEL TANK SUPPORT

ESE-M2C96-B, SAE-10W-30 ENGINE OIL REF.
MAY BE USED AS AN ASSEMBLY AID ON TUBES
NO OTHER MATERIAL TO BE USED. N800152-S100
2 REQD.
• INSTALL HOSE TO SECOND BEAD ON TUBE. 9B337 REF. 20-30 FT. LB.
TYPICAL INSTALLATION N800173-S100
CLAMP MUST BE ON HOSE AND FLUSH TO 7 PLACES MARKED
1/8" FROM END OF HOSE WHERE APPLICABLE. 2 REQD.

D INSTALL HOSE ONTO TUBES .62 MM. CLAMP

MUST BE ON HOSE AND FLUSH TO 1/8" FROM
END OF i-iuifc W H t H t APPLICABLE.
V2130-C

FIG. 21 Fuel and Vapor Emission Control Systems—Continental Mark V

 385265-S2
SIDE RAIL REF
9B337REF.
384790

381877 REF

SPRING POCKET
REF.

385265 PEF TYPICAL INSTALLATION

6 PLACES MARKED •
9030 - CAP-FUEL
9034 - PIPE ASSY.

VALVE ASSY. - VAPOR

9291 REF. 9B593
SIDE RAIL REF FUEL TANK
SUPPORT REF
385467-S32B
TYPICAL INSTALLATION 2REQ'D.
11 PLACES MARKED #

381136S080A
9A228 - VAPOR LINE

9291 - FUEL LINE

CARBON CANISTER REF.

FUEL PUMP REF 9B337 - FUEL RETURN LINE

9291 REF.
— 9B337 REF.
FUEL TUBE TO
CARB. REF.
ESE-M2C96-B, SAE-10W-30 ENGINE
OIL MAY BE USED ON 9034 AND/OR
TYPICAL INSTALLATION 9072 AS AN ASSEMBLY AID. NO OTHER
381140-S135A-460ENG. 4 PLACES MARKED O
NO. 4C/M REF MATERIAL MAY BE USED.
U 381140-S110A - 400 ENG.
382119S100 FUEL TUBE TO
2 REQ'D. CARB. REF. 381136-S150A-460 ENG.
VIEW X
V " 381136-S100A-400 ENG.

385766-S32
2 REQ'D.
385766-S32
2 REQ'D

ESE-M2C96-B, SAE-10W-30 ENGINE OIL N800150-S100

MAY BE USED AS AN ASSEMBLY AID FOR 9064 ASSY. REF 2 REQ'D.
ASSEMBLY OF FUEL HOSE ON TUBES, MEMBER FUEL
NO OTHER MATERIAL MAY BE USED. 382119-S100
TANK SUPPORT
2 REQ'D.
* INSTALL HOSE TO SECOND BEAD ON TUBE.
CLAMP MUST BE ON HOSE AND FLUSH TO N800152-S100
1/8" FROM END OF HOSE WHERE APPLICABLE 2 REQ'D.
20-30 FT-LBS. 9092 - STRAP ASSY. UNDERBODYREF.
• INSTALL HOSE ONTO TUBE .62 MIN. CLAMP
2 REQ'D.
MUST 6E ON HOSE AND FLUSH TO 1/8" FROM
END OF HOSE WHERE APPLICABLE.
V2131-D

FIG. 22 Fuel and Vapor Emission Control Systems—Lincoln Continental

24-50-20 Fuel Tanks and Lines 24-50-20

SPECIFICATIONS
Approximate Approximate
1977 Fuel Tank Capacity 1977 Fuel Tank Capacity
(In U.S. Gallons) (In U.S. Gallons)
Car Line Model/Usage Usable Car Line Model/Usage Usable

Bobcat 2.3L Calif. Sedan 11.7 Thunderbird All except 351 Calif. 26.0
Pinto/Bobcat All sedans except 2.3L Calif. Thunderbird 351 Calif. Only 22.0
Bobcat 13.0 Mark V All 22.0
Pinto/Bobcat All station wagons 14.0 Ford/Mercury All sedans 24.2
Mustang Base car 13.0 Ford/Mercury All station wagons except
Mustang Auxiliary fuel tank 16.5 Mercury with 400 CID Engine 21.0
Granada/Monarch All 19.2 Mercury Station wagon with 400 CID
Maverick/Comet All 19.2 Engine 19.0
LTD Il/Cougar All sedans 26.0 Lincoln 460 CID Engine 24.2
LTD Il/Cougar Station Wagons 21.3 Lincoln 400 CID Engine Calif. Only 20.0
Ranchero All 26.0
CV1114-H
24-51-1
DESCRIPTION
The fuel filters used on all engines
except those using the Motorcraft model
2700 VV carburetor are of one-piece
construction and cannot be cleaned. The
model 2700 VV uses a replaceable
element type filter in the fuel inlet of the
REMOVAL AND INSTALLATION
FUEL FILTER
All Models Except 2700 VV
Carburetor, All Engines
Removal
1. Remove the air cleaner.
2. Loosen (screw-type) or remove
(spring-type) the clamp securing the
inlet hose to the fuel filter line.
If filter is located in line, loosen
or remove outlet hose clamp.
3. Unscrew the fuel filter from the
carburetor on those models that are
so equipped. Disconnect the fuel filter
hose from the metal line and discard
the clamp, filter and hose.
TOOLT63P-9171-A
SPACE
SHOULD BE
.00.06
FIG. 1 Installing Crimp—Type Clamps
Fuel Filter
Fuel Filter
carburetor. Inside the one-piece filter is
a magnet to trap metallic particles which
might be present in the fuel. Replace the
filter at the specified service interval or
if it becomes clogged or restricted.
Installation
1. Install new clamps on a new inlet hose
and connect the hose to the filter and
line. Thread the filter into the
carburetor inlet port if so equipped.
Tighten the filter.
2. Position the fuel line hose clamps and
tighten the clamps securely (Fig. 1).
3. Start the engine and check for fuel
leaks.
Engines Equipped with 2700 VV
Carburetor
Removal
1. Remove the air cleaner.
2. Loosen (screw-type) or remove
(spring-type) the clamp securing the
CLAMPS MUST BE LOCATED ON THE
FLAT PORTION OF THE FUEL TUBE
AND FUEL FILTER INLET. (MUST
MISS THE BEADS).
STEP TWO
V2058-A
24-51-1
CA4247-A
NOTE: When replacing fuel filters,
make sure you have the correct one
specified for the engine and carburetor
being serviced.
fuel line to the fuel-inlet fitting.
Remove the line.
3. Unscrew the fuel-inlet fitting and
remove the fuel filter, gasket and
spring (Fig. 2).
Installation
1. Install the fuel filter spring, filter,
inletfittinggasket and the gasket into
the carburetor.
2. Position the fuel line and clamp onto
the fuel inlet fitting and tighten the
clamp securely.
3. Start the engine and check for leaks.
4. Replace the air cleaner.
'RING
FILTER
ASKET
V2057-A
FIG. 2 Model 2700 VV Carburetor-
Fuel Filter—Typical
24-60-1
Throttle Linkage
SUBJECT
ADJUSTMENTS
Accelerator Cable
Accelerator Cable Mounting Bracket
ADJUSTMENTS
DOWNSHIFT LINKAGE-
AUTOMATIC TRANSMISSION
All Models
Adjustment instructions are given on
the illustrations, Figs. 1 through 8.
ACCELERATOR CABLE
All Models
Removal
1. Refer to the applicable illustration.
2. Using a suitable tool, push the
accelerator cable nylon bushing out of
the accelerator pedal arm. Remove
the retaining clip attached to the cable
at the dash panel inside the vehicle.
3. Disconnect the accelerator cable at
the carburetor throttle lever. Be sure
to pull on the connector and not the
cable.
4. Disconnect the cable-attaching screw
from the engine bracket.
5. Remove the screws attaching the
cable to the dash panel.
6. Remove the cable from the dash
panel.
Installation
1. Position the cable end through the
dash panel and install the attaching
screws.
Throttle Linkage
PAGE SUBJECT
ADJUSTMENTS (Cont'd.)
60-1 Accelerator Pedal Assembly
60-1 Downshift Linkage
2. Install the cable to the engine
mounting bracket with one screw.
3. Connect the cable to the carburetor
throttle lever. Install the cable sound
absorber attaching clip.
4. Press the snap-in nylon bushing on
the accelerator cable into the
accelerator pedal arm.
ACCELERATOR CABLE
MOUNTING BRACKET
All Models
Removal
1. Remove the accelerator cable
mounting screw. Remove the cable
from the bracket.
2. Remove the bolts securing the
accelerator cable mounting bracket to
the engine. On Pinto/Bobcat and
Mustang 2.3L engines, disconnect
automatic transmission kickdown rod
(if equipped).
Installation
1. Install the accelerator cable mounting
bracket on the engine and torque the
attaching bolts to specification.
Reinstall the cable and attaching
screw. On Pinto/Bobcat and
24-60-1
PART
24-60
PAGE
60-1
(10-1
CN4043-A
Mustang 2.3L engines, reconnect
automatic transmission kickdown rod
(if equipped).
ACCELERATOR PEDAL ASSEMBLY
All Models
Removal
1. Using a suitable tool, pu*h the
accelerator cable nylon bushing out of
the accelerator pedal arm.
2. Remove the two nuts attaching the
accelerator pedal assembly to the
floor.
3. If replacing the assembly and if the
vehicle is equipped with a pedal pad
cover, uncrimp the pedal pad cover
and remove from the pedal.
Installation
1. Install the pedal pad cover, if so
equipped, and carefully crimp the
retaining tabs.
2. Position the pedal assembly cm the
two mounting studs and install the
two attaching nuts. Check to be sure
that carpeting and/or sound deadener
is properly assembled. Torque to
specifications.
3. Install the snap-in nylon bushing of
the accelerator cable into the
accelerator pedal arm.
 I
N602549-S51M KICKDOWN ADJ.
2 REQ'D. SCREW REF.
10-15 FT-LB )
9A758 ASSY. REF.

ACCELERATOR BRACKET
-9K713ASSY.
N602549-S51M
10-15 FT-LB INTAKE
2 REQ'D. MANIFOLD REF.
N602549-S51M
55981-S36M 7A186 ASSY. REF. 2 REQ'D.
383212-S2
FRONT OF ENGINE 10-15 FT-LB
FRONT OF ENGINE 9A758 ASSY. REF.

55981-S36M

9728 ASSY. REF.

2.8 LITER 7A186ASSY.
VIEWZ 7B146 REF. 9A758 ASSY. REF. REF.

Z3 LITER AUTOMATIC TRANSMISSION

VIEW IN CIRCLE X SAME AS MAIN VIEW EXCEPT AS SHOWN
AUTO. TRANS. ONLY
VIEWZ
\ 97409-S2
INTAKE 2 REQ'D.
55981-S36M
MANIFOLD REF.

2.3 LITER STANDARD TRANSMISSION

SAME AS MAIN VIEW EXCEPT AS SHOWN

VIEWZ
7A186ASSY.
TRANSMISSION KICKDOWN ROD
CARB REF. (AUTOMATIC TRANS. ONLY)

ABSORBER ASSY. (6201670)

9E728 RETAINER

SLIDING INNER MEMBER

FRONT OF ENGINE 25MIN.

7B146
AUTO. TRANS.
ONLY 9726
KICKDOWN RETRACTING ACCELERATOR ASSY.
SPRING 9E728 REF.

ADJUSTMENT OF THE TRANS. K.D. CONTROL DASH PANEL

REF.
1. WITH CARBURETOR HELD AT W.O.T. POSITION AND ABSORBER ASSY. REF.
THE KICKDOWN ROD 7A186 HELD DOWNWARD
AGAINST THE "THROUGH DETENT" STOP. ADJUST
THE KICKDOWN ADJUSTING SCREW TO OBTAIN .01
TO .06 CLEARANCE BETWEEN SCREW AND
THROTTLE ARM.

2. RETURN SYSTEM TO IDLE.

V1954-D

FIG. 1 Throttle and Downshift Linkage—Pinto and Bobcat with 2.3L and 2.8L Engines
 9A758 ASSY. REF. KICK DOWN ADJ. N6O2549-S51M
SCREW REF. 2 REQ'D. *
10-15 FT-LB
55981-36M 9728 ASSY. REF.

9A758 ASSY. REF.

N602549-S51M
2 REQ'D.
10-15 FT-LB FRONT OF VEHICLE
7A186ASSY. REF.
AUTO. TRANS. ONLY
9728
VIEW Z - 2.8 LITER ENGINE INTAKE MANIFOLD REF. ACCELERATOR BRACKET 9726
ACCELERATOR ASSY.
2.3 LITER STANDARD TRANSMISSION
SAME AS MAIN VIEW EXCEPT AS SHOWN 7A186 ASSY.
9A758 ASSY. REF. AUTO. TRANS. ONLY
KICKDOWN ROD 9A788REF.PARTOF
KICKDOWN ADJ ACCELERATOR BRACKET
9K713ASSY. 383212-S2 (6501670) ASSY.
SCREW REF.
2 REQ'D.

N602549-S51M PEDESTAL AND STUD

2 REQ'D.
10-15 FT-LB

FRONT OF VEHICLE MAIN VIEW

2.8 LITER STANDARD AND
AUTOMATIC TRANSMISSION
VIEW Z - 302 CID ENGINE INTAKE CD
MANIFOLD REF
3
7T
Q
(Q
CD
7A186 ASSY
REF.
7A186 ASSY. REF.
2.3 LITER AUTOMATIC TRANSMISSION
SAME AS MAIN VIEW EXCEPT AS SHOWN
383212-S2

DASH PANEL REF

9726 ASSY.

9A758 ASSY. REF.

7B146 VIEWY
7B146 REF.
KICKDOWN
VIEW IN CIRCLE X RETRACTING f) ^ v ^ 9 A 7 8 8 REF. PART OF
302 2V SPRING >/ (6501670) ASSY.
ABSORBER ASSY. REF.

PEDESTAL AND STUD

ADJUSTMENT OF THE TRANS. K.D. CONTROL

1. WITH CARBURETOR HELD AT W.O.T. POSITION AND

THE KICKDOWN ROD 7A186 HELD DOWNWARD 97409-S2
AGAINST THE "THROUGH DETENT" STOP, ADJUST 7A186 ASSY. AUTO. TRANS.
THE KICKDOWN ADJUSTING SCREW TO OBTAIN .01
TO .08 CLEARANCE BETWEEN SCREW AND K>
THROTTLE Afifvi.

2. RETURN SYSTEM TO IDLE.

V1955-D

FIG. 2 Throttle and Downshift Linkage—Mustang

 ASSY. REF.

55981-S36M

KICKDOWN
ADJUSTMENT
SCREW
VIEWZ

7A186 (REF.)
VIEWW
FOR 351 W ENGINE VIEWX
TYPICAL - ALL
383212-S2- ENGINES

7B146 7A186 ASSY.

(REF.) 33921 REF.
TRANSMISSION NUT-JAM
57632-S2 KICKDOWN
55981-S36M TORQUE 6 FT-LB
/ 2 REQ'D. ROD MINIMUM
Jf 10-15 FT-LB
VIEW IN CIRCLE V
AUTO. TRANS. 8 CYLINDER 7E310REF.
BOLT KICKDOWN ADJ.
9728 REF.
6 CYLINDER 302217-S2 BOLT
VIEWW INSTALLATION FOR 34792-S2 WASHER

SPRING - 7B146 VIEWW 9A758REF.

FOR 302 2V ENGINE AUTO. TRANS. SAME
AS STD. TRANS. EXCEPT
AS SHOWN .7A394ASSY. 7B182
V 2 REQ'D.
15-25 FT-LB

REF. ACCELERATOR VIEWZ

SHAFT AND BRACKET ASSY. 6 CYLINDER
383212-S2
ABSORBER ASSY. (6501670)
Q
CO
55981-S36M RETAINER - 9E728
7A186 REF. 2 REQ'D.
AUTO. TRANS. ONLY CABLE ASSY.
9A758 SLIDING INNER MEMBER

INSTALLATION FOR 55981-S36M

302 2V 8 CYLINDER 55736-S36
SAME AS MAIN VIEW 2 REQ'D.
EXCEPT AS SHOWN 10-15 FT-LB

97409-S2 9A758ASSY. REF

9728
ACCELERATOR
ADJUSTMENT OF THE TRANS. K.D. CONTROL BRACKET
9726 9 A 788
1. WITH CARBURETOR HELD AT W.O.T. POSITION AND ACCELERATOR PART OF
THE KICKDOWN ROD 7A186 HELD DOWNWARD ASSY. (6501670) ASSY.
AGAINST THE "THROUGH DETENT" STOP, ADJUST
THE KICKDOWN ADJUSTING SCREW TO OBTAIN .01
TO .08 CLEARANCE BETWEEN SCREW AND
THROTTLE ARM.
VIEWY
2. RETURN SYSTEM TO IDLE. TYPICAL - ALL ENGINES
NOTE: COIL TO BE MAIN VIEW
MOUNTED OVER INSTALLATION FOR STANDARD
CABLE BRACKET TRANSMISSION 6 CYLINDER
(9728 REF.)
V1956-C
PIG. 3 Throttle and Downshift Linkage—Monarch and Granada
 33921-S2 NUT HAM
TORQUE 6 FT-LB
MINIMUM

KICKDOWN VIEWZ 7E310

SOUND ABSORBER ADJUSTMENT BOLT KICKDOWN
SCREW ADJUSTMENT
9A758 ASSY.
9E728REF. 7B182A
REF. VIEW IN CIRCLE X
7A186 ASSEMBLY
SLIDING INNER
MEMBER KICKDOWN ROD
7A186 ASSEMBLY

7B182 ASSEMBLY
REF.

9726 ASSEMBLY
REF.
9728 REF.

7A394 ASSEMBLY
REF. 7B182 ACCELERATOR SHAFT
AND BRACKET ASSY.
6 CYLINDER ENGINE AUTOMATIC
383212-S2 6 CYLINDER ENGINE
TRANSMISSION SAME AS STANDARD
VIEWZ
TRANSMISSION EXCEPT AS SHOWN
7B146-
KICKDOWN RETRACTING
SPRING
DASH PANEL ABSORBER ASSEMBLY
CABLE ASSY REF. (6501670)
9A758 9A758 ASSEMBLY REF.

7B146REF. 9E728 REF.

VIEW IN CIRCLE W
9A758 ASSY. Q
REF (Q
9726
ACCELERATOR ASSY.

t
55981-S36M
9728 REF.
302 - 2V 8 CYLINDER ENGINE
VIEWZ
1. WITH CARBURETOR HELD AT W.O.T. POSITION AND NOTE: COIL TO BE
THE KICKDOWN ROD 7A186 HELD DOWNWARD MOUNTED OVER VIEWY
AGAINST THE "THROUGH DETENT" STOP, ADJUST DASH PANEL REF.
CABLE BRACKET
THE KICKDOWN ADJUSTING SCREW TO OBTAIN .01
TO .08 CLEARANCE BETWEEN SCREW AND INSTALLATION FOR STANDARD TRANSMISSION 6 AND 8 CYLINDER ENGINES
THROTTLE ARM. 6 CYLINDER ENGINE VIEWY

2. RETURN SYSTEM TO IDLE.

K>

FIG. 4 Throttle and Downshift Linkage— Maverick and Comet

 REF.
9A758 ASSY. 9A758 ASSY.
9A758 ASSY.
9728
REF.

57632-S2

55914-S36M'
55914-S36M 55914-S36M
9728 REF.

302 ENG. INSTALLATION

351 "W" ENG. INSTALLATION VIEWZ
VIEW Z
LTD I I . COUGAR 400 4V ENG. INSTALLATION
THUNDERBIRD VIEWZ
9A768 THUNDERBIRD ONLY
CABLE ASSY.
ACCELERATOR
55914-S36M BRACKET
55981-S36M
9728
2REQ-D.
9E728
9A758 ASSY.
RETAINER
REF.
VIEWW

351M AND 400 ENG. INSTALLATION SLIDING INNER MEMBER

VIEWZ .25MIN.
LTD II - THUNDERBIRD - COUGAR 9726
ACCELERATOR ASSY.

DASH PANEL
9E728REF.
I"
REF.

VIEWW
AUTO. TRANSMISSION
COLUMN SHIFT CABLE
7A186ASSY. REF. IS TO BE ROUTED
383212-S2 INBOARD OF KICKDOWN
ROD 7A186
TYPICAL ACCELERATOR DASH PANEL REF. 9E728 REF.
LINKAGE INSTALLATION
KICKDOWN
302 ENGINE SHOWN
ADJUSTMENT
SCREW

7A186 ASSY. REF.

VIEW IN CIRCLY Y

97409-S2

KICKDOWN CONTROL ADJUSTMENT

VIEW IN CIRCLE X
1. WITH CARBURETOR HELD AT W.O.T. POSITION
AND THE KICKDOWN ROD 7A186 HELD DOWNWARD
AGAINST THE "THROUGH DETENT" STOP, ADJUST
THE KICKDOWN ADJUSTING SCREW TO OBTAIN
.01 TO .08 CLEARANCE BETWEEN SCREW AND
THROTTLE ARM. VIEWV
2. RETURN SYSTEM TO IDLE.
V1609-F

FIG. 5 Throttle and Downshift Linkage—LTD II, Thunderbird, Cougar and Ranchero
 9A758 ASSY.

25MIN.

9728 REF.

55981-S36M 55981-S36M
9E728 REF.

VIEWW
REF ABSORBER ASSY.
FOR 460 ENG. INSTALLATION
DASH PANEL REF

VIEWX

FOR 351M AND 400-2V ENG. INSTALLATION VIEWV

VIEWW KICKDOWN ADJUSTING
SCREW REF.
RETAINER
LARGE HOOK VIEWW - 9E728

SLIDING INNER
MEMBER
383212-S2

9726
9728 VIEWX ACCELERATOR ASSY.
ACCELERATOR
BRACKET
7A186REF. VIEWV
9E728
REF.

7A186 9726 ASSY. REF.

KICKDOWN ROD

VIEW Y ABSORBER ASSY.

55981-S36M (6501670)

9728
REF.
VIEWW
FOR 400-4V ENG. INSTALLATION 7A186REF.

ADJUSTMENT OF THE TRANS. K.D. CONTROL DASH PANEL REF.

1. WITH CARBURETOR HELD AT W.O.T. POSITION AND
THE KICKDOWN ROD 7A186 HELD DOWNWARD 97409-S2
AGAINST THE "THROUGH DETENT" STOP, ADJUST
THE KICKDOWN ADJUSTING SCREW TO OBTAIN .01 VIEWZ
TO .08 CLEARANCE BETWEEN SCREW AND
THROTTLE ARM. VIEWY

2. RETURN SYSTEM TO IDLE. V1610-F

FIG. 6 Throttle and Downshift Linkage—Ford and Mercury

 9A758 ASSEMBLY
9A758 ASSEMBLY REF. 7A186 ASSEMBLY
383212-S2
TYPICAL CABLE INSTALLATION
ALL ENGINES

55914-S36M
VIEWW 97409-S2
VIEWX
460-4V INSTALLATION

VIEW IN CIRCLE V
57632-S2 2 REQUIRED
10-15 FT-LB
.25MIN.

9A758 ASSEMBLY

DASH PANEL REF.

9A758
9E728REF.
7A186 KICK DOWN ROD CABLE ASSY. 55981-S36M 2 REQUIRED

VIEWX RETAINER 9E728

SLIDING INNER MEMBER
c:
ABSORBER ASSY. REF.
7B146
SPRING VIEWW
VIEWW
9726
ACCELERATOR ASSY.

VIEWZ

LARGE HOOK

DASH PANEL
REF

ABSORBER ASSY. (6501670)

KICKDOWN CONTROL ADJUSTMENT

1. WITH CARBURETOR HELD AT W.O.T. POSITION AND THE SOUND ABSORBER
KICKDOWN ROD 7A186 HELD DOWNWARD AGAINST THE
"THROUGH DETENT" STOP, ADJUST THE KICKDOWN ADJUSTING
SCREW TO OBTAIN .01 TO .08 CLEARANCE BETWEEN SCREW
AND THROTTLE ARM. * VIEWZ
2. RETURN SYSTEM TO IDLE.
V1611-F

FIG. 7 Throttle and Downshift Linkage—Continental Mark V

 9A758 ASSY. REF.
9A758 ASSY. REF.
9726 ASSY. REF.

ABSORBER ASSY. REF.

57632-S2
2 REQD.
10-15 LB. FT.
55914-S36M
9728
ACCELERATOR BRACKET DASH PANEL REF

r
7A186 REF.

VIEW Z
9728 REF

VIEW Y
RETAINER
9E728
SLIDING INNER MEMBER
9A788 PART OF
(6501670) ASSY.

460-4V INSTALLATION PEDESTAL AND STUD

9A758 ASSY.
REF. VIEW V

55736-S2
2 REQD. VIEW V
10-15 LB. FT.

55914-S36M

9726
ACCELERATOR ASSY.

7A394REF.

DASH PANEL REF.

7A186 REF.

* 12 MIN.
9A758 ASSY. REF.

9E728 REF.

ADJUSTMENT OF THE TRANS. K.D. CONTROL

ABSORBER ASSY.
1. WITH CARBURETOR HELD AT W.O.T. POSITION AND REF.
THE KICKDOWN ROD 7A186 HELD DOWNWARD VIEW W
AGAINST THE "THROUGH DETENT" STOP, ADJUST
THE KICKDOWN ADJUSTING SCREW TO OBTAIN .01
TO .08 CLEARANCE BETWEEN SCREW AND VIEW X
THROTTLE ARM.

2. RETURN SYSTEM TO IDLE.

V1723-E

FIG. 8 Throttle and Downshift Linkage—Lincoln Continental

26-01-1
EXHAUST SYSTEM
PART TITLE
Four Cylinder Engine
Single Exhaust System
General Exhaust System
Six Cylinder Engine Single Exhaust System
V-8 Dual Exhaust System
GENERAL INFORMATION
This Part covers the general exhaust
s y s t e m , a d j u s t m e n t s and repair
procedures.
Always refer to the master parts
c a t a l o g for p a r t s u s a g e and
interchangeability before replacing a
component part of the exhaust system.
The exhaust system must be free of
leaks, binding, grounding and excessive
vibrations.
DESCRIPTION AND APPLICATION
Fig. 1 lists the various exhaust system
applications.
SINGLE EXHAUST SYSTEMS
The factory-installed single exhaust
system in a vehicle with a 4-cylinder
engine consists of a muffler inlet pipe,
connected to the exhaust manifold, which
is, in turn, connected to a muffler. The
vehicle may also be equipped with a
catalytic converter.
The single exhaust system in a vehicle
with an in-line 6-cylinder engine is the
same basic design as that for the 4-
cylinder engine.
The in-line V-6 single exhaust system
consists of a catalytic converter, inlet pipe
assembly, muffler and supporting
hangers. The V-8 single exhaust system
is similar to the V-6 in-line system except
for the addition of a resonator and the
Exhaust System
PART NO. PART TITLE
V-8 Dual Exhaust System
26-02 V-8 Single Exhaust System
26-01 V-6 Exhaust Systems
26-10
These conditions are usually caused
by loose, broken or misaligned clamps,
shields, brackets or pipes. If any of these
conditions exist, check the exhaust
system components and alignment.
Adjust or replace as necessary to
maintain the specified clearances (refer to
the illustrations in each Part).
Brackets, clamps and insulators
should be replaced if they are damaged
or badly corroded. Do not attempt to
repair these parts.
number of catalytic converters required.
INLET PIPE EXTENSION AND
MUFFLER ASSEMBLY
Some exhaust systems include a
catalytic converter. Refer to Parts 26-02,
26-03, 26-10 or 26-20 for appropriate
replacement procedures.
DUAL EXHAUST SYSTEMS
Dual exhaust systems used with the
V-8 engine consist of two one-piece
catalytic converter and inlet pipe
extension assemblies connecting the
exhaust manifolds to the muffler inlet
"H" pipe which is connected to the
muffler.
The dual exhaust system may or
may not be equipped with a resonator.
Refer to Part 26-22 for replacement
procedures.
26-01-1
GROUP
(hOOO)
PART NO.
26-22
26-20
26-03
CN4033-A
CN4034-A
Inspect the inlet pipe(s), outlet
pipe(s), catalytic converters, resonator(s)
and muffler(s) for cracked joints, broken
welds and corrosion damage that would
result in a leaking exhaust system.
Inspect the clamps, brackets and
insulators for cracks and stripped or
badly corroded bolt threads. When pipe
clamp(s) are loosened and/or removed to
replace a pipe, muffler or resonator,
replace the clamp(s) if there is reasonable
doubt that its service life is limited.
EXHAUST SHIELD REPAIR A N D /
OR REPLACEMENT—ALL
VEHICLES SO EQUIPPED
Exhaust shields, consisting of formed
metal sheets, attach to the exhaust system
or the catalytic converter connections
using various methods.
Exhaust shields are not subject to
repair other than replacing missing/
damaged attaching parts such as clamps
or screws and removing debris that may
collect in the shield area. If an exhaust
shield is damaged or shows evidence of
deterioration it should be replaced rather
than repaired.
Removal/Installation procedures are,
in most cases, a matter of removing the
26-01-2 General Exhaust System 26-01-2

shield attachments and shield; new parts. The car lines exhaust positioning of exhaust shields and
installation is the reverse process using illustrations indicate the types and proper clamps.
EXHAUST SYSTEM

Model Number of
Sta. Ran- Converters Engines Released For
Car Line Sedan Wagon chero System 0 1 2 2\3 2.8 200 250 302 351 4fi§ Can. Cal.
XXX,

XXX
Pinto/ Single X X X X

XXX
Bobcat Single X X X
Single X X
Mustang X Single X X X X X X
X Single X X X X
XXX

XXX
XXX
Maverick/ Single X X X X
Comet Single X X
Single X X

xxxx

....
Granada/ X Single X X X X
Monarch 5700 Single X X X
X Single X X
5700 Single X
X Single X X
302 351W 351M 400 400 460 460
2V 2V 2V 2V 4V 4V PI
XXX

XXX

LTD II
xxxx
Single X X X X

xxxx
X Single X X X
Single X X
X Single X
X X
X

X X
X

Single
xxxx

XXX

Cougar Single X X X X

xxxx
X Single X X X
Single X X
X Single X X X
X X
X

Thunder- X Single X X X X X
bird X Single X X X X X X
X Single X X X X
xxxx

xxxx
Ford/ Single X

XXX
X
X X X XXX

Mercury X Single X X
X Single X
Dual X

X XX
Single X X
X Single X X
400 400 460
2V 4V 4V
Lincoln X Single X X X
X Single X X X X
MarkV X Single X X X X
X Dual X X X X
X Single X X X X X
CU1497-E

FIG. 1 Exhaust System Applications

REPAIR
CATALYTIC CONVERTER the hole with a 13/32 drill and use a 3/8"
FASTENER diameter bolt of suitable length and a
Catalytic converters should not be locking nut. See the following chart for Stud Thread

replaced because they have broken studs, replacement studs and appropriate Converter Flange and Length

stripped threads or loose nuts. The lengths. 4 " Round Outlet 3 / 8 - 16 x 2.8:J"
following procedure is recommended for Converters with Loose Clinch or Inlet 3/8 - 16 x 1.50"
repairing these fasteners: Weld Nuts in the Flange 5 " Round Outlet 3 / 8 - 16 x 1.50"
Converters with Threaded 1. Remove the loose nut. 4"x7" Outlet 3/8 1 6 x 3 . 2 5"
Flanges 2. Dress the flange surface upon which Oval Inlet 3/8 16x2X0"
Remove damaged studs and install the bolt and washer will rest.
new studs or a bolt of suitable length. If 3. Fasten the joint with a suitable 3/8" Note: Use 45358-S7 Nut for all applications.
the flange thread has minor damage, bolt, lock nut and flat washer between
retap the hole with a 3/8-16 tap. If the the bolt head and the dressed flange CN4040-A
flange thread cannot be repaired, resize surface.
26-02-1 Four-Cylinder Engine Single Exhaust System
Four Cylinder
Single Exhaust System
SUBJECT
DESCRIPTION
REMOVAL AND INSTALLATION
Catalytic Converter
Inlet Pipe-(Front) With
Catalytic Converter
DESCRIPTION
The four-cylinder Pinto/Bobcat and
Mustang use a single-pipe type exhaust
system. The production exhaust system
differs from the service replacement
system in the number of basic pieces
used.
The Pinto/Bobcat uses either a one
converter exhaust system (U.S. vehicles)
or a non-converter system available only
on Canadian vehicles. The Mustang is
equipped with a one converter system
REMOVAL AND INSTALLATION
Typical factory installed exhaust
systems for the 2300 cc engines are shown
in Figs. 1 thru 3.
Removal
1. Raise the vehicle.
2. Remove the screws that attach the
front hanger insulator to the inlet pipe
bracket.
3. Support the muffler assembly with a
soft wire and remove the inlet pipe to
muffler assy slip joint clamp.
4. Remove the attaching nuts securing
the inlet pipe to the exhaust manifold
and remove the inlet pipe.
5. Replace any damaged parts.
Installation
1. Clean the exhaust manifold outlet
seat.
2. Insert the inlet pipe in the muffler
pipe and install but do not tighten the
clamp.
3. Position the inlet pipe to the manifold
flange and loosely install the
attaching nuts.
4. Loosely attach the front hanger
insulator to the inlet pipe bracket.
5. Align the exhaust system to conform
to clearance specifications. Starting at
the rear of the system, torque all nuts,
screws or bolts.
PAGE SUBJECT
02-1 REMOVAL AND INSTALLATION (Cont'd.)
Inlet Pipe - (Front) Without
02-2
Catalytic Convener
Muffler Assembly
02-1
only. Factory installed exhaust systems
have two pieces for a non-converter
system and three pieces for a converter
system. The Non-Converter System has
an inlet pipe which connects to the engine
exhaust manifold, and a muffler inlet
pipe, muffler and tailpipe, all welded
together. On catalytic converter system,
the converter assembly is a bolt on unit
connected between the inlet pipe and the
muffler. Flat flange connections are used.
6. Check the system for leaks and lower
the vehicle.
INLET PIPE—(FRONT) WITH
CATALYTIC CONVERTER
Removal
1. Raise the vehicle.
2. Support the muffler assembly with a
soft wire.
3. Remove the bolts that attach the
converter inlet flange to the inlet pipe.
4. Remove the screws that attach the
front hanger insulator to the inlet pipe
bracket.
5. Remove the nuts attaching the inlet
pipe flange to the exhaust manifold
and remove the inlet pipe.
6. Replace any damaged parts.
Installation
1. Clean the exhaust manifold and
catalytic converter flange seats.
2. Position the inlet pipe to the manifold
and install but do not tighten the
attaching nuts.
3. Install the front hanger bracket
insulator to inlet pipe bracket. Do not
tighten the attaching screws.
4. Using a new gasket, position the inlet
pipe to the catalytic converter. Align
the upper (and lower if so equipped)
heat shield, to the converter inlet
26-02-1
PART
26-02
PAGE
02-1
02-1
CN4065-A
The exhaust system is usually
serviced in three pieces for a non-
converter system and four pieces for a
converter system. The rear section of the
muffler inlet pipe (intermediate muffler
inlet) is furnished separate from the
muffler. For exact service replacement
parts information, refer to the master
parts catalog.
flange and loosely start the attaching
bolts.
5. Remove the wire support for the
muffler assembly.
6. Align the exhaust system to proper
clearance specifications and starting
at the front, tighten all nuts, screws,
and bolts to specification.
7. Check the exhaust system for leaks
and lower the vehicle.
MUFFLER ASSEMBLY
Removal
1. Raise the vehicle by means of the
frame lift points to allow the axle full
downward travel. This will provide
the clearance necessary to remove and
replace the muffler and pipe.
2. Non-catalytic converter vehicles—
loosen and remove the inlet* pipe
clamp.
3. Catalytic converter equipped
vehicles—remove the rear converter
to muffler pipe flange connection
attaching nuts. (Figs. 1 through 3.)
4. Remove the attaching screws from
the rear hanger assembly to muffler
support.
5. Slide the muffler assembly rearward
to disconnect it from the catalytic
converter.
26-02-2 Four-Cylinder Engine Single Exhaust System
6. Remove the attaching screws from
the intermediate support on the
muffler inlet pipe and remove the
muffler assembly.
7. Replace any damaged parts.
Installation
1. Position the muffler assembly over
the rear axle and loosely attach the
intermediate support bracket.
2. Non-catalytic converter vehicles—
assemble the muffler assembly to the
inlet pipe from the manifold and
loosely attach the retaining clamp.
3. Catalytic converter vehicles—
position the muffler inlet pipe flange
to the converter flange. Install but do
not tighten the attaching nuts.
4. Position the muffler rear support
bracket and loosely install the
attaching screws.
5. Align the exhaust system to conform
to the proper clearance specifications
and, starting from the muffler inlet
pipe connection, torque all nuts and
screws to specifications.
6. Check the system for leaks and lower
the vehicle.
CATALYTIC CONVERTER
Removal
1. Raise the vehicle.
2. Remove the upper and lower heat
shields, if so equipped, attached to the
converter.
3. Remove the front and rear catalytic
converter flange fasteners.
4. Separate the catalytic converter inlet
and outlet flange connections.
26-02-2
5. Remove the converter.
Installation
1. Align the heat shield brackets to the
inner flanges on the converter and
position the catalytic converter to the
inlet pipe using a new gasket. Loosely
install the attaching bolts.
2. Install the muffler inlet flange to the
converter outlet flange. Loosely
install the attaching nuts.
3. Attach the heat shields to the
converter.
4. Align the exhaust system to
specification and starting at the front
of the system, tighten all nuls and
bolts to specification.
5. Check the system for leaks and lower
the vehicle.
 5B266 5E212 ASSY. REF.
40962-S2
ASSY. ENG. RELEASE
1.28 2REQ'D.
5246 ASSY 5F222 ASSY.
AT REAR FLANGE 108 IN-LB MAX.

C/M BRKT. REF.

FRT. FLOOR PAN REF

AT REAR FLANGE
C_ OF CRANK
5230
ASSY. REF.
5246 ASSY. REF. 5A246 ASSY.
387265-S2
2 REQ'D.
20-30 FT-LB NO. 3 CROSSMEMBER REF.
STATIC AUDIT TORQUE
SECTION B
- 20-36 FT-LB
5.67 5230 ASSY. REF. 381877-S2
45358-S7 • 2 REQ'D.
5.49
2 REQ'D. 108 IN-LB MAX.
5246 ASSY. REF.
20-30 FT-LB
5F224 ASSY. VIEWV
INLET PIPE GAGING 55914-S2
5E258 ASSY 6 REQ'D.
90 IN-LB MAX. TORQUE

4c N-800064-S2
2 REQ'D.
MUST BE FULLY INSTALLED
TO SHOULDER OF STUD
FLOOR PAN REF.

SIDE RAIL REF.

BRKT. MUFFLER INLET

PIPE SUPPORT REF.

5246 ASSY. REF. 5230 ASSY. REF.

• 387039-S7 '•94 SHOCK BRKT
2 REQ'D. \ V\V /R.H. 5230 ASSY. REF.
25-35 FT-LB 382400-S2 5230 ASSY. REF. 5C263 ASSY.
20-35 FT-LB 2 REQ'D.
STATIC AUDIT TORQUE FOR MANUAL TRANS. ONLY 40962-S2
5A242 ASSY. 4 REQ'D.
TIGHTEN SECURELY
108 IN-LB MAX.
'DIFFERENTIAL REF 5246 ASSY. REF.

VIEWX
FLOOR PAN REF.

% END OF STUD WITH SHORTEST THREAD LENGTH TO BE

5230 ASSY. REF
SCREWED INTO MANIFOLD.

• TIGHTEN NUTS ALTERNATELY TO MAINTAIN TORQUE

AND DRAW FLANGE EVENLY.

DIFFERENTIAL REF \ 40962-S2

2 REQ'D.
CROSSMEMBER REF 1O8 4N-LBSMAX. N4052A

FIG. 1 Exhaust System Mustang—2.3L Engine

 387265-S2
2 REQ'D.
20-30 FT-LB
STATIC AUDIT TORQUE 5A246 ASSY.
20-36 FT-LB UNDERBODY
REF.

REAR FACE
OF BLOCK

TRANS. EXT. REF.

| ^^5)f~- -t_. 5E212 ASSY. REF
ENG.RELEASE

n
<
Q.

N-80O0064-S2
2 REQ'D. rn
MUST BE FULLY INSTALLED
TO SHOULDER OF STUD
(D
5*
a>

40962-S2
4 REQ'D. 5230 ASSY. REF.
387039-S7 TIGHTEN SECURELY
2 REQ'D. 108 IN-LB MAX.
25-35 FT-LB
20-35 FT-LB
STATIC AUDIT TORQUE

THE TOLERANCE ON DIMENSIONS ARE ± .25 UNLESS

OTHERWISE SHOWN.

* END OF STUD WITH SHORTEST THREAD LENGTH TO BE

SCREWED INTO MANIFOLD.
DIFFERENTIAL REF
• TIGHTEN NUTS ALTERNATELY TO MAINTAIN TORQUE
AND DRAW FLANGE EVENLY.

N4053A

FIG. 2 Exhaust System Pinto/Bobcat—Station Wagon—2.3L Engine

 .68 FOR 7.3 CONV. 6210786 REF
* N-800064-S2
2 REQ'D. EXHAUST MANIFOLD REF. MEMBER RR FLR.
MUST BE INSTALLED TO / SIDE REF.
SHOULDER OF STUD. / .33 FOR 12 CONV.

4 REAR FACE
SHOCK BRKT. REF

TRANS. EXT. REF.

5230 ASSY. REF.
381877-S2
4 REQ'D.
TIGHTEN SECURELY
108 IN-LB MAX.
44.02 FOR
7.3 CONV. 5230 ASSY. REF. 5C263 ASSY.
• 387039-S7 - 48.62 FOR" 5.16 FOR
2 REQ'D. 5246 ASSY. REF. 12 CONV. 7.3 & 12 CONV. VIEWV
25-35 FT-LB
20-25 FT-LB BRKT. EXHAUST 5C247 ASSY.
STATIC AUDIT TORQUE HANGER REF.

5E212 ASSY. REF.

CONVERTER ASSY.

VIEWU VIEWT
INLET PIPE GAGING
CROSSMEMBER REF.
I VIEWW I 5230 ASSY. REF.
381877-S2
4 REQ'D.
TIGHTEN SECURELY
5246 ASSY. REF.
108 IN-LB MAX.
SECTION A

387265-S2
2 REQ'D.
20-30 FT-LB
STATIC AUDIT TORQUE
20-36 FT-LB

THE TOLERANCE ON THESE DIMENSIONS ARE + .25 5246 ASSY. REF.

45358-S7 UNLESS OTHERWISE SHOWN.
5E258 ASSY. 2 REQ'D.
20-30 FT-LB * END OF STUD WITH SHORTEST THREAD LENGTH TO BE
SCREWED INTO MANIFOLD OR FLANGE.
55914-S2
6 REQ'D. TIGHTEN NUTS ALTERNATELY TO MAINTAIN TORQUE
90 IN-LB MAX. TORQUE AND DRAW FLANGE EVENLY. N4054-A

FIG. 3 Exhaust System Pinto/Bobcat—Sedan—2.3L Engine

26-03-1
V-6 Engine Exhaust System
SUBJECT
DESCRIPTION
REMOVAL AND INSTALLATION
Catalytic Converter
DESCRIPTION
The V-6 Pinto/Bobcat and Mustang
are equipped with a single exhaust
system. The factory installed system
consists of the welded "Y"-pipe (muffler
inlet pipe), one catalytic converter and
REMOVAL AND INSTALLATION
INLET PIPE—(FRONT)
Removal
1. Raise the vehicle.
2. Support the muffler assembly with a
soft wire.
3. Remove the screws that attach the
front hanger insulator to the inlet pipe
bracket.
4. Remove the bolts that attach the
converter inlet flange to the inlet pipe.
5. Remove the nuts attaching the mlet
pipe flange to the exhaust manifold
and remove the inlet pipe.
6. Replace any damaged parts.
Installation
1. Clean the exhaust manifold and
catalytic converter flange seats.
2. Position the inlet pipe to the manifold
and install but do not tighten the
attaching nuts.
3. Install the front hanger bracket
insulator to inlet pipe bracket. Do not
tighten the attaching screws.
4. Using a new gasket, position the inlet
pipe to the catalytic converter. Align
the upper and lower heat shield to the
converter inlet flange and loosely
start the attaching bolts.
5. Remove the wire support for the
muffler assembly.
6. Align the exhaust system to proper
clearance specifications and starting
at the front, tighten all nuts, screws,
and bolts to specification.
7. Check the exhaust system for leaks
and lower the vehicle.
V-6 Exhaust Systems
PAGE SUBJECT
03-1 REMOVAL AND INSTALLATION (Cont'd.)
Inlet Pipe
03-1 • Muffler and Resonator
either a muffler assembly or muffler and
resonator assembly used only on the
Mustang. The exhaust system is usually
serviced in separate pieces consisting
of an inlet pipe, catalytic converter,
MUFFLER AND RESONATOR
Removal
1. Raise the vehicle by means of the
frame lift points to allow the axle full
downward travel. This will provide
the clearance necessary to remove and
replace the muffler and pipe.
2. Catalytic converter equipped
vehicles—remove the rear converter
to muffler or resonator pipe flange
connection attaching nuts.
3. Remove the attaching screws from
the rear hanger assembly to muffler
support.
4. Slide the muffler assembly rearward
to disconnect it from the catalytic
converter.
5. Remove the attaching screws from
the intermediate support on the
muffler inlet pipe and remove the
muffler assembly.
6. Replace any damaged parts.
Installation
1. Position the muffler assembly over
the rear axle and loosely attach the
intermediate support bracket.
2. Catalytic converter vehicles—
position the muffler inlet pipe flange
to the converter flange. Install but do
not tighten the attaching nuts.
3. Position the muffler rear support
bracket and loosely install the
attaching screws.
4. Align the exhaust system to conform
to the proper clearance specifications
and, starting from the muffler inlet
26 03-1
PART
26-03
PAGE
03-1
CN4059-A
resonator and inlet pipe assembly (if
so equipped) and a muffler and tail-
pipe assembly. For exact service re-
placement parts information, refer to
the master parts catalog.
pipe connection, torque all n its and
screws to specifications.
5. Check the system for leaks and lower
the vehicle.
CATALYTIC CONVERTER
Removal
1. Raise the vehicle.
2. Remove the upper and lower heat
shields, if so equipped, attached to the
converter.
3. Remove the front and rear catalytic
converter flange fasteners.
4. Separate the catalytic convener inlet
and outlet flange connections
5. Remove the converter.
6. Replace any damaged parts.
Installation
1. Align the heat shield brackets to the
inner flanges on the converter and
position the catalytic converter to the
inlet pipe using a new gasket. Loosely
install the attaching bolts.
2. Install the muffler inlet flange to the
converter outlet flange. Loosely
install the attaching nuts.
3. Attach the heat shields to the
converter.
4. Align the exhaust system to
specification and starting at the front
of the system, tighten all nuts and
bolts to specification.
5. Check the system for leaks and lower
the vehicle.
 387265-S2
2 REQ'D.
20-30 FT-LB
STATIC AUDIT TORQUE
20-36 FT-LB REAR FLOOR
5F222 ASSY. .CROSSMEMBER
FUEL TANK REF.
/REF.
5C263 ASSY.
5A242 ASSY
40962-S2
4 REQ'D.
108IN-LBSMAX.

40962-S2
2 REQ'D.
108IN-LBSMAX.

381877-S2
2 REQ'D.
108 IN-LBSMAX.

• 387039-S7
4 REQ'D.
25-35 FT-LB
20-35 FT-LB
STATIC AUDIT TORQUE

5246 ASSY. REF.

/ I VIEW T
N-800064-S2 I
4 REQ'D.

* END OF STUD WITH SHORTEST THREAD LENGTH TO BE

SCREWED INTO MANIFOLD OR FLANGE.

TIGHTEN NUTS ALTERNATELY TO MAINTAIN TORQUE

AND DRAW FLANGE EVENLY. NO. 3 CROSSMEMBER SHOCK B R M
R.H. REF
5230 ASSY. REF.
FUEL TANK REF.
DIFFERENTIAL REF
SECTION B
I VIEWY 1
FIG. 1 Exhaust System—Pinto/Bobcat, Sedan—2.8L Engine
 EXHAUST MANIFOLD REF

* N-800064-S2 6210786 REF.

4 REQ'D.
MUST BE INSTALLED TO
SHOULDER OF STUD
MEMBER RR FLR.
SIDE REF.
387039-S7
381877-S2
4 REQ'D.
4 REQ'D.
25-35 FT-LB
TIGHTEN SECURELY
20-35 FT-LB
108 IN-LB MAX.
STATIC AUDIT
TORQUE

381877-S2
4 REQ'D.
TIGHTEN SECURELY
108 IN-LB MAX.

^-^1 \ \ -45358-S7*
| \ j \*387340-S2 2 REQ'D.
' X ^ \ 2 REQ'D. 20-30 FT-LB
5F224 ASSY.

* END OF STUD WITH SHORTEST THR EAD LENGTH TO BE 55914-S2

SCREWED INTO MANIFOLD OR FLANGE. 6 REQ'D.
Qfl IK|.I R MAV TOROIIF
TIGHTEN NUTS ALTERNATELY TO MAINTAIN TORQUE SECTION C C SECTION D D
AND DRAW FLANGE EVENLY.
N4057-A
FIG. 2 Exhaust System—Pinto/Bobcat, Station Wagon—2.8L Engine
 387265-S2
2REQD. 5C263 ASSY.
20-30 FT-LB

5246 ASSY. REF.

5A242 ASSY. 4O962-S2
4REQD.
106 IN.-LBS. MAX.

REAR ENG.
MOUNT REF.

NO. 3 CROSSMEMBER REF.

EXHAUST MANIFOLD
R/H REF.

387039-S7
4REQD.
25-35 FT. LB.
20-35 FT. LB.
STATIC AUDIT TORQUE
*N-800064-S2
4REQD.
MUST BE INSTALLED TO
SHOULDER OF STUD.

EXHAUST MANIFOLD
L/HREF.

DIMENSIONS SHOWN WITHOUT TOLERANCE ARE FOR

QUALITY AUDIT PURPOSE. THE TOLERANCE ON THESE
DIMENSIONS ARE t .25 UNLESS OTHERWISE SHOWN'
sje END OF STUD WITH SHORTEST THREAD LENGTH TO BE
SCREWED INTO MANIFOLD OR FLANGE.

• TIGHTEN NUTS ALTERNATELY TO MAINTAIN TORQUE

AND DRAW FLANGE EVENLY.

FIG. 3 Exhaust System—Mustang—2.8L Engine

26-10-1 6-Cylinder Engine Single Exhaust System
6-Cylinder Engine
Single Exhaust System
SUBJECT
DESCRIPTION
REMOVAL AND INSTALLATION
Resonator Inlet Pipes
DESCRIPTION
The Maverick, Comet, Granada and
Monarch with 6-cylinder engines have
basically the same type single muffler
exhaust system. (See Fig. 1.) These
systems have a resonator inlet pipe,
resonator, resonator outlet pipe and a
REMOVAL AND INSTALLATION
RESONATOR INLET PIPE (FRONT)
WITHOUT CATALYTIC
CONVERTER
Removal
1. Raise the vehicle.
2. Remove the "U" bolt clamp between
the inlet pipe and resonator pipe slip
joint connection.
3. Loosen the attaching screws at the
muffler rear hanger support.
4. Slide the resonator/muffler assembly
rearward to disengage the inlet pipe
slip joint connection.
5. Remove the inlet pipe to exhaust
manifold attaching nuts and remove
the inlet pipe from the vehicle.
Installation
1. Clean the exhaust manifold outlet
seat.
2. Insert the inlet pipe into the resonator
pipe and install but do not tighten the
"U" bolt clamp.
3. Position the inlet pipe to the exhaust
manifold and loosely install the
attaching nuts. Be sure the gasket is
properly seated in the exhaust
manifold.
4. Align the exhaust system to conform
to clearance specifications shown.
PAGE SUBJECT
.....10-1 REMOVAL AND INSTALLATION (Cont'd.)
Muffler and Resonator
10-1 Catalytic Converter
muffler. On some systems, a catalytic
converter is used between the resonator
inlet pipe and the resonator.
Service replacement parts for these
exhaust systems usually consist of more
pieces than do the factory-installed
5. Starting from the exhaust manifold,
tighten all screws, nuts or bolts to
specification.
6. Check the exhaust system for leaks
and lower the vehicle.
RESONATOR INLET PIPES
(FRONT) WITH CATALYTIC
CONVERTER
Removal
1. Raise the vehicle.
2. Support the resonator/muffler
assembly with a soft wire.
3. Remove the bolts that attach the
converter inletflangeto the inlet pipe.
4. Remove the bolts that attach the front
hanger bracket to the inlet pipe
bracket.
5. Remove the nuts attaching the inlet
pipe flange to the exhaust manifold
and remove the inlet pipe.
6. Replace any damaged parts.
Installation
1. Clean the exhaust manifold and
catalytic converter flange seats.
2. Position the inlet pipe to the exhaust
manifold and loosely install the
attaching nuts. Be sure the gasket is
properly seated in the exhaust
manifold.
26-10-1
PART
26-10
PAGE
10-1
10-2
CN4035-A
systems. Refer to the master parts catalog
for information on the available service
assemblies.
3. Install the front hanger bracket to
inlet pipe bracket. Do not tighten the
attaching bolts.
4. Using a new gasket, position :he inlet
pipe to the catalytic converter. Align
the upper and lower heat shield, (if so
equipped) to the converter inlet flange
and loosely start the attaching bolts.
5. Remove the wire support from the
resonator/muffler assembly.
6. Align the exhaust system to conform
to clearance specifications and
starting at the front, tighten all nuts,
screws, and bolts to specification.
7. Check the exhaust system for leaks
and lower the vehicle.
MUFFLER AND RESONATOR
Removal
1. Raise the vehicle by means of the
frame lift points to allow the axle full
downward travel. This will provide
the clearance necessary to remove and
replace the resonator and muffler
assembly.
2. Non-catalytic converter vehicles—
loosen and remove the inlet pupe "U"
bolt clamp.
3. Catalytic converter equipped
vehicles—remove the rear converter
26-10-2 6-Cylinder Engine Single Exhaust System
to resonator pipe flange connection
attaching nuts.
4. Remove the attaching screws from
the rear hanger assembly to muffler
support.
5. Slide the resonator and muffler
assembly rearward until the resonator
pipe is separated from the inlet pipe
or catalytic converter.
6. Remove the attaching screws from
the intermediate support bracket to
resonator and remove the resonator
and muffler assembly.
7. Replace any damaged parts.
Installation
1. Position the resonator and muffler
assembly over the rear axle and
loosely attach the intermediate
support bracket.
2. Non-catalytic converter vehicles—
assemble the resonator assembly to
the inlet pipe from the manifold and
loosely attach the retaining "U" bolt
clamp.
3. Catalytic converter vehicles—
position the resonator inlet pipe
flange to the converter flange. Install
but do not tighten the attaching nuts.
4. Position the muffler rear support
bracket and loosely install the
attaching screws.
5. Align the exhaust system to conform
to the proper clearance specifications
and, starting from the resonator inlet
pipe connection, torque all nuts and
screws to specifications.
6. Check the system for leaks and lower
the vehicle.
CATALYTIC CONVERTER
Removal
1. Raise the vehicle.
2. Loosen the intermediate and rear
exhaust system hanger bracket
attaching bolts.
3. Remove the upper and lower heat
shields, if so equipped, attached to the
converter.
26-10-2
4. Remove the front and rear catalytic
converter flange fasteners.
5. Slide the resonator/muffler assembly
rearward and separate the catalytic
converter inlet and outlet flange
connections.
6. Remove the converter.
Installation
1. Align the heat shield brackets to the
inner flanges on the converter and
position the catalytic converter to the
inlet pipe using a new gasket. Loosely
install the attaching bolts.
2. Install the resonator inletflangeto the
converter outlet flange. Loosely
install the attaching nuts.
3. Attach the heat shields to the
converter.
4. Align the exhaust system to
specification and starting at the front
of the system, tighten all nuts and
bolts to specification.
5. Check the system for leaks and lower
the vehicle.
 EXHAUST NO. 1 BODY CROSSMEMBER REF.
MANIFOLD REF

150 r J--N\l|-79MIN- 20
°
>
- 250 . ! \ VT' .66MIIM. 250

REAR SPRINGS REF 9453 - 200 ENG.

9451 - 250 ENG.
FUELTANK REF GASKET REAR ENG.
FROM SURFACE OF 1.64 MOUNT REF
VIEW R MANIFOLD FLANGE 1.56
• 387039-S7 5C257 ASSY. REF.
5D203 - INTERMEDIATE
MAVERICK/COMET 2 REQ'D VIEWR SUPPORT BRACKET
25-35 FT-LB
VIEWS
381877-S2
2 REQ'D.
1.20 - 200-1V TIGHTEN SECURELY
1.08 - 250-1V 8-14 FT-LB
5C257
5E276 MUFFLER &
RESONATOR ASSY.

5246 - INLET
PIPE ASSY.
TRANS. REF.

SECTION C

GRANADA/MONARCH ONLY

SAME AS VIEW W EXCEPT AS SHOWN

5 F 2 2 2 - UPPER
HEAT SHIELD
VIEwT|
5C257 ASSY. REF.

THIS LINE MUST 387159-S ASSY.

2535
BE HORIZONTAL FT-LB
TIGHTEN NUTS ALTERNATELY AND
EVENLY TO MAINTAIN TORQUE.
5E212-CATALYTIC
CONVERTER 45358-S7 •
VIEWX
2 REQ'D.
20-30 FT-LB
5A242 - FRONT
VIEWY
B C
VIEW R NON-CONVERTER SYSTEM
5F224 ASSY. SAME AS MAIN VIEW
GRANADA/MONARCH
BRACKET EXCEPT AS SHOWN 5 246 ASSY
5C247 - REAR
5E258 ASSY. 5C257 ASSY. REF. SUPPORT BRACKET
5C257 ASSY. REF. 5E276 ASSY. REF.
LOWER HEAT SHIELD
(IF SO EQUIPPED)
381877-S2 REAR SPRING
6 REQ'D.
108IN-LBMAX.
SIDEMEMBER REF.

* END OF STUD WITH SHORTEST THREAD LENGTH TO BE SCREWED REAR ENG. MOUNT REF
INTO MANIFOLD AND CONVERTER ASSY. 381877-S2
.85 MIN 4 REQ'D.
TIGHTEN NUTS ALTERNATELY TO MAINTAIN TORQUE AND DRAW 2 REQ'D.
8-14 FT-LB S 11 FT. LB.
FLANGE EVENLY.
TIGHTEN SECUKtLY TIGHTEN SECURELY
U1562-C

FIG. 1 Exhaust System—Maverick/Comet Shown—Granada/Maverick Similar

26-20-1
V-8 Single Exhaust System
SUBJECT
DESCRIPTION
REMOVAL AND INSTALLATION
DESCRIPTION
The basic single exhaust system used
with V-8 engines consists of a muffler and
a resonator and/or diffuser. This basic
system is subject to the addition of one
or two catalytic converters as indicated
in the exhaust systems application chart,
Section 26-01.
The factory-installed exhaust systems
differ from the service replacement
systems in the number of pieces used.
When making a service replacement,
REMOVAL AND INSTALLATION
The removal and installation
procedures given apply to all vehicle
models unless otherwise noted. Refer to
the appropriate system illustration when
servicing exhaust system.
RESONATOR "Y" PIPE (FRONT)
WITHOUT CATALYTIC
CONVERTER—MAVERICK,
COMET, GRANADA AND
MONARCH
Removal
1. Raise the vehicle.
2. Remove the "U" bolt clamp between
the inlet "Y" pipe and resonator pipe
slip joint connection, (see Fig. 2).
3. Loosen the attaching screws at the
muffler rear hanger support.
4. Slide the resonator/muffler assembly
rearward to disengage the "Y" pipe
slip joint connection.
5. Remove the attaching nuts securing
the resonator inlet "Y" pipe to the
exhaust manifolds and remove the
"Y" pipe from the vehicle.
V-8 Single Exhaust System
PAGE
20-1
20-1
refer to the master parts catalog for the
current assemblies.
Single exhaust systems are used with
Thunderbird, Continental Mark V and
Lincoln C o n t i n e n t a l vehicles.
Continental Mark V requires a dual
exhaust system with the R.P.O.3.001:1
rear axle assembly.
Detailed illustrations of the various
V-8 Single Exhaust Systems are found at
Installation
1. Clean the exhaust manifold outlet
seat.
2. Insert the inlet "Y" pipe into the
resonator pipe and install but do not
tighten the "U" bolt clamp.
3. Position the "Y" pipe to the exhaust
manifold and loosely install the
attaching nuts. Be sure the gasket is
properly seated in the exhaust
manifold.
4. Align the exhaust system to conform
to clearance specifications shown in
(Fig. 2).
5. Starting from the exhaust manifold,
tighten all screws, nuts or bolts to
specifications.
6. Check the exhaust system for leaks
and lower the vehicle.
RESONATOR INLET PIPE (FRONT)
WITH CATALYTIC CONVERTER
Removal
1. Raise the vehicle.
2. Support the resonator/muffler
assembly with a soft wire.
26-20-1
PART
26-20
CN4044-A
the rear of this Part. They are: Fig. 1. .
. Mustang; Fig. 2. . . Granada/Monarch
and Maverick/Comet; Fig. 3. . .
Thunderbird/LTD H/Cougar Sedans;
Fig. 4. . . L T D II/Cougar Station
Wagons and LTD II Ranchero; Fig. 5.
. . Ford/Mercury without catalytic
converter; Fig. 6. . . Ford/Mercury with
two catalytic converters; Fig. 7. . . Mark
V; Fig. 8. . . Lincoln Continental.
3. Remove the bolts that attach the
converter inlet flange to the "Y" pipe.
4. Remove the bolts that attach the front
hanger bracket to the inlet pipe
bracket.
5. Remove the nuts attaching the "Y"
pipe flange to the exhaust manifold
and remove the inlet pipe.
6. Replace any damaged parts.
Installation
1. Clean the exhaust manifold and
catalytic converter flange seats.
2. Position the inlet "Y" pipe tp the
exhaust manifold and loosely install
the attaching nuts. Be sure the gasket
is properly seated in the exhaust
manifold.
3. Install the front hanger bracket to
inlet pipe bracket. Do not tighten the
attachment bolts.
4. Using a new gasket, position the inlet
pipe to the catalytic converter. Align
the upper and lower heat shield (if so
equipped) to the converter inlet flange
and loosely start the attaching bolts.
26-20-2
5. Remove the wire support from the
resonator/muffler assembly.
6. Align the exhaust system to conform
to clearance specifications shown in
Fig. 2 and starting at the front,
tighten all nuts, screws, and bolts to
specification.
7. Check the exhaust system for leaks
and lower the vehicle.
RESONATOR INLET P I P E -
MUSTANG
Removal
1. Raise the vehicle.
2. Support the resonator/muffler
assembly with a soft wire. (See Fig. 1.)
3. Remove the bolts that attach the
converter inlet flange to the inlet pipe.
4. Remove the bolts that attach the front
hanger bracket to the inlet pipe
bracket.
5. Remove the nuts attaching the inlet
pipe flange to the exhaust manifold
and remove the inlet pipe.
6. Replace any damaged parts.
Installation
1. Clean the exhaust manifold and
catalytic converter flange seats.
2. Position the inlet pipe to the exhaust
manifold and loosely install the
attaching nuts. Be sure the gasket is
properly seated in the exhaust
manifold.
3. Install the front hanger bracket to
inlet pipe bracket. Do not tighten the
attachment bolts.
4. Using a new gasket, position the inlet
pipe to the catalytic converter. Align
the upper and lower heat shield (if so
equipped) to the converter inlet flange
and loosely start the attaching bolts.
5. Remove the wire support from the
resonator/mufTler assembly.
6. Align the exhaust system to conform
to clearance specifications shown in
Fig. 1 and starting at the front,
tighten all nuts, screws, and bolts to
specification.
7. Check the exhaust system for leaks
and lower the vehicle.
MUFFLER INLET "Y" PIPE SINGLE
EXHAUST—LTD II, COUGAR,
THUNDERBIRD, FORD, MERCURY,
LINCOLN AND MARK V
Removal
1. Raise the vehicle.
2. Units equipped with exhaust shields
—Remove the screws and clamps that
secure the shields to the right hand
and left hand catalytic converter
assemblies and remove shields.
3. Support the muffler in car position
with a soft wire.
4. Remove the "U" bolt clamp at the
muffler inlet connection and discard.
V-8 Single Exhaust System
5. Units without catalytic converters
— Remove and discard the nuts
attaching the inlet "Y" pipe to the
right hand and left hand manifolds.
Disengage the inlet "Y" pipe from
the manifolds.
6. Units with catalytic converters
—Remove and discard the bolts
attaching the inlet "Y" pipe flat
flanges to the converter flat flanges.
7. Units with shields
—Remove the brackets used to attach
the flat flanges and shields.
8. Units without shields
—Remove and discard the flag nut
assemblies.
Disengage the inlet "Y" pipe from
the catalytic converter and discard
gaskets (both sides).
9. Separate the inlet "Y" pipe from the
muffler slip joint connection. If it is
necessary to obtain clearance to
separate the inlet pipe joints, remove
the rear hanger to outlet pipe
attachments.
Installation
1. Units without catalytic converters
— Clean manifold spherical gasket
faces.
2. Units with catalytic converters
— Clean converter flat flange faces.
Loosen manifold nuts, right hand
and left hand, enough to allow
converter movement without binding.
3. Slide a new "U" bolt clamp over the
outlet end of the inlet "Y" pipe.
4. Insert the inlet pipe into the muffler
slip joint and loosely secure the "U"
bolt clamp. The inlet pipe tab must
fully engage the muffler alignment
slot.
5. Units without catalytic converters
—Position the inlet pipe to the
manifolds and loosely install new
attaching nuts.
6. Units with catalytic converters
—Install new gaskets between the
inlet "Y" pipeflatflangeand the right
hand and left hand catalytic
converters and position the converter
to the "Y" pipe.
Install new bolts at each of the right
hand and left hand catalytic
converter/inlet pipeflatflangejoints.
7. On units without shields
—Install a new flag nut to each bolt
and alternately torque the bolts to
specification.
8. On units with shields
—Install a bracket assembly (shield
and flange attaching) to the forward
side of the left hand and right hand
catalytic converterflatflange.Engage
the bolts and alternately torque to
specification.
9. Align the system to specification, see
Figs. 3, 4, 5, 6, 7 and 8.
26-20-2
10. With the system held to alignment
specification:
Assure that the inlet pipe tab is
fully engaged into the muffler
alignment slot and alternately torque
the "U" bolt nuts to specification.
Alternately torque the right hand
and left hand manifold nuts to
specification.
Tighten the rear hanger to outlet
pipe attachments to specification, if
required.
NOTE: Alternate torque of joint
fasteners is required to provide
uniform clamping in order to prevent
joint distortion, a major cause of
leaks and system misalignment.
11. Remove alignment restraints and soft
wire muffler supports.
12. Check the exhaust system or leaks
and proper alignment.
13. On applicable models, install catalytic
converter exhaust shields, left hand
and right hand, to specification.
14. Lower the vehicle.
MUFFLER AND RESONATOR-
MAVERICK, COMET, GRANADA,
MONARCH
Removal
1. Raise the vehicle on a hoist that
permits the axle to lower to the full
extent of its travel. This will provide
the clearance necessary to replace the
muffler and resonator.
2. Without catalytic converter—loosen
the "Y" pipe "U" bolt clamp at the
connection with resonator pipe.
3. With catalytic converter—remove the
rear converter flange attaching nuts.
4. Remove the attaching screws from
the rear hanger assembly to muffler
support.
5. Slide the resonator and muffler
assembly rearward to disconnect it
from the inlet pipe or the catalytic
converter flange.
6. Remove the attaching screws from
the intermediate support to resonator
assembly and remove resonator,
connecting pipe and muffler
7. Replace damaged parts.
Installation
1. Position the resonator and muffler
assembly to the inlet "Y" pipe or
converter flange connection. The
converter seat must be cleaned prior
to attaching the resonator pipe.
Loosely install a new "U" bolt clamp
or flange attaching nuts.
2. Position the resonator in the
intermediate hanger bracket and
loosely install the attaching screws.
3. Position the muffler to the rear
hanger bracket and loosely install the
screws.
4. Align the exhaust system to conform
to the clearance specifications.
26-20-3
5. Starting from the inlet "Y" pipe
outlet end, torque all nuts and bolts
to specifications.
6. Check the system for leaks.
7. Lower the vehicle.
MUFFLER AND RESONATOR
ASSEMBLY—MUSTANG
Removal
1. Raise the vehicle by means of the
frame lift points to allow the axle full
downward travel. This will provide
the clearance necessary to remove and
replace the muffler, resonator and
pipe.
2. Remove the rear converter to
resonator pipe flange and U-bolt
connection attaching nuts (Fig. 1).
3. Remove the attaching screws from
the rear hanger assembly to muffler
support.
4. Slide the muffler and resonator
assembly rearward to disconnect it
from the catalytic converter pipe.
5. Remove the attaching screws from
the intermediate support on the
muffler inlet pipe and remove the
resonator/muffler assembly.
6. Replace any damaged parts.
Installation
1. Clean the catalytic converter flange
seat.
2. Position the resonator and muffler
assembly over the rear axle and
loosely attach the intermediate
support bracket.
3. Position the muffler rear support
bracket and loosely install the
attaching screws.
4. Position the resonator pipe and flange
to the converter flange and slip joint.
Install but do not tighten the
attaching nuts.
5. Align the exhaust system to conform
to the proper clearance specifications
and, starting from the resonator pipe
connection, torque all nuts and
screws to specifications.
6. Check the system for leaks and lower
the vehicle.
MUFFLER ASSEMBLY—LTD II,
THUNDERBIRD, COUGAR, FORD,
MERCURY, LINCOLN AND MARK
V converter.
Removal
1. Raise the vehicle on a hoist that
permits the rear axle to lower to the
full extent of its travel. This will
provide the clearance necessary to
remove the muffler assembly.
2. Support the muffler inlet pipe with a
soft wire and remove the "U" bolt
clamp at the inlet pipe to muffler inlet
connection.
3. Remove the rear support bracket to
muffler assembly attachment screws.
For LTD II, Thunderbird, and
V-8 Single Exhaust System
Cougar sedans, remove the rear
prestole attaching clamp screw.
4. Remove the screws securing the
intermediate support bracket to the
muffler.
5. Separate the muffler to inlet pipe
connection and remove the muffler
assembly.
Installation
1. Slide a new "U" bolt clamp over the
outlet end of the inlet pipe.
2. Position the muffler assembly on the
inlet pipe and loosely install the
clamp. Be sure that the tab is fully
inserted into the locating slot and
muffler.
3. Position the muffler to the
intermediate support bracket. Install
the attaching screws to specification.
4. Attach the screws holding the rear
support bracket and tighten to
s p e c i f i c a t i o n . For LTD I I ,
Thunderbird, and Cougar sedans,
loosely install the prestole clamp.
5. Align the exhaust system to conform
to the clearance specifications.
NOTE: If specified alignment
specifications cannot be obtained, the
right hand and left hand manifold
attachments should be loosened.
After specifications are obtained,
tighten the manifold attaching nuts to
specification while holding
clearances.
6. Position and alternately torque the
"U" bolt clamp nuts at the inlet pipe
to muffler connection to specification.
Be sure the tab and slot are properly
engaged.
7. For LTD II, Thunderbird and
Cougar, properly position the rear
hanger and secure the prestole clamp
screw to specification.
8. Remove the temporary wire supports,
check the system for leaks, and lower
the vehicle.
CATALYTIC CONVERTER-
MUSTANG/GRANADA/
MONARCH/MAVERICK/COMET
Removal
1. Raise the vehicle.
2. Remove the upper and lower heat
shields, if so equipped, attached to the
3. Remove the front and rear catalytic
converter flange fasteners.
4. Separate the catalytic converter inlet
and outlet flange connections.
5. Remove the converter.
6. Replace any damaged parts.
Installation
1. Align the heat shield brackets to the
inner flanges on the converter (Figs.
1 and 2) and position the catalytic
converter to the inlet pipe using a new
gasket. Loosely install the attaching
bolts.
26-20-3
2. Install the muffler inlet flange to the
converter outlet flange. Loosely
install the attaching nuts.
3. Attach the heat shields to the
converter.
4. Align the exhaust system to
specification and starting at the front
of the system, tighten all nuts and
bolts to specification.
5. Check the system for leaks and lower
the vehicle.
CATALYTIC CONVERTER—LTD II,
THUNDERBIRD, COUGAR, FORD,
MERCURY, MARK V AND
LINCOLN CONTINENTAL
Removal
1. Raise the vehicle.
2. Remove the exhaust shield(s), if so
equipped, from the catalytic
converter(s). (See Figs. 3-8.)
3. Support the exhaust inlet pipe in its
relative position by securing the pipe
to the No. 3 frame crossmember with
soft wire.
4. Remove and discard bolts attaching
the converter and inlet "Y" pipe flat
flanges (both sides).
Units with shields, remove the
brackets that attach the shields and
flatflanges(both sides).
Units without shields, remove and
discard flag nut assemblies (both
sides).
5. Remove the converter flange
attaching nuts holding the converters
to the exhaust manifold and inlet pipe
(both sides).
6. Slide the inlet pipe rearward until the
catalytic converter(s) can be removed.
It may be necessary to disconnect the
rear hanger-to-outlet pipe attachment
to obtain sufficient clearance to
separate the converter at manifold
connection(s).
7. Discard gasket(s) and damaged parts.
Installation
1. Clean the inlet "Y" pipe flange face.
2. Position the catalytic converter(s) to
the exhaust manifold. Loosely install
the attaching nuts.
3. Install new gaskets between the inlet
**Y" pipe/converter flat flanges.
Position the inlet pipe flange to the
converter outlet flange connections
and insert new attaching bolts. On
units without shields, loosely install
flag nuts to the bolts, and on units
with shields, position attaching
brackets forward of the converter flat
flange and loosely engage the bolts.
4. Alternately tighten the converter to
inlet pipe flange connection(s) to
specification.
5. Align the system to proper clearance
specifications.
6. Alternately tighten the manifold nuts
to specification.
26-20-4
7. Check the system for leaks.
NOTE: Alternate torque of joint
fastener is required to provide
uniform clamping in order to prevent
joint distortion, a major cause of
system leaks and misalignment.
V-8 Single Exhaust System 26-20-4
Install the exhaust shield(s) to the
catalytic converter(s) to specification.
See Figs. 3-8.
9. Lower the vehicle.
 EXHAUST MANIFOLD REF
MEMBER RR FLR. SIDE REF.

381877-S2
4REO/D.
TIGHTEN SECURELY
108 IN-LB MAX.

FROM SURFACE OF 1.64

MANIFOLD FLANGE 1.56 5C263-
INTERMEDIATE
SUPPORT
BRACKET

381877-S2
4REO/D.
TIGHTEN SECURELY
108 IN-LB MAX.

SECTION A

• END OF STUD WITH SHORTEST THREAD LENTGH TO BE

SCREWED INTO MANIFOLD AND CONVERTER ASSY.

TIGHTEN NUTS ALTERNATELY TO MAINTAIN TORQUE AND DRAW

FLANGE EVENLY TO EXHAUST MANIFOLD AND CONVERTER ASSY
U1580-B

FIG. 1 Exhaust System—Mustang With 302 V-8 (No Catalytic Converter)

NO. 1 BODY CROSSMEMBER REF EXHAUST
MANIFOLD REF
GASKET-9451
2REQ'D.
J5C257REF.

REAR ENG.
INLET PIPE EXTENSION
MOUNT REF BODY CROSSMEMBER REF 1.64 FROM SURFACE OF
SECTION A - 5D294
1.56 MANIFOLD FLANGE 5246 ASSY. REF. L.H
1.15 MIN.
FROM SURFACE 3.03 SECTION B REAR ENG. MOUNT REF.
2.95 5C247 - REAR SUPPORT BRACKET
EXHAUST
MANIFOLD REF 5C257 ASSY. REF

BODY PINION BUMPER

BRKT. REF.
5E281 - GASKET 40967-S2 SIDEMEMBER REF
2 REQ'D.
HEAT VALVE REF. 10-20 FT-LB 381877-S2
REAR SPRINGS
4 REQ'D. FUELTANK REF. REF.
8-14 FT-LB
TIGHTEN SECURELY VIEWR

381877-S2
2 REQ'D.
TIGHTEN SECURELY
5C257 ASSY. REF
8-14 FT-LB
SD203 - INTERMEDIATE MUFFLER &
RESONATOR
VIEWT ASSY.- 5C257
SAME AS VIEW W EXCEPT AS SHOWN
5246 ASSY. R E F . ^ I VIEW X . 5 E276ASSY. REF
5C25 ASSY. REF.

387159-S ASSY.
TIGHTEN NUTS ALTERNATELY (CANADA 302 GRANADA/MONARCH ONLY, L.H.)
THIS LINE MUST AND EVENLY TO MAINTAIN TORQUE
5 F 2 2 2 - UPPER VIEW Z
BE HORIZONTAL 387265-S2 • HEAT SHIELD
2 REQ'D.
20-30 FT-LB

387340-S2 *
2 REQ'D.
MUST BE INSTALLED TO
SHOULDER OF STUD
5A242 ASSY. REF.

CATALYTIC 5A242 - FRONT HANGER

CONVERTER

* END OF STUD WITH SHORTEST THREAD LENGTH TO

BE SCREWED INTO MANIFOLD AND CONVERTER ASSY.

• TIGHTEN NUTS ALTERNATELY TO MAINTAIN TORQUE AND 5F224 -

DRAW FLANGE EVENLY TO EXHAUST MANIFOLD AND BRACKET 45358-S7G NON-CONVERTER SYSTEM
CONVERTER ASSY. 2 REQ'D. SAME AS MAIN VIEW
' 20-30 FT-LB EXCEPT AS SHOWN

386547-S2
5 E 2 5 8 - LOWER HEAT 55914-S2 2 REQ'D
b Mtuu. 8-14 FT-LB
90 IN-LB MAX REAR ENG. MOUNT REF. TIGHTEN SECURELY |U1563-C

FIG. 2 Exhaust System—Granada/Monarch/Maverick/Comet

 HOOK MUST BE INSERTED
FROM SURFACE OF IN SLOT ON - 5C264
MANIFOLD FLANGE
USE EXISTING FEA
3.03 WITH SPACER BUMPER BOLT
2.96 REAR SUPPORT BRACKET
-5A246ASSY.
1.64 WITHOUT SPACER
1.56 5230 OR 5E209
ASSY. REF.

SPACER REF.
USED ON L.H. SIDE FOR 302-2V TAB MUST BE INSTALLED
USED ON R.H. SIDE FOR 351-2V INSIDE OF FRAME.
& ALL400ENGS.
387265-S2
4 REQ'D. 5E259 ASSY. L.H.
5246 ASSY. REF. 20-30 FT-LB 5E258 ASSY. R.H.
LOWER HEAT SHIELD
55915-S2 55915-S2
2 REQ'D. 4 REQ'D
376699-S2 48 IN-LB MAX. TORQUE 90 IN-LB MAX. TORQUE
2 REQ'D. ON SIDE 5A246 ASSY. REF.
FOR CATALYTIC CONVERTER
OPPOSITE SPACER 387040-S7 TYPICAL HEAT SHIELD INSTALLATION
ONLY TYPICAL BOTH SIDES
4 REQ'D. (IF SO EQUIPPED) * FRAME REF.
385382-S2
25-35 FT-LB 5230 FOR 302-2V, 351-2V
2 REQ'D. ON
SPACER SIDE & 400-2V
5E209 FOR 400-4V
MUFFLER ASSY.

NO. 3 BODY MOUNT HOLE

NO. 4 CROSSMEMBER REF.

40900-S2
-"=G£r 2 REQ'D.
15-25 FT-LB
5D255 ASSY.
INTERMEDIATE
SUPPORT BRACKET
CLAMP MUST BE PARALLEL
5230 OR 5E209 TO GROUND LINE WITHIN 10°
ASSY. REF.
LOCATE CLAMP FROM END OF .74 SECT. E
MUFFLER ASSY. AS SHOWN .99

A PLANE PASSING THRU THE C OF THE FUEL TANK REF.

SCREWS MUST BE HORIZONTAL WITHIN ± .12 TRANS. OIL PAN REF.
FRAME REF.
.72 FRT. FLANGE REAR FACE OF BLOCK PITMAN ARM

0
SECT. C ALL ENGS. 2.00 R

Q SECT. A
.53

MAX. STRG. GEAR TRAVEL

5230 OR 5E209
ASSY. REF.

@REAR FLANGE LESS SHIELD

OF NO. 3 CROSSMEMBER SECT. D SECT. B U1583-B

FIG. 3 Exhaust System - LTD Il/Thunderbird/Cougar Sedan

 5F226L.H. to
5F223 R.H.
TAB MUST BE
3.03 FROM SURFACE OF
2.95 MANIFOLD FLANGE SPACER SIDE
UPPER HEAT
SHIE
RTEDIN SLOT
BRACKET- REAR SUPPORT BRKT.
T
64 FROM SURFACE OF
56 MANIFOLD FLANGE SIDES WITHOUT 5F227 ASSY. L.H. ' - 5A246
SPACER 5F224 ASSY. R.H. STATION WAGON
HOOK MUST BE INSERTED NO. 4CROSSMEMBER REF.
SPACER REF. IN SLOT ON - 5C264 230 - R E F .
R.H. SIDE ONLY 351 & 400 5299 - PLATE
SIDE OPPOSITE SPACER 40980-S2
• 385382-S2 2 REQ'D.
15-25 FT-LB
INTERMEDIATE
387265-S2 SUPPORT BRKT
4 REQ'D. - 5D255
20-30 FT-LB | FLANGE
MUST FACE
FORWARD

EXHAUST PLANE PASSING THRU THE C_ OF THE

5E259 ASSY. L.H
MANIFOLD REF SCREWS MUST BE HORIZONTAL WITHIN ± .
5E258ASSY. R.H.
55915-S2 LOWER HEAT
4 REQ'D. SHIELD
FOR CATALYTIC LONG CLAMP -
15-S2 90 IN-LB MAX.TORQUE
CONVERTER ONLY 5C264
• 387040-S7. TYPICAL BOTH SIDES 2 REQ'D. MUFFLER
4 REQ'D. 48 IN-LB MAX TORQUE ASSY. - 5230 5A246 ASSY. REF. CO
25-35 FT-LB
20-30 FT-LB
4 . 7 2 - 3 0 2 ENG. TYPICAL HEAT
INSTALLATION
SHIELD RANCHERO
(SAME AS STATION WAGON
en
4 . 6 0 - 351/400 ENGS.
STATIC AUDIT TORQUE IF SO EQUIPPED EXCEPT AS SHOWN)
FRAME REINFORCEMENT

X
INBOARD OF Q
REINF. FAC TORQUE 25-35 FT-LB

14-351/400 ENGS.
CHECK AT 5.34
.02-302 ENG FORWARD OF LOWER
BOLT OF BRKT. &
INS. ASSY. 5A246
C6 TRANS. OIL PAN REF

CLAMP MUST
BE PARALLEL
TO GROUND SECTION E
LINE
FRAME OUTER , 246 WITHIN 10°
C6 TRANS. OIL PAN REF ASSY. REF
MEMBER R.H. 3.12
SECTION F SECTION C
GAGE DIM.
REAR FACE OF BLOCK
CHECK AT 8.58 LOCATE CLAMP FROM END OF
FORWARD OF FACE MUFFLER ASSY. AS SHOWN
OF BRKT. & INS. MUFFLER ASSY.
ASSY. 5A246 REF.

.72 TO FRONT
FLANGE

NO. 3CROSSMEMBER 5E214ASSY. REF. MAX. STRG. GEAR TRAVEL

SECTION A SECTION B
* END OF STUD WITH SHORTEST THREAD LENGTH
TO BE SCREWED INTO MANIFOLD.
SECTION D FRAME REF.
* TIHHTFIM Ml ITS A| TFRNATFI V AMn P\/PM| REAR FLANGE
TO MAINTAIN TORQUE. OF NO. 3 CROSSMEMBER
U1587-B

FIG. 4 Exhaust System—LTD II and Cougar (Station Wagon) and LTD II Ranchero
 5A246 - REAR
DIMS. AT TOP OF PIPE SUPPORT BRACKET

40954
2 REQ'D.
TIGHTEN SECURELY
387040-S2 15-25 FT-LB
2 REQ'D.
\^y / i - * • v 25-35 FT-LB
3.03 FROM SURFACE OF
2.95 MANIFOLD FLANGE
TIGHTEN MANIFOLD NUTS ALTERNATELY WITH THE SECTION A
LOWER MANIFOLD NUTS TIGHTENED TO TORQUE NO. 3 CROSSMEMBER REAR FLANGE
SPECIFICATIONS PRIOR TO TIGHTENING THE UPPER
NUTS TO TORQUE SPECIFICATIONS. OUTLET PIPE
REF.
40975
VIEW OF R.H. MANIFOLD CONNECTION 2 REQ'D.
400 ONLY TIGHTEN SECURELY
12-20 FT-LB
376699-S2 5E209 FOR 460-4V
2 REQ'D. FOR 400 5230 FOR 400-2V
4 REQ'D. FOR 460 MUFFLER ASSY.

387040-S7
2 REQ'D. FOR 400
4 REQ'D. FOR 460 NOTE: LOCATE CLAMP FROM
25-35 FT-LB END OF PIPE AS SHOWN

1.64 FROM SURFACE OF

1.56 MANIFOLD FLANGE
TORQUE TO SPECIFICATION WHILE
HOLDING THE SPECIFIED CLEARANCE
TO THE NO. 3 CROSSMEMBER (L.H. & R.H.)
SPRING POCKET
VIEW OF MANIFOLD CONNECTION
400 L.H. ONLY 2267 ASSY. REF.
460 L.H. AND R.H. BRAKE TUBE

387159-S ASSY.
25-35 FT-LB
U-BOLT SADDLE MAY BE
ROTATED THRU 180° FROM
POSITION SHOWN.

OUTLET PIPE
5230 OR 5E209 2 REQ'D.
ASSY. REF. TIGHTEN SECURELY
NO. 4 CROSSMEMBER REF 15-25 FT-LB
381877-S2 STRIPE OF ORANGE PAINT
2 REQ'D. FOR IDENTIFICATION
TIGHTEN SECURELY
5D255ASSY. 12-20 FT-LB
HUB OF
PITMAN ARM SECTION C INTERMEDIATE
FRAME REF. SUPPORT
OUTLET PIPE REF.

381877
2 REQ'D.
TRANS. CONVERTER TIGHTEN SECURELY OUTLET PIPE REF.
.58 CLEARANCE 12-20 FT-LB 5A246 - REAR
HSG. C-6
SECTION D 40980-S2 SUPPORT BRACKET
SECTION B
WHEN ASSEMBLED .96 CLEARANCE BETWEEN 2 REQ'D.
# END OF STUD WITH THE SHORTEST THREAD MUFFLER REAR SUPPORT AND REAR SUSPENSION TIGHTEN SECURELY
LENGTH TO BE SCREWED INTO MANIFOLD. UPPER ARM MOUNTING BRACKET. 15-25 FT-LB U1584-B

FIG. 5 Exhaust System—Ford/Mercury Sedan and Station Wagon—With no Catalytic Converters

 DIMS. AT TOP OF PIPE
FRAME REF.
.75

L.H. R.H.
3.30 L 40954-S2
I I 74 SECTION A
*» .-«-.99 NO. 3 CROSSMEMBER REAR FLANGE 2 REQ'D.
TIGHTEN SECURELY
NOTE: LOCATE CLAMP FROM 3.03 FROM SURFACE OF FRT. FLR. PAN 15-25 FT-LB
END OF PIPE AS SHOWN 2.95 MANIFOLD FLANGE 25 FT-LB
1.64 FROM SURFACE OF
1.56 MANIFOLD FLANGE
5230 ASSY. REF.
VIEW OF R.H. MANIFOLD CONNECTION 5E209 ASSY. REF.
5E212R.H.
5E214 L.H. SECTION C
CATALYTIC CONVERTER HUB OF PITMAN
RM
5246 ASSY. REF.
75 T 0 P ) T M A N ARM
OUTLET PIPE
EXHAUST 387265-S2 •
MANIFOLD REF 4 REQ'D. 5E214 ASSY.
20-30 FT-LB REF. 40975-S2
• 376899-S2 2 REQ'D.
2 REQ'D. FOR 400 TIGHTEN SECURELY
4 REQ'D. FOR 460 VIEW OF CONVERTER CONNECTION FOR HSG. C-6 12-20 FT-LB
387040-S7 ALL CONVERTERS
SECTION B
2 REQ'D. FOR 400 20-35 FT-LB TORQUE
4 REQ'D. FOR 460 5E209 FOR 400-4V & 460-4V
5230 FOR 400-2V
25 35 FT LB ^ ^ ^ MAN|FOLD CONNECT|ON
MUFFLER ASSY.
400 L.H. ONLY
460 L.H. & R.H. 5 2 4 6 - INLET PIPE
TORQUE TO SPECIFICATION WHILE HOLDING THE A Y^A
SPECIFIED CLEARANCE TO NO. 3 CROSSMEMBER,
(L.H. & R.H.) 381877-S2 K
Jf
/ l REQ'D.
TIGHTEN SECURELY
fg
Y 12-20 FT-LB

387159-S ASSY.
i 25-35 FT-LB
TIGHTEN U-BOLT WITH CHASSIS FRAME IN
UPRIGHT POSITION. U-BOLT SADDLE MAY BE OUTLET PIPE REF.
ROTATED THRU 180° FROM POSITION SHOWN
HOOK OF - 5C264 MUST BE INSERTED IN
5C264 SLOT O N - 5 E 2 5 9 - L . H . & 5 E 2 5 8 - R . H . ASSY. 5299 ASSY. REF.
REAR SUPPORT BRKT
NO. 4 CROSSMEMBER REF.
4D980 40980-S2
2 REQ'D. 5E226 - L.H. ONLY
OUTLET PIPE REF. 2 REQ'D.
TIGHTEN SECURELY TIGHTEN SECURELY
15-25 FT-LB —"I 5E212 ASSY. R.H. PART OF 5E259
&5E258ASSY. 15-25 FT-LB FRAME ASSY
5E214 ASSY. L.H. '
STATIC AUDIT (REF.) "
CATALYTIC CONVERTERNr £ f .-
1.00 5-25 FT-LB
5D255 -
UA INTERMEDIATE SUPPORT

SECTION D
WHEN ASSEMBLED, .96 CLEARANCE
BETWEEN MUFFLER REAR SUPPORT • END OF STUD WITH SHORTEST THREAD
5246 REF.
Af\iD REAR SUSPEF-iSiGN UPPER AR"" 3T!s T Q RP ^ r R r w r r s jrjTn MAWirni n
5E258 ASSY.-R.H | MOUNTING BRACKET. • TIGHTEN BOLTS EVENLY AND ALTERNATELY
VIEW FOR CONVERTER CONNECTION
TO MAINTAIN TORQUE.
(IF SO EQUIPPED) U1585-B

FIG. 6 Exhaust System - Ford/Mercury Sedan and Station Wagon - With Two Catalytic Converters
 5E212 R.H. NO. 4 CROSSMEMBER REF.
5E214L.H.
FRAME

I
/ CATALYTIC
/ CONVERTER REF.

MANIFOLD FLANGE 5D255 -

460 L.H. & R.H. /,' \ 5B266 - GASKET INTERMEDIATE
400 L.H. ONLY SUPPORT BRACKET

P HEAT VALVE REF.

* I! 400 R.H. ONLY

EXHAUST
MANIFOLD REF.
¥385382-S2
2 REQ'D.
400 ENG. R.H.
CONVERTER
ASSY. REF. MUFFLER & RESONATOR ASSY.
*376699-S2
A PLANE PASSING THRU THE (£ OF THE 5C258 - 460 ENG.
4 REQ'D. 460 ENG. • 387265-S2
SCREWS MUST BE HORIZONTAL WITHIN ± .12 5E276 - 400 ENG.
2 REQ'D. 400 ENG. L.H 4 REQ'D.
20-30 FT-LB VIEWV VIEW Z & VIEW S
• 387040-S7
4 REQ'D. TYPICAL CONVERTER CONNECTION 5D204 ASSY
20-35 FT-LB

VERTICAL (^
MUFFLER ASSY 381877-S2
REF. 2 REQ'D.
TIGHTEN SECURELY
5 2 4 6 - INLET PIPE
12-20 FT-LB

5256-REAR
LOCATE CLAMP FROM END OF SUPPORT BRKT. X
PIPE AS SHOWN

CLAMP MUST BE PARALLEL

40980
2 REQ'D.
TIGHTEN SECURELY
15-25 FT-LB
I"
TO GROUND LINE WITHIN 10°
CO

HOOK OF - 5C264 MUST BE INSERTED IN

SLOTON-5E258L.H.& SPRING POCKET
REF.
VIEWS
5F226 L.H. ONLY
PART OF 5E259 ,75 FOR 49 STATES FOR 400 ENG. ONLY
UPPER HEAT SHIELD &5E258ASSY. .83 FOR CALIF.
.44 FOR 49 STATES
I .34 FOR CALIF. <7=jR SECTION C
5E212 ASSY. R.H. R E F
5E214 ASSY. L.H.
I P 2 TRANS. OIL * END OF STUD WITH SHORTEST THREAD LENGTH
5B266 - GASKET TO BE SCREWED INTO MANIFOLD.
2 REQ'D.
MAX. STRG. GEAR * TIGHTEN NUTS ALTERANTELY TO MAINTAIN TORQUE AND
.50 FOR 49 STATES
TRAVEL .72 FOR CALIF. TO DRAW FLANGE EVENLY.
95 SECTION B
I TIGHTEN BOLTS ALTERNATELY TO MAINTAIN
TORQUE AND TO DRAW FLANGE EVENLY.

SECTION D
AT REAR FLANGE

5E259 ASSY. L.H.
5E258 ASSY. R.H.
I
TYPICAL HEAT SHIELD INSTALLATION
(IF SO EQUIPPED) *"•—
NO. 3 CROSSMEMBER REF.
Ml
DIMS. TAKEN AT TOP OF PIPE
LOWER HEAT SHIELD U1566-B

FIG. 7 Exhaust System—Continental Mark V

 HOOK OF - 5C264 MUST BE INSERTED IN 387160-S ASSY. 5299 PLATE
5E212 ASSY. R.H. R F ( - 5C264 - CLAMP, SLOT ON - 5E258 - R.H. & 5E259 - L.H. ASSY. TORQUE 25-35 FT-LB TIGHTEN " U " BOLT
5E214 ASSY. L.H. WHILE HOLDING THE SPECIFIED CLEARANCE
CATALYTIC CONVERTER 5F266 - L.H. ONLY UPPER HEAT SHIELD OF MUFFLER ASSY. TO DRIVE SHAFT.
PART OF 5E259
& 5E258 ASSY.
5246 ASSY. REF
BRACKET
5F224 ASSY. R.H.
5F227 ASSY. L.H.
58266 GASKET
2 REQ'D
58266 GASKET
2 REQ'D.

5C257 ASSY. REF

5246 REF. 5E276 ASSY. REF
VIEWW 5C257 ASSY. REF.
LOCATE CLAMP FROM END OF PIPE AS SHOWN 5E276 ASSY. REF.
5E259 ASSY. L.H LOWER HEAT SHIELD
5E212 ASSY. R.H. REF. 5E258ASSY. R.H
5E214 ASSY. L.H. REF. VIEWT VIEWU

VIEW OF CONVERTER CONNECTION FOR

ALL CONVERTERS
FLOOR PAN REF

SEAT BELT REINF. REF.

DRIVE SHAFT REF
1.64 FROM SURFACE OF
1.56 MANIFOLD FLANGE MUFFLER & RESONATOR ASSY
5C257 ASSY. - 400 ENG.
460 L.H. & R.H. 5E276 ASSY. - 460 ENG.
400 L.H. ONLY

HEAT VALVE REF. 5 2 4 6 - INLET PIPE

400 R.H. ONLY

2 REQ'D.
5E212 ASSY. R.H. REF. 8-14 FT-LB
EXHAUST 5E214 ASSY. L.H. REF.
MANIFOLD REF
5E212ASSY. R.H. REF.
5E214 ASSY. L.H. REF.
• 376699-S2
4 REQ'D. 460 ENG. 5D203 ASSY.
2 REQ'D. 400 ENG. L.H REAR SUPPORT
BRACKET
• 385382-S2
2 REQ'D. 400 ENG. R.H
REAR SUPPORT
BRACKET 5A246 ASSY
40980-S2
TORQUE TO 25-35 FT-LB WHILE HOLDING THE SPECIFIED , 3 REQ'D.
CLEARANCE OF INLET PIPE OR CONVERTER ASSY. TO NO 460 4V ENGINE j 17 -25 FT-LB
3 CROSSMEMBER AND DRIVE SHAFT 20-35 FT-LB. 381877-S2
NO. 3 CROSSMEMBER 2 REQ'D.
REAR FLANGE 8-14 FT-LB

• END OF STUD WITH SHORTEST THREAD LENGTH 5C257 ASSY. REF.

TO BE SCREWED INTO MANIFOLD. 5E276 ASSY. REF.

• TIGHTEN NUTS ALTERNATELY TO MAINTAIN TORQUE

AND TO DRAW FLANGE EVENLY. L.H.
SPRING POCKET -
R.H. REF.
•*• TIGHTFN ROI TS Al TFRMATFI V TO MAINTAIN DIMS. TAKEN AT TOP OF PIPE
400 ?V FNGINE
TORQUE AND TO DRAW FLANGES EVENLY.
SECTION B IEW U U1567-C

FIG. 8 Exhaust System—Lincoln Continental

26-22-1
V-8 Dual Exhaust Systems
SUBJECT
DESCRIPTION
Dual Exhaust System -
Without Resonator
Dual Exhaust System -
With Resonator
REMOVAL AND INSTALLATION
Catalytic Converter - Ford/Mercury/Mark V . . . 22-2
DESCRIPTION
DUAL EXHAUST SYSTEM
WITHOUT RESONATOR
The dual-pipe exhaust systems
without resonators are of all the same
basic design. The H-shaped inlet pipe
assembly is of one-piece construction.
Muffler and outlet pipe on the factory
installation is a welded assembly. All
systems without a resonator are equipped
with a diffuser or alternator in the outlet
pipe system.
REMOVAL AND INSTALLATION
The replacement procedures given
apply to all vehicle models and to right
and left assemblies of dual exhaust
systems unless otherwise noted.
INLET " H " PIPE—FORD,
MERCURY AND MARK V
Removal
1. Raise the vehicle.
2. Remove the "U" bolt clamps at the
muffler inlet connections.
3. Support the mufflers in their proper
position using soft wire.
4. Remove the nuts attaching the inlet
pipe to converter flat flange
connections. Do not remove the inlet
pipe to right hand or left hand
manifold connection nuts.
5. Slide the inlet pipe rearward until the
catalytic converter can be removed.
6. Disconnect the inlet pipe from the
catalytic converter connection. It may
be necessary to disconnect the rear
hanger to outlet pipe attachment in
V-8 Dual Exhaust Systems
Ford, Mercury and Continental Mark V
PAGE SUBJECT
REMOVAL AND INSTALLATION (Cont'd.)
Inlet H-Pipe -
22-1 Ford/Mercury/Mark V
M u f f l e r a n d Qiffuser - Ford/Mercury
22-1 . . ,,,
Muffler and Resonator Assembly
_ Mark v
Normal service parts procedure is to
furnish the H-pipe as a single, welded
assembly, while the muffler and outlet
pipe are serviced separately and
assembled with clamps. Refer to the
master parts catalog for current service
parts systems.
DUAL EXHAUST SYSTEM WITH
RESONATOR
As factory-installed, this system
consists of a welded H-pipe assembly
order to obtain sufficient clearance to
separate the converter connection.
Installation
1. Slide the "U" bolt clamp(s) over the
muffler end(s) of the "H" inlet pipe.
2. Position the inlet pipe to the muffler
slip joint connection(s) and loosely
install the "U" bolt clamp(s). Be sure
the tab(s) on the inlet pipe is properly
located in the muffler slot(s).
3. Install a new gasket to the right hand
and left hand converter studs.
4. Position the inlet pipe to the converter
flat flange connections and loosely
install the attaching nuts.
5. Tighten the left hand and then the
right hand flat flange connection
attaching nuts to specification.
NOTE: If a catalytic converters)
is being replaced along with the inlet
pipe, the converter(s) should be
installed to the manifold(s) loosely,
then the inlet pipe to converters) flat
26-22-1
PART
26-22
PAGE
22-1
22-2
.D * A ^
22-2
CN4032-A
connected to two welded muffler-
resonator assemblies (Figs. 1 and 2).
For service replacement, the H-pipe
is furnished as a single welded assembly,
but the muffler/resonator, and outlet
pipe are available separately. Refer to the
master parts catalog for current service
parts.
Two catalytic converters are
connected to most dual exhaust systems.
These converters are located between the
exhaust manifold and the inlet "H" pipe.
flange connection attaching nuts must
be installed and tightened to
specification BEFORE the manifold
to converter attaching nuts to insure
proper alignment.
6. Tighten the "IT bolt clamp(s) at the
muffler slip joint(s) to specification.
Be sure the tab and slot are properly
engaged.
7. Tighten the rear hanger to muffler
o u t l e t p i p e a t t a c h m e n t to
specification, if required.
8. Check the exhaust system for leaks
and alignment and install the exhaust
shields to inlet pipe(s) as required.
9. Lower the vehicle.
CATALYTIC CONVERTER—FORD,
MERCURY AND MARK V
Removal
1. Raise the vehicle.
2. Remove the exhaust shield(s), if so
equipped, from the catalytic
converter(s).
26-22-2
3. Support the exhaust inlet pipe in its
relative position by securing the pipe
to the No. 3 frame crossmember with
soft wire.
4. Remove and discard bolts attaching
the converter and inlet "Y" pipe flat
flanges (both sides).
Units with shields, remove the
brackets that attach the shields and
flatflanges(both sides).
Units without shields, remove and
discard flag nut assemblies (both
sides).
5. Remove the converter flange
attaching nuts holding the converters
to the exhaust manifold and inlet pipe
(both sides).
6. Slide the inlet pipe rearward until the
catalytic converter(s) can be removed.
It may be necessary to disconnect the
rear hanger-to-outlet pipe attachment
to obtain sufficient clearance to
separate the converter at manifold
connection(s).
7. Discard gasket(s) and damaged parts.
Installation
1. Clean the inlet "Y" pipe flange face.
2. Position the catalytic converter(s) to
the exhaust manifold. Loosely install
the attaching nuts.
3. Install new gaskets between the inlet
"Y" pipe/converter flat flanges.
Position the inlet pipe flange to the
converter outlet flange connections
and insert new attaching bolts. On
units without shields, loosely install
flag nuts to the bolts, and on units
with shields, position attaching
brackets forward of the converter flat
flange and loosely engage the bolts.
4. Alternately tighten the converter to
inlet pipe flange connection(s) to
specification.
5. Align the system to proper clearance
specifications.
6. Alternately tighten the manifold nuts
to specification.
7. Check the system for leaks.
NOTE: Alternate torque of joint
fastener is required to provide
uniform clamping in order to prevent
joint distortion, a major cause of
system leaks and misalignment.
8. Install the exhaust shield(s) to the
catalytic converter(s) to specification.
9. Lower the vehicle.
V-8 Dual Exhaust Systems
MUFFLER AND DIFFUSER—-FORD
AND MERCURY
Removal
1. Raise the vehicle on a hoist that
permits the rear axle to lower to the
full extent of its travel. This will
provide the clearance necessary to
remove the muffler assembly.
2. Support the muffler inlet pipe with a
soft wire and remove the **U" bolt
clamp at the inlet pipe to muffler inlet
connection(s).
3. Remove the rear support bracket
screws.
4. Remove the screw securing the
intermediate support bracket to the
mufTler(s).
5. Separate the muffler to inlet pipe
connection(s) and remove the muffler
assembly.
6. Replace "U" bolt clamps and any
other worn or damaged parts.
Installation
1. Slide the "U" bolt clamp(s) over the
outlet end(s) of the inlet pipe.
2. Position the muffler assembly on the
inlet pipe and loosely install the
clamp(s). Be sure that the tab is fully
inserted into the locating slot.
3. Position the muffler to the
intermediate support bracket.
Loosely install the attaching screws.
4. Attach the screws holding the rear
support bracket and tighten to
specification.
5. Align the exhaust system to conform
to the clearance specifications.
NOTE: If specified alignment
specifications cannot be obtained, the
right hand and left hand manifold
attachments should be loosened.
After specifications are obtained,
tighten the manifold attaching nuts to
specification while holding
clearances.
6. Tighten intermediate support bracket
screws to specification.
7. Position and secure the "U" bolt(s) at
the inlet pipe to muffler connection(s)
to specification. Be sure the tab and
slot are properly engaged.
8. Remove the temporary wire support,
check the system for leaks, and lower
the vehicle.
26-22-2
MUFFLER AND RESONATOR
ASSEMBLY—CONTINENTAL
MARK V
Removal (Refer to Fig. 2) For Service
System Replacement
1. Raise the vehicle on a hoist that
permits the axle to lower to the full
extent of its travel. This will provide
the clearance necessary to remove the
muffler and outlet pipe.
2. Support the inlet pipe with a soft wire.
3. Cut the muffler outlet pipe(s} at the
kick-up area just above the muffler(s).
4. Remove the screws which attach the
resonator(s) to the rear hanger(s).
Remove the resonator(s) and pipe(s).
5. Remove the screws securing the
muffler(s) to the intermediate support
bracket(s).
6. Remove the clamp(s) securing the
inlet pipe(s) to the muffler(s)
7. Separate the muffler(s) from the inlet
pipe(s) and remove the muffler(s).
8. Replace any damaged or badly rusted
parts and the "U" bolt clamps.
Installation
1. Position the muffler(s) and outlet
pipe(s) to the intermediate support
bracket(s) and loosely install the
attaching screws.
2. Slide the muffler(s) onto the inlet
pipe(s) and properly position the
clamp(s). Be sure to maintain the
specified clearances for the clamp and
locating tab and be sure that ihe tab
is fully inserted into the locating slot.
3. Install a clamp on each resonator inlet
and slide each resonator onto the
muffler outlet. Loosely install the
"U" bolt clamp(s) snug, but not tight.
4. Attach the resonator(s) to the rear
hanger bracket(s), install and lighten
the attaching screws to specification.
5. Align the exhaust system to conform
to the clearance specifications.
NOTE: If the alignment clearances
cannot be obtained, loosen the right
hand and left hand manifold
attachments until the necessary
clearance can be obtained. Tighten
the manifold bolts to specification.
6. Tighten intermediate support bracket
screws to specification.
7. Tighten the "U" bolt clamps at the
inlet pipe(s) to muffler connection(s)
and at the muffler outlet(s) to
resonator inlet connection(s) to
specification.
8. Remove the temporary suppon wire,
check the exhaust system for leaks
and lower the vehicle.
CATALYTIC CONVERTER 381877 S2 STRIP OF ORANGE PAINT
5E212R.H. REF. 4REQ'D. THIS LOCATION - EITHER SIDE
5E214 L.H. REF. 1.64 FROM SURFACE OF TIGHTEN SECURELY FOR IDENTIFICATION R.H.
1.56 MANIFOLD FLANGE 12-20 FT-LB SIDE.

5E212ASSY. R.H. REF.

5E214 ASSY. L.H. REF OUTLET PIPE
I 5A246 R.H.
REF.
5256 L.H.
REAR SUPPORT
NOTE: LOCATE CLAMP FROM BRACKET
END OF PIPE AS SHOWN
40980-S2
2 PLACES
4REQ'D.
TIGHTEN SECURELY FRAME REF.
15-25 FT-LB

VIEW OF L.H. & R.H. MANIFOLD CONNECTION

VIEW OF CONVERTER CONNECTION
TORQUE TO SPECIFICATION WHILE HOLDING THE
SPECIFIED CLEARANCE TO NO. 3 CROSSMEMBER. 2.44
(L.H. & R.H.)
.48

SECTION D
VIEWW L.H. SHOWN R.H. SYM. OPPOSITE
' 2267 ASSY. REF.
BRAKE TUBE

4001 ASSY. REF.

I TIGHTEN SECURELY
I 15-25 FT-LB

1.06
FLR. PAN

CTR. FLR. PANREINF.

5230
ASSY. REF.
5D255 INTERMEDIATE
HANGER L.H. SHOWN, R.H. OPP.
2REQ'D. SECTION B

381877-S2 * END OF STUD WITH SHORTEST THREAD LENGTH

4REQ'D. TO BE SCREWED INTO MANIFOLD.
TIGHTEN SECURELY
12-20 FT-LB • TIGHTEN BOLTS ALTERNATELY TO MAINTAIN
TORQUE AND TO DRAW FLANGE EVENLY.
R.H.
WHEN ASSEMBLED .96 CLEARANCE
BETWEEN MUFFLER REAR SUPPORT [VIEW X I
SECTION A AND REAR SUSPENSION UPPER ARM
NO 3. CROSSMEMBER REAR FLANGE MOUNTING BRACKET. RIGHT SIDE SHOWN
U1586-B

FIG. 1 Exhaust System—Ford/Mercury Sedan and 460 PI V-8

 CATALYTIC CONVERTER 5299 - PLATE
5E212 R.H. 2 REQ'D.
5E214L.H. NO. 4 CROSSMEMBER REF.
FROM SURFACE OF 5F208ONLY
1.64 MANIFOLD FLANGE REMOVE PAPER BACKING AND
1.56 L.H. & R . H . INSTALL WITH ADHESIVE SIDE
ADJACENT TO CONVERTER FLANGE.

INTERMEDIATE
RESTRICTOR - SUPPORT BRACKET
5 F 2 0 8
- 5D255
2 REQ'D. (2 REQ'D.)
(1-R.H. & 1 L.H.)
5246 REF. 5D204 REAR SUPPORT
BRACKET
387265-S2
CONVERTER 4 REQ'D. 381877-S2
ASSY. REF. 20-36 FT-LB 2 REQ'D. 5D203R.H.
2 REQ'D. 5D204 L.H.
VIEW V | 8-14 FT-LB
TYPICAL BOTH SIDES A PLANE PASSING THRU THE C_ OF THE ^ i
SCREWS MUST BE HORIZONTAL WITHIN ± .12 | ^
5D204 ASSY. - L.H.

•¥• 387O4O-S7 1.46

4 REQ'D. L.H. & R.H.
20-35 FT-LB
5C257 ASSY. R.H. REF.
5C258ASSY. L.H. REF.

5C257 ASSY
REF.

SECTION G

->4 MUFFLER ASSY.

^ REF.
CLAMP MUST BE PARALLEL
TO GROUND LINE WITHIN 10° L 0 C A T E C L A M p F R Q M E N DQ F

PIPE AS SHOWN

1.02
.88

• END OF STUD WITH SHORTEST THREAD LENGTH

TRANS. OIL TO BE SCREWED INTO MANIFOLD.
PAN REF.
SECTION D • TIGHTEN BOLTS ALTERNATELY TO MAINTAIN
SECTION C AT REAR FLANGE TORQUE AND TO DRAW FLANGE EVENLY.
SECTION A
MAX STRG GFAR
TRAVEL SECTION B NO. 3 CROSSMEMBER REF. U1572-C

FIG. 2 Exhaust System—Continental Mark V

27-00-1 Cooling System 27-00-1

GROUP
COOLING SYSTEM
(8000)
PART TITLE PART NO. PART TITLE PART NO.

Fan Drive Clutch 27-05 General Cooling System Service 27-01

Flex-Blade Fan 27-06 Radiators 27-03

CN4038-A

PART
General Cooling System Service 27-01

SUBJECT PAGE SUBJECT PAGE

GENERAL INFORMATION 01-1 REMOVAL AND INSTALLATION

Fan Drive Belt 01-4
DIAGNOSIS 01-1 Four and Six-Cylinder Engine
Cooling Fan 01-4
TESTING Radiator Hose 01-4

Cooling System Pressure Test 01-2 Thermostat 01-5

Fan Drive Clutch Test 01-3 V-8 Engine Cooling Fan 01-4

General Test Procedures 01-2

Radiator Cap Pressure Test 01-2 CLEANING AND INSPECTION

Thermostat Test - Thermostat Cleaning Cooling System 01-5

Removed 01-3
SPECIFICATIONS 01-6
ADJUSTMENTS
Drive Belts 01-4

CN4039-A

GENERAL INFORMATION
This part covers general cooling system component removal, disassembly, procedures and specifications, refer to the
system diagnosis service. For cooling assembly, installation and repair pertinent Part of this Group.

DIAGNOSIS
»Refer to the following Diagnosis
Chart for cooling system problems, their
possible cause and recommended
correction. Refer to the pertinent Part for
testing and repair.
The most frequent cooling system
complaints are leakage and overheating.
Either of these problems will soon render type of solution is not being used in the
the vehicle inoperable. cooling system, a vegetable dye may be
Most vehicles use an Ethylene glycol added to aid in locating external leakage.
base anti-freeze solution to which the
manufacturers have added a dye color.
The dye color makes the anti-freeze
solution an excellent leak detector. If this
27-01-2
Problem
• Loss of coolant.
• Engine overheats.
• Engine fails to reach normal operating
temperature.
TESTING
GENERAL TEST PROCEDURES
Visual Inspection
A. Check for leakage at:
1. All hoses and hose connections.
2. Radiator seams, radiator core, and
radiator drain petcock.
3. All block core plugs and drain plugs.
4. Edges of all cooling system gaskets.
5. Transmission oil cooler.
6. Vehicle heating system components.
7. Water pump shaft and bushing.
B. Examine oil dipstick for evidence of
coolant contaminated engine oil.
C. Check radiator for evidences of oil in
coolant (leakage at transmission oil
cooler).
COOLING SYSTEM PRESSURE
TEST
1. Shut the engine off. To prevent loss
of coolant and to avoid the danger of
being burned, let the engine cool
before removing the radiator cap.
When removing the radiator cap,
place a cloth over the cap and rotate
the cap SLOWLY counterclockwise
to the safety stop and allow the
pressure to escape completely. Then,
turn the cap again SLOWLY
counterclockwise past the safety stop
to remove.
2. Adjust the radiator coolant (Fill or
drain) to one inch below the filler
neck opening before testing. Wet the
rubber sealing surface of the cap
before installing the cap tightly on the
radiator.
3. Disconnect the electrical connector
from the engine temperature sending
unit and remove the temperature
General Cooling System Service
Possible Cause
' • Pressure cap and gasket.
• Leakage.
• External Leakage.
• Internal Leakage.
• Low coolant level.
• Loose fan belt.
• Pressure cap.
• Radiator or A/C condenser obstruction.
• Closed thermostat.
• Fan drive clutch.
• Ignition.
• Temp gauge or cold light.
• Engine
• Open thermostat.
• Temperature gauge or cold light.
sending unit from the manifold.
With the radiator cap installed and
the cooling system pressure relieved,
only a small amount of coolant will
be lost when the sending unit is
removed.
4. Install the adapter fitting from the
Rotunda Pressure Tester 21-0012 (or
equivalent) (male thread on one end,
and a hose connector on the other end
to accommodate the tester hose)
tightly into the intake manifold or
cylinder head in place of the sending
unit. (See Fig. 1).
5. Remove the radiator overflow hose
from the retainer clips. Make sure the
hose isfirmlyinstalled on the radiator
overflow nipple and is in good
condition. Insert the free end of the
overflow hose into a container of
water.
6. Attach the pressure pump and gauge
(Fig. 1) to the adapter fitting and
pressurize the cooling system to the
cap LOWER LIMIT as shown in the
test chart.
No bubbles should appear in the
water container when the system is
pressurized to the LOWER LIMIT.
If the system is satisfactory at the
lower limit, gradually increase the
system pressure until a slight stream
of bubbles appears in the water
container. This is the upper limit of
the pressure cap.
Replace any radiator cap that
exceeds the specified UPPER LIMIT
pressure without discharging bubbles.
7. If the radiator cap does not hold
pressure, remove and wash the cap in
clean water to dislodge all foreign
27-01-2
Correction
• Inspect and test. Replace if necessary.
• Pressure test system.
• Inspect hose, hose connection, radiator, ejges
of cooling system gaskets, core plugs and drain
plugs, transmission oil cooler lines, water Dump,
heater system components. Repair or replace
as required.
• Disassemble engine as necessary - check tor:
cracked intake manifold, blown head gaskets,
warped head or block gaskets surfaces, crocked
cylinder head or engine block.
• Fill as required. Check for coolant loss.
• Adjust.
• Test. Replace if necessary.
• Remove bugs, leaves, etc.
• Test, replace if necessary.
• Test, replace if necessary.
• Check timing and advance. Adjust as required.
• Check electrical circuits and repair as required.
Refer to electrical section.
• Check water pump, block for blockage.
• Test, replace if necessary.
• Check electrical circuits and repair as required.
Refer to electrical section. CQ1403-A
particles from the gaskets. Check the
sealing surface in the radiator filler
neck.
Inspect the cam lock flanges on
both sides of the filler neck for
maximum cap engagement.
8. Pressurize the cooling system as
outlined in Step 6 (using a radiator
cap that operates within the specified
upper and lower pressure limits) and
observe the gauge reading for
approximately two minutes. See
Specifications. Pressure should not
drop during this time.
RESULTS: If the pressure drops,
check for leaks at the engine to heater
core hoses, engine to radiator hoses,
bypass hose, water valve hose (if
applicable), thermostat housing
gasket, radiator and heater core, etc.
Also refer to engine system checks if
a leak cannot be located in the cooling
system. Any leaks which are found
must be corrected and the system
rechecked.
If the system holds pressure
proceed to Step 9.
9. Release the system pressure by
loosening the radiator cap and
remove the adapter. Reinstall the
temperature sending unit, check
coolant level and replenish (if
necessary) with the correct coolant
solution.
RADIATOR CAP PRESSURE TEST
Refer to Fig. 1
1. Remove the radiator cap from the
radiator filler neck.
2. Immerse the radiator cap in water
and install on the shallow filler neck
of the Rotunda 21-0012 Radiator Cap
27-01-3
Pressure Test Adapter or equivalent
adapter.
NOTE: The adapter is designed to
accept both deep and shallow neck
radiator caps.
3. Immerse the filler neck seal in water
and install in the filler neck adapter.
NOTE: The filler neck seal is
reversible so that it may be used on
either a deep or shallow radiator filler
neck. It will also fit either end of the
radiator cap pressure test adapter.
4. Install the filler neck adapter with
filler neck seal on the deep filler neck
end to the radiator cap pressure test
adapter.
5. Connect the female quick disconnect
fitting of the pressure test pump to the
male quick disconnect fitting of the
filler neck adapter.
6. SLOWLY depress the plunger of the
pressure test pump until the pressure
gauge reading stops increasing and
note the highest pressure reading
obtained.
NOTE: If the plunger of the pump
is depressed too fast, an erroneous
pressure reading will result.
7. Release the pressure by turning the
pressure relief screw
counterclockwise. Then tighten the
pressure relief screw and repeat Step
6 (at least twice) to be sure the
pressure test reading is repeatable
within the acceptable gauge reading
limits of the radiator cap and is not
erratic. Refer to Specifications..
8. If the pressure test gauge readings are
not within the acceptable gauge
reading limits, replace the radiator
cap. If the pressure test gauge
readings are within the acceptable
gauge reading limits, perform the
Cooling System Pressure Test.
THERMOSTAT TEST-THERMOSTAT
REMOVED
Remove the thermostat and immerse
it in boiling water. Replace the
thermostat if it does not open at least
0.230" after one minute at 212°F.
If the problem being investigated is
insufficient heat, the thermostat should
be checked for leakage. This may be done
by holding the thermostat up to the
lighted background. Leakage of light all
around the thermostat valve (thermostat
at room temperature) indicates that the
thermostat is unacceptable and should be
replaced. It is possible, on some
thermostats, that a slight leakage of light
at one or two locations on the perimeter
of the valve may be detected. This should
be considered normal.
FAN DRIVE CLUTCH TEST
Spin the fan blade. A resistance
should be felt. If there is no resistance or
very high resistance, the minimum and
maximum fan speeds must be checked as
follows:
General Cooling System Service
RADIATOR CAP
PRESSURE TEST PUMP
(ROTUNDA WRE-500-85)
FIG. 1 Pressure Test Pump and Attachments
Minimum Slip Fan Drive
Requirement Test
1. Using a suitable marker, mark the
water pump pulley hub, one of the fan
blade attaching bolts and the
crankshaft pulley.
2. Connect a tachometer to the engine.
3. Install a throttle adjusting tool.
4. Connect a Sun Strobe Light. This can
be a SLT-1 or SLT-2 Strobotach or a
STA-1 Strobe Trigger adapter for the
Sun Distributor Test Stand.
5. Start the engine and run it at
approximately 1500 rpm until engine
temperature has normalized.
6. Adjust the engine to the specified
engine testing speed (Part 27-03).
7. Operate the Strobe Light at 2000 rpm
and aim it at the water pump pulley.
Adjust the engine speed until the light
flashes and the water pump pulley
mark are synchronized.
8. Aim the timing light at the fan blade
attaching bolts. Adjust the Strobe
Light until it is synchronized with the
fan blades (fan blade appears to stand
still).
9. The fan speed must not be greater
than the specified minimum fan test
speed at 2000 water pump rpm.
10. Turn the engine off.
11. If the fan speed was greater than the
specified minimum fan test speed,
check for proper parts usage.
If the correct parts are used,
replace the fan drive clutch.
If the part(s) are not the correct
ones, replace the part(s) and perform
the test again.
12. If the Maximum Slip Fan Drive
Requirement Test is going to be
performed, do not remove the
tachometer, Strobe Light or throttle
27-01-3
RADIATOR CAP PRESSURE
TEST ADAPTOR
FILLER NECK SEAL
TEMPERATURE SENDER
PRESSURE HOSE ADAPTER
FILLER NECK ADAPTOR
QUICK DISCONNECT
FITTINGS
adjusting tool.
13.If a Maximum Slip Fan Drive
Requirement Test is not going to be
performed, remove the tachometer,
Strobe Light and Throttle adjusting
tool.
Maximum Slip Fan Drive
Requirement Test
1. If the Minimum Slip Fan Drive
Requirement Test was not performed,
follow steps 1 thru 5 under Minimum
Slip Fan Drive Requirement Test.
2. Block off areas on each side of the
core in the engine compartment and
the front of the grille. This will raise
the temperature of the air striking the
clutch control unit and should cause
the fan to operate at maximum speed.
3. Place the air conditioning selector to
the maximum position and the blower
switch to the high position.
4. Adjust the Strobe Light to 2000 rpm.
5. Start the engine and adjust it until the
water pump pulley is synchronized
with the Strobe Light. This will be
near the engine testing speed given in
the specifications.
6. Turn off the air conditioning blower
switch.
7. Synchronize the timing light with the
marked fan to clutch attaching bolts.
8. The fan speed must meet or exceed
the specified maximum slip fan test
speed at 2000 water pump rpm.
9. If the fan speed was less than the
specified maximum slip fan test
speed, check for proper parts usage.
If the correct parts are used,
replace the fan drive clutch.
If the part(s) are not the correct
ones, replace the part(s) and perform
the test again.
27-01-4
ADJUSTMENTS
DRIVE BELTS
The fan drive belt(s) should be
properly adjusted at all times. Loose
drive belt(s) cause improper alternator,
fan and water pump operation. A belt
that is too tight places a severe strain on
the water pump and the alternator
bearings.
Properly tensioned drive belts
minimize the noise and also prolong
service life of the belt. Therefore, it is
recommended that a belt tension gauge
be used to check and adjust the belt
tension. Any belt that has operated for a
minimum of 10 minutes is considered a
used belt, and, when adjusted, it must be
adjusted to the reset tension shown in the
specification.
REMOVAL AND INSTALLATION
FOUR AND SIX-CYLINDER ENGINE
COOLING FAN
Removal
Remove the screws and washers
assemblies attaching the fan to the water
pump hub. Remove the fan.
Installation
Position the fan and spacer on the
water pump hub. Loosen fan belt, if
necessary. Install the lock washer and
screws and torque the capscrews to
specifications. Adjust the fan belt tension
to specifications.
V-8 ENGINE COOLING FAN
On a car with an air conditioner or
extra-cooling radiator, a fan drive clutch
may be used (see Specifications). Cars
without air conditioning or equipped
with Flex-Blade Fan utilize a pulley-to-
fan spacer.
Removal
1. Remove the radiator upper support
and fan guard or shroud. Remove the
screw and washer assemblies
attaching the fan and spacer (or drive
clutch) to the water pump hub.
Remove the fan and spacer (or drive
clutch).
2. If equipped with a fan drive clutch,
remove the attaching screw and
washer assemblies and separate the
fan from the drive coupling.
Installation
1. Position the replacement fan on the
drive clutch and install the washer
and screw assemblies. Torque the
capscrews evenly and alternately to
specifications.
2. Position the fan and spacer (or drive
clutch) on the water pump hub and
install the washer and screw
assemblies. Loosen the belt, if
necessary. Torque the capscrews
e v e n l y a n d a l t e r n a t e l y to
specifications. Adjust the fan belt
tension to specifications. Then, check
General Cooling System Service 27-01-4
Belt Tension
1. Install the belt tension tool on the
drive belt (Fig. 2) and check the
tension following the instructions of Tool-T63L-8620-A
the tool manufacturer.
2. If adjustment is necessary, loosen the
alternator mounting and adjusting
arm bolts. Move the alternator
toward or away from the engine until
the correct tension is obtained.
Remove the gauge. Tighten the
alternator adjusting arm and
mounting bolts. Install the tension
gauge and check the belt tension.
3. Follow similar procedures for
adjusting Thermactor air pump, air Q1039-A
conditioner compressor and power
steering pump drive belts. FIG. 2 Checking Drive Belt Tension
the fan drive clutch flange-to-water
pump hub for proper mating. Install
the radiator upper support and fan
guard or shroud.
FAN DRIVE BELT
Removal
If equipped with power steering and/
or air conditioning and Thermactor
exhaust emission control system it will be
necessary to loosen and remove the drive
belts before the fan drive belt can be
removed.
1. On a car with power steering (except
Lincoln Continental), loosen the
power steering pump at the mounting
bracket and remove the drive belt.
On a car with an air conditioner,
remove the compressor drive belt.
2. Loosen the alternator mounting and
adjusting arm bolts. Move the
alternator toward the engine. Remove FLATS
the belt(s) from the alternator and B2952-A
crankshaft pulleys, and lift them over
the fan. FIG. 3 Installing Thermostat—Typical
Installation In-Line 6 and V-8
1. Place the belt(s) over the fan. Insert
the belt(s) in the water pump pulley,
crankshaft pulley and alternator
pulley grooves. Adjust the belt
tension to specifications.
2. On a car with an air conditioner, , OUTLET CONNECTION
install and adjust the compressor - 8594
drive belt to specifications.
3. On a car with power steering (except THERMOSTA--8575
Lincoln Continental), install the (OUTLET SIDIE TO
RADIATOR)
power steering pump drive belt and
tighten the pump at the mounting
bracket. Adjust the drive belt tension
to specifications.
RADIATOR HOSE
Removal
Radiator hoses should be replaced as
(11271 B
directed in the pertinent car Maintenance
Schedule or whenever they become
cracked, rotted or have a tendency to FIG. 4 4-Cylinder Thermostat and
collapse. Housing—Disassembled View
27-01-5 General Cooling System Service 27-01-5

Drain the radiator; then loosen the
clamps at each end of the hose to be
removed. Slide the hose off the radiator
connection and the engine water outlet
connection (upper hose) or the water
pump connection (lower hose).
Installation
Position the clamps at least 1/8 inch
from each end of the hose. Coat the
connection areas with an approved
water-resistant sealer and slide the hose
on the connections. Make sure the
clamps are beyond the bead and placed
in the center of the clamping surface of
the connections. Tighten the clamps. Fill
the radiator with the recommended
permanent antifreeze and water mixture.
Operate the engine for several minutes,
then check the hoses and connections for
leaks.
THERMOSTAT (REFER TO FIGS. 3,
4 AND 5.)
On V-6 engines, the thermostat is
located on the bottom of the water pump
housing. The thermostat housing
connects to the radiator lower hose,
rather than the upper, as is customary on
all other engines.
Removal
1. Drain the radiator so that the coolant
level is below the thermostat.
2. Disconnect the heater return hose at
the thermostat housing located on the
left front lower side of engine.
3. Remove the coolant outlet housing
retaining bolts. Pull the elbow away
from the cylinder head or manifold
(water pump on V-6) sufficiently to 3. Connect heater return hose to
provide access to the thermostat. thermostat housing.
Remove the thermostat and gasket. 4. Fill the cooling system with the
recommended Permanent Antifreeze
Installation and water mixture. If equipped with
Check the thermostat before a crossflow radiator, follow the
installing it, following the procedure special instructions in Part 27-03
under Thermostat Test, Part 27-01, regarding checking coolant level.
Section 1.
Check for leaks and proper coolant
1. Clean the coolant outlet housing and level after the engine has reached
cylinder head or manifold gasket normal operating temperatures.
surfaces. Coat a new gasket with
water resistant sealer. Position the
gasket on the cylinder head opening.
The gasket must be positioned on the
cylinder head or the intake manifold,
before the thermostat is installed,
except on 351M, and 400 and 460
C1D engines, where the thermostat is
installed in the block (351M* and 400)
or intake manifold (460) first, and
then the gasket is installed.
To prevent incorrect installation of
the thermostat, the water outlet
casting on all engines except 351M,
400, 460 and 2800cc models contains
a locking recess into which the
thermostat is turned and locked.
Install the thermostat with the bridge
section (Figs. 3 and 4) in the outlet
casting. Turn the thermostat
clockwise to lock it in position on the
flats cast into the outlet elbow.
2. Position the coolant outlet elbow
against the cylinder head, or the Q1124-B
intake manifold. Install and torque
the retaining bolts to specifications. FIG. 5 V-6 Thermostat and Housing

CLEANING AND INSPECTION

CLEANING COOLING SYSTEM
To remove rust, sludge and other
foreign material from the cooling system,
use Rotunda Cooling System Cleanser.
Removal of such material restores
cooling efficiency and avoids
overheating. Always remove the
thermostat prior to pressure flushing. A
pulsating or reversed direction of
flushing water flow will loosen sediment
more quickly than a steady flow in the
normal direction of coolant flow. In
severe cases where cleaning solvents will
not properly clean the cooling system for
efficient operation, it will be necessary to
use the pressure flushing method.
Various types offlushingequipment are
available.
2741-6 General Cooling System Service 27-01-6

SPECIFICATIONS

COOLING SYSTEM CAPACITIES

CAPACITY (QTS.)
VEHICLE ENGINE OPTIONS U.S. IMP.

Pinto/Bobcat 2.3L S/C 8.7 7.2

A/C 9.1 7.6
2.8L S/C 8.5 7.0
A/C 9.2 7.6
Mustang 11 2.3L S/C 8.5 7.6
A/C 9.1 7.6
2.8L S/C (M/T) 8.3 6.9
(A/T) 8.8 7.3
A/C (& Rallye) 9.0 7.5
302 S/C & A/C 16.3 13.5
Maverick/Comet 200 S/C 8.7 7.2
A/C 8.9 7.4
250 S/C & A/C 9.6 8.0
302 S/C 13.5 11.2
A/C 14.1 11.7
Granada/Monarch 200 S/C 9.7 8.1
250 S/C 10.5 8.7
A/C 10.7 8.9
302 S/C & A/C 14.6 12.1
351W S/C & A/C 15.7 13.0
LTD Il/Cougar 302 S/C 14.8 12.3
A/C 15.1 12.5
LTD Il/Cougar/Thunderbird 351W S/C 15.9 13.2
A/C 16.2 13.5
351M S/C, A/C, or 3.00:1 Axle Ratio 17.0 14.1
Police & Taxi 17.5 14.5
400 S/C, A/C, 3.00:1 Axle Ratio 17.0 14.1
Police 17.5 14.5
Ford/Mercury/Meteor 351M S/C, A/C, 3.00:1 Axle Ratio 17.2 14.3
400 S/C, A/C, 3.00:1 Axle Ratio 17.2 14.3
Police, T.T. Ill 17.7 14.7
460 S/C,A/C 18.5 15.4
Police, T.T. Ill 19.0 15.8
Continental Mark V 400 S/C, A/C, T.T. 17.5 14.5
460 S/C, A/C, T.T. 19.4 16.0
Lincoln Continental 400 A/C 17.1 14.2
460 A/C 18.5 15.4
A/C with 3.00:1 Axle Ratio 19.0 15.8

CODES: S/C = Standard Cooling

A/C = Air Conditioning
T.T. = Trailer Towing (Class II or III)
M.T. = Manual Transmission
A.T. = Automatic Transmission

(1) Capacities include heater.

(2) Service refill recommendations are a 50/50 mixture of water and permanent coolant/anti-freeze flujd meeting Ford Specification ESE-M97B18-C.

(3) Cooling systems with a recovery bottle require an additional 1 quart of fluid.

(4) DO NOT add coolant to the bottle.

(5) Cape cities are estimated and may vary as much as 15% from specification.

CQ 1153-D
 27-01-7 General Cooling System Service 27-01-7

TORQUE VALUES (ALL CARS) DRIVE BELT TENSIONS (lbs.)

NOTE: All specifications are given in ft-lbs unless otherwise noted. Size Newly Installed Used
(1) UptoiOMin. Over 10 Mi n.
Fan shroud assembly to radiator where applicable 24-48 in-lbs
Fan to pulley hub (All engines) 12-18 1/4" 50-80 40-80 (2) 40-60 (2)
Radiator hose clamps (200 CIO Except 1/4" 120-160 90-160(3) 75-120(4)
Maverick-Comet standard radiator) 16-24 ;n-lbs
(1) Read tension immediately after belt is installed, before it stretches or
(All others) 20-30 in-lbs
seats in pulley grooves.
Transmission oil cooler tubes to oil cooler - all engines 9-12
(2) If less than 40 pounds, readjust to 40-60 pounds.
SPECIAL SERVICE TOOLS (ALL CARS) (3) If less than 90 pounds, readjust to 90-120 pounds.
(4) If less than 75 pounds, readjust to 90-120 pounds.
Description Ford Tool No.
Belt Tension Gauge T63L-8620-A THERMOSTATS
Starts to Open°F 188°-195°
Fully Open 212°-215°

CQ1090-F

RADIATOR PRESSURE CAP

Vehicle Specified Cap Lower Limit (PSI) Upper Limit (PSI)
Application Pressure (PSI) (Must Retain) (Must Relieve)
Mustang/Pinto/
Bobcat, Maverick/ 13 11 17
Comet

Ford/Mercury,
LTD I I/Cougar,
Thunderbird/
Continental/Mark 16 13 19
V, Lincoln Conti-
nental, Granada/
Monarch
• ^ " •' ••••' 11 •! • • —

CQ1402-B
27-03-1
Radiators
SUBJECT
DESCRIPTION
Constant - Full Cooling System
Crossflow Radiators
Diagnosis
Downflow Radiators
Filling Cooling System
DESCRIPTION
RADIATOR
Standard and extra-cooling radiators
are installed in production, but service
replacement radiators are usually of the
extra cooling type.
DOWN FLOW RADIATORS
These radiators are the tube and slit-
fin-core type with the tubes arranged for
vertical flow of the coolant. The radiator
bottom header tank on automatic
transmission cars contains a heat
exchanger for cooling the transmission
oil.
CROSSFLOW RADIATORS
These radiators are of the tube and
slit-fin-core type with the tubes arranged
horizontally for crossflow of the .coolant.
Two header tanks, one on each side of the
radiator, provide uniform distribution of
the coolant to the cross-flow tubes. The
header tank, or chamber, on the left side
of the radiator contains a heat exchanger
for cooling the transmission fluid.
Special Filling Instructions-
Crossflow Radiators
Coolant level cannot be accurately
checked while the engine is running, due
to the construction of this radiator.
Check the level while the engine is cold
and fill to about 2 1/2-4 inches below the
fill cap seat (Fig. 1).
FILLING COOLING SYSTEM
On initial fill or refilling the cooling
system, the following procedures must be
followed to prevent air entrapment and
inadequate coolant levels. This does not
apply to cooling systems equipped with
coolant recovery or constant full systems.
1. Check all hose clamps for proper
tightness. Be sure radiator drain cock
is closed.
2. Position heater temperature selector
in the maximum heat position.
Radiators 27-03-1
PART
27-03
PAGE SUBJECT PAG£
DESCRIPTION (Cont'd.)
03-1 Radiator 03-1
03-1
03-2 REMOVAL AND INSTALLATION
03-1 Automatic Transmission Oil Cooler 03-3
03-1 Radiator 03-2
CN4049-A
3. Fill cooling system to 2 1/2-4 inches
below the fill cap seat (cross-flow) or
1 1/2 inches below the fill cap seat
(down-flow).
4. Leave radiator cap off and run engine
until thermostat opens (hot coolant
flows through radiator upper hose).
5. Stop engine and add coolant to 1 1/2
inches below fill cap seat (crossflow)
or 1/4 inch below fill cap seat (down-
flow). Install radiator cap.
CONSTANT-FULL COOLING
SYSTEM
This system is based around a 13 PSI
pressure cap (vehicles with downflow
radiators), or a 16 PSI pressure cap
(vehicle with crossflow radiators) and a
plastic reservoir and hose. When the
coolant in the radiator expands to the
overflow point, it passes through the
pressure cap and into the plastic reservoir
(Fig. 2). When the coolant in the radiator
cools down and therefore contracts, it FIG. 1 Cold Fill Level—Crossflow
pulls coolant from the reservoir through Radiator
a vacuum relief valve in the pressure cap,
back into the radiator. 4. Fill the plastic reservoir bottle to the
The advantages of the system are the HOT LEVEL mark. Install the
extra coolant carried in the expansion reservoir cap.
tank and the fact that any air bubbles 5. Start the engine and allow to warm to
trapped in the cooling system are vented normal operating temperature.
in the plastic reservoir, rather than 6. Check the level of coolant in the
causing excessive aeration of the coolant. plastic reservoir. If the level i* below
Filling Constant Full Cooling the HOT LEVEL mark, add coolant
System—Mustang W/Optional to the plastic reservoir bottle only.
302 CID—V-8 UNDER NO CIRCUMSTANCES
SHOULD THE R A D I A T O R
1. Check all hose clamps for proper PRESSURE CAP BE REMOVED
tightness. Be sure radiator drain cock W H I L E T H E E N G I N E IS
is closed. RUNNING.
2. Set the heater temperature selector
lever to the maximum heat position. Filling Constant Full Cooling
3. Fill the cooling system through the System—Except Mustang W/
filler neck in the radiator upper hose 302 CID V-8
until the coolant level is up to the 1. Check all hose clamps for proper
bottom of thefillerneck. (See Fig. 3.) tightness. Be sure radiator drain cock
Install the radiator cap. is closed.
27-03-2
2. Place heater temperature selector in
maximum heat position.
3. Fill radiator completely and fill
plastic reservoir to cold fill mark.
Install radiator and plastic reservoir
caps.
4. Run engine until thermostat opens
(coolant flowing through radiator
upper hose becomes hot).
5. Stop engine and add coolant to
reservoir as necessary to adjust level
to hot fill mark.
DIAGNOSIS
In the event no coolant is observed in
the reservoir, or when a coolant level
RADIATOR CAP - 8100
TRANSFER HOSE
RESERVOIR -
8C045
Q1269B
FIG. 2 Constant-Full Cooling
System—Ford/Mercury w /
400 CID V-8 and Class III
Trailer Towing Package
REMOVAL AND INSTALLATION
RADIATOR
Removal
1. Drain the cooling system. Disconnect
the radiator upper and lower hoses
from the radiator.
On a vehicle with an automatic
transmission, disconnect the
automatic transmission fluid cooler
inlet and outlet lines from the
radiator.
2. Crossflow radiators
a. If equipped with fan shroud,
remove two upper shroud attaching
bolts at radiator support. Lift fan
Radiators
change does not occur, check the system
as follows:
1. With the engine cold, remove the
radiator pressure cap, and inspect the
filler neck sealing gasket for foreign
material between the gasket and cap
diaphragm. Rinse cap in clean water.
The radiator pressure cap used on
this system is unique; replace only
with the proper cap.
2. Remove the radiator overflow-to-
reservoir hose at the radiator filler
neck connection and at the bottle.
3. Inspect the reservoir hose for
obstruction, cracks or cuts. Replace
if necessary. •
RADIATOR CAP
-8100
STRAP TO POWER
STEERING LINE
PLASTIC T I E .
- 95873 N.
SCREW-383152
(2 REQUIRED)
TORQUE TO
12-16 FT-LBS
NOTE: TORQUE LOWER HOSE
CLAMP INTO POSITION BEFORE
FAN SHROUD IS INSTALLED
RESERVOIR -
EXISTING HOLE & SLOT 80045
IN FENDER APRON
FIG. 3 Constant Full Cooling System—Mustang W/Optional 302 CID V-8
Engine
shroud sufficiently to disengage
lower retaining clips and lay
shroud back over fan.
b. Remove radiator upper support
attaching bolts and remove
support(s). Lift the radiator from
vehicle.
Downflow radiators
a. If equipped with fan shroud,
remove four attaching bolts, two at
each side of radiator. Lay shroud
back over fan.
b. Remove radiator attaching bolts,
two at each side of radiator. Lift
radiator from vehicle.
27-03-2
4. Inspect filler neck nipple to neck
flared soldered joint for possible
separation. Repair if necessary.
5. Reinstall the hose with a 3/8 to 5/8
inch clearance to bottom of plastic
reservoir.
6. Pressure test the system.
7. Replenish the coolant in the radiator
and reservoir, as required.
8. Reinstall the radiator pressure cap.
RADIATOR -
8005
HOSE & CLAMP
- 88274
FAN SHROUD
-8146
POSITION SHROUD TO MAINTAIN A
MINIMUM OF .38 RADIAL CLEARANCE
SCREW-383152 TO THE FAN TIP
(4 REQUIRED)
TORQUE TO
24-48 IN-LBS
Q1270B
Installation
1. If a new radiator is to be installed,
remove the drain cock from thcold
radiator and install it on the new
radiator.
2. If a new radiator is to be installed on
vehicles equipped with automatic
transmission, transfer the oil cooler
line connectors to the new radiator,
using oil resistant sealer.
3. Position the radiator assembly into
the vehicle.
a. On downflow radiators, install the
four attaching bolts, two on each
side of the radiator.
27-03-3
b. On crossflow radiator, install upper
supports and secure with bolts.
4. On vehicles with a u t o m a t i c
transmissions, connect the oil cooler
lines.
5. Place fan shroud into clips on lower
radiator support of crossflow
radiator. Secure to upper support
with two bolts. Position shroud to
downflow radiator and secure with
two bolts each side of radiator.
Position shroud to maintain a
minimum of 0.38 inch minimum
radial clearance to fan blade tips.
6. Connect the radiator upper and lower
hoses. Close the drain cock. Fill the
cooling system.
7. Operate the engine and check for
leaks at the hose connections and the
automatic transmission fluid cooler
lines. Check the a u t o m a t i c
transmission and radiator fluid level.
AUTOMATIC TRANSMISSION OIL
COOLER
Replacement of the automatic
transmission oil cooler in the radiator
tank, as given below, is usually performed
by radiator specialty shops on a sub-let
basis. However, the operation can be
performed in a dealer service department,
providing proper equipment is available.
Only manufactured or natural gas
torches should be used to perform
radiator repairs. Do not use acetylene.
No attempt should be made to repair
a fractured radiator tank. Should a
fractured tank be encountered, it must be
replaced. Tank repairs usually result in
repeat failures, due to the flexible nature
of the tank.
Removal
1. Drain the cooling system.
2. Remove the radiator from the vehicle,
following the procedure outlined
previously.
3. Thoroughly clean the radiator
assembly internally and externally by
submerging in a tank filled with a
caustic solution. Then, using clean
water, flush until the caustic solution
is removed from all internal and
external surfaces. NOTE: Caution
Radiators 27-03-3
COOLER ASSEMBLY
COOLER ASSEMBLY
45221-S7 2 REQ'D. BEFORE
SOLDERING TORQUE
TO 20-50 IN-LB
SOLDER OIL COOLER
(THREADED DESIGN)
FITTINGS COMPLETELY
SOLDER OIL COOLER
TO TANK
(BEAD DESIGIV
FITTINGS COMPLETELY
TO TANK
TYPICAL CROSSFLOW AND
DOWNFLOW RADIATORS
FIG. 4 Typical Radiator Oil Cooler Installation
should be exercised during the Retaining ring tangs should point
disassembly and assembly solder away from tank (Fig. 4).
operation of radiator components. 2. Puddle-solder the oil cooler fittings
Avoid excess heat concentration completely to the tank.
which could result in burning through 3. Seat the tank assembly in the header
the radiator sheet metal or loosening well and solder securely, completely
an adjoining soldered area. filling the well. Use 40-60 solder with
On downflow radiators, apply heat either zinc chloride 30 (BAUME) or
to separate support tabs from lower 5-B NALCO flux.
tanks. 4. Resolder the supports in position on
4. Remove the radiator tank containing downflow radiator.
the defective oil cooler. 5. Flush off all excess acid, internally
5. Melt the puddled solder from the oil and externally.
cooler inlet and outlet fittings. 6. Pressure-test the radiator assembly to
Remove the retaining rings from the 14-16 PSI for leaks.
fittings.
6. Remove the defective oil cooler. 7. Paint as required.
8. Install the radiator and fan shroud to
7. Clean the soldered surface areas and
inspect and tin as necessary to assure the vehicle. Install the connectors in
proper solder bonding. the oil cooler inlet and outlet fittings
and connect the transmission oil
Installation cooler lines.
1. Install the replacement oil cooler
assembly into the tank openings and 9. Connect the hoses to the radii)tor inlet
secure cooler with new retaining and outlet connections.
rings. For threaded design, torque 10. Flush the cooling system and refill
retainer to 20-50 in-lb; for bead with the recommended mixture of
design, push ring past fitting bead. all season coolant.
27-05-1
Fan Drive Clutch
SUBJECT
DESCRIPTION AND OPERATION
Fan Drive Clutch .
DESCRIPTION AND OPERATION
FAN DRIVE CLUTCH
The fan clutch (Figs. 1, 2 and 3)
permits use of a powerful fan without
paying the penalty of power loss or noise.
B1593-B
FIG. 1 Typical Fan Drive Clutch
Installation
REMOVAL AND INSTALLATION
FAN DRIVE CLUTCH
Removal
1. Remove the radiator upper support
and/or fan guard or shroud.
2. Loosen the fan belt. Remove the bolt
and washer assemblies attaching the
fan drive clutch to water pump hub
(Fig. 1). Remove the fan drive clutch
and fan as an assembly.
Fan Drive Clutch
PAGE SUBJECT
REMOVAL AND INSTALLATION
05-1 Fan Drive Clutch
SPECIFICATIONS
It is basically a temperature-controlled
fluid coupling that regulates fan speed
according to the temperature of the air
coming through the radiator core and
BI-METAL STRIP
CONTROL PISTON B2631-B
FIG. 2 Fan Drive Clutch With Flat Bi-
Metal Spring
3. Remove the attaching bolt and
washer assemblies and separate the
fan from the drive clutch.
Installation
1. Position the fan on the drive clutch.
Install the bolt and washer assemblies
and torque to specifications.
2. Position the fan drive clutch and fan
assembly and belt to the water pump
27-05-1
PART
27-05
PAGE
05-1
05-2
CA4250-A
flowing around the bi-metal control valve
located on the forward face of the clutch.
Pulley ratios and slip-speeds are given
in the Specification Section of this Part.
BI-METAL SPRING
B1932-C
FIG. 3 Fan Drive Clutch With Coil Bi-
Metal Spring
hub (Fig. 4). Install and torque the
attaching bolt and washer assemblies
evenly and a l t e r n a t e l y to
specifications. Then, check the fan
drive clutch flange-to-water pump
hub for proper mating. Adjust the fan
belt tension to specifications.
3. Install radiator upper support and/or
fan guard or shroud.
27-05-2 Fan Drive Clutch 27-05-2

FAN ASSEMBLY
(TYPICAL) -
8600

BOLT AND WASHER

ASSEMBLY 5/16x24
(4 PLACES)

BOLT AND WASHER

ASSEMBLY 5/16 x 18
(4 PLACES)
FAN DRIVE CLUTCH
ASSEMBLY (TYPICAL)
-8A616

Q1404-A

FIG. 4 Fan Drive Clutch and Fan

SPECIFICATIONS
TORQUE VALUES (ALL CARS) - FT LB
NOTE: All specifications are given in ft.-lbs. unless otherwise noted.
Fan to Fan Clutch - All Engines 12-18 Fan Clutch to Water Pump - A l l Engines 12-18

FAN DRIVE CLUTCH SPECIFICATIONS

Engine RPM
Fan Test Speed @ 2000 Water Pump RPM
Water Pump Required to Run
Pulley Water Pump Minimum RPM Minimum RPM
Vehicle Engine Cooling Option Ratio 2000 RPM

LTD I I , Cougar,
Thunderbird, A/C and/or
Mark V, Ford, 460 Trailer Tow 1.25:1 1600 1600 500
Mercury, Police (All)
Lincoln Continental

Granada, Monarch
(Ghia) 351-W A/C 1.13:1 1770 1600 500

Granada 302 STD .96:1 2040 1600 500

Monarch (Ghia) 302 A/C 1.13:1 1770 1600 500

Mustang 302 A/C 1.25:1 1600 1600 500

CQ1095D
27-06-1 Flex-Blade Fan 27-06-1

Flex-Blade Fan

DESCRIPTION
DESCRIPTION
The flex blade fan (Fig. 1) consists of
a spider stamping of either 5-blade or 7-
blade configuration, to which are riveted
the flexible blade assemblies. Other than
the riveted flexible blades, the fan is
conventional in appearance and is
removed and replaced in the same
manner as a standard fan (Part 27-01).
OPERATION
Because the blades flex as engine rpm
increases, the flex-blade fan tends to use
less power and to generate less noise than
does a conventional rigid cooling fan of
fixed pitch. This fan adjusts itself to the
engine speed without the use of
complicated drive mechanisms. No test
or adjustment is therefore required,
beyond keeping the fan drive belt
adjusted to the proper (standard) tension.

B3143-A

FIG. 1 Flex-Blade Fan

28-01-1 Starting System 28-01-1

GROUP
STARTING SYSTEM
(11000)
PART TITLE PART NO. PART TITLE PART NO.

Positive Engagement Starter 28-02 Starting System General Service 28-01

Solenoid Actuated Starter 28-03

CA4248-A

Starting System General Service

CA4249-A

GENERAL INFORMATION
The function of the starting system is
to crank the engine at a speed fast enough
to permit the engine to start. Heavy
cables, connectors, and switches are used
in the starting system because of the large
current required by the starter while it is
cranking the engine. The amount of
resistance in the starting circuit must be
kept to an absolute minimum to provide
maximum current for starter operation.
Loose or corroded connections, relay
contacts, or partially broken cables will
result in slower than normal cranking
speeds, and may even prevent the starter
from cranking the engine.
In cases of starting system trouble,
the owner may have discharged the
battery before calling for assistance. A
road service procedure is presented in
each Part to aid the service technician in
such cases of starting trouble. Be sure to
follow diagnosis procedures in order to
locate the cause of the starting difficulty.
The road service is not a part of the
diagnosis procedures.
28-02-1 Positive Engagement Starter 28-02-1

PART
Positive Engagement Starter 28-02

SUBJECT PAGE SUBJECT £

DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION
Positive Engagement Starter 02-1 Positive Engagement Starter 02-4

TESTING OVERHAUL
Bench Tests 02-2 Positive Engagement Starter 02-4
On-Vehicle Testing 02-2
Road Service 02-1 SPECIFICATIONS 02-8

CN4050-A

DESCRIPTION AND OPERATION

POSITIVE ENGAGEMENT STARTER
The starting system includes the
starter motor with an integral positive-
engagement drive, the battery, a remote
control starter switch (part of the ignition
switch), the neutral-start switch
(automatic transmission with floor shift
only), the starter relay, and heavy circuit
wiring.
Turning of the ignition key to the
START position actuates the starter
relay, through the starter control circuit.
The starter relay then connects the
battery to the starter.
Vehicles equipped with an automatic
transmission and a console or floor
mounted shift lever have a neutral-start
switch in the starter control circuit,
which prevents operation of the starter if
the selector lever is not in the N (neutral)
or P (park) position.
Vehicles equipped with an automatic
transmission and a column shift do not
use a neutral-start switch. The ignition
switch mechanism in the steering column
is designed so that the ignition switch can
STARTER RELAY
— BATTERY
* START SWITCH &
SAFETY SWITCHES
IN OPERATED POSITION
(MAVERICK/COMET)
1
SEE VEHICLE WIRING DIAGRAM .11083 H
FIG. 1 Starting Circuit
be turned to the start position only when starter drive plunger lever and thus the
the selector lever is in NEUTRAL or drive is forced into engagement with the
PARK. flywheel ring gear.
When the starter is not in use, one of When the movable pole shoe is fully
the field coils is connected directly to seated, it opens the field coil grounding
ground through a set of contacts (Fig. 1). contacts and the starter is then in normal
When the starter is first connected to the operation. A holding coil is i:.sed to
battery, a large currentflowsthrough the maintain the movable pole shot: in the
grounded field coil, actuating a movable fully seated position during the time that
pole shoe. The pole shoe is attached to the the starter is turning the engine.

CAUTION—Use only a 12-volt WATER FOR A MINIMUM OF 15

TESTING
ROAD SERVICE
On road service calls, connect a 12-
volt booster battery to the system for
cases of a starter that will not crank the
engine or a starter that cranks the engine
very slowly.
Use of Battery Jumper Cables
The following instructions contain
precautions that should be observed to
avoid possible injury to yourself or
damage to the vehicle. Be certain that
transmission is in park or neutral.
power supply. You can damage a 12-volt
starting motor and ignition system
extensively by connecting it to a 24-volt
power supply (two 12-volt batteries in
series, or a 24-volt motor-generator set).
WARNING - Keep out of reach of
children. Batteries contain SULFURIC
ACID. Avoid contact with skin, eyes
or clothing. Also, shield your eyes
when working near the battery to
protect against possible splashing of
the acid solution. In case of acid
contact with skin, eyes, or clothing,
FLUSH IMMEDIATELY WITH
MINUTES. If acid is swallowed, drink
large quantities of milk or water,
followed by milk of magnesia, a beaten
egg or vegetable oil. CALL A PHYSI-
CIAN IMMEDIATELY.
Hydrogen and oxygen gases are
produced during normal battery oper-
ation. This gas mixture can explode if
flames, sparks or lighted tobacco are
brought near the battery. When charg-
ing or using a battery in an enclosed
space, always provide ventilation and
shield your eyes.
NOTE — Battery has safety vent
caps with above warnings.
28-02-2
Use particular care when connect-
ing a booster battery to prevent sparks.
Before jump starting, turn the heater
A/C blower "ON" and leave it on after
the engine starts until after the jumper
cables are removed. Turn all the lights
"OFF" before jump starting and leave
them off after the engine starts until
after the jumper cables are removed.
To jump start: (1) connect ends of
one cable to positive (+) terminals of
each battery, (2) connect one end of
other cable to negative (-) terminal of
"good" battery, (3) connect other end
of cable to engine block on vehicle
being started (NOT TO NEGATIVE
(-) TERMINAL OF BATTERY). Use
the starting instructions in the "Get-
ting to Know Your Car" section of
this guide. To prevent damage to other
electrical components on vehicle being
started, make certain that engine is at
idle speed before disconnecting jumper
cables. When disconnecting cables,
remove cable from engine block before
disconnecting cable from battery posi-
tive terminal.
If the starter does not turn the engine
over, even with the booster battery
attached, refer to the following tests. Be
certain that correct battery polarity is
observed when using a booster battery;
positive to positive, and negative to
negative connection of the jumper cables.
Be sure that all lights are turned off and
all doors are closed when using a booster
battery. The starter should not be
operated continuously for periods longer
than 30 seconds at a time. An interval of
at least two minutes should be observed
between such cranking periods to protect
the starter from overheating.
ON-VEHICLE TESTING
Disconnect vacuum line to
thermactor by-pass valve before
performing any cranking tests. After
tests, run engine 3 minutes before
connecting vacuum line.
Starter Drive and Starter Test
This test is to diagnose a starter drive
that occasionally slips.
Flood the warm engine by pumping
the accelerator eight to ten times. Turn
the ignition key to start and hold it in the
start position. The engine should fire
immediately, but should not start and
run. The starter should continue to crank
the engine. This indicates a normal
acceptable starter drive. If the engine
stops turning and the starter spins at high
speed, the drive is not operating properly
and should be replaced. Whenever
possible, remove the plunger cover to
observe if the plunger pole is operating on
the vehicle. Do not damage the exposed
switch during starter installation or
removal.
Positive Engagement Starter
Alternate Starter Drive Test
1. With the transmission in park or
neutral only, pull the push-on
connector from the starter relay
terminal(s).
2. Connect a remote control starter
switch to the starter relay "S" and
"BATTERY" terminals.
3. Turn the ignition switch key to the
ON position and depress the remote
control starter switch. As soon as the
engine begins to run, turn ignition key
to "OFF" position while holding the
remote control switch in the START
position. The dead engine should now
be cranked by the starter.
4. Observe if the starter is cranking the
dead engine and if it continues to
crank the engine until the remote
control switch is released. If the
starter does not crank the dead
•engine, the drive assembly is slipping.
5. Repeat the test at least three times in
succession to detect intermittent
operation.
Starter Cranking Circuit Test
Excessive resistance in the starter
circuit can be determined from the results
of this test. Make the test connections as
shown in Fig. 2. Crank the engine with
the ignition OFF. This is accomplished
by disconnecting the push-on connec-
tor(s) at the starter relay and by
connecting a remote-control starter
switch from the battery terminal of
the starter relay to the "S" terminal
of the relay.
The voltage drop in the circuit will be
indicated by the voltmeter (0 to 2 volt
range). Maximum allowable voltage drop
should be:
1. 0.5 volt with the voltmeter negative
lead connected to the starter terminal
and the positive lead connected to the
battery positive terminal (Fig. 2,
connection 1).
2. 0.1 volt with the voltmeter negative
lead connected to the starter relay
(battery side) and the positive lead
connected to the positive terminal of
the battery (Fig. 2, connection 2).
3. 0.3 volt with the voltmeter negative
lead connected to the starter relay
(battery side) and the positive lead
connected to the positive terminal of
the battery (Fig. 2, connection 3).
4. 0.1 volt with the voltmeter negative
lead connected to the negative
terminal of the battery and the
positive lead connected to the engine
ground (Fig. 2, connection 4).
Starter Load Test
Connect the test equipment as shown
in Fig. 3. Be sure that no current is
flowing through the ammeter and heavy-
duty carbon pile rheostat portion of the
c i r c u i t ( r h e o s t a t at maximum
counterclockwise position).
28-02-2
Crank the engine with the ignition
OFF, and determine the exact reading on
the voltmeter. This test is accomplished
by disconnecting the push-on connector
"S" at starter relay and by connecting a
remote-control starter switch from the
positive battery terminal to the " S "
terminal of the starter relay.
Stop cranking the engine, and reduce
the resistance of the carbon pile until the
voltmeter indicates the same reading as
that obtained while the starter cranked
the engine. The ammeter will indicate the
starter current draw under load.
BENCH TESTS
Starter No-Load Test
The starter no-load test will uncover
such faults as open or shorted windings,
rubbing armature, and bent armature
shaft. The starter can be tested, at no-
load, on the test bench only.
Make the test connections as shown
in Fig. 4. The starter will run at no-load.
Be sure that no current is flowing
through the ammeter (rheostat at
maximum counterclockwise position).
Determine the exact reading on the
voltmeter.
Disconnect the starter from the
battery, and reduce the resistance of the
rheostat until the voltmeter indicates the
same reading as that obtained while the
starter was running. The ammeter will
indicate the starter no-load current draw.
Armature Open Circuit Test
An open circuit armature may
sometimes be detected by examining the
commutator for evidence of burning. A
STARTER
J1259-E
FIG. 2 Starter Cranking Circuit Test
 28-02-3 Positive Engagement Starter 28-02-3

CARBON PILE RHEOSTAT

VOLTMETER
AMMETER

POSITIVE LEAD

TO OTHER CIRCUITS

STARTER RELAY -ft- J TO IGNI'ION

SWITCH

STARTER SWITCH
(ON IGNITION
SWITCH)

TO IGNITION
COIL
(PINTO AND
TO BATTERY MAVERICK) STARTER
BATTERY

JI086-H

FIG. 3 Starter Load Test

JUMPER LEAD-
DO NOT CONNECT
LEAD TO BEARING KEEF BOTH
POSITIVE SURFACE FIELD ['RUSHES
AND hOLl. ING COIL
LEADS
GROUND LEAD
AWAY FROM
i-R",ME

9 DISCONNECT
HOLDING COIL
GROUND LEAD
INSERT INSULATOR
BETWEEN CONTACTS

VOLTMETER POSITIVE LEAD- VOLTMETER

TOUCH TO COMMUTATOR POSITIVE
BATTERY J1088-D LEAD
J1087-E J1094-D

FIG. 4 Starter No-Load Test on Test FIG. 5 Armature Grounded Circuit FIG. 6 Field Grounded Circuit "est
Bench Test

spot burned on the commutator is caused
by an arc formed every time the
commutator segment, connected to the
open circuit winding, passes under a
brush.
Armature and Field Grounded
Circuit Test
This test will determine if the winding
insulation has failed, permitting a
conductor to touch the frame or shown in Fig. 6. If the voltmeter indicates
armature core. any voltage, the field windings are
To determine if the armature grounded.
windings are grounded, make the
connections as shown in Fig. 5. If the
voltmeter indicates any voltage, the
windings are grounded.
Grounded field windings can be
detected by making the connections as
28-02-4
REMOVAL AND INSTALLATION
POSITIVE ENGAGEMENT STARTER
All Models Except Pinto, Bobcat,
Mustang and Granada/Monarch
302 V-8
1. Disconnect negative battery cable.
2. Raise the vehicle on a hoist and
position stands (models with 8-cyl.
engine and Ford 6-cyl.).
3. Disconnect the starter cable at the
starter terminal.
4. Remove the starter mounting bolts.
5. Remove the starter assembly. On
some models it is necessary to turn
the wheels to the left or right to
remove the starter.
6. Position the starter assembly to the
flywheel housing, and start the
mounting bolts.
7. Snug all bolts, while holding the
starter squarely against its mounting
surface and fully inserted into the
pilot hole. Torque the bolts to
specification.
8. Connect the starter cable and lower
vehicle. Connect battery cable.
Pinto, Bobcat and Mustang
Removal
1. Remove ground cable from battery.
2. Raise car on hoist and remove four
bolts retaining crossmember under
bell housing.
3. Remove the flex coupling clamping
screw at attachment point to steering
gear.
OVERHAUL
POSITIVE ENGAGEMENT STARTER
Use the following procedure when it
becomes necessary to completely
overhaul the starter. Figs. 8 and 9
illustrate a disassembled starter.
Disassembly
1. Loosen the brush cover band
retaining screw and remove the brush
cover band and the starter drive
plunger lever cover. Observe the lead
positions for assembly and then
remove the commutator brushes from
the brush holders.
2. Remove the through bolts, starter
drive end housing, and the starter
drive plunger lever return spring.
3. Remove the pivot pin retaining the
starter gear plunger lever and remove
the lever and the armature.
4. Remove the stop ring retainer.
Remove and discard the stop ring
retaining the starter drive gear to the
end of the armature shaft, and remove
the starter drive gear assembly.
5. Remove the brush end plate.
6. Remove the two screws retaining the
ground brushes to the frame.
Positive Engagement Starter
4. Remove (3) three nuts and bolts that
attach steering gear to crossmember.
5. Disengage steering gear from flex
coupling and pull steering gear down
to provide access to starter motor.
6. Disconnect starter cable from motor.
7. Remove starter motor attaching bolts
(3) and remove motor.
Installation
1. Position starter motor to engine and
holdfirmlyin place against mounting
surface, then install (3) attaching
bolts.
2. Install starter cable to motor.
3. Position steering gear splined shaft to
flex coupling and steering gear to
crossmember. (Observe line on
coupling at flat on shaft.)
4. Install (3) attaching bolts and nuts to
steering gear and crossmember.
5. Install clamping screw to flex
coupling.
6. Install crossmember using (4) bolts
and nuts. Lower car to floor.
7. Connect battery ground cable.
Granada/Monarch—302 V-8
Removal
1. Remove ground cable from battery.
2. Hoist vehicle.
3. Disconnect starter cable from starter.
STARTER DRIVE
PLUNGER LEVER
PLUNGER RETURN
SPRING
BUSHING
DRIVE END HOUSING
STARTER DRIVE
WASHER
FIG. 8 Positive Engagement Starter Disassembled—Except 2800 V-6 Engines
28-02-4
4. Remove the thru bolt and nut
retaining the insulator to mounting
bracket.
5. Remove the two bolts retaining the
insulator to block and remove the
insulator from the vehicle.
6. Position jack under engine and raise
it.
7. Remove starter retaining bolts and
remove starter.
Installation
1. Position starter to flywheel housing
and install the two retaining bolts.
2. Connect starter cable to starter.
3. Position insulator to vehicle and start
the two retaining bolts to cylinder
block.
4. Lower engine and install thru bolt
and nut retaining insulator to
mounting bracket. Torque all bolts
and remove jack.
5. Lower vehicle.
J1640-A
FIG. 7 Starter Cable Mounting
2800cc V-6 Pinto, Bobcat and
Mustang
POLES
J1644-B
28-02-5
7. On the field coil that operates the
starter drive gear actuating lever,
bend the tab up on the field coil
retaining sleeve and remove the
sleeve.
8. Remove the three coil retaining
screws, using Tool 10044-A and an
arbor press (Fig. 10). The arbor press
prevents the wrench from slipping out
of the screw. Unsolder the field coil
leads from the terminal screw, and
remove the pole shoes and coils from
the frame. Use a 300-watt iron.
9. Cut (or unsolder) the insulated brush
leads from the field coils, as close to
thefieldconnection point as possible.
10. Remove the starter terminal nut,
washer, insulator and terminal from
the starter frame. Remove any excess
solder from the terminal slot.
Cleaning and Inspection
1. Use a brush or air to clean the field
coils, armature, commutator,
armature shaft, brush end plate, and
drive end housing. Wash all other
parts in solvent and dry the parts.
2. Inspect the armature windings for
broken or burned insulation and
unsoldered connections.
3. Check the armature for open circuits
and grounds.
4. Check the commutator for run out
(Fig. 11). Inspect the armature shaft
and the two bearings for scoring and
excessive wear. If the commutator is
rough, or more than 0.005 inch out-
of-round, turn it.
5. Check the brush holders for broken
springs and the insulated brush
holders for shorts to ground. Tighten
any rivets that may be loose. Replace
the brushes if worn to 1/4 inch in
length.
6. Inspect the field coils for burned or
broken insulation and continuity.
7. Check the field brush connections
and lead insulation. A brush kit and
a contact kit are available. All other
assemblies are to be replaced rather
than repaired.
8. Examine the wear pattern on the
starter drive teeth. The pinion teeth
must penetrate to a depth greater than
1/2 the ring gear tooth depth (Fig.
12), to eliminate premature ring gear
and starter drive failure.
9. Replace starter drives and ring gears
with milled, pitted or broken teeth or
evidence of inadequate engagement
(Fig. 12).
Assembly
1. Install the starter terminal, insulator,
washers, and retaining nut in the
frame (Fig. 13). Be sure to position
the slot in the screw perpendicular to
the frame end surface.
2. Position the coils and pole pieces,
with the coil leads in the terminal
Positive Engagement Starter 28-02-5
STARTER DRIVE
PLUNGER LEVER
POLE SHOE +j$f
SCREW
3RUSH
END
3
LATE
BUSHING
^SSY.
COIL RETAINING FLANGE
DRIVE -—COIL RETAINING SLEIEVE
END
HOUSING
POLE SHOES
JI646-A
FIG. 9 Positive Engagement Starter Disassembled—2800 V-6 Engines
screw slot, and then install the the armature shaft and position the
retaining screws (Fig. 10). As the pole armature in the starter frame.
shoe screws are tightened, strike the
frame several sharp blows with a soft-
faced hammer to seat and align the USE Arbor Press TO HOLD
pole shoes, then stake the screws. Tool IN SCREW SOCKET
3. Install the solenoid coil and retainer
ool-10044-A
and bend the tabs to retain the coils
to the frame.
4. Solder the field coils and solenoid
wire to the starter terminal using
rosin core solder. Use a 300-watt iron.
5. Check for continuity and grounds in
the assembled coils.
6. Position the new insulated field
brushes lead on thefieldcoil terminal.
Install the clip provided with the
brushes to hold the brush lead to the
terminal. Solder the lead, clip, and
terminal together, using rosin core BE SURE TO^SEAT^DRIVE HEA
solder (Fig. 13). Use a 300-watt iron. IN SCREW SOCKET"**' J1059-D
7. Position the solenoid coil ground
terminal over the nearest ground FIG. 10 Pole Shoe Screw Removal
screw hole.
8. Position the ground brushes to the Dial Indicator
starter frame and install the retaining
screws (Fig. 13).
9. Position the starter brush end plate to ROTATE
the frame with the end plate boss in ARMATURE SHAFTS
the frame slot. ON BEARING SURFACES
10. Apply a thin coating of Lubriplate
777 on the armature shaft splines.
Install the starter motor drive gear
assembly to the armature shaft and
install a new stop ring. Install a new
stop-ring retainer. "V" Blocks
11. Position the fiber thrust washer 11091-C
(except molded commutator
armatures) on the commutator end of FIG. 11 Commutator Runout Check
28-02-6
NORMAL WEAR PATTERN
FIG. 12 Pinion and Ring Gear Wear Patterns
12. Position the starter drive gear plunger
lever to the frame and starter drive
assembly, and install the pivot pin.
13. Partially fill the drive end housing
bearing bore with grease
(approximately 1/4 full). Position the
starter drive plunger lever return
spring and the drive end housing to
the frame and install and. tighten the
through bolts to specification (55 to
75 in-lbs.). Do not pinch the brush
leads between the brush plate and the
frame. Be sure that the stop ring
retainer is seated properly in the drive
housing.
14. Install the brushes in the brush
holders. Be sure to center the brush
springs on the brushes.
15. Position the drive gear plunger lever
cover on the starter and install the
brush cover band with a gasket.
Tighten the band retaining screw.
16. Check the starter no-load current
draw.
Starter Drive Replacement
1. Loosen and remove the brush cover
band and the starter drive plunger
lever cover (Figs. 8 and 9).
2. Loosen the through bolts enough to
allow removal of the drive end
housing and the starter drive plunger
lever return spring.
3. Remove the pivot pin retaining the
starter drive plunger lever and
remove the lever.
Positive Engagement Starter 28-02-6
MILLED CONDITION-
EXCESSIVE WEAR ON
2 OR 3 TEETH
MILLED TOOTH-METAL
BUILD-UP WILL NOT
PERMIT ENGAGEMENT
SMALL WEAR PATTERN
MILLED GEARS
J 1372-A
4. Remove the drive gear stop ring 2. Remove the two through bolts from
retainer and stop ring from the end of the starter frame.
the armature shaft and remove the 3. Remove the drive end housing, and
drive gear assembly. the plunger lever return spring.
5. Apply a thin coating of Lubriplate 4. Remove the starter drive plunger
777 on the armature shaft splines. lever pivot pin and lever, and remove
Install the drive gear assembly on the the armature.
armature shaft and install a new stop
ring.
6. Position the starter gear plunger lever GROUND BRUSH
on the starter frame and install the STARTER DRIVE
pivot pin. Be sure that the plunger ACTUATING COIL
lever properly engages the starter AND H O L D I N G ,
COI
drive assembly.
7. Install a new stop-ring retainer. K.
Partially fill the drive end housing
bearing bore with grease
(approximately 1/4 full). Position the
starter drive plunger lever return
spring and drive end housing to the
starter frame, and then tighten the
through bolts to specifications (55 to
75 in-lbs.).
8. Position the starter drive plunger
lever cover and the brush cover band,
with its gasket, on the starter. Tighten
the brush cover band retaining screw.
K V FIELD
Brush Replacement
GROUND BRUSH O USHES
1L
Replace the starter brushes when they
are worn to 1/4 inch. Always install a
IV
complete set of new brushes.
1. Loosen and remove the brush cover J1092-E
band, gasket, and starter drive
plunger lever cover. Remove the
brushes from their holders. FIG. 13 Field Coil Assembly
28-02-7
5. Remove the brush end plate.
6. Remove the ground brush retaining
screws from the frame and remove the
brushes.
7. Cut the insulated brush leads from
the field coils, as close to the field
connection point as possible.
8. Clean and inspect the starter motor.
9. Replace the brush end plate if the
insulator between the field brush
holder and the end plate is cracked or
broken.
10. Position the new insulated field
brushes lead on the field coil
connection. Position and crimp the
clip provided with the brushes to hold
the brush lead to the connection.
Solder the lead, clip, and connection
together, using rosin core solder (Fig.
13). Use a 300-watt iron.
11. Install the ground brush leads to the
frame with the retaining screws.
12. Clean the commutator with 00 or 000
sandpaper.
13. Position the brush end plate to the
starter frame, with the end plate boss
in the frame slot.
14. Install the armature in the starter
frame.
15. Install the starter drive gear plunger
lever to the frame and starter drive
assembly, and install the pivot pin.
16. Partially fill the drive end housing
bearing bore with grease
(approximately 1/4 full). Position the
return spring on the plunger lever,
and the drive end housing to the
starter frame. Install the through
bolts and tighten to specified torque
(55 to 75 in-lbs.). Be sure that the stop
ring retainer is seated properly in the
drive end housing.
17. Install the commutator brushes in the
brush holders. Center the brush
springs on the brushes.
18. Position the plunger lever cover and
the brush cover band, with its gasket,
on the starter. Tighten the band
retaining screw.
19. Connect the starter to a battery to
check its operation.
Positive Engagement Starter
Armature Replacement
1. Loosen the brush cover band
retaining screw and remove the brush
cover band, gasket, and the starter
drive plunger lever cover. Remove the
brushes from their holders.
2. Remove the through bolts, the drive
end housing, and the drive plunger
lever return spring.
3. Remove the pivot pin retaining the
starter gear plunger lever, and remove
the lever.
4. Remove the armature. If the starter
drive gear assembly is being reused,
remove the stop ring retainer and the
stop ring from the end of the armature
shaft, and remove the drive.
5. Place the drive gear assembly on the
new armature with a new stop ring.
6. Install the armature in the starter
frame.
7. Position the drive gear plunger lever
to the frame and drive gear assembly
and install the pivot pin.
8. Partially fill the drive end housing
bearing bore with grease
(approximately 1/4 full). Position the
drive plunger lever return spring, the
drive end housing and the front end
plate to the starter frame, and then
install and tighten the through bolts
to specification. Be sure that the stop
ring retainer is seated properly in the
drive housing.
9. Place the brushes in their holders, and
center the brush springs on the
brushes.
10. Position the plunger lever cover and
the brush cover band, with its gasket,
and then tighten the retaining screw.
11. Connect the starter to a battery to
check its operation.
Starter Terminal
Removal
1. Loosen the brush cover band
retaining screw and remove the brush
cover band and the starter drive
plunger lever cover. Observe the lead
positions for assembly and then
remove the commutator brushes from
the brush holders.
28-02-7
2. Remove the through bolts, starter
drive end housing, starter drive
plunger lever return spring, and the
brush end plate.
3. Remove the pivot pin retaining the
starter gear plunger lever and remove
the lever and the armature assembly.
4. Unsolder the field coil and solenoid
wire leads from the terminal screw.
Use a 300-watt soldering iron.
5. Remove the starter terminal nut,
washer, insulator and terminal from
the starter frame.
Installation
1. Install the new starter terminal,
insulator, washers, and retaining nut
in the frame (Fig. 8). Be sure to
position the slot in the screw
perpendicular to the frame end
surface.
2. Solder the field coils and solenoid
wire to the starter terminal using
rosin core solder. Use a 300-watt iron.
3. Check for continuity and grounds in
the assembled coils.
4. Position the starter brush end plate to
the frame with the end plate boss in
the frame slot.
5. Position the armature in the starter
frame.
6. Position the starter drive gear plunger
lever to the frame and starter drive
assembly, and install the pivot pin.
7. Partially fill the drive end housing
bearing bore with grease
(approximately 1/4 full). Position the
starter drive plunger lever return
spring and the drive end housing to
the frame and install and tighten the
through bolts to specification (55 to
75 in-lbs.). Do not pinch the brush
leads between the brush plate and the
frame. Be sure that the stop ring
retainer is seated properly in the drive
housing.
8. Install the brushes in the brush
holders. Be sure to center the brush
springs on the brushes.
9. Position the drive gear plunger lever
cover on the starter and install the
brush cover band with a gasket.
Tighten the band retaining sc *ew.
10. Check the starter no-load current
draw.
28-02-8 Positive Engagement Starter 28-02-8

SPECIFICATIONS
POSITIVE ENGAGEMENT STARTER
Positive Engagement Starter Motor Starter Brushes
Normal Min. Through
Current Draw Engine Stall Max. No. Mfg. Weai Spring Bolt
Dia. Under Normal Cranking Torque Load Load Length Limit Tension Torque Mounting
(Inches) Load Speed @5 Volts (Amps) (Amps) (Inches) (Inches) (Ounces) (In-Lbs) Bolt Torque
(Amps) (rpm) (Ft Lbs) (Ft-Lbs)
4 150-200 180-250 9.0 460 ', 70 0.50 0.2fi 40 55-75 15-20
4-1/2 150-180 150-290 15.5 670 80 0.50 0.2fi 80 55-75 15-20
Maximum Commutator runout is 0.005 inch. Maximum starting circuit voltage drop (battery positive terminal to starter
terminal) at normal engine temperature is 0.5 volt.

SPECIAL TOOLS
Ford Tool No. Former No. Description
TOOL10044-A 10044-A Generator Pole
Screw Wrench
CJ1430-C
28-03-1 Solenoid Actuated Starter 28-03-1

PART
Solenoid Actuator Starter 28-03

SUBJECT PAGE SUBJECT PAGE

DESCRIPTION AND OPERATION 03^ REMOVAL AND INSTALLATION

Solenoid Actuated Starter 03-4
TESTING
OVERHAUL
Bench Tests 03-3
Solenoid Actuated Starter , 03-5
On-Vehicle Testing 03-2
Road Service 03-2 SPECIFICATIONS 03-7

CN4042-A

DESCRIPTION AND OPERATION

DESCRIPTION
Starter
Major assembly components of the
solenoid actuated starter are the frame
and field coil assembly, armature
assembly, brush plate assembly, drive
assembly, shift lever assembly, drive
housing assembly and starter solenoid
assembly (Fig. 1).
The motor is a four-brush, four-field,
four-pole wound unit.
The solenoid assembly is mounted to
a flange on the starter drive housing. The
entire shift lever mechanism and the
solenoid plunger are enclosed in the drive
housing, thus protecting them from
exposure to dirt and road splash.
A metal heat shield protects the
solenoid from heat radiated by the
exhaust pipe and manifold. Without this
shield, plastic parts of the solenoid will
be damaged by excessively high
temperatures, and the solenoid will fail.
shifts the starting motor pinion into mesh
with the engine flywheel ring gear.
Simultaneously, the main contacts of
the solenoid are closed and battery
current is directed to the starting motor,
causing the armature to rotate.
After the engine starts, the starter
drive is disengaged only when the
ignition switch is released from the
START to the ON position. This opens
the circuit to the starter solenoid and the
solenoid return spring causes the shift
SOLENOID
CONNECTOR LINK
lever to disengage the starter drive from
the engineflywheelring gear.
The starting motor is protected from
short duration excessive speed by an
overrunning clutch incorporated in the
starter drive. The overrunning clutch
permits the drive pinion gear to rotate
faster than the armature as the engine
starts and picks up speed, thus protecting
the armature from being driven by the
engine.
HEAT SHIELD
•SHIFT FORK
PINION

Always install a heat shield whenever

a starter has been removed and repaired
or replaced, or whenever the shield has
fallen off or has been damaged.
The solenoid incorporates two
windings: a pull-in winding and hold-in
BRUSH-
winding. Together they provide the
magnetic attraction to pull the solenoid
plunger into the solenoid.
OPERATION OVER-RUNNING CLUTCH
Solenoid
Engine cranking occurs when the
J1414-C
solenoid on the starter is energized
through the starter control (ignition)
switch. When energized, the solenoid FIG. 1 Starter—Cross Section
28-03-2 Solenoid Actuated Starter 28-03-2

Connector Link
The positive engagement starter (Part
28-02) requires a starter relay to carry the
heavy battery current to the starter
windings. In the solenoid actuated
starter, this function is handled by
contacts in the solenoid. In vehicle SOLENOID LINK

production, however, a starter relay is

installed on vehicle lines with either type
of starter. This simplifies vehicle building BATTERY

in the assembly plants.

The solenoid actuated starter is
installed in vehicles with a starter relay,
a special "connector link" is installed on
the solenoid (Fig. 3). This link connects
the battery terminal with the solenoid
operating windings. Thus, when the key
is turned to the START position, the
starter relay is actuated, sending battery
current to the starter solenoid. The STARTER
START SWITCH AND SAFETY
current operates the solenoid and then SWITCHES IN CLOSED
the starter through solenoid internal POSITION*
contacts.
When replacing starters or starter
solenoids, be sure to replace the link. If *SEE VEHICLE WIRING DIAGRAMS BOOK J1642B
a link is not used on a starter relay
equipped vehicle, the vehicle will not FIG. 2 Starter Circuit—With Starter Relay—Lincoln Only
start.

J1641D

FIG. 3 Solenoid Connector Link

TESTING
ROAD SERVICE
On road service calls, connect a
booster battery to the system when a
starter will not crank the engine or cranks
the engine very slowly. Be certain the
transmission is in park or neutral. If the
starter does not turn the engine over,
even with booster battery attached, refer
to the following tests. Be certain that
correct battery polarity is observed when
using a booster battery; positive-to-
positive and negative-to-negative
connection of the auxiliary cables.
ON VEHICLE TESTING
Starter Cranking Circuit Test
These tests will determine whether or
not there is excessive resistance in the
cranking circuit. Make each test
connection as shown in Fig. 4. Be certain
the transmission is in park or neutral.
While cranking the engine, observe the
voltage drop reading for each test.
Disconnect and ground the high tension
lead from the ignition coil to prevent the
engine from starting. Connect a remote
control switch between the battery
terminal of the starter relay and the S
terminal of the relay. The voltage drop
in the circuit will be indicated by the
voltmeter (0 to 2 volt range). Maximum
allowable voltage drop should be:
28-03-3
0.5 volt with the voltmeter negative
lead connected to the starter terminal
and the positive lead connected to the
battery positive terminal (Fig. 4,
connection VI).
2. 0.3 volt with the voltmeter negative
lead connected to the starter terminal
and the positive lead connected to the
starter relay (battery side) (Fig. 4,
connection V2).
FIG. 4 Starter Cranking Circuit Test
CARBON PILE RHEOSTAT
AMMETER REMOTE CONTROL
POSITIVE LEAD ^STARTER SWITCH
POSITIVE LEADS
STARTER
FIG. 5 Starter Load Test
Solenoid Actuated Starter
3. 0.2 volt with the voltmeter negative
lead connected to the starter relay
(battery side) and the positive lead
connected to the positive terminal of
the battery (Fig. 4, connection V3).
4. 0.1 volt with the voltmeter negative
lead connected to the negative
terminal of the battery and the
positive lead connected to the engine
ground (Fig. 4, connection V4).
STARTER
J1413C
BATTERY STARTER TESTER
STARTER
SOLENOID
28 03-3
Starter Load Test
Connect the test equipment as shown
in Fig. 5. Be sure that no current is
flowing through the ammeter and heavy-
duty carbon pile rheostat portion of the
c i r c u i t ( r h e o s t a t at m a x i m u m
counterclockwise position).
Crank the engine with the ignition
OFF and transmission in park or leutral,
and determine the exact reading on the
voltmeter. For Lincoln only this test is
accomplished by disconnecting the push-
on connector from the " I " terminal on
the relay and by connecting a jumper
from the battery terminal of the starter
solenoid to the ignition switch " S "
terminal of the relay.
Stop cranking the engine, and reduce
the resistance of the carbon pile until the
voltmeter indicates the same reacing as
that obtained while the starter cranked
the engine. The ammeter will indicate the
starter current draw under load.
Starter Solenoid Test
If the solenoid does not pull in (starter
load test) measure the voltage between
the starter mounted solenoid .switch
terminal and ground with the ignition
switch closed. If the reading is 10 volts
or more, a worn or damaged solenoid is
indicated. Remove the starter assembly
for solenoid replacement.
BENCH TESTS
Starter No-Load Test
This test will uncover such faults as
open or shorted windings, rubbing
armature, and bent armature.
IGNITION SWITCH
Red-Blue
REMOTE
CONTROL!
SWITCH J1415-C
28-03-4 Solenoid Actuated Starter 28-03-4

Make the test connections as shown

in Fig. 6. The starter will run at no load.
Be sure that no current is flowing
through the ammeter (rheostat at
maximum counterclockwise position).
Determine the exact reading on the
voltmeter.
Disconnect the starter from the
battery, and reduce the resistance of the
rheostat until the voltmeter indicates the
same reading as that obtained while the
starter was running. The ammeter will
indicate the starter no-load current draw.

TESTER

J1417-A JU18-A

FIG. 7 Armature Grounded Circuit FIG. 8 Field Grounded Circuit Test

BATTERY
BENCH TEST J1416-C
FIG. 6 Starter No-Load Test on Test
Bench
Armature Open Circuit Test
An open circuit armature may
sometimes be detected by examining the
commutator for evidence of burning. A
spot burned on the commutator is caused
Test
by an arc formed every time the
commutator segment, connected to the
open circuit windings, passes under a
brush.
Armature and Field Grounded
Circuit Test
This test will determine if the winding
insulation has failed, permitting a
conductor to touch the frame or
armature core.
To determine if the armature
windings are grounded, make the
connections as shown in Fig. 7. If the volt
meter indicates any voltage, the windings
are grounded.
Grounded field windings can be
detected by making the connections as
shown in Fig. 8. If the voltmeter indicates
any voltage, the field windings are
grounded.

REMOVAL AND INSTALLATION

SOLENOID ACTUATED STARTER
Removal
1. Disconnect the battery ground cable,
and raise the vehicle on a hoist.
2. Disconnect the cable and wires at the
terminals on the solenoid.
3. On Thunderbird and Continental
Mark V—loosen the two front brace
attaching bolts. Remove all other
brace attaching bolts and allow brace
to hang.
4. Turn the front wheels fully to the
right. Remove the two bolts attaching
the steering idler arm to the frame.
5. Remove the starter mounting bolts
and remove the starter assembly.
Installation
1. Position the starter assembly to the
starter mounting plate and start the
mounting bolts.
2. Snug the starting motor mounting
bolts while holding the starter
squarely against the mounting surface
and fully inserted into the pilot hole.
Torque the mounting bolts to 15 to 20
ft.-lbs.
3. Connect the cable and wires to the
terminals on the solenoid (Fig. 9).
Tighten the battery cable nut to 45 to
95 in-lbs torque.
4. Install and tighten the brace attaching r
J1434-B
b o l t s on T h u n d e r b i r d and
Continental Mark V models.
5. Install the steering idler arm bracket FIG. 9 Starter Cable Connections
to the car frame. Tighten the bolts to
28 to 35 ft-lbs torque, lower the
vehicle, and connect the battery
ground cable.
28-03-5
OVERHAUL
SOLENOID ACTUATED STARTER
Disassembly
1. Disconnect the copper strap from the
starter terminal on the solenoid,
remove the retaining screws and
remove the solenoid from the drive
housing (Fig. 10).
2. Loosen the retaining screw and slide
the brush cover band back on the
starter frame for access to the
brushes.
3. Remove the commutator brushes
from their holders. Hold each spring
away from the brush with a hook,
while sliding the brush out of the
holder.
4. Remove the through-bolts and
separate the drive-end housing,
starter frame and brush end plate
assemblies.
5. Remove the solenoid plunger and
shift fork assembly. If either the
plunger or fork is to be replaced, they
can be separated by removing the roll
pin.
6. Remove the armature and drive
assembly from the frame. Remove the
drive stop ring and slide the drive
assembly off the armature shaft.
Remove the drive stop ring retainer
from the drive housing.
BRUSH END PLATE
ASSEMBLY-11049
SHIFT FORK-11067
DRIVE ASSEMBLY
-11350
DRIVE STOP RING-11222
DRIVE STOP RING RETAINE
-11223
DRIVE PINION THRUST WASHER-11036
FIG. 10 Starter Disassembled
Solenoid Actuated Starter
Cleaning and Inspection
1. Do not wash the drive because the
solvent will wash out the lubricant,
causing the drive to slip. Use a brush
or compressed air to clean the drive,
field coils, armature, commutator,
armature shaft front end plate, and
rear end housing. Wash all other parts
in solvent and dry the parts.
2. Inspect the armature windings for
broken or burned insulation and
unsoldered connections.
3. Check the armature for open circuits
and grounds.
4. Check the commutator for runout
(Fig. 11). Inspect the armature shaft
and the two bearings for scoring and
excessive wear. On a starter with
needle bearings apply a small amount
of grease to the needles. If the
commutator is rough, or more than
0.005 inch out-of-round, turn it down.
5. Check the brush holders for broken
springs and the insulated brush
holders for shorts to ground. Tighten
any rivets that may be loose. Replace
the brushes if worn to 1/4 inch in
length.
6. Check the brush spring tension.
Replace the springs if the tension is
28-03-5
not within specified limits (80 ounces
minimum).
7. Inspect the field coils for buried or
broken insulation and continuity.
Check the field brush connections
and lead insulation. A brush kit is
available. All other assemblies are to
be replaced rather than repaired.
8. Examine the wear pattern on the
starter drive teeth. The pinion teeth
must penetrate to a depth greater than
1/2 the ring gear tooth depth (Fig.
12), to eliminate premature ring gear
and starter drive failure.
Dial Indicator
ROTATE
ARMATURE SHAFTS •
O N BEARING SURFACES v
" V Blocks
J1091-C
FIG. 11 Commutator Runout Check
SOLENOID ASSEMBLY-11390
PLUNGER 11393
J1403-E
28-03-6
9. Replace starter drives and ring gears
with milled, pitted or broken teeth or
evidence of inadequate engagement
(Fig. 12).
Assembly
1. Install a small amount of Lubriplate
(or equivalent) on the armature shaft
splines. Install the drive assembly on
the armature shaft and install a new
stop ring (Fig. 10).
2. Apply a small amount of Lubriplate
(or equivalent) on the shift lever pivot
pin. Position the solenoid plunger and
shift lever assembly in the drive
housing.
3. Place a new retainer in the drive
housing. Apply a small amount of
Lubriplate (or equivalent) to the drive
end of the armature shaft. Place the
armature and drive assembly into the
drive housing. Be sure that the shift
lever tangs properly engage the drive
assembly.
4. Apply a small amount of Lubriplate
(or equivalent) on the commutator
end of the armature shaft.
5. Position the frame andfieldassembly
to the drive housing. Be sure that the
frame is properly indexed to the drive
housing assembly.
6. Position the brush plate assembly to
the frame assembly. Be sure that the
brush plate is properly indexed to the
NORMAL WEAR PATTERN
FIG. 12 Pinion and Ring Gear Wear Patterns
Solenoid Actuated Starter
frame. Install the through-bolts and
tighten to 45 to 85 in-lbs.
7. Place the brushes in their holders.
Pull each spring away from the holder
with a hook to allow entry of the
brush. Center the brush springs on
the brushes. Press the insulated brush
leads away from all other interior
components to prevent possible
shorts.
8. Position the rubber gasket between
the solenoid mounting and the upper
outside surface of the frame. Position
the starter solenoid with metal gas (if
used), and install the solenoid
mounting screws.
9. Connect the copper strap to the
starter terminal on the solenoid.
10. Position the cover band and tighten
the retaining screw.
11. Connect the starter to a battery to
check its operation.
Brush Replacement
Replace the starter brushes when they
are worn to 1/4 inch. Always install a
complete set of hew brushes.
1. Disconnect the copper strap from the
starter terminal on the solenoid.
2. Loosen the retaining screw and slide
the brush cover band back on the
starter frame for access to the
brushes.
MILLED CONDITION.
EXCESSIVE WEAR ON
2 OR 3 TEETH
SMALL WEAR PATTERN
28-03-6
3. Remove the commutator brushes
from their holders. Hold each spring
away from the brush with a hook,
while sliding the brush out of the
holder.
4. Remove the through-bolts and
separate the drive end housing, starter
frame and brush end plate assemblies.
5. Remove the ground brush retaining
screws from the frame and remove the
brushes.
6. Cut the insulated brush leads from
the field coils, as close to the field
connection point as possible.
7. Clean and inspect the starter motor.
8. Replace the brush end plate, if the
insulator between the field brush
holder and the end plate is cracked or
broken.
9. Position the new insulated field
brushes lead on the field coil
connection. Position and crimp the
clip provided with the brushes to hold
the brush lead to the connection.
Solder the lead, clip, and connection
together, using rosin core solder. Use
a 300-watt iron.
10. Install the ground brush leads to the
frame with the retaining screws.
11. Clean the commutator with 00 or 000
sandpaper.
12. Apply a small amount of Lubriplate
on the commutator end of the
armature shaft.
MILLED TOOTH-METAL
BUILD-UP WILL NOT
PERMIT ENGAGEMENT
MILLED GEARS
J 1372-A
28-03-7 Solenoid Actuated Starter 28-03-7

13. Position the rubber gasket over the making certain that the insulated components to prevent pcssible
solenoid plunger lever, then position brush lead is not between the shorts.
the frame to the end housing so that through-bolt and the frame, and 16. Slide the cover band into position and
the wide slot in the frame clears the tighten to 45 to 85 in-lbs. tighten the retaining screw.
plunger lever and the end housing 15. Place the brushes in their holders.
dowel is indexed with its frame slot. Pull each spring away from the holder 17. Connect the copper strap to the
14. Position the brush plate assembly to with a hook to allow entry of the starter terminal on the solenoid.
the frame assembly. Be sure that the brush. Center the brush springs on 18. Connect the starter to a battery to
brush plate is properly indexed to the the brushes. Press the insulated brush check its operation.
frame. Install the through-bolts, leads away from all other interior

SPECIFICATIONS
SOLENOID ACTUATED STARTER
Bolt Torque
Solenoid Actuated Starter Motor Starter Brushes (Ft.-Lbs.)
Normal Through 5/16 h .
Current Draw Engine No. Mfg. Wear Spring Bolt Bolt Three
Dia. Under Normal Cranking Load Length Limit Tension Torque Hole Mfg.
(Inches) Load (Amps) Speed (rpm) (Amps) (Inches) (Inches) (Ounces) (In-Lbs)
@70°F.
4-1/2 180-210 140-170 70 0.50 0.25 40 45-85 15-20
M a x i m u m C o m m u t a t o r r u n o u t is 0 . 0 0 5 i n c h . M a x i m u m s t a r t i n g c i r c u i t v o l t a g e d r o p ( b a t t e r y p o s i t i v e t e r m i n a l t o s t a r t e r
t e r m i n a l ) at n o r m a l e n g i n e t e m p e r a t u r e is 0.5 v o l t .

SPECIAL TOOLS
Ford Tool No. Former No. Description
TOOL 10044-A 10044-A Generator Pole
Screw Wrench
1452-B
29-01-1
ENGINE EMISSION
CONTROL SYSTEMS
PART TITLE
E6R System
Engine Diagnosis and Service
Emission Systems General Service
SUBJECT
GENERAL INFORMATION
Air Cleaner Mounted Switches
Emission Related Fuel System
Components
Emission Related Miscellaneous
Components
GENERAL INFORMATION
The Engine Emission Control
Systems section of this Manual is
designed to cover those adjustments and
service operations required to meet
factory specifications for passenger cars.
General information for emission
reduction systems and miscellaneous
emission related parts will be covered in
Part 29-01, while service for the various
components will be carried in the
individual Parts. Engine Diagnosis is
covered in Part 29-02.
IDENTIFICATION
Each passenger car is equipped with
a decal containing emission control data
that applies specifically to that vehicle
and engine. This data is critical to the
servicing of the emission systems (Fig. 1).
When performing services listed in
Part 29-02, refer to this decal located
either on the engine or, in the case of
Pinto and Bobcat, on the inside front of
the engine compartment hood.
Engine Emission Control Systems
PART NO. PART TITLE
29-07 General Service
29-02 Thermactor System
All Models
PAGE SUBJECT
GENERAL INFORMATION (Cont'd.)
01-3 Emission Related Spark Control
Components
01-1 Identification
01-3
EMISSION-RELATED FUEL SYSTEM
COMPONENTS
Fuel Deceleration Valve
Deceleration valves are used to
provide enriched mixture on engine
deceleration with closed throttle (Figs. 2
and 3). When this occurs with closed
throttle, the valve provides momentary
fuel/air flow, bypassing the carburetor.
The deceleration valve is used with two
carburetors, the Motorcraft 5200 2V used
on the 2.3L engine and the 2150 2V used
on the 2.8L V-6.
The deceleration valve has two ports
and a threaded base that attaches to the
intake manifold of the engine. The
operation of the valve is controlled by
application of vacuum to the smaller of
the two side ports. When the vacuum is
applied to the control port, the valve
opens and pulls a fuel/air mixture from
the carburetor deceleration system into
the intake manifold (Fig. 3).
On the conventional system, control
vacuum is applied directly from the
29-01-1
GROUP
(9000)
PART NO.
29-01
29-03
CA4253-A
PART
29-01
PAGE
01-2
01-1
CA4254-A
engine intake manifold. In this way, the
decel valve will open any time the
manifold vacuum reaches the specified
limit and close when vacuum falls below
this figure.
A / C Modulated Fuel Decel Valve
On Mustang vehicles with the 2.8L V-
6 engine, the fuel deceleration system is
tied into vehicle air conditioner (Fig. 4).
In this way the system is prevented from
operating when the air conditioner is
OFF, and allowed to operate when the air
conditioner is ON. The interlock is
designed to prevent the deceleration
system from acting upon engine idle
when the air conditioner is OFF.
Electric Assisted Choke
All passenger cars except those with
the Motorcraft model 5200 2V
carburetor, use an electrically-assisted
choke thermostatic spring heater as an
aid to fast choke release and better
emission characteristics during engine
warm-up (Fig. 5). The heaters are
temperature sensitive and operate from
29-01-2 Emission Systems General Service 29-01-2

FORD MOTOR COMPANY SHIFT MAINT. Q the spark port line is evacuated. The
L
1 VEHICLE EMISSION CONTROL INFORMATION 1
SCHED. SCHED. D sintered metal restrictor located in the
ENGINE FAMILY 302 D" (1CVS) EGR/CATALYST/PCV MAKE ALL ADJUSTMENTS WITH EN
vent valve diaphragm acts as a spark
ENGINE DISPLACEMENT 302 CID
GINE AT NORMAL OPERATING delay valve slowing spark advance.
TEMPERATURE. A/C AND HEADLIGHTS
SPARKPLUG ARF52 GAP .048,052
OFF. CONSULT SERVICE PUBLICATIONS When spark port vacuum decreases,
FOR ADDITIONAL INSTRUCTIONS ON
VALVE HYD - THE FOLLOWING PROCEDURES.
the check valve closes and the dump
LASH NOT ADJ IGNITION TIMING - ADJUST WITH valve opens the distributor vacuum line
HOSES DISCONNECTED AND PLUGGED
TRANSMISSION/GEAR AUTO/NEUT AUTO/DRIVE MAN/NEUT AT THE DISTRIBUTOR; AND AT THE to atmosphere. Venting the distributor
IGNITION TIMING 6° BTDC
VACUUM SWITCH. IF EQUIPPED WITH
CCT SYSTEM.
vacuum line to atmosphere prevents fuel
TIMING RPM 500 CURB IDLE - ADJUST WITH ALL VAC- migration to the distributor diaphragm
CHOKE SETTING INDEX ; ^ _ _ ^
UUM HOSES CONNECTED. AIR CLEANE
IN POSITION AND THROTTLE SOLENO D
and returns the distributor to zero
FAST IDLE HIGH CAM 2100 POSITIONER ENERGIZED (IS SO EQUIPPED). vacuum advance.
RPM KICKDOWN IDLE MIXTURE - PRESET AT THE FAC
TORY. DO NOT REMOVE THE LIMITER
Cold Start Spark Advance
CURBIDLE A/C 650 CAP(S). EXCEPT IN ACCORDANCE WITJ\ (CSSA)
RPM NON-A/C 650 SERVICE PUBLICATIONS.
TSPOFF A/C ""~\ ^-"^ On some engines, a Cold Start Spark
RPM NONA/C Advance System (CSSA) is added to the
IDLE MIXTURE ARTIFICIAL ENRICHMENT RPM distributor spark control system (Fig.
STD. FLOW GAIN 30 110 "REPLACE PCV WITH HIGH FLOW VALVE 11).
PCV VALVE RESET 4080 NO. EV 93 AT AND AFTER 30.000 MILES.
HIGHF LOW GAIN 8CM80
This system momentarily traps spark
PCVVA IVE RESET 80 120 CATALYST port vacuum on the distributor spark
advance diaphragm when the engine
D7BE-9C485-MA 7-025 coolant temperature is below 125° F. The
vacuum path is from the carburetor
A4056-C
vacuum tap, through the Distributor
Retard Control Valve (DRCV), through
FIG.1 Typical Emission Control Decals the CSSA PVS, through the cooling
PVS and to the distributor.
current supplied from the center tap of operated vacuum switching devices. A At and above the CSSA PVS tem-
the alternator when the engine is running typical three-port PVS is used in the perature, the CSSA PVS is operated.
(Fig. 7). cooling system to increase engine idle Vacuum then reaches the distributor
The temperature sensitive electric rpm when the engine overheats (Fig. 8). as follows: from the carburetor spark
choke assist system consists of a choke When cold, the 3-port PVS provides port, through the SDV, through the
cap, thermostatic spring, a bi-metal a path through the top and center ports. CSSA PVS, through the cooling PVS
temperature sensing disc (switch), and a When hot, only the center and bottom and to the distributor.
ceramic positive temperature coefficient ports are connected. In the case of the Above 235° F., the cooling PVS
(PTC) heater. The current to operate the cooling PVS, this provides carburetor operates, directing intake manifold
system is supplied from the center tap of spark port vacuum to the distributor vacuum to the distributor. In an over-
the alternator to the temperature sensing vacuum advance under normal (cool) temperature situation at idle, this will
switch. conditions and switches to engine increase engine rpm by providing
The system is grounded through a manifold vacuum for increased idle speed increased vacuum. When the engine
ground strap connected to the carburetor when the engine is abnormally hot. As temperature decreases, spark will once
body. At t e m p e r a t u r e s below soon as the engine cools off, carburetor more be controlled from the spark port
approximately 60 degrees F, the switch spark port vacuum is once again selected of the carburetor.
is open and no current is supplied to the and the idle speed decreases as the spark Electric Ported Vacuum Switch
ceramic heater located within the is retarded again. (PVS)
thermostatic spring. Normal Distributor Vacuum Vent Valve The electric PVS is used in some
thermostatic spring choking action then Some engines equipped with the Thermactor equipped engines that have
occurs. At temperatures above Motorcraft model 2700 carburetor catalytic converters in the exhaust
approximately 60 degrees F, the require a distributor vacuum vent valve.
temperature sensing switch closes and The primary functions of the valve are to
current is supplied to the ceramic heater. prevent fuel migration to the distributor
As the heater warms, it causes the and to act as a delay valve.
thermostatic spring to pull the choke The distributor vacuum vent valve
plates open within 1 to 1-1/2 minutes. (Fig. 9) helps control exhaust emissions
The electric choke system used on the by delaying vacuum spark advance
5200 2V carburetor is installed between during light acceleration and by
the choke thermostatic spring and the "dumping" vacuum to eliminate vacuum
choke casting and heats whenever the advance during heavy acceleration,
engine is running. deceleration and idle. The valve also
eliminates fuel migration to the
EMMISION RELATED SPARK
distributor diaphragm.
CONTROL COMPONENTS When spark port vacuum is applied
Ported Vacuum Switches (PVS) to the vent valve diaphragm (Fig. 10), the
These switches are used in several dump valve closes, the check valve opens STER

places in emission control and other and the distributor diaphragm begins to A<iO75-A

engine systems. They consist of two- evacuate through the sintered metal FIG. 2 Adjustable Fuel Deceleration
three- or four-port coolant temperature restrictor. At the same time, any fuel in Valve
29-01-3 Emission Systems #e\ 29-01-3

system. It is a combined vacuum

switching device and electric signalling
device that is used in two versions: CARBURETOR
normally closed electric contacts and
normally open electric contacts (Fig. 12).
Spark Delay Valves (SDV)
Spark delay valves are installed on
many engines to permit closer control of
vacuum operated emission related
equipment. All SVD's have an internal
sintered orifice to slow air flow in one 3) MIXTURE FLOWS INTO INTAKE
direction, a check valve to allow free air FUEL/AIR
MANIFOLD.
flow in the opposite direction, and a filter. MIXTURE HOSE
They can be installed on previous model
year vehicles (Fig. 13).
INTAKE MANIFOLD
EMISSION RELATED
MISCELLANEOUS COMPONENTS
PCV Valve and Crankcase Vent WHEN MANIFOLD VACUUM IS
Cap HIGH, VALVE OPENS.

All engines are equipped with a closed HOSE CARRIES FUEL-AIR MIXTURE
crankcase emission control system that FROM CARBURETOR TO VALVE.

features a filler cap ventilated to the FUEL

DECEL VALVE
crankcase and a vacuum-operated A4076-A
Positive Crankcase Ventilation (PCV)
valve (Fig. 15).
When the engine is running, vapors FIG. 3 Conventional Fuel Deceleration System (2150 Carburetor Shown)
that may escape past piston rings are
pulled back into the intake manifold,
causing fresh air to flow into the OPERATION - A / C OFF
crankcase through thefillercap. Periodic SOLENOID IN VACUUM OFF
maintenance is required to keep system VALVE IS NOT ENERGIZED

operating properly. A/C SWITCH

AIR CLEANER MOUNTED A/C SWITCH IS IN

OFF POSITION
SWITCHES
Cold Weather Modulator (Fig.
16)
The Cold Weather Modulator is a DECEL VALVE
IS INOPERATIVE
vacuum modulator located in the air WITH NO VACUUM
cleaner on some models. During engine
operation in cold ambient tempera-
tures, it prevents the air cleaner duct NO VACUUM IS
APPLIED TO
door from opening to non-heated CARBURETOR
duct door from opening to non-heated DECELERATION
CIRCUIT
intake air. When available air from the
"fresh air" intake is above 55° F., the cold OPERATION - A/C ON
3) SOLENOID IN VACUUM
weather modulator does not operate. VALVE IS ENERGIZED
Normally, the duct air door will be
closed to outside air any time vacuum
from the bimetal sensor is applied. This
7 ) A/C SWITCH IS IN
occurs when the outside temperature is ON POSITION
low enough to require heated air for
carburetor intake. When the vacuum is NORMALLY CLOSED
cut off, the door will open. This occurs DECEL VALVE
when temperature rises high enough to OPERATES NORMALLY.
operate the bi-metal sensor. It also
happens during acceleration in cold
conditions. When this situation is
encountered, the Cold Weather FROM
CARBURETOR
Modulator, inserted in the vacuum line FUEL-AIR MIXTURE FROM
between the bi-metal sensor and the CARBURETOR DECEL CIRCUIT
ENTERS INTAKE MANIFOLD.
vacuum duct motor, will close the A4077-B
vacuum to the motor and hold the duct
door open. FIG. 4 A/C Modulated Fuel Decel System
29-01-4 Emission Systems General Service 29.01-4

POSITIVE TEMPERATURE
COEFFICIENT (PTC) CERAMIC
ELECTRIC
HEATER
CHOKE
CAP

TEMPERATURE
SENSITIVE
BIMETALLIC DISC

CENTER TAP OF
ALTERNATOR
(BLACK IDENTIFICATION RING)

FIG. 7 Typical Electric Assisted

Choke Wiring—Temperature
QUICK-DISCONNECT
TERMINAL Sensitive Type Shown

GROUND STRAP

V1595-B

FIG. 5 Temperature Sensitive Type Electric Assisted Choke

VACUUM DIAPHRAGM
AND SPRING

B 3104-A

FIG. 8 Cooling PVS—Typical

CHECK VALVE

RESTRICT DR
BI-METAL SPRING
SEAT

DUMP VALVE

DIAPHRAGM

TO DISTRIBUTOR
CONNECTOR
A4251-A
V2132-B
FIG. 9 Distributor Vacuum Ven*
FIG. 6 Constant Operating Type Electric Assisted Choke Valve
29-01-5 Emission Systems General Service 29-01-5

DISTRIBUTOR
VACUUM VENT
VALVE

VENT
OPENING
AIR CLEANER

CARB.

SPARK
PORT
DISTRIBUTOR

A4252-A

FIG. 10 Typical Vent Valve Installation

DRCV OR
RESTRICTOR SPARK PORT

oDIST. 2350

VACUUM TAP
INTAKE MANIFOLD
COOLANT PVS
CSSA PVS (OPTIONAL)

A4063-C

FIG. 11 Cold Start Spark Advance (CSSA) System—Typical

29-01-6 Emission Systems General Service 29-01-6

CONTACTS OPEN
WITH HOT COOLANT (235°F.)

CONTACTS CLOSED
WITH COLD COOLANT

NORMAL PVS OPERATION

CONTACTS CLOSED WITH
HOT COOLANT (235°F.)

ENGINE COOLANT OPERATED

CONTACTS OPEN WITH

NORMALLY CLOSED (COLD) COLD COOLANT

NORMALLY OPEN (COLD)

ENGINE COOLANT OPERATED

A4078-A

FIG. 12 Electric Ported Vacuum Switches

FILTER PACK

INTERED ORIFICE

SINTERED ORIFICE
SINTERED ORIFICE

CHECK VALVE

'CHECK VALVE V1826-A

FIG. 13 Spark Delay Valve (SDV), Mono Delay Shown

29-01-7 Emission Systems General Service 29-01-7

CHECK VALVE

DISTRIBUTOR I
L

FIG. 14 Spark Delay Valve (SDV)

Schematics

CRANKCASE VENT
TUBE EXTENSION HOSE
CRANKCASE VENT
TUBE HOSE -
CRANKCASE VENT 6A664
HOSE

GROMMET-
.58 I.D.

CRANKCASE
VENT TUBE - 6759

A4070-B

FIG. 15 Typical PCV System

29-01-8 Emission Systems General Service 29 01-8

COLD WEATHER MODULATOR

TO DUCT VALVE
VACUUM MOTOR

COLD START OPERATION O-RINGSEAL

COLD WEATHER MODULATOR

VACUUM MOTOR

DUCT

© MANIFOLD VACUUM IS i J V A L V E OPEN FOR FU..L HEAT

HIGH (ABOVE 8 INCHES). (BLOCKS FRESH AIR INLET).

©,CHECK VALVE OPENS. FULL VACUUM

TO MOTOR. HEATED AIR FROM HEAT SHROUD

ACCELERATION (MODULATOR TEMPERATURE BELOW 55° F.) O-RING SEAL

5 ® BI-METAL © . VACUUM IS TRAPPED.

REMAINS SEATED

VALVE STAYS ON FULL HEAT

1J MANIFOLD VACUUM IS (BLOCKS FRESH AIR NLET).
^ LOW (BELOW 8 INCHES)

HEATED AIR FROM HEAT SHROUD

WARM ENGINE (MODULATOR TEMPERATURE ABOVE 55° F.) O-RING SEAL ^

(^CONTROLLED VACUUM ^
BIMETAL UNSEATED. TO MOTOR. /

• L

© ABOVE
MANIFOLD VACUUM
8 INCHES. NORMAL TEMPERATURE
CHECK VALVE CONTROL.
REMAINS SEATED.
HEATED AIR FROM HEAT SHROUD
A4079-A

FIG. 16 Cold Weather Modulator Operation

29-02-1 Engine Diagnosis and Service 29-02-1

PART
Engine Diagnosis and Service 29-02

SUBJECT PAGE SUBJECT PAGE

GENERAL INFORMATION 02-1 DIAGNOSIS PROCEDURES
Procedure Index 02-56
DIAGNOSIS CHARTS
Diagnosis Chart Index 02-2 SPECIFICATIONS 02-88

CA4263-A

GENERAL INFORMATION
The following information comprises
the Engine Diagnosis and Service
procedures related to emission system
related components. The diagnosis and
related service routines provided here are
the only authorized service procedures
for 1977 Ford Cars. Refer to Volume 5
of this Manual for Maintenance
Procedures.
29-02-2 Engine Diagnosis and Service 29-02-2

DIAGNOSIS CHARTS

ENGINE DIAGNOSTIC CHARTS

CONDITION PAGE

Routine 101 - Engine will not crank - starter spins 02-3

Routine 102 - Engine Will Not Crank 02-4
Routine 103 - Engine Cranks Slowly 02-6
Routine 104 - Engine Cranks Normally - Will Not Start 02-7
Routine 105 - Engine Cranks Normally - Starts Hard When Cold 02-9
Routine 106 - Engine Cranks Normally - Starts Hard When Hot 02-10
Routine 107 - Engine Idles Rough - Misses 02-12
Routine 108 - Engine Idle Speed Varies 02-14
Routine 109 - Engine Misses at High Speed 02-17
Routine 110 - Engine Misses at Low Speed 02-19
Routine 111 - Engine Stalls at Idle - Engine Cold 02-21
Routine 112 - Engine Stalls at Idle - Engine Hot 02-23
Routine 113 - Engine Stalls During Deceleration Or On Quick Stop 02-25
Routine 114 - Engine Hesitates/Stalls During Acceleration 02-26
Routine 115 - Engine Has Poor Acceleration 02-28
Routine 1 1 6 - Engine Has Less Than Normal Power 02-30
Routine 117 - Exhaust System Backfire 02-32
Routine 118 - Engine Surges 02-33
Routine 119 - Excessive Fuel Consumption 02-35
Routine 120 - Excessive Oil Consumption 02-38
Routine 121 - Engine Diesels - Continues To Run After Shut Off 02-40
Routine 122 - Engine Noise 02-42
Routine 122A - Spark Knock or Pinging 02-43
Routine 123 - Engine Vibration 02-45
Routine 1 2 4 - Engine Fails To Reach Normal Operating Temperature 02-46
Routine 125 - Loss of Coolant Or Engine Overheats 02-47
Routine 126 - Smoke From Vehicle Exhaust System 02-49
Routine 127 - High Floor Pan Temperature 02-51
DIAGNOSTIC CHART REFERENCE ONE 02-52
DIAGNOSTIC CHART REFERENCE TWO 02-53

CA1421-C
29-02-3 Engine Diagnosis and Service 29-02-3

ROUTINE NO. 101

ENGINE WILL NOT CRANK — STARTER SPINS

VERIFY THE CONDITION PER SHOP MANUAL STARTER DRIVE TEST

REMOVE STARTER AND INSPECT FOR BROKEN OR WORN STARTER

DRIVE

NOT OK OK
_f t
REPLACE STARTER DRIVE. INSPECT PERFORM STARTER BENCH TESTS.
FLYWHEEL ASSEMBLY AND REPAIR AND / OR
REPLACE AS REQUIRED.

NOT OK OK

REPAIR AND/OR REPLACE STARTER REPAIR AND/OR REPLACE FLYWHEEL

ASSEMBLY AS REQUIRED. AND RING GEAR ASSEMBLY.

CA1357-A
29-02-4 Engine Diagnosis and Service 29-02-4
ROUTINE NO. 102
ENGINE WILL NOT CRANK

VERIFY THE CONDITION

OK

PERFORM SSD-2, CHECK THE

STEP 1 IF A COLD TRANSMISSION
START SPARK NEUTRAL SWITCHES
ADVANCE (CSSA) FOR PROPER
IS USED. FUNCTION.

NOT OK OK
1
REPLACE OR REPAIR CHECK CABLE
AS REQUIRED. CONNECTIONS AT
BATTERY AND AT
STARTER TERMINAL.

NOT OK OK
1
CLEAN AND TIGHTEN PERFORM BATTERY
CONNECTIONS. CAPACITY TEST

NOT OK OK

CHARGE THEN RETEST CONNECT

BATTERY.
NOT OK OK
t
REPLACE BATTERY. CONNECT A 12-VOLT
TEST LIGHT IN SERIES
WITH BATTERY POSITIVE
POST AND BATTERY
CABLE. LIGHT SHOULD
NOT GLOW.
OK
NOT OK
I
INVESTIGATE ELECTRI- NOT OK
CAL SYSTEM. REPAIR/
REPLACE AS REQUIRED CONT'D. ON NEXT PAGE.
VOLTMETER NEGATIVE
LEAD TO NEGATIVE
POST OF BATTERY.
CONNECT
VOLTMETER POSITIVE
LEAD TO POSITIVE
POST OF BATTERY.
TURN IGNITION KfEY
TO START POSITION
AND LISTEN FOR
CLICK. RELAY
SHOULD CLICK.
OK
t
OBSERVE VOLTAGE

NOT OK OK
t t
VOLTAGE REMAINS LESS THAN 10 VOLTS
SAME - M O V E - EXAMINE CABLE
VOLTMETER POSITIVE FROM RELAY TO
LEAD TO STARTER STARTER FOR
TERMINAL OF RELAY. CHAFING OR
ABRASION RESULTING
NOT OK OK IN SHORT TO GROUND.

VOLTAGE REMAINS NOT OK OK

REPLACE RELAY. i
SAME - MOVE
VOLTMETER POSITIVE REPLACE OR REPAIR REMOVE STARTflR
LEAD TO TERMINAL AS REQUIRED. AND PERFORM
STUD IN STARTER. BENCH TESTS.

NOT OK OK NOT OK OK
t
REMOVE NUT AND VOLTAGE REMAINS REPAIR OR ADJUST PERFORM TESTS
WASHER FROM SAME - REMOVE AS REQUIRED. FOR ENGINE SEIZIMG
TERMINAL STUD. AND REPAIR STARTER AND/OR LOCK-UP.
CLEAN OR REPLACE
AS REQUIRED. CAI::58-C 1
29-02-5 Engine Diagnosis and Service 29-02-5

ROUTINE NO. 102

ENGINE WILL NOT CRANK-CONTINUED

NOT OK

MOVE VOLTMETER
POSITIVE LEAD TO
BATTERY TERMINAL
OF RELAY.

OK

NO VOLTAGE - CLEAN VOLTAGE STAYS THE

CONNECTIONS OR SAME - MOVE
REPLACE CABLE AS VOLTMETER POSITIVE
REQUIRED. LEAD TO " S "
TERMINAL OF RELAY.
(VEHICLES W/O
RELAY CONNECT TO
" S " TERMINAL OF
SOLENOID ON
STARTER.)

NO VOLTAGE -
CHECK NEUTRAL AND
i
VOLTAGE STAYS THE
SAME-CONNECT
IGNITION SWITCHES, JUMPER WIRE FROM
AND CONNECTING RELAY BRACKET TO
WIRES. GOOD GROUND.
RELAY SHOULD
CLICK AND STARTER
CRANK. (VEHICLE
W/O RELAY REMOVE
STARTER AND BENCH
TEST SOLENOID.)

NOT OK OK

REPLACE RELAY. CLEAN CONNECTION

BETWEEN RELAY
BRACKET AND
GROUND.

CA1358-A2
29-02-6 Engine Diagnosis and Service 29-02-6

ROUTINE NO. 103

ENGINE CRANKS SLOWLY

VERIFY THE CONDITION

PERFORM BATTERY CAPACITY TEST

NOT OK
I
RECHARGE AND RETEST BATTERY.

NOT OK OK

CONNECT A 12-VOLT TEST LIGHT OK

REPLACE BATTERY.
IN SERIES WITH BATTERY
POSITIVE POST AND BATTERY
CABLE. LIGHT SHOULD NOT GLOW. CONNECT VOLTMETER NEGATIVE LEAD
TO STARTER TERMINAL STUD AND
VOLTMETER POSITIVE LEAD TO THE
BATTERY POSITIVE POST. INSURE THAT
NOT OK OK- THE CHOKE PLACE IS FULLY OPENED
1 (VERTICAL POSITION) AND DISCONNECT
INVESTIGATE ELECTRICAL SYSTEM. COIL PRIMARY WIRE (BATTERY SIDE).
REPAIR OR REPLACE AS NECESSARY. CRANK THE ENGINE AND OBSERVE
VOLTMETER READING. IT SHOULD NOT
EXCEED 0.5 VOLTS.

NOT OK OK
I
DISCONNECT AND CLEAN CONNECTION AT CONNECT VOLTMETER NEGATIVE LEAD TO
POSITIVE BATTERY POST, RELAY AND AT NEGATIVE BATTERY POST, AND VOLTMETER
STARTER TERMINAL. POSITIVE LEAD TO STARTER MOUNTING BOLT
OR ENGINE GROUND. INSURE THAT THE CHOKE
PLATE IS FULLY OPENED (VERTICAL POSITION)
AND DISCONNECT COIL PRIMARY WIRE (BATTERY
SIDE). CRANK THE ENGINE AND OBSERVE
VOLTMETER READING. IT SHOULD NOT EXCEED
0.1 VOLTS.

NOT OK OK
\
DISCONNECT AND CLEAN CONNECTIONS AT REMOVE STARTER AND PERFORM BENCH TESTS.
NEGATIVE BATTERY POST AND GROUND CABLE
CONNECTIONS AT ENGINE BLOCK.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM ENGINE CHECKS FOR SEIZING,

HIGH FRICTION, OR OVER HEATING.

NOT OK

REPAIR AND/OR REPLACE AS REQUIRED.

CA1359-B
29-02-7 Engine Diagnosis and Service 29-02-7
ROUTINE NO. 104
ENGINE CRANKS NORMALLY — WILL NOT START
VERIFY THE CONDITION USING THE CORRECT STARTING
PROCEDURE AND CHECK FOR FLOODING.

INSPECT VACUUM HOSES, ELECTRICAL WIRING, FUEL SYSTEM AND

AIR CLEANER FOR LEAKS, DAMAGE, BLOCKAGES, AND PROPER
CONNECTIONS. ALSO CHECK FOR FUEL IN TANK.

NOT OK OK

CHECK FOR WEAK AND/OR NO SPARK AT

REPAIR AND/OR REPLACE AS REQUIRED.
ANY SPARK PLUG.

NO SPARK OR WEAK SPARK OK -GOOD SPARK

PERFORM STEP II OF SSD-14 COIL RESERVE PERFORM STEP I OF SSD-12 (ALSO STEP IV
VOLTAGE CHECK (PERFORM THIS TEST IF 2700) AUTOMATIC CHOKE CHECK
WHILE CRANKING). PROCEDURE.

NOT OK OK NOT OK OK

CRANK ENGINE
REPAIR AND/OR CHECK IGNITION REPAIR AND/OR
REPLACE AS WITH CHOKE
WIRES, CAP AND REPLACE AS
REQUIRED. ROTOR FOR REQUIRED. (2700 VENTURI
DAMAGE. CHECK VALVE) HELD
FOR MOISTURE CLOSED AND
ON ROTOR, CAP, CHECK FOR FUEL
SPARK PLUGS WETTING IN THE
AND WIRE DISCHARGE AREA.
CONNECTIONS.
CRANK ENGINE NOT OK OK
TO VERIFY
DISTRIBUTOR
OPERATION. PERFORM STEP
11A OF
REFERENCE TWO.

NOT OK OK
t NOT OK
REPAIR AND/OR PERFORM STEP IV t
REPLACE AS OF SSD-14 —
REQUIRED. SPARK PLUG REPAIR AND/OR
REQUIRED REPLACE AS
VOLTAGE. REQUIRED.
(PERFORM THIS
TEST WHILE
CRANKING.)
OK
NOT OK NOT OK

REPAIR AND/OR PERFORM STEPS

REPLACE AS 2,21, AND 22 OF
REQUIRED. REFERENCE TWO.

NOT OK OK
t f
REPAIR AND/OR CONTINUED ON NEXT PAGE CONTINUED ON NEXT PAGE
REPLACE AS
REQUIRED.
CA1360-B1
29-02-8 Engine Diagnosis and Service 29-02-8

ROUTINE NO. 104

ENGINE CRANKS NORMALLY — WILL NOT START —CONTINUED

OK OK

I
PERFORM STEPS 12, 13, 14, 15, 16, 17 AND
19 OF REFERENCE TWO (INTERNAL).

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. CHECK BASIC TIMING WHILE CRANKING.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. CHECK PCV SYSTEM FOR PROPER

OPERATION.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. CHECK TO SEE THAT THE EGR VALVE W LL
CLOSE. PERFORM STEPS IC, 1, 2 AND 3 OF
SSD-1.

NOT OK OK
i
PERFORM CYLINDER COMPRESSION AND / OR
REPAIR AND / OR REPLACE AS REQUIRED.
LEAKAGE TEST (WET AND DRY).

NOT OK

PERFORM VALVE TRAIN ANALYSIS SSD 17.

REPAIR AND/OR REPLACE AS REQUIRED. REPAIR AND/OR REPLACE AS REQUIRED.

CA1360-C2
29-02-9 Engine Diagnosis and Service 29-02-9

ROUTINE NO. 105

ENGINE CRANKS NORMALLY — STARTS HARD WHEN COLD

VERIFY THE CONDIT3ON USING PROPER STARTING PROCEDURE.

INSPECT VACUUM SYSTEMS, ELECTRICAL SYSTEMS, FUEL SYSTEMS,

EVAPORATIVE CONTROL SYSTEM AND AIR CLEANER FOR DAMAGE,
LEAKS, BLOCKAGE OR IMPROPER CONNECTIONS.

NOT OK OK
t f
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM STEPS 23A & C THRU O, 7, 17,
AND 11 OF REFERENCE TWO ( EXTERNAL ).

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED.

CHECK STEPS 10 AND 22 QF REFERENCE ONE
IN COMBINATION WITH SSD-14 STEP II
IGNITION SYSTEM COIL RESERVE VOLTAGE,
STEP IV SPARK PLUG REQUIRED VOLTAGE.

NOT OK OK
t JL
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM EGR SYSTEM CHECK SSD-1 PART I
B AND C 1, 4, 5 AND PART V AND IX

NOT OK OK
f
REPAIR AND/OR REPLACE AS REQUIRED. CHECK PCV SYSTEM SSD-11 PART 1 A, B, C, D,

NOT OK OK
* t
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM CYLINDER COMPRESSION AND / OR
LEAKAGE TEST.

NOT OK
OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM VALVE TRAIN ANALYSIS SSD 17.
REPAIR AND/OR REPLACE AS REQUIRED.

CA1361-C
29-02-10 Engine Diagnosis and Service 29-02-10

ROUTINE NO. 106

ENGINE CRANKS NORMALLY — STARTS HARD WHEN HOT
VERIFY THE CONDITION USING PROPER STARTING PROCEDURES.

INSPECT VACUUM SYSTEMS, ELECTRICAL SYSTEMS, FUEL. SYSTEMS,

EVAPORATIVE CONTROL SYSTEM AND AIR CLEANER FOR DAMAGE,
LEAKS, BLOCKAGE AND PROPER CONNECTIONS.

I
NOT OK OK
t
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM STEPS 17, 23A AND D THRU O, 19, 24,
29D, 11 AND 14 OF REFERENCE TWO (EXTERNAL).

NOT OK OK
t
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM EGR SYSTEM CHECK SSD-1
PART I B AND C 1, 4, 5 AND PART V.

NOT OK OK
t t
REPAIR AND/OR REPLACE AS REQUIRED. CHECK FOR OVERHEATING.

NOT OK OK
t
PERFORM ROUTINE 125 AND REPAIR
AND/OR REPLACE AS REQUIRED. CHECK STEPS 10, 13 REFERENCE ONE IN
COMBINATION WITH SSD-14 STEP II
IGNITION SYSTEM COIL RESERVE VOLTAGE,
STEP IV SPARK PLUG REQUIRED VOLTAGE:.

NOT OK OK
t
REPAIR AND/OR REPLACE AS REQUIRED. CHECK PCV SYSTEM SSD-11 PART I
A, B, C. D.

NOT OK OK

CHECK EXHAUST HEAT CONTROL VALVE

\i
REPAIR AND/OR REPLACE AS REQUIRED.
SSD-10 AND RESTRICTED EXHAUST SYSTEIM.

NOT OK OK
t
REPAIR AND/OR REPLACE AS REQUIRED. CONTINUED ON NEXT PAGE

CA1362-B1
29-02-11 Engine Diagnosis and Service 29-02-11
ROUTINE NO. 106
ENGINE CRANKS NORMALLY —
STARTS HARD WHEN HOT
OK

PERFORM STEPS 10,13,14,16,19 AND

29 OF REFERENCE TWO ( INTERNAL ).

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM CYLINDER COMPRESSION AND / OR

LEAKAGE TEST.

NOT OK OK
t
PERFORM VALVE TRAIN ANALYSIS SSD-17.
REPAIR AND/OR REPLACE AS REQUIRED.
REPAIR AND/OR REPLACE AS REQUIRED.

CA1362-B2
29-02-12 Engine Diagnosis and Service 29-02-12
ROUTINE 107

ENGINE IDLES ROUGH/MISSES

WARM OR COLD ENGINE
VERIFY THE CONDITION

OK
f
INSPECT VACUUM SYSTEMS, ELECTRICAL SYSTEMS, FUEL SYSTEMS,
EVAPORATIVE CONTROL SYSTEM, AIR CLEANER FOR DAMAGE,
LEAKS, OR IMPROPER CONNECTIONS. PERFORM STEP 8A, REF-
ERENCE TWO.

NOT OK OK
J
REPAIR AND/OR REPLACE AS REQUIRED. WITH ENGINE RUNNING REMOVE LINE FROM
EVAPORATIVE EMISSION CANISTER TO AIR
CLEANER.

NOT OK OK

REPLACE EVAPORATIVE CANISTER.. CHECK THE INTEGRITY OF ALL VACUUM

SYSTEMS AND CHECK FOR INTAKE MANIFOLD
LEAKS.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM REFERENCE TWO, STEPS 9, 14, 1 7, 19,
(EXTERNAL)

NOT OK OK

PERFORM AIR CLEANER TEMPERATURE

REPAIR AND/OR REPLACE AS REQUIRED.
CONTROL AND DELAY VALVE DIAGNOSIS SSD-9
ONLY IF ENGINE IDLES ROUGH WHEN COLD

NOT OK

REPAIR AND/OR REPLACE AS REQUIRED. OK

CHECK REFERENCE ONE STEPS 7,8, 10, 11, 12, 1!

17, 21, 22, IN COMBINATION WITH SSD-14 STEP
II IGNITION SYSTEM COIL RESERVE AND STEP
IV SPARK PLUG REQUIRED VOLTAGE AND
SSD-15, PART E.

NOT OK OK

PERFORM EGR SYSTEM SSD-1 PART I "CHECK

REPAIR AND/OR REPLACE AS REQUIRED. OF EGR VALVE WHEN ON THE ENGINE"
PROCEDURE B AND C STEPS 1, 4, 5 AND
PART IX.

NOT OK OK
f t
REPAIR AND/OR REPLACE AS REQUIRED. CONTINUED ON NEXT PAGE

CA1363-C1
29-02-13 Engine Diagnosis and Service 29-02-13

ROUTINE 107
ENGINE IDLES ROUGH/MISSES —CONTINUED

OK

PERFORM VACUUM AMPLIFIER SSD-1 PART V -

"EGR VENTURI VACUUM AMPLIFIER DIAGNOSTIC
PROCEDURE"

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. •PERFORM POSITIVE CRANKCASE VENTILATION

SYSTEM SSD-11 PART A - "CHECK PCV SYSTEM
FUNCTION" 1,2,3.

NOT OK OK

I
REPAIR AND/OR REPLACE AS REQUIRED. CHECK FOR RESTRICTED EXHAUST SYSTEM.

NOT OK OK
*
+
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM CARBURETOR SSD-13 IDLE FUEL
MIXTURE —ADJUST

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. '•PERFORM CARBURETOR REFERENCE TWO

STEPS 15, 16, 18, 19, 23 AND 29. ( INTERNAL )

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED PERFORM COMPRESSION AND / OR CYLINDER

LEAKAGE TEST.

NOT OK OK

PERFORM VALVE TRAIN ANALYSIS SSD-17.

REPAIR AND/OR REPLACE AS REQUIRED REPAIR AND/OR REPLACE AS REQUIRED.

IF ENGINE IDLES ROUGH ONLY WHEN COLD, PERFORM THIS STEP AFTER PERFORMING CAR-
BURETOR REFERENCE TWO, STEPS 15, 16,18, 19, 23 AND 29.
PERFORM REFERENCE TWO, STEP 23 ONLY IF NOT PERFORMED EARLIER IN ROUTINE.
NOTE: IF ENGINE IDLES ROUGH/MISSES ONLY WHEN COLD, PERFORM REFERENCE TWO, STEP
23 BEFORE PERFORMING STEPS 9, 11,AND 24.
CA1363-C2
29-02-14 Engine Diagnosis and Service 29-02-14

ROUTINE NO. 108

ENGINE IDLE SPEED VARIES
VERIFY THE CONDITION

A
INSPECT VACUUM SYSTEMS, ELECTRICAL SYSTEMS, FUEL SYSTEMS,
EVAPORATIVE CONTROL SYSTEM, AND AIR CLEANER FOR DAMAGE,
LEAKS, BLOCKAGE OR IMPROPER CONNECTIONS.

NOT OK OK

REPAIR AND /OR REPLACE AS REQUIRED. WITH ENGINE AT OPERATING TEMPERATURE

CHECK IDLE SPEEDS. PERFORM STEP 7 OF
REFERENCE ONE.

NOT OK OK
t
ADJUST SPEEDS AS REQUIRED. WITH ENGINE RUNNING REMOVE LINE FROM
EVAPORATIVE EMISSION CANISTER TO AIR
CLEANER.

NOT OK OK
t
REPLACE EVAPORATIVE CANNISTER. CHECK CARBURETOR SOLENOID THROTTLE
POSITIONER FOR PROPER FUNCTION.

NOT OK OK
t
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM STEPS 7, 9, 10, 14, 17, 19, 23A,
O AND N, 24, 26 AND 28 OF REFERENCE
TWO ( EXTERNAL ).

NOT OK OK
t

REPAIR AND/ OR REPLACE AS PERFORM SSD-7 —FUEL DECELERATION

REQUIRED.
VALVE CHECK.

NOT OK OK
t t
REPAIR A N D /OR REPLACE AS REQUIRED.
CHECK STEPS 10, 11 OF REFERENCE ONE
IN COMBINATION WITH SSD-14 STEP II
IGNITION SYSTEM COIL RESERVE VOLTAGE,
STEP IV SPARK PLUG REQUIRED VOLTAGE.

NOT OK

REPAIR AND/OR REPLACE AS REQUIRED.

CONTINUED ON NEXT PAGE
J
CA1364-C1
29-02-15 Engine Diagnosis and Service 29-02-15

ROUTINE NO. 108

ENGINE IDLE SPEED VARIES —CONTINUED
OK

REMOVE VACUUM HOSE FROM DISTRIBUTOR

AT IDLE.

NOT OK OK

PERFORM SSD-3. REPAIR AND / OR REPLACE PERFORM EGR SYSTEM SSD-1 PART I -
CHECK OF EGR VALVE WHEN ON THE
AS REQUIRED. ENGINE, BAND C STEPS 1,4, 5 AND
PART I I .

NOT OK OK
t
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM VACUUM AMPLIFIER SSD-1 PART
V EGR VENTURI AMPLIFIER DIAGNOSTIC
PROCEDURE

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM POSITIVE CRANKCASE VENTILATION

SYSTEM SSD-11 PART A CHECK PCV FUNCTION
1,2,3,4.

NOT OK OK
t
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM CARBURETOR SSD-13
IDLE FUEL MIXTURE —ADJUST.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM STEPS 15, 16, 18, 19, 23, 27,
AND 29 OF REFERENCE TWO . ( INTERNAL )

NOT OK OK
t
PERFORM AIR CLEANER TEMPERATURE
REPAIR AND/OR REPLACE AS REQUIRED.
CONTROL AND RELAY SSD-9.

NOT OK OK
t f
REPAIR AND/OR REPLACE AS REQUIRED. CHECK ENGINE FOR OVERHEATING

NOT OK

PERFORM ROUTINE 125.

OK

CONTINUED ON NEXT PAGE

CA1364-C2
29-02-16 Engine Diagnosis and Service 29-02-16

ROUTINE NO. 108

ENGINE IDLE SPEED VARIES— CONTINUED

OK

PERFORM CYLINDER COMPRESSION

AND/OR LEAKAGE TEST.

OK
I NOT OK
REPAIR AND/OR REPLACE AS REQUIRED.
PERFORM VALVE TRAIN ANALYSIS
SSD 17. REPAIR AND/OR REPLACE
AS REQUIRED.

CA1364-A3
29-02-17 Engine Diagnosis and Service 29-02-17
ROUTINE 109
ENGINE MISSES AT HIGH SPEED
VERIFY THE CONDITION

INSPECT VACUUM HOSES, ELECTRICAL WIRING, FUEL SYSTEM,

AIR CLEANER, DUCT, VALVE, ELEMENT, EVAPORATIVE SYSTEM
FOR LEAKS, DAMAGE OR IMPROPER CONNECTIONS.

NOT OK OK

REPAIR AND/OR REPLACE COMPONENTS INSPECT DUCT DOOR TO VERIFY THAT IT

AS REQUIRED. IS IN THE FULLY OPEN POSITION WITH
WARMED UP ENGINE.

NOT OK OK
t
INSPECT, TEST, REPAIR AND / OR REPLACE CHECK STEPS 10, 11, 12, 13, 17, 22 OF
AS OUTLINED IN SSD-9. REFERENCE ONE IN COMBINATION
WITH SSD-14 STEP II IGNITION SYSTEM
COIL RESERVE VOLTAGE, STEP IV
SPARK PLUG REQUIRED VOLTAGE.

NOT OK OK
i
PERFORM SPARK DELAY VALVE DIAGNOSIS
REPAIR AND/OR REPLACE AS REQUIRED.
PROCEDURE SSD-2.

NOT OK OK

REPLACE COMPONENTS AS NECESSARY. PERFORM STEPS 7, 9, 10, 14, 17, 19, 23A
AND 26 OF REFERENCE TWO ( EXTERNAL ).

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM STEP 20 OF REFERENCE TWO.

NOT OK OK
t
PERFORM STEPS 21 AND 22 OF REFERENCE PERFORM STEPS 25, 12, 13, 15, 16,18
TWO. REPAIR AND/OR REPLACE AS AND 27 OF REFERENCE TWO ( INTERNAL ).
REQUIRED

NOT OK OK
_J t
REPAIR AND/OR REPLACE AS REQUIRED. CONTINUED ON NEXT PAGE

CA1365-C1
29-02-18 Engine Diagnosis and Service 29-02-18

ROUTINE 109
ENGINE MISSES AT HIGH SPEED —CONTINUED
OK

CHECK ENGINE OPERATING TEMPERATURE

FOR OVERHEATING.

NOT OK
t OK
PERFORM ROUTINE NO. 125. t
PERFORM CYLINDER COMPRESSION AND/OR
LEAKAGE TEST.

NOT OK OK

PERFORM VALVE TRAIN ANALYSIS SSD-17.

REPAIR AND/OR REPLACE AS NECESSARY. REPAIR AND/OR REPLACE AS REQUIRED.

CA1365-B2
29-02-19 Engine Diagnosis and Service 29-02-19

ROUTINE NO. 110

ENGINE MISSES AT LOW SPEEDS
VERIFY THE CONDITION

INSPECT VACUUM SYSTEMS, ELECTRICAL SYSTEMS, FUEL SYSTEMS,

EVAPORATIVE CONTROL SYSTEM AND AIR CLEANER FOR DAMAGE,
LEAKS, BLOCKAGE, AND IMPROPER CONNECTIONS.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. CHECK INTEGRITY OF ALL VACUUM SYSTEMS,

AND CHECK FOR INTAKE MANIFOLD LEAKS.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. INSPECT HIGH TENSION WIRING FOR PROPER
ROUTING AND CONNECTIONS

NOT OK OK

REROUTE, REPAIR AND / OR REPLACE

AS REQUIRED. CHECK STEPS 10, 17 AND 22 OF REFERENCE
ONE IN COMBINATION WITH SSD-14 STEP II
IGNITION SYSTEM COIL RESERVE VOLTAGE,
STEP IV SPARK PLUG REQUIRED VOLTAGE.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM STEPS 9, 10, 14, 17, 19, 23A, 0,
AND 26 - REFERENCE TWO ( EXTERNAL ).

NOT OK OK

ADJUST, REPAIR AND/OR REPLACE PERFORM EGR SYSTEM DIAGNOSIS

AS REQUIRED. PROCEDURE SSD-1 PART I B AND C STEPS
1, 4 AND 5, PART V AND IX.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. CHECK ENGINE OPERATING TEMPERATURE

FOR OVERHEATING.

NOT OK OK
i
PERFORM ROUTINE 125. CONTINUED ON NEXT PAGE

CA1366-C1
29-02-20 Engine Diagnosis and Service 29-02-20

ROUTINE NO. 110

ENGINE MISSES AT LOW SPEEDS —CONTINUED

PERFORM STEPS 15, 16, 25 AND 27 OF REFEREKCE

TWO ( INTERNAL ).

NOT OK OK

PERFORM CARBURETOR SSD-13 IDLE FUEL

REPAIR AND/OR REPLACE AS REQUIRED.
MIXTURE —ADJUST.

NOT OK OK
i
PERFORM CYLINDER COMPRESSION AND/OR
REPAIR AND/OR REPLACE AS REQUIRED. LEAKAGE TEST.

NOT OK OK

PERFORM VALVE TRAIN ANALYSIS SSD-17.

REPAIR AND/OR REPLACE AS REQUIRED. REPAIR AND/OR REPLACE AS REQUIRED.

CA1366-B2
29-02-21 Engine Diagnosis and Service 29-02-21

ROUTINE NO. 111

ENGINE STALLS AT IDLE —ENGINE COLD

VERIFY THE CONDITION

INSPECT VACUUM SYSTEMS, ELECTRICAL SYSTEMS, FUEL SYSTEMS,

EVAPORATIVE CONTROL SYSTEM AND AIR CLEANER FOR DAMAGE,
LEAKS, OR IMPROPER CONNECTIONS.

NOT OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM SSD-12

NOT OK

PERFORM STEP 23 - REFERENCE II CHECK FOR CARBURETOR ICING.

REPAIR, REPLACE AND/OR ADJUST CHOKE
MECHANISM TO SPECIFICATIONS.

NOT OK OK

THAW CARBURETOR AND ADD ANTI-ICING PERFORM STEPS 5, 6, 8, 9, 19, 24 AND

ADDITIVE TO FUEL. 30 OF REFERENCE TWO.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM EGR SYSTEM SSD-1 PART I "CHECK
OF EGR VALVE WHEN ON THE ENGINE" B
AND C STEPS 1, 4, 5 AND PART IX.

NOT OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM SSD-1 PARTS II AND I I I .

NOT OK •5V

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM POSITIVE CRANKCASE VENTILATION

SYSTEM SSD-11 PART I. CHECK PCV SYSTEM
FUNCTION A, B, C, D.

NOT OK

REPAIR AND/OR REPLACE AS REQUIRED. CONTINUED ON NEXT PAGE

CA1367-C1
29-02-22 Engine Diagnosis and Service 29-02-22

ROUTINE NO. 111

ENGINE STALLS AT IDLE —ENGINE COLD —CONTINUED
I
OK
I
CHECK HEAT CONTROL VALVE SSD-10

NOT OK OK
t
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM CARBURETOR SSD-13
IDLE FUEL MIXTURE —ADJUST.

NOT OK OK
t
PERFORM STEPS 17, 19, 23 OF
REPAIR AND/OR REPLACE AS REQUIRED.
REFERENCE TWO (EXTERNAL).

NOT OK OK
• t
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM STEPS 16, 18, 23 AND 29
OF REFERENCE TWO ( INTERNAL ).

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED.
CHECK STEPS 10, 11, 12 AND 13 OF REFER
ENCE ONE IN COMBINATION WITH SSD-14
STEP II IGNITION SYSTEM COIL RESERVE
VOLTAGE, STEP IV SPARK PLUG RE-
QUIRED VOLTAGE, SSD-15, PART E

NOT OK OK
t
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM SPARK CONTROL DIAGNOSIS SSD-3.

NOT OK OK
t
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM AIR CLEANER TEMPERATURE
CONTROL AND DELAY SSD-9.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM CYLINDER COMPRESSION

AND/OR LEAKAGE TEST.

OK
NOT OK
t
PERFORM VALVE TRAIN ANALYSIS SSD-17.
REPAIR AND/OR REPLACE AS REQUIRED. REPAIR AND/OR REPLACE AS REQUIRED.

CA1367-B2
29-02-23 Engine Diagnosis and Service 29-02-23

ROUTINE 112
ENGINE STALLS AT IDLE —ENGINE HOT
VERIFY THE CONDITION

OK

WITH ENGINE RUNNING, REMOVE LINE FROM

EVAPORATIVE EMISSION CANISTER TO AIR
CLEANER.

NOT OK OK
t
REPLACE CANISTER. INSPECT VACUUM SYSTEMS, ELECTRICAL
SYSTEMS, FUEL SYSTEMS, EVAPORATIVE
CONTROL SYSTEM, AIR CLEANER FOR
DAMAGE, LEAKS OR IMPROPER CONNECTIONS.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. VERIFY CHOKE PLATE IS OPEN.

NOT OK OK
t
REPAIR , REPLACE AND/OR ADJUST CHOKE PERFORM REFERENCE TWO STEPS 4, 7, 9,
MECHANISM TO SPECS. STEPS 23A, C AND 14, 17, 19, 23, 24, 28 AND 30 ( EXTERNAL ).
D, REFERENCE TWO.

NOT OK OK
t
REPAIR AND/OR REPLACE. PERFORM EGR SYSTEM SSD-1 PART I;
CHECK OF EGR VALVE WHEN ON ENGINE
B & C STEPS 1, 4, 5.

NOT OK OK
•
REPAIR AND/OR REPLACE AS REQUIRED.
PERFORM VACUUM AMPLIFIER SSD-1 PART V
EGR VENTURI VACUUM AMPLIFIER
DIAGNOSTIC PROCEDURE

NOT OK OK
t
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM POSITIVE CRANKCASE VENTILATION
SYSTEM SSD-11 PART I. CHECK PCV SYSTEM
FUNCTION PARTS A, B, C, D.

NOT OK

CONTINUED ON NEXT PAGE

REPAIR AND/OR REPLACE AS REQUIRED.
CA1368-C1
29-02-24 Engine Diagnosis and Service 29-02-24

ROUTINE 112
ENGINE STALLS AT IDLE —ENGINE HOT —CONTINUED
OK

CHECK HEAT CONTROL VALVE SSD-10 AND

CHECK EXHAUST SYSTEMS FOR
RESTRICTIONS.

NOT OK OK
t
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM CARBURETOR SSD-13—IDLE FUEL.
MIXTURE —ADJUST.

NOT OK OK
t
PERFORM STEPS 10, 16, 17, 18, 19, 13E, 15
REPAIR AND/OR REPLACE AS REQUIRED.
REFERENCE TWO (INTERNAL).

NOT OK OK
t
REPAIR AND/OR REPLACE AS REQUIRED.
CHECK REFERENCE ONE-STEPS 10, 11,12 AND
13 IN COMBINATION WITH SSD-14 STEP II IG-
NITION SYSTEM COIL RESERVE VOLTAGE AND
STEP IV "SPARK PLUG REQUIRED VOLTAGE".
PERFORM STEP 22, REFERENCE ONE.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM AIR CLEANER TEMPERATURE

CONTROL PROCEDURE SSD-9.

NOT OK OK
f t
REPAIR AND/OR REPLACE AS REQUIRED. CHECK ENGINE FOR OVERHEATING.

NOT OK

PERFORM ROUTINE 125.

CA1368-C2
29-02-25 Engine Diagnosis and Service 29-02-25

ROUTINE 113
ENGINE STALLS DURING DECELERATION OR ON QUICK STOP

VERIFY THE CONDITION

OK

INSPECT VACUUM SYSTEMS, ELECTRICAL SYSTEMS, FUEL SYSTEMS,

EVAPORATIVE CONTROL SYSTEM, AIR CLEANER FOR DAMAGE,
LEAKS OR IMPROPER CONNECTIONS.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM REFERENCE TWO, STEPS 4, 7, 9, 17,

19, 24 AND 2 a ( EXTERNAL )

NOT OK OK
f
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM REFERENCE ONE STEPS 10,11,7
AND 8.

NOT OK OK
T
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM REFERENCE TWO, STEPS 13, 15, 16,
17, 18 AND 19. (INTERNAL)

NOT OK OK
t
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM CYLINDER COMPRESSION AND / OR
LEAKAGE TEST.

NOT OK OK
t
PERFORM VALVE TRAIN ANALYSIS SSD-17.
REPAIR AND/OR REPLACE AS REQUIRED. REPAIR AND/OR REPLACE AS REQUIRED.

CA1369-C
29-02-26 Engine Diagnosis and Service 29-02-26

ROUTINE 114
ENGINE HESITATES/STALLS DURING ACCELERATION
VERIFY THE CONDITION
OK

INSPECT VACUUM SYSTEMS, ELECTRICAL SYSTEMS, FUEL SYSTEMS,

EVAPORATIVE CONTROL SYSTEM, AIR CLEANER FOR DAMAGE,
LEAKS, OR IMPROPER CONNECTIONS.

NOT OK OK
• f
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM REFERENCE TWO STEPS 6, 7, 9, 10,
14, 17, 19, 11, AND 23 (EXTERNAL).

NOT OK OK
t T
REPAIR AND/OR REPLACE AS REQUIRED. CHECK STEPS IN REFERENCE ONE 10, 11, 12,
13, 22, 26, IN COMBINATION WITH SSD-14
STEP II - "IGNITION SYSTEM COIL RESERVE
VOLTAGE" AND STEP IV "SPARK PLUG
REQUIRED VOLTAGE."

NOT OK OK
T
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM REFERENCE TWO STEP 20.

NOT OK OK

PERFORM REFERENCE TWO STEPS 21 AND 22 PERFORM REFERENCE TWO STEPS 13, 15, 16, 19,
— REPAIR AND/OR REPLACE AS REQUIRED. 23 AND 25 ( INTERNAL).

NOT OK OK
i
PERFORM EGR SYSTEM SSD 1 PART I - "CHECK
REPAIR AND/OR REPLACE AS REQUIRED. OF EGR VALVE WHEN ON THE ENGINE"
PROCEDURES B ABD C STEPS 1, 4, 5 AND PART
IX.

NOT OK OK
t f
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM VACUUM AMPLIFIER SSD 1 PART V -
"EGR VENTURI VACUUM AMPLIFIER DIAGNOSTIC
PROCEDURE"

NOT OK OK
t
REPAIR AND/OR REPLACE AS REQUIRED. CONTINUED ON NEXT PAGE
1
CA1370-C1
29-02-27 Engine Diagnosis and Service 29-02-27

ROUTINE 114
ENGINE HESITATES/STALLS DURING ACCELERATION — CONTINUED

CHECK FOR RESTRICTED EXHAUST SYSTEM

AND EXHAUST CONTROL VALVE OPERATION
SSD-10.

NOT OK OK
I
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM AIR CLEANER TEMPERATURE
CONTROL SYSTEM PROCEDURE SSD-9.

NOT OK OK
I I
REPAIR AND/OR REPLACE AS REQUIRED.
PERFORM CYLINDER COMPRESSION AND/OR
LEAKAGE TEST.

NOT OK OK
I I
REPAIR AND/OR REPLACE AS REQUIRED. REPLACE SPARK PLUGS AS NECESSARY.

NOT OK OK
I
PERFORM VALVE TRAIN ANALYSIS SSD-17.
REPAIR AND/OR REPLACE AS REQUIRED. REPAIR AND/OR REPLACE AS REQUIRED.

CA1370-B2
29-02-28 Engine Diagnosis and Service 29-02-28

ROUTINE NO. 115

ENGINE HAS POOR ACCELERATION
VERIFY THE CONDITION

INSPECT VACUUM SYSTEMS, ELECTRICAL SYSTEM, FUEL SYSTEM,

EVAPORATIVE CONTROL SYSTEM AND AIR CLEANER FOR DAMAGE,
LEAKS, OR IMPROPER CONNECTIONS.

NOT OK OK
T t
CHECK STEPS IN REFERENCE ONE 10, 11, 12,
REPAIR AND/OR REPLACE AS REQUIRED.
13, 7, 8, 26, 27 AND 22 IN COMBINATION WITH
SSD-14 STEP II - "IGNITION SYSTEM COIL
RESERVE VOLTAGE" AND STEP IV SPARK
PLUG REQUIRED VOLTAGE. PERFORM
SSD-15, PART E AND STEP 29 OF REFERENCE
ONE.

NOT OK OK

PERFORM SSD-3 AND REPAIR AND / OR REPLACE PERFORM STEPS 6, 7,9, 10, 11, 14, 17, 19,
AS REQUIRED. 23A, 26,- REFERENCE TWO. (EXTERNAL)

NOT OK OK
t t
REPAIR AND/OR REPLACE AS REQUIRED. CHECK EGR SYSTEM SSD-1 STEPS I - B AND
C 1,4, 5, STEP V, AND PART IX.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. CHECK AIR CLEANER AND DELAY VALVES
SSD-9

NOT OK OK

REPAIR AND /OR REPLACE AS REQUIRED. CHECK FOR STUCK HEAT CONTROL VALVE
SSD-10 AND RESTRICTED EXHAUST SYSTEM

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM STEPS 20, 14, 15, 16, 27
REFERENCE TWO.

NOT OK OK
1
IF STEP 20 IS NOT OK PERFORM STEPS 21, CONTINUED ON NEXT PAGE
2 2 — REFERENCE TWO AND REPAIR AND / OR
REPLACE AS REQUIRED.

CA1371-C1
29-02-29 Engine Diagnosis and Service 29-02-29

ROUTINE NO. 115

ENGINE HAS POOR ACCELERATION — CONTINUED
I
OK

CHECK FOR OVERHEATING

NOT OK OK

PERFORM ROUTINE 125. VISUALLY CHECK BELT DRIVEN COMPONENTS

FOR ROTATION.

NOT OK OK
t
CHECK FOR PARTIALLY LOCKED OR
REPAIR AND/OR REPLACE AS REQUIRED.
DRAGGING BRAKES.

NOT OK OK
f
REPAIR AND/OR REPLACE AS REQUIRED. CHECK FOR CLUTCH SLIPPAGE (M/T) OR
MALADJUSTED A/T.

NOT OK OK
t
REPAIR AND/OR REPLACE AS REQUIRED. CHECK VALVE TIMING AND TIMING CHAIN
OR BELT.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM CYLINDER COMPRESSION AND / OR

LEAKAGE TEST.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. REPLACE SPARK PLUGS AS NECESSARY IF

NOT ALREADY DONE.

NOT OK OK
t
PERFORM VALVE TRAIN ANALYSIS SSD-17.
REPAIR AND/OR REPLACE AS REQUIRED. REPAIR AND/OR REPLACE AS REQUIRED.

CA1371-B2
29-02-30 Engine Diagnosis and Service 29-02-30
ROUTINE NO. 116
ENGINE HAS LESS THAN NORMAL POWER
VERIFY THE CONDITION

INSPECT VACUUM SYSTEMS, ELECTRICAL SYSTEMS, FUEL SYSTEMS,

EVAPORATIVE CONTROL SYSTEM AND AIR CLEANER FOR DAMAGE,
LEAKS OR IMPROPER CONNECTIONS.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. CHECK AUTOMATIC TRANSMISSION FLUID

LEVEL.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. CHECK FOR CLUTCH SLIPPAGE (M/T), OR

MALADJUSTMENT OF TRANSMISSION (A/T).

NOT OK OK
t t

L REPAIR AND/OR REPLACE AS REQUIRED. PERFORM STEPS 6, 7, 9, 10, 14, 17, 19, 20, 21D, 23A,
24 & 26 - REFERENCE TWO (EXTERNAL).

NOT OK OK
t •
IF STEP 20 IS NOT OK PERFORM STEPS 21,22 PERFORM STEPS 10, 11, 12, 13, 16. 18, 26, 27 & 29
— REFERENCE TWO AND REPAIR AND / OR - REFERENCE ONE. SSD-15, PART E.
REPLACE AS REQUIRED.

OK
NOT OK
t
PERFORM EGR SSD-1 STEPS I-B AND C 1, 4, 5, AND
REPAIR AND/OR REPLACE AS REQUIRED.
PARTS V AND IX.

NOT OK OK
t t
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM PCV SSD-11 STEPS I-A, B, C, D.

NOT OK OK
i
PERFORM SSD-11 STEPS I-D, H AND
REPAIR AND/OR REPLACE AS REQUIRED. CHECK AIR CLEANER PER DIAGNOSIS SSD-9.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. CONTINUED ON NEXT PAGE

CA1372-CI
29-02-31 Engine Diagnosis and Service 29-02-31

ROUTINE NO. 116

ENGINE HAS LESS THAN NORMAL POWER —CONTINUED

CHECK HEAT CONTROL VALVE SSD-10 AND

FOR RESTRICTED EXHAUST SYSTEM.

NOT OK OK
* t
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM STEPS 10, 13, 16, 15, 19, 25 AND 27
REFERENCE TWO (INTERNAL).

NOT OK OK
t
REPAIR AND/OR REPLACE AS REQUIRED. CHECK FOR OVERHEATING.

NOT OK OK

PERFORM ROUTINE 125. VISUALLY CHECK BELT DRIVEN COMPONENTS

FOR ROTATION.

NOT OK OK

CHECK FOR PARTIALLY LOCKED OR

REPAIR AND/OR REPLACE AS REQUIRED. DRAGGING BRAKES.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. CHECK VALVE TIMING AND TIMING CHAIN
OR BELT.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM CYLINDER COMPRESSION AND/OR

LEAKAGE TEST.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. REPLACE SPARK PLUGS AS NECESSARY.

NOT OK OK
t J_
PERFORM VALVE TRAIN ANALYSIS SSD-17.
REPAIR AND/OR REPLACE AS REQUIRED. REPAIR AND/OR REPLACE AS REQUIRED.

CA1372-B2
29-02-32 Engine Diagnosis and Service 29-02-32

ROUTINE 117
EXHAUST SYSTEM BACKFIRE

VERIFY THE CONDITION

INSPECT VACUUM SYSTEMS & IGNITION WIRING FOR LEAKS

AND/OR IMPROPER ROUTING.

NOT OK OK
t i
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM STEPS 10, 11, 12, AND 13 OF
REFERENCE ONE.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM PROCEDURE B OF SSD-4

(NON-CATALYTIC) OR SSD-5 (CATALYTIC)

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM SSD-7 AND STEP 18 REFERENCE

TWO.

NOT OK OK
t t
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM CYLINDER COMPRESSION AND / OR
LEAKAGE TEST

NOT OK OK
t t
INSPECT FOR STICKING OR BURNED VALVES. VERIFY PROPER CAMSHAFT TIMING AND/OR
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM VALVE TRAIN ANALYSIS SSD-17.
REPAIR AND/OR REPLACE AS REQUIRED.

NOT OK
t
REPAIR AND/OR REPLACE AS REQUIRED.

CA1373-B
29-02-33 Engine Diagnosis and Service 29-02-33

ROUTINE 118
ENGINE SURGES
VERIFY THE CONDITION

INSPECT VACUUM SYSTEMS, ELECTRICAL SYSTEMS, FUEL SYSTEM,

EVAPORATIVE CONTROL SYSTEM, AND AIR CLEANER FOR DAMAGE,
BLOCKAGES, LEAKS, AND PROPER CONNECTIONS.

NOT OK OK
t f
REPAIR AND/OR REPLACE AS REQUIRED.
CHECK STEPS IN REFERENCE ONE 10, 11, 12, 13,
19, 20 AND 22 IN COMBINATION WITH SSD-14
STEP II - "IGNITION SYSTEM COIL RESERVE
VOLTAGE" AND STEP IV "SPARK PLUG REQUIRED
VOLTAGE."

NOT OK OK
t
PERFORM COMPRESSION BALANCE (ELECTRICAL)
REPAIR AND/OR REPLACE AS REQUIRED. STEP 17 REFERENCE ONE.

NOT OK OK
t t
PERFORM CYLINDER COMPRESSION AND/OR PERFORM SSD-3 SPARK CONTROL SYSTEMS
LEAKAGE TEST. AND SPARK DELAY VALVE.

NOT OK OK
t
PERFORM STEP 25 OF REFERENCE TWO AND PERFORM SSD-1 PARTS I, III, IV, V AND IX
REPAIR AND/OR REPLACE AS REQUIRED. EGR SYSTEM DIAGNOSIS.

NOT OK OK
f t
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM SSD-11 PART A "PCV SYSTEM'
1,2,3,4.

NOT OK OK
t i
PERFORM SSD-II STEPS I-D, AND II. PERFORM STEPS 6, 9, 10, 14, 19, 22, 23 AND 26
REPAIR AND/OR REPLACE AS REQUIRED. OF REFERENCE TWO. (EXTERNAL)

NOT OK OK
t
PERFORM STEP 23 OF REFERENCE TWO (IF CONTINUED ON NEXT PAGE
APPLICABLE) AND REPAIR AND / OR REPLACE
AS REQUIRED.

CA1374-C1
29-02-34 Engine Diagnosis and Service 29-02-34

ROUTINE 118
ENGINE SURGES —CONTINUED
I
OK

PERFORM STEP 20 OF REF. TWO.

J
NOT OK OK
1

PERFORM STEPS 21 & 22 OF REF. TWO

AND REPAIR AND / OR REPLACE AS PERFORM SSD-13 IDLE FUEL MIXTURE. — ADJUS
REQUIRED.

NOT OK OK
t
PERFORM SSD-9, AIR CLEANER TEMPERATURE
REPAIR AND/OR REPLACE AS REQUIRED.
CONTROL & DELAY VALVE.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM STEPS 10, 13, 15, 16, 19, 25 AND 27
OF REFERENCE TWO. (INTERNAL)

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. CHECK FOR RESTRICTED EXHAUST SYSTEM

AND PERFORM SSD-10.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM CYLINDER COMPRESSION AND / OR

LEAKAGE TEST.

NOT OK OK
t
PERFORM VALVE TRAIN ANALYSIS SSD-17.
REPAIR AND/OR REPLACE AS REQUIRED. REPAIR AND/OR REPLACE AS REQUIRED.

CA1374-B2
29-02-35 Engine Diagnosis and Service 29-02-35

ROUTINE NO. 119

EXCESSIVE FUEL CONSUMPTION
VERIFY THE CONDITION

INSPECT VACUUM SYSTEMS, ELECTRICAL SYSTEMS, FUEL SYSTEMS,

EVAPORATIVE CONTROL SYSTEM AND AIR CLEANER FOR DAMAGE,
LEAKS, AND IMPROPER CONNECTIONS.

NOT OK OK
t t
REPAIR AND/OR REPLACE AS REQUIRED. CHECK TIRES FOR PROPER PRESSURE.

NOT OK OK
t
INFLATE TIRES TO PROPER SPECIFICATIONS. CHECK TO SEE THAT AIR CLEANER DOOR
IS IN OPEN POSITION.

NOT OK OK
f f
PERFORM SSD-9 INSPECT AIR CLEANER FILTER ELEMENT.

NOT OK OK
_t f
REPLACE AS REQUIRED. PERFORM STEPS 1 C, 5, 23A, H, I,O,J, K. 10, 14,
17, 9, 20D OF REFERENCE TWO (EXTERNAL).

NOT OK OK
f
REPAIR AND/OR REPLACE AS REQUIRED.

CHECK STEPS 10, 11A, 11 D, 12, 13, 17 OF REF-

ERENCE ONE IN COMBINATION WITH STEP II
OF SSD-14 - IGNITION SYSTEM COIL RESERVE
VOLTAGE AND STEP IV - SPARK PLUG RE-
QUIRED VOLTAGE. PERFORM SSD-15, PART E.

NOT OK OK

PERFORM EGR SYSTEM SSD-1 PART 1-

REPAIR AND/OR REPLACE AS REQUIRED. CHECK OF EGR VALVE WHEN ON THE
ENGINE" B AND C; 1,4, 5; PART IX.

NOT OK

REPAIR AND/OR REPLACE AS REQUIRED. CONTINUED ON NEXT PAGE

CA1375-C1
29-02-36 Engine Diagnosis and Service 29-02-36

ROUTINE NO. 119

EXCESSIVE FUEL CONSUMPTION CONTINUED
OK

PERFORM VACUUM AMPLIFIER SSD-1 PART V

EGR VENTURI VACUUM AMPLIFIER
DIAGNOSTIC PROCEDURE.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM POSITIVE CRANKCASE VENTILATIOfv

SYSTEM SSD-11 PART I. CHECK PCV SYSTEM
FUNCTION PARTS A, B, C, D.

NOT OK OK
t
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM STEPS 12, 11, 13, 14, 15, 16, 18
23B, C, 25, 27 AND 29 OF REFERENCE
TWO.

NOT OK OK

•
PERFORM STEP 20 OR REFERENCE TWO.
REPAIR AND/OR REPLACE AS REQUIRED.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM HEAT VALVE SSD-10 AND CHECK
FOR RESTRICTED EXHAUST SYSTEM.

NOT OK OK

CHECK FOR PARTIALLY LOCKED OR

REPAIR AND/OR REPLACE AS REQUIRED.
DRAGGING BRAKES.

NOT OK OK
_L
CHECK FOR CLUTCH SLIPPAGE ( M / T ) , OR
REPAIR AND/OR REPLACE AS REQUIRED. IMPROPER T R A N S M I S S I O N OPERATION A N D
FLUID LEVEL ( A / T ) .

J
NOT OK OK
t
CONTINUED ON NEXT PAGE
REPAIR AND/OR REPLACE AS REQUIRED.

CA1375-B2
29-02-37 Engine Diagnosis and Service 29-02-37

ROUTINE NO. 119

EXCESSIVE FUEL CONSUMPTION — CONTINUED

I
ox
PERFORM CYLINDER COMPRESSION
AND/OR LEAKAGE TEST.

NOT OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM VALVE TRAIN ANALYSIS

SSD 17. REPAIR AND/OR REPLACE
AS REQUIRED.

CA1375-A3
 29-02-38 Engine Diagnosis and Service 29-02-38

ROUTINE NO. 120

EXCESSIVE OIL CONSUMPTION

VERIFY THE CONDITION

THE MOST COMMON CAUSE OF OIL LOSS IS LEAKAGE. TO VERIFY AN EXCESSIVE OIL CONSUMPTION COMPLAINT, IT IS
NECESSARY THAT A THOROUGH INSPECTION BE MADE TO INSURE THAT LEAKAGE DOES NOT EXIST. THE FOLLOWING
STEPS SHOULD BE FOLLOWED TO VERIFY AN EXCESSIVE OIL CONSUMPTION COMPLAINT:

A. STEAM CLEAN THE ENGINE (IF NECESSARY) TO REMOVE ACCUMULATED DIRT AND / OR OIL.

B. DRAIN ENGINE OIL AND CHANGE THE OIL FILTER.

C. FILL THE CRANKCASE WITH THE SPECIFIED AMOUNT OF THE RECOMMENDED GRADE OF OIL. (CHECK TO BE
SURE THE CORRECT DIPSTICK HAS BEEN INSTALLED.)

D. PERFORM POSITIVE CRANKCASE VENTILATION SYSTEM SSD-11 PART I A, B, C, D.

E. DRIVE THE VEHICLE UNDER NORMAL CONDITIONS UNTIL THE ENGINE IS AT NORMAL OPERATING TEMPERATURE,
WITH THE VEHICLE ON A LEVEL SURFACE, PLACE A CLEAN PAPER UNDER THE ENGINE (TO AID IN DETECTING LEAK-
AGE).

F. SHUT OFF ENGINE AND CHECK FOR LEAKAGE AT:

1. VALVE ROCKER ARM COVER GASKETS.

2. OIL PAN GASKET.
3. CYLINDER BLOCK FRONT COVER GASKET.
4. CYLINDER BLOCK TO FUEL PUMP GASKET AND FUEL PUMP AIR VENT.
5. INTAKE MANIFOLD SEALS.
6. CRANKSHAFT SEALS.
7. DISTRIBUTOR HOUSING O-RING.
8. OIL FILTER
9. OIL PRESSURE SENDING UNIT.

G. WHEN ALL CAUSES OF LEAKAGE (IF ANY) HAVE BEEN REPAIRED, CHECK THE OIL LEVEL AND USE A FILE OR
CENTER PUNCH TO MARK THE DIPSTICK AT THE INDICATED LEVEL.

H. RECORD THE ODOMETER READING. HAVE THE CUSTOMER OPERATE THE ENGINE FOR THE APPROXIMATE NUM-
BER OF MILES INDICATED BY THE COMPLAINT AND THEN RETURN IT TO YOU FOR EXAMINATION.

I. WHEN CUSTOMER RETURNS THE VEHICLE, VERIFY THE ODOMETER READING, CHECK THE OIL LEVEL, AND RE-
INSPECT THE ENGINE FOR SIGNS OF OIL LEAKAGE.

J. ADD A MEASURED AMOUNT OF OIL AS NECESSARY TO BRING THE OIL LEVEL TO THE PREVIOUSLY INSCRIBED
MARK ON THE DIPSTICK.

K. IF OIL CONSUMPTION IS NOT WITHIN SPECIFIED LIMITS, PROCEED WITH OIL CONSUMPTION DIAGNOSIS AS OUT-
LINED BELOW.

NOTE: A NEW ENGINE MAY REQUIRE UP TO 6,000 MILES OF OPERATION IN ORDER TO PROPERLY SEAT (BREAK IN) THE
PISTON RINGS. FOR THIS REASON, THE ENGINE SHOULD NOT BE CONDEMNED AS LONG AS OIL ECONOMY IS IM-
PROVING WITH MILEAGE ACCUMULATION. IF OIL ECONOMY CEASES TO IMPROVE WITH MILEAGE ACCUMULATION
CORRECTIVE ACTION SHOULD BE TAKEN.

CONTINUED ON NEXT PAGE

CA1376-A1
29-02-39 Engine Diagnosis and Service 29-02-39

ROUTINE NO. 120 —CONTINUED

PERFORM CYLINDER COMPRESSION AND / OR

LEAKAGE TEST.

NOT OK OK

DISASSEMBLE ENGINE. MAKE REPAIRS AS DRIVE VEHICLE UNDER NORMAL CONDITIONS

NECESSARY TO CORRECT LOW OR ERRATIC UNTIL ENGINE IS AT NORMAL OPERATING
COMPRESSION. TEMPERATURE. STOP ENGINE. REMOVE AND IN-
SPECT SPARK PLUGS FOR "WET" OIL DEPOSITS.

NOT OK

CHECK FOR EXCESSIVE VALVE STEM TO GUIDE CLEARANCE, WORN,

LOOSE, OR DAMAGED VALVE STEM SEALS, CRACKED INTAKE
MANIFOLD, LEAKING INTAKE MANIFOLD GASKET, AND/OR LEAKAGE
FROM THE ROCKER ARM SUPPORT BOLT HOLES INTO THE
CYLINDER HEAD INTAKE RUNNERS. CHECK POSITIVE CRANKCASE
VENTILATION SYSTEM FOR IMPROPER OR RESTRICTED OPERATION.
MAKE ALL NECESSARY REPAIRS AND/OR REPLACEMENTS.

OK

PERFORM VALVE TRAIN ANALYSIS SSD-17.

REPAIR AND/OR REPLACE AS REQUIRED.

CA1376-A2
29-02-40 Engine Diagnosis and Service 29-02-40

ROUTINE NO. 121

ENGINE DIESELS —
CONTINUES TO RUN AFTER SHUT OFF
VERIFY THE CONDITION

INSPECT VACUUM SYSTEMS, ELECTRICAL SYSTEMS, FUEL SYSTEMS,

EVAPORATIVE CONTROL SYSTEM, AND AIR CLEANER FOR DAMAGE,
BLOCKAGES, LEAKS, AND IMPROPER CONNECTIONS. CHECK TO
INSURE THAT PROPER GRADE OF FUEL IS BEING USED. PERFORM
STEP 8 OF REFERENCE TWO.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. CHECK THE POSITION OF THE AIR CLEANER
DUCT DOOR TO INSURE THAT IT IS IN THE
WARM ENGINE (OPEN) POSITION.

NOT OK OK
i
PERFORM SSD-9 AND REPAIR AND / OR CHECK THE INTEGRITY OF ALL VACUUM
REPLACE AS REQUIRED. SYSTEMS AND CHECK FOR INTAKE
MANIFOLD LEAKS.

NOT OK OK
t A
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM STEPS 10, 11,7, AND 8 OF
REFERENCE ONE STEPS 28 AND 30
OF REFERENCE TWO AND CHECK
THROTTLE SOLENOID POSITIONER
FOR PROPER FUNCTION.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED.

RECHECK FOR DIESELING. PERFORM STEPS 3, 4, 7, 9, 17, 23A, O, 24
AND 26 OF REFERENCE TWO (EXTERNAL).

IF ENGINE STILL DIESELS

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM CARBURETOR SSD-13 IDLE FUEL

MIXTURE —ADJUST.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM SSD-7 —FUEL DECELERATION

VALVE DIAGNOSIS.

NOT OK

CONTINUED ON NEXT PAGE

REPAIR AND /OR REPLACE AS REQUIRED

CA1277-B1
29-02-41 Engine Diagnosis and Service 29-02-41

ROUTINE 121
ENGINE DIESELS —
CONTINUES TO RUN AFTER SHUT OFF —CONTINUED
I
OK
t
CHECK ENGINE FOR OVERHEATING.

NOT OK OK
I
PERFORM EGR SYSTEM SSD-1, PART I
PERFORM ROUTINE 125. B & C STEPS 1, 4 AND 5.

NOT OK OK
JL
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM VACUUM AMPLIFIER SSD-1, PART V.

NOT OK OK
t
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM STEPS 17, 18, 19, 24, 27 AND 15 OF
REFERENCE TWO (INTERNAL).

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. CHECK EXHAUST HEAT CONTROL VALVE

PER SSD-10 AND CHECK FOR RESTRICTED
EXHAUST SYSTEM.

NOT OK

REPAIR AND / OR REPLACE AS REQUIRED.

NOT OK OK
i
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM VALVE TRAIN ANALYSIS SSD-17.
REPAIR AND/OR REPLACE AS REQUIRED.

CA1377-B2
 29-02-42 Engine Diagnosis and Service 29-02-42

ROUTINE NO. 122

ENGINE NOISE
NOISY ENGINE OPERATION COVERS A WIDE RANGE OF CONDITIONS, THEREFORE, TO MAKE THE MOST EFFICIENT USE
OF DIAGNOSTIC AIDS TO CORRECT THE CONDITION, AN ACCURATE VERIFICATION OF THE SYMPTOMS MUST BE MADE.
WHEN THE SYMPTOM IS IDENTIFIED AS TO THE TYPE AND GENERAL LOCATION OF THE NOISE, PROCEED TO THE
APPLICABLE STEP OUTLINED BELOW. IT WILL BE SEEN THAT MANY OF THE STEPS ARE BASED ON SIMILAR SYMPTOMS
AND, INDEED MAY BE A MATTER OF INDIVIDUAL INTERPRETATION. THEREFORE, IF THE MOST LIKELY STEP FAILS TO
CORRECT THE CONDITION, PROCEED TO THE NEXT LIKELY STEP, AND SO ON UNTIL THE CONDITION IS CORRECTED.

A. THERMACTOR SYSTEM NOISE

THE THERMACTOR SYSTEM IS NOT COMPLETELY NOISELESS. UNDER NORMAL CONDITIONS, NOISE RISES IN PITCH
AS ENGINE SPEED INCREASES TO DETERMINE IF EXCESSIVE NOISE IS THE FAULT OF THE THERMACTOR SYSTEM,
DISCONNECT THE DRIVE BELT AND OPERATE THE ENGINE, IF THE NOISE DISAPPEARS, REFER TO SSD-4 OR SSD-5.

B. LIGHT CLICKING —VARIES WITH ENGINE SPEED

USUALLY CAUSED BY IMPROPERLY ADJUSTED, FAILED. OR MALFUNCTIONING VALVE TRAIN COMPONENTS. INSERT
FEELER GAUGE BETWEEN ROCKER ARM AND VALVE STEM TIP AND/OR EXERT PRESSURE ON ROCKER ARM, IF
NOISE IS ELIMINATED, ADJUST CLEARANCE TO SPECIFICATION. IF CONDITION PERSISTS, INSPECT FOR WORN OR
MALFUNCTIONING VALVE TRAIN COMPONENTS. PERFORM SSD 17. IF NO FAILURE IS DETECTED, CHECK FOR EX-
CESSIVE VALVE STEM TO VALVE GUIDE WEAR ACCORDING TO SHOP MANUAL PROCEDURES. CORRECT AS NEC-
ESSARY. IF VALVE TRAIN COMPONENTS ARE ELIMINATED AS A POSSIBLE CAUSE, CHECK FOR ACCESSORY COM-
PONENT NOISE BY LOOSENING AND/OR REMOVING DRIVE BELTS ONE AT A TIME UNTIL NOISE STOPS'. INVESTIGATE
FUEL PUMP AND/OR PUMP DRIVE AS POSSIBLE CAUSE.

C. SHARP RAPPING —VARIES WITH ENGINE SPEED

USUALLY CAUSED BY MANFUNCTIONING HYDRAULIC LIFTER AND MAY BE LOCATED WITH THE AID OF A
STETHOSCOPE. IF THE PROBLEM ISN'T CORRECTED, PERFORM STEP B.

D. HISSING
INSPECT VACUUM SYSTEMS FOR LEAKAGE DUE TO LOOSE OR BROKEN CONNECTIONS AND/OR FAILED PARTS.
INSPECT MANIFOLDS FOR LEAKS. PERFORM CYLINDER COMPRESSION OR LEAKAGE TESTS TO IDENTIFY/ISOLATE
HEAD GASKET LEAKS.

NOTE: IF NOISE IS ISOLATED TO THERMACTOR SYSTEM, PERFORM SSD-1, PART IX.

E. SHARP SNAPPING NOISE DURING ACCELERATION

PERFORM STEPS 21, 22 AND 23 OF REFERENCE ONE FOR HIGH TENSION CIRCUIT LEAKAGE.

F. SQUEAKS AND/OR SQUEALS

LOOSEN DRIVE BELTS ONE AT A TIME TO DETERMINE IF ACCESSORY COMPONENT OR WATER PUMP IS AT FAULT.

G. HEAVY SQUEAL DURING ACCELERATION

CHECK FOR ACCESSORY DRIVE BELT SLIPPAGE AND ADJUST TENSION OR REPLACE AS REQUIRED.

H. RINGING, GRINDING OR COMBINATION OF BOTH

CHECK FOR LOOSE, BENT OR IMPROPER PULLEYS. CHECK FOR FRONT END BRACKET INTERFERENCE BETWEEN
ROTATING PARTS AND SURROUNDING COMPONENTS CAUSED BY MISALIGNMENT OF ENGINE, ENGINE
COMPONENTS, OR SURROUNDING COMPONENTS. CHECK FOR WORN OR DAMAGED WATER PUMP OR ACCESSORY
COMPONENTS BY LOOSENING DRIVE BELTS ONE AT A TIME UNTIL NOISE STOPS.

NOTE: IF NOISE IS ISOLATED TO THERMACTOR SYSTEM, PERFORM SSD-4 OR 5.

I. BUZZING OR WHISTLING DURING ENGINE OPERATION
PERFORM RADIATOR CAP FUNCTIONAL CHECK AND VERIFY PROPER CAP SEALING. IF ENGINE OVERHEATING IS
INDICATED, PERFORM ROUTINE 125. CHECK FOR INTERFERENCE WITH THE FAN OR FRONT END DRIVE COMPO-
NENTS BY FOREIGN MATERIAL OR LOOSE, OR BROKEN SURROUNDING PARTS. CHECK FOR LOOSE CARBURETOR
MOUNTING. CHECK FOR VACUUM LEAKS. CHECK POWER STEERING, CHECK SSD-1, PART IX "BACKPRESSURE EGFt".

CA1378-D
29-02-43 Engine Diagnosis and Service 29-02-43

ROUTINE NO. 122A

SPARK KNOCK OR PINGING
VERIFY THE CONDITION

CHECK WITH OWNER AS TO GRADE OF

FUEL BEING USED.
OK
NOT OK

ADVISE OWNER OF PROPER GRADE OF FUEL. CHECK ENGINE FOR OVERHEATING.

NOT OK OK

PERFORM ROUTINE 125. USE ROTUNDA ENG. SYSTEM ANALYZER

OR EQUIVALENT TO CHECK STEPS IN REF.
ONE 10, 11, 12, 13, 20 AND 22 IN COMBINA-
TION WITH SSD-14 STEP II "IGNITION SYS-
TEM COIL RESERVE VOLTAGE" AND STEP
IV "SPARK PLUG REQUIRED VOLTAGE".
PERFORM SSD-15, PART E.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM COMPRESSION BALANCE (ELEC-

TRICAL) STEP 17 OF REFERENCE ONE.

NOT OK OK

PERFORM CYLINDER COMPRESSION AND/ PERFORM "SPARK CONTROL SYSTEM AND

OR LEAKAGE TEST. SPARK DELAY VALVE" SSD-3.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM PART 1A, B, C, PCV SYSTEM

SSD-11.

NOT OK OK

PERFORM SSD-11 STEPS 1-D AND II REPAIR PERFORM STEPS 9, 6, 3, A, 23A, 26 AND 17
AND/OR REPLACE AS REQUIRED. OF REF. TWO (EXTERNAL).

NOT OK OK

PERFORM STEP 23 OF REF. TWO (IF APPLI- PERFORM SSD-9, "AIR CLEANER TEMP.
CABLE) AND REPAIR AND/OR REPLACE AS CONTROL".
REQUIRED.
OK
NOT OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM STEPS 10, 13. 15, 16, 19, 20, 25
AND 27 OF REF. TWO (INTERNAL).

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. CONTINUED

CA1378-C1
29-02-44 Engine Diagnosis and Service 29-02-44

ROUTINE NO. 122A

SPARK KNOCK OR PINGING - CONTINUED
OK

SUBSITUTE KNOWN GOOD FUEL PUMP.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. REINSTALL ORIGINAL FUEL PUMP.

INSTALL KNOWN GOOD DISTRIBUTOR.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. REINSTALL ORIGINAL DISTRIBUTOR.

PERFORM CYLINDER LEAKAGE AND/OR
COMPRESSION CHECK.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM SSD-1 "EGR BACKPRESSURE"

CA1378-C2
29-02-45 Engine Diagnosis and Service 29-02-45

ROUTINE NO. 123

ENGINE VIBRATION

VERIFY THE CONDITION

CHECK INTEGRITY OF MOTOR MOUNTS, VIBRATION DAMPER

AND FAN

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. CYCLE ENGINE ACCESSORY COMPONENTS.

NO CHANGE

LOOSEN DRIVE BELTS ONE AT A TIME AND

OPERATE ENGINE TO ASCERTAIN- IF
VIBRATION IS CAUSED BY ACCESSORY
COMPONENTS.

NOT OK OK

CHECK ALL MOVING INTERNAL ENGINE

REPAIR AND/OR REPLACE AS REQUIRED.
COMPONENTS FOR PROPER OPERATION.

NOT OK
t
REPAIR AND/OR REPLACE AS REQUIRED.

CA1379-A
29-02-46 Engine Diagnosis and Service 29-02-46

ROUTINE NO. 124

ENGINE FAILS TO REACH NORMAL OPERATING TEMPERATURE

VERIFY THE CONDITION BY THE USE OF A THERMOMETER

—i
NOT OK OK
I I
REPLACE THERMOSTAT CHECK OPERATION OF TEMPERATURE SENDING
UNIT, GAUGE OR LIGHT.

NOT OK
I
REPAIR AND/OR REPLACE AS REQUIRED.

CA1 :*80-A
29-02-47 Engine Diagnosis and Service 29-02-47

ROUTINE NO. 125

LOSS OF COOLANT OR ENGINE OVERHEATING
VERIFY THE CONDITION

1
CHECK COOLANT LEVEL AND CONDITION, REPLACE REQUIRED
COOLANT AND CLEAN RADIATOR CAP SEAL AND SEAT.

NOT OK (LOSS OF COOLANT) OK (ENGINE OVERHEATS)

1
INSPECT FAN BELT WEAR AND TENSION,
CHECK FOR OBVIOUS EXTERNAL LEAKS
RADIATOR FINS FOR DIRT OR DAMAGE.
CHECK ENGINE OIL FOR CONTAMINATION BY
CHECK FOR OBVIOUS COOLANT, AIR AND
COOLANT.
EXHAUST FLOW RESTRICTIONS. CHECK
IDLE RECIRCULATION FLAP IF VEHICLE
IS SO EQUIPPED.

NOT OK OK NOT OK OK
t
REPAIR AND/OR PRESSURE TEST CHECK ADJUST, REPAIR CHECK COOLANT
REPLACE AS REQUIRED. FOR EXTERNAL LEAKS AND/OR REPLACE AS CIRCULATION BY
IN RADIATOR CAP, IN REQUIRED. REMOVING CAP AND
COOLING AND HEATING OPERATING AT 2000
SYSTEM. RPM. CHECK FLOW AT
FILLER NECK AFTER
ENGINE WARMS UP.

NOT OK OK
NOT OK OK
i
• REPLACE THERMOSTAT. CHECK OPERATION OF
REPAIR AND/OR PRESSURE TEST CHECK FAN CLUTCH IF
REPLACE AS REQUIRED. FOR INTERNAL LEAKS. APPLICABLE.
NOT OK

REPLACE WATER PUMP. OK

CHECK TEMPERATURE
NOT OK SENDING UNIT, GAUGE
i AND/OR WARNING
NOT OK OK LIGHT. (IF EQUIPPED
t PERFORM FAN CLUTCH WITH COOLING PVS,
DISASSEMBLE ENGINE SEE ENGINE DRIVE TEST AND CHECK FOR VACUUM
TO THE EXTENT OVERHEATS REPLACE FAN CLUTCH AT PVS OUTLET WITH
REQUIRED TO PROCEDURE. IF REQUIRED. ENGINE IN OVERHEAT
DETERMINE THE CONDITION AT IDLE.
CAUSE AND TO
REPAIR INTERNAL
LEAKAGE.

NOT OK
OK
REPAIR AND/OR REPLACE
COOLING PVS TEMPERATURE PERFORM STEPS 7, 10,
11, 13 OF REFERENCE CONTINUED ON
SENDING UNIT .AND/OR
WARNING LIGHT AS REQUIRED. ONE'PERFORM SSD-15, NEXT PAGE
PART E.

CA1381-B1
29-02-48 Engine Diagnosis and Service 29-02-48

ROUTINE NO. 125

LOSS OF COOLANT OR ENGINE OVERHEATING — CONTINUED

NOT OK OK
t
PERFORM SSD-3 AND CHECK FOR RESTRICTED
REPAIR AND/OR EXHAUST, PERFORM
REPLACE AS REQUIRED. SSD-10.

OK

NOT OK
f
REPAIR AND/OR CLEAN SYSTEM WITH
REPLACE AS REQUIRED. MANUFACTURERS
RECOMMENDED
COOLING SYSTEM
CLEANER.

NOT OK OK

REMOVE RADIATOR, REMOVE WATER PUMP

CLEAN AND/OR AND CHECK FOR
REPLACE AS REQUIRED. DAMAGED IMPELLER
ETC.

NOT OK OK
•
REPLACE WATER PUMP. DISCONNECT RADIATOR
REMOVE THERMOSTAT
AND PRESSURE FLUSH
BLOCK AND HEAD
COOLANT PASSAGES.

NOT OK
t
DISASSEMBLE ENGINE
AND CHECK FOR
BLOCKED COOLANT
PASSAGES. REPAIR
AS REQUIRED.

CA1381-A2
29-02-49 Engine Diagnosis and Service 29-02-49

ROUTINE NO. 126

SMOKE FROM VEHICLE EXHAUST SYSTEM

VERIFY THE CONDITION

INSPECT FUEL SYSTEMS, EVAPORATIVE CONTROL SYSTEM AND AIR

CLEANER FOR DAMAGE, LEAKS, BLOCKAGE AND IMPROPER CONNEC-
TIONS. INSPECT SPARK PLUGS FOR OIL OR CARBON DEPOSITS.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. CHECK CONDITION OF AIR CLEANER AND

AIR CLEANER FILTER ELEMENTS FOR
CLOGGING AND CONTAMINATION.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM SSD-11 STEPS A 1 , 2, 3 & 4

PCV SYSTEM DIAGNOSIS.

NOT OK OK
•
REPAIR AND/OR REPLACE AS REQUIRED. PERFORM STEPS 11A, 11D, 19A, 17, 14 A N D
23 OF REFERENCE TWO ( E X T E R N A L ) .

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. ON AUTOMATIC TRANSMISSION VEHICLES,

APPLY 16" HG. VACUUM TO TRANSMISSION
MODULATOR (BOTH PRIMARY AND
SECONDARY ON D.A.D. TRANSMISSIONS.)

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. CHECK THE INTEGRITY OF ALL VACUUM

SYSTEMS AND CHECK FOR INTAKE
MANIFOLD LEAKS.

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. CONTINUED ON NEXT PAGE

CA1382-C1
29-02-50 Engine Diagnosis and Service 29-02-50

ROUTINE NO. 126

SMOKE FROM VEHICLE EXHAUST SYSTEM — CONTINUED
OK

PERFORM EGR SYSTEM CHECK SSD-1, PART

I STEPS B, C (-1,-4, -5) AND PART V AND IX.

NOT OK OK

t_
REPAIR AND/OR REPLACE AS REQUIRED.
PERFORM STEP C OF SSD^ (NON-CATALYTIC I
OR STEP C (I-IX) OF SSD-5 (CATALYTIC)

NOT OK
OK

REPAIR AND/OR REPLACE AS REQUIRED.

PERFORM STEPS 10, 11, 13, 15, 16, 18, 19, 27
AND 29 OF REFERENCE TWO (INTERNAL).

NOT OK OK

REPAIR AND/OR REPLACE AS REQUIRED. PERFORM CYLINDER COMPRESSION AND/OR

LEAKAGE TEST.

NOT OK OK

PERFORM VALVE TRAIN ANALYSIS SSD-1

REPAIR AND/OR REPLACE AS REQUIRED.
REPAIR AND/OR REPLACE AS REQUIRED.

CA1382-C2
 29-02-51 Engine Diagnosis and Service 29-02-51

ROUTINE NO. 127-HIGH FLOOR PAN TEMPERATURES

(CATALYST EQUIPPED VEHICLES ONLY)

1. PERFORM SSD-5 PART Cl, STEPS 1-5, AND PARTS C-VI AND C-VM IF APPLICABLE.

2. DISCONNECT WIRING TO SOLENOID VALVE.

3. WHILE THE ENGINE IS AT IDLE CONDITION, PLACE FINGER OVER OPEN END OF VACUUM HOSE TO BY-
PASS VALVE. NO VACUUM SHOULD ATTRACT YOUR FINGER. IF IT DOES, REPLACE SOLENOID.

4. IF BY-PASS VALVE OR SOLENOID ARE NOT AT FAULT, REPLACE FLOOR PAN SWITCH.*

5. RECONNECT BY-PASS VALVE HOSE AND SOLENOID WIRING.

•NOTE: ON PINTO, BOBCAT, MUSTANG, MAVERICK, COMET, GRANADA AND MONARCH FRONT SEAT OF
VEHICLE MUST BE REMOVED TO REPLACE THE FLOOR PAN SWITCH. ON ALL OTHER VEHICLES,
SWITCH IS LOCATED ON THE TOEBOARD.

CA1450-B
29-02-52 Engine Diagnosis and Service 29-02-52

ELECTRICAL SYSTEM DIAGNOSIS

REFERENCE ONE

1. Check battery using Rotunda tester or equivalent.

2. Check starter draw.
3. Check battery voltage during cranking.
4. Check cranking speed.
5. Check basic timing while cranking.
6. Check spark plug firing voltage while cranking.
7. Check low idle speed with and without TSP. NOTE: When idle speed is adjusted, also perform
fuel bowl vent procedure SSD-16 (if equipped).
8. Check fast idle speed.
9. Check engine idle manifold vacuum.
10. Check basic timing - per SSD-15.
11. Check retard timing - per SSD-15.
12. Check mechanical advance — per SSD-15.
13. Check total advance at 2500 RPM - per SSD-15.
14. Check ignition coil primary voltage 1000 RPM (measured at "Bat" terminal).
15. Check battery voltage - 1000 RPM.
16. Check spark plug firing voltage per SSD-14 (loaded or on quick acceleration).
*17. Check compression balance 1-8 cylinders (electrical — no EGR).
*18. Check ignition system coil reserve voltage - 1000 RPM, per SSD-14.
*19. Check distributor rotor high voltage gap drop, per SSD-14.
20. Check coil and spark plug wire resistance, per SSD-14.
21. Inspect coil and spark plug wires and connections.
22. Check condition of cap and rotor.
23. Check ignition coil condition and operation, per SSD-14.
24. Check primary wiring in ignition system, per SSD-14.
25. Check charging rate to battery with engine operating at approximately 1000 RPM.
26. Check spark delay valve for correct operation (SSD-2).
27. Use auxiliary vacuum source to check integrity of vacuum advance and retard diaphragm.
28. Check distributor dwell at normal engine idle and at 2500 RPM.
29. Check function of vacuum switch.
NOTE: Check and adjust fuel decel valve to specifications after any idle speed adjustment is performed.

* On catalyst equipped vehicles, do not perform Steps 17r 18, and 19 until vehicle passes Step 16.

CA1419-C
 29-02-53 Engine Diagnosis and Service 29-02-53

REFERENCE TWO
CARBURETOR AND FUEL SYSTEM DIAGNOSIS
TO DETERMINE IF A FUEL SYSTEM PROBLEM EXISTS, USE THE APPROPRIATE COMBINATION OF THE FOLLOWING
DIAGNOSIS STEPS AS OUTLINED IN THE PROBLEM DIAGNOSTIC PROCEDURES. ALL DISCREPANCIES SHOULD BE
REPAIRED, ADJUSTED, CLEANED AND / OR REPLACED AS REQUIRED. IDLE MIXTURE SHOULD BE VERIFIED AND/OR
ADJUSTED AFTER CARBURETOR INTERNAL REPAIRS.

1. CHECK FUEL SUPPLY IN FUEL TANK

A. CHECK FOR FUEL AVAILABILITY
B. CHECK FOR FUEL CONTAMINATION
C. CHECK FOR FUEL LEAKS IN TANK AND FUEL LINES
D. CHECK FOR DAMAGED PARTS IN TANK AND FUEL LINES

2. CHECK FUEL DELIVERY TO CARBURETOR

A. CHECK FOR FUEL DELIVERY TO FILTER PRIOR TO REMOVING FILTER FROM CARBURETOR
B. CHECK FOR FUEL DELIVERY THROUGH FILTER(S) TO CARBURETOR
C. CHECK FOR FUEL PUMP LEAKS
D. CHECK FOR DAMAGE, LEAKS, BLOCKAGES AND/OR IMPROPER CONNECTIONS.
E. CHECK FOR CONTAMINATION
F. CHECK FOR DAMAGED PARTS

3. CHECK CARBURETOR VACUUM HOSES, FUEL LINES, AND PCV LINE

A. CHECK FOR LEAKS
B. CHECK FOR DAMAGED PARTS
C. CHECK FOR IMPROPER ASSEMBLY
D. CHECK FOR CONTAMINATION

4. CHECK ELECTRICAL CONNECTIONS

A. CHECK FOR IMPROPER ASSEMBLY
B. CHECK FOR SHORTED CIRCUIT
C. CHECK FOR DAMAGED PARTS

5. CHECK CHOKE HEAT SUPPLY SYSTEM

A. CHECK FOR AIR LEAKS
B. CHECK FOR DAMAGED PARTS
C. CHECK FOR IMPROPER ASSEMBLY
D. CHECK FOR MISSING PARTS (EXTERNAL ONLY).

6. CHECK AIR CLEANER

A. CHECK FILTER ELEMENT(S) FOR CONTAMINATION
B. CHECK HEAT CONTROL VALVE FOR FUNCTION (SSD-9)
C. CHECK FOR DAMAGED PARTS
D. CHECK FOR IMPROPER ASSEMBLY

7. CHECK THROTTLE LINKAGE AND THROTTLE PLATES

A. CHECK FOR BINDING
B. CHECK FOR FULL TRAVEL
C. CHECK FOR IMPROPER ASSEMBLY
D. CHECK FOR CONTAMINATION
E. CHECK FOR DAMAGED PARTS

8. CHECK ENGINE SPEED ADJUSTMENTS

A. CHECK CURB IDLE SPEED
B. CHECK LOW IDLE SPEED W/O TSP (NOTE. WHEN IDLE SPEED IS ADJUSTED,
ALSO PERFORM FUEL BOWL VENT ADJUSTMENT PROCEDURE PER SSD-16)
C. CHECK FAST IDLE SPEED
NOTE: ALL ENGINE SPEED ADJUSTMENTS AND CHECKS SHOULD BE PERFORMED AFTER ENGINE HAS BEEN
PROPERLY WARMED AND AFTER VACUUM, IGNITION, FUEL, AND/OR MECHANICAL PROBLEMS HAVE
BEEN PROPERLY CORRECTED — THEN FINAL ADJUSTMENTS SHOULD BE MADE ACCORDING TO SPEC-
IFICATION. CA1420-C1
29-02-54 Engine Diagnosis and Service 29-02-54

9. CHECK SECONDARY THROTTLE LINKAGE AND CHOKE LOCKOUT LINKAGE

A. CHECK FOR LINKAGE BINDING
B. CHECK FOR DAMAGED PARTS
C. CHECK FOR IMPROPER ASSEMBLY
D. CHECK FOR CONTAMINATION

10. CHECK AIR VALVE PLATE, METERING NEEDLES AND / OR JETS (MODEL 4350 4V)
A. CHECK FOR BINDING
B. CHECK FOR DAMAGED PARTS
C. CHECK FOR IMPROPER ASSEMBLY
D. CHECK FOR CONTAMINATION

11. CHECK ACCELERATOR PUMP SYSTEM

A. CHECK FOR FUEL DISCHARGE
B. CHECK FOR BINDING
C. CHECK FOR IMPROPER ADJUSTMENT
D. CHECK FOR FUEL LEAK
E. CHECK FOR CONTAMINATION
F. CHECK FOR IMPROPER ASSEMBLY
G. CHECK FOR DAMAGED PARTS

12. CHECK FOR FUEL IN FUEL BOWL

A. USE FUEL GAUGE TO CHECK FOR FUEL IN BOWL (WHEN GAUGE IS AVAILABLE) (EXCEPT 27- 2V)
B. CHECK FOR CONTAMINATION AND, IF REQUIRED, CLEAN CARBURETOR PER SSD-18
C. DISASSEMBLE AND CHECK ITEM # 1 3 AS REQUIRED

13. CHECK FUEL INLET SYSTEM COMPONENTS

A. CHECK FOR CONTAMINATION AND, IF REQUIRED, CLEAN CARBURETOR PER SSD-18
B. CHECK FOR BINDING
C. CHECK FOR DAMAGE
D. CHECK FOR IMPROPER ASSEMBLY
E. CHECK FOR FUEL LEVEL
F. CHECK FOR FLOAT ALIGNMENT
G. CHECK FLOAT FOR LEAKS

14. CHECK FUEL BOWL VENTS

A. CHECK FOR RESTRICTION IN CARBURETOR OR VENT LINE
B. CHECK FOR IMPROPER ADJUSTMENT
C. CHECK FOR IMPROPER ASSEMBLY
D. CHECK FOR BINDING
E. CHECK FOR SEALING (INTERNAL VENT 2700 2V AT IDLE)

15. CHECK FUEL METERING SYSTEMS (IDLE & MAIN)

A. CHECK FOR CONTAMINATION
B. CHECK FOR FUEL LEAKS
C. CHECK FOR AIR LEAKS
D. CHECK FOR RESTRICTIONS
E. CHECK FOR IMPROPER ASSEMBLY
F. CHECK FOR DAMAGED PARTS
G. CHECK FOR IMPROPER IDLE FUEL MIXTURE (SSD-13)

16. CHECK FUEL ENRICHMENT SYSTEM

A. CHECK FOR AIR LEAK
B. CHECK FOR FUEL LEAK
C. CHECK FOR RESTRICTIONS
D. CHECK FOR DAMAGED PARTS
E. CHECK FOR IMPROPER ASSEMBLY
F. CHECK FOR CONTAMINATION
G. CHECK FOR IMPROPER ALIGNMENT OF VENTURI VALVE KICKER (2700 2V)
H. CHECK FOR IMPROPER ADJUSTMENT OF VENTURI VALVE KICKER (2700 2V)
CA1420-C2
29-02-55 Engine Diagnosis and Service 29-02-55

17. CHECK ALTITUDE COMPENSATOR (IF EQUIPPED)

A. CHECK FOR BINDING
B. CHECK FOR AIR LEAK
C. CHECK FOR FUEL LEAK ( 2150 2V AND 5200 2V )
D. CHECK FOR CONTAMINATION
E. CHECK FOR DAMAGED PARTS
F. CHECK FOR IMPROPER ASSEMBLY
G. CHECK FOR IMPROPER ADJUSTMENT ( 4350 4V AND YFA 1V CLOSED AT SEA LEVEL )

18. CHECK FUEL DECELERATION SYSTEM

A. CHECK FOR CONTAMINATION
B. CHECK FOR RESTRICTION
C. CHECK FOR IMPROPER ASSEMBLY
D. CHECK FOR DAMAGED PARTS
E. CHECK FOR PROPER ADJUSTMENT
F. CHECK FOR AIR LEAKS

19. CHECK VENTURI VALVE SYSTEM ( 2700 2V )

A. CHECK FOR BINDING
B. CHECK FOR CONTAMINATION
C. CHECK FOR IMPROPER ASSEMBLY
D. CHECK FOR LEAKS ( VACUUM ) SEE SSD-19
E. CHECK FOR DAMAGED PARTS
F. CHECK FOR IMPROPER ADJUSTMENT ( SEE SPECIFICATIONS )

20. CHECK FUEL PUMP FUEL DELIVERY

A. CHECK PRESSURE AND VOLUME WITH ORIGINAL FILTER
B. CHECK PRESSURE AND VOLUME WITH NEW FILTER
C. CHECK FOR CONTAMINATION
D. CHECK FOR FUEL LEAK

21. CHECK FUEL TANK

A. CHECK FOR LEAKS
B. CHECK FOR SOURCES WHERE DIRT OR WATER MAY ENTER
C. CHECK TANK FILTER AND PICK-UP FOR FUNCTION
D. CHECK GAS TANK CAP FOR PROPER FUNCTION

22. CHECK FUEL LINES FROM TANK TO PUMP

A. CHECK FOR CONTAMINATION
B. CHECK FOR KINKS OR DAMAGED PARTS
C. CHECK FOR LEAKS
D. CHECK FUEL RETURN LINE IF EQUIPPED

23. CHECK CHOKE SYSTEM PER SSD-12

A. CHECK PER SSD-12 ( LINKAGE )
B. CHECK PER SSD-12 ( HEAT )
C. CHECK PER SSD-12 ( ELECTRIC ) ( STEPS II AND IV FOR 2700 2V )
D. CHECK FOR PULLDOWN ( EXCEPT 2700 2V )
E. CHECK FOR DECHOKE (VISUAL)
F. CHECK CAM CLEARANCE ( EXCEPT 2700 2V ) ONLY IF PROBLEM IS FOUND IN D. ABOVE
G. CHECK CHOKE PLATE ALIGNMENT
H. CHECK CHOKE CAP INDEX SETTING
I. CHECK FOR IMPROPER ASSEMBLY
J. CHECK FOR DAMAGED PARTS
K. CHECK FOR CONTAMINATION
L. CHECK CHOKE METERING ROD INDEX ( 2700 2V ) PER CHOKE SET PROCEDURE, STEPS 1-5
M, CHECK FAST IDLE CAM SETTING ( 2700 2V ) PER CAM SET PROCEDURE, STEPS 1-5
N. CHECK HIGH CAM FINGER SETTING ( 2700 2V ) PER HIGH CAM FINGER SETTING PROCEDURE
O. CHECK CHOKE METERING ROD SEATING ( 2700 2V ) FULLY DEPRESS CHOKE METERING ROD AND CHECK
FOR STICKING OR BINDING

CA 1420-C3
29-02-56 Engine Diagnosis and Service 29-02-56

24. CHECK HOT IDLE COMPENSATOR

A. CHECK FOR DAMAGED PARTS
B. CHECK FOR AIR LEAK
C. CHECK IMPROPER TEMPERATURE CALIBRATION ( EXCEPT 4350 4V )
D. CHECK FOR CONTAMINATION
E. CHECK FOR IMPROPER ASSEMBLY
F. CHECK FOR RESTRICTION
G. CHECK TO MAKE SURE BI-METALLIC STRIP IS COOL AND THAT COMPENSATOR PLUG IS SEATED BEFORE
ATTEMPTING TO MAKE CARBURETOR IDLE ADJUSTMENT ( 4350 4V )
25. CHECK SPARK PORT, EGR PORT, AND / OR ELA VENTURI PORT
A. CHECK FOR RESTRICTION
B. CHECK FOR CONTAMINATION
C. CHECK FOR PROPER ASSEMBLY
D. CHECK FOR DAMAGED PARTS
E. CHECK FOR AIR LEAKAGE
26. CHECK EXTERNAL GASKETS AND GASKET SURFACES
A. CHECK FOR AIR LEAKS
B. CHECK FOR FUEL LEAKS
C. CHECK FOR PROPER ASSEMBLY
D. CHECK FOR DAMAGED PARTS
E. CHECK FOR PROPER TYPE OF GASKET
27. CHECK INTERNAL GASKETS AND GASKET SURFACES
A. CHECK FOR AIR LEAKS
B. CHECK FOR FUEL LEAKS
C. CHECK FOR PROPER ASSEMBLY
D. CHECK FOR DAMAGED PARTS
E. CHECK FOR CONTAMINATION
F. CHECK FOR PROPER TYPE OF GASKET
28. CHECK DASHPOT AND BRACKET
A. CHECK FOR PROPER ADJUSTMENT
B. CHECK FOR PROPER ASSEMBLY
C. CHECK FOR DAMAGED PARTS
D. CHECK FOR CONTAMINATION
29. CHECK CRANKING SYSTEM ( 2700 2V )
A. CHECK FOR FUEL LEAKS ( SSD-19 )
B. CHECK FOR DAMAGED PARTS CA1420-B4
C. CHECK ELECTRICAL CIRCUTS ( SSD-12, PART IV )

EMISSION CONTROL SYSTEM DIAGNOSIS AND SERVICE PROCEDURES

SERVICE/DIAGNOSIS PROCEDURE PAGE

SSD-1 EGR System 02-57

SSD-2 Spark Delay Valve 02-59

SSD-3 Spark Control Systems and Spark Delay Valve 02-60
SSD-4 Thermactor System - Non-catalytic 02-61
SSD-5 Thermactor System - Catalytic 02-63

SSD-7 Fuel Decel Valve 02-69

SSD-9 Air Cleaner Temperature Control 02-70

SSD-11 PCV System 02-71

SSD-12 Ai omatic Choke 02-71

SSD-13 Idle Fuel Mixture 02-79

SSD-14 Ignition System Diagnosis 02-81

SSD-15 Ignition Timing 02-85

SSD-16 Fuel Bowl Vent Clearance 02-85

SSD-17 Valve Train Diagnosis 02-86

SSD-18 Carburetor Cleaning Procedures 02-87

SSD-19 Leak Checks - Carburetor Systems 02-89

CA1422-B
29-02-57
SSD-l—EGR SYSTEM DIAGNOSIS
The EGR delay valve diagnosis is
described under delay valve diagnosis
(SSD-2).
I. Check of EGR Valve When on
the Engine. (Remote Type EGR
Valve)
NOTE: If the engine is equipped with an
Integral Type Backpressure Transducer/
EGR Valve do not perform this check,
instead proceed to Part VI.
A. Start the engine and warm it up until
engine coolant temperature is above
the calibrated temperature of the
EGR PVS valve as indicated below
according to the color code of the
PVS valve:
Color Code Temperature (°F.)
Pink Top Above 90°
Black Top Above 100°
Plain Dichromate
or Blue Top Above 133°
Yellow Top Above 1550
CA1387-I
B. Check all vacuum hoses in the
system to be sure they are open and
not broken, split or cracked and fit
snugly onto the connectors. Remove
the EGR vacuum supply hose from
the EGR valve, plug and hook a
vacuum hose from the EGR valve to
an external, gauged, variable vacuum
source with increments of one in.
Hg., 0.10 in. Hg. graduations and a
minimum capacity of 10 in. Hg.
C. Gradually apply vacuum to the EGR
valve and simultaneously observe the
movement of the EGR valve stem.
1. With the engine at idle, the stem
should visually be observed to start
to move within ±1.0 Hg of the
diaphragm signal vacuum as noted
for the low flow point noted on the
EGR valve flow chart per the
s p e c i f i c a t i o n s (to observe
movement, mark stem).
2. If valve does not meet "start to
open" specification, replace.
3. With the engine off, apply 8 in. Hg
vacuum to the EGR valve and
trap. Vacuum should remain
within 1 in. Hg for a minimum of
30 seconds. Replace the EGR
valve if out of specification.
4. With the engine at idle, apply
vacuum to the EGR valve of at
least 8 in. Hg. The valve should
move to the full extent of its travel
and engine should roughen, RPM
should decrease a n d / o r stop
completely. If idle quality doesn't
change there is no EGR flow and
if the specifications of Step 3 have
been met something is plugging the
EGR system. Perform cleaning
procedure to determine problem.
Engine Diagnosis and Service
5. With the hose routings properly
connected, restart the engine and
stabilize temperatures. If the
engine idle q u a l i t y is not
acceptable, the EGR valve may
not be sealing properly. If this
condition is encountered, install a
new EGR valve and a new gasket.
Adjust engine idle to specified
curb idle. See engine tune-up decal.
Recheck the idle condition of the
engine. If there is no improvement
in the idle quality, the problem is
elsewhere. The original EGR valve
should be re-installed and further
engine diagnosis should be
performed to determine the
malfunctioning component. If
there is improvement in idle
quality, retain the new EGR valve
on the engine.
II. To Check the Carburetor EGR
Port, Perform the Following
Steps:
A. Attach a vacuum gauge directly to
the EGR port on the carburetor
using a suitable hose.
B. With the engine running, open the
carburetor throttle quickly and
momentarily to at least the 1/2 wide
open p o s i t i o n . ( N o t e : avoid
overspeeding).
C. Observe the vacuum gauge for a
quick rise and fall as the throttle is
opened and closed. If a vacuum is
evident, the EGR port is open and
OK. If no vacuum is evident, the
EGR port in the carburetor is
plugged or restricted and should be
cleaned.
III. EGR TVS-PVS Functional
Check
Verify that the EGR valve, external
vacuum passages, and/or solenoid valve
(if equipped) are functional.
A. Perform TVS functional check, SSD-
9, Steps 13-a, b and c. (If so
equipped.)
B. PVS with Two Connectors
1. Disconnect both vacuum hoses at
the PVS valve. Connect vacuum
gauge to either connector on the
PVS. Connect manifold vacuum or
auxiliary vacuum source of at least
10 in. Hg to other connector.
2. Start engine and warm it up until
engine coolant temperature is
above the calibration temperature
of the EGR PVS as previously
indicated.
a. If no reading is noted on vacuum
gauge—PVS has failed and
should be replaced.
b. If vacuum is noted—PVS is OK.
C. PVS with Three Connectors
1. Disconnect EGR vacuum hose at
carburetor and connect manifold
29-02-57
vacuum or auxiliary vacuum
source to hose.
2. Disconnect EGR vacuum hose at
EGR valve and connect a vacuum
gauge to the hose.
3. Start engine and warm it up until
engine coolant temperature is
above the calibration temperature
of the EGR PVS as previously
indicated.
a. If no reading is noted on vacuum
gauge—PVS has failed and
should be replaced.
b. Ifvacuum is noted—PVS is OK.
D. PVS with Four Connectors
1. Disconnect vacuum hoses at the
PVS valve. Connect a vacuum
gauge to either of the two ports
marked "D" and "M". Connect a
vacuum supply to the other.
2. Start engine and warm it up until
engine coolant temperature is
above the calibration temperature
of the EGR PVS as previously
indicated.
a. If there is no vacuum reading—
that portion of the PVS is OK.
b. If vacuum is noted—the PVS is
defective and should be replaced.
3. Connect the gauge to either one of
the bottom two ports marked
" E " and " S " and the vacuum
supply to the other.
a. If vacuum is noted—the PVS is
OK.
b. If there is no vacuum reading—
the PVS is defective and should
be replaced.
IV. Step Not Required for 1977
V. Backpressure EGR Diagnostic
Procedure (Remote EGR Valve
and Transducer)
A. Remove air cleaner assembly from
carburetor to observe the EGR
valve. Place air cleaner assembly in
such a position so that vacuum hoses
are not disconnected from the air
cleaner TVS switch.
B. 1. EGR Backpressure System Integrity
Check EGR system vacuum hose
routing for proper connection—refer
to e m i s s i o n s c a l i b r a t i o n s
publications—correct as required.
B.2. Check Integrity of Backpressure
Transducer to Sensor Tube Joint
The brazed joint between the EGR
transducer and the steel exhaust
pressure sensing tube should be rigid.
If this brazed joint has separated (as
indicated by relative movement of
the pressure sensing tube within the
flared opening on the transducer
body), replace the EGR
backpressure transducer.
C. Backpressure Transducer Leak
Check (NOTE: Transducer and
sensor tube must not be hot for this
29-02-58
step. If transducer assembly is hot to
the touch, use shop air or freon to
cool.)
C. 1. Disconnect vacuum source to EGR
backpressure transducer diaphragm
and plug.
C.2. Start the engine—immediately place
the throttle on high step or fast idle
cam (1500-2000 rpm). Using leak
check or leak detector fluid, coat the
sensor tube joint at the transducer.
C.3.Check for evidence of exhaust gas
leakage (bubbles from detector fluid)
at the sensor tube joint. If bubbles
are evident, replace the EGR
backpressure transducer.
C.4.If Step 3 was satisfactory, firmly
grasp the transducer and attempt to
wiggle the transducer in several
directions (do not use excessive
force, to avoid bending the tube or
bracket). Add more leak check or
detector fluid if necessary. If bubbles
appear at the sensor tube-to-
transducer joint or along the sensor
tube, replace the EGR backpressure
transducer.
D. EGR System Function Check
D.I.Reconnect the vacuum source to the
EGR backpressure transducer
diaphragm.
D.2.Warm up engine to normal operating
temperature.
D.3.With Transmission in Neutral
a. While slowly opening and closing
the throttle, the EGR valve stem
must be observed to move upward,
appear to oscillate, and move
downward to the closed position
when the engine returns to idle.
CAUTION: Do not exceed 1/2
throttle or 2500 rpm.
If engine performance seems
rough, proceed to check EGR
system with engine under load.
If the valve stem moves or operates
properly and the engine shows
very little roughness and variation
in speed d u r i n g this test
sequence—the EGR system is
functioning properly. Discontinue
diagnostic procedure.
b. If the EGR valve does not appear
to operate properly, for instance
valve appears to move near full
stroke (approx. 0.4 in.), does not
have noticeable oscillation and the
engine does not have exceptional
roughness, proceed to check EGR
system with engine under load.
c. When a vehicle has a severe drive
problem which appears at throttle
tip in/driveaway (severe stumble
or surge during driveaway or tip
in) the EGR system must always
be checked under load in sequence
with Steps D-3a and D-3b.
Engine Diagnosis and Service
D AWith Transmission in Drive
NOTE: Throttle positions for the
following tests must be equal to or
greater than those used in D-3a to
assure similar EGR valve motion
and also exposure of the carburetor
EGR vacuum supply port.
a. Properly brake vehicle. Apply
throttle slightly and hold constant.
CAUTION: Do not exceed 1250
rpm.
If the engine begins to roll and
surge excessively—replace the
EGR backpressure transducer.
b. Vehicles equipped with manual
transmission must be tested in
third gear with rear wheel free of
the ground and engine load created
by applying the foot brake. Apply
throttle slightly and foot brake
simultaneously to create engine
load—do not stall engine with
brake load.
CAUTION: Do not exceed 2000
rpm.
If engine begins to roll and surge
excessively—replace the EGR
backpressure transducer.
E. 1. If the EGR valve stem does not move
and/or oscillate properly (as
described in Step D), disconnect the
transducer vacuum supply hose at
the TVS or PVS nipple and connect
a vacuum gauge to the TVS or PVS
nipple. Slowly open and close
throttle (as in Step D) and observe
vacuum signal in gauge:
a. If vacuum signal is less than 4.0 in.
Hg., check EGR PVS (SSD-1, Part
III) or air cleaner TVS switch
(SSD-5, Part C). Also check EGR
port on carburetor per SSD-1, Part
II.
b. If vacuum signal is 4.0 in. Hg. or
greater, the problem is associated
with the backpressure transducer
or the EGR valve. Check EGR
valve system and backpressure
transducer as follows:
F.I.Check EGR valve on engine per
SSD-1, Parts B and C, Steps 1 thru
4.
a. If EGR valve functions properly
per above, remove EGR valve and
transducer and inspect passages in
EGR spacer, EGR valve and
transducer for deposits or loose
particles.
b. If EGR valve, spacer and
transducer cavities are free of
deposits or loose particles, replace
transducer with new part and
verify backpressure functioning
according to Step D. If EGR valve
functions properly, leave new part
on. Otherwise, replace with
original part.
29-02-58
F.2.If the EGR valve, spacer and
transducer have deposits, clean EGR
valve and spacer per SSD-1, Part IV.
Also clean backpressure pick-up in
control chambers with small wire
brush or scraper.
CAUTION: Do not use liquid
solvents or compressed air on
transducer.
F.3.If any repairs were made in Step F,
verify backpressure functioning
according to Step D. If the EGR
valve does not move and/or oscillate,
replace backpressure transducer.
VI. Backpressure EGR
Transducer Procedure (Integral
Type B/P EGR Valve)
A. Remove air cleaner assembly from
carburetor, if required, to observe
EGR valve. Place air cleaner
assembly in such a position so that
vacuum hoses are not disconnected
from the air cleaner TVS switch.
B. Inspect EGR system vacuum routing
for proper connections—refer to
vehicle calibration book or emissions
calibrations publications. Check
vacuum supply to valve per SSD-1,
Part II and III.
C. Inspect integral EGR valve assembly
for obvious external defects, «uch as
loose or broken support brackets,
loose or broken diaphragm vacuum
nipple, and exhaust blowouts at base
to upper cover gasket or base to
carburetor spacer gasket. (Replace
valve if obviously damaged or
replace spacer gasket if dam.iged.)
D. EGR system function check
D. l.Warm up engine to normal operating
temperature.
D.2.a. With the engine in neutral,
slowly open and close the
throttle. Observe the EGR valve
stem or underside of the
diaphragm to which the valve
stem is attached. The stt:m and
diaphragm must move upward,
appear to oscillate, am: move
downward to closed position
when the engine returns to idle.
b. If unable to detect if valve
strokes and oscillates Step
D.2.(a), open throttle to 2000 to
2500 rpm and hold at a steady
speed. Then remove ami pinch
off vacuum hose. With vacuum
hose disconnected, engine speed
should increase significantly (at
least 50 rpm increase).
CAUTION: Do not exceed 1/2
throttle or 2500 rpm in Step D.2.
c. If valve operates properly in Step
D.2.(a), i.e. valve moves and
oscillates, or in Step D.2.(b) (idle
speed increases), the EGR
29-02-59 Engine Diagnosis and Service 29*02-59

system is functioning properly. carburetor, Reference Two, Part Procedure

Discontinue diagnostic
procedure.
d. If engine does not appear to
operate properly in Steps D.2.(a)
or D.2.(b) (has exceptional
roughness or stalls), make the
following check: At normal idle
speed, remove the vacuum hose
to the EGR valve and cap this
hose. Connect another hose
between the EGR valve and a
manifold vacuum source.
If the idle speed d r o p s
significantly or the engine begins
to run exceptionally rough or
stalls with the hose from the
manifold vacuum supply to the
valve, replace the EGR valve.
25, depending on the vacuum
source to the load control valve.
2. If vacuum signal is 4.0 in. Hg or
greater, remove the gage, reinstall
the vacuum hose on the EGR
vacuum load control valve and
proceed as follows:
F. Remove the vacuum hose between
the EGR vacuum load control valve
and the EGR backpressure
transducer at the vacuum load
control valve and connect a vacuum
gage to the vacuum load control
valve port.
1. Remove the hose from the venturi
port on the carburetor to the
vacuum load control valve at the
valve.
/. Mono Delay Valve
l.(a) Set external vacuum source to 10"
Hg.
(b) Connect black side of delay valve
to vacuum source.
(c) Connect the 24" section of vacuum
hose to gauge and to colored side
of delay valve.
(d) Apply vacuum and observe time in
seconds for gauge to read from 0"
to 8" Hg with a constant 10" Hg
vacuum source.
2. The minimum and maximum time
for the valve to reach 8" Hg should
be as follows:
Time in Seconds

VII. EGR Vacuum Load Control 2. Raise the engine idle speed to Color Code I.D. No. Min. Max.
(WOT) Valve Diagnositc 1200-1500 rpm in neutral and Black/Gray 1 0.6 1.6
Procedure observe vacuum signal. Black/Brown 2 1.0 3.0
a. If vacuum signal is less than 4.0 Black/White 5 2.7 9.3
A. Remove air cleaner assembly from Black/Yellow 10 4.5 13.2
carburetor to observe the EGR in. Hg, replace "the EGR vacuum
lead control valve. Black/Blue 15 6.8 18.8
valve. Place air cleaner assembly in Black/Green 20 8.0 26.0
such a position so that vacuum hoses b. If vacuum signal is 4.0 inches of Black/Orange 30 11.6 38.0
are not disconnected from the air Hg or greater, apply one of the Black/Red 40 14.0 47.2
cleaner TVS switch. following vacuum levels, from
B. Check EGR system vacuum hose an external source, to the venturi
CV1382-B
routing for proper connection—refer port of the load control valve,
to e m i s s i o n s c a l i b r a t i o n s and observe the first gage signal: When checking the delay valve, care
publications. must be exercised to prevent oil or
C. Warm up engine to normal operating Decal Color Vacuum Level (in. Hg) dirt from getting into the valve as
t e m p e r a t u r e and c o n n e c t this will impair the functioning.
Blue 3.0
tachometer. 3. Replace the delay valve if the above
Red 4.5
D. While slowly opening and closing the test showed it to be malfunction-
throttle, the EGR valve stem must be CA4264-A ing. Otherwise, re-install delay
observed to move upward and/or valve to its original position.
oscillate and move downward to the //. Dual Delay Valve
closed position when the throttle is l.(a) Set external vacuum source to 10"
released to the idle position. If the gage signal does not drop Hg.
to less than 2.0 in. Hg, replace (b) Connect the 24" section of vacuum
CAUTION: Do not exceed 1/2 the lead control valve. If the
throttle or 3000 rpm when opening hose to gauge and to DIST nipple
gage signal drops to less than 2.0 of delay valve.
or closing throttle. in. of Hg and does not return to
If the EGR valve stem moves and/or (c) Connect black side of delay valve
greater than 4.0 in. of Hg when and CARB nipple of delay valve to
oscillates properly, the EGR system the external source vacuum is
is functioning satisfactorily. vacuum source.
removed from the venturi port, (d) Prevent vacuum from being
Discontinue diagnostic procedure. replace the lead control valve.
E. If the EGR valve stem does not move applied to CARB nipple while
and/or oscillate properly (as applying 10" Hg vacuum to black
SSD-2—SPARK DELAY VALVE
described in Step D), disconnect the side of valve.
vacuum supply hose between the To determine if a delay valve is (e) Apply vacuum to the CARB
EGR vacuum load control valve and operating correctly, use the following nipple and observe time in seconds
the TVS, at the vacuum load control procedure: for gauge to read from 0" to 8" Hg
valve, and connect a vacuum gage to with a constant 10" Hg vacuum
Equipment Required source.
the hose. Raise engine speed to 1200-
1500 rpm in neutral and observe A. Vacuum gauge—USG Model 12121- 2. The minimum and maximum time
vacuum signal: 1, 2" dia., 0-30" Hg vacuum gauge for the valve to reach 8" Hg should
with 0.2" OD vacuum hose nipple be as follows:
1. If vacuum signal is less than 4.0 in.
Hg, proceed as follows: adaptor and 24" or 5/32" ID Time in Seconds
a. Perform EGR PVS procedure distributor vacuum hose or Color Code I.D. No. Min. Max.
SSD-1, Part III. equivalent.
Black/White 5 2.7 9.3
b. Perform air cleaner TVS switch B. Stop watch or wrist watch with a Black/Yellow 10 4.5 13.2
procedure SSD-9, Part II. sweep second hand. Black/Blue 15 6.8 18.8
c. Perform either EGR port on C. External vacuum source capable of Black/Green 20 8.0 26.0
carburetor procedure SSD-1, maintaining a constant vacuum (10"
Part II, or spark port on Hg minimum). CA1383B
29-02-60 Engine Diagnosis and Service 29-02-60

When checking the delay valve, care When checking the delay valve, care opened and closed. If a vacuum is
must be exercised to prevent oil or must be exercised to prevent oil or evident the system is OK. If no
dirt from getting into the delay valve dirt from getting into the valve as vacuum is evident check the vacuum
as this will impair the functioning. this will impair its function. lines, "T" (if applicable) and port in
3. Replace the delay valve if the above 3. Replace the delay valve if the above carburetor for plugging and correct.
test showed it to be inoperative. test showed it to be inoperative. (5) For vehicles with a Cooling PVS
Otherwise, re-install delay valve to Otherwise, re-install delay valve to check vacuum reading at distributor
its original position. its original position. at normal idle and engine operating
///. Retard Delay Valve temperature. If vacuum reading is 2
l.(a) Set external vacuum source to 10" in. Hg or less the PVS is OK. If
V. Distributor Vacuum Vent Valve vacuum reading is greater than 2 in.
Hg.
Procedure: Hg remove the top vacuum line (the
(b) Connect colored side of delay valve l.a) Set an external vacuum source to
to vacuum source. line that goes to the carburetor) at
10 inches Hg. PVS. If vacuum reading is still
(c) Connect the 24" section of vacuum b) Connect the "VAC" side (side
hose to gauge and to white side of greater than 2 in. Hg, PVS is
with code number) of the vacuum leaking and should be replaced.
delay valve. vent valve to vacuum source.
(d) Apply vacuum and observe time in (6) Remove the vacuum gauge, " T "
c) Connect a 24 inch section of fitting, connector (where used), re-
seconds for gauge to read from 0" vacuum hose to a gage and to the
to 8" with a constant 10" Hg install SDV (where used), and re-
other side of the vacuum vent connect all vacuum lines.
vacuum source. valve.
2. The minimum and maximum time (7) Re-install air cleaner and i:orque
d) Apply vacuum and observe time in wing nut to specifications.
for the valve to reach 8" Hg should seconds for the gage to read for 0
be as follows: inches Hg to 8 inches Hg while
applying a constant 10 inches Hg
vacuum. ///. Dual Delay System
Time in Seconds
2. The minimum and maximum time (1) Remove air cleaner. Remove dual
Color Code I.D. No. Min. Max.
for the valve to reach 8 inches of Hg delay SDV (3 port) and check per
White/Pink 5 2.7 9.3 vacuum should be as follows:
White/Brown 2 1.0 3.0
dual delay valve procedure (SSD-2).
White/Green 20 8.0 26.0
Install a connector between the spark
Time in Seconds port line and the distributor line.
CA1384-B Code No. Minimum Maximum
Connect a vacuum gauge to the line
removed from the manifold port
20 16 36.8 (black side) of the dual delay valve.
40 28 67.6
When checking the delay valve, care (2) Start engine and note if vacuum
must be exercised to prevent oil or CA4265-A reading is obtained. If vacuum is
dirt rrom getting into the valve as e v i d e n t , vacuum lines and
this will impair the functioning. connections to intake manifold are
3. Replace the delay valve if the above When checking the vacuum vent OK. If no vacuum, check lines, "T"s
test showed it to be inoperative. valve, care must be exercised to and manifold fitting for plugging and
Otherwise, re-install delay valve to prevent oil or dirt from getting into leaks and correct.
its original position. the valve, as this will impair its (3) Remove gauge from line and plug
IV. Air Cleaner Delay Valve function. line. Install "T" fitting at primary
Procedure: 3. Replace the vacuum vent valve if the side of distributor and connect
above test showed it to be defective. vacuum gauge.
l.a) Set external vacuum source to 10" Otherwise, re-install valve to its
Hg. original position. (4) W i t h e n g i n e r u n n i n g and
b) Connect colored side of delay valve transmission in neutral momentarily
to vacuum source. Note: .20" OD open throttle (1/2 open).
to .27" OD adaptor may be (5) Observe the vacuum gauge for a
required to connect colored side of SSD-3—SPARK CONTROL quick rise and fall as the throttle is
valve to vacuum source. SYSTEMS AND SPARK DELAY opened and closed. If a vacuum is
c) Connect the 24" section of vacuum VALVE evident, the system is OK. If no
hose to gauge and to white side of vacuum is evident check the vacuum
delay valve. A. Spark Control Systems lines, and the spark port for plugging
d) Apply vacuum and observe time in /. Non-Thermal Control System or leaking and correct.
seconds for gauge to read from 0" (1) Remove air cleaner. Remove SDV if (6) Remove gauge and "T" fitting from
to 8" Hg with a constant 10" Hg so equipped and check per the delay primary side of distributor and
vacuum source. valve procedure (SSD-2). Install a install on secondary side. With
2. The minimum and maximum time connector in place of the SDV in engine running vacuum should be
for the valve to reach 8" Hg should order to carry out system checks. noted. If no vacuum, check vacuum
be as follows: (2) Install "T" fitting and vacuum gauge line and connection to " T " for
at distributor. plugging and correct.
Time in Seconds (3) With engine at normal operating (7) Remove "T" fitting, vacuum gauge,
Color Code I.D. No. Min. Max. temperature and with transmission plug, and connector. Install dual
White/Red 40 14.0 47.2 in neutral, momentarily open delay valve and reconnect all
White/Green 20 8.0 26.0 throttle (1/2 open). vacuum lines.
White/Blue 20 8.0 26.0 (4) Observe the vacuum gauge for a (8) Re-install air cleaner and torque
CA1434-B quick rise and fall as the throttle is wing nut to specification.
29-02-61
IV. Cold Start Spark Advance System
NOTE: Perform Steps 1 through 5
only if engine complaint is spark
knock or pinging.
CAUTION: Do not leave transmission in
drive during Steps 2 and 4 for longer than
15 seconds.
1. Connect a tachometer to the engine
and start the engine.
2. With brake pedal depressed and
transmission in drive (see Caution
above), accelerate engine and record
rpm at which spark knock or pinging
occurs.
3. To allow transmission to cool, put
engine in neutral and accelerate to
1500 rpm three times for 15-30
seconds each time.
4. Remove vacuum advance line from
distributor and plug. Restart engine
and repeat Step 2 (see Caution above)
to recorded rpm.
5. If spark knock or pinging reoccurred
with vacuum a d v a n c e line
disconnected, stop engine and
proceed to next step. If spark knock
or pinging did not reoccur, the
system has a faulty CSSA PVS and/
or retard delay valve or check valve
(if so equipped). Repair and/or
replace as required.
6. Remove air cleaner. Remove SDV if
so equipped and check per delay
valve procedure (SSD-2). Install
connector in place of SDV. Remove
vacuum check valve or retard delay
valve (if so equipped) and check per
vacuum check valve or retard delay
valve procedure. Install connector in
place of check valve or retard delay
valve.
7. Install "T" fitting and vacuum gauge
at distributor primary.
8. Remove vacuum line from bottom
port of Cold Start PVS and cap.
9. With engine at normal operating
temperature and at idle the vacuum
reading should be zero. If vacuum is
not zero, the Cold Start PVS is
defective and should be replaced.
10. Remove cap and reconnect the
removed line to the bottom port of
the Cold-Start PVS.
11. Remove vacuum line from top port
of Cold-Start PVS and plug.
12. For vehicles with a Cooling PVS
check vacuum reading at distributor
at normal idle. If vacuum reading is
2 in. Hg or less the Cooling PVS is
OK. If vacuum reading is greater
than 2 in. Hg remove the top vacuum
line (the line that goes to the
carburetor) at Cooling PVS and
plug. If vacuum reading is still
greater than 2 in. Hg Cooling PVS
is leaking and should be replaced.
Engine Diagnosis and Service
13. W i t h e n g i n e r u n n i n g and
transmission in neutral momentarily
open the throttle (1/2 open).
14. Observe vacuum gauge for a quick
rise and fall as the throttle is opened
and closed. If vacuum is evident the
spark advance system is OK. If no
vacuum is evident, check the vacuum
lines, ports in the Cold-Start and
Cooling PVS's, and the carburetor
vacuum port for plugging and
correct.
15. Remove "T" fitting, vacuum gauge,
plug and connectors. Install SDV
and check valve or retard delay valve
(if used) and reconnect all vacuum
lines.
16. Re-install air cleaner and torque
wing nut to specifications.
V. Delay Valve By-Pass System (PVS
Operated)
1. Remove air cleaner.
2. Remove SDV and check per Delay
Valve Procedure SSD-2. Install a
connector in place of SDV. Remove
vacuum line at distributor and install
a T-fitting and vacuum gauge.
3. With engine idling at normal
operating temperature and with
transmission in neutral, momentarily
open throttle (1/3 open).
4. Observe the vacuum gauge for a
quick rise and fall as the throttle is
opened and closed. If a vacuum is
evident, the system is OK. If no
vacuum is evident, check the vacuum
lines, T's and port in carburetor for
plugging. Correct as required.
5. Shut engine off.
6. Remove vacuum gauge, "T" fitting,
and connector. Reinstall SDV and
reconnect vacuum hoses.
7. Remove vacuum check valve and
check per Vacuum Check Valve
Check Procedure.
8. Reinstall check valve in hose to
distributor.
9. Install connector and vacuum gauge
in vacuum hose from PVS to check
valve.
10. With engine running at normal
o p e r a t i n g t e m p e r a t u r e and
transmission in neutral, momentarily
open throttle (1/2 open).
11. Observe the vacuum gauge for
evidence of vacuum. If vacuum
reading is two inches Hg or less, PVS
is OK. If vacuum reading is greater
than two inches Hg the PVS is
defective and should be replaced.
12. Remove vacuum gauge, connector
and plugs (where used), reinstall
check valve and reconnect all
vacuum hoses.
13. Reinstall air cleaner and torque to
specifications.
29-02-61
Vacuum Check Valve Check
Procedure
To determine if a check valve is operating
correctly the following service procedure
should be used:
Equipment Required:
(a) Vacuum Gauge—with 3/16" OD
vacuum hose nipple adaptor.
(b) Vacuum Source
Procedure:
1. For checking function:
(a) Set vacuum source at 5 in. Hg.
(b) Apply vacuum to the check side of
the check valve and trap. After 30
seconds the vacuum should not be
less than 4 in. Hg. If it is, replace
the valve.
2. For flowing function:
(a) Set vacuum source at 5 in. Hg.
(b) Connect gauge to check side (same
side source was connected to in
(I))-
(c) Apply vacuum to opposite side
used in (1). Reading on gauge
should be same as source. If it is
not, replace the valve.
SSD-4—THERMACTOR NON-
CATALYTIC CONVERTER
EMISSION SYSTEM CHECK
The thermactor non-catalyst system
consists of the following major
components:
Belt-drive air pump supply pump
Air by-pass valve
Check valve(s)
Internal or external air manifold(s)
Air supply tubes
Crossover tube to connect RH and
LH air manifolds (internal system
only)
Air Cleaner Temperature sensor
Electric PVS (ported vacuum switch)
high temperature coolant lock out
Solenoid vacuum valve
EGR vacuum load control valve (for
EGR and thermactor) (WOT)
Vacuum delay valve (idle air dump)
Thermactor idle vacuum valve
Thermactor vacuum vent valve
Procedure:
A. Air Pump Supply Test
1. Remove air cleaner.
2. Inspect all hoses and hose
connections in the system for any
abnormal conditions and correct
and/or repair and/or replace as
necessary.
3. Check the air pump belt tension and
adjust to specification. (See
Procedure "B" of this procedure.)
4. With the transmission in neutral or
park and the parking brake on, warm
the engine to normal operating
temperature.
5. Stop the engine and disconnect the
air supply hose(s) from the air pump
29-02-62
to the air by-pass valve at the air by-
pass valve.
6. Insert the thermactor pump pressure
gauge (special service tool T75L-
9486-A or equivalent) in the end
of the hose disconnected from the
by-pass valve. Clamp the hose
securely to the air supply tester
to prevent it from blowing out.
CAUTION: Position the air pump
supply tester so that the air blast
emitted will be harmlessly
dissipated.
7. Connect a tachometer to the engine
and start the engine.
8a. Slowly increase engine speed to 1000
rpm and observe the pressure
produced at the test gage. The air
pump pressure must be 2.25 (2 1/4)
psi minimum.
8b. If special service tool is not avail-
able, increase engine speed to 1500
rpm, place hand over the open
hose. Air flow should be heard
and felt.
9. If air flow does not comply with
minimum requirements listed in Step
8, install a new air pump and repeat
Step 8.
10. Turn off the engine. Remove all test
equipment and reconnect the air
supply hose to the air by-pass valve
and tighten the hose clamp. Torque
the air cleaner nut to specification if
the cleaner was removed.
B. Thermactor Air Pump Drive Beit
Adjustment
1. Install the belt tension gauge
(special service tool T75L-8620-A
or equivalent) on the drive belt
and check the tension following
the instructions of the tool manu-
facturer. Compare the belt tension
and adjust as necessary.
2. If adjustment is necessary, loosen the
air pump mounting and adjusting
arm belts. Move the air pump toward
or away from the engine until the
correct tension is obtained. Use air
pump belt tensioning tool (special
service toolT75L-9480-A or equiv-
alent) to hold belt tension while
tightening the mounting bolts.
Remove the gauge. Tighten the air
pump adjusting arm and mounting
bolts. Install the tension gauge and
check the belt tension.
CAUTION: Do not use a pry bar.
3. Check all air pump pulleys and
mounting bolts and torque to
specification.
CAUTION: Any belt that has
operated for a minimum of ten
minutes is considered a used belt;
and when adjusted, it must be
adjusted to the tension shown in the
specifications for used belts.
Engine Diagnosis and Service
C. Air By-pass Valve Functional Tests
Determine if the air by-pass valve is
functioning properly by performing the
following operation:
1. If necessary, warm the engine to
normal operating temperature with
the transmission in neutral or park
and the parking brake on.
2. Stop the engine and remove the air
by-pass valve-to-air manifold check
valve hose at the by-pass valve. For
a tee system, remove both hoses
connecting the by-pass valve to the
check valves. Remove any restricting
device in the sense vacuum hose.
Install a tachometer on the engine.
3. With the transmission in neutral or
park and the parking brake on, start
the engine. Accelerate the engine to
1500 rpm. Verify that air is flowing
from the air by-pass valve hose
connection(s) by placing hand over
valve connection. Air flow should be
felt and heard.
4. With transmission in neutral or park
and parking brake on, accelerate to
1500 rpm. With hand held over the
by-pass valve connection
momentarily (approximately 5 to 8
seconds) pinch off the vacuum hose
to the by-pass valve to duplicate the
air by-pass cycle. Release the
pinched vacuum hose. Air flow
through the by-pass valve should
be felt and heard to diminish or
stop for a short period of time,
then resume as before (normal air
flow). The length of time required
to resume normal flow cannot be
specified since the time interval is
dependent on engine vacuum and
length of time the vacuum line is
pinched off. Air will be discharged
through the exhaust ports in the
side of the valve silencer cover.
If this complete cycle does not occur,
the valve is defective and it must be
replaced.
5. Perform the following test ONLY if
the air pump supply tester is
available:
Install the thermactor pump
pressure gauge (special service tool
T75L-9486-A or equivalent) to the
air by-pass valve outlet using a short
length of appropriate diameter hose.
If the air by-pass valve has two
outlets, plug the one without the
tester. Increase engine speed to 1000
rpm. Observe the pressure produced
at the test gauge. The air pressure
must be 2.25 (2 1/4) psi minimum.
If the air pressure is not within
specifications, replace the valve.
6. Turn off the engine, remove all test
equipment and connect the air
supply hose(s) to the air by-pass
valve(s), and tighten all clamps.
Determine if the air by-pass valve
29-02-62
controls are functioning properly by
performing the following operations:
D. Check Valve Test
1. With the engine stopped, inspect
the hose(s) from the check valve to
the by-pass valve for any leaks due
to cracks, splits, holes, etc. Replace
if required.
2. Inspect the hose clamp(s) it the
check valve for being properly
positioned and tightened. Correct,
position, tighten or replace as
required.
3. Disconnect the thermactor hose(s)
from check valve to the by-pass
valve at the by-pass valve end.
4. Connect the thermactor check
valve tester (special service tool
T75L-9487-A or equivalent), to
the open end of the check valve
hose. Position the hose clamp and
tighten to specification.
5. Squeeze the rubber bulb, on the
tester, to force as much air from
the bulb as possible. Quickly
release the bulb and start timing.
The bulb should remain collapsed
(not return to its original free
shape) for at least 15 seconds.
6. If the test bulb does not return to
its original free shape for 15
seconds, the check valve and hose
are good. Remove the check valve
tester from the end of the hose and
reinstall the hose on the by-pass
valve. Position and tighten the
hose clamp to specification
7. If the test bulb returns to its
original free shape in 15 seconds or
less, check both hose and check
valve further.
8. Remove the test bulb from the end
of the hose. Remove the hose from
the check valve. Install a 6 to 18
inch length of appropriate
diameter hose to the check valve
and test bulb. Position and tighten
to specification a hose clamp at
each end of the hose. Repeat Step
5 above.
9. If the test bulb does not return to
its original free shape for 15
seconds it indicates the check valve
is good and the original by-pass
valve to check valve hose is
defective. Remove the test hose
from the check valve and test bulb.
Install a new hose of the proper
part number, to the check valve
and test bulb. Position and tighten
to specification a hose clamp at
each end of the hose. Repeat Step
5 to be sure the new hose does not
leak. After test remove the hose
clamp and test bulb. Install the
hose on the by-pass valve nipple.
Position and tighten the hose
clamp to specification.
29-02-63
10. If the test bulb returns to its
original free shape (Step 8) in 15
seconds or less, the check valve
should be replaced.
11. Test the new check valve for leaks
before installing on the engine.
Connect a 6 to 18 inch length of
appropriate diameter hose to the
new check valve and test bulb.
Position a hose clamp at each end
of the hose and tighten to
specification. Repeat Step 5 above.
12. Remove the hose from the check
valve. Install the new check valve
on the engine and torque to
specification. Visually inspect the
original hose for any surface
condition that would cause a
problem in the near future.
Replace with a new hose if
required. Install the hose on the
check valve and by-pass valve
nipples. Route the hose as
required. Position and tighten to
specification a hose clamp at each
end of the hose.
E. Thermactor System Noise Test
NOTE: The thermactor system is not
completely noiseless. Under normal
conditions, noise rises in pitch as engine
speed increases. To determine if
excessive noise is the fault of the air
injection system, disconnect the drive
belt and operate the engine. If the noise
disappears, proceed with thermactor
noise diagnosis (Fig. 1):
SSD-5 THERMACTOR CATALYTIC
CONVERTER EMISSION SYSTEM
CHECK
The thermactor catalytic converter
system consists of the following major
components:
. Belt-drive air pump supply pump
. Air by-pass valve
. Check valve(s)
. Internal or external air mani-
fold(s)
. Air supply tubes
. Crossover tube to connect RH
to LH air manifolds (internal
system only)
. Differential vacuum valve (Decel)
. Air cleaner temperature sensor
. Electric PVS (potted vacuum
switch) high temperature coolant
lock out
Engine Diagnosis and Service
THERMACTOR NOISE DIAGNOSIS CHART
1. Excessive Belt Noise
Possible Cause
a. Loose belt.
b. Seized pump.
c. Loose pulley.
d. Loose or broken mounting brackets or bolts.
2. Excessive Pump Noise (Chirps, Squeaks & Ticks)
Possible Cause
Insufficient break-in or damaged pump.
3. Excessive Mechanical Clicking Noise
Possible Cause
a. Over torqued mounting bolt.
b. Excessive flash on the air pump adjusting
arm boss.
c. Distorted adjusting arm.
d. Adjusting arm bolt too long (bottom of
the bolt boss is pushed in).
4. Excessive Thermactor System Noise
(Putt-putt, Whirring or Hissing)
Possible Cause
a. Leak in hose.
b. Loose, pinched or kinked hose.
c. Hose touching other engine parts.
d. By-pass valve inoperative.
e. Check valve inoperative.
f. Pump mounting fasteners loose.
g. Restricted or bent pump outlet fitting.
h. Pump failure.
FIG. 1 Thermactor Noise Diagnosis—Non-Catalytic System
Solenoid vacuum valve
EGR vacuum load control valve
(for EGR and thermactor)
(WOT)
29-02-63
Correction
Tighten to specification using special service tool
No. T57L-9480-A or equivalent to hold belt ten-
sion and Belt Tension Gauge No. T63L-8620-A or
equivalent to check tension.
Caution: Do not use a pry bar to move the air
pump.
Replace pump.
Replace pulley and/or pump if damaged. Torque
bolts to specification (130-180 in-lbs).
Replace parts as required and torque bolts to
specification.
Correction
Check the thermactor system for damage and
make any necessary corrections. If less than 500
miles in service, allow for a 500 mile break-in
period. Replace the pump if the noise continues
after a 500 mile break-in period.
Correction
Torque to 25 ft-lbs.
Remove flash from the boss.
Replace adjusting arm.
Replace pump using a proper length bolt.
Correction
Locate source of leak using soap solution and
replace damaged hoses.
Reassemble, straighten or replace hose and
clamps as required.
Adjust hose to prevent contact with other engine
parts.
Test by-pass valve and replace if found damaged.
Test check valve and replace if found damaged.
Torque fasteners to specification.
Inspect fitting and remove any flash blocking the
air passage way. Replace bent fittings.
Replace pump.
CA4267-A
Vacuum delay valve (idle air
dump)
Thermactor idle vacuum valve
Thermactor vacuum vent valve
29-02-64
Procedure:
A. Air Pump Supply Test
1. Remove air cleaner.
2. Inspect all hoses and hose connec-
tions in the system for any abnor-
mal conditions and correct and/or
repair and/or replace as necessary.
3. Check the air pump belt tension
and adjust to specifications. (See
Procedure "B" of this Diagnostic
Procedure.)
4. With the transmission in neutral
or park and the parking brake on,
warm the engine to normal operat-
ing temperature.
5. Stop the engine and disconnect
the air supply hose(s) from the
air pump to the air by-pass valve
at the air by-pass valve.
6. Insert the thermactor pump pres-
sure gauge (special service tool
T75L-9486-A or equivalent) in
the end of the hose disconnected
from the by-pass valve. Clamp the
hose securely to the thermactor
pump pressure gauge to prevent
it from blowing out.
CAUTION: Position the thermactor
pump pressure gauge so that the air
blast emitted will be harmlessly
dissipated.
Engine Diagnosis and Service
7. Connect a tachometer to the engine
and start the engine.
8a. Slowly increase engine speed to 1000
rpm and observe the pressure
produced at the pressure gauge. The
air pressure must be 2.25 (2-1/4) psi
minimum.
8b. If the special service tool is not
available, increase the engine speed
to 1600 rpm, place hand over the
open hose. Air flow should be
heard and felt.
9. If air flow does not comply with
minimum requirements listed in Step
8, install a new air pump and repeat
Step 8.
10. Turn off the engine. Remove all test
equipment and reconnect the air
supply hose(s) to the air by-pass
valve and tighten the hose clamp(s).
Torque the air cleaner nut to
specifications if the air cleaner was
removed.
B. Thermactor Air Pump Drive Belt
Adjustment
1. Install the belt tension gauge
(special service tool T75L-8620-A
or equivalent) on the drive belt and
29-02-64
check the tension following the
i n s t r u c t i o n s of t h e t o o l
manufacturer. Compare the belt
tension to the specified belt tension
and adjust as necessary.
2. If adjustment is necessary, loosen the
air pump mounting and adjusting
arm belts, move the air pump toward
or away from the engine un:il the
correct tension is obtained. Use air
pump belt tensioning tool (special
service toolT75L-9480-A or equiv-
alent) to hold belt tension while
tightening the mounting bolts.
Install the tension gauge and check
the belt tension.
CAUTION: Do not use a pry bar.
3. Check all air pump pulleys and
mounting bolts and torque to
specification.
CAUTION: Any belt that has
operated for a minimum of one
minute is considered a used belt; and
when adjusted, it must be adjusted
to the tension shown in the
specifications for used belts.
C(I). Air By-Pass Valve Functional
Tests (Normally Closed By-Pass Valve
Fig. 3.
Determine if the air by-pass valve is
functioning properly by performing the
following operations:
29-02-65
1. If necessary, warm the engine to
normal operating temperature with
the transmission in neutral or park
and the parking brake on.
2. Stop the engine and remove the air
by-pass valve to air manifold check
valve hoses at the by-pass valve. For
a tee system, remove both hoses
connecting the by-pass valve to the
check valves. Install a tachometer on
the engine.
3. With the transmission in neutral or
park and the parking brake on, start
the engine. Accelerate the engine to
1500 rpm. Verify that air is flowing
from the air by-pass valve hose
connection(s) by placing hand over
valve connection. Air flow should be
heard and felt.
4. Remove the vacuum hose from the
by-pass valve and plug the vacuum
hose. With the engine at 1500 rpm
and hand held over the by-pass valve
connection, there should be virtually
no air flow felt or heard. Air flow will
be discharged through the exhaust
ports in the end of the valve
silencer cover. If air flow is felt or
heard through the by-pass valve
connection, the valve should be
replaced.
5. Stop the engine. Remove the plug
from the vacuum hose.
6. Reinstall the vacuum hose on the by-
pass valve sense vacuum nipple.
7. If available, install the thermactor
pump pressure gauge (special serv-
ice tool T75L-9486-A or equiva-
lent) to the air by-pass valve outlet
using a short length of appropriate
diameter hose. If the air by-pass
valve has two outlets, plug the
one without the tester. Start the
engine and increase engine speed
to 1000 rpm. Observe the pressure
produced at the test gauge. The
air pressure must be 2.25 (2-1/4)
psi minimum. If the air pressure
is not within specification, replace
the valve.
8. Turn off the engine, remove all test
equipment and connect the air
supply hoses(s) to the air by-pass
valve and tighten all hose clamp(s).
Determine if the air by-pass valve
controls are functioning properly by
performing the following operation(s).
C(II). Differential Vacuum Valve
(Decel) Functional Check
1. If necessary, warm the engine to
normal operating temperature with
the transmission in neutral or park
and parking brake on.
2. Stop the engine and remove the air
by-pass valve to air manifold check
valve hose at the by-pass valve. For
a tee system, remove both hoses.
Install a tachometer on the engine.
Engine Diagnosis and Service
TIMED AIR BYPASS VALVE
SPRING
AIR OUTLET
FIG. 2 Timed Air By-pass Valve
3. Start the engine. With hand held
over the by-pass valve outlet
c o n n e c t i o n s a c c e l e r a t e to
approximately 2500 rpm. Release the
throttle for a normal return to engine
idle rpm. During the deceleration
period, the air flow in the valve outlet
should be felt and/or heard to
momentarily diminish or stop and
then resume as before (normal air
flow). Air flow will be discharged
through the exhaust ports in the
end of the by-pass valve silencer
cover. The air flow interruption
during deceleration cannot be spe-
cified due to variations in the rate
of deceleration and manifold
vacuum.
4. If the by-pass valve meets test
requirements, but does not function
as described in Step 3, check to be
sure the decel valve is receiving a
vacuum signal. If the decel valve is
receiving a signal then the by-pass
valve is to be replaced.
5. Turn off the engine. Remove all test
equipment and reconnect all related
components of the thermactor
system.
C(III). Electric PVS (Ported Vacuum
Switch) High Temperature Coolant
Lock Out Vacuum Check
1. Disconnect vacuum line (air by-pass
valve to PVS valve) at the air by-pass
valve and connect to a vacuum
gauge.
2. With transmission in park or neutral
and the parking brake on, start
engine and let idle.
29-02-65
NSE VACUUM
AIR INLET
A4270A
3. With engine temperature stabilized,
check for a vacuum signal.
If no vacuum signal is noted, PVS
should be replaced.
If idle vacuum is indicated, the PVS
valve is OK.
C(IV). Thermactor System: Solenoid
Vacuum Valve
A. Normally Closed Valve, Type I
NOTE: A normally closed, Type I,
solenoid vacuum valve is used in
conjunction with a Type I air cleaner
temperature switch (see Procedure
SSD-9: Air Cleaner Temperature
Control and Delay Valve, Step No.
8) which is identified according to
the Vehicle Specifications.
la. Determine engine air cleaner
ambient temperature is above
65°F.
lb. Engine must be at normal
operating temperature.
2. While the engine is at idle
condition, disconnect vacuum hose
to thermactor air by-pass valve.
Thermactor air should dump to
atmosphere through the exhaust
ports in the end of the valve
silencer cover. Re-connect va-
cuum hose.
If thermactor air dumps to
atmosphere, the solenoid hose
connections are correct.
NOTE: Vacuum supply always
goes to the bottom vacuum
fitting on the solenoid vacuum
valve.
29-02-66
Disconnect vacuum supply hose
at the solenoid valve. Place
finger over end of open vacuum
hose. Your finger should be
attracted to the hose opening by
the vacuum supplied by the
engine manifold. If vacuum
supply is not observed, check
and/or replace vacuum sources
as required. Re-connect vacuum
hose.
3. Disconnect wiring to solenoid
vacuum valve.
a. Determine which wire has
voltage when the ignition switch
is in the RUN position.
b. Connect wire which has voltage
to solenoid vacuum valve.
4a. While the engine is at idle
condition, ground the other
exposed terminal on the solenoid
vacuum valve to chassis ground.
Thermactor air should not dump
to atmosphere.
4b. Connect wire removed in Step 3a
to solenoid v a c u u m valve.
Thermactor air should not be
dumped to atmosphere.
5. Replace solenoid vacuum valve if
s t a t e m e n t 4a is not a t r u e
statement.
Re-install related system
components.
B. Normally Opened Valve, Type 2
NOTE: A normally open, Type 2,
solenoid vacuum valve is used in
conjunction with a Type 2 air cleaner
temperature switch (see Diagnostic
Procedure SSD-9, Air Cleaner
temperature Control and Delay
valve, Step No. 9) which is identified
a c c o r d i n g to the V e h i c l e
Specification.
la. Determine engine air cleaner
.ambient temperature is above
65°F.
lb. Engine must be at n o r m a l
operating temperature.
2a. While the engine is at idle
condition, disconnect vacuum hose
to thermactor air by-pass valve.
Thermactor air should dump to
atmosphere through the exhaust
ports in the end of the valve
silencer cover.
2b. If t h e r m a c t o r air dumps to
atmosphere, the solenoid hose
connections are correct. Re-
connect vacuum hose.
NOTE: Vacuum supply always
goes to black input nozzle on
solenoid valve.
3. Disconnect wiring to solenoid
vacuum valve.
a. Determine which wire has
voltage when the ignition switch
is in the RUN position.
b. Connect wire which has voltage
to solenoid vacuum valve.
Engine Diagnosis and Service
4a. While the engine is at idle
condition, ground the other
exposed terminal on the solenoid
vacuum valve to chassis ground.
Thermactor air should be dumped
to atmosphere.
4b. Connect wire removed in Step 3a
solenoid vacuum valve.
Thermactor air should not be
dumped to atmosphere.
5. Replace solenoid vacuum valve if
s t a t e m e n t 4b is not a t r u e
statement.
Re-install related system
components.
C(V). Vacuum Reservoir Check
(Required on some catalyst converter
control systems)
a) D i s c o n n e c t vacuum hose on
reservoir which connects to electric
solenoid valve vacuum nipple.
b) Connect 10-30" vacuum gauge with
suitable length of 3/16 vacuum hose
to reservoir.
c) Remove manifold vacuum hose from
reservoir and connect external
vacuum source to this nipple. Charge
reservoir to 14 in. Hg vacuum from
external source and trap. Vacuum or
gauge Step (b) should not drop more
than 1 in. in one minute. Replace
reservoir if out of specification.
d) Remove all test equipment, reinstall
vacuum lines to the reservoir and
torque all clamps and air cleaner to
specification.
C(VI). Vacuum Delay Valve Check
(only required on vehicles equipped
with a delay valve in the by-pass valve
vacuum line)
Delay Valve Functional Test
Equipment Required:
a) Vacuum gauge—USG Model 12121-
1, 2" dia. 0-30" Hg vacuum gauge
with .20" OD vacuum hose nipple
adaptor and 2 4 " of 5 / 3 0 " ID
D i s t r i b u t o r Vacuum Hose or
equivalent.
b) Stop watch or wrist watch with a
sweep second hand.
c) External vacuum source capable of
maintaining a constant vacuum
(10"Hg minimum).
NOTE: The vacuum gauge must
have a small interval volume and be
free from external leakage.
Procedure:
1. a) Set external vacuum source to 10"
Hg.
b) Connect colored side of delay valve
to vacuum source.
NOTE: .20" OD to .27" OD
adaptor may be required to
connect colored side of valve to
vacuum source.
c) Connect the 24" section of vacuum
hose to gauge and to white side of
delay valve.
29-02-66
d) Apply vacuum and observe time in
seconds for gauge to read from 0"
to 8" Hg with a constant 10" Hg
vacuum source.
2. The minimum and maximum time
for the valve to reach 8" Hg should
be as follows:
Time in Seconds
Color Code I.D. No. Min. Max.
White/Red 40 14.0 472
White/Green 20 8.0 260
White/Blue 20 8.0 260
CA4271-A
When checking the delay valve, care
must be exercised to prevent oil or
dirt from getting into the valve as
this will impair its function.
Diagnosis Guide:
Replace delay valve if any of the
above tests show the valve is mal-
functioning.
C(VII). Temperature Vacuum System
(TVS) Valve (Only on applicable
models)
See Procedure SSD-9, Step 13: Air
Cleaner Temperature Control and Delay
Valve.
C(VIII). Thermactor Idle Vacuum
Valve Diagnostic Procedure
Preparation
NOTE: Insure that bypass valve is OK
per SSD-5, Step C.
A. Remove the thermactor idle vacuum
(TIV) valve from the connector on
the air bypass valve.
B. Install a vacuum hose on the small
nipple on the TIV valve and connect
it to one leg of a 3-way "tee".
C. Connect the second leg of the "tee"
to a vacuum gage and connect the
third leg of the " t e e " to the
connector on the bypass valve.
D. Connect a vacuum gage to the ntake
manifold.
E. Warm up the engine to normal
operating temperature.
Procedure
1. With engine at idle in neutral,
disconnect the hose at the large
diameter port of the TIV, and from
another vacuum source, apply 3-1/2-
4 in. Hg to the large port.
Vacuum level on the gage at the
bypass valve should increase to
within 3 in. Hg or less of intake
manifold vacuum.
2. If the vacuum does not increase to
within 3 in. Hg or less, the TIV
should be replaced.
3. If, when the 3-1/2-4 in. Hg vacuum
source is removed from the TIV, the
gage reading does not drop to 1.0 in.
Hg or less, the TIV should be
replaced.
29-02-67
4. At the conclusion of the above
procedure, remove all test equipment
and reconnect all vacuum hoses,
connectors and the TIV valve.
C(IX). Air By-Pass Valve Functional
Tests (Timed By-Pass Valve with
Vacuum Vent Fig. 4)
Determine if the air by-pass valve is
functioning properly by performing the
following operations:
1. If necessary, warm the engine to
normal operating temperature with
the transmission in neutral or park
and the parking brake on.
2. Stop the engine and remove the air
by-pass valve to check valve hose at
the by-pass valve. For a tee system,
remove both hoses connecting the
by-pass valve to the check valves.
Cap the by-pass valve vacuum vent
nipple. Remove, or short circuit, any
restricting or delaying device in the
sense vacuum hose. Install a
tachometer on the engine.
3. With the transmission in neutral or
park and the parking brake on, start
the engine. Accelerate the engine to
1500 rpm. Verify that air is flowing
from the air by-pass valve hose outlet
connection(s) by placing hand over
the valve connection. Air flow
should be felt and heard. If no air
flow is detectable, the valve must be
replaced.
4. With the transmission in neutral or
park, and the parking brake on,
accelerate to 1500 rpm. With hand
held over the by-pass valve outlet,
momentarily (approximately 5 to 8
seconds) pinch off the sense vacuum
hose to the by-pass valve to simulate
the air by-pass cycle. Release the
pinched hose. Air flow through the
by-pass valve should be felt and
heard to diminish or stop for a short
period of time, then resume as before
(normal airflow).The length of time
required to resume normal air flow
cannot be specified since the time
interval is dependent on engine
vacuum, and the length of time the
vacuum line is pinched off. Air will
be discharged through the exhaust
ports in the valve silencer cover. If
this cycle does not occur, the valve
must be replaced.
5. Stop the engine and remove the cap
from the vacuum vent nipple, and
leave nipple open.
6. With the transmission in neutral or
park and the parking brake on, start
the engine. Accelerate the engine to
1500 rpm. Virtually no air flow
should be detectable from the by-
pass valve outlet(s). Air will be
discharged from exhaust ports in the
silencer housing. If air flow can be
Engine Diagnosis and Service
felt and heard at the by-pass valve
outlet(s) the valve must be replaced.
7. Stop engine. Correctly connect hoses
to the sense vacuum nipple and the
vacuum vent nipple.
8. Perform the following test ONLY if
the air pump supply tester is
available:
Install the thermactor pump
pressure gauge (special service
toolT75L-9486-A or equivalent)
to the air by-pass valve outlet
using a short length of appro-
priate diameter hose. If the air
by-pass valve has two outlets,
plug the one without the tester.
Increase engine speed to 1000
rpm. Observe the pressure pro-
duced at the test gauge. The air
pressure must be 2.25 (2-1/4)
psi minimum. If the air pressure
is not within specifications, re-
place the valve.
9. Turn off the engine, remove all test
equipment and connect the air
supply hoses(s) to the air by-pass
valve(s), and tighten all clamps.
C(X). EGR Vacuum Load Control
(WOT) Valve Test
1. With the engine warmed up,
tachometer connected, and engine
off, remove the air cleaner assembly
from the carburetor, placing the air
cleaner assembly in such a position
so that the vacuum hoses are not
disconnected from the cold weather
modulator valve(s) on the air
cleaner.
2. Disconnect the vacuum supply hose,
between the EGR vacuum load
control valve and the vacuum
reservoir, at the EGR vacuum load
control valve and connect a vacuum
gage to the EGR vacuum load
control valve. Disconnect the
vacuum supply hose between the
venturi port of the carburetor and
the EGR vacuum load control valve
at the vacuum load control valve.
3. Start the engine and raise the speed
to 1200-1500 rpm in neutral and
observe the vacuum signal on the
gage:
a. If the vacuum signal is less than 4.0
in. Hg, replace the EGR vacuum
load control valve.
b. If the vacuum signal is 4.0 in. Hg
or greater, apply one of the
following vacuum levels from an
external source to the venturi port
of the load control .valve and
observe the first gage signal:
Decal Color Vacuum Level (in. Hg)
Blue 3.0
Red 4.5
CA4272A
29-02-67
If the first gage signal does not
drop to less than 2.0 in. Hg, replace
the load control valve. If the gage
signal drops to less than 2.0 in. Hg
and does not return to greater than
4.0 in. Hg when the external
source vacuum is removed from
the venturi port, replace the
vacuum load control valve.
(XXI). Thermactor Vacuum Vent Valve
Functional Test
1. If necessary, remove the air cleaner
assembly.
2. Disconnect the vacuum tubing or
connector block from the valve (note
the orientation for reinstallation).
NOTE: It may be necessary to
remove the valve from the bracket or
air cleaner tray to gain access to the
vacuum ports on the valve.
3. Connect the black (or cover) vacuum
port to a manifold vacuum source.
4. Connect an external vacuum source
to the white (or body) vacuum port.
5. Start the engine. With the engine at
idle, in neutral, apply 10 in. Hg
vacuum to the white port and trap.
If 10 in. cannot be obtained, replace
the valve.
6. Remove the manifold vacuum source
line from the black port. The trapped
vacuum should drop to zero. Replace
the valve if the trapped vacuum does
not drop to zero.
7. Remove all test equipment,
reconnect all vacuum hoses and
connectors and reinstall the valve
and air cleaner assembly (if removed
in Step 1).
D(I). Check Valve Test
1. With the engine stopped, inspect the
hose(s) from the check valve to the
bypass valve for any leaks due to
cracks, splits, holes, etc. Replace if
required.
2. Inspect the hose clamp(s) at the
check valve for being properly
positioned and tightened. Correct,
position, tighten or replace as
required.
3. Disconnect the thermactor hose(s)
from check valve to the bypass valve
at the bypass valve end.
4. Connect the thermactor check valve
tester (special service tool T75L-
9487-A or equivalent) to the open
end of the check valve hose.
Position the hose clamp and tight-
en to specification.
5. Squeeze the rubber bulb, on the
tester, to force as much air from the
bulb as possible. Quickly release the
bulb and start timing. The bulb
should remain collapsed (not return
to its original free shape) for at least
15 seconds.
29-02-68
6. If the test bulb does not return to its
original free shape for 15 seconds,
the check valve and hose are good.
Remove the check valve tester from
the end of the hose and reinstall the
hose on the bypass valve. Position
and tighten the hose clamp to
specification.
7. If the test bulb returns to its original
free shape in 15 seconds or less, both
hose and check valve are
questionable.
8. Remove the test bulb from the end
of the hose. Remove the hose from
the check valve. Install a 6 to 18 inch
length of appropriate diameter hose
to the check valve and test bulb.
Position and tighten to specification
a hose clamp at each end of the hose.
Repeat Step 5 above
9. If the test bulb does not return to its
original free shape for 15 seconds, it
indicates the check valve is good and
the original bypass valve to check
valve hose is defective. Remove the
test hose from the check valve and
test bulb. Install a new hose of the
proper part number, to the check
valve and test bulb. Position and
tighten to specification a hose clamp
at each end of the hose. Repeat Step
5 to be sure the new hose* does not
leak. After test, remove the hose
clamp and test bulb. Install the hose
on the bypass valve nipple. Position
and tighten the hose clamp to
specification.
10. If the test bulb returns to its original
free shape (Step 8) in 15 seconds or
less, the check valve is defective
and is to be replaced.
11. Test the new check valve for leaks
before installing on the engine.
Connect a 6 to 18 inch length of
appropriate diameter hose to the new
check valve and test bulb. Position
and tighten to specification a hose
clamp at each end of the hose.
Repeat Step 5 above.
12. Remove the hose from the check
valve. Install the new check valve on
t h e e n g i n e and t o r q u e to
specification. Visually inspect the
original hose for any surface
condition that would cause a
problem in the near future. Replace
with a new hose if required. Install
the hose on the check valve and by-
pass valve nipples. Route the hose as
required. Position and tighten to
specification a hose clamp at each
end of the hose.
E. Floor Pan Thermal Switch System
Check
1. Disconnect wiring to the vacuum
solenoid valve.
Engine Diagnosis and Service 29-02-68
THERMACTOR NOISE DIAGNOSIS CHART
Problem Possible Cause Correction
1. Excessive Belt Noise. a. Loose belt. Tighten to specification using special ::rvice tool
No. T75L 9480-A or equivalent to ho i belt ten-
sion and Belt Tension Gauge No. T 6 3 . -8620-A or
equivalent to measure belt tension.
Caution: Do not use a pry bar to mov; the air pump.
b. Seized pump. Replace pump.
Replace pulley and/or pump if damaged. Torque
c. Loose pulley
bolts to specification (130-180 in-lbs).
d. Loose or broken mounting brackets Replace parts as required and torque bolts to
or bolts. specification.
2. Excessive Pump Noise. Insufficient break-in or damaged pump. Check the thermactor system for defects and make
any necessary corrections. If less than 500 miles in
(Chirps, Squeaks & Ticks)
service, allow for a 500 mile break-in :enod. Replace
the pump if the noise continues after ; 500 mile
break-in period.
3. Excessive Mechanical Clicking Noise. a. Over torqued mounting bolt. Torque to 25 ft-lbs.
b. Excessive flash on the air pump Remove flash from the boss.
adjusting arm boss.
c. Distorted adjusting arm. Replace adjusting arm.
d. Adjusting arm bolt too long (bottom Replace pump using a proper length t )lt.
of the bolt boss is pushed in).
4. Excessive Thermactor System Noise. a. At Driving Speeds and At Idle:
(Putt-putt, Whirring or Hissing)
• Leak in hose. Locate source of leak using soap solu on and replace
leaking hoses.
• Loose, pinched or kinked hose. Reassemble, straighten or replace hos; and clamps as
required.
• Hose touching other engine parts. Adjust hose to prevent contact with r. :her engine parts.
• Bypass valve inoperative. Test by-pass valve and replace if it fai ; test.
• Check valve inoperative. Test check valve and replace if it fails test.
• Pump mounting fasteners loose. Torque fasteners to specification.
• Restricted or bent pump outlet Inspect fitting and remove any flash b ocking the air
fitting. passage way. Replace bent fittings.
• Pump failure. Replace pump.
b. At Idle Only:
• Air dumping through by-pass valve. On many vehicles the thermactor sys- :m has been
designed to dump air at idle to prevent overheating
the catalyst. This condition is normal. Determine
that the noise persists at operating speeds before
replacing the air pump.
CA4273-A
a. Determine which wire has B+ b. If fuses in fuse par;el a r e
voltage when the ignition switch is satisfactory, check for "open
in the "ON" position. circuits" in the circuitry:
b. Connect a test light in series with i. Check the integrity of the wires,
ground. loose connections, cracks,
c. Start the engine. broken wires, etc. Repair and/or
d. Test light should glow at all times replace as necessary.
while the engine is running.
e. If test light glows, wiring and floor ii. Check connector, at air cleaner
pan switch are satisfactory, except switch, for any physical damage
for condition in Step 3. and proper connect ion(s).
2. If test light does not glow: Repair a n d / o r replace as
a. Inspect fuses in the fuse panel, necessary.
i. If a fuse is blown, check circuits iii. Check connector, at floor pan
for s h o r t s . Repair a n d / o r switch, for any physical damage
replace as necessary, and proper connection(s).
ii. Check for electric continuity— Repair a n d / o r replace as
test light should glow. necessary.
29-02-69 Engine Diagnosis and Service 29-02-69

iv. Check intermediate connector, SENSE VACUUM

at dash panel, for any physical
. damage and p r o p e r
connection(s). Repair and/or
replace as necessary.
3. Thermal floor pan switch check
(vehicle may be hot enough to
activate the system).
a. Determine the location of floor
pan switch.
b. Cool floor pan switch, with freon,
from under the floor pan until the
floor is cold to the touch.
c. With the test light connected,
according to Step 1, the light
should glow.
d. If test light does not glow, replace AIR OUTLET

the floor pan switch.

F. Thermactor System Noise Test
NOTE: The thermactor system is not AIR INLET
completely noiseless. Under normal
conditions, noise rises in pitch as engine
speed increases. To determine if excessive
noise is the fault of the air injection
system, disconnect the drive belt and
operate the engine. If the noise RELIEF VALVE
disappears, proceed with the following
diagnosis: MAIN SPRING
SSD-7—FUEL DECELERATION RELIEF SPRING
A4274-A
VALVE CHECK
NOTE: For vehicles equipped with
FIG. 3 Normally Closed Air By-pass Valve
transmission interlocked fuel decel
system see Appendix A. For M/T 2.8L
engine with fuel decel control system
perform Appendix B.
Procedure .
Marvel-Schebler Valve (Two hose
connections)
For vehicles equipped with a PVS
interlocked fuel decel system insure that VACUUM VENT
manifold idle vacuum is available at the
fuel decel valve with the engine at normal
operating temperature. If manifold
vacuum is evident the PVS and vacuum CONNECTS TO VACUUM
SOLENOID OR VACUUM
SPRING
lines are OK. If no or low vacuum is SWITCH
evident check vacuum lines, PVS ports MAIN POPPET SENSE VACUUM
and intake manifold fitting for plugging (INT. MAN.)
and leaks and correct.
1. Engine must be at normal operating AIR OUTLET

temperature.
2. Connect tachometer and timing
light. •AIR INLET
3. Ignition timing and engine idle rpm
must be at specification. Correct as
necessary.
4. Remove air cleaner.
5. Visually inspect the hoses,
connections and valve for any
abnormal conditions. Repair or
replace as necessary.
6. Check for leaking diaphragm by RELIEF VALVE
trapping 15 in. Hg vacuum in the
diaphragm cavity. Vacuum must not
A4175-A
drop below 10 in. Hg in 5 seconds.
Otherwise, replace valve.
7. Disconnect the rubber hose that
connects the carburetor to the fuel FIG. 4 Timed Air By-pass Valve with Integral Vacuum Differential Function
29-02-70
decel valve at the carburetor and
plug the hose.
8. With transmission in neutral and
parking brake applied, increase
engine speed to 3000 rpm and hold
for five seconds. Release the throttle
and note if engine immediately
returns to normal idle speed. If
engine speed does not return, check
for linkage hang-up and correct
before proceeding to the next step.
9. Remove plug from hose and install
a "T" and a vacuum gauge into the
hose between the valve and the
carburetor.
NOTE: The ID of the "T" connector
must be at least 1/4" for those legs
of the " T " not connected to the
vacuum gauge.
CAUTION: On vehicles equipped
with A/C interlocked decel valve,
check the function by teeing a
vacuum gauge into the intake
manifold to valve vacuum line at the
valve and deactivating the device.
With the engine running at normal
operating temperature at idle,
manifold vacuum should be
approximated on the gauge. Remove
the vacuum gauge and leave the
device deactivated while performing
Step 10.
10. Increase engine speed to 3000 rpm
and hold for 5 seconds. Measure the
time required for the vacuum to drop
to zero when the throttle is released.
This time should be within
specifications. If time is out of
specification, do the following:
Insure that vacuum is available
from the 3/16" vacuum control
hose.
Verify that the idle fuel mixture is
within specification. Reset as
required.
Adjust decel valve until time is
within specification. If decel valve
time cannot be adjusted to
specification or the decel valve is
a non-adjustable valve, replace the
decel valve and check the new
valve time to insure it is within
specification. Correct as required.
11. Reactivate any device(s) deactivated
prior to Step 10, remove test
equipment, and reinstall system
components using a new hose clamp
on FDV hose at carburetor.
SSD-9—AIR CLEANER
TEMPERATURE CONTROL
Vacuum Operated Systems
Check
NOTE: On vehicles equipped with an air
cleaner retard delay valve, check the
valve according to SSD-2.
On vehicles equipped with a cold
weather modulator, by-pass the
Engine Diagnosis and Service
modulator by connecting the two
vacuum lines from the modulator.
CAUTION: This check must be
performed in ambients of not less than
60°F.
Do not immerse any part of the
vacuum-operated duct and valve
assembly in water.
1. Apply parking brake and block
wheels.
2. Remove the air cleaner cover and
element. Jnspect heat riser tube and
zip tube for proper installation and/
or damage. Repair or replace as
required.
3. Remove items necessary to see the
duct door.
4. Remove the vacuum line at the duct
and valve. Look to confirm that the
duct door is in the open (fresh air
side) position. If the duct door is in
the closed position, check for binding
and sticking. Repair and/or replace
as required.
5. Place a magnetic based temperature
indicator (Kent-Moore J22973 or
equivalent) as near as possible to the
temperature sensor on the air inlet
side.
N O T E : Do not allow t h e
temperature indicator magnet to
touch the temperature sensor.
If the air cleaner is aluminum, loop
a piece of electrical or masking
tape (adhesive side out) and press
it against the temperature
indicator magnet. Press the tape
and the indicator against the air
cleaner, as near as possible to the
temperature sensor on the inlet
side.
6. Start the engine. If the duct door is
closed, proceed to Step 7. If the duct
door is not closed, turn off the
engine. Cool the temperature sensor
by spraying with liquid from a small
can of R-12 refrigerant and a ZRE-
6271 can adapter for 20 seconds after
liquid contacts sensor.
CAUTION: Do not cool the
temperature sensor while the engine
is running. If R-12 refrigerant is
drawn into the carburetor while the
engine is running, poisonous
phosgene gas will be exhausted into
the test area. Conduct this procedure
only in well-ventilated area.
Restart the engine. If the duct door
is closed, proceed to Step 7. If duct
door is open during idle, check
related vacuum system per Appendix
"A".
7. Reinstall the air cleaner cover
without installing the wing nut(s).
8. With the engine running, observe the
duct door. When the duct door starts
to open, remove the air cleaner cover
and note the temperature reading of
29-02-70
the temperature indicator. It should
be w i t h i n t h e f o l l o w i n g
specifications:
For sensors color coded with a
brown stripe: temperature ihould
not exceed 90°F.
For sensors color coded with a
black or pink stripe: temperature
should not exceed 100uF.
For sensors color coded with a
blue or yellow stripe: temperature
should not exceed 115°F.
(a) If the temperatures are greater
than those specified, replace the
sensor.
(b) If the air temperature is greater
than 120°F and the door is less
than 5/8 inch open, recheck Step
4. If the door is not binding or
sticking, replace the sensor.
If the duct door does not start to
open within 5 minutes, remove the
air cleaner cover and note the
temperature. If temperature is less
than those specified, the
temperature is insufficient to
operate the duct door. Reinstall
the air cleaner cover without
installing the wing nut(s) and run
engine until the specified
temperature is reached. If the duct
door has not started to open by
then, replace the sensor.
9. Turn off the engine. Remove all test
instruments and make sure no dirt or
sand is on the air cleaner tray or
cover on the inside of the air cleaner
element. If dirt is present, the
assembly should be cleaned per the
maintenance procedure. Reinstall
the system components and lighten
the wing nut to specification.
10. Cold Weather Modulator (only on
applicable models).
a. Cool the cold weather modulator
to 40°F or less. The modulator can
be cooled by spraying with liquid
R-12 refrigerant and a ZRE-6271
can adapter or equivalent. Allow
sufficient time for the modulator
temperature to stabilize and the
modulator valve to close.
CAUTION: Do not cool the cold
weather modulator while the
engine is running. If R-12
refrigerant is drawn into the
carburetor while the engirte is
running, poisonous phosgene gas
will be exhausted into the test area.
Conduct this procedure only in a
well-ventilated area.
b. A 24 inch length of 1/4 inch ID
vacuum hose should be used
between the cold weather
modulator and the vacuum gage.
Using an external vacuum source,
apply a minimum of 16 inches of
vacuum to the vacuum motor side
29-02-71
of the modulator and trap the
vacuum. The modulator must hold
at least 5 inches Hg vacuum for 30
seconds, otherwise replace the
modulator.
c. With blue CWM
Warm the modulator to 70°F or
above. The modulator should not
hold vacuum at or above this
temperature. If the modulator does
not function as indicated, it must
be replaced.
d. With green CWM
Warm the modulator to 80°F or
above. The modulator should not
hold vacuum at or above this
temperature. If the modulator does
not function as indicated, it must
be replaced.
APPENDIX "A"
All Engines
A. Check air cleaner vacuum system
integrity. Repair or replace as
required.
B. Check the duct door for sticking or
binding by depressing with fingers
and allowing the internal vacuum
motor spring to return the door to
the normal position. Correct any
sticking or binding before proceeding
D. If the ventilation system passes the
with test.
C. Disconnect the vacuum hose from
the vacuum motor connector tube.
D. Using an external vacuum source,
apply a minimum of 16" Hg vacuum
and trap. The vacuum motor should
2. Clean PCV System:
remain closed for 60 seconds. If not,
replace the duct and valve assembly.
SSD-11—PCV SYSTEM, HOSES
AND TUBES—CHECK AND CLEAN
ALL VEHICLES—ALL ENGINES
1. Check PCV System Function:
A-l.With the Engine Idling (Except 2.3L
Engines)
• Remove oil filler cap.
• Hold V-44 PCV valve tester or
equivalent over the opening in the
valve cover, making sure there is a
positive seal between the tester and
cover.
• Start the engine and allow it to
operate at the idle speed.
• If the ball settles in the good (green)
area, the system is functioning
properly. If the ball settles in the
repair (red) area, servicing of the
system is needed.
NOTE: If the V-44 PCV Tester or
equivalent is not applicable, use
Alternate A-2.
A-2.With Vehicle Idling at Normal
Operating Temperature (Except
2.3L Engines)
• Remove the PCV valve from its
mounting. If the valve is functioning
properly and not plugged, a hissing
Engine Diagnosis and Service
air noise will be heard as the air
passes through the valve, and a
strong vacuum should be felt when
a finger is placed over the valve inlet.
While finger is over the valve inlet,
check for vacuum leaks in the hose
line and at all connections.
• Re-install the PCV valve, then
remove the crankcase air inlet hose
at the air cleaner connection. Loosely
hold a small piece of stiff paper (such
as a 3 x 5 memo card or parts tag
card) over the opening at the end of
the inlet hose.
• The paper should be sucked against
the hose opening with a noticeable
force after sufficient time has lapsed
for the crankcase pressure to lower
(usually about a minute or more).
B. For 2.3L Engines Only
• Remove PCV valve from engine.
Install a known good PCV valve. If
idle quality improves, the original
valve was not functioning normally.
C. With the Engine Stopped (Except
2.3L Engines)
• Remove the PCV valve from its
mounting and shake it. A metallic
clicking noise should be heard,
indicating the valve is free.
above tests, the system is functioning
and no further service is required. If
it fails any of the tests, replace the
PCV valve and clean the PCV system
per Step 2.
R e m o v e t h e PCV S y s t e m
components, filler cap, PCV valve,
hoses, tubes fittings, etc. from the
engine.
Soak the rubber ventilation hose(s) in
a low volatility petroleum base
solvent.
Clean the rubber ventilation hose(s)
by passing a suitable cleaning brush
through them.
Thoroughly wash the rubber hoses in
a low volatility petroleum base
solvent and dry with compressed air.
Thoroughly wash the crankcase
breather cap if so equipped in a low
volatility petroleum base solvent and
shake dry. Do NOT dry with
compressed air, damage to the
filtering media may result.
Thoroughly clean tubes, fittings,
connections to assure unobstructed
flow of emission gases.
Install a new PCV valve and re-
install previously removed hoses,
tubes, fittings, etc. to their proper
location.
Replace any system component that
shows signs of damage, wear or
deterioration as required.
Replace any hose or tube that cannot
be cleaned satisfactorily.
29-02-71
SSD-12—AUTOMATIC CHOKE
CHECK PROCEDURE 2150 2V
CARBURETOR
(2.8L, 3 0 2 , 3 5 1 and 4 0 0 CID
Engines)
/. Freedom of Linkage and System
Integrity Check
With the engine off, perform the
following operations:
1. Remove air cleaner, verify that the
hold-down wingnut has not been
over torqued thus causing the air
cleaner housing to interfere with the
choke plate operation. Also confirm
that vacuum hoses, solenoid, and
electric choke wires are properly
connected and intact. Correct as
required.
2. Check the following for freedom of
operation: throttle system, choke
plate, all linkages, fast idle cam,
altitude compensator air bypass
plate, if so equipped. Correct as
required.
//. Choke Heat System Leakage and
Flow and Flow Meter (Except SS1M,
400)
1. Connect choke flow meter (special
service tool T75L-9850-A or equivalent)
to choke cold air supply tube.
2. Warm engine to normal operating
temperature and, at curb idle,
observe flowmeter reading.
3. If flowmeter reading is within
specification, remove and proceed to
Section III.
4. If theflowmeterreading is not within
specification, clean, repair or replace
as r e q u i r e d to meet flow
specifications.
///. Electric Choke Function and
Choke Plate Pulldown Check
1. Disconnect the stator lead at choke
cap terminal and connect a test light
in series with ground.
2. The light should glow at all times
while engine is running.
3. If light does not glow, either the
alternator or choke wire is defective
and should be repaired as necessary.
4. Place test light in series with choke
terminal and stator lead. If light does
not glow, replace choke cap
assembly. If light glows, turn off
engine. Remove light.
5. Manually open throttle and set on
fast idle cam. Remove (see Caution
in Step 10) the hot air supply tube at
the choke housing and install a choke
tester (special service tool LRE-34618
or equivalent). Cool choke housing per
choke tester manufacturer's instruction
until bimetal closes choke plate lightly
in air horn.
NOTE: Do not use choke tester
manufacturer's time specification.
6. With throttle set on the highest step
of the fast idle cam:
29-02-72
Record the index position of the
choke bimetal cap for later use in
resetting the cap.
Loosen retaining screws and rotate
bimetal cap 90 degrees in the closing
(rich) direction, and retighten
screws.
Activate pulldown motor by
applying vacuum to external vacuum
tube.
Manually insure that the pulldown
motor is fully retracted.
If motor does not fully retract with
vacuum, test pulldown motor
diaphragm for leakage.
If pulldown motor diaphragm is
leaking and motor will not retract
fully with vacuum, perform vertical
hard gage measurement while
manually forcing the motor to the
fully retracted position.
NOTE: Insure that choke plate
linkage is not interferred with or
erroneous measurement may
result.
Measure vertical hard gage clearance
between choke plate and center of
carburetor air horn wall nearest the
fuel bowl.
Pulldown setting should be within
specifications.
If choke plate opening requirement
is met, proceed to Step 7.
If choke pulldown motor is leaking
or will not fully retract with vacuum,
replace the motor.
Adjust choke plate vertical hard
gage setting to value measured in
previous steps by turning adjustment
screws.
Apply Loctite 290 or equivalent to
adjusting screw threads at base of the
motor after adjustment. Allow 15
minutes set-up time.
Every time that the pulldown
adjustment is made, perform the
following fast idle cam setting
procedure:
Open and close the throttle slightly
and watch where the fast idle
sc/rew contacts the fast idle cam.
(The fast idle screw should be set
to the approximate high cam speed
when making the cam setting.)
The fast idle screw should strike
the second highest step at the "V"
on the fast idle cam. The
adjustment is made with the cam
adjusting screw.
After making the cam adjustment,
allow the choke plate to close.
Check the choke plate to be sure
it closes tightly in the air horn.
7. This completes the pulldown check.
Next, install new choke cap gasket
and reset the choke bimetal cap to
previously recorded recommended
Engine Diagnosis and Service
index position, and install new choke
cap clamp. Reset retaining screws.
Check and/or reset (according to
specified procedure) fast idle speed to
specifications if necessary. Recool
choke housing per III-5, if required.
8. Reconnect terminal and alternator
stator lead.
9. Disconnect the choke tester (LRE-
34618 or equivalent) from the
carburetor.
10. Install plug or cap in choke housing
heat inlet port at carburetor.
CAUTION: On 2.8L engine, move
fast idle cam to kickdown step to
avoid excessive rpm.
Start the engine without touching
throttle and observe the following:
a. If .diaphragm retracts.
b. Record the time from engine start
up until the choke plate rotates to
a vertical position.
If diaphragm fails to retract refer to
Appendix A.
Complete rotation of the choke plate
to vertical should occur within
specification. If time exceeds
specifications, repeat Electric Choke
Function. If time still exceeds
specifications replace choke cap and
repeat Electric Choke Function.
If choke plate to vertical time is still
not within specifications, check
alternator and lead wire per shop
manual. Repair and/or replace as
required.
11. Remove the plug from the choke
heat inlet. Reinstall the hot air
supply tube (see Caution below).
CAUTION: Exercise extreme care in
removing, reinstalling and checking
for leaks in the choke hot air supply
tube, as its retaining nut could be
easily cross-threaded.
12. Check choke heat system.
a. Connect flow meter to choke cold
air supply tube.
b. Warm engine to normal operating
temperature and, at curb idle,
observe flowmeter reading.
c. If flowmeter reading is within
specification, remove meter. If
flowmeter reading is not within
specifications, clean, repair, or
replace as required to meet flow
meter specifications.
IV. Altitude Compensator Assembly—
Internal
1. Remove the aneroid housing (the
outermost housing) and gasket by
removing the three machine screws.
2. This exposes the poppet valve
assembly. Check the poppet valve for
freedom of operation. Confirm that
the poppet valve is free and returns
to the seated position.
3. If poppet valve is sticky or binds,
spray choke cleaner (C9AZ-19A5O1-
29-02-72
B or equivalent) on the poppet valve
and guide area to remove any
deposits. Make sure that valve is
completely free by depressing the
valve.
4. If further cleaning is required,
remove altitude compensator
assembly from the carburetor
(removing four machine screws) and
clean with lead-free fuel, or
equivalent. If unable to free-up the
valve, replace the a l t i t u d e
compensator assembly.
5. If required, reinstall the aneroid
housing and gasket onto the valve
housing (three machine screws).
6. Re-install systems components,
torque air cleaner wing nut to
specifications.
YFA 1V Carburetor (200 and
250 CID Engines)
/ . Freedom of Linkage and System
Integrity Check
With the engine off, perform the
following operations:
1. Remove air cleaner. Verify that
vacuum hoses, solenoid and electric
choke wires are properly connected
and intact. Correct as required.
2. Check the following for freedom of
operation: throttle system, choke
plate and shaft, all linkages, fast idle
cam, etc. Correct as required.
//. Choke System Leakage and Flow
1. Disconnect the choke clean air hose
(rubber) from the carburetor air horn
and attach choke flow meter
(special service tool T75L-9850-A
or equivalent) to the hose. Dis-
connect and plug EGR vacuum
hose at EGR valve and dist ributor
vacuum advance hose.
2. Warm the engine to normal
operating temperature. Place
transmission in neutral. Bring engine
up to 900-1000 rpm and observe
choke flow meter reading.
3. If flow meter reading is within
specification, remove flow meter.
Reconnect the clean air host; to the
carburetor, EGR hose to EGR valve,
and distributor advance hose to
distributor primary. Proceed to
Section III.
4. If the flow meter reading is not
within specification, refer to
Appendix "A".
/ / / . Choke Funtional Tests
1. Disconnect the stator lead at choke
cap terminal and connect a test light
in series with the stator lead and
ground.
2. The test light should glow with the
engine running.
3. If light does not glow, either the
alternator or choke wire is defective.
Correct as required.
29-02-73
4. Restart engine and warm to normal
operating temperature. Place test
light in series with choke terminal
and alternator stator lead. If light
does not glow, replace choke cap
assembly. (Engine and choke cap
must be warmed to normal operating
temperature whenever choke cap is
replaced.) If light glows, turn off
engine. Reconnect choke terminal
and alternator stator lead.
5. Remove (see Caution in Step 10) the
hot air supply tube at the qarburetor
choke housing. Attach Rotunda
choke tester (14 0206 or equiva-
lent). Manually set fast idle cam
on high step. Cool choke housing
until choke plate just closes.
6. Check for choke resistance by
securing an ohmmeter across the
choke cap terminal and choke
ground strap.
7. This value should be within
specification. If range is exceeded,
replace choke cap and repeat III
beginning with Step 4.
8. Recool choke housing until choke
plate just closes. (If choke plate is
closed, this step should not be
performed.)
9. Remove Rotunda choke tester
(14 0206 or equivalent).
10. With heat tube removed and choke
plate closed (fast idle screw is
positioned on high step of cam), start
engine without touching throttle and
see that choke opens to a vertical
position with electrical assist only.
Record choke come-off time. If
choke does not open with electrical
assist only, replace choke cap and
repeat III beginning with Step 4.
CAUTION: Exercise extreme care in
removing, reinstalling and checking
for leaks in the choke hot air supply
tube as its retaining nut and/or
choke housing can easily be cross-
threaded.
11. Stop engine. Remove instruments
and.reinstall related system
components. Torque carburetor
wingnut (in air cleaner) to
specification.
IV. Choke Plate Pulldown
1. Remove the air cleaner assembly,
then remove the choke thermostatic
spring housing and gasket from the
carburetor.
2. Bend a 0.026 in. diameter wire gauge
at a 90 degree angle approximately
1/8-inch from one end. Insert the
bent end of the gauge between the
choke piston slot and the right hand
slot in the choke housing. Rotate the
choke piston lever counterclockwise
until the gauge is snug in the piston
slot. (See Fig. 5).
Engine Diagnosis and Service
A1386-A
FIG. 5 Choke Plate Pulldown
Adjustment
3. Exert a light pressure on the choke
piston lever to hold the gauge in
place, then use a drill with a diameter
equal to the specified pulldown
clearance between the lower edge of
the choke plate and the carburetor
bore to check clearance.
4. To adjust the choke plate pulldown
clearance, bend the choke piston
lever as required to obtain the
specified setting. When bending the
lever, be careful not to distort the
piston link.
5. Install the choke thermostatic spring
housing and gasket. Set the housing
to specifications.
V. Dechoke
1. Remove the air cleaner.
2. Hold the throttle plate fully open and
close the choke plate as far as
possible without forcing it. Use a
drill of the proper diameter to check
the clearance between the choke
plate and air horn.
3. If the clearance is not within
specification, adjust by bending the
arm on the choke trip lever. Bending
the arm downward will increase the
clearance, and bending it upward
will decrease the clearance. Always
recheck the clearance after making
any adjustment.
4. If the choke plate clearance and fast
idle cam linkage adjustment was
performed with the carburetor on the
engine, adjust the engine idle speed.
Adjust the dashpot (if so equipped).
VI Fast Idle Cam Index Setting
1. Position the fast idle screw on the
kickdown step of the fast idle cam
against the shoulder of the high step.
2. Adjust by bending the choke plate
connecting rod to obtain the
specified clearance between lower
edge of the choke plate and the
carburetor bore.
29-02-73
5200 2S/2V Carburetor (2.3L
Engines)
Section I—Freedom of Linkage and
System Integrity Check
1. Apply parking brake and block
wheels.
2. Connect tachometer.
3. Bring engine to normal operating
temperature.
4. Turn off the engine.
5. Remove air cleaner assembly and
plug vacuum line(s) to air cleaner
assembly.
6. Verify that vacuum hoses, solenoid
and electric choke wires are properly
connected and intact, check that all
carburetor hold down nuts are
torqued to specification. Correct as
required.
7. Check all carburetor linkages for
freedom of operation. Repair or
replace and adjust as required.
Section II—Bimetal and Linkage
Functional Check
1. Inspect if bimetal index is set to
specification. Correct as required.
2. With throttle held at 1/4 open
position, rotate and hold choke
plates to the closed plate position.
Release choke plates; they should
rotate smoothly to the fully open
position. If choke plates do not rotate
smoothly, clean and/or repair, then
bring engine to normal operating
temperature and recheck.
Caution No. 1: If bimetal assist
spring is to be removed during
repair, extreme care must be taken so
as not to deform the spring.
Caution No. 2: If fast idle cam latch
assembly is removed during repair,
the choke plates must be in the closed
plate position prior to reinstalling the
fast idle cam latch assembly to the
choke housing. This will prevent
damage to the delicate latch bimetal.
3. Cool the choke bimetal with a
Rotunda choke tester (14 0206)
or equivalent by blowing the cool air
directly onto the choke bimetal
housing cover. Cool housing for
seven (7) minutes, then open throttle
linkage to 1/4 open position and
slowly release throttle. If the choke
plates do not lightly seat themselves
in the air horn bores, continue
cooling for an additional minute,
then open and close the throttle as
mentioned above. If plates still do
not close, repeat Section I, Step No.
6 and Section II, Steps No. 2 and 3.
4. Manually open choke plates to
vertical position and open and close
throttle to allow the cam to drop to
the K/D position. Release choke
plates (choke plates will not close
completely) and observe that the fast
idle adjusting screw is seated on the
29-02-74
kickdown step of the fast idle cam.
If this condition is met, proceed
quickly to Section III. If this
condition is not met, repair or
replace fast idle cam latch assembly,
following Caution No. 2 as outlined
in Section II, Step No. 2. Then recool
bimetal (if necessary) according to
Section II, Steps No. 3 and 4 and
proceed quickly to Section III.
Section III—Electric Choke Functional 2. Check the following for freedom of
Test
1. Without touching throttle, start the
engine, position throttle and hold
approximately 2500 RPM. Check
the time for the choke plates to rotate Flow Meter
to the vertical position and the time
for the fast idle cam to drop from the
K/D position to the curb idle
position.
a) If time to rotate is within
specification, let engine run until
the fast idle cam drops to the curb
idle position or a maximum of an
additional 2 minutes.
If cam does not drop within
specification, check fast idle cam
latch assembly installation as
outlined in Section II, Step No. 2,
Caution No. 2. If installation is
satisfactory, replace fast idle cam
latch assembly and check if cam
drops.
If cam drops within specification,
no further tests are required. Turn
off the engine; remove all test
equipment and reinstall system
components. Torque wing nuts to
specification.
b) If time to rotate is not within
specification, proceed to Step No.
2.
2. Disconnect the stator lead at the
choke cap terminal or at the lead
connector and connect it to one lead
of a test light. Connect the second
test light lead to ground.
3. With engine running, observe one of
the following conditions:
a) If the light does not glow, either
the alternator is not functioning or
the automatic choke wire from the
stator has an open circuit and
should be repaired as necessary.
Then, repeat Section II, Steps No.
3 and 4 and Section III.
b) If the light glows, replace the
choke bimetal assembly. Proceed
to Step No. 4.
4. Turn off the engine, remove all test
equipment and reinstall systems
components. Torque wing nuts to
specification.
Engine Diagnosis and Service
4350-4V Carburetor (460 CID
Engine)
/. Freedom of Linkage and System
Integrity Check
With the engine off, perform the
following operations:
1. Remove air cleaner, verify that the
vacuum hoses, solenoid and electric
choke wires are properly connected
and intact. Correct as required.
operation: Throttle system (pri. and
sec), air valve, choke plate, all
linkages, fast idle cam, etc. Correct
as required.
//. Choke Heat System Leakage and
1. Disconnect the choke clean air hose
from the carburetor air horn and
attach a flow meter to the hose.
2. Warm engine to normal operating
temperature and observe flow meter
reading.
3. If flow meter reading is within
specification, remove theflowmeter,
reconnect the clean air hose to the
carburetor and proceed to Section
III.
4. If the flow meter reading is not
within specification, refer to
Appendix A.
///. Choke Functional Checks
1. Disconnect the stator lead at choke
cap terminal and connect a test light
in series with ground.
2. The light should glow at all times
wnile engine is running.
3. If light does not glow, either the
alternator or choke wire is dam-
aged and should be replaced as
necessary.
DRILL GAUGE OF SPECIFIED
CLEARANCE SIZE
CHOKE PLATE
"% '**' FAST IDLE ADJUSTMENT SCREW
FIG. 6 Checking and Adjusting Initial Choke Plate Pulldown
29-02-74
4. Place test light in series with choke
terminal and stator lead. If light does
not glow, replace choke cap
assembly. If light glows, turn-off
engine.
5. Remove (see caution in Step 9) the
hot air supply tube at the choke
housing and install a choke tester
(Rotunda 14 0206 or equivalent).
Cool choke housing per choke tester
manufacture's instruction until
bimetal closes choke plate lightly in
air horn.
6. Check for choke resistance by
adequately securing an ohmmeter
across the choke cap terminal and
choke ground strap.
7. This value should be within
s p e c i f i c a t i o n s . If o u t of
specifications, replace choke cap
assembly. Remove Ohmmeter.
8. Apply external vacuum 16" (Hg) ±
2" to pulldown control diaphragm.
Measure (at lower edge) choke plate
opening. Pulldown setting should be
within specifications for minimum
choke plate opening. If choke plate
minimum opening is met, continue
with diagnosis. Reset pulldown if
found to be out of specification.
9. Remove choke tester from adaptor.
10. Start the engine without touching
throttle and observe the following:
If diaphragm retracts.
On applicable models, the fast idle
cam should rotate and throttle
should move to kickdown step of
cam in specified time.
The choke plate should open to the
vertical stop position within the
specified time.
-$ TAPER-LOCK CHOKE SHAFT
SCREW (LEFT HAND THREAD)
FAST IDLE CAM
ADJUSTING SCREW
0.0IS6 INCH
WIRE GAUGE
APPLY LIGHT PRESSUFIE
TO CHOKE LEVER
V1967B
29-02-75
If any of these conditions are not met,
repair and/or replace according to
Appendix A.
11. Re-install hot air supply tube.
CAUTION: Use extreme care in re-
installing the hot air supply tube as
its retaining nut could easily be
cross-threaded.
12. Stop t h e e n g i n e . R e m o v e
instruments and reinstall related
system components. Torque the air
cleaner wing nuts to specification.
IV. Choke Plate Pulldown Check
1. Remove the choke thermostatic
spring housing assembly.
2. Open throttle about half-throttle and
position the fast idle adjusting screw
on the high step of the fast idle cam.
3. Bend a 0.036 diameter wire gauge at
a 90 degree angle approximately 1/8
inch from its end. Insert the bent end
of the gauge between the choke
piston slot and the upper edge of the
right-hand slot in the choke housing.
(Fig. 6).
4. Rotate the choke thermostat lever
counterclockwise until the gauge is
snug in the piston slot. Hold the
gauge in position with light force on
the lever and move the top of the
choke rod away from the carburetor
while moving the bottom of rod
toward carburetor to remove end
play from linkage.
5. Using a drill gauge or equivalent,
check initial choke pulldown
clearance (Fig. 6) by placing the
gauge against the inner wall of the
choke air horn at approximately the
centerline of the carburetor and
check clearance from wall to lower
edge of choke plate.
6. If the clearance is not within
specifications, adjust clearance by
turning the hex-head lock screw on
the choke shaft in a clockwise
direction three (3) full turns.
(NOTE: Lock screw is left hand
threaded.) Pry choke lever from
choke shaft to break taper lock.
Choke lever should rotate freely on
the choke shaft.
7. Hold the drill gauge with diameter
equal to specified pulldown
clearance between the lower edge of
the choke plate and air horn wall,
maintaining light closing force on
choke plate.
8. With choke piston snug against the
0.036 inch wire gauge, the top of the
choke rod hold away from the
carburetor while moving the bottom
of the rod toward the carburetor to
remove end play from linkage and
the choke plate held against the drill
gauge, tighten the hex-head screw on
the choke shaft.
Engine Diagnosis and Service
9. Reinstall the choke thermostatic
spring housing assembly.
10. Check altitude compensator
assembly (if so equipped) as follows:
a. Remove the aneroid housing
(outer most housing) and gasket by
removing the three machine
screws.
b. This exposes the poppet valve
assembly. Check the poppet valve
for freedom of operation. If poppet
valve is free, proceed to (lOd).
c. If poppet valve is sticky or binds,
spray choke cleaner (C9AZ-
19A501-B or equivalent) on the
poppet valve and guide area to
remove any deposits. Make sure
that valve is completely free by
depressing the valve. If unable to
free-up the valve, replace the
altitude compensator assy.
d. Re-install the aneroid housing and
gasket onto the valve housing
(three machine screws).
11. Re-install system components.
Torque carburetor wing nut (in air
cleaner) to specifications.
2700 VV Carburetor (California
302/351 Engines)
/. Freedom of Linkage and System
Integrity Check With the Engine Off,
Perform the Following Operations:
1. Remove the air cleaner. Confirm
that vacuum hoses, solenoid and
electric wires are intact and properly
connected. Correct as required.
2. Check the following for freedom of
operation: Throttle system linkage,
all choke linkages (fast idle cam,
levers, etc.). The throttle should be
held open slightly for this check.
Correct as required and/or clean
according to the choke linkage
cleaning procedure.
//. Choke Heat System Leakage and
Flow with Flow Meter
1. Connectflowmeter T75L-985O-A or
equivalent to choke cold air supply
tube. (Use a 9/32" ID (Minimum)
adaptor between the choke tester and
the cold air supply tube.)
2. Warm engine to normal operating
temperature and at curb idle, observe
flow meter reading.
3. If flow meter reading is within
specification, remove and proceed to
Section III.
4. If flow meter reading is not within
specification, clean, repair or replace
as r e q u i r e d to meet flow
specifications.
///. Electric Choke Function and
Kickdown Check
1. Bring engine to normal operating
temperature and turn off.
29-02-75
Disconnect the stator lead at the
choke cap terminal. Connect a test
light in series with the stator lead and
ground.
2. The light should glow at all times
while engine is running.
3. If light does not glow, check
alternator and choke wire and repair
as necessary.
4. Place test light in series with choke
terminal and stator lead. If light does
not glow, replace choke cap
assembly. If light glows, turn off
engine.
NOTE: If choke cap is replaced,
repeat Step 4 to check system and
heat bi-metal disc to close contact on
electric choke cap.
5. Remove (see caution in Step 13) the
hot air supply tube at the choke
housing and install a choke tester
(Rotunda 14 0206 or equivalent).
6. Open to 1/2 throttle to set the fast
idle lever on the specified Step of the
fast idle cam (Fig. 7).
7. Cool choke housing per choke tester
manufacturer's instructions until the
cam lever just touches the cam
adjusting screw. Do not follow choke
t e s t e r manufacturer's time
specifications.
8. High cam lever diaphragm check.
a. Open the throttle and manually
move high cam lever to its
retracted position.
b. Close throttle with high cam lever
retracted.
c. Open and close throttle to observe
if high cam lever automatically
positions itself between fast idle
cam and cam lever.
d. Repeat Steps a, b, and c three times
to assure proper operation.
e. If high cam lever function is OK,
proceed with Step 9. If not OK,
refer to Appendix " A " for
corrective action.
9. Remove choke tester. Start engine
without touching throttle. Open
throttle—the choke high cam lever
diaphragm should retract. If
diaphragm fails to retract, refer to
Appendix "A" for corrective action.
Shut engine off.
10. Install choke tester (Rotunda
14 0206) or equivalent.
11. Open to 1/2 throttle to set the fast
idle lever on the specified Step of the
fast idle cam.
12. Cool choke housing per instructions
until the cam lever just touches the
cam adjusting screw. Do not follow
choke tester manufacturer's time
specification.
13. Remove choke tester from adaptor
and reconnect alternator stator lead
to choke terminal.
29-02-76
CAUTION: Exercise extreme care in
removing, re-installing and checking
for leaks in the choke hot air supply
tube, as its retaining nut could be
easily cross-threaded.
14. Start the engine without touching the
throttle. Record the time in seconds
required for the choke metering rod
to move downward to the seated
position. Recorded time should be
within specification.
15. If time exceeds specification, repeat
Steps 10-14.
16. If time still exceeds specification,
proceed to Appendix "A".
17. Choke heat system check:
a. Connect a flow meter to the choke
cold air supply tube.
b. Warm engine to normal operating
temperature—and, at curb idle,
observe flow meter reading.
c. If flow meter reading is within
specification, remove meter.
HIGH CAM LEVER
DIAPHRAGM
FIG. 7 Motorcraft Model 2700 VV Carburetor
Engine Diagnosis and Service
d. If flow meter reading is not within
specification, clean, repair, and/or
replace as required to meet flow
meter specification.
18. Remove instruments and re-install
related system components.
IV. Fuel Enrichment Circuit Check
1. Disconnect the wiring harness at the
carburetor cranking enrichment
solenoid and place a test light in
series with the wiring harness
connector. While cranking the
engine, the light should glow.
(NOTE: Probe both sides of the
connector since one side is a ground.)
If light does not glow, proceed to
Step 2. If light does glow, proceed to
Step 3.
2. Disconnect the engine water
temperature switch. With the engine
cold (less than 120°F) measure the
resistance of the "C" (cold) socket
terminal to engine ground. The
VENTURIVALVES
29-02-76
resistance should be less than 1 ohm.
With the engine hot (greater than
120°F but less than 242°F) measure
the resistance of the " C " (cold)
socket and " H " (hot) socket
terminals. The resistance reading of
both socket terminals should
indicate an open circuit (ohms
reading off scale). If either condition
above is not met, replace the water
temperature switch. Otherwise,
proceed with checking the wiring
harness for continuity.
3. Disconnect the wiring harness from
the carburetor cranking enrichment
solenoid and place a test light in
series with the connector on the
cranking solenoid and the positive
terminal of the battery. The other
terminal of the connector run to
ground. If the test light glows, the
continuity of the solenoid is
acceptable. If the test light does not
CONTROL VACUUM
REGULATOR
29-02-77 Engine Diagnosis and Service 29-02-77

glow or is very dim, replace the

solenoid according to Appendix B.
4. Check for solenoid activation (test
light glows) by placing fingers on the
solenoid case to feel a distinct click DIAL INDICATOR
TOOL-4201-C
(or an audible sound) when battery
voltage is applied. Repeat three
times. If a click is felt (or heard) the
solenoid activation is acceptable. If
a click is not felt or heard, replace the
solenoid according to Appendix B.
2700 CARBURETOR COLD
ENRICHMENT METERING ROD
ADJUSTMENT PROCEDURE
Special Tools Needed:
1) Dial indicator Tool-4201-C
2) Choke stator cap weight T77L-9848-
A
Procedure:
1) Remove choke cap.
2) Install choke weight on the choke bi-
metal lever (Fig. 8)
3) Remove air cleaner stud and install
dial indicator with the tip on the top
surface of the rod. With the choke
weight in place, adjust dial indicator STATOR CAP
to read zero. Make sure the zero T77L-9848-A
A4276-A
repeats. This is critical.
4) Remove stator cap and reinstall it at
index position. (Set choke on high
cam if procedure is performed with FIG. 8 Adjusting Cold Enrichment Metering Rod
carburetor On engine.) mark on the choke casting (see Check for leaks in diaphragm
5) Verify that dial indicator reading is specification). Make sure the fast idle assembly if time is excessive.
.125" ± .005". If not, proceed to cam lever is still in the corner of the Replace diaphragm assembly if
Step 6. two steps. restriction cannot be cleared.
6) Turn the choke rod indexing nut to 6. Remove the stator cap and reinstall Choke Plate Does Not Open to
achieve specification. The choke the choke cap, making sure that the Vertical Position in Specified Time
metering rod travel will be upwards tang is engaged in the choke bimetal
towards the dial indicator. lever. Check for binding linkage.
Remove thermo assembly and
7) Repeat Steps 2 thru 6 to establish APPENDIX A (EXCEPT 2700 VV
repeatability. Adjust if necessary. inspect the vacuum piston linkage for
CARBURETOR) binding between the pin and the
8) Remove the stator cap and dial Diaphragm Fails to Retract slotted link. Hold the vacuum piston
indicator. 1. Check for binding of linkage—repair at the bottom of its bore by inserting
9) Re-install the choke cap at index or replace as required. a paper clip in the vacuum slot and
assuring that the bimetal tang is 2. Check for cracked vacuum hose (on above the top of the piston. Then
properly inserted in the cam bimetal carburetors with external vacuum rotate the thermo spring lever to
lever. Re-install air cleaner stud. supply, check vacuum supply to check binding.
2700 CARBURETOR CAM SET diaphragm). If plate does not rotate to vertical
PROCEDURE 3. Check for plugged vacuum channel position in prescribed time, replace
(2V carburetor). Remove vacuum choke thermo assembly.
Special Tool: Stator Cap T77L-9848-A
hose at diaphragm. Connect a
1. Remove choke cap. Choke Heat System Flow Not Within
vacuum source to the hose and trap.
2. Hold throttle lightly closed with a Specification
If a vacuum reading is maintained,
rubber band to maintain cam
the system is plugged. Clean, repair* 1. Check for leaks; tighten connections
position.
and/or replace as required. in the hot air circuit.
3. Place the fast idle lever in the corner
4. Check for vacuum leak at gasket 2. Disconnect the hot air tube from the
between the steps (see specification
surfaces or ruptured diaphragm. choke housing.
for proper step setting) of the fast idle
5. Check for loose attachment. Correct, 3. Connect choke flow meter to hot air
cam with the high cam diaphragm
repair or replace as required. connection on the choke housing.
assembly in its retracted position.
4. Install Stator Cap T77L-9848-A. Fast Idle Cam Does Not Rotate or 4. If choke flow meter reading is within
Turn the stator cap clockwise until Does Not Meet Minimum Time specification, check air supply
the lever contacts the adjusting Specification system. Clean, repair or replace as
screw. Check adjustment and reset as necessary.
5. Turn the fast idle cam adjusting required to insure that fast idle screw 5. If choke flow meter reading is not
screw until the index mark on the rests on fast idle cam K.D. step when within specification, clean, repair or
stator cap lines up with the specified diaphragm is fully retracted. replace as necessary.
29-02-78
Choke Pulldown Adjustment
1. Make certain that choke plate is
lightly closed in carburetor air horn.
(If engine is warm use choke tester,
Rotunda 14 0206 or equivalent,
to cool choke until choke plate
lightly closes in the air horn.)
2. Note index position of bimetal cap
and wrap choke cap 90 degrees in the
rich direction (CCW) from that
position and secure.
3. Activate pulldown motor manually
or with external vacuum if the
pulldown motor has an external
vacuum tube.
4. Set specified clearance between
choke plate and the center of the
carburetor air horn nearest to the
fuel bowl by turning the adjusting
screw at the back of the pulldown
motor.
5. After the adjustment is made, apply
Locitite 290 or equivalent to the
threads of the adjusting screw where
it enters the pulldown motor.
6. Return choke cap to its original
position.
Appendix "A" (2700-VV
Carburetor)
/. Choke High Cam Lever Diaphragm
Fails to Retract
A. Check for binding, misaligned
linkages, broken parts,
contamination and/or loose parts.
Repair and/or replace.
B. If repair or replacement was made,
check choke high cam lever
diaphragm to see if it retracts, by
repeating Section III, SSD-12 (Steps
5-8). If diaphragm retracts, return to
Diagnostic Procedure, Step 9.
Otherwise, perform Steps 1-4 of C.
C. If repair or replacement was not
made, proceed as follows:
1. Remove carburetor.
2. Remove high cam pulldown
diaphragm cover and check the
sealing surface for a cracked, bent,
distorted or chipped surface or
contamination. Replace or repair
as required.
3. Using special service hand vacuum
pump or equivalent, apply a vacuum
to the vacuum passage in the high
cam pulldown diaphragm flangeo If a
vacuum reading is maintained, the
system is plugged. If plugged, clean
as required.
4. Remove the high cam pulldown
diaphragm from its base, being
careful not to tear or distort it.
Inspect it for pinholes, cracks, or
decomposed diaphragm material:
a. If the high cam pulldown
diaphragm is satisfactory,
reinstall the diaphragm cover
taking care to align all vacuum
Engine Diagnosis and Service
passages. Check linkage and
diaphragm for freedom of
movement. Install carburetor on
vehicle making all necessary
connections, and return to Step
9.
b. If the high cam pulldown
diaphragm needs replacement,
proceed as follows:
1) Unscrew diaphragm assembly.
2) While holding the throttle
lightly in the closed throttle
position, rotate the fast idle
cam so the fast idle lever and
the high cam choke lever rest
on a cam step. The fast idle
lever should now be resting at
the bend in the high cam
choke lever.
3) Still holding the throttle in the
closed position, gently screw
diaphragm assembly onto
shaft until it bottoms. Then to
align the vacuum passage and
hole in the diaphragm, rotate
the diaphragm
counterclockwise until
aligned.
N O T E : The high cam
pulldown diaphragm can only
be adjusted in increments of
one full turn. The vacuum
passage in the diaphragm
must be aligned with the
vacuum passage on the flange.
4) Install diaphragm spring and
cover assuring that the
vacuum passages are aligned
and that the mechanism works
freely.
5) Using special service vacuum
pump or equivalent, and
blocking vacuum passage
which enters choke housing
from the underside of throttle
body, apply a vacuum to the
choke hot air inlet making
sure that the fast idle lever is
free to allow cam and choke
lever movement. The high
cam diaphragm should
retract.
6) If the pulldown diaphragm
fails to retract, remove the
choke cap and apply a vacuum
using the special service hand
vacuum pump or equivalent to
the heat restrictor vacuum
passage next to the choke
bimetal. Again the vacuum
passage in the underside of
throttle body near the choke
housing must be plugged,
clean as required. If the
pulldown diaphragm retracts,
reinstall choke cap, inspecting
gasket and cap to insure their
good condition and install
29-02-78
carburetor on vehicle. If the
diaphragm still fails to retract
check for leaks in choke
housing at the lead seals and
at pulldown diaphragm
seating surface. Repair or
replace as necessary.
7) Install carburetor on vehicle
making necessary connections
and check to make sure the
required mechanism is
functional on running vehicle.
//. If the Choke Metering Rod
Mechanism Fails to Move Downward
Within the Specified Time.
A. Disconnect the stator lead at choke
cap terminal. Connect a test light in
series with stator lead and ground.
B. The light should glow at all times
while engine is running.
C. If light does not glow, either
alternator or choke wire is defective
and should be repaired as necessary.
D. Place test light in series with choke
terminal and stator lead. If light does
not glow, replace choke cap
assembly. If light glows, turn off
engine.
E. Check for damaged, missing, and/or
misaligned parts. Check for dirt,
grease or any foreign material on
moving parts. Repair or replace and
clean as required. If any linkage is
repaired or replaced check choke set
and cam set. If necessary, reset per
choke set and cam set procedure
(attached).
F. If any corrective action is taken in
Steps A thru E, re-install Stator lead
and then perform electric choke
function check, Section III, Steps 10
through 14. If choke metering rod
moves downward within the specified
time, return to Diagnostic Procedure
Step 17; otherwise, proceed to Step G.
If no corrective action is taken in Step
E proceed to Step G.
G. Remove carburetor from vehicle.
1. Remove the retaining ("E") ring
which holds the choke operating
rod to the cam lever and remove
the linkage from the cam lever.
2. Open the throttle slightly and
check cam lever for freedom of
movement. The choke cap spring
should provide the only resistance
and the cam lever should spring
back to the original position.
3. If movement is OK, proceed with
Step 4. If the cam movement is still
not free, remove the throttle body
from the carburetor. Remove the
choke cap and disassemble the
choke shaft, the cam lever, and the
fast idle cam. Check the surfaces
of all parts for grease, foreign
material, bends, cracks, or
distortion. Clean and replace parts
29-02-79
as necessary. If a new fast idle cam
is installed, refer to the 2700
carburetor cam set procedure.
Install throttle body on carburetor
and torque to specifications.
4. Check remaining parts of choke
system for freedom of movement
by manually moving choke
operating rod up and down. The
movement should be free.
If movement is OK, proceed with
Step "e". If the movement is not
free, remove the retaining ("E")
ring and pin from the choke
metering rod lever.
Carefully lift the choke metering
rod, the choke CVR rod, and the
choke metering rod lever up and
out of the air horn as far as the
choke operating rod will allow.
Inspect the parts for foreign
material, bends, distortion or
breakage, clean and replace as
necessary. If the choke CVR needs
replacing, replace and set per
control vacuum regulator (CVR)
adjustment procedure.
5. Make sure the choke operating rod
is connected to the cam lever with
the retaining ("E") ring.
6. Install carburetor on vehicle
making sure all parts operate
freely. Connect all vacuum hose(s)
and electrical wires.
Appendix "B (2700 VV
Carburetor)
/. Replacement of Electric Cranking
Solenoid
A. Remove carburetor from vehicle.
B. Remove electric solenoid from main
body of carburetor.
C. Coat the "O" ring seal of the new
solenoid with a mild solution of soap
and water. This is important as a
damaged "O" ring may result in a
fuel leak.
D. Install the cranking solenoid to the
carburetor being careful not to
damage the " O " ring. Torque to
specification.
E. Install carburetor on the vehicle
m a k i n g all t h e n e c e s s a r y
connections.
2700 VV Carburetor High Cam Finger
Setting Procedure
Open to 3/4 throttle and depress choke
operating rod to full travel, then close
throttle. The fast idle lever should be
resting at the bend in the high cam choke
lever. If not, repair and/or replace as
required.
2700 W CARBURETOR CHOKE
LINKAGE CLEANING
PROCEDURE
1) Remove choke cap.
2) Using Automatic Choke Cleaner
(C9AZ-19A501-B) or equivalent,
Engine Diagnosis and Service
spray inside of choke cap on and
near the bi-metal until dirty de-
posits and dirt buildup is washed
away.
3) Using the Wand Provided with the
Cleaner, spray all areas of the choke
thermostat shaft inside and out of
choke housing. Also, spray the entire
choke linkage external to the
carburetor. Use abundant amount of
spray and move the choke
thermostat lever, the fast idle lever,
and the fast idle cam moderately
while spraying.
4) Blow the choke parts previously
cleaned with compressed air until
visibly dry. Again, move the
moveable parts moderately while
blowing dry.
5) Repeat Steps 3 and 4.
6) Install choke cap gasket, choke cap
(making sure that it is properly
indexed) and choke cap retainer ring.
Torque screws to specification.
Control Vacuum Regulator (CVR)
Adjustment Procedure
NOTE: The cold enrichment metering
rod adjustment must be checked and/or
set before making this adjustment.
1. Loosen the screws on the choke cap
and rotate it 180 degrees clockwise
(rich direction) from index and cycle
the throttle to set the cam.
2. Press lightly on the CVR rod, if there
is any downward travel, the rod is
not seated and must be adjusted. If
there is no downward travel, turn the
adjusting screw counterclockwise
until there is some travel and proceed
with the adjustment.
3/32" ALLEN WRENCH
FIG. 9 Adjusting CVR Rod
29-02-79
3. Turn the CVR rod clockwise until
the adjusting nut just begins to
rise (see Fig. 9).
4. Again, press lightly on the CVR
rod—if any springback can be seen,
the rod is not fully seated. Turn the
adjusting screw clockwise by 1/4
turn increments until no springback
can be seen.
5. Reset the choke cap to the specified
setting.
SSD-13 IDLE FUEL MIXTURE
I. Propane Enrichment Method
A. AH Vehicles Not Equipped with
2700-VV Carburetors
CAUTION: Block the wheels before
starting the engine.
NOTE: Remove and reinstall air cleaner
when necessary to perform adjustments.
1. Connect a tachometer and bring the
engine to normal operating
temperature.
NOTE: If the engine has a "Dura
Spark I" ignition system (gray coil
tower), use a tachometer rated for
this type of ignition system.
2. Disconnect the evaporative emission
purge hose from air cleaner.
Disconnect the crankcase ventilation
closure hose from the air cleaner
assembly and plug the air cleaner
hole.
3. Step Not Required For 1977.
4. Adjust curb idle to specification.
NOTE:With transmission in neutral,
run engine at approximately 2500
rpm for IS seconds before each
speed check. The idle speed must
be set to specification with air
cleaner assembly installed.
A4277-A
29-02-80
5. For vehicles equipped with
Thermactor systems, reivse the
dump valve vacuum lines as follows:
a. For dump valves with one or two
vacuum lines at the side,
disconnect and plug the line(s).
b. For dump valves with one vacuum
line at the top, check line to see if
it is connected to intake manifold
vacuum. If not, remove and plug
the line at the dump valve and
connect a slave line from the dump
valve vacuum fitting to an intake
manifold vacuum fitting.
6. Plug gas tool T75L-9600-A or
equivalent into the air cleaner
evaporative purge nipple. With the
engine idling and transmission in
proper mode (see engine emission
sticker), slowly open the valve
until the engine speed reaches
a maximum and then begins to
drop—note the maximum amount of
speed increase. If speed will not drop,
check bottle gas supply. If necessary,
repeat this operation with a new
bottle gas supply.
a. If speed increase is within
specification, but not "0" rpm,
proceed to Step 7. If speed increase
is "0" and minimum specification
is "0", proceed to Step 6d.
b. If speed increase is higher than
specification:
—Enrich the mixture without
propane by turning the mixture
screw(s) counterclockwise in
equal amount(s) until the rpm
increases as necessary (i.e., if the
increase was 80 rpm and the
desired reset increase is 50 rpm,
the mixture screw(s) should be
adjusted to attain a 30 rpm
increase).
NOTE: Use Tool T75L-9500-A
or equivalent if it is required to
remove the idle mixture limi-
ted s). Use Tool T77L-9500-A
or equivalent if it is required to
install the idle mixture limiter
cap(s).
—Repeat Steps 4 and 6.
c. If speed increase is lower than
specification;
— Lean the mixture
without propane by turning the
mixture screw(s) clockwise in
equal amount(s) until the rpm
decreases as necessary (i.e., if the
increase was " 0 " rpm and the
desired reset increase is 20 rpm,
the mixture screw(s) should be
leaned to attain a 20 rpm
decrease).
—Repeat Steps 4 and 6.
d. If speed increase is "0" rpm and
the m i n i m u m speed gain
specification is "0", perform the
Engine Diagnosis and Service
following speed drop test. (Note:
Perform speed drop test using
conditions specified for propane
test.)
1) Turn the mixture limiter(s)
counterclockwise to the
maximum rich position. (If the
limiter(s) have been removed, do
not enrich, assume the mixture
screw(s) are already set at the
maximum rich position). Then,
lean the idle fuel mixture by
turning the mixture limiter(s) or
screw(s) clockwise equally as
specified. Note the drop in
engine rpm.
a) If the speed drop is equal to or
greater than the specified
minimum speed drop, return
the mixture limiter(s) to the
maximum rich position or the
mixture screw(s) to the
position found above. Proceed
to Step 7 (i.e., if the engine
speed before m i x t u r e
adjustment was 650 rpm and
the speed drop specification is
100 rpm minimum, proceed to
Step 7, if the engine speed
drops to at least 550 rpm or
the engine stalls).
b) If the speed drop is less than
the specified minimum speed
drop, leave the mixture
limiter(s) or screw(s) in the
adjusted position and repeat
Steps 4 and 6 (i.e., if the engine
speed before m i x t u r e
adjustment was 650 rpm and
speed drop specification is 100
rpm minimum, repeat Steps 4
and 6 if the engine speed does
not drop to 550 rpm or less).
7. If the idle mixture limiter cap(s) were
removed, install new service limiter
cap(s) at the maximum rich stop.
Check speed increase after
installation of the service limiter
cap(s) to be sure that installation of
the limiters did not disturb the
setting. If setting is within
specification, proceed to Step 8.
Otherwise, correct as required.
NOTE: Pre-soaking the limiter
cap(s) in hot water will soften the
material and reduce the effort
required to install the cap(s) on the
screw heel(s).
8. Remove tool from air cleaner
purge nipple and reinstall all sys-
tem components removed in Step
2.
9. Set curb idle speed to specification
(retard line connected) if Step 4
required an idle speed adjustment.
10. Turn off the engine. Disconnect
tachometer and make sure that wing
29-02-80
nut(s) in the air cleaner is torqued to
specification.
B. All Vehicles Equipped with 2700-
VV Carburetors
CAUTION: Block the wheels before
starting the engine.
NOTE: Remove and reinstall air cleaner
when necessary to perform adjustments.
1. Connect a tachometer and bring the
engine to normal operating
temperature.
NOTE: If the engine has a "Dura
Spark I" ignition system (gray coil
tower), use a tachometer rated for
this type of system.
2. Disconnect the evaporative emission
purge hose from air cleaner.
Disconnect the crankcase ventilation
closure hose from the air cleaner
assembly and plug the air cleaner
hole.
3. Adjust curb idle to specification.
NOTE: With transmission in
neutral, run engine at approximately
2500 rpm for 15 seconds before each
speed check. The idle speed must be
set to specification with air cleaner
assembly installed.
4. Where specified, install (using a
"Tee" fitting) a calibrated air leak
Tool T77L-9500-A or equivalent
into the PCV line.
5. For vehicles equipped with
Thermactor systems, revise the
dump valve vacuum line(s) as
follows:
a. For dump valves with one or two
vacuum lines at the side,
disconnect and plug the line(s).
b. For dump valves with one vacuum
line at the top, check line to see if
it is connected to intake manifold
vacuum. If not, remove and plug
the line at the dump valve and
connect a slave line from the dump
valve vacuum fitting to an intake
manifold vacuum fitting.
6. Plug gas Tool T75L-9600-A or
equivalent into the air cleaner
evaporative purge nipple. With the
engine idling, and the transmission
in the proper mode (see engine
emission decal), slowly open the
valve until the engine speed reaches
a maximum and then begins to
drop - note the maximum ;imount
of speed increase. If speed will
not drop, check bottle gas supply.
If necessary, repeat this operation
with a new bottle gas supply.
a. If speed increase is within
specification, proceed to Step 7.
b. If speed increase is higher than
specification:
—Enrich the mixture without
propane by turning the mixture
screws clockwise in equal
29-02-81
amount(s) until the rpm increases
as necessary (i.e., if the increase
was 80 rpm and the desired reset
increase is 50 rpm, the mixture
screws should be adjusted to attain
a 30 rpm increase).
—Repeat Steps 3 and 6.
c. If speed increase is lower than
specification:
—Lean the mixture without
propane by turning the mixture
screws counterclockwise in equal
amounts until the rpm decreases as
necessary (i.e., if the increase was
" 0 " rpm and the desired reset
increase is 20 rpm, the mixture
screws should be leaned to attain
a 20 rpm decrease).
—Repeat Steps 3 and 6.
NOTE: Do not turn the mixture
screws more than 4 turns from
a lightly seated position.
7. Remove special service tool from
air cleaner purge nipple and
reinstall all system components
removed in Step 2. Also, remove
"TEE" from the PCV line that was
installed in Step 4.
8. Set curb idle speed to specification
(retard line connected) if Step 3
required an idle speed adjustment.
9. Turn off the engine. Disconnect
tachometer and make sure that wing
nut(s) in the air cleaner is torqued to
specification.
II. Optimum Idle Method—
Alternate Method
(To be used only when propane
enrichment equipment is not
available)-CALIFORNIA ONLY
CAUTION: Block the wheels before
starting the engine.
NOTE: Remove and reinstall air cleaner
when necessary to perform adjustments.
A. Connect a tachometer and bring the
engine to normal operating
temperature.
NOTE: If the engine Tias a "Dura
Spark I" ignition system (gray coil
tower), use a tachometer rated for
this type of ignition system.
B. Disconnect the evaporative emission
purge hose from the air cleaner.
C. For vehicles equipped with
thermactor systems, revise the dump
valve vacuum lines as follows:
1. For dump valves with one or two
vacuum lines at the side,
disconnect and plug the line(s).
2. For dump valves with one vacuum
line at the top, check line to see if
it is connected to intake manifold
vacuum. If not, remove and plug
the line at the dump valve and
connect a slave line from the dump
valve vacuum fitting to an intake
manifold vacuum fitting.
Engine Diagnosis and Service
D. Remove idle mixture limiter cap(s)
(if so equipped) with special serv-
ice tool T75L-9500-A or the
equivalent.
E. With transmission in neutral, run
engine at approximately 2500 rpm
for 15 seconds.
F. With the transmission selector in
drive (automatic transmissions) or
neutral (manual transmissions),
adjust the idle to curb idle rpm plus
the optimum idle speed range rpm (if
the specified optimum idle speed
range rpm is "0", simply adjust to
curb idle rpm).
G. With the transmission selector in
drive (automatic transmissions) or
neutral (manual transmissions),
adjust idle mixture screw(s) to obtain
maximum idle rpm, leaving the
screw(s) in the leanest position that
will maintain this "maximum idle
rpm".
NOTE: For 2700 carburetors lean is
counterclockwise (don't turn idle
mixture screws more than 4 turns
counterclockwise from a lightly
seated position).
For all other carburetors, lean is
clockwise.
H. Repeat Steps E, F and G above until
further adjustment of the idle
mixture screw(s) does not increase
the idle rpm.
I. If the specified optimum idle speed
range rpm is "0", proceed to Step K.
Otherwise, proceed to the next step.
J. With the transmission selector in
drive (automatic transmissions) or
neutral (manual transmissions), turn
mixture screw(s) equally in the lean
direction by 1/4 turn increments
until curb idle is obtained.
K. Install (except 2700 carburetor) new
service idle limiter cap(s) at the
maximum rich stop. Check idle
speed to insure that limiter
installation did not disturb the
setting. Correct, if required.
NOTE: Pre-soaking limiter cap(s) in
hot water will soften the material and
reduce the effort required to install
the cap(s) on the screw heels.
L. Turn off the engine, disconnect the
tachometer, reinstall all system
components and torque the air
cleaner wing nuts to specification.
SSD-14—IGNITION SYSTEM
To properly diagnose the ignition system
the following steps must be taken:
If for any reason any "Dura Spark"
two-piece distributor cap (cap and
adaptor) must be removed, the top
portion of the cap must be removed first,
followed by the rotor and then the
bottom portion of the cap.
CAUTION: On catalytic converter
equipped engines, no spark plug wire
29-02-81
should be removed for more than 30
seconds for the coil reserve and rotor-to-
cap voltage drop tests combined. Engine
rpm should be increased to measurement
speed before spark plug wire removal to
keep the test time to a minimum.
If for any reason any "Dura Spark"
high tension wire is disconnected, the
interior of the terminal boot must be
greased with silicone grease D7AE-
J9A331-AA or equivalent before
reconnection. This should be performed
by applying a thin layer of the silicone
grease (using a clean small screwdriver)
to the boot interior from the terminal to
the end of the boot.
Unless otherwise specified, all high
voltage measurements are to be made
with only a "clamp on" type high voltage
probe connected to the coil to distributor
high tension wire.
I. High Voltage Portion (All
Engine Lines)
A. Visually inspect all wires,
connections and related system
components for any abnormal
conditions. Repair and/or replace as
required.
B. Measure the Ignition System Coil
Reserve Voltage. Specification: 28
Kv minimum.
To make this measurement, connect
a special service Diagnostic Console
360036 or equivalent, capable of
displaying high voltage and engine
rpm readings to the vehicle. Its
"clamp on" voltage pickup must be
connected to the coil to distributor
high tension wire. With the engine
running at 1000 rpm, observe engine
operation and read scope pattern for
any abnormal conditions. Note
abnormal condition and proceed.
With engine running at 1000 rpm,
(see Caution in Note 2 and
following), remove one spark plug
wire from its plug, not allowing the
wire to arc to ground and read the
highest open circuit voltage
indicated on the scope.
CAUTION: For this test, do not
remove the following while engine is
running:
No. 1 or No. 8 wire on V-8 engines
No. 3 or No. 5 wire on 1-6 engines
No. 1 or No. 4 wire on V-6 engines
No. 1 or No. 3 wire on 4 cyl.
engines
If this reading fails, the problem may
be in the system module (breakerless
distributor), the ignition coil, the
primary wiring circuits or in the coil
to the distributor high voltage wire.
Regardless of the reading, continue
with the tests.
29-02-82
a. Check coil to distributor high
voltage wire. Specification: 5K
Ohms per inch max. Replace if
required.
b. Check primary (low voltage)
portion. Repair and/or replace as
required.
(1) Step IIA (Dura Spark II)
(2) Step IIB (Dura Spark I)
C. Measure the Distributor Rotor-to-
Cap Voltage Drop
Specification: 8 Kv. Max.
To make this measurement connect
a special service Diagnostic Console
360036 or equivalent high voltage
probe to the coil to distributor high
voltage wire. Remove one spark plug
wire from its spark plug and ground
the wire to the engine block with an
appropriate ground wire connected
to the spark plug terminal. Run the
engine at idle and do not allow a
spark gap to occur between ground
and the spark plug wire.
If this test fails, the problem is in
the distributor rotor or the
distributor cap, or both. First,
replace the rotor and rerun the
test. If the test again fails, replace
the distributor cap.
D. Measure Spark Plug Required
Voltage
Specification: 8-20 Kv.
To make this measurement connect
a special service Diagnostic Console
360036 or equivalent high voltage
probe to the coil to distributor high
voltage wire. Momentarily bring
engine to approximately 2000 rpm,
and read the highest spark plug high
voltage requirement for each
cylinder.
1. If the required voltage fails low,
remove the probe from the coil
wire and connect it to each spark
plug wire to determine which
spark plug is low.
NOTE: When measuring required
voltage on individual plug wires,
the minimum specification is
reduced to 6 Kv.
Remove the spark plug from any
cylinder having a required voltage
less than approximately 6 Kv. and/
or significantly lower voltage than
other cylinders during acceleration
and inspect for closed gap, bridged
gap fouled insulator nose, or
cracked ceramic. Repair or replace
as required.
2. If required voltage is more than
approximately 20 Kv. and/or
significantly (50 percent) higher
than other cylinders, use the same
procedure as shown above (1) to
locate the problem cylinder. Check
both the spark plug and the high
voltage spark plug wire. Remove
Engine Diagnosis and Service
PIN NO. 1 PIN NO. 3
ELECTRONIC MODULE CONNECTORS - HARNESS SIDE
FIG. 10 Primary Connections (Dura Spark II)
spark plug and inspect for
excessively worn or burnt
electrodes, or high resistance
between terminal and center
electrodes or high resistance
between terminal and center
electrode. Repair or replace as
required.
E. Spark Plug Wires
Specification: 5K Ohms Per Inch
Max.
To properly inspect the spark plug
wire harness, first remove all wires
from the spark plugs by twisting the
spark plug boot carefully to loosen its
seal on the plug insulator. Remove
the wire by pulling on the plug boot.
Disconnect the wire separators from
the valve covers, and remove the
d i s t r i b u t o r cap from t h e
distributor—leaving the plug wires
connected to the cap. Do not remove
the spark plug wires from the cap
except for replacement. Using an
ohmmeter, check the resistance of
each wire by connecting one motor
lead to the spark plug terminal (use
adaptor if available) and the other
lead to the distributor cap insert.
Replace any wires that are not within
specification. Visually inspect the
spark plug boots for possible damage
due to heat or handling. Replace as
required.
II. Primary (Low Voltage) Portion
Note 1: An accurate volt-ohmmeter is
required.
Note 2: Check power supply voltage.
Repair or replace as required.
29-02-82
PIN NO. 6
A4278-A
A.Dura Spark II (All engines, 49
states; 2.3L engine, California)
1. Disconnect both connectors at the
ignition module and make the tests
at the vehicle harness. If the results
are not what they should be, conduct
the test specified.
2. If the checks listed in Fig. 11 are OK,
substitute a known good module
(grounding of module not required).
a. If the substitution corrects the
malfunction, reconnect the
original module to verify that no
intermittent failure or repair
elsewhere in the system was the
cause. If the problem still
exists, replace the original module.
b. If the substitution module does not
correct the problem, recon nect the
original module.
3. If the engine idles smoothly but
becomes rough when accelerated
(1000-2000 rpm) see Appendix "C".
B.Dura Spark I (All engines, except
2.3L California)
1. Perform Ignition Module Shut-down
Test
a. Verify that module and ignition
coil connectors are securely
attached.
b. Connect the voltmeter across the
primary terminal of the ignition
coil (+ lead on BAT terminal) with
meter set on 10 V DC scale.
c. With ignition switch off, voltmeter
should read "0" Volts.
d. Observe the voltmeter while
turning the ignition swich to the
"ON" position.
29-02-83 Engine Diagnosis and Service 29-02-83

(1) If the indicator of the meter

momentarily deflects upscale
and returns to zero, the ignition
module shut-down circuit is OK. Test Voltage Between Should Be If Not, Conduct*
Continue with the tests. Module Bias Test
KEY ON Pin # 3 and Engine Ground Battery Voltage ±0.1
(2) If the voltage remains between 4 volts
and 12 volts, this may indicate
a faulty shut-down circuit. Pin # 5 and Engine Ground Battery Voltage ±0.1 Battery Source Test
Substitute a known good module volts
and repeat the test. CRANKING P i n # 1 and Engine-Ground 8 to 12 volts Cranking Test
(a) If the shut-down circuit is OK, Jumper#5to#6- More than 6 volts Starting Circuit Test
reconnect the original module Read Coil "Bat" Term. &
to verify that no intermittent Engine Ground**
or repair elsewhere to the Pin#7andPin#8 1/2 volt minimum Distributor Hardware
system caused the test to fail. wiggle Test
If the test still fails, replace the
original module and continue
with the tests.
(b) If the shut-down circuit is not
OK, reconnect the original
module and continue with the Test Resistance Between Should Be If Not, Conduct**
tests.
KEY OFF Pin#7andPin#8 400 to 800 ohms Magnetic Pick-up
(3) If there is no deflection of the
P i n # 6 and Engine Ground Oohms (Stator) Test
indicator, continue with the
Pin # 7 and Engine Ground More than 70,000 ohms
tests. P i n # 8 and Engine Ground More than 70,000 ohms
2. Disconnect both connectors at the
ignition module (Fig. 12) and make Pin#3and Coil Tower 7,000 to 13,000 ohms Coil Test
the tests, given in Fig. 11 at the Pin#5and Coil "Bat" 1.0 to 2.0 ohms
vehicle harness. If the results are not Term. Dura Spark II
what they should be, conduct the test 0.5 to 1.5 ohms
specified. Dura Spark I
3. If the checks listed in Fig. 11 are OK P i n # 5 and Engine Ground More than 4 ohms Short Test
and the ignition module was not Pin#3and Coil "Bat" 0.7 to 1.7 ohms Resistance Wire Test
replaced in the shut-down test, Term. (Except Dura Dura Spark II
substitute a known good module Dura Spark 1)
(grounding of module not required).
*See Appendix " A " for test specified. **Test duration shall be less than 30 seconds (Dura Spark I)
a. If the substitution corrects the
problem, reconnect the original
module to verify that not A4279-A
intermittent or repair elsewhere in
the system was the problem cause. FIG. 11 Diagnosis—Dura Spark I/Dura Spark II
If the problem still exists, replace
IGNITION
the original module. SWITCH

b. If the substitution module does not

correct the problem, reconnect the
original module.
4. If the engine idles smoothly but
becomes rough when accelerated
(1000-2000 rpm), see Appendix "C".
APPENDIX "A"
Tests Specified in Fig. 11
Module Bias Test
Measure the voltage at Pin 3 to engine
ground with the ignition key "ON".
If the voltage observed is less than
PIN NO.5
power source voltage, repair the volt-
age feed wiring to the module for ELECTRONIC MODULE CONNECTORS

running conditions. HARNESS SIDE

Battery Source Test PIN NO. 7

1. Connect the voltmeter leads from PIN NO. 3

the battery terminal at the coil to

engine ground, without dis-
connecting the coil.
2. Install a jumper wire from the
other terminal of the coil connect-
or to a good ground. FIG. 12 Primary Connections-Dura Spark I
29-02-84
3. Turn the lights and accessories off.
4. Turn the ignition switch "ON".
a. If the voltmeter reading is
between:
(1) 4.9 and 7.9 volts (Dura Spark II)
(2) 11.0 and 14.0 volts (Dura Spark
I)
the primary circuit from the
power supply to the coil is
satisfactory.
b. If the voltmeter reading is less
than:
(1) 4.9 volts (Dura Spark II)
(2) 11.0 volts (Dura Spark I)
check the primary wiring for
worn insulation, broken strands,
and loose or corroded terminals.
Repair a n d / o r replace as
required. Also check the
resistance wiring for defects
(Breakerless and Dura Spark II).
Repair and/or replace as
required.
c. If the voltmeter reading is greater
than 7.9 volts (Breakerless and
Dura Spark II), the resistance wire
should be replaced.
Cranking Test
Measure the voltage at Pin 1 to engine
ground with the engine cranking. If the
voltage observed is not 8 to 12 volts,
repair the voltage feed to the module for
starting conditions.
Starting Circuit Test
If the reading is not more than 6 volts,
the ignition by-pass circuit is open or
grounded from either the starter solenoid
or the ignition switch to pin No. 5 or
primary connections at the coil. Repair
or replace as required.
Distributor Hardware Test
1. Disconnect three-wire weatherproof
connector at distributor pigtail.
2. Connect a D.C. voltmeter on 2.5 volt
scale to two parallel blades. With the
engine cranking, the meter needle
should oscillate.
3. Remove distributor cap and check
visually for damage or misassembly.
Repair and/or replace as required.
a. Sintered iron armature (6 or 8
toothed wheel) must be tight on
sleeve, and the roll pin aligning
armature to sleeve must be in
position.
b. Sintered iron stator must not be
broken.
c. Armature must rotate when engine
is cranked.
4. If the hardware is OK, but the meter
doesn't oscillate, replace the
magnetic pick-up assembly.
Magnetic Pick-up Test
1. Disconnect three-wire weatherproof
connector at distributor pigtail.
2. Resistance of pickup coil measured
between two parallel blades in the
Engine Diagnosis and Service
distributor connector must be 400-
800 ohms.
3. Resistance between the third blade
(ground) and the distributor bowl
must be zero ohms.
4. Resistance between either parallel
blade and engine ground must be
greater than 70,000 ohms.
5. If any test fails, the distributor stator
assembly must be replaced.
6. If above readings are not the same as
measured in the original test, check
for defective harness. Repair and/or
replace as required.
7. If the above checks OK, the signal
generator portion of the distributor
is OK.
Ignition Coil Test
The ignition coil must be diagnosed
separately from the rest of the ignition
system.
1. Primary resistance must be:
a. 1.0-2.0 ohms (Dura Spark II)
b. 0.5-1.5 ohms (Dura Spark I)
2. Secondary resistance must be 7,000-
13,000 ohms.
3. If the coil is still suspected, bench
test on coil tesier by following the
manufacturer's instructions, for a
standard coil. Repair and/or replace
as required.
If reading differs from original test,
check for worn or damaged har-
ness. Repair and/or replace as
required.
Short Test
If the resistance from Pin No. 5 to engine
ground is less than 4 ohms, check for
short to ground at the terminals of the
ignition coil or in the primary wiring to
the coil. Repair as required.
CORRECT POSITION
FIG. 13 Checking Initial Timing Firing Point
29-02-84
Resistance Wire Test (Breakerless and
Dura Spark II)
If the resistance between Pin No. 3 and
coil "bat" term is not to specification,
replace the resistance wire.
Appendix "C"
(All Ignition System)
An engine that idles smoothly but
becomes rough when accelerated (1000-
2000 rpm) can indicate crossed orange
and purple primary ignition wires in the
engine harness between the distributor
and the module. When this condition
exists, the initial timing marks can be
properly aligned but the distributor will
be as much as 22 degrees from its normal
position.
1. With the ignition key off, rotate the
engine to initial timing mark firing
point.
2. Remove the distributor cap.
a. If one of the "spokes" of the
armature is opposite the pole of the
stator (Magnetic pick-up coil), the
ignition primary circuit is OK. See
Fig. 13.
b. If the stator pole is between two
"spokes", the primary wires are
probably crossed. If the condition
shown in figure 13 :.s seen,
proceed to Step 3.
3. Visually check the color continuity
of both the orange and purple wires
through the distributor to engine
harness connector (A) and through
the module to engine harness
connector (B) before separating the
connectors. (Fig. 10 or 12).
INCORRECT POSITION
A4281-A
29-02-85
4. Disconnect the two connectors and
check continuity of both the orange
and the purple wires through the
engine harness.
a. If color and electrical continuity in
3 and 4 are good, the problem is
not in the orange and purple wire
harness. Substitute the distributor
stator assembly and/or the
ignition module with known good
components to check for crossed
wires in these components.
b. If not, cut open the engine harness,
cut, cross, splice, solder and tape
wires corresponding to the orange
and purple wires of the distributor
and retape the harness.
5. Return the distributor to the normal
position and/or reset initial timing
per SSD-15, Step A, if required, and
verify effectiveness of fix.
SSD-15—IGNITION TIMING
Application: All Engines
If for any reason any "Dura Spark" two-
piece distributor cap (cap and adaptor)
must be removed, the top portion of the
cap must be removed first, followed by
the rotor and then the bottom portion of
the cap.
If for any reason any "Dura Spark" high
tension wire is disconnected, the interior
of the terminal boot must be greased with
silicone grease D7AE-19A331-AA or
equivalent before reconnection. This
should be performed by applying a thin
layer of the silicone grease (using a clean
small screwdriver) to the boot interior
from the terminal to the end of the boot.
A. Basic Timing
1. Clean the surface of the front damper
and place a white mark on the proper
degree line on the damper and
pointer according to specification.
2. Disconnect the vacuum line(s) at the
distributor and plug.
3. Step not used for 1977.
4. Connect an appropriate high energy
timing light to the No. 1 spark plug
wire.
CAUTION: For the "Dura Spark IM
ignition system, only clamp-on type
timing devices, which have an
inductive pickup, may be used.
5. Connect a tach-dwell meter. Start
the engine and warm up. Set
timing idle speed to specification.
CAUTION: For the "Dura Spark I"
ignition system be sure to use a
tachometer rated for this type of
ignition system.
6. Check engine initial timing. If within
± 2 degrees of the specification, do
not reset.
7. If more than ± 2 degrees, loosen the
distributor hold-down bolt and
Engine Diagnosis and Service
adjust initial timing to specification
by rotating the distributor against
rotor rotation to advance the timing,
or with rotor rotation to retard the
timing. When the white mark (Step
1) is directly in line with the pointer,
ignition timing is correct. Torque
hold-down bolt. Recheck timing
after hold-down bolt has been
torqued.
B. Centrifugal Advance
1. Check centrifugal advance by
accelerating engine (in neutral) to
2500 rpm. If ignition timing advance
is noted during acceleration, the
centrifugal advance mechanism is
functional. If not, remove distributor
and replace.
C. Total Advance
1. Install a vacuum gauge in the
vacuum line from the carburetor
source to the vacuum advance
diaphragm (outer diaphragm on dual
diaphragm distributors). Increase
engine speed to 2500 rpm to verify
available vacuum. If no vacuum is
available within 60 seconds, vacuum
system is at fault, perform SSD-3. If
a vacuum is available, perform Step
C-2.
2. Install distributor vacuum line
(without spark delay valves) to outer
diaphragm (on dual diaphragm
distributor). Accelerate engine to
2500 rpm. Total advance should now
be greater than in Part " B " if
advance mechanism is functional. If
not, replace vacuum advance
components as required.
D. Vacuum Retard (Dual Diaphragm
Distributor)
1. Install vacuum gauge in vacuum line
from the intake manifold source to
the vacuum retard diaphragm (inner
diaphragm on dual diaphragm
distributors). With the engine at idle
verify available vacuum. If vacuum
is not available, correct vacuum
system as required. If vacuum is
available, perform Step D-2.
2. Remove the vacuum gauge and
reinstall the vacuum line to the
retard diaphragm (inner diaphragm
on dual diaphragm distributors).
Ignition timing should retard. If no
retard is indicated, replace vacuum
retard components as required.
E. Step Not Required For 1977
Vehicles,
SSD-16—FUEL BOWL VENT
CLEARANCE
/. 2150-2V Carburetors
1. Inspect the valve and linkage for
damage, leaks and/or improper
connections.
2. Check for plugged bowl vent tube by
connecting a vacuum source to the
29-02-85
bowl vent tube. If a vacuum is
maintained the tube is plugged.
Clean and repair and/or replace as
required.
3. If necessary, bring engine to normal
operating temperature.
4. Check TSP-off speed (for 2.8L which
does not have a solenoid, check curb
idle speed) to specifications. Adjust
as required.
5. With TSP deenergized (at curb idle
for 2.8L) and vent valve plunger
depressed, measure the clearance
between the vent valve plunger and
the actuating lever.
6. Clearance should be within
specifications. Bend actuating lever
as required to obtain the specified
clearance.
//. 4350 Carburetor (With TSP)
1. Inspect the valve and linkage for
damage, leaks, and/or improper
connections.
2. Check curb idle speed and TSP de-
energizer speed to specifications.
Adjust as required.
3. Set throttle to TSP de-energized
position (with engine off).
4. Adjust clearance between tip of
adjusting screw on bowl vent arm
and tang on the accelerator pump
drive lever to .001" to .003". Then
turn the adjusting screw one full turn
clockwise.
5. Check for movement of bowl vent
when carburetor is at TSP de-
energized. Repair and/or replace as
required.
//. 4350 Carburetor (Without TSP)
1. Inspect the valve and linkage for
damage, leaks, and/or improper
connections.
2. Check curb idle speed and fast idle
speed to specifications. Adjust as
required.
3. Set throttle to "high cam" position
(with engine off).
4. Gauge clearance between top of
adjusting screw on bowl vent arm
and tang on accelerator pump drive
lever.
5. If measured clearance is not within
specification, turn adjusting screw to
obtain required clearance.
6. Check for movement of bowl vent
when carburetor is at curb idle.
Repair and/or replace as required.
Internal Fuel Bowl Vent
Clearance Set and External Vent
Check
2700 Carburetor Internal Vent Setting
1. Inspect the valve and linkage for
damage.
2. Disconnect the bowl vent line at the
carburetor. Check for plugged vent
line by connecting a hand vacuum
pump to the vent line. If a vacuum
29-02-86
is maintained the line is plugged.
Clean, repair and/or replace as
required. With the line already
disconnected at the carburetor,
disconnect the line at the carbon
canister. Check for any liquid
in the line by blowing shop air
through it. Clean, repair and/or
replace as required.
NOTE: If the bowl vent line has
liquid in it, the canister must also be
checked for liquid.
3. If necessary, bring engine to normal
operating temperature.
4. Check idle speed (with TSP
energized or at curb idle for
c a r b u r e t o r s w / o T S P ) to
specifications. Adjust as required.
5. With TSP energized (at curb idle for
carburetors w/o TSP) measure
clearance between accelerator pump
rod and accelerator pump level (Fig.
14).
6. Clearance should be within
specifications. If incorrect, turn
accelerator pump adjusting nut to
obtain specification.
NOTE: Apply a slight downward
pressure on the top of the nylon vent
adjusting nut to take up linkage
clearances when making this
adjustment.
YFA Carburetors
1. Check curb idle rpm to specification
with solenoid activated. Adjust as
required.
2. Stop engine and turn ignition key to
"on" position so that the solenoid is
activated but the engine is not
running.
3. Open throttle so that throttle vent
lever does not touch the fuel bowl
vent rod.
4. Close throttle and measure the travel
of the fuel bowl vent rod at point
"A" from open throttle position
(Step 3 above) to idle position (Step
2 above). Travel of the fuel bowl vent
rod at point "A" should be .020
±.010.
5. If out of specification, bend throttle
vent lever at indentation to obtain
required travel.
SSD-17—VALVE TRAIN
INSPECTION
/. Removal of Rocker Cover
A. Remove air cleaner.
B. Disconnect and remove any hoses,
wires, spark plug leads and
components that would interfere
with the removal of the rocker arm
cover.
C. Remove the rocker arm cover bolts.
D. Remove the rocker arm cover.
Engine Diagnosis qnd Service 29-02-86
CLEARANCE
.010"
A4282-A
FIG. 14 Setting Internal Vent
valve stem oil seals or guide
/ / . Static Valve Train Analysis
mounted oil seals.
Check for damaged and/or severely worn
parts, for correct assembly and assure use 5. Check valve lash—mechanical
tappet applications.
of correct parts, by proceeding as follows,
with the static engine analysis. 6. Check collapsed tappet gap—
A. Rocker Arm A s s e m b l i e s — hydraulic tappet applications.
individually mounted. 7. Check installed spring height.
1. Check for loose mounting stud and H. Overhead Cam Follower Arm and
nut or bolt. Lash Adjuster Assemblies
2. Check for plugged oil feed in 1. Check for broken or severely worn
rocker arm. parts.
B. Rocker Arm Shaft Assemblies I. Camshaft—Overhead Camshaft
1. Check for loose mounting bolt(s). Applications
2. Check for plugged oil feeds. 1. Check for plugged oil feed.
C. Push Rods 2. Check for correct cam lift
1. Check for bent push rods.
D. Valve Spring Assembly—with or
without damper spring
1. Check for broken or damaged
parts.
E. Retainer and Keys—both 2 piece
and 1 piece retainers
1. Check for proper seating of keys
on valve stem and in retainer.
F. Positive Rotator and Keys
1. Check for proper seating of keys
on valve stem and in positive
rotator.
G. Valves and Cylinder Head
1. Check cylinder head gasket for
proper installation. (For 2.8L
engine, make sure there are three
fingers visible on front of left head
and threefingersvisible on rear of
right head.)
2. Check for plugged oil drain back
holes. V1976A
3. Check for worn or damaged valve
tips. FIG. 15 Adjusting Fuel Bowl Vent
4. Check for missing or damaged Valve—YFA IV Carburetor
29-02-87
The above static checks are to be made
on the engine prior to the following
dynamic procedure.
/ / / . Dynamic Valve Train Analysis
CAUTION: DO NOT USE THIS
PROCEDURE FOR OVERHEAD
CAMSHAFT ENGINES.
Start the engine and while running at
idle check for proper operation of all
parts. Check the following items under
firing engine operating conditions:
A. R o c k e r Arm A s s e m b l i e s —
individually mounted
1. Check for plugged oil feed in
rocker arm.
B. Rocker Arm Shaft Assemblies
1. Check for plugged oil feeds.
2. Check for proper overhead valve
train lubrication.
If a condition of insufficient oiling
is suspected, accelerate engine to
1200 ± 100 rpm with transmission
in neutral and engine at normal
operating temperature. Oil should
spurt from rocker arm oil holes
such that valve tips and rocker
arms are well oiled and/or, with
rocker arm cover off, oil splash
may overshoot rocker arm. If
oiling is insufficient for this
condition to occur, check oil
passages for blockage.
C. Push Rods
1. Check for bent push rods.
2. Check for proper rotation of push
rods.
D. Positive Rotator and Keys
1. Check for proper operation of
positive rotator.
E. Valves and Cylinder Head
1. Check for plugged oil drain back
holes.
2. Check for missing or damaged
•valve stem oil seals or guide
mounted oil seals.
IV. Reinstallation of Rocker Cover
A. Remove old gasket from cover.
B. Scrape both the rocker arm cover rail
on the cylinder head and the gasket
flange on the cover to remove all
traces of the old gasket if necessary.
C. Install a new gasket and replace the
cover on the engine.
D. Reinstall the rocker arm cover bolts
and tighten in accordance with
applicable sequence and torque
specification. To avoid interference
with the distributor, it is suggested
that a 1/4 inch drive and 10 mm
universal socket be used to remove or
reinstall the rear rocker arm cover
bolt.
E. Reconnect all hoses, wires, spark
plug leads and components that were
removed in Part I.
Engine Diagnosis and Service
SSD-18—CARBURETOR CLEANING
PROCEDURE
5 2 0 0 Carburetors
This procedure is to be used if
contamination must be removed from the
carburetor.
After cleaning the carburetor, flush the
fuel system and change the fuel filter.
For carburetor disassembly and assembly
refer to Part 24-10 in this Manual.
1. Remove the carburetor from the
vehicle.
2. Remove the following: (Note which
items were removed from Primary
and which from Secondary)
a. Remove the air horn
b. Remove high speed bleeds
c. Remove well tubes
d. Remove main metering jets
e. Remove idle jets
f. Remove limiter cap and idle
adjustment screw (Note number of
turns off seat)
3. Clean the fuel bowl and all of the
items removed in Step 2.
4. Using compressed air, blow out the
following main body channels in the
following order:
a. Primary idle channel from
adjustment screw opening.
b. Primary and secondary idle
channels from idle jet opening.
c. Fuel bowl and primary and
secondary main metering jet
channels.
d. Primary and secondary main well
channels.
5. Using compressed air, dry off the
items removed in Steps 2 b, c, d, e,
and f above.
6. Install new fuel filter.
7. Adjust dry float setting per Part 24-
10.
8. Reassemble the carburetor using a
new air horn gasket.
9. Check and reset as necessary:
a. Choke pulldown
b. Cam set
10. Reinstall carburetor on vehicle.
11. Check all idle speeds and idle fuel
mixture to specification. Adjust as
required.
2150 Carburetor
This procedure is to be used if
contamination must be removed from the
carburetor.
After cleaning the carburetor, flush the
fuel system and change the fuel filter.
For carburetor disassembly and assembly
refer to Part 24-25 of this Manual.
1. Disassemble and clean carburetor in
the following sequence:
a. Remove air horn.
b. Note position on idle limiter caps.
c. Clean fuel bowl. Remove and clean
float, inlet needle and seat, inlet
filter screen.
29-02-87
2. If further cleaning is required,
remove carburetor from vehicle and:
a. Clean fuel bowl. Remove and clean
booster hold down screw, booster
assembly, pump weight, pump
check ball.
b. Remove and clean accelerator
pump cover, pump spring, power
valve cover, power valve, main
metering jets.
3. Using compressed air, dry all parts,
blow out all channels in booster
assembly (if applicable), main body
and air horn.
4. Reassemble carburetor in reverse
order of Steps 1 and/or 2. Use new
gaskets for the following as required:
Enrichment valve
Enrichment valve cover
Booster assembly
Accelerator pump diaphragm
Install new fuel filter.
5. If required, reinstall assembled
carburetor to specification on vehicle
using new gaskets.
6. Check fuel level to specification and
adjust as required.
7. Reinstall air horn to specification
with new gasket.
8. Check all idle speeds and idle fuel
mixture to specification. Adjust as
required.
4350 Carburetors
This procedure is to be used if
contamination must be removed from the
carburetor.
After cleaning the carburetor, flush the
fuel system and change the fuel filter.
For carburetor disassembly and assembly
refer to Part 24-26 of this Manual.
1. Clean carburetor in the following
sequence:
a. Set choke on high cam position
and scribe a line on the air horn
corresponding to the bottom of the
"V" notch on the accelerator
pump lever.
b. Remove external connections, air
horn hold down screws, and air
cleaner stud. Lift air horn
assembly v e r t i c a l l y from
carburetor and place on a flat
surface.
c. Clean fuel bowl.
d. Clean air horn assembly.
e. Remove needle drop limiter and
float assembly. Clean as required.
f. R e m o v e p r i m a r y a n d
supplementary inlet needle and
seat assemblies. Remove fuel inlet
filter and gasket.
2. If further cleaning is required,
remove external connections, remove
carburetor from vehicle and:
a. Separate main body and throttle
body assemblies.
b. Remove and clean accelerator
pump weight and pump check ball.
29-02-88
c. Clean carburetor bodies.
3. Replace fuel inlet assemblies, inlet
filter and gasket with new
components.
4. Set dry float level to specifications
and check supplementary inlet valve
for proper operation.
5. Align scribe line on air horn with
"V" notch and check clearance (see
chart) between needle drop limiter
and primary inlet seat. Adjust as
required by bending the foot on the
limiter.
Limiter-to-Seat
Applicable Description Clearance (Inch)
460 CID/AUitude
Compensator Equipped 0.065
460 CIO/49 States 0.035
CA4283-A
6. Reassemble carburetor on vehicle
using new retainers at choke rod and
pump rod.
7. Manually check operation of air
valve and choke linkage to ascertain
freedom of movement. Repair and/
or replace as required-
8. Make all external connections to
carburetor on vehicle.
9. Check all idle speeds and idle fuel
mixture to specifications. Adjust as
required.
Carter YFA Carburetors
This procedure is to be used if
contamination is to be removed from the
carburetor.
After cleaning the carburetor, flush the
fuel system and change the fuel filter.
For carburetor disassembly and assembly
refer to Part 24-06 of this Manual.
1. Remove carburetor from engine and:
a. Remove air horn.
b. Clean fuel bowl. Remove and clean
float, inlet needle and seat, inlet
filter screen, and blow out inlet
channels with compressed air.
c. Remove and clean idle jet and
pump discharge weight and ball.
d. Remove and clean step-up spring,
metering rod, main metering jet
and pump diaphragm assembly
(Fig. 16).
e. Using compressed air, dry all
parts, blow out all channels, parts,
and fuel bowl.
f. Reassemble carburetor in reverse
order (Steps B, C and D).
g. Adjust dry float setting to
specification and reassemble air
horn with new gasket.
2. Reinstall carburetor on vehicle with
new gasket.
Engine Diagnosis and Service
3. Install new fuel filter.
4. Check all idle speeds and idle fuel
mixture. Adjust as required and
install new limiter at maximum rich
position.
NOTE:
DO NOT REMOVE, ADJUST/
OR TURN METERING ROD
ADJUSTING SCREW DURING
DISASSEMBLY OR ASSEMBLY
OF CARBURETOR.
A4284-A
FIG. 16 Removing Metering Rod
2700 Carburetors
This procedure is to be used if
contamination is to be removed from the
carburetor.
After cleaning the carburetor flush the
fuel system and change the fuel filter.
For carburetor disassembly and
assembly, refer to Part 24-27 of this
Manual.
1. Clean carburetor in the following
sequence:
a. Use compressed air to dry all parts.
2. Remove the carburetor from the
vehicle.
a. Remove air horn assembly.
b. Clean fuel bowl.
c. Remove and clean float assembly.
d. Remove fuel filter (Appendix
"B"), fuel inlet needle and seat.
e. Remove and clean accelerator
pump weight, pump check ball,
and pump channels.
f. Remove the cranking solenoid and
clean passage. See Appendix "A",
for solenoid check procedure.
g. Blow out main well passages in air
horn with 30 psi air pressure.
3. Replace fuel inlet needle and seat
using new components.
4. Replace fuel filter according to
Appendix "B".
5. Install cranking solenoid with a new
lubricated "O" ring to the specified
torque.
6. Set the dry float level to
specification.
7. Assemble carburetor using a new air
horn gasket and new retainers at the
choke and pump rods.
8. Manually check operation of venturi
valve and choke linkage for freedom
of movement. Repair and/or replace
as required.
9. Install carburetor on vehicle making
all necessary external connections.
NOTE: Choke heat tube nut
connector may easily be cross
threaded (use care).
29-02-88
10. Check choke heat system, according
to SSD-12, Section III, Step 17.
11. Check idle speed and idle fuel
m i x t u r e to c o m p l y w i t h
specification. Adjust as required.
Appendix "A" (2700 Carburetor)
If electric cranking enrichment solenoid
fails to click or if checking a new solenoid
(Carburetor removed from vehicle).
1. Remove electric solenoid from the
main body of the carburetor.
2. Apply a lead from the positive
terminal of the vehicle battery to the
cranking enrichment solenoid
connector. Touch the solenoid body
or case to a clean metal surface on
the vehicle to provide a good ground.
Observe if the cranking solenoid
pintle retracts. If it does retract,
proceed with Step 3. If not:
A. Check the battery for required
voltage and its connectors for
continuity.
B. Ensure that the solenoid body or
case has a good ground.
C. If battery and ground are OK,
replace the cranking enrichment
solenoid and make voltage check
on the new one.
3. Apply 5" Hg with a hand vacuum
pump to outlet of cranking sole-
noid and observe for z^;ro leak.
Repeat three times operadng sole-
noid between each check. If OK,
proceed with Step 4. If not OK,
replace solenoid and repeat checks
starting with Step 2.
4. Install solenoid in main body of
carburetor. Use a new " O " ring
(lubricated with a mild soap and
water solution) on the nose of the
solenoid and torque to specification.
5. Remove Air Horn Assembly
A. Plug choke jet.
B. Place 5" Hg vacuum on cranking
channel discharge hole. If no leak
at the solenoid, unplug choke jet
and proceed with Step 6. lif leaking
at the solenoid, check for zhoke jet
blockage. If still leaking, remove
solenoid and check "O" ring for
proper seating. Repeat Step 4.
C. If "O" ring is cut, go back to Step
4. If "O" ring looks OK, then start
from Step 3 and proceed
6. Install air horn on body making all
necessary connections.
Appendix "B"—Fuel Filter
Replacement
1. Remove the air cleaner assembly.
2. Loosen the retaining clamp securing
the fuel filter hose to the fuel filter.
3. Remove the hose and discard the
retaining clamp.
4. Unscrew the fuel filter from the
carburetor.
5. Install a new filter and torque to
specification.
29-02-89 Engine Diagnosis and Service 29-02-89

6. Install a new clamp on the inlet hose
and connect the hose to the new
filter.
7. Position the fuel line hose clamp to
secure the hose to the new fuel filter.
8. Start the engine and inspect for fuel
leaks. Correct as required.
9. Re-install the air cleaner assembly
and t o r q u e wing n u t ( s ) to
specification.
SSD-19—LEAK CHECKS -
CARBURETOR SYSTEMS
/. Veatori Valve System (2700)
Check for vacuum leaks.
1. Remove carburetor from vehicle.
2. Open throttle plate fully.
3. Cover both ports located at the rear
of the choke side throttle bore with
finger.
4. Depress diaphragm shaft fully.
5. Cover rectangular hole on top of
main body with finger.
6. Release diaphragm shaft.
7. Shaft should not move. If it does,
repair and/or replace as required.
//. Cranking Enrichment System (2700)
Check for fuel leaks.
1. Apply 8 inches of vacuum to cold
enrichment jet.
2. Seal off cold enrighment discharge
channel with finger.
3. The 8 inches of vacuum should be
maintained for a minimum of 30
seconds. If it is not, repair and/or
replace as required.

SPECIFICATIONS
VACUUM AMPLIFIER CODING
Part Number
Prafiw A 3nffiv
Code Number Amplification Bias Rating Service Bias
rriTIX 01 oUTTIX on Unit Ratio of Unit of Unit (In. Hg.) Specification
(Basic No. 9E4S1)
.Stamped in "Yellow"
• D52E-B1A,-B2A,-B3A 10-0 10:1 0 0-.5
D52E-A1A.-A2A.-A3A 10-5 10:1 .5 .2-.8
D5TE-A1A,-A2A,-A3A 10-1 10:1 1.0 .7-1.3
D5TE-B1A.-B2A.-B3A 10-15 10:1 1.5 1.2- 1.8
D50E-A1A.-A2A.-A3A 10-2 • 10:1 2.0 1.7-2.3
Stamped in "White"
D5DE-A1A.-A2A.-A3A 14-0 14:1 0 0-.5
D5OE-B1A.-B2A.-B3A 14-1 14:1 1.0 .7-1.3
D5TE-C1A.-C2A.-C3A 14-2 14:1 2.0 1.7-2.3
D5AE-A1A.-A2A.-A3A 14-3 14:1 3.0 2.7 - 3.3
Stamped in "Red"
D5TE-D3A 18-0 18:1 0 0-.5

: The different numerals in the suffix denote alternate vendor sources: " 1 " for Fram, "2" for Marvel Scheblor, " 3 " for Ranco. CA1441-A
29-03-1 Thermactor System 29-03-1

PART
Thermactor System 29-03
SUBJECT PAGE SUBJECT PAGE
GENERAL INFORM ATION GENERAL INFORMATION (Cont'd.
Air Bypass Valve 03-1 Exhaust Check Valve 03-3
Air Supply Pump 03*1 Vannim Fliffprpntial X/nl\/P (VDV) 03-2
Differential Valve Delay Vacuum Vent Valve . 03-2
Valve (DVDV) 03-2
CA4257-A

GENERAL INFORMATION
A 'Thermactor"air injection system
is installed on all vehicles. The
Thermactor Exhaust Control System
(Fig. 1) reduces carbon monoxide and
hydrocarbon content of combustion by-
product gases, by injecting fresh air into
the hot exhaust gas stream as it leaves the
combustion chamber. A pump supplies
air under pressure to the exhaust port
near the exhaust valve, by either an
"external" air manifold, or through
''internal" drilled-passages in the
cylinder head or exhaust manifold. The
oxygen in the fresh air, plus the heat of
the exhaust gases, causes further
oxidation (burning), which converts the
exhaust gases into carbon dioxide and
water.
The air supply pump does not have a
pressure relief valve, this function being
controlled by the air bypass valve (Fig.
3).
AIR BYPASS VALVE
Three air bypass valves are used for
1977, non-catalytic systems and one for
catalytic converter equipped systems
(Figs. 4 and 5).
The timed bypass valve operates as
follows: During normal operation,
vacuum is equalized on both sides of the
diaphragm (Fig. 4). The diaphragm
CHECK VALVE
INLET HOSE -
9B466
return spring holds the valve closed,
allowing thermactor pump air to flow to
the exhaust ports.
During deceleration, the sudden rise
of intake manifold vacuum under the
diaphragm overcomes return spring
pressure and pulls the valve downward.
Thermactor air is then diverted to the
atmosphere momentarily, because
vacuum is quickly equalized again on
both sides of the diaphragm through a
small orifice in the diaphragm.
The normally-closed, timed bypass
valve used with catalytic systems
operates as follows: During normal

The major components (Fig. 1 and 2)

of a typical Thermactor system include:
a. Air supply pump—belt driven from
crankshaft pulley or from
alternator VACUUM
VACUUM HOSE
b. Air bypass valve TO VDV
DIFFERENTIAL
VALVE (VDV) -9E441
c. Vacuum differential valve (VDV)
with some systems
d. Air supply system—external or
internal
e. Cylinder heads with air passages to AIR BYPASS VALVE
exhaust ports BRACKET - 9B466
f. Air supply check valves
g. Vacuum reservoir—some models
AIR BYPASS VALVE
h.Air supply pump muffler— INLET HOSE -
Mustang, with 302 CID V-8 9F287
j. Vacuum Vent Valve (with 2700
Carburetor)

AIR SUPPLY PUMP

The belt driven air pump (Fig. 3) AIR SUPPLY PUMP
takes air in through an impeller-type
centrifugal air filter fan, thus eliminating
the need for a separate air filter. Dust and
dirt particles cannot enter the pump
because these heavier-than-air
contaminants are thrown from the air A4084-C
intake by centrifugal force. FIG. 1 Typical Thermactor System Components
29-03-2 Thermactor System 29-03-2

operation, engine intake manifold

vacuum applied through the VDV holds
the normally-closed valve upward,
allowing thermactor air to flow to the
cylinder head(s) and blocking the vent
port (Fig. 5). When engine intake
manifold rises or drops sharply (such as
during acceleration or deceleration, or
system blockage or failure), the VDV
operates and momentarily cuts off the
vacuum to the bypass valve. The spring
pulls the stem down, seating the valve to
cut off pump air to the exhaust manifold,
and opening the dump valve at the lower
end of the bypass valve to momentarily
divert the pump air to the atmosphere. In
the case of excess pump volume or a
downstream restriction, the excess
pressure will unseat the valve in the lower
portion of the bypass valve and allow a
partial flow of pump air to the A4085-A
atmosphere. At the same time, the valve
in the upper part of the bypass is still FIG. 2 Mustang 302 CID V-8 Thermactor System
unseated, allowing a partial flow of pump
air to the exhaust manifold to meet
system requirements.
A timed air by-pass valve is used with
some thermactor systems (Fig. 6).
This by-pass valve contains an
integral vacuum differential function and
a vacuum vent. A separate VDV is not
required with this valve. When the vent
is blocked, the valve functions as a timed
by-pass valve just as was used in past
years with a VDV. When the vent is open
to atmospheric pressure, however, and a
vacuum of 4" Hg or more is applied to
the source port, the valve goes
immediately to the "dump" mode.
VACUUM DIFFERENTIAL VALVE
(VDV)—CATALYST SYSTEMS
The vacuum differential valve (VDV)
A4086-A
controls the operation of the bypass valve
that doesn't have an integral differential FIG. 3 Thermactor Air Supply Pump
valve (Fig. 7). once again closes the dump valve and 2700 variable venturi carburetor require
The VDV is inserted in the vacuum applies vacuum to the bypass valve, vacuum venturi valves (Fig. 9). The
control line to the bypass valve and serves which again directs pump air to the primary function of the new valve is to
to cut off the vacuum and de-energize the exhaust ports. isolate a portion of the vacuum system in
bypass valve. The differential valve such a way as to prevent the migration
consists of a diaphragm connected to a DIFFERENTIAL VALVE DELAY of fuel from the carburetor to the air
dump valve that controls the vacuum to VALVE(DVDV) bypass valve.
the bypass valve. During normal This delay valve is used to delay air
operation, vacuum is equalized on both bypass during periods of low engine The thermactor vacuum vent valve
sides of the diaphragm and the spring manifold vacuum. The D V D V is (Fig. 10) stops fuel from entering the
holds the dump valve closed. When installed in series with the VDV (Fig. 8). retard delay valve, vacuum reservoir, and
sudden higher than normal vacuum is the air bypass valve by "dumping*'
This installation of a delay valve in
encountered, such as under deceleration vacuum to atmosphere during idle and
the sense vacuum line delays operation of
conditions, vacuum is higher on the wide open throttle operations.
the vacuum differential valve during
dump valve side of the diaphragm and
sudden drops in manifold vacuum such When vacuum is applied to the vent
the diaphragm operates the dump valve.
as during hard acceleration. During valve diaphragm, the vacuum dump
As the dump valve operates, the vacuum
sudden deceleration, however, the valve closes, the check valve opens and
signal to the bypass valve is diverted
sudden rise in intake manifold vacuum the vacuum reservoir is evacuated and
through the built-in filter system to
opens the check in the delay valve, the air bypass valve diaphragm is
atmosphere. When the vacuum bleeding
passing the signal along instantly. actuated at the same time, any fuel in
through the bypass timing orifice in the
VDV has equalized on both sides of the VACUUM VENT VALVE the vacuum lines ahead of the vent
diaphragm, the diaphragm return spring Some 1977 engines which use the valve and check valve is evacuated.
29-03-3 Thermactor System 29-03-3

When vacuum decreases (idle or wide
open throttle operation) the check valve
closes, the vent valve diaphragm relaxes
and the vacuum dump valve opens. Air
enters the vent valve opening, flows
through the retard delay valve at a
controlled rate, eventually de-activating
the air bypass valve. With this system,
fuel-bearing air from the carburetor port
is not allowed to pass the check valve or
the vent valve.
EXHAUST CHECK VALVE (FIG.
11)
The exhaust gas check valve allows
thermactor air to enter the exhaust port
drillings, but prevents the reverseflowof
exhaust gases in the event of improper
operation of system components. The
valve is located between the bypass valve
and the exhaust port drillings, either
mounted on the external air manifold or
directly on the engine.

BY-PASS TIMING
ORIFICE

BY-PASS TIMING INTAKE MANIFOLD

ORIFICE VACUUM

DIAPHRAGM RETURN
SPRING

AIR PASSAGE
TO
ATMOSPHERE

PARTIAL VACUUM
AIR SILENCING
CHAMBER HIGH VACUUM

THERMACTOR AIR

NORMAL POSITION BY-PASS POSITION \/1837B

FIG. 4 Timed Bypass Valve

29-43-4 Thermactor System 29-03-4

NORMAL OPERATION

MAN I FOLD VACUUM

PULLS DIAPHRAGM UP.
AIR INLET
FROM VALVE IS UNSEATED
THERMACTOR
PUMP

AIR FROM THERMACTOR

PUMP FLOWS FREELY TO
EXHAUST MANIFOLD.
AIR OUTPUT
TO EXHAUST
MANIFOLD

VENT PORT
SEALED OFF
SILENCER AND
VENT OPENINGS

PRESSURE RELIEF OPERATION

DUMP" OPERATION

WHEN VACUUM SIGNAL
3} PARTIAL THERMACTOR
AIR FLOW TO EXHAUST
MANIFOLD TO MEET
VALVE SEATS AND SYSTEM REQUIREMENTS.
BLOCKS THERMACTOR
AIR FLOW TO EXHAUST
MANIFOLD.

VALVE OPENS
TO ALLOW
THERMACTOR
AIR FLOW TO
SPRING PULLS
ATMOSPHERE.
STEM DOWN
PARTIAL THERMACTOR
AIR FLOW TO ATMOSPHERE.

A4087-A

FIG. 5 Bypass V a l v e - Normally Closed

VACUUM VENT

CONNECTS TO VACUUM
SOLENOID OR VACUUM
SWITCH
SENSE VACUUM
"(INT. MAN.)

AIR OUTLET-

• AIR INLET

"RELIEF VALVE

A4175-A

FIG. 6 Timed Air By-Pass Valve With Integral Vacuum Differential Function
29-03-5 Thermactor System 29-03-5

3) DIAPHRAGM RETURN SPRING HOLDS DIAPHRAGM

UPWARD, CLOSING DUMP VALVE CUT-OFF OPERATION

(?) VACUUM EQUALIZED ON BOTH

BYPASS TIMING
ORIFICE
SIDES OF DIAPHRAGM, THROUGH
BYPASS TIMING ORIFICE
(4) DIAPHRAGM IS MOMENTARILY
PULLED DOWN.
©3 ) ORIFICE DELAYS INCREASE
ABOVE DIAPHRAGM.

2 ) VACUUM
INCREASES
B6LOW
DIAPHRAGM

©4 ) BYPASS
VACUUM TO
VALVE
1 THIGHER THAN NORMAL
VACUUM FROM SOLENOID
®5) VACUUM IN BYPASS VALVE
LINE IS DUMPED TO ATMOSPHERE
VACUUM VALVI-: DURING
ENGINE DECELERATION.
VACUUM VALVE DUMP THROUGH FILTER, CAUSING
BYPASS VALVE TO DUMP ( ¥ ) VACUUM DUMP VALVE
THERMACTOR AIR. OPENS MOMENTARILY.
NORMAL OPERATION
A4088-B

FIG. 7 Vacuum Differential Valve (VDV)—Catalyst Systems Only

VACUUM DIFFERENTIAL
VALVE

DELAY
VALVE DUMF'VALVE

FILT-IR
INTAKE MANIFOLD

AIR BY-PASS
VALVE

RESTRICTOR

A4176-A

A4256-A
Fig. 8 Differential Valve Delay Valve
FIG. 9 Thermactor Vacuum Vent
Valve
29-03-6 Thermactor System 29-03-6

TVS ^THERMACTOR VACUUM

/ VENT VALVE

| AIR CLEANER £*] 1

n^—-—VENT
tcARB J i l l L \jr*~^ OPENING
kV V RETARD DELAY
C\ /VALVE
|—ff / RESERVOIR
PORTED ^ / *
VACUUM /
/
CHECK VALVE

AIR BY-PASS 1 j
VALVE k. )

A4257-A

PIG. 10 Typical Vent Valve Installation

CHECK VALVE

A4089-B

FIG. 11 Exhaust Check Valve

29-07-1 Exhaust Gas Recirculation System 29-07-1

PART
Exhaust Gas Recirculation System 29-07
All Models
SUBJECT PAGE SUBJECT PAGE
GENERAL INFORMATION Integral Backpressure Transducer/EGR Valve . . . 07-2
EGR Backpressure Transducer 07-1 Spacer Entry EGR System 07-1
EGR Valve 07-1 Venturi Vacuum Amplifier 07-1

CA4258-A

GENERAL INFORMATION
The Exhaust Gas Recirculation
System (EGR) is designed to re-
introduce small amounts of exhaust gas
into the combustion cycle, thus reducing
the generation of nitrous oxides (NOX).
The amount of exhaust gas re-introduced
and the timing of the cycle are controlled
by various factors such as engine vacuum
and temperature. Typical systems are
shown in Fig. 1.
EGR VALVE
The EGR valve (Fig. 2) is a vacuum-
operated unit that attaches to a spacer
that fits under the carburetor. When the
valve is open, exhaust gas is permitted to
enter the intake manifold passages. When WITH SINGLE CONNECTOR VVA (1974 TYPE)
the valve is closed, internal or external
sealing takes place, preventing the flow RESERVOIR
VACUUM
of exhaust gases into the intake passages.
\

SPACER ENTRY EGR SYSTEM

On this type of system, exhaust gases
are routed to the EGR valve, which is
attached to a spacer mounted between
the carburetor and the intake manifold
(Fig. 3).

VENTURI VACUUM AMPLIFIER

(WA)

The EGR V e n t u r i Vacuum

Amplifiers (Figs. 4 and 5) use a relatively
weak venturi vacuum signal in the throat
of the carburetor to shape a strong intake
manifold vacuum signal to operate the
EGR valve. This makes it possible to
achieve an accurate, repeatable and
almost exact proportion between venturi FIG. 1 Typical EGR System Components
air flow and EGR flow. Thus, it assists
in controlling oxides of nitrogen
emissions with minimal sacrifice in
vehicle driveability. A relief valve is also used to "dump" throttle acceleration, when maximum
The amplifier connects to a vacuum or cancel the output EGR signal power is required from the engine.
reservoir and contains a check valve to whenever the venturi vacuum signal is EGR BACKPRESSURE
maintain adequate vacuum supply equal to, or greater than, the intake TRANSDUCER
regardless of variations in engine manifold vacuum. This allows the EGR Some EGR systems employ a
manifold vacuum. valve to close at or near wide-open Backpressure Transducer connected to
29-07-2 Exhaust Gas Recirculation System 29-07-2

an adapter between the EGR valve and
the intake manifold. The transducer
modulates EGR flow by varying the
EGR valve vacuum signal according to
exhaust backpressure. The exhaust
pressure is sensed in the pressure cavity
of the transducer spacer (Fig. 6).
INTEGRAL BACKPRESSURE
TRANSDUCER/E6R VALVE
For 1977, some EGR systems use a
new Integral Backpressure Transducer/
EGR Valve (Fig. 7).
This valve performs both the
backpressure sensing and EGR metering
functions of the separate units. The new
assembly has an internal exhaust gas
chamber with a transducer diaphragm
which senses exhaust backpressure
through a hollow valve stem. Thus, EGR
flow is constantly metered according to
exhaust backpressure.

POPPET TYPE INTERNAL TAPERED STEM TYPE

_ ^VACUUM
NIPPLE
SPRING
VACUUM NIPPLE

DIAPHRAGM
ANGLE BACKSTOP DIAPHRAGM
STROKE LIMITER
POPPET VALVE
VALVE SEAT

RESTRICTOR ORIFICE '

USE D TO CONTR O L F LOW OUTLET
V1875-C

FIG. 2 Typical EGR Valve

CARBURETOR EGR VALVE

UPPER
GASKE

CARBURETOR
SPACER

EXHAUST GAS
FROM
CROSSOVER
PASSAGE

V2040-B

FIG. 3 Spacer Entry EGR System—Typical

29-07-3 Exhaust Gas Recirculation System 29-07-3

CONNECTOR
ASSEMBLY

O - OUTPUT TO EGR VALVE

R - FROM RESERVOIR
SHEET METAL SCREW
M OR S - MANIFOLD VACUUM
VACUUM RESERVOIR R V - VENTURI VACUUM
A - ATMOSPHERE

V1851-B

FIG. 4 Venturi Vacuum Amplifier—Single Connector Type

AMPLIFIER CODED FOR PORT CONNECTIONS:

O - OUTPUT TO EGR VALVE V - VENTURIVACUUM

R - FROM RESERVOIR A - ATMOSPHERE (VENT)
S - VACUUM SOURCE
(SPARK OR EGR PORT)

MARVELSCHEBLER

V2041-A

FIG. 5 Venturi Vacuum Amplifier—Dual Connector Type

29-07-4 Exhaust Gas Recirculation System 29-07-4

TO EGR VALVE AIR FILTER

EGR VALVE

TO EGR VACUUM
SOURCE VIA EGR
PVS VALVE

EGR TRANSDUCER EXHAUST

ADAPTOR PRESSURE PROBE

EXHAUST GAS TO
EXHAUST GAS INTAKE MANIFOLD
ENTRANCE FROM CROSSOVER

A4178-A

FIG. 6 EGR Valve Exhaust Backpressure Transducer

TRANSDUCER VALVE

EXHAUST GAS TRANSDUCER

CHAMBER ATMOS. VENT

VALVE
DIAPHRAGM

^TRANSDUCER
DIAPHRAGM

1
/ X EGR GAS
OUTLET
ORIFICE EGR GAS BACKPRESSURE
INLET INLET A4259-A

FIG. 7 Typical Integral Backpressure Transducer/EGR Valve

 DECIMAL AND METRIC EQUIVALENTS

Fractions Decimal In. Metric M M Fractions Decimal In. Metric MM.

1/64 .015625 .39688 33/64 .515625 13.09687
1/32 .03125 .79375 17/32 .53125 13.49375
3/64 .046875 1.19062 35/64 .546875 13.89062
1/16 .0625 1.58750 9/16 .5625 14.28750
5/64 .078125 1.98437 36/64 .578125 14.68437
3/32 .09375 2.38125 19/32 .59375 15.08125
7/64 .109375 2.77812 39/64 .609375 15.47812
1/8 .125 3.1750 5/8 .625 15.87500
9/64 .140625 3.57187 41/64 .640625 16.27187
5/32 .15625 3.96875 21/32 .65625 16.66875
11/64 .171875 4.36562 43/64 .671875 17.06562
a/16- .1875 4.76250 11/16 .6875 17.46250
13/64 .203125 5.15937 45/64 .703125 17.85937
7/32 .21875 5.55625 23/32 .71875 18.25625
15/64 .234375 5.95312 47/64 .734375 18.65312
1/4 .250 6.35000 3/4 .750 19.05000
17/64 .265625 6.74687 49/64 .765625 19.44687
9/32 .28125 7.14375 25/32 .78125 19.84375
19/64 .296875 7.54062 51/64 .796875 20.24062
5/16 .3125 7.93750 13/16 .8125 20.63750
21/64 .328125 8.33437 53/64 .828125 21.03437
11/32 .34375 8.73125 27/32 .84375 21.43125
23/64 .359375 9.12812 55/64 .859375 21.82812
3/8 .375 9.52500 7/8 .875 22.22500
25/64 .390625 9.92187 57/64 .890625 22.62187
13/32 .40625 10.31875 29/32 .90625 23.01875
27/64 .421875 10.71562 59/64 .921875 23.41562
7/16 .4375 11.11250 15/16 .9375 23.81250
29/64 .453125 11.50937 61/64 .953125 24.20937
15/32 .46875 11.90625 31/32 .96875 24.60625
31/64 .484375 12.30312 63/64 .984375 25.00312
1/2 .500 12.70000 1 1.00 25.40000
 METRIC-ENGLISH CONVERSION TABLE

to get equivalent to get equivalent

Multiply by number of: Multiply by number of:

LENGTH ACCELERATION
Inch 25.4 millimetres (mm) Foot/sec2 0.304 8 metre/sec2 (m/s2)
Foot 0.304 8 metres (m) Inch/sec2 0.025 4 metre/sec2
Yard 0.914 4 metres
Mile 1.609 kilometres (km) TORQUE
Pound-inch 0.112 98 newton-metres (N-m)
AREA Pound-foot 1.355 8 newton-metres
Inch2 645.2 millimetres^ (mm2)
6.45 centimetres2 (cm2) POWER
Foot2 0.092 9 metres2 (m2) Horsepower 0.746 kilowatts (kW)
Yard2 0.836 1 metres2
PRESSURE OR STRESS
VOLUME Inches of water 0.249 1 kilopascals (kPa)
Inch3 16 387. mm3 Pounds/sq. in. 6.895 kilopascals
16.387 cm3
0.016 4 litres (1) ENERGY OR WORK
Quart 0.946 4 litres BTU 1 055. joules (J)
Gallon 3.785 4 litres Foot-pound 1.355 8 joules
Yard3 0.764 6 metres3 (m3) Kilowatt-hour 3 600 000. joules (J = one W's)
or 3.6x106
MASS
Pound 0.453 6 kilograms (kg) LIGHT
Ton 907.18 kilograms (kg) Foot candle 1.076 4 Iumens/metre2 (Im/m2)
Ton 0.907 tonne (t)
FUEL PERFORMANCE
FORCE Miles/gal 0.425 1 kilometres/litre (km/I)
Kilogram 9.807 newtons(N) Gal/mile 2.352 7 litres/kilometre (I/km)
Ounce 0.278 0 newtons
Pound 4.448 newtons VELOCITY
Miles/hour 1.609 3 kilometres/hr. (km/h)
TEMPERATURE
Degree Fahrenheit (t°F-32)t 1.8 degree Celsius
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