1975-76 Ford Car Shop Manual Volume II Engine

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Group Index
I Identification
If10
I Brakes
12
,~
I Suspension
14
I~
I Clutch and Manual Transmission
1f16
16
Automatic Transmission
IL-.A_u_t_o_m_a_ti_c_T_ra_n_s_m_is_s_io_n
17
1~
Codes
10
1;: :Wheels,
'!v====h==ee==1s==,==T==i
r==e==s,==W====he==e==1==H==u==b==s==a==nd====B==ea==r==i
n==g==s================~1 ~
11
Tires,
Wheel Hubs and Bearings
I~s==te==e==ri
n==g============================================~1~
Steering
13
Vol.
Vol.
I~o==r==i
v==i==ng====A==x==1
e==s==a==n==d==O==r==i
v==e==s==h==a==ft==s=============================1
~
Driving
Axles
and Drive
Shafts
15
1975-76
CAR
SHOP
MANUAL
~===========================================================~
II
II
Vehicle Identification
I
Gasoline Engines
m
m
Ignition System
Fuel System
II
II
II
Exhaust System
Cooling System
Volume II
Engine
Starting System
Emission Controls
[@8i1ti-fi-ca-t-io-n-C-o-d-e-s------'------------1130
30
Identification Codes
31
I~
I Charging System
I~L==i==9==ht==i
l ==g====Sy==s==t==em===========================================1
I32
32
Lighting
System
Vol.
Vol
33
Instruments, Clusters and Controls
11
Wiring Harnesses,
Harnesses, Connectors and Circuit Protection
34
|134
Iiss
I Auxiliary
35
Equipment
~IV==e==n==t==i
Ia==t==in==g==,==H==e==at==in==g==a==n==d==A==i
==ti==o==n1=='n==g============~1136
36
Ventilating,
Heating and Air==r==C==o==n==di
Conditioning
I Speed Control and Sure-Track Brake System
37
1137
1~I==d==e==nt==if==i
c==a==ti==o==n==C==o==d==e==s======================================1140
Identification
Codes
40
41
[~
I Seats
I!=~====i
n==d==o==w==G===1
a==ss===a==nd===M==e==C==h==a==ni==s==m==s=======================1142
Window
Glass
and Mechanisms
42
V I
Vol
a
.,.
Ford Parts and Service Division
Training and Publications Department
VOl.
vol
Stationary Window Glass
I Doors, Hood, Luggage Compartment Door & Tailgate
43
43
1[44
44
11
45
I Interior Trim
1145
~=============================================================:
I Tops and Exterior Finishes
1146
46
~============================================================:
Shell, Exterior Trim,
Trim, Frame &
& Underbody
I Body Shell,
1147
47
I~M==a==i==nt==e==n
a==n==c==e==a==n==d==L==u==br==i
c==a==ti==on====.============================:=:1150
Maintenance
and Lubrication,
50
First Printing-September,
PrintingSeptember, 1975
igan
Ford Motor Company, Dearborn,
Dearborn, Mich
Michigan
DAVE GRAHAM AUTO LITERATURE, INC.
2009 ALL RIGHTS RESERVED
FORWORD
The Ford Shop Manuals consist of five Volumes: 1 - Chassis, 2

- Engine, 3
- Electrical, 4 -
Body, and 5 - Pre-delivery, Maintenance and Lubrication. These Volumes provide Service
Technicians with complete information covering normal serice repairs on all 1975 and 1976 model
vehicles built by the Ford Motor Companies in the U.S. and Canada.
NOTE: The Information In this manual applies to both 1975 and 1976 model year vehicles
unless otherwise specified.
Information in each Volume is divided into Groups, each covering a general system (Group 41
41
Seats). For easy reference, each Group is broken into smaller segments called Parts (Part 41-50
41-50
Seat and Shoulder Belts). There is one Part for each component within each system, plus a general
service Part for information common to several similar components. Page numbers are consecutive
within each Part (41-50-1, -2, -3).
The table of contents on the first page of
of each Volume indicates the Groups contained in that
Volume, and a tab locator is provided for locating each Group. The first page of
of each Group has a
Part Index, and each Part has a page index for locating individual service operations.
The descriptions and specifications contained in this manual were in effect
effect at the time the 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.
e.
BACK TO GROUP INDEX
Ford Parts and Service Division

Training and Publications Department

20-00-1
20-00-1
GROUP
20
PART 20-01 Vehi cl e Identification
model year vehicles unless otherNOTE: The information in this Part applies to both 1975 and 1976 Illodel
CR1966-A
wise specified.
GENERAL DESCRIPTION
OFFICIAL VEHICLE
IDENTIFICATION NUMBER
The official Vehicle Identification

Number (VIN) (Fig. 1)
I) 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
I) is affixed on the
(V.C. Label) (Fig. 1)
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.
V.c. label also contains the
Vehicle Identification Number. This
number is also used for warranty
identification of the vehicle. The first
BACK TO GROUP INDEX
number indicates the model year. The

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:
IOO,OOl-Ford, Torino, Elite,
100,001-Ford,
Mustang, Thunderbird, Granada,
Maverick, and Pinto.
500,OOI-Mercury,
500,00 I-Mercury, Meteor,
Montego, Cougar, Comet, Monarch and
Mercury Bobcat.
800,OOl-Lincoln Continental and
800,001-Lincoln
Continental Mark IV.
The remaining information on the
V.C.
V.c. Label consists of the following
vehicle identification codes:
The BODY code is two numerals and

a letter identifying the body style.
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 twoletter 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
20-01-2
Car Identification Codes
r6S63H100001r
<y~6S63H 1 0 0 0 0 1 ^
(VEHICLE
DENTIF ICATION NUMBER)
(VEHICLE IIDENTIFICATION
NUMBER)
MFD.
MFD. BY FORD MOTOR CO~
CO. IN U.S.A.
U.S.A.
DATE:
GVWR 5892
DATE: 07/75
5892
GAWR:
GAWR: FRONT 2964, REAR 2928
2928
DATE: 07/75
GAWR: FRONT 2964
3H100001
6S63HI00002
6S63H100002
14
~13
PASSENGER^
PASSENGER.
I
TYPE
TYPE
Tffi~:~r @
6)(7)(8)
( 99 )
10
(10
11
(UNITED STATES)
2j
BODY SERIAL CODE

CODE
BODY
0
CD
T)
MODEL YEAR
YEAR CODE
CODE
MODEL
( j o ) TRANSMISSION CODE
@
G)
T )
o
o
CD
CD
CONSECUTIVE
CONSECUTIVE UNIT NO.
NO. ( T ) VINYL ROOF
ROOF TYPE/COLOR
($}
PASSENGER
VEH. )DENT. NO.

II TYPE
TYPE
VEH.IDENT.NO.
BODY | COLOR | TRIM | TRANS. | AXLE
AXLE | DSO
DSO
1C
DA
90
53H
1C
DA
X
2
90
(EXPORT)
MFD.
co.
MFD. BY
BY FORD MOTOR CO.
OF CANADA LTD.
lTD.
THIS VEHICLE CONFORMS TO

ALL APPLICABLE FEDERAL MOTOR
IN
STANDARDS IN
VEHICLE SAFETY STANDARDS
OF
EFFECT ON THE DATE OF
MANUFACTURE SHOWN ABOVE
TRIM CODE
TRIM
T)
ASSEMBLY PLANT CODE

CODE
T )
BODY TYPE
TYPE CODE
CODE
BODY
J )
ENGINE CODE
CODE
ENGINE
J5) VEHICLE
VEHICLE TYPE
TYPE
@
BODY COLOR CODE
l)
GVWR 5892
REAR 2928
MANUFACTURED FOR
THIS VEHICLE MANUFACTURED
EXPORT ONLY ON DATE
SHOWN ABOVE.
THIS VEHICLE CONFORMS TO ALL

APPLICABLE FEDERAL MOTOR
VEHICLE SAFETY STANDARDS IN
IN
EFFECT ON
ON THE
THE DATE OF
OF MANUFACTURE SHOWN ABOVE.
F0033/R0155
FOO33/RO155. liENT. NO.
MFD.
IN U.S.A.
MFD. BY
BY FORD MOTOR CO. IN
VEH. IDENT. NO. I|
TYPE
BODY I COLOR I TRIM I TRANS. I AXLE I DSO
( j j ) REAR AXLE CODE
MADE IN CANADA
(CANADA)
\2)() DISTRICT
DISTRICT - SPECIAL
SPECIAL EQUIPMENT
EQUIPMENT
U)
ACCESSORY RESERVE LOAD
Y1410-H
FIG. 1 Vehicle Identification and

and Certification Labels-1976
Labels1976 Shown, 1975
1975 Similar
FIG.
BACK TO GROUP INDEX

20-01-3
1975 IDENTIFICATION CODES
DISTRICT
DISTRICT CODES
CODES
FORD
DISTRICT CODES
CODES
DISTRICT
ASSEMBLY PLANT
PLANT CODES
ASSEMBLY
LINCOLN-MERCURY
LINCOLN-MERCURY
Code Letter
Code
A
A
B
B
E
E
F
G
G
H
H
J
K
K
P
P
R
R
S
T
T
U
U
W
W
X
X
Y
Y
Z
Z
Atlanta
(Canada)
Oakville (Canada)
Mahwah
Mahwah
Dearborn
Dearb
orn
Chicago
Ch
icaqo
Lorain
Lorain
Los Angeles
Los
City
Kansas City
Cities
Twin Cities
San Jose
San
(Pilot)
Allen Park (Pilot)
Metuchen
Metuchen
Louisville
Louisville
Wayne
St. Thomas
St.
Wixom
St. Louis
St.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
00
11
11
15
16
17
21
21
22
23
26
31
31
32
33
34
41
41
42
46
51
51
52
53
54
84
90's
District
.............
.................
.................
.0
.................
.................
.................
_0
. ................
. ................
.................
.................
0.
.................
Special
Boston
New York
New
Philadelphia
Philadelphia
Washington
Atlanta
Dallas
Jacksonville
Memphis
Buffalo
Buffalo
Cincinnati
Cincinnati
Cleveland
Detroit
Detroit
Chicago
St. Louis
St.
Twin Cities
Denver
Los Angeles
Los
Oakland
Seattle
Home Office Reserve
Export
Export
ENGINE CODES
No. of
Cyls.
Codes
A
C
F .
H
L
S
T
Y
Z
8
8
.. 8
8
6
8
.
20-01-3
6
. 44
6
Displacement
OF CANADA
CANADA
FORD OF
460-4V
460-4V (Police)
302-2V
351-2V
250-1
V
250-1V
400-2V
200-1V
200-1
V
139-2V (2.3L)
169-2V (2.8L)
Mercury
Code
Region
A1
A1
A2
A3
A4
A6
A7
12
Central
Eastern
Atlantic
Atlantic
Midwestern
Western
Pacific
Export
Export
Type
Codes
MANUAL
MANUAL
Speed
. * 33 Speed
5
6
V
V
W
W
X
X
Y
Y
U
U
Z
Z
.
.
.
.
.
.
* 4 Speed
4 Speed @
@
AUTOMATIC
AUTOMATIC
XP
(C-3)
XP(C-3)
XP
(C-4)
XP(C-4)
FMX
FMX
FMX
b
FMX b
XPL
(C-6)
XPL(C-6)
XPL
XPL (Special)
(Special)
REAR AXLE
A X L E RATIO CODES
CODES
Conventional
Lock
Ratio
2
7
6
9
G
5
3
2.75
3.40
3.00
3.25
3.55
3.07
2.79
R
X
@
Borg-Warner (R.A.D.)
@Borg-Warner
(R.A.D.
BACK TO GROUP INDEX
.
.
.
.
.
.
.
B1
B1
B2
B2
B3
B3
B4
B4
B6
B6
B7
B7
12
12
District
no
00
Special
Boston
Buffalo
New York
Pittsburgh
Pittsb
urgh
Newark
Philadelphia
Washington
Atlanta
Charlotte
Memphis
Jacksonville
Richmond
New 0Orleans
rleans
Louisville
Chicago
Cleveland
Milwaukee
Lansing
Indianapolis
Ci
ncinnati
Cincinnati
Detroit
Dallas
Kansas City
Omaha
St. Louis
Davenport
Houston
Twin Cities
Los Angeles
San Jose
Salt Lake City
Seattle
Phoenix
Denver
Government
Government
Home Office Reserve
Red Cross
American Red
Recreational Vehicle Pool
Company
Body Co
mpany
Transportation Services
Export
11
n
12
12
13
13
14
15
16
17
21
21
22
23
24
24
25
26
28
41
41
42
43
45
45
46
47
48
48
52
53
54
55
56
57
58
71
71
72
72
73
74
75
76
83
83
84
84
85
86
86
87
89
90's
EXTERIOR PAINT
PAINT COLOR
COLOR CODES
CODES
EXTERIOR
TRANSMISSION CODES
CODES
TRANSMISSION
Ford
Code
Code
F.O.G.(WT)
* F.O.G.
(WT)
M-32J
Number
Code
1C
1C
1G
1G
1H
1H
2B
2E
2M
2Q
20
3E
3E
3G
3G
3Q
4V
4Z
46
47
5M
5M
5Q
50
5T
5Y
5W
5W
6D
60
6E
6E
6N
6N
6Q
9D
90
.....
.... .
.....
.... .
.... .
.0
.... .
.... ..
.... .
....
.....
.
.....
..
.....
.... .
.....
......
....
.....
.....
'"
.0
....
1724-A
5299-A
5363-A
3560-A
2008-A
3413-A
5433-A
5097-A
5094-A
5364-A
5233-A
5125-A
5328-A
5404-A
5144-A
5247-A
5145-A
5365-A
5296-A
3341-A
5080-A
5029-A
5133-A
5418-A
. ....
.. .
.. .
..
.. .
..
.. .
..
.. .
..
. ...
"
.. .
"
. ....
. ....
. ....
. ....
.. .
...
.. .
...
.. ....
. ....
. ....
.. .
..
.. .
..
.. .
...
. ....
. ...
.. .
...
.. .
...
M-32J
Number
Color
Code
Black
Black
Silver Met.
Met.
Med.
Met.
Med. Slate Blue Met.
Brt. Red
Red
Red
Red
Dk. Red
Red
Ok.
Maroon Met.
Met.
Brt.
Met.
Brt. Blue Met.
Brt.
k. Blue Met.
Met.
Brt. 0
Dk.
Pastel
Pastel Blue
Blue
Dk. Yellow Green Met.
Ok.
Met.
Lt.
Met.
Lt. Green Gold Met.
Ok.
Met.
Dk. Jade Met.
Lt. Green
Green
Lt.
Med. Chestnut Met.
Med.
Met.
Ok.
Met.
Dk. Brown Met.
Saddle Bronze Met.
Met.
(RPO) UNIQUE COLORS (NON POLISH)

POLISH)
Dk. Copper Met.

Met.
Ok.
Orange
Orange
Yellow
Brt. Yellow
Brt.
Maize Yellow
Dk. Gold
Gold Met.
Met.
Ok.
White
White
3K
3M
3M
4T
5J
5J
5U
5U
. ....
....
.......
. ...
.....
. ...
. ...
. ....
. . . ..
.....
5210-A
5213-A
5211-A
5071-A
5298-A
Color
. ...
.
.. ..
.. ..
.
.
.. ..
. ...
Brt. Blue Met.

Met.
Silver Blue Met.
Met.
Med. Ivy
Met.
Ivy Bronze Met.
Dk. Ginger Met.
Ok.
Met.
Tan Met.
(RPO) UNIQUE
COLORS (POLISH)
UNIQUECOLORS
2G
2G
6G
6G
. ....
....
....
. ....
5070-A . ... Med. Red Met.

5086 ...
Brt. Gold Yellow Met.
Met.
. ..
(RPO) DIAMOND FLARE (POLISH)

UJ
1
2P
2P
3P
3P
3R
41
41
45
51
51
52
54
. .. .. ....
.
......
....
. ....
....
. ....
....
......
....
..
..0. .....
. ....
....
....
. ....
. ....
.0
5411-A
5397-A
5401-A
5303-A
5412-A
5410-A
5395-A
5302-A
5409-A
.. ...
Silver Met.
Met.
Med~
Met.
Med. Taupe Met.
. ...
. ...
. ...
. ...
.. ...
. ...
. ...
Silver Blue Met.

Met.
Brt. Lime Gold Met.
Met.
Aqua Blue Met.
Met.
Ginger Bronze Met.
Met.
Copper Met.
Met.
Unique Gold Met.
Met.
. ...
Med.
Met.
Med. Blue
Blue Met.
CY1411-H

BODY SERIAL
SERIAL AND STYLE
STYLE CODES
CODES
IODY
Body
Body lody
lody
Type
Style Body Type
Sfriil Styl.
Vefcidt
Slrill
V.icl.
Code
Code Cod.
Cod.
ELITE
ELITE
21
21
TORINO/
RANCHERO
RANCHERO
25
25
27
27
65M
65M
Model
2-Dr. Hardtop
Hardtop
2-or.
Vehicle
Body Body
Type
Style Body Type
Serial Style
Serill
Code Code
Code
MERCURY
MERCURY
49
49
53B
53B
4-Dr. Pillar
Pillar H'lfdtop
Hardtop
4or.
51
51
65B
65 B
2-Dr. Hardtop
Hardtop
2-or.
50
50
53B
53B
4-Dr. Pillar
Pillar Hardtop
Hardtop
4-or.
52
52
65B
65 B
2-Dr. Hardtop
Hardtop
2-or.
Montcalm
Montcalm
(Meteor)
(Meteor)
Gran
Gran MarquIs
Marquis
Torino
TOrino
65B
65B
2-Dr. Hardtop
Hardtop
2or
53B
53B
4-Dr. Sedan
Sedan Hardtop
Hardtop
4or.
Torino
Gran Torino
30
30
650
650
2-Or. Hardtop
Hardtop
2or.
31
31
53D
530
4-Dr Sedan
Sedan Hardtop
Hardtop
4or.
32
32
65 K
65K
2-Dr. Hardtop
Hardtop
2or.
33
33
53K
53K
4-Dr. Sedan Hardtop

Hardtop
4-or.
Brougham
Gran Torino Brougham
60
60
53L
53L
4-Dr. Pillar
Pillar Hardtop
Hardtop
4-or.
61
61
65L
65L
2-Dr. Hardtop
Hardtop
2or.
62
62
53K
53K
4-Dr. Pillar
Pillar Hardtop
Hardtop
4or.
64
64
65K
2-or.
2-Dr. Hardtop
Hardtop
38
38
65R
65R
2-Dr. Hardtop
Hardtop
2or.
Sport
Gran Torino Sport
63
63
53H
53H
4-or.
4-Dr. Pillar Hardtop
Hardtop
71B
71B
Torino
Station Wagon <2)

@
StatIOn
66
66
65H
65H
2or.
2-Dr. Hardtop
Hardtop
Rideau
500
Rideau500
(Meteor)
(Meteor)
Marquis
Marquis Brougham
Brougham
Marquis
42
42
710
710
Torino
Gran Torino
70
70
71B
71B
4-Dr. Wagon
W a g o n0
4or.
Rideau
Rideau 50U(Meteor)
500(Meteor)
43
43
47
47
71 K
71K
Torino SQUIre
Squire
Gran TorinO
71
71
71B
71B
4-Dr. Wagon
W a g o n0
4or.
Montcalm (Meteor)
(Meteor)
970
Ranchero 500
500
74
74
71H
71H
4-Dr. Wagon
W a g o n0
4-or.
48
48
97R
97R
Ranchero GT
GT
76
76
71K
4-Dr. Wagon
W a g o n0
4or.
Marquis
Marquis
^
MarquIs
Marquis Brougham
Brougham
Standard
Ranchero
49
49
97K
Ranchero SQutre
Squire
30
30
54 B
54B
4-Dr. Sedan
4or.
31
31
93
93
62B
62B
65F
65F
2-Dr. Sedan
S e d a nCD
2or.
COUGAR
FORD
FORO
52
52
60 D
600
2-Dr. Pillar Hardt

H a r dop
t o p~ Custom 500
500
2or.
53
53
53D
530
4-Dr. Pillar Hardtop@)

Hardtop
4or.
62
62
60H
60 H
53H
53H
2-or.
Hardtop
53L

Hardtop
4or.
Hardtop
2-0r.
66
66
60 L
60L
53K
68
68
60 K
60K

Hardtop
2-0r.
72
72
71D
710
4-Dr. Wagon
W a g o n0
4-or.
63
63
64
64
65
65
MONARCH
34
34
54H
54 H
4-or.
4-Dr. Sedan
35
35
66 H
66H
2-Dr. Sedan
2-or.
37
37
54K
54 K
4-or.
4-Dr. Sedan
38
38
66K
2-or.
2-Dr. Sedan
MERCURY
20
20
64H
64 H
3-or.
3-Dr. Runahout
Runabout
BOBCAT
22
22
73H
73H
2-or.
2-Dr. Villager
Villager
BOBCAT
23
23
62B
2-Dr. Sedan
@
Sedan
24
24
64B
64B
3-Dr. Model
@)
Model
25
25
73B
2-or.
@)
2-Dr. Wagon
Wagon
02
02
53B
53B
4-or.
4-Dr. Sedan/Hardtop
Sedan/Hardtop
LTD Brougham
Brougham
LTO
03
03
65B
65B
2-or.
2-Dr. Hardtop
Hardtop
04
04
530
53D
4or.
4-Dr. Sedan Hardtop
Hardtop
500 Ranchero
Ranchero
Custom 500
0
07
650
65D
2-or.
2-Dr. Hardtop
Hardtop
Standard
XR-7
Hardtop
2-Dr. Hardtop
LTO
LTD

Hardtop
4or.

Hardtop
4-0r.
Landau
LTD Landau
MONTEGO
Ghia
Montego
Montego MX
74
74
71H
71H
4-Dr. Wagon
4-0r.
LT00
LTD
10
10
53K
4-or.
4-Dr. Sedan Hardtop
Hardtop
Montego
76
76
71 K
71K
4-Dr.
4-or. Wagon
Country
S q u i r e0
Count
ry SQuire
11
11
65KK
65
2-or. Hardtop
2-Dr.
Hardtop
Brougham
81
81
54 H
54H
4-Dr. Sedan
4-or.
Standard
08
710
71D
Montego MX
MX (Metal)
82
82
66H
66H
2-Dr. Sedan
2-0r.
18
18
71K
71 K
Villager (Woodgrain)
(Woodgrain)
Station Wgns.
4-0 r.
Wgns. 4-Dr.
02
60F
2-or.
2-Dr. Sedan
Stllndard
Standard
03
69 F
69F
Mach I1
Standard
83
83
54 K
54K
4-Dr. Sedan
4or.
84
84
81
81
66 K
66K
65A
2-Dr. Sedan
2-or.
2-Dr.
2or. Hardtop
04
60H
CONTINENTAL
CONTINENTAL 82
53A
4-Dr.
Hardtop
4or. Sedan Hllrdtop
05
69RR
69
3-or.
3-Dr. Model
2-or. Sedan
2-Dr.
3-or. Model
3-Dr.
MARK IV
MARK
IV
89
10
62BB
62
2-Dr. Sedan
91
91
650
62A
2-Dr.
Hardtop
2-0r. H,Hdtop
MAVERICK
MAVERiCK
11
11
64BB
64
3-or. Model
3-Dr.
92
54
A
54A
4-Dr.
4or. Sedan
12
12
73B
2-or. Wagon
2-Dr.
93
93
620
620
Sport Sedan
2-or. Sport
2-Dr.
Sedan
THUNDERBIRD 87
THUNDERBIRD
65K
2-or. Hardtop
2-Dr.
LINCOLN
Mod.1
Model
40
40
COMET
GRANADA
GRANADA
20-01-4
Car Identification
Codes
Car
20-01-4
CD Also ""GT"
GT"
Ghla
Ghia
MUSTANG II
PINTO
2-Dr.
2-or. Sedan
Standard
StandiHd
Grabber
Grabber
Also available w/Dual

w/oual Face Rear Seats
o Also Available w/Rear

w/Rear Face Seats
Ghia
@) Canada Only
CY1615B
CY1615-B
V
I N Y L ROOF
VINYL
ROOF TYPE/COLOR
TYPE/COLOR CODE
(FIRST LETTER
LETTER OF CODE = TYPE OF ROOF)
(SECOND LETTER
LETTER OF CODE == COLOR
COLOR OF
OF ROOF)
Code
Vinyl Type
Code
Vinyl Type
Code
Vinyl Color
Code
Vinyl Color
B
B
C
Cross Hatch Full 2-Door

Cross Fratch
f-tatch Halo Style
4-Door
4-Door
Levant
Levant Full
Levant
Levant Half
Half (1/2)
(1/2)
Normande
Norman'de
Odense Full
H
J
Odense Three-Quarter
Three-Quarter (3/4)
(3/4)
Odense Embassy
(Basket
(Basket Handle)
Normandie
Normandie Three-Quarter
(3/4)
Normandie
Normandie Half
Half (1/2)
(1/2)
Odense Half
Half (1/2)
(1/2)
L
A
B
T
K
y
Y
M
G
Aqua
Black
Black
Blue
Brown
Brown
Copper
Copper
Gold
Gold Flare
Green (Light)
R
0
D
Z
Z
P
S
Jade
Red
Red
Saddle
Saddle
Silver
Silver
Silver Blue
Silver
Tan
Taupe
Taupe
White
White
D
0
E
F
G
Example:
DA^^
Exampl,e: Code
Co~DA~
Levant
Bla
Levant
Black
Full
Full
K
L
N
U
u
J
W
w
CY1615Bl
CY1615-B1
BACK TO GROUP INDEX

20-01-5
20-01-5
INTERIOR TRIM
TRIM CODES
CODES
INTERIOR
Code
Trim Scheme
COMET
COMET
(LIB Bench)
Corinth. Vinyl (L/B
KA ............. Black
KB .......... Med. Blue
KG
Lt. Green
KU
Tan
(LIB Bucket)
Corinth. Vinyl (L/B
LB .............. Blue
LA ............. Black
LU ............. Tan
Barletta B/Cloth
B/Cloth and
and
Barletta
Corinth. Vinyl
Vinyl (L/B
(LIB Bench)
Bench)
Corinth.
MA ....... Black
MB ...... Med. Blue
MG ........ Lt. Green
MU . Tan
Corinth. Vinyl (L/B Bucked
Bucket)
PB . . Med. Blue
PU . Tan
MARK IV
MARK
IV
Media Velour
Velour B/Cloth
Media
B/Cloth
(LIB
Split Bench)
Bench)
(L/B Split
AD .. Dk.
Ok. Red
Red
AD
Natural
Grain Leather**
Natural Grain
Leather**
and Mateao
Vinyl (L/B
and
Mateao Vinyl
(L/B
Split Bench)
Bench)
Split
BA
Black
BA ...... Black
BB
Blue
BB .......... Med.
Med. Blue
BO
Red
BD .. Ok.
Dk. Red
BG
Green
BG ....... Green
BK
BK ......... Aqua
Aqua
BN
W/Red*
BN .... W/Red*
BP
BP . . . Silver
Silver
BQ
BQ ......... W/Blue*
W/Blue*
BU
BU ............... Tan
Tan
BW
BW .......... W/Black*
W/Black*
BZ ......... Saddle
B5 ........ W/Green*
B9 . . . . . . . .. W/Saddle*
Natural Grain leather**
Leather**
and Mateao Vinyl (LIB
(L/B
Split Bench)
ON
DN . W/Red*
OU
DU ........ Tan
OZ
DZ Saddle
Kashmir*** BICloth
B/Cloth and
Corinth. Vinyl (LIB
(L/B
Split Bench)
EA .. Black
EB
EB Med.
Med. Blue
ED
ED . Ok.
Dk. Red
Red
EG
EG ....... Green
EU
EU Tan
Tan
Media Velour and
and Corinth.
Corinth.
Vinyl (LIB
(L/B Split Bench)
FK Aqua
*White
White Trim with Color Components.
Components.
BACK TO GROUP INDEX
Code
Code
GB
GO
GD
GG
GU
Trim Scheme
Trim
Majestic BICloth
B/Cloth
...... Med. Blue
....... Dk.
Ok. Red
Green
Tan
COUGAR
(LIB Bucket)
Corinth. Vinyl (L/B
AA ........... Black
AA
AD ......... Dk.
Ok. Red
AG
Green
AN ........... W/Red*
AQ ......... W/Blue*
AS .. . . Med. Silver Blue
AU .............. Tan
AW .......... W/Black*
AZ ...... Saddle/Tan
. . .. W/Green*
WIG reen*
A5
. . ... W/Saddle*
A9
Natural Grain Leather**
and Mateao Vinyl (L/B
Split Bench)
OA ............. Black
DA
DB
Med.
Med. Blue
DO
Ok. Red
DD ........... Dk.
DG ............. Green
ON ........... W/Red*
DN
OQ ........... W/Blue*
DQ
OS .. . . .. Med.
DS
Med. Silver Blue
OU
DU ............... Tan
OW
DW .......... W/Black*
OZ
Saddle/Tan
DZ
05
D5
W/Green*
09 . . . .. W/Saddle*
D9
Verona B/Cloth and Corinth.
Vinyl (LIB
(L/B Split Bench)
EB
Med.
Med. Blue
Dk. Red
ED
Ok.
EG . . . . . . . . . . . .. Green
EG
ES
ES . . . . .. Med.
Med. Silver Blue
EU ............... Tan
EZ
Saddle/Tan
Corinth. Vinyl (L/B
Split Bench)
HA
Black
HB .......... Med.
Med. Blue
HD
Dk. Red
HO
Ok.
HG
HG ............ Green
HN ...... W/Red*
HN
HQ ........ W/Blue*
HS
HS ... Med.
Med. Silver Blue
HU
HU ............... Tan
Tan
HW .......... W/Black*
W/Black*
HZ .... SaddlelTan
Saddle/Tan
H5 . . . W/Green*
H9 . . .. W/Saddle*
Code
Code
Trim Scheme
Scheme
FORD
Barletta B/Cloth
BICloth and
Corinth. Vinyl (L/B
(LIB Bench)
AA
AA
Black
AB
Med. Blue
AG
Green
AU
Tan
Ruffino/Corinth. Vinyl
Ruffino/Corinth.
Vinyl
(L/B Bench)
Bench)
(L/B
BB .. . . . . . . . .. Med.
Med. Blue
Blue
BB
BG
Green
BG
Green
BU
Tan
BU
Tan
BZ ........... Saddle
Saddle
BZ
Summit B/Cloth
B/Cloth and
and Corinth.
Corinth.
Summit
Vinyl
(L/B
Bench)
Vinyl (L/B Bench)
OA
Black
DA
Black
DB.
. . . . . . . . .. Med.
Med. Blue
Blue
DB
DG
Green
DG
Green
OU ........ Tan
Tan
DU
Ruffino/Corinth.
Vinyl
(L/B Bench)
Bench)
(L/B
EB
....
.
.
. . .. Med.
Blue
EB
Med. Blue
EG
Green
EG
Green
EU
Tan
EU
Tan
EZ
Saddle
EZ
Saddle
Ruffino/Corinth.
Vinyl
(LIB
Bench)
(L/B Bench)
FB
Med.
FB
Med. Blue
Blue
FO
Red
FD
Red
FG
Green
FG
Green
FN
W/Red*
FN
W/Red*
FQ
W/Blue*
FQ
W/Blue*
FU
Tan
FU ............... Tan
FW
W/Black*
FW
W/Black*
F5
W/Green*
F9 . . . . . . . . .. W/Saddle*
Westminster B/Cloth and
Corinth. Vinyl (L/B Bench)
GA
Black
Med. Blue
GB
Med.
GG
GG
Green
GU ............... Tan
GU
Niles B/Cloth and
and Corinth.
Corinth.
(L/B Flight Bench)
Vinyl (LIB
HA
Black
Med. Blue
HB
Med.
HD
Dk. Red
Red
HO
Ok.
HG
HG ........... Green
HU ............ Tan
Tan
HU
HZ ......... Saddle
Vinyl
(LIB
(L/B Flight
Flight Bench)
Bench)
JB
JB ....... Med.
Med. Blue
Blue
JO
Ok.
JD
Dk. Red
Red
JG
JG ........... Green
IN
JN ..... W/Red*
Code
Trim Scheme
Scheme
JQ
W/Blue*
JU
Tan
JW
W/Black*
JZ
Saddle
J5
W/Green*
J9
W/Saddle*
Kashmir***
Kashmir*** B/Cloth
B/Cloth and Corinth.
Vinyl (L/B Split Bench)
KB
Med. Blue
KD
Dk.
KO
Ok. Red
KG
Green
KU .............. Tan
KZ
Saddle
Corinth. Vinyl (LIB
(L/B
Split Bench)
MB ........ Med. Blue
MD
Dk.
MO
Ok. Red
MG .......... Green
MU ............ Tan
MZ ........ Saddle
Poly knit and Corinth.
Dynasty Polyknitand
Med. Blue
NB .......... Med.
ND
Dk.
NO
Ok. Red
NG .......... Green
NU ............... Tan
Westminster BICloth'
B/Cloth and
Corinth. Vinyl (LIB
(L/B
Split Bench)
RA
Black
RB
Blue
RD
Red
RO
RG ............ Green
RG
RU
RU
Tan
(L/B Split Bench)
(LIB
SB
SB
Blue
SD
Dk. Red
SO
Ok.
SG
S6
Green
SU
Tan
SU
SZ . .. . . . . .. .
Saddle
Dynasty Polyknit and
Corinth Vinyl (LIB
(L/B Bench)
TB
Blue
TD
Dk. Red
TO
Ok.
TG
Green
TU ............. Tan
Corinth. Vinyl (LIB
(L/B Bench)
UB ...... Blue
UB
UD
Dk. Red
Red
UO
Ok.
UG ...... Green
UG
UU ...... Tan
Tan
UU
LINCOLN
B/Cloth and
and
Kashmir*** BICloth
Corinth. Vinyl (LIB
(L/B Bench)
Corinth.
*-Seating
**Seating Surfaces.
Surfaces. **-100%
***100% Nvlon
Nylon Fabric - Cashmere
Cashmere like appearance.
appearance.
CY1419F
CY1419F

20-01-6
20-01-6
INTERIOR TRIM CODES - Continued

Code
Trim Scheme
BA ............. Black
Med. Blue
BB .......... . Med.
BD .......... .. Ok.
Dk. Red
BO
BG ............ .. Green
BG
BJ
BJ .............. . Taupe
BU ..... Tan
BY .............. Gold
and Mateao Vinyl
(L/B Bench)
OA
DA ......... ..... Black
DB .......... Med.
Med. Blue
OB
DO
DD .. ....... ... Ok.
Dk. Red
DG .............. Green
OG
DJ .............. Taupe
OJ
DN ............ W/Red*
ON
DQ ............. W/Blue*
00
OU
DU ....... Tan
DW .... ....... W/Black*
OW
DY ..... .......... Gold
D3 ........ W/Taupe*
03
D4 ............ W/Tan*
04
WlTan*
D5 ........... . W/Green*
05
D8 ........... W/Gold*
08
and Mateao Vinyl (L/B
Split Bench)
EA ............ .. Black
Med. Blue
EB .......... Med.
Dk. Red
ED .......... .. Ok.
EG ............ .. Green
EJ ... ............ Taupe
EN ............ W/Red*
EO
EQ ............ W/Blue*
EU ... Tan
EW ........... W/Black*
EY ............... Gold
W/Taupe*
E3 ... WlTaune*
E4 ........... . WATan*
WfTan*
E5 ........... W/Green*
E8 ... W/Gold*
Kashmir*** B/Cloth and
Corinth. Vinyl (L/B
Split Bench)
FA .............. Black
FB
Med. Blue
Med.
FD
Dk. Red
Ok.
FG .............. Green
FJ
FJ
Taupe
FU . Tan
Gold
FY
Natunl
and Mateao Vinyl
(LIB
(L/B Bench)
Med. Blue
HB
Med.
HD ........... . Ok.
Dk. Red
HO
HG ............. . Green
HJ ............ .. Taupe
HU ................ Tan
HY . .............. Gold
Media Velour B/Cloth
B/Cloth
(L/B Split Bench)
Med. Blue
JB ....... ..... Med.
JD .. . ......... Ok.
Dk. Red
JO
JG ............. . Green
JJ . .............. Taupe
JR . .............. Jade
JU ........... Tan
JY ...... ......... Gold
and Mateao Vinyl
(L/B Split Bench)
KB ........... Med.
Med. Blue
KO
KD ............. . Ok.
Dk. Red
KG
KG ... .... ........... Green
KJ ............... . Taupe
KR .............. . Jade
KU ............... Tan
KY ............... . Gold
.... .......
............
...............
...............
...........
Whitt Trim with Color Components.

-white
BACK TO GROUP INDEX
Trim Scheme
Code
'
MAVERICK
Randon
Randon Stripe
Stripe B/Cloth
B/Cloth and
and
Corinth.
Vinyl
(L/B
Bench)
BA
BA . ................ Black
Black
BB
BB . ........... Med.
Med. Blue
Blue
Green
BG
BG .............. .. Green
BU
BU ................ Tan
Tan
Tooled/Corinth.
Tooled/Corinth. Vinyl
Vinyl
(L/B
(L/B Bench)
Bench)
HA
.
.............
Black
HA
Black
HB
HB ............ . Med.
Med. Blue
Blue
HG
Green
HG ......... ... Lt.
Lt. Green
HU
HU ............... Tan
Tan
Aurora
Aurora B/Cloth
B/Cloth and
and Corinth.
Corinth.
Vinyl
(L/B Bench)
Vinyl(L/B
Bench)
JA
JA ...... ........ Black
Black
JB
Med.
JB ..........
Med. Blue
Blue
JG
Green
JG ........... . Lt.
Lt. Green
JU
JU ...... Tan
Tan
Corinth.
Corinth. Vinyl
Vinyl (L/B
(L/B Bench)
Bench)
KA
KA . ............. Black
Black
KB . .....
Med.
Med. Blue
KG ........... . Lt. Green
KU .... Tan
Corinth. Vinyl (L/B Bucket)
LA
Black
Med.
Med. Blue
LB
LU .... Tan
(L/B Bucked
Bucket)
Corinth. Vinyl (LIB
Med.
PB
Med. Blue
PB
PU .... Tan
..
.....
.... ..... .....

...... .....
...... .....
"Seating Surfaces.
**Seating
Code
Trim Scheme
Trim Scheme
Code
KA .............. Black
MERCURY
Med. Blue
KB ........... Med.
Barletta B/Cloth and
KD ............ Ok.
Dk. Red
KO
KG .............. Green
AA ............. . Black KG
KN ............ W/Red*
Med. Blue
AB .......... . Med.
KQ ............ W/Blue*
KO
Med. Green
AG ......... . Med.
KU . ............... Tan
AU ................ Tan
KW ........... W/Black*
K5 ........... W/Green*
(L/B Bench)
K9 .......... W/Saddle*
BB ........... . Med.
Med. Blue
BG
BG .......... Med.
Med. Green
Foxton B/Cloth and
BU
BU ................ Tan
BZ ............. Saddle
LA . ............. Black
Valino/Corinth. Vinyl
Blue
LB
(L/B Flight Bench)
LG . ............. Green
EB . ............. Med.
Med. Blue
LU .. ................ Tan
ED ............. Ok.
Dk. Red
EO
EG
EG .............. Green
(L/B Bench)
EU ................ Tan
MB . ................ Blue
EZ ................ Saddle MG . ............ Green
Natural Grain Leather** and
MU ................... Tan
Mateao Vinyl (L/B Split Bench) MZ . .................. Saddle
FA ................. Black Dynasty Polyknit and Corinth.
FB ............ Med.
Med. Blue
FO
FD ................ Ok.
Dk. Red
OB
QB . ............... Blue
FG
FG ................ Green
00
QD . ............. Ok.
Dk. Red
FN ............. W/Red* OG
QG .............. Green
FQ ............. W/Blue*
FO
OU
QU .............. Tan
FU ................. Tan
Kashmir*** BICloth
B/Cloth and
FW ........... W/Black*
Corinth. Vinyl
F5 ........... W/Green*
(L/B Flight Bench)
F9 ........... W/Saddle*
RB . .......... Med.
Med. Blue
Foxton B/Cloth and Corinth.
RD . ........... Ok.
Dk. Red
Vinyl (L/B Bench)
RG
Green
RG . ................ Green
GA .................. Black
RU
RU ................ Tan
GB ............ Med.
Med. Blue
RZ
RZ . ............. Saddle
Saddle
GG
GG .............. Green
Valino/Corinth.
Vinyl
GU ................. Tan
(LIB
(L/B Split
Split Bench)
Bench)
GZ ............. Saddle SA
SA . ............. Black
Black
SB
SB . ........... Med.
Med. Blue
Blue
(L/B Bench)
SO
Red
SD ............ Ok.
Dk. Red
HB ........... Med.
Med. Blue
SG
Green
SG . ................ Green
HO
HD ............. Ok.
Dk. Red
SN
W/Red*
SN . ........... W/Red*
HG ............... Green SO
SQ . ........... W/Blue*
W/Blue*
HU ................ Tan SU
Tan
SU
Tan
HZ ................ Saddle SW
SW . .................. W/Black*
W/Black*
Media Velour B/Cloth Mateao
SZ
SZ . ............ Saddle
Saddle
Vinyl (LIB
(L/B Split Bench)
S5
W/Green*
S5 . ........... W/Green*
JA . .............. Black S9
W/Saddle*
S9 . .......... W/Saddle*
JB
Med. Blue Kashmir***
Med.
Kashmir*** B/Cloth
B/Cloth and
and Corinth.
Corinth.
JO
JD . .............. Red
Vinyl
Vinyl (L/B
(L/B Split
Split Bench)
Bench)
JG .............. Green TA
TA . ............. Black
JU ......... Tan TB
Med.
Blue
TB
Med. Blue
TO
TD ............ Ok.
Dk. Red
Mateao Vinyl (L/B Split Bench) TG
TG .
Green
II
..........
............
...........
.............
***100% Nylon Fabric - Cashmere like appearance.
CY1411-F1
CY1419-F1

20-01-7
20-01-7
INTERIOR TRIM
TRIM CODES -- Continued
INTERIOR
Code
Trim Scheme
................ Tan
Saddle
Dynasty Polyknit
and
Polyknitand
Corinth. Vinyl
(LIB Split
Split Bench)
(L/B
Med. Blue
Blue
UB ... ........ Med.
Ok. Red
UO ........... Dk.
UD
Med. Green
Green
UG .... ...... Med.
UU ............... Tan
(LIB Split
Split Bench)
(L/B
VB ........ ... Med. Blue
Ok. Red
VO .. .......... Dk.
VD
VG ............. Green
Tan
VU ................ Tan
VZ ............. Saddle
Saddle
VZ
Summit B/Cloth
Vinyl (L/B
(LIB Bench)
Bench)
Vinyl
Black
WA ........... ... Black
Blue
WB ... .......... . Blue
WB
Green
WG .. ............ Green
Tan
WU ... ............. Tan
WU
Ruffino/Corinth.
Vinyl
(LIB Bench)
Bench)
(L/B
Blue
YB .............. Blue
YB
Green
YG .. ............ Green
YG
YU ............... Tan
Tan
YU
YZ .. ........... Saddle
YZ
Saddle
MONTEGO
MONTEGO
Barletta
Barletta B/Cloth
B/Cloth and
and
Corinth.
Corinth. Vinyl
Vinyl (LIB
(L/B Bench)
Bench)
AA
AA ... ........... Black
Black
AB
AB .. ... ...... Med.
Med. Blue
Blue
AU
AU ................ Tan
Tan
Tahiti/Corinth.
Tahiti/Corinth. Vinyl
Vinyl
(LIB
(L/B Bench)
Bench)
BA
BA ............. Black
Black
BB
BB .... ....... Med.
Med. Blue
Blue
BU
BU ................ Tan
Tan
Barletta
Barletta B/Cloth
B/Cloth and
and
Corinth.
Corinth. Vinyl
Vinyl
(LIB
(L/B Bench)
Bench)
CA ......... ..... Black
Black
CB
CB ... ........ Med.
Med. Blue
CG
CG .. ............ Green
CU
CU ................ Tan
CZ ............. Saddle
Ruffino/Corinth.
Vinyl
(LIB Bench)
Vinyl(L/B
OA
DA .............. Black
DB
DB .... ....... Med.
Med. Blue
OG
DG ............... Green
Green
DO
DQ .......... .. W/Blue*
OU
DU ............... Tan
Tan
OW
DW ........... W/Brack*
W/Black*
OZ
DZ ........... .. Saddle
05
D5 ...... ..... W/Green*
09
D9 .......... W/Saddle*
TU
TZ
TZ
............
*White
'White Trim with Color Components.
Components.
BACK TO GROUP INDEX
Trim Scheme
Code
Mateao/Corinth. Vinyl
(LIB Split
Split Bench)
(L/B
EB .......... . Med. Blue
EG .. ....... ..... Green
EU ............... Tan
EZ ............. Saddle
B/Cloth and
Kismet B/Cloth
Corinth. Vinyl
(LIB Flight
Flight Bench)
(L/B
GA
Black
GB ......... .. Med. Blue
GG ............. Green
GU ......... ....... Tan
GZ ...... ....... Saddle
(LIB Flight
Flight Bench)
Bench)
(L/B
HA ............. Black
HB ......... .. Med. Blue
HG ............. Green
HQ ........... . W/Blue*
HQ
HU ...... .......... Tan
HW ......... .. W/Black*
HZ ............. Saddle
H5 ............ W/Green*
H9
.......... W/Saddle*
B/Cloth and
Arden Velour B/Cloth
Corinth. Vinyl
(LIB Split Bench)
(L/B
KB .......... Med.
Med. Blue
KG .............. Green
KU ............... Tan
Edinburg B/Cloth and
Corinth. Vinyl
(LIB
(L/B Bench)
LA ............. Black
LB .............. Blue
LZ ............. Saddle
Brockton B/Cloth and
Corinth. Vinyl
(LIB
(L/B Flight Bench)
MA .............. Black
MB ................ Blue
MZ ............. Saddle
Carmel B/Cloth and Corinth.
Vinyl
(L/B Bench)
Vinyl(L/B
NA .............. Black
NB .............. Biue
Blue
NU . ............... Tan
II
Dynasty Poly
knit and
Polyknit
Corinth. Vinyl (LIB
(L/B Bench)
PB
PB . .............. Blue
PG
PG . ............ Green
Green
PU
PU .............. . Tan
Tan
MUSTANG
Corinth. Vinyl (LIB
(L/B Bucket)
AA ............. Black
AB .......... Med.
Med. Blue
AG ............. . Green
Green
AN ...... ...... W/Red*
AN
Code
AQ
AQ
AU
AW
A4
A5
Trim Scheme
.... .... ....
W/Blue*
................ Tan
........... W/Black*
............ W/Tan*
........... W/Green*
Corinth. Vinyl
(LIB Bucket)
(L/B
BA .............. Black
BB .......... Med. Blue
Ok. Red
BD
BO ........... . Dk.
BG ...... ... .. - .. Green
BN ........... . W/Red*
BQ ............ W/Blue*
BU ................ Tan
BW .......... W/Black*
B4 ................... W/Tan*
W/Tan*
B4
B5 ............ W/Green*
Picton B/Cloth
B/Cloth and
and Corinth
Picton
Vinyl (L/B
(LIB Bucket)
Vinyl
Bucket)
Med. Blue
Blue
CB ........... Med.
CB
CD ............ Dk.
Ok. Red
Red
CD
Green
CG .............. Green
CG
CU . ....... "....... Tan
CU
Tan
Westminster B/Cloth
B/Cloth and
and
Westminster
Corinth. Vinyl
Vinyl (L/B
(LIB Bucket)
Corinth.
Bucket)
OA .............. Black
Black
DA
DB ........... Med.
Med. Blue
Blue
DB
DO ........... Dk.
Ok. Red
Red
DD
OG
DG .............. Green
Green
OU
DU ................ Tan
Tan
Corinth.
Corinth. Vinyl
Vinyl (LIB
(L/B Bucket)
Bucket)
EA
EA .............. Black
Black
Media B/Cloth
B/Cloth
(LIB
(L/B Bucket)
Bucket)
FH
FH .......... Cranberry
Picardy B/Cloth and Corinth.
Vinyl
Vinyl (LIB
(L/B Bucket)
Bucket)
GB ............... Blue
GO
GD . ........... Ok.
Dk. Red
GU ................ Tan
PINTO
Dallas/Corinth. Vinyl
(H/B Bucket)
AA .............. Black
AB ............ Med.
Med. Blue
AG . ............. Green
AU ................ Tan
Manston B/Cloth and Corinth.
Vinyl (H/B Bucket)
BA ................ Black
BB
BB ........... Med.
Med. Blue
BC
BC ............. Orange
BG
BG .............. Green
Green
BU
BU . ................. Tan
Tan
Corinth. Vinyl
Vinyl
(H/B Bucket)
CA . ............. Black
CB . .......... Med.
Med. Blue
CB
CG
CG .............. Green
Green
**Seating Surfaces.
Surfaces. ***100% Nylon Fabric - Cashmere like appearance.
appearance.
Trim Scheme
Code
................
CU
CU
Tan
Dynasty
Polyknitand
Dynasty Polyknit
and
Corinth. Vinyl (H/B Bucket)
EB . ......... - .... Blue
EG . ............ Green
EU
Tan
II
Dynasty Poly
Polyknitand
knit and
Corinth. Vinyl (H/B Bucket)
FB .......... " .... Blue
FG ............. Green
FU ............... Tan
THUNDERBIRD
THUNDERBIRD
Picton B/Cloth
Vinyl (L/B
(LIB Split
Split Bench)
FB . .......... Med. Blue
FD . ........... Dk.
Ok. Red
FG .............. Green
FZ . ............ Saddle
Aurora B/Cloth
(LIB Split
Split Bench)
Vinyl (L/B
HA . ............. Black
Med. Blue
HB . .......... Med.
HG . ............. Green
HZ . ............ Saddle
Mateao Vinyl
(LIB Split Bench)
(L/B
. ............. Black
JA
JB . ........... Med.
Med. Blue
Ok. Red
JD . ........... Dk.
JG . ............. Green
IN
JN . ........... W/Red*
JQ
JQ ............... W/Blue*
JU . ......... Saddle/Tan
JW . .......... W/Black*
JZ . .............. Saddle
J5 . ........... W/Green*
J6 . .......... W/Copper*
W/Copper*
J9 ........... W/Saddle*
Mateao Vinyl (LIB
(L/B Split Bench)
KA . ............. Black
Med. Blue
KB . ........... Med.
KC . ............ Apricot
Apricot
KC
KD . ........... Ok.
Dk. Red
KO
KG . ............. Green
KG
KN . ........... W/Red*
KN
KP . ............. Silver
KP
KQ ............ W/Blue*
KO
Saddle/Tan
KU . .......... Saddle/Tan
KW . .......... W/Black*
W/Black*
KW
KZ . ............ Saddle
K5 . ............ W/Green*
W/Copper*
K6 . ........... W/Copper*
K9 . ......... W/Saddle*
K9
and
Media Velour B/Cloth and
Vinyl
Corinth. Vinyl
(LIB
(L/B Split Bench)
MC
Apricot
MC
. .......... Apricot
CY1419-F2
CY1419-F2

20-01-8
20-01-8
Car Identification
Codes
Car
20-01-8
20-01-8
INTERIOR TRIM
TRIM CODES
CODES -- Continued
Continued
INTERIOR
Code
Code
Trim Scheme
Scheme
Trim
TORINO/ELITE/RANCHERO
TORINO/EUTE/RANCHERO
Akron/C'orinth. Vinyl
Akron/Corinth.
(LIB Bench)
Bench)
(L/B
AA
Black
AA
Black
AB .......... Med.
Med. Blue
Blue
AB
AG
Green
AG
Green
AU
Tan
AU
Tan
Barletta B/Cloth
B/Cloth and
and
Barletta
Corinth. Vinyl
Vinyl (L/B
(LIB Bench)
Bench)
Corinth.
BA
Black
BA
Black
BB
Med. Blue
Blue
BG ............. Green
Green
BG
BU
Tan
BU
Tan
(LIB Bench)
(L/B
CA
Black
CB
Med. Blue
CG
Green
CQ
W/Blue*
Tan
CU
Tan
W/Black*
CW
CZ .......... Saddle
C5 .......... ' W/Green*
W/Green*
C9 . . . . . . . . . W/Saddle*
(LIB Bucket)
(L/B
oA
Black
DA
DB
Med. Blue
oQ
W/Blue*
DQ
OU
Tan
DU
Tan
OW
W/Black*
DW
05
D5
W/Green*
09
. . . . . . W/Saddle*
D9
Mateao/Corinth.
Vinyl
(LIB
Bench)
(L/B Flight
Flight Bench)
EA
Black
EA
Black
EB
Med.
EB
Med. Blue
Blue
EQ
W/Blue*
EQ
W/Blue*
EU
Tan
EU
Tan
EW
W/Black*
EW
W/Black*
E5
W/Green*
E5
W/Green*
E9
E9 . . . . . . . . .. W/Saddle*
W/Saddle*
Westminster
Westminster B/Cloth
B/Cloth and
and
Corinth.
Corinth. Vinyl
Vinyl
(LIB
(L/B Split
Split Bench)
Bench)
FA
Black
FA
Black
FB
Med.
FB
Med. Blue
Blue
FG
Green
FG
Green
FU
Tan
FU
Tan
FZ
Saddle
FZ
Saddle
Mateao/Corinth.
Vinyl
(L/B
(L/B Split
Split Bench)
Bench)
GA
Black
GA
Black
GB
Med.
Med. Blue
Blue
GO
Red
GD
Red
GG
Green
GG
Green
GN
W/Red*
GN
W/Red*
GQ
W/Blue*
GQ
W/Blue*
GU
Tan
GU ............... Tan
GW
W/Black*
GW
W/Black*
GZ
Saddle
GZ
Saddle
G5
W/Green*
G5
W/Green*
G9
G9 .. . . . . . .. W/Saddle*
W/Saddle*
Westminster
Westminster B/Cloth
B/Cloth and
and
Corinth.
Corinth. Vinyl
Vinyl (LIB
(L/B Bench)
Bench)
Code
Code
Trim Scheme
Scheme
Trim
JA
JA
JB
JB
JG
JG
JU
JU
JZ
JZ
. . . . .. . . . . . . .. Black
Black
Med. Blue
Blue
Med.
. . . . . . . . . . . . .. Green
Green
Tan
Tan
Saddle
Saddle
Ruffino/Corinth.
(L/B Bench)
Bench)
(L/B
KA
Black
KA
Black
KB
Med. Blue
Blue
KB
Med.
KG
Green
KG
Green
KU
Tan
KU
Tan
KZ
Saddle
KZ
Saddle
Kashmir***
Corinth. Vinyl
Split Bench)
(L/B Split
LB
Med. Blue
Lo
Red
LD
Red
LG . . . . . . . . . . . . .. Green
Tan
LU
Tan
LZ
Saddle
Sterling B/Cloth and
(LIB Bench)
Corinth. Vinyl (L/B
MR
Green
Tan
MU ............. Tan
MZ
Saddle
Kirsten B/Cloth and
MB
Blue
MG . . . . . . . . . . .. Green
Tan
MU
Tan
Linares B/Cloth and
PA
Black
PB
. . . . . . . . .. Blue
PB
PU
Tan
PU
Tan
Edinburg B/Cloth and
Corinth. Vinyl (LIB
(L/B Bench)
QA ............. Black
QB
Blue
QB
Corinth. Vinyl (LIB
(L/B Bench)
RB
Blue
RB
RG
RG . . . . . . . . . . . . Green
Green
RU
Tan
RU
Tan
MERCURY BOBCAT
Ruffino/Corinth Vinyl
Vinyl
(LIB
(L/B Bucket)
AA
Black
AB
Med.
AB
Med. Blue
AG
Lt.
AG
Lt. Green
Green
AU
Tan
AU
Tan
Ruffino/Corinth.
Vinyl
(LIB
(L/B Bucket)
Bucket)
BA
Black
BA
Dynasty
Dynasty Polyknit
Polyknit and
and
Corinth.
Corinth. Vinyl
Vinyl (LIB
(L/B Bench)
Bench)
CB
Blue
CB
Blue
CG
Green
CG
Green
CU
Tan
CU
Tan
Manston
Manston B/Cloth
B/Cloth and
and
Corinth.
Corinth. Vinyl
Vinyl (H/B
(H/B Bucket)
Bucket)
oA
Black
DA
Black
Code
Code
Trim
Trim Scheme
Scheme
DB
Blue
DB
Blue
DG
oG . . . . . . . . . . . . Green
Green
DU
Tan
oU
Tan
Corinth. Vinyl
Vinyl (H/B
(H/B Bucket)
Bucket)
Corinth.
EA
Black
EA
Black
EB
Blue
EB
Blue
EG
Green
EG
Green
EU
Tan
EU
Tan
GRANADA
GRANADA
Corinth. Vinyl
(L/B
(LIB Bucket)
AA
Black
AA
Black
AD
Dk.
Ok. Red
Red
AE
Silver
Silver Blue
AG
Med. Green
Green
AU
Tan
Tan
Kashmir***
Corinth. Vinyl
(L/B
(LIB Flight Bench)
BD
Dk.
BO
Ok. Red
Red
BE .. . . . . . . .. Silver Blue
BG
Med. Green
BU
Tan
Tan
CA
Black
CD
Dk.
Ok. Red
CE . . . . . . . . .. Silver Blue
CG
Med. Green
CU
Tan
CU
Tan
DO
Ok. Red
DD
Dk.
DE
Silver Blue
oG
Med.
DG
Med. Green
OU
Tan
DU
Tan
Corinth. Vinyl
(L/B Flight Bench)
EA
Black
ED
Ok.
Dk. Red
EE
EE .. . . . . . . .. Silver Blue
EG
Med.
EG
Med. Green
EU
Tan
EU
Tan
Leather**
(LIB
(L/B Bucket)
Fo
Ok.
FD
Dk. Red
Red
FE
Silver Blue
FE
FU
Tan
FU
Tan
Corinth.
Corinth. Vinyl
Vinyl
(LIB
(L/B Flight Bench)
GA
Black
GO
Ok.
GD
Dk. Red
Red
GE
Silver
GE
Silver Blue
Blue
GG
Med.
GG
Med. Green
Green
GU
Tan
GU
Tan
Westminster B/Cloth
B/Cloth and
and
Corinth.
Corinth. Vinyl
Vinyl
Bench)
(L/B Flight Bench)
HE
Silver Blue
Blue
HE
Silver
HG
Med. Green
Green
HG
Med.
HU
Tan
HU
Tan
Corinth. Vinyl
Vinyl
Corinth.
(LIB
(L/B Bench)
Bench)
JA
JA .. . . .. .. . . . . .. Black
Black
Jo
Ok.
JD
Dk. Red
Red
JE
Silver
JE
Silver Blue
Blue
*White
"White Trim
Trim with
with Color
Color Components.
Components. **Seating
**Seating Surfaces.
Surfaces. ***100%
***100% Nylon
Nylon Fabric
Fabric -- Cashmere
Cashmere like
like appearance.
appearance.
BACK TO GROUP INDEX
Code
Code
Trim
Trim Scheme
Scheme
JG
JG
JU
JU
Med.
Med. Green
Green
Tan
Tan
Natural
Natural Grain
Grain Leather
Leather
(L/B
(LIB Flight
Flight Bench)
Bench)
LD
Dk.
Lo
Ok. Red
Red
LE
Silver
LE
Silver Blue
Blue
LU
Tan
LU
Tan
MONARCH
MONARCH
Corinth. Vinyl
(L/B
(L/B Bucket)
AA
Black
AA
Black
AD
Dk.
AD
Ok. Red
Red
AE
Silver
Silver Blue
AG
Med. Green
Green
AU
Tan
Tan
Kashmir***
Corinth. Vinyl
(L/B
(LIB Flight
Flight Bench)
BD
Dk.
Bo
Ok. Red
Red
BE . . . . . . . . .. Silver
Silver Blue
BG ......... Med. Green
BU
Tan
Tan
Corinth. Vinyl
(L/B Bucket)
CA
Black
CD
Dk.
Ok. Red
CE
Silver Blue
CG
Med. Green
CU
Tan
Tan
Corinth. Vinyl (L/B
(LIB Bucket)
DD
Dk.
DO
Ok. Red
DE
Silver Blue
DG
Med. Green
oG
Med.
DU
Tan
OU
Tan
Corinth. Vinyl
(L/B Flight Bench)
(LIB
EA
Black
Dk. Red
Red
E
Ok.
EE . . . . . . . . .. Silver Blue
EE
EG
Med. Green
EG
Med.
EU
Tan
EU
Tan
Leather**
(L/B Bucket)
(LIB
FD
Dk. Red
Red
FD
Ok.
FE . . . . . . . . .. Silver Blue
FE
FU
Tan
FU
Tan
F9 .. . . . . .. W/Tobacco*
F9
Corinth. Vinyl
Vinyl
Corinth.
(L/B Flight Bench)
(LIB
GA
Black
GD
Dk. Red
Red
GO
Ok.
GE
Silver Blue
Blue
GE
Silver
GG . . . . . . .. Med.
Med. Green
Green
GG
GU
Tan
GU
Tan
Westminster B/Cloth
B/Cloth and
and Corinth.
Corinth.
Westminster
Vinyl (LIB
(L/B Flight Bench)
Bench)
Vinyl
HE
Silver Blue
Blue
HE
Silver
HG .. ..
Med. Green
Green
HG
Med.
HU
Tan
HU
Tan
Natural Grain
Grain Leather
Leather
Natural
(L/B Flight
Flight Bench)
Bench)
(LIB
LD
Dk. Red
Red
LO
Ok.
LE
Silver Blue
Blue
LE
Silver
LU
Tan
LU
Tan
CY1419-F3
CV1419-F3

20-01-9
20-01-9
1976 IDENTIFICATION CODES

DISTRICT CODES
LINCOLN-MERCURY
ASSEMBLY PLANT CODES

Code Letter
A
A
B
E
F
F
G
G
H
H
J
K
P
R
R
S
S
T
T
U
W
W
X
X
Y
Y
Z
Z
Atlanta
Oakville (Canada)
(Canada)
Mahwah
Mahwah
Dearborn
Dearborn
Chicago
Lorain
Lorain
los
Los Angeles
Kansas City
Twin Cities
San
San Jose
Allen
Allen Park
Park (Pilot)
(Pilot)
Metuchen
louisville
Louisville
Wayne
St. Thomas
Wixom
St. Louis
ENGINE COOES
CODES
Codes
A
A
C
C
F
H
L
S
s
T
Y
Y
Z
Z
No.
No. of
Cyls.
Displacement
8
8
8
B
8
6
8
6
4
6
6
460-4V
460-4V
302-2V
351-2V
250-1V
400-2V
200-1V
139-2V
169-2V
(Police)
(2.3L)
(2.8L)
(2.BL)
TRANSMISSION CODES
Codes
Type
MANUAL
3 Speed
.. 3
4 Speed
. 4 Speed
Speed @
@
. 4 Speed
Speed (b)
(b)
1
5
6
7
AUTOMATIC
XP (C-3)
. . XP
. . XP (C-4)
FMX
XPL (C-6)
. . XPL (Special)
V
V
W
W
X
X
U
u
Z
z
.. .
DISTRICT CODES
FORD
Code
Code
00
11
11
15
16
17
17
21
21
22
23
26
31
31
32
33
34
41
41
42
46
51
51
52
53
54
84
90's
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
District
Code
District
Special
Boston
New York
Philadelphia
Washington
Atlanta
Dallas
Jacksonville
Memphis
Buffalo
Cincinnati
Cleveland
Detroit
Chicago
St. Louis
Twin Cities
Denver
Los Angeles
Oakland
Seattle
Home Off. Reserve
Export
00
11
11
12
13
14
15
16
17 . . .
21
21
22
22
23
24
25
26
28
41
41
42
43
45
46
47
48
52
52
53
54 .
55
56
57
58
71
71
72
73
74
75
76
83
84
. .
85
86
87
89
90's
Special
Boston
Buffalo
New York
Pittsburgh
Newark
Philadelphia
Washington
Atlanta
Atlanta
Charlotte
Memphis
Jacksonville
Richmond
New Orleans
FORD OF CANADA
Mercury
Mercury
Code
Region
Region
Ford
Ford
Code
A1
A1
A2
A3
A4
A6
A7
12
Central .
Eastern .
Atlantic . .
Midwestern
Western
Pacific
Export
B1
B1
B2
B3
B4
B6
B7
12
REAR AXLE RATIO CODES

Conventional
2
4
4
6
9
7
5
5
3
3
4
4
....
....
....
....
....
....
....
Lock
Ratio
K
M
M
2.75
3.40
3.00
3.25
3.55
3.07
2
79
2.79
3 18
3.18
R
R
P
P
N
N
L
M
Louisvi~e
LouisviHe
Chicago
Cleveland
Milwaukee
Lansing
Indianapolis
Cincinnati
Detroit
Dallas
Kansas City
Omaha
St. louis
Louis
Davenport
Houston
Twin Cities
Los Angeles
San Jose
Salt lake
Lake City
Seattle
Seattle
Phoenix
Denver
Government
Home Off. Reserve
American Red Cross
Recreational Veh.
Veh. Pool
Body Company
Transportation Services
Export
EXTERIOR PAINT COLOR CODES

Code
1C
1C
1G
1H
2B
2E
2M
2M
2R
2U
3D
3E
3G
3S
3T
4Y
46
47
49
5B
5M
5Q
50
5T
5V
56
6E
........
........
.......
........
. ........
..
.
......
........
. ..... ,
. ......
. ........
. ......
. ........
. ........
. ....... ,
. ........
........
..
..
........
.........
.
. ......
. ..... ,
. ........
. ........
........
..
. ." .....
M-32J
Number
1724-A
5299-A
5363-A
3560-A
2008-A
3413-A
5440-A
5455-A
5087-A
5097-A
5094-A
5443-A
5004-A
5233-A
5328-A
5404-A
5005-A
5035-A
5144-A
5247-A
5145-A
5297-A
5181-A
5080-A
@ Borg Warner
BACK TO GROUP INDEX
....
...
. ...
."
...
....
..
. .. ..
....
....
....
....
....
....
... ..
..
... ..
..
..
. .. ..
...
. ...
. ..
. . .,
...
....
. . .,
...
.... . .,
....
....
. . . .,
...
..
. .. ..
. . .,
...
... . .
....
....
. . .,
...
....
....
Color
Code
M-32J
Number
Black
Silver Met.
Med Slate Blue Met.
Met
Med.
Bit. Red
Brt.
Candyapple Red
Dk. Red
Ok.
Brt. Red
Brt.
B i t Red
Med. Blue Met.
Med.
Brt. Blue Met.
Dk. Blue Met.
Brt. Ok.
Lt. Blue
Brt. Med. Blue
Dk. Yellow Green Met.
Ok.
Dk. Jade Met.
Ok.
Lt. Green
Dk. Green
Ok.
Copper Met.
Med. Chestnut Met.
Med.
Dk. Brown Met.
Ok.
Saddle Bronze Met.
Tan
Yellow Orange
Brt. Yellow
6P
6P
6R
6S
6U
6W
7A
7E
8B
8D
80
8E
8F
9A
9D
90
5406-A
5046-A
1526-A
5441-A
5439-A
5445-A
5402-A
5186-A
5064-A
5183-A
5459-A
1619-A
5418-A
(b) Hummer
.......
.......
.......
........
........
. ........
........
..
........
..
........
........
..
. ........
. ........
........
Color
....
....
. ..
...
.....
..
. ...
..
. ...
..
. . ..
..
. . ..
..
..
. ...
. . ..
..
. ...
..
.....
..
.....
..
Cream
Dk. Yellow
Ok.
Chrome Yellow
Tan
Lt. Gold
Lt. Jade
Med. Green Gold
Med. Ginger Met.
Dk. Brown
Ok.
Med. Orange Met.
Tangerine
White
White
(RPO) UNIQUE COLORS (NON POLISH)

3M
4T
48
5U
5U
57
58
6T
6V
........
..
........
. ........
....... ,
..
........
. ........
. ...... ,
. ........
5213-A
5211-A
5435-A
5298-A
5425-A
5425-A
5436-A
5456-A
5456-A
5460-A
. . ..
..
. ...
..
. . ..
..
. ...
..
. . ..
..
. . ..
..
. ...
..
. . ..
..
Silver Blue Met.

Med. Ivy Bronze Met.
Med. Ivy Bronze Met.
Tan Met.
Dk. Ginger Met.
Ok.
Ginger Bronze Met.
Dk. Gold Met.
Med. Ok.
Med. Gold Met.
Code
M-32J
Number
Color
(RPO) DIAMOND BRT. (POLISH)

2S
. ........ 5444-A
Ok. Red Met.

Dk.
(RPO) DIAMOND FLARE (POLISH)
1J
2P
3P
3R
6Y
45
51
51
54
59
7F
........
. ...... "
........
..
........
........
..
........
..
. ........
. ........
. ........
..
........
5411-A
5397-A
5401-A
5303-A
5461-A
5410-A
5395-A
5409-A
5450-A
5449-A
. ...
..
. ...
..
. . ..
..
. ...
..
. ...
..
. . ..
..
. . ..
..
. . ..
..
. . . ..
5462-A
5463-A
5458-A
545B-A
. . ". . Rose Met.

. ...
. . Lt. Jade Met.
. ...
. . Lt. Apricot Met.
Met
... Silver Met.
Med. Taupe Met.
Brt. Blue Met.
Silver Blue Met.
Brt. Yellow Gold Met.
Aqua Blue Met.
Ginger Bronze Met.
Gold Bronze Met.
Med. Chestnut Met.
Med. Jade Met.
(CRYSTALS)
2T
7B
8A
BA
........
.......
.......
CY1411-J

20-01-10
20-01-10
BODY SERIAL
SERIAL AND
AND STYLE
STYtE:CODES
BODY
CODES
Body
Body Body
Body
StYle
Serial
S"ill Style
Code
Code Code
Code
Vehicle
Vehicle
21
21
65H
Body Type
Type
Body
Model
Model
Vehicle
Vehicle
Body
Body
Serial
Serill
Code
Code
2-0r. Hardtop
2-Dr.
Gran Torino
(XL) Elite
Elite
(XL)
MERCURY
MERCURY
TORINO/
TORINO/
25
65B
65
B
2-0r. Hardtop
2-Dr.
RANCHERO
RANCHERO
27
53B
4-0r. Sedan Hardtop

4-Dr.
Torino
Torino
30
650
65D
2-or. Hardtop
2-Dr.
31
31
530
53D
4-or. Sedan Hardtop

4-Dr.
Gran Torino
32
65K
65
K
2-or. Hardtop
2-Dr.
33
53K
4-or. Sedan
Sedan Hardtop
4-Dr.
40
71B
Torino
Torino
42
710
71D
Gran Torino
Gran
43
71K
Gran Torino
Torino Squire
Gran
47
970
97D
Ranchero 500
Torino Brougham
Gran Torino
Station Wagon
Station
W a g o n@
48
97R
97
R
Ranchero GT
GT
Ranchero
49
97K
Ranchero Squire
Ranchero
Ranchero
Ranchero
30
54BB
54
4-0r. Sedan
4-Dr.
31
31
62BB
62
2-0r. Sedan Fastback

2-Dr.
COUGAR
COUGAR
93
65F
2-0r. Hardtop
2-Dr.
FORD
FORD
52
600
60D
2-0r. Pillar
Pillar Hardtop
2-Dr.
H a r d t o p~
Custom 500
53
530
53D
4-or. Pillar Hardtop@

4-Dr.
Hardtop
(D
62
60H
2-or. Pillar Hardtop

2-Dr.
LTD
63
53H

4-Dr.
64
53L

4-Dr.
65
60LL
60

2-Dr.
66
53K
4-0r. Pillar Hardtop

4-Dr.
68
60KK
60

2-Dr.
72
72
710
71D
74
74
76
81
81
54H
54 H
82
82
83
66H
66 H
2-or.
2-Dr. Sedan
54K
54 K
4-or.
4-Dr. Sedan
84
84
66K
66 K
LINCOLN
81
81
CONTINENTAL
82
CONTINENTAL 82
MARK IV
89
89
650
65D
2-or.
2-Dr. Hardtop
Hardtop
MAVERICK
MAVERICK
91
91
62A
92
54A
54 A
GRANADA
GRANADA
CD
Body Type
Type
Body
Model
Model
49
53B
4-Dr.
4-0r. Pillar
Pillar Hardtop
Rideau500
Rideau 500 @)
51
51
65B
2-Dr.
2-0r. Hardtop
Montcalm
Montcalm@)
50
53B
4-Dr.
4-0r. Pillar
Pillar Hardtop
52
65
B
65B
2-Dr.
2-0r. Hardtop
60
53L
4-Dr.
4-0r. Pillar
Pillar Hardtop
61
61
65L
2-Dr.
2-0r. Hardtop
62
53K
4-Dr.
4-0r. Pillar
Pillar Hardtop
64
65
K
65K
2-Dr.
2-0r. Hardtop
63
53H
4-Dr.
4-0r. Pillar
Pillar Hardtop
66
65
H
65H
2-Dr.
2-0r. Hardtop
70
71B
4-0r. Wagon0
4-Dr.
Wagon@
Rideau500(2)
Rideau 500
71
71
71B
4-0r_ Wagon
4-Dr.
Montcalm
Marquis
Gran Marquis
Marquis Brougham
Marquis
74
71H
7lH
4-Dr.
4-0r_ Wagon
76
71K
4-Dr.
4-0r. Wagon
Marquis Brougham
34
54
H
54H
4-Dr.
4-0r. Sedan
Standard
35
66
H
66H
2-Dr.
2-0r. Sedan
37
54
54KK
4-Dr.
4-or. Sedan
38
66
K
66K
2-Dr.
2-0r. Sedan
MERCURY
MERCURY
20
64
H
64H
3-Dr.
3-or. Runabout
BOBCAT
22
2-Dr.
2-or. Villager
23
23
73H
62B
24
64
B
64B
2-Dr.
2-or. Sedan
Sedan @
3-or. Model
@
3-Dr.
Model
Cat
Bob Cat
25
73B
73B
2-Dr.
2-0r. Wagon @
(Canada Only)
Montego
MONARCH
MONARCH
COMET
COMET
Body
Body
Style
Style
Code
Code
Standard
XR-7
LTD Landau
MONTEGO
Ghia
02
53B
4-Dr.
4-or. Sedan/Hardtop
LTD Brougham
03
65B
2-Dr.
2-D r. Hardtop
04
53D
530
4-Dr. Sedan Hardtop

Hardtop
4-or.
4-or.
4-Dr. Wagon 00
Custom 500 Ranch @

(?)
07
65D
650
2-Dr. Hardtop
2-or.
71H
71H
4-or.
4-Dr. Wagon
LTD
10
53 K
53K
4-Dr. Sedan Hardtop

4-or.
71K
4-or.
4-Dr. Wagon
Country Squire
11
11
65 K
65K
2-Dr. Hardtop
2-0r.
4-0r.
4-Dr. Sedan
Standard
08
71D
710
Montego MX (Metal)
Villager (Woodgrain)
Montego MX
Montego Brougham
Wgns. 4-0
4-Dr.
Station Wgns.
r.
18
71K
02
60F
2-Dr. 4-Pass.
2-or.
2-or.
2-Dr. Sedan
03
69 F
S9F
3-Dr. 4-Pass.
3-or.4-Pass.
60B
60B
2-or.
2-Dr. Hardtop
Hardtop
04
60H
2-or.
2-Dr. 4-Pass.
53B
4-0r.
4-Dr. Sedan Hardtop
Hardtop
05
69 R
69R
3-0r.4-Pass.
3-Dr. 4-Pass.
Mach I
Mach
10
10
62B
2-Dr. Sedan
2-or.
Standard
2-or.
2-Dr. Sedan Fastback
Fastback
11
11
64 B
64B
3-Dr. Sedan
3-0r.
4-or.
4-Dr. Sedan
12
12
73B
738
2-Dr. Wagon
2-or.
THUNDERBIRD 87
87
65K
Ghia
MUSTANG
PINTO
"GT"
(?) Also available w/oual
w/Dual Face
Face Rear
Rear Seats
Seats 0
(3) Also Available w/Rear Face
Face Seats
Seats @
Canada
Canada Only
Also "GT"
Base
Ghia
2-Dr. Hardtop
Hardtop
2-or.
Released and
and Schedule for "Fleet
Released
'Fleet Only" for
for U.S.A.
CY1615-C
CY1615C
VINYL
V I N Y L ROOF TYPE/COLOR CODE
CODE
(FIRST
(FIRST LETTER
LETTER OF
OF CODE
CODE
Code
B
B
C
0D
E
F
=
= TYPE
TYPE OF
OF ROOF)
ROOF)
Vinyl Type
Cross
Cross Hatch
Hatch Full
Full 2-Door
2-Door
Cross
Cross Hatch
Hatch Halo
Halo Style
Style
4-Door
Levant
Levant Full
Full
Levant (1/2)
(1/2)
Levant
Normandie Full
Full
Normandie
Odense Full
Full
Odense
Example Code^ DA
Exa~Ple
~DA~
Levcmt
Levant
Full
Full
Black
Black
(SECOND LETTER OF CODE
= COLOR OF ROOF)
ROOF)
=
Code
Vinyl
Vinyl Type
Type
Code
Vinyl Color
Code
Vinyl Color
H
H
JJ
Odense
Odense (3/4)
(3/4)
Odense
Odense Embassy
Embassy
(Basket
(Basket Handle)
Handle)
Normandie
Normandie (3/4)
(3/4)
Normandie
Normandie (1/2)
(1/2)
Odense (1/2)
(1/2)
Odense
Cross-Hatch (3/4)
(3/4)
Cross-Hatch
Cross-Hatch (1/2)
(1/2)
Cross-Hatch
Levant (3/4)
(3/4)
Levant
A
B
C
0D
G
H
Black
Blue
Blue
Apricot
Apricot
Red
Red
Green
Green
Rose
Rose
Taupe
Taupe
Copper
Copper
Aqua
Aqua
Gold Flare
Flare
Gold
N
P
P
R
R
S
S
TT
U
U
V
W
W
Y
Y
ZZ
Lipstick
Red Lipstick
Silver
Silver
Jade
Jade
Silver Blue
Blue
Silver
K
K
LL
N
N
P
P
R
R
S
S
JJ
K
K
LL
M
M
Brown
Brown
Tan
Tan
Cream
Cream
White
White
Gold
Gold
Saddle
Saddle
CY1615-C 1
CY1615-C1
BACK TO GROUP INDEX

20-01-11
20-01-11
INTERIOR TRIM
TRIM CODES
CODES
INTERIOR
Trim Scheme
Code
Code
Trim Scheme
PINTO
PINTO
Colton/Corinth. Vinyl
Vinyl
Colton/Corinth.
(H/B Bucket)
Bucket)
(H/B
AA
AB
AB
AG
AG
AU
AU
DB
DO
DD
DG
DG
DU
DU
GA
GA
GO
GD
GG
GG
GU
GU
HA
HB
HD
HG
HU
.................. Black
................... Blue
................... Green
................... Tan
Alpine B/Cloth
B/Cloth &&
Alpine
Kiwi Vinyl
Vinyl
Kiwi
(UB Bucket)
Bucket)
(L/B
................... Blue
................... Red
.................. Green
................... Tan
Concord B/Cloth &
&
Corinth. Vinyl
(H/B Bucket)
, . " " , .... " , ... , Black
....... , . , . , . " ... , Blue
Green
Tan
(UB
(L/B Bucket)
Black
"
.... , . " ... , ..... Blue
Red
Green
Tan
0"
I.'"
'00
'
0'"
0"
0.0
" .
'
'
"'"
,.,.,
"
AB
AG
AG
AU
.,.
"'"
'
I"
II'"
' . '
I.
Black
Blue
Green
Tan
o.
"'
""
0.1
I.
I"
1'1
"'
O.
1.1
"'
Blue
Red
Green
Tan
I
Concord B/Cloth &

&
Corinth. Vinyl
(H/B Bucket)
GA
GB
GB
GG
GG
GU
GU
" " ' 0 '
.,.
0'"
.0000
Black
Blue
Green
Tan
Tan
I
Vinyl
(LIB
(L/B Bucket)
HA
HB
HB
HD
HD
HG
HG
HU
HU
"'1
1.1.
0.
"
"'"
0"
I"
""
0"
I'
BD
BN
Ba
BQ
BU
BV
BW
B4
CB
CH
CH
CU
CV
"'
DA
DB
DD
DU
DV
o'
Alpine B/Cloth &

&
Corinth. Vinyl
(LIB
(L/B Bucket)
DB
DO
DD
DG
DG
DU
DU
BB
" ,
",.'
BA
AU
MERCURY BOBCAT
Colton/Ruffino
Cotton/Ruffino Vinyl
(H/B Bucket)
AA
AA
AD
o.
0.'
AB
" '
AA
Black
Blue
Red
Red
Green
Green
Tan
Tan
I
0.0'
EB
EB
ED
ED
EU
EU
EV
Alpine
Alpine B/Cloth
B/Cloth &&
Corinth. Vinyl
Corinth. Vinyl
(UB Bucket)
(L/B
(L/B
(UB Bench)
""
.,
'
"'
'
'
' . '
""
""
'
'
'
I.
MAVERICK
Random Stripe B/Cloth
B/Cloth
&
& Corinth.
Corinth. Vinyl
Vinyl
(UB
(L/B Bench)
Bench)
Black
BA
Black
Blue
BB
Green
BG
BG
Green
Tan
BU
BU
Tan
Tooled/Corinth.
Tooled/Corinth. Vinyl
Vinyl
(LIB
(L/B Bench)
Black
HA
Blue
HB
HB
Green
HG
HG
Tan
HU
HU
Tan
I"
.0.'
,.
I.
1.1.1.
1'1
I"
I'
I"
1'.0.0
I'
'
1.1
"."
I"
KU
LA
LB
LU
PB
PU
QB
aB
QU
au
RB
RU
.,.
'
'"'
I'
I"
"
,.,
" ,
'
0."
""0
0.'
"'
0"
0"
'
0""
JA
JB
JG
JU
"'1
"
I'
I.
o.
1.1
"'"
0"
Black
Blue
Green
Tan
KA
KB
KB
KG
KG
KU
KU
"1
" " " " " ,
1.0.
I'
I'"
" " " "
I,
"",
""
I'
Black
Blue
Green
Tan
'
Corinth.
Corinth. Vinyl
Vinyl
(LIB
(L/B Bucket)
LA
LB
LB
LU
LU
'I
1.1
1'1
'
1.0'
1.1.1'1
Black
Blue
Tan
Tan
Corinth. Vinyl
Vinyl
(LIB
(L/B Bucket)
PB
PB
PU
PU
QU
au
................... Tan
Alpine
Alpine B/Cloth
B/Cloth &&
Corinth. Vinyl
(L/B
(LIB Bucket)
RB ................... Blue
RU ................... Tan
GRANADA
Corinth. Vinyl
(L/B
(LIB Bucket)
AA
1.1
I.
AD
AN
A4
CA
CD
CD
CE
CE
CN
CN
CU
CU
CW
C4
C7
DD
DO
DE
DE
DU
DU
EA
EA
ED
ED
EE
EE
EN
EN
EU
EU
EW
EW
E4
E4
E7
E7
Blue
Tan
Tan
FD
FD
'
Black
""
'
Silver Blue
'
Red
W/Red
WIRed
o.
Tan
W/Black
................W/Black
W/Tan
W/Silver Blue
Kasman B/Cloth &
&
Corinth. Vinyl
(L/B Flight Bench)
(LIB
Red
Silver Blue
Tan
Corinth. Vinyl
(L/B Bucket)
(LIB
Black
Red
Silver Blue
W/Red
WIRed
Tan
W/Black
W/Tan
W!Tan
W/Silver Blue
Kasman B/Cloth &
&
Corinth. Vinyl
(L/B Bucket)
(LIB
Red
Silver Blue
Tan
Corinth. Vinyl
(L/B Flight Bench)
(LIB
Black
Red
Silver Blue
W/Red
WIRed
Tan
Tan
W/Black
W/Tan
W/Tan
W/Silver Blue
Natural Grain Leather
(L/B Bucket)
Bucket)
(LIB
Red
Red
0'"
"
I.'
AW
BD
BE
BU
""'
AU
A7
00.0000000
AE
Corinth. Vinyl
(LIB
(L/B Bench)
. .................. Blue
QB
aB
"'"
",.
'
COMET
Barletta B/Cloth &
&
Corinth. Vinyl
(LIB
(L/B Bench)
I.
I'
"'"
I'
I""
"."
"
0.'
I'
1.1'"
I'
KG
"'
I"
KB
""'"
KA
(L/B
(UB Bucket)
.................. Black
.................. . Blue
.................. Green
.................... Tan
Corinth. Vinyl
(L/B
(UB Bench)
Ben~h)
.................. Black
................... Blue
.................. Green
................... Tan
Corinth. Vinyl
(L/B
(LIB Bucket)
Black
" , .. , . " " . , ..... , Blue
Tan
Corinth. Vinyl
(L/B Bucket)
Blue
Tan
Alpine B/Cloth &
&
Corinth. Vinyl
(L/B Bucket)
(LIB
Blue
Tan
Alpine B/Cloth &
&
Corinth. Vinyl
(L/B Bucket)
(LIB
Blue
Tan
'
" ,
JU
JG
"'".'.
I.
JA
JB
1.1
00
""
1.1'.'
I."
,'.".
""
, . " " ,
"'"
""
Trim Scheme
Corinth. Vinyl
Code
Barletta B/Cloth
B/Cloth &&
Trim Scheme
MUSTANG
................. . Black
.................. . Blue
.................. . Red
.................. . Tan
(UB Bucket)
(L/B
................. . Black
.................. . Blue
.................. . Red
................ . W/Red
WIRed
................. W/Blue
Tan
. , . " , . , ... " " .. Cream
'.,.,."
.. , . , .. W/Black
.... , .. " ...... , . W/Tan
&
Media B/Coth &
Corinth. Vinyl
(UB Bucket)
(L/B
Blue
. , .. " . , ... , .. , Cranberry
Tan
Gold/Cream
Westminster B/Cloth &
&
Westminster
Corinth. Vinyl
(LIB
(L/B Bucket)
Black
Blue
Red
Tan
Gold/Cream
&
Sterling B/Cloth &
Corinth. Vinyl
(L/B Bucket)
Blue
Red
Tan
Gold/Cream
I
Code
.,.,
0.0
1.0
000.
"'
"'
I.
o.
""
0.0
I.
I",
I"
0.0
1.100
"'
0'"
O'
1.1
00
1.1
"'
0"
""
0"
O.
1.0
00
01
0""
I'
"",
..,
",
"
.00
1.1.00
10""
0.'
0.0""
'
'
0'
0"
'
",
00
'
I"
CY1419-G
CY1419G
BACK TO GROUP INDEX

20-01-12
20-01-12
INTERIOR TRIM CODES

- Continued
INTERIOR
Code
Trim Scheme
.................. Silver
Silver
W/Red
WIRed
................... .Tan
Tan
W/Black
................ " ' W/Tan
........... . W/Silver
W/Silver Blue
Corinth. Vinyl
(LIB Flight Bench)
(L/B
GA .................. Black
Red
GD .................. .Red
GE ............. . Silver Blue
WIRed
GN ................. W/Red
Tan
GU ................... Tan
GW .............. . W/Black
G4 ................ . W/Tan
W/Silver Blue
G7 ........... . W/Silver
Westminster B/Cloth
Westminster
&& Corinth. Vinyl
(LIB Flight Bench)
(L/B
Red
HD
Red
HE ............. . Silver Blue
HU .................. .Tan
Tan
Corinth. Vinyl
(LIB
(L/B Bench)
Black
JA
JD
Red
Red
JE
Silver Blue
IN
WIRed
JN
W/Red
JU
Tan
Tan
JW
W/Black
J4
W/Tan
J7
W/Silve(
W/Silver Blue
(LIB
(L/B Flight Bench)
LD
Red
Red
LE .
... , Silver Blue
LN
WIRed
W/Red
LU
Tan
Tan
LW ................ W/Black
L4
.... ...
W/Tan
L7
.. , , W/Silver Blue
(LIB
(L/B Bucket)
MD
Red
Red
MU " " ' " . " " " ' ........ Tan
Tan
Touraine B/Cloth
B/Cloth &
Corinth. Vinyl
(LIB
(L/B Bucket)
NO
Red
ND
Red
NU
Tan
NU
Tan
FE
FN
FU
FW
F4
F7
I.
I.
1.1
""
" " '
I.'
""
" " " " " "
1.
""
' " .
" " ,
" " . ,
",."",
"
,'
"
"""
,."
""
I . " '
"","
""""
I."
"
AA
AD
AD
AE
AE
"
""
""
" ,
I."
"".
""
" " ' .
""
MONARCH
Corinth. Vinyl
Vinyl
(LIB
(L/B Bucket)
Bucket)
.... Black
Red
Red
.......... " Silver Blue
" ,
"
"'"
'
I . " '
1.'"
I.'
Code
Trim Scheme
AN . ............ " ' " W/Red

WIRed
Tan
AU ................... Tan
AW
W/Black
A4
W/Tan
W/Silver Blue
A7 ............ W/Silver
Kasman B/Cloth &&
Corinth. Vinyl
(LIB Flight Bench)
(L/B
Red
BD . .................. Red
BE ............. . Silver Blue
BU ................... Tan
Tan
Corinth. Vinyl
(LIB Bucket)
(L/B
CA .................. Black
CD .................. . Red
Red
CE ............. . Silver Blue
CN ................. WIRed
W/Red
CU
Tan
Tan
CW .............. . W/Black
W/Tan
C4
C7 ............ W/Silver Blue
Kasman B/Cloth &
&
Corinth. Vinyl
(LIB
(L/B Bucket)
DD
Red
Red
DE
Silver Blue
DU
Tan
Tan
Corinth. Vinyl
(L/B Flight Bench)
EA
" ' ........ Black
ED
Red
Red
EE
EE , .. ... " .. , , Silver Blue
EN
. WIRed
EN " ... , ' .. ..
W/Red
EU
Tan
EU , ' .. , ... " ' .. , , , .. Tan
EW ... " , ' .
... W/Black
E4
...
.. " . , . , . W/Tan
E7 .... " ... " , W/Silver Blue
(LIB
(L/B Bucket)
FD
Red
...
FD " . ' , ...
Red
FE
.. , ... Silver Blue
FE " ..
FN
FN ...... , . " ... , ... WIRed
W/Red
FU
Tan
FU
Tan
FW
W/Black
F4
W/Tan
F4
F7
W/Silver Blue
F7
Corinth. Vinyl
(L/B Flight Bench)
GA
Black
GD
Red
GD ' " .. " ' . ,
.. " ' " . Red
GE
Silver Blue
GE
GN
WIRed
GN
W/Red
GU
Tan
GU
Tan
GW
W/Black
W/Black
G4
G4 " ' ........... ' " W/Tan
W/Tan
G7
W/Silver Blue
G7
'"
1.1
I.
""
""
Westminster
Westminster B/Cloth
&& Corinth. Vinyl
(L/B Flight Bench)
HD . .......... Cranberry
Cranberry Red
Silver Blue
HE .............. Silver
Tan
HU . .................. Tan
(LIB Flight Bench)
(L/B
Red
LD . .................. Red
LE . ............. Silver Blue
WIRed
LN . ................ W/Red
LU ......................Tan
Tan
LW . ............... W/Black
L4 . ................. W/Tan
L7 . ........... W/Silver Blue
Leather
(LIB Bucket)
(L/B
MD ................... Red
Red
MD
M9 ............. W/Tobacco
Touraine B/Cloth &&
Corinth. Vinyl
(LIB Bucket)
(L/B
ND ................... Red
Red
TORINO/RANCHERO
Akron/Corinth. Vinyl
(LIB Bench)
(L/B
"'
' . , . " " "
AA
AB
AG
AU
AZ
"
,'
",
'
"""
",
",
""
",
'"
"
" , . " .
" " " " , .
'"
,.
I."
"'".".
""
',
""
'
BA
BB
BG
BG
BZ
""
'"
CA
CB
CB
CG
CG
CQ
CO
CU
CU
CW
CZ
CZ
C5
C9
",,"
"'"'
'I
'
" ' "
"
""'."
"'
,.1
Trim Scheme
""""
Code
1.1'
,.
1-'
"'
FA
FA
FB
FB
FG
FG
FZ
FZ
"'"
I.
I.'
,.
'
"'
"'
""
I.,
'.
I.'
'.
,.
1.1
I."
1.1.
I.
'
"'"
""
..,
"
"""
.."
"
"
'.
'
Trim Scheme
(L/B
(LIB Split
Split Bench)
GA .................. Black
GB
Blue
GG
Green
GQ
W/Blue
GO
GU
Tan
Tan
GW ............... W/Black
GZ
Saddle
G5
W/Green
G9 ............ "" W/Saddle
Linares B/Cloth &&
Corinth. Vinyl
(L/B
(LIB Bench)
PA .................. Black
PB ................... Blue
PZ
Saddle
Dynasty Polyknit &&
Corinth. Vinyl
(L/B
(LIB Bench)
RB ................
Blue
Green
RG
RU . .................. Tan
Tan
(L/B
(LIB Bucket)
SA
Black
SB
Blue
SG
Green
SQ
SO
W/Blue
SW
W/Black
SZ ., .. " , . " , . , .. , , Saddle
S5 , , ' . " ' " " " ' " ' " W/Green
S9
.. " . " , W/Saddle
""
Black
Blue
Green
Tan
Tan
, . , . , ... " , .. " , . Saddle
Barletta B/Cloth &
&
Corinth. Vinyl
(L/B Bench)
(LIB
.... , ... " " " , .. , Black
., ........ ". " ' .... Blue
, .... , ... " . " , .. , Green
. .. , ... " " . " , . , Saddle
(L/B Bench)
(LIB
. " , " " ' ... " "
... Black
Blue
Green
W/Blue
Tan
Tan
W/Black
Saddle
W/Green
W/Saddle
Westminster B/Cloth
Corinth. Vinyl
Vinyl
& Corinth.
(L/B Split Bench)
(LIB
. "" .. ' ........... Black
Blue
Green
Saddle
Code
"","
""
1.1
1.1.
" . ' 1 " " ' "
""
"'
",.",
ELITE
Westminster B/Cloth
Corinth. Vinyl
Vinyl
& Corinth.
(L/B Bench)
(LIB
AA
Black
AB . ... " .. , .. " " ' . " . Blue
Red
AD
Red
AG . .. "" " " ' . " ' " "" Green
AG
AY
Gold
AZ
Saddle
(L/B Bench)
(LIB
BA
Black
BB , ... , .... , ... , , .. , . Blue
BB
Red
BD
BD
Red
Green
BG
Green
BG
BY
Gold
Saddle
BZ
Kasman B/Cloth
B/Cloth &
Corinth. Vinyl
Vinyl
(L/B Split Bench)
(LIB
Blue
CB
CB
Red
CD
Red
CD
. " " , .
"
"
"'
,.,
.,
" " " "
'
"'".
I"
"
"
,.
""
"'
""
"'
" '
I.'
"
""
"
"'
" .
""
I . ' . " ' " ,
I"
" ' . " ' .
I.,
"'"
"
" " " "
'.',
CY1419-G1
CY1419G1
BACK TO GROUP INDEX

20-01-13
20-0113
20-01-13
INTERI
oRTTRIM
RIM CODES C
onII nue d
INTERIOR
Continued
Trim Scheme
Code
CG
CG
CY
CZ
OA
DA
DB
DO
DD
DG
DG
ON
DN
OQ
DQ
OW
DW
OY
DY
OZ
DZ
05
D5
08
D8
09
D9
EA
EB
EB
ED
EG
EG
EZ
Green
Gold
Saddle
(L/B Split Bench)
(LIB
Black
Blue
Red
................. . Green
W/Red
WIRed
W/Blue
W/Black
Gold
Saddle
W/Green
W/Gold
............... W/Saddle
(L/B Bucket)
(LIB
Black
Blue
Red
Green
Saddle
(L/B Bucket)
Black
Blue
Red
... , .. , .......... , Green
W/Red
WIRed
"'"
"'"
""
""
1'1'"
I.
"'"
II.
""
""
"'
II
"'"
'
"'"'"
III
,I,.".
.,.
I.
1.1
""""
1.1.1
I'
"'"
I"
.,
"'
AA ................. . Black
AB ................. " ' Blue
AZ ................ . Saddle
Tahiti/Corinth. Vinyl
(LIB
(L/B Bench)
BA
Black
BB ................. , . Blue
BZ ................ . Saddle
Barletta B/Cloth &
&
Corinth. Vinyl
(L/B Bench)
(LIB
CA ................. . Black
CB
CB
Blue
""
HA
HB
HG
HG
HQ
HU
HW
HZ
H5
H9
MONTEGO
Barletta B/Cloth
& Corinth.
Corinth. Vinyl
(L/B Bench)
(LIB
'"
GA
GB
GG
GG
GZ
EB
EB
EG
EG
EU
EU
EZ
FA
FB
FB
FD
FO
FG
FG
FN
FN
FQ
FQ
W/Blue
~/Blue
FW
W/Black
FY
Gold
FZ
Saddle
F5
W/Green
F8 ................ . W/Gold
F9
W/Saddle
.,.
OA
DA
DB
OG
DG
OQ
DQ
DU
OW
DW
OZ
DZ
05
D5
09
D9
"'""'
",.
""1
",".,
1".1"
""
"'"
""
CG
CG
CZ
",",".,
""
""
""
11.11
"'"
1.1
""
Code
"'"
1.1
II
"",
KA
KB
KG
KG
KZ
LA
LA
LB
LB
LG
LG
LQ
LQ
LW
LW
Ll
\2
L5
L5
L9
L9
Trim Scheme
" " , ""
I . ' I"
Saddle
(L/B Bench)
Black
Blue
Green
................. W/Blue
Tan
............... W/Black
Saddle
W/Green
W/Saddle
(L/B Split Bench)
Blue
Green
Tan
Saddle
Kismet B/Cloth &
&
Corinth. Vinyl
(L/B Flight Bench)
(LIB
Black
Blue
Green
Saddle
Valino. Corinth. Vinyl
(LIB
(L/B Flight Bench)
Black
Blue
Green
W/Blue
................... Tan
W/Black
Saddle
W/Green
W/Saddle
Westminster B/Cloth
Corinth. Vinyl
& Corinth.
(L/B Split Bench)
(LIB
.................. Black
Blue
.................. Green
Saddle
Mateao/Corinth.
Vinyl
(LIB
Split Bench)
(L/B Split
Bench)
Black
Black
Blue
Blue
Green
Green
W/Blue
W/Blue
W/Black
W/Black
................. Saddle
Saddle
W/Green
W/Green
W/Saddle
W/Saddle
"
""
"'"
""
I"
""
I'"
I"
I,.
""
""
"'
""
""
I"
II'
I.'
"
II"
111.1
AA
AA
AB
AB
AD
AD
AG
AG
AN
AQ
AU
AU
AV
AW
A5
AS
A8
A9
BA
BA
BB
BD
BG
BG
BN
BN
BQ
BU
BV
BW
B5
B8
B9
""
II
.,
.,
",.
I'"
I'"
"'
""
CG
CG
CY
CU
CU
CB
CB
CD
CD
OA
DA
DB
DB
DD
OG
DG
ON
DN
DQ
DU
OU
OV
DV
DW
OW
D5
05
Trim Scheme
W/Gold
D8
08
D9 ............... W/Saddle
09
"'"
""
I.
Black
Blue
Red
Green
W/Red
WIRed
W/Blue
Tan
Gold/Cream
W/Black
W/Green
W/Gold
W/Saddle
(LIB
(L/B Split Bench)
Black
Blue
Red
Green
W/Red
WIRed
W/Blue
Saddle/Tan
SaddlelTan
Gold/Cream
W/Black
W/Green
W/Gold
. ..... , ........ W/Saddle
Picton B/Cloth &
&
Corinth. Vinyl
(LIB
(L/B Split Bench)
................... Blue
................... Red
Green
. .................. Gold
. ............. SaddlelTan
Saddle/Tan
(LIB
(L/B Split Bench)
.................. Black
................... Blue
Blue
Red
Red
Green
. ................ WIRed
W/Red
W/Blue
Saddle/Tan
SaddlelTan
. .......... , Gold Cream
W/Black
................ W/Green
I
I.
"'.'
","
",.
"'"
1.1
II
'
I'
",".
"'"
"""
","
""
1.1
'
I"
.,
1.1
"'
""
'"
I.'
"'
II
"'"
..........
""
"'
"'"'"'""
II
I.
"'"
"'"
","
I.'
","
11.1.'
I.
II
I.'
I"
1.1
1.1
",".
""
1.1
I"
""
FORD
Barletta B/Cloth
& Corinth.
Corinth. Vinyl
(LIB
(L/B Bench)
COUGAR
(LIB
(L/B Bucket)
""
1.1
"""
""
I'"
""
""
Code
Blue
Green
................... Tan
",.,
11.11.,
II"
I.'
I"
""
.,
PB
PG
PG
PU
PU
II
Dynasty Polyknit &

&
Corinth. Vinyl
(LIB
(L/B Bench)
I.'
"'.'
"",
"'"
Trim Scheme
Code
Green
.................. Black
AB . .................. Blue
Saddle
AZ
(LIB
(L/B Bench)
Blue
BB
Green
BG
BG
BZ
Saddle
Redondo B/Cloth &
&
Corinth. Vinyl
(L/B Bench)
(LIB
Black
DA
OA
Blue
DB
DG
Green
OG
Gold
DY
OY
Saddle
DZ
(L/B Bench)
(LIB
Blue
EB
EB
Green
EG
EG
EN
W/Red
EN
WIRed
EQ
EQ . ................ W/Blue
W/Black
EW
Gold
EY
Saddle
EZ
W/Green
E5
W/Gold
E8
W/Saddle
E9
(LIB
(L/B Bench)
FB . .................. Blue
FB
FD . ............... Ok.
Dk. Red
FO
FG
FG . ................. Green
FN . ................ WIRed
W/Red
FN
FQ
FQ . ................ W/Blue
FW . ............... W/Black
FY . .................. Gold
FZ . ................ Saddle
FZ
F5 ................ W/Green
F8 . ................ W/Gold
W/Saddle
F9
Westminster
Westminster B/Cloth
B/Cloth
& Corinth.
Corinth. Vinyl
Vinyl
(LIB
(L/B Bench)
GA . ................. Black
GA
GB ................... Blue
GB
Green
GG
GG
GZ
Saddle
AA
"'
",.
1.1
"'
'"
"'"
I"
""
""
'"
1.1
I,
II
I,.
",."
.,.
'
""
I"
""
"
I.,.
""
""
"'
1.1
.,
II
"""
"","
"'
"'
"'"'"
""
"'
","
",
"'"
III"'"
III'"
11'1
.,.,.
",.
",".","
1.1
1.11
""
"'
CY1419-G2
C
Y1419G2
BACK TO GROUP INDEX

20-01-14
20-01-14
20-01-14
INTERIOR TRIM
TRIM CODES
CODES
- Continued
INTERIOR
Code
Code
Trim Scheme
HA
HA
Cllde
Code
Vancleave B/Cloth
B/Cloth &&
Vancleave
SG
Corinth. Vinyl
Vinyl
Corinth.
SY
(LIB Flight
Flight Bench)
Bench)
(L/B
SZ
Trim Scheme
................. . Green
GB
Gold
GG
............... " ' Saddle
GZ
Black
HO
HD
II
JO
JD
TG
................. . Green
SaddlelTan
UU ............ . Saddle/Tan
HN
W/Red
WIRed
TZ
HW
(L/B Split Bench)
HY
.................. Green
IN ................. W/Red
JN
WIRed
YO
YD
JO
JQ
JV
JV
JW
JW
J5
J5
J8
J9
J9
KB
KB
KO
KD
KG
KG
KY
KZ
KZ
MB
MB
MO
MD
MG
MG
MZ
MZ
NB
NO
ND
NG
NG
NU
NU
RA
RB
RB
RO
RD
RG
RG
RY
RY
RZ
RZ
SB
SB
SO
SD
TB
Blue
JG
JU
JU
TA
. .................. Red
.................. Green
YB
W/Blue
SaddlelTan
Saddle/Tan
............. Gold/Cream
................ W/Black
................ W/Green
W/Gold
............... W/Saddle
Kasman B/Cloth &
&
Corinth. Vinyl
Vinyl
Corinth.
(LIB
(L/B Split Bench)
Blue
Ok. Red
Dk.
Green
Gold
Saddle
Corinth. Vinyl
(LIB
(L/B Split Bench)
Blue
Ok.
Dk. Red
Green
Saddle
Oynasty
Dynasty Polyknit &
Corinth. Vinyl
(L/B Split Bench)
Blue
Ok.
Dk. Red
Green
............. SaddlelTan
Saddle/Tan
Westminster B/Cloth
B/Cloth
& Corinth.
Corinth. Vinyl
Vinyl
(LIB
(L/B Split Bench)
Black
................... Blue
Ok.
Dk. Red
Red
.................. Green
................... Gold
................. Saddle
Vinyl
(L/B Split Bench)
Blue
................ Ok.
Dk. RAd
Red
II
""
"'"
""
""
II"
""
II
"'"
"'"
""
II
"'"
Blue
.................. . Red
Green
SaddlelTan
Saddle/Tan
I.
HQ
HO
'"
AB
AG
AG
............ "" W/Black
. .................. Gold
.............. "" Saddle

H5 . ............... W/Green
H8 . ................ W/Gold
H9 ............... W/Saddle
HZ
Barletta B/Cloth
Corinth. Vinyl
(LIB Split Bench)

(L/B
AZ
BB
BG
BZ
EB
EB
EO
ED
EG
EG
EU
EU
EV
FA
FB
FB
FO
FD
FG
FG
FN
FN
FO
FQ
FU
FU
FV
FV
FW
F5
F5
F8
F8
F9
F9
GA
GA
JB
Black
JD
JO
Blue
JG
Green
JY
Saddle
(L/B
(LIB Bench)
Blue
Green
Saddle
(LIB
(L/B Flight Bench)
Blue
Red
................. . Green
Saddle/Tan
SaddlelTan
Gold/Cream
Natural Grain Leather*
& Mateo
(LIB
(L/B Split Bench)
Black
Blue
................... Red
................. . Green
W/Red
WIRed
................. W/Blue
.............. SaddlelTan
Saddle/Tan
............ . Gold/Cream
................ W/Black
................ W/Green
W/Green
................. W/Gold
W/Gold
............... W/Saddle
Flanders B/Cloth &
Corinth. Vinyl
Vinyl
(LIB
(L/B Bench)
. ................. Black
JZ
"'
III'
",
","".,
II.
"",".
II
","
II
"'"
II
'
"'
1.11
II.,
II"
QB
OB
00
OD
QG
OG
QU
OU
RB
RO
RD
RG
RG
RY
RZ
VD
VO
VG
VU
W
W
""
Blue
WA
Red
WB
Green
WG
Gold
Saddle
WY
",""","
""
II".
II'.
"",""
II
II'
Corinth.
Vinyl
Cori nth. Vi
nyl
(L/B Split Bench)
VB
WZ
Dynasty
Oynasty Polyknit &
&
""
"'
W/Blue
& Corinth. Vinyl

&
"'
TY
Touraine B/C &

&
(LlBench)
(L/Bench)
AA
MERCURY
"'
"'"'"
YU
"
"'"
YG
"
(L/B
(LIB Split
Split Bench)
HG
Ok. Red
Dk.
Corinth.
Cori nth. Vinyl
Vi nyl
Saddle
"'"
(LIB Bench)
(L/B
(LIB Flight
Flight Bench)
Bench)
(L/B
JB
JB
I'"
HD
HO
UG
Ok. Red
Dk.
Saddle
HZ
HZ
.................. . Blue
UO
UD
"'
TD
TO
UB
""
Wilshire
Wilshire B/Cloth
B/Cloth &&
. .................. Blue
Gold
Blue
HB
HY
HY
(LIB Bench)
(L/B
HG .................. Green
HG
SA
SB
SB
SD
SO
SG
SG
SN
SN
SQ
SO
SU
SU
SV
SW
S5
58
S8
59
S9
Trim Scheme
.................. Green
Corinth. Vinyl
Ok. Red
Dk.
Code
Oynasty Polyknit
Polyknit &&
Dynasty
................... Blue
HB
HB
Trim Scheme
Code
YB
Blue
YG
YG
Red
Green
Saddle/Tan
SaddlelTan
Wilshire B/Cloth &
&
Corinth. Vinyl
(LIB
(L/B Flight Bench)
Blue
Red
Green
Gold
Saddle
(L/B Split Bench)
(LIB
Black
.................. . Blue
Red
............... "" Green
W/Red
............... "' WIRed
. ................ W/Blue
. ............. SaddlelTan
Saddle/Tan
Gold/Cream
Gold/Cream
............... W/Black
................ W/Green
W/Green
................. W/Gold
W/Gold
............... W/Saddle
W/Saddle
YN
YN
YQ
YO
YW
yy
YY
'"
""
III
""
""
1."
11.1
""
yz
YZ
Y5
Y8
Y9
"'"
"'
""
III
II
,.,.,
ZB
ZD
ZO
ZG
ZG
ZZ
. ................. Black
Blue
. .................. Red
. ................. Green
. .................. Gold
Saddle
(L/B
(LIB Split Bench)
. .................. Blue
Red
Green
Saddle/Tan
SaddlelTan
Gold/Cream
Redondo B/Cloth &
&
Corinth.
Cori nth. Vinyl
Vi nyl
(L/B Bench)
Black
Blue
Green
...................Green
Gold
Saddle
(LIB Bench)
(L/B
Blue
Green
W/Red
WIRed
W/Blue
W/Black
Gold
Saddle
W/Green
W/Gold
W/Saddle
Dynasty Polyknit &
Oynasty
Corinth. Vinyl
(L/B Bench)
(LIB
Blue
Red
Green
. ................ Saddle
II
""
""
II
""
""
""
","
",.
""
II"
III
11
""
""
11.11
","."
""
""
11.11
II
III"
"
1.11
""
""
""
"'"
"'"
"'"
THUNDERBIRD
Kasman B/Cloth &
Corinth. Vinyl
(L/B Split Bench)
FB . .................. Blue
FB
FD
Red
Red
FO
FR ................... Jade
FR
SaddlelTan
FU
Saddle/Tan
FU
FY ................... Gold
FY
I.
'"
I'"
11
1.1
'"
CY1419-G3
CY1419G3
BACK TO GROUP INDEX

20-01-15
20-01-15
INTERIOR TRIM CODES

- Continued
INTERIOR
Trim Scheme
Code
Aurora B/Cloth &&

Corinth. Vinyl
(LIB Split Bench)
(L/B
HA
Black
HB
Blue
HR
Jade
HZ ................. Saddle
Mateo Vinyl
(LIB Split Bench)
(L/B
JA
Black
JB
Blue
IN
JN
W/Red
WIRed
JO
JQ
W/Blue
JR
Jade
W/Black
JW
JZ
Saddle
W/Jade
J5
W/Gold
J8
J9 ............... W/Saddle
& Mateao Vinyl
&
(LIB
(L/B Split Bench)
KA .................. . Black
KB
Blue
KD
Red
Red
KN
WIRed
W/Red
KO
KQ
W/Blue
KR ...................... . Jade
KU ... , ............. Saddle!Tan
Saddle/Tan
KW
W/Black
KY ...................... . Gold
K5
W/Jade
K8
W/Gold
K9
W/Saddle
(LIB
(L/B Split Bench)
OD
QD
Red
Red
QY
Gold
(LIB
(L/B Split Bench)
RD
RD
Red
Red
RY
Gold/Cream
o.
o.o.
o.o.
....
....
o..o.
o.
o.
o.o..o.o.
....
o.
o.
o.o.
...
o.o.
..
o.
...
o..o.
..
o.
....
o.
o.
..
o.
o.o.o.
...
o.
o.
o.
o..o.
.....
.......
o.
o.
...
...
o..o.
o.
..
o.
o.
..
...
......
.o.o.
o.
......
o.
o.o.
o.
........
o.
..............
o.
.o.
.o.
o.
o.
.........
o.
o.
o.o.
.......
o.
......
..............
...........
o.
..........
.........
o.
...............
.............
o.
..
...........
o..o.o.
o.o.o..o.o.
.............
...
....
o.o..o.
o.
o.
o.
o.
.....
.........................
...................
...............
Code
BB
BD
BN
BO
BQ
BU
BW
BY
BZ
B5
B8
Trim Scheme
................... Blue
.................... Red
.Red
WIRed
W/Red
............. " " . W/Blue
Tan
Tan
............... W/Black
Gold
Saddle
................. W/Jade
W/Gold
89
W/Saddle
B9
(LIB Split Bench)
(L/B
CK
Aqua
&& Mateao Vinyl
(L/B Split Bench)
Apricot
DC
Cran/Rose
DH
DN
W/Lip/Red
DR
Jade
DV
Gold/Creme
D5
W/Jade
D9
W/Saddle
(L/B Split Bench)
EK
Aqua
Majestic B/Cloth &
Corinth. Vinyl
(L/B Split Bench)
GB
Blue
GD
Red
Red
Tan
GU
Tan
"'"
.o..o.o.
.o.
AA
Black
AB
Blue
AB
AD
Red
AD .................. . Red
AU
Tan
AU
Tan
AY .................... . Gold
AZ ................... .. Saddle
Leather*
&
& Corinth.
Corinth. Vinyl
Vinyl
(LIB
(L/B Split Bench)
BA .................... .. Black
Black
o.
...............
.................
o.
o.
o.
o.o.
....
o.
o.o.
..
o.
o.
...
....
o.
o.
o.
...
...
....
.....
o.
.....
o.
o.
o.
o.o.
o.
o.
..
o.o.
o.
.................
o.
o.
..........
...
o.
o.o.
....
......
....................
....
o.
.......
......
.............
..
o.
......................
......
o.
o.
.........
o.o.
o.
.........
.................
LINCOLN
Kasman B/Cloth &
&
Corinth. Vinyl
(LIB
(L/B Bench)
BB . .......................... Blue
BD ......................... . Red
Red
BJ ........................ . Taupe
BR
Jade
Tan
BU
BU
Tan
BY
Gold
Leather*
&
& Mateao Vinyl
Vinyl
(LIB
(L/B Bench)
Black
DA
Blue
DB
DB
Red
DD
DD .....................Red
Taupe
DJ
DJ
DN
DN .................... WIRed
W/Red
DO
DQ ................... W/Blue
DR
Jade
DR
Tan
DU
DU
Tan
W/Black
DW
DW
W/Black
DY
DY ..................... . Gold
Gold
o.
o.
......
o.o.
o.
.......
......................
................
Kasman B/Cloth &

&
Corinth. Vinyl
(L/B Split Bench)
...
.o.
MARK IV
o.
o.
.....
o.o.
.................
.o.
o.
o.
o.
......
...................
................
..............
.....
o.
o.
o.o.
o.
..........
...........
Code
Trim Scheme
03 . .............. W/Taupe
W!Taupe
D3
D4 ................. W/Tan
W!Tan
D5
W/Jade
D8 . ................ W/Gold
&& Mateao Vinyl
(L/B Split Bench)
EA . ................. Black
EB
Blue
EO
Red
ED
Red
EJ
Taupe
EN
W/Red
WIRed
EO
EQ
W/Blue
ER
Jade
Tan
EU
Tan
W/Black
EW
EY
Gold
W!Taupe
E3
W/Taupe
W!Tan
E4
W/Tan
W/Jade
E5
E8
W/Gold
Kasman B/Cloth &
&
Corinth. Vinyl
(LIB Split Bench)
(L/B
FB . ....................... Blue
FD
Red
Red
FJ
Taupe
FJ
FR
Jade
FU
Tan
FU
Tan
FY .................... Gold
& Mateao Vinyl
(L/B Bench)
(LIB
HA
Black
HB ............................ Blue
Red
Red
HD
Taupe
HJ
HR ............................... Jade
HU
Tan
Tan
HY
Gold
(L/B Split Bench)
(LIB
JA
Black
Blue
JB .....................Blue
Red
Red
JD
Taupe
JJ
JR
Jade
JU ........................ Tan
Tan
JY .................... Gold
Leather*
& Mateao
Mateao Vinyl
Vinyl
&
(L/B Split Bench)
KA
KA
Black
KB
KB
Blue
KD
Red
KD
Red
KJ .................... Taupe
Taupe
KJ
"'"
..o.
o..o.
.o.
......
o.o.
o.o.
.....
..o.
o.
..
o.o.
.....
....
..o.
..
....
....
o.
o.
.....
o.
.....
o.
o.o..o.
o.
o.o.
o.o.
....
......
'O
............
W/Red
WIRed
. .................. Tan
Tan
. .............. W/Black
. .................. Gold
. ............... W/Taupe
W!Taupe
W/Tan
. ............ .. W!Tan
",
o.o.
....
o.o.
o..o..o.o.
........
.......
o.
o..o.o.
W/Jade
W/Gold
o.
o.
o.
...
........
o.o..o.
o.
o.
. ................ W/Blue
. .................. Jade
......
o.
o.
.........
.................
o.
o.
.........
..............
..
o.o..o.o.
o.
KN
KO
KQ
KR
KU
KW
KY
K3
K4
K5
K8
Trim Scheme
o.
o.o..o.o.
o.
o.
o.
o.
o.o.o.o.o.o.o.
o.o..o..o..o.
......
...
....
......
..
o.
o.o.
o..o.o.
..o.
o.
Code
o.
o.o.
o.
o.
.....
..
......
o.o.
........
...
o.
o.
....
....
o.
o.
......
..................
...
o.
.....
......
o.
o.
.....
o.
o.
.....
o.
.......
o.
....
.....................
..............
o.
......
..................
................
o.
.......
o.
.........
o.
o.o.
...
o.
...
..........
..................
.....
o.
o.
......
o.
o.
........
o.
o.o.o.
o.
........
....
o.
......
CY1419-G4
CY1419G4
BACK TO GROUP INDEX

21-01-1
21-01-1
21-01-1
21-01-1
Gasoline Engines
GROUP
Gasoline Engines
PAGE
PART 21-01
21-01
21-01-1
21-01-1
General Gasoline Engine Service .........
PART 21-05
21-051
21-05-1
..
2300 cc
cc Four-Cylinder
Four-Cylinder Engine .........
PART 21-10
200 and 250 CID
200and250CID
21-10-1
21-10-1
...
Six-Cylinder
Six-Cylinder Engines .' ............
PART 21-12
21-12-1
2800 cc
cc V-6 Engines .................
21
21
PAGE
PART 21-21
302 and 351W CID
V-8 Engine ......................
PART 21-22
351
M and
and 400
400 CI0
CID
351 M
V-8 Engines .... ..... ......... ...
PART 21-24
460 CI0
CID V-8 Engines ................
PART 21-27
460 CID Police
Interceptor Engine ... , ............
21-21-1
21-21-1
21-22-1
21-22-1
21-24-1
21-24-1
21-27-1
21-27-1
PART 21-01
21-01 General Gasoline Engine Service
Page
COMPONENT INDEX
INDEX
Ventilation System
Hydraulic Valve Clearance -Except 2.3 and 2.8

2.8 Engines
01-7
DIAGNOSIS AND TESTING
Timing Chain Deflection
01-4
01-6
Timing Gear Backlash --
Play . . . . . . . . . . . . . . . . .
Camshaft End Play.
01-6
Camshaft Lobe Lift
01-4
.
01-4
Play
Crankshaft End Play............
.....
01-7
Flywheel Clutch Face Runout -Manual-Shift Transmissions
01-7
Flywheel Runout - Automatic

Transmissions . . . . . . . . . . . . . . . . . ..
Transmissions.
01-7
Hydraulic Valve Lifter and

Hydraulic Lash Adjuster
Adjuster. . .. . . . . . . . . .
01-5
BACK TO GROUP INDEX
Page
Positive Closed-Type Crankcase
ADJUSTMENTS
Compression Test
INDEX
COMPONENT INDEX
Engines
V-6 Engines..
.. .... . .. .. .. ......
Timing Gear Runout
01-6
01-6
GENERAL INFORMATION
01-2
OVERHAUL
OVERHAUL
Repair .. . . . . . ... .... . . ...
Camshaft Repair.
01-14
Cleaning and Inspection . . . . . . . . . . . . ..
01-16
Crankshaft
01-14
.. . . .. .. ..
Cylinder Block.....................
Block
01-15

21-01-2
21-01-2
General Gasoline Engine Service
.------------------o--r-------.,....-,--------------------r------.
COMPONENT INDEX
Page
OVERHAUL (Cont'd.)
(Cont'd.)
COMPONENT INDEX
Crankshaft Rear Oil Seal --
Cylinder Head
Head
01-13
01-12
01-10
01-9
302 and 351W V-8
01-9
SPECIAL SERVICE
TOOLS
SERVICETOOLS
01-21
01-21
2800 cc Engine
Flywheel Ring Gear - Manual
Fitting Main or Connecting Rod

.
01-14
Shift Transmission
Piston,
Piston, Pins
Pins and
and Rings
01-14
Rocker Arm Stud Nut
Valves
01-13
Bearings with Plastigage
REMOVAL AND INSTALLATION

INSTALLATION
Replacement - 302 V-8

Rocker Arm Stud Replacement
Core Plugs
01-10
Crankshaft Rear Oil Seal

Seal -Except 2800 cc
cc Engine
Page
"
01-11
01-11
NOTE: The infonnation

information in this Part applies to both 1975 and 1976 model year vehicles unless otherwise
specified.
wise
CR1966-A
CR1966-A
GENERAL INFORMATION
INFORMATION
All passenger car engines incorporate
All
closed-type crankcase ventilation
ventilation
aa closed-type
system and exhaust emission control
on all
all engines.
engines. All engine emission
system on
control systems are covered in detail in
29 (Diagnosis) and Volume 5
Group 29
(Maintenance).
(Maintenance).
To maintain the required exhaust
levels, the carburetor and
emission levels,
be kept in good operating
engine must be
recommended
condition and meet recommended
specifications.
adjustment specifications.
tests, adjustments
adjustments
When performing tests,
repairs to the engine,
engine, ignition system
or repairs
system, it is
is essential to follow the
or fuel system,
procedures and specifications in Groups
21, 23,
23, 24
24 and 29
29 of this Manual.
Before replacing damaged or worn
engine components such as the
BACK TO GROUP INDEX
crankshaft, cylinder heads, valve guides,

valves, camshafts or cylinder block, be
valves,
sure the part(s) are not repairable.
The following sections cover engine
adjustment and repair procedures.
tests, adjustment
In addition, the cleaning and inspection
procedures are covered. Engine assembly
of
and repair specifications are at the end of
each specific Part.
For engine removal, disassembly,
adjustment
assembly, installation and adjustment
procedures, refer to the pertinent Part of
of
this Group.
For quick engine identification, refer
Certification Decal shown
to the Safety Certification
in Fig.
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
refer to the engine
identification
identification chart to determine the
engine type and size. An engine
identification
identification tag is also attached to the
engine. The symbol code on the
identification
identification tag (Fig. 1) identifies each
engine for determining parts usage; i.e.,
engine cubic inch displacement
displacement and
model year.
The charge level and engine code
number determine if parts are unique to
specific engines. The engine plant codes
designate where and when engines were
built. It is imperative that the codes on
the
be used when
the engine identification tag be
ordering parts or making inquiries about
the engine. The pertinent
pertinent codes are
shown in the Master Parts Catalog to
designate unique parts.

21-01-3
21-01-3
rSS63H100001r
(VEHICLE
NUMBER)
(VEHICLE IDENTIFICATION
IDENTIFICATION NUMBER)
SAFETY CERTIFICATION DECAL (TYPICAL)

MFD. BY FORD MOTOR CO. IN U.S.A.
DATE: 07
GVWR 5892
5S92
07 74
74
GAWR:
2964. REAR 2928
292X
GAWR FRONT 2964.
G)
THIS VEHICLE CONFORMS TO ALL

APPLICABLE
APPLICABLE FEDERAL MOTOR
VEHICLE SAFETY STANDARDS IN
EFFECT ON THE DATE OF MANU1\1ANUFACTURE SHOWN ABOVE
ABOVE.
CD
CD
PASSENGER~------~13
PASSENGER
*oS6.*HI00()()l
'X\\\. I^LNT. NO.
TYP1
TYPI
TRA~S.
AXU
m\~\~
(9)
7)(8)
CD
DSO
10
(10
12
11
(J)
(UNITED STATESI
STATES!
o
o
CONSECUTIVE UNIT NO.

NO. M M VINYL
TYPE COLOR
VINYL ROOF
ROOF TYPE/COLOR
CODE
BODY SERIAL CODE
M M TRIM
TRIM CODE
MODEL
MODE L YEAR
YEAR CODE
CODE
@
MO) TRANSMISSION CODE
( j 7 ) REAR AXLE CODE
@
@ DISTRICT SPECIAL EQUIPMENT
@ VEHICLE TYPE
TRANSMISSION CODE
ASSEMBL Y PLANT CODE

ASSEMBLY
CODE
REAR AXLE CODE

DISTRICT
BODY TYPE
TYPE CODE
SPECIAL EQUIPMENT
VEHICLE TYPE
ENGINE CODE
ENGINE
BODY COLOR CODE
ENGINE COOES
CODES
FORD
FORO
METEOR
CODE
TORINO
PINTO
ELITE
RANCHERO BOBCAT
GRANADA
MAVERICK
MUSTANG
TIBIRD
T/BIRO
MERCURY
COMET
M0NTEG0
MONTEGO MONARCH COUGAR LINCOLN
MARK IV
2300CC-2V
yY
2800CC-2V
200-1
200-IVV
T*
250-1V
302
2V
3022V
351W2V
3b1W-2V
3b1M?V
351
ML'V
400-2V
4002V
460-4V
4604V
PI
460-4V PI
1975M.
* 19751
yY
Z
Z
CJ
.... &AI
CJ
&I(
CJ
CJ
Low Comp.
Export
CJ
i ! i
~l
Conv.
I:i.
Low Comp.
Export
Conv.
&AI
~
0
Low Comp.
Export
CJ
t:
Low Comp
Export
,;
Low Comp.
Export
t:
Low Comp.
Export
CJ
t
!
Conv.
II(
.... &AI
Low Comp.
Export
CJ
Low Comp.
Export
I.e
.... &AI
~l
Conv.
CJ
Low Comp.
Export
&AI
It
CJ&,
Conv.
CJ
Low Comp.
Export
Conv.
CJ
Low Comp.
Export
'>
CJ
$
t:
Conv.
ENGINES
E
0
Low Comp.
Export
Low Comp.
Export
t
l:
<3i
Conv.
f---..-----
T*
L
F
F
H
H**
H**
Q
Q
Q
Q
s
S
**Granada/Monarch Only
A3688-E
A3688
E
Identification
FIG. 1 Engine Identification
BACK TO GROUP INDEX

21-01-4
21-01-4
If one, or more cylinders read low,

If
squirt approximately one (1) tablespoon
of
of engine oil on top of the pistons in the
low reading
r e a d i n g cylinders.
c y l i n d e r s . Repeat
Repeat
low
compression pressure check on these
cylinders.
I f compression
c o m p r e s s i o n improves
improves
1. If
considerably, the piston rings are at
fault.
2. If
If compression does not improve,
2.
valves are sticking or seating poorly.
3. If
If two adjacent
adjacent cylinders indicate low
compression pressures and squirting
oil on the pistons does not increase
the compression, the cause may be a
the
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
following
quick reference chart (Fig. 2) be used
when checking cylinder compression
c h a r t has been
pressures. The chart
calculated so that the lowest reading
number is 75 percent of the highest
reading.
Example
If, after
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
specifications
155PSI,the engine is within specifications
compression is considered
considered
and the compression
satisfactory.
CAMSHAFT LOBE LIFT
All Except 2300cc Engine
Check
Check the lift
lift of
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

2.
arms, remove the valve rocker arm
shaft(s) assembly as detailed in the
pertinent part.
On the stud mounted rocker arms,
remove the rocker arm stud nut,
fulcrum seat, oil deflector
deflector and rocker
arm. Use the adapter for ball-end
push rods.
3.
3. Make sure the push rod is in the valve
lifter socket. Install a dial indicator in
lifter
such a manner as to have the ball
socket adapter of the indicator on the
end of the push rod and in the same
plane as the push rod movemen
movementt (Fig.
4).
3 or 4).
POSITIVE CLOSED-TYPE
CRANKCASE VENTILATION
SYSTEM
All
A l l emission
e m i s s i o n system
s y s t e m related
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
2.
choke plate in the wide open position.
3. Install a compression gauge in No.
No.11
cylinder.
4. Install an auxiliary starter switch in
4.
starting circuit. Using the
the
the starting
auxiliary starter switch, crank the
engine (with the ignition switch off)
off)
at least five compression strokes and
record the highest reading.
Note the approximate number of
of
compression strokes required
required to
compression
obtain the highest reading.
5. Repeat the test on each cylinder as
5.
was required to obtain the highest
reading on the No. 1 cylinder.
Test Conclusion
The indicated compression pressures
specification if the
are considered within specification
lowest reading cylinder is within 75
ppercent
e r c e n t of
of tthe
h e hhighest.
i g h e s t . (See the
the
percentage chart given in Fig. 2.)
Tool-6565
PUSH ROD
Too/-6565-AB
A3129-A
A3129A
FIG.
FIG. 3 Testing Camshaft Lobe
LiftRocker Shaft Mounted
Lift-Rocker
Rocker Arms
Maximum
PSI
PSI
Minimum
PSI
PSI
Maximum
PSI
PSI
Minimum
Maximum
PSI
PSI
PSI
PSI
134
134
136
136
138
138
140
140
142
142
144
144
146
146
148
148
150
150
152
152
154
154
156
156
158
158
160
160
162
162
164
164
166
166
168
168
170
170
172
172
101
101
102
102
104
104
105
105
107
107
108
108
110
110
111
111
113
113
114
114
115
115
117
117
118
118
120
120
121
121
123
123
124
124
126
126
127
127
129
129
174
174
176
176
178
178
180
180
182
182
184
184
186
186
188
188
190
190
192
192
194
194
196
196
198
198
200
200
202
202
204
204
206
206
208
208
210
210
212
212
131
131
132
132
133
133
135
135
136
136
138
138
140
140
141
141
142
142
144
144
145
145
147
147
148
148
150
150
151
151
153
153
154
154
156
156
157
157
158
158
214
214
216
216
218
218
220
220
222
222
224
224
226
226
228
228
230
230
232
232
234
234
236
236
238
238
240
240
242
242
244
244
246
246
248
248
250
250
Minimum
PSI
PSI
160
160
162
162
163
163
165
165
166
166
168
168
169
169
171
171
172
172
174
174
175
175
177
177
178
178
180
180
181
181
183
183
184
184
186
186
187
187
CA1005A
CA1005A
FIG. 2 Quick Reference Compression Pressure Limit Chart

FIG.
BACK TO GROUP INDEX

21-01-5
21-01-5
valve
1. Remove the air cleaner and the valve
rocker arm cover.
2. Measure the distance between the
major
5)
major and minor diameters (Fig. 5)
of
of each cam lobe with a Vernier
caliper and record the readings. The
difference
difference in the readings on each cam
is the lobe lift.
Tool-6565
DIMENSION A
A MINUS
DIMENSION B EQUALS
EaUALS
THE CAM LOBE LIFT
Tool-6565-AB
Tool~S6s.AB
21-01-5
21-01-5
Tool~420UC
Tool-4207.C
A2958.A
A 29 58-A
Camshaft Lobe
FIG. 44 Testing Camshaft
Lift-Stud Mounted Rocker
LiftStud
Arms
4. Connect an auxiliary starter switch in

the starting circuit. Crank the engine
with the ignition switch OFF. Bump
crankshaft over until the tappet or
the crankshaft
lifter is on the base circle of the
lifter
camshaft lobe. At this point, the push
camshaft
rod will be in its lowest position.
5. Zero the dial indicator. Continue to
crankshaft slowly until the
rotate the crankshaft
push rod is in the fully raised position
(highest indicator reading).
6.
6. Compare the total lift recorded on the
indicator with specifications.
7.
7. To check the accuracy of the original
indicator reading, continue to rotate
the crankshaft
crankshaft until the indicator
reads zero.
zero. If the lift on any lobe is
below specified
specified wear limits, the
camshaft
ve lifters
camshaft and the val
valve
lifters
operating on the worn lobe(s) must be
replaced.
8.
8. Remove the dial indicator and
auxiliary starter switch.
On the rocker shaft type mounted
rocker arms,
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.
Part.
After installing the
the rocker
rocker arms,
arms, do
do
not rotate the
the crankshaft until the
hydraulic valve lifters have had
time to
to bleed down.
down. To
To do
sufficient time
may cause serious valve
otherwise may
damage. Manually
Manuallybleeding
bleedingdown
downwill
will
damage.
reduce the
the waiting time
time requirement.
requirement.
reduce
9.
9. Install the
the valve
valve rocker arm cover(s)
cover(s)
and the air cleaner.
cleaner.
2300cc Engine
Check the lift of each lobe in
consecutive order and make
make aa note of the
readings.
readings.
BACK TO GROUP INDEX
A
A3454-B
A3454B
much oil in the system or too low

an oil
Iowan
oil
level. Air may also be drawn into the
lubricating system through an opening in
in
a damaged oil pick-up tube. Air in the
system will cause a loss of
of hydraulic
pressure. Assembled valve lifters
be
lifters can be
tested with Tool 6500-E to check the leak
leak
down
down rate. The leak
leak down
down rate
specification
specification is the time in seconds for the
plunger to move a specified
specified distance of
of
its travel while under a 50 lb. load. Test
the valve lifters as follows:
1. Disassemble and clean the lifter
lifter to
remove all traces of engine oil.
Lifters
Lifters cannot be checked with
engine oil in them. Only the testing
fluid can be used.
used.
2. Place the valve lifter
lifter in the tester,
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
manufacturer of the tester.
Using kerosene or any other fluid will
not provide an accurate test.
3. Place the 5/16-inch
5/16-inch steel ball
provided with the tester in the
plunger cap (Fig. 6).
FIG. 5 Measuring Camshaft Lobe Lift
If the readings
readings do not meet
3. If
specifications, replace the camshaft
follower.
and corresponding cam follower.
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 2300cc
23OOcc engirie
engine are a
zero-lash hydraulic device, similar in
construction
construction and operation to the
hydraulic valve lifters used on push-rod
engines.
engines. They are cleaned, inspected and
checked in the same manner. The
instructions below apply equally to the
lash adjuster. Leak-down rates for the
lash adjuster and hydraulic lifters are
covered in the Specifications Section of
the engine Part.
Hydraulic valve lifter noise may be
caused by improper operating clearance
as a result of loose adjusting nuts or
improper initial adjustment. Always
check rocker arm to valve
valve stem clearance
before replacing a valve lifter.
lifter.
Dirt, deposits of gum and varnish and
in the lubricating oil can
air bubbles iI1
cause hydraulic valve lifter failure or
malfunction.
Dirt, gum
gum and
and varnish can
can keep
keep a
valve from
from seating and
and cause
causeaaloss
loss
check valve
hydraulic pressure.
pressure. An
An open
open valve
valvedisc
disc
of hydraulic
will cause the
the plunger to force oil back
will
the valve
valve lifter reservoir during the
the
into the
is being
being lifted
lifted and
and force
force
time the push rod is
the valve
valve from its
its seat.
seat. Air bubbles in
in the
lubricating system can be
be caused by
by too
Tool-6500-E
5-B
FIG. 6 Placing Steel Ball in Valve

Lifter Plunger
4. Adjust the length of the ram (Fig.

(Fig. 7)
4.
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
Timing mark.
mark.
the Start Timin~
Use the center mark on the pointer
scale as
as the Stop Timing point instead
of the original Stop Timing mark at
the top of the scale.
scale.
5.
5. Work the valve
valve lifter plunger up
up and
fills with fluid
down until the lifter fills
and all traces of air bubbles have
disappeared.
6.
6. Allow the ram and weight to force the
lifter plunger downward.
downward.
valve lifter
Measure the exact time it takes for the
Start
pointer to travel from the Start
to the Stop
Stop Timing marks of
Timing to
the tester.
tester.
the
7. A
A valve
valve lifter that isis satisfactory must
7.
have aa leak-down rate (time in
seconds) within the minimum and
maximum limits specified.
specified.
21-01-6
CAMSHAf=T
CAMSHAFT
THRUST PLATE
FIG. 7 Adjusting the Ram Length

If the valve lifter
lifter is not within
8. If
specifications, replace it with a new
lifter. It is not necessary
necessary to
lifter.
disassemble and clean new valve
lifters before testing, because the oil
contained in new lifters is test fluid.
fluid from the cup and
9. Remove the fluid
lifter by
bleed the fluid from the lifter
working the plunger up and down.
This step will aid in depressing the
lifter plungers when checking the
valve clearance.
CAMSHAFT END PLAY
2300cc Engine
camshaft drive belt
Remove the camshaft
cover. Push the camshaft
camshaft toward the rear
of the engine.
engine. Install a dial indicator so
that the indicator
indicator point is on the
camshaft
camshaft sprocket attaching screw or
gear hub. Zero the dial indicator.
indicator.
Position a large screwdriver between the
camshaft
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
excessive, replace the thrust plate
play is excessive,
(Fig. 8).
at the rear of the cylinder head (Fig.
Remove the dial indicator and install the
camshaft drive belt cover.
All Except 2300cc Engine
On all V-8
V-8 engines,
engines, prying against the
aluminum-nylon camshaft sprocket, with
the
the valve train
train load
load on
on the
the camshaft, can
break or damage the sprocket. Therefore,
the rocker arm adjusting nuts must be
backed off, or the rocker arm and shaft
shaft
sufficiently to
assembly must be loosened sufficiently
free the camshaft. After checking the
camshaft end play, adjust the valve
clearance.
clearance.
Push the camshaft toward the rear of
the engine.
engine. Install aa dial indicator so
so that
the indicator point is
is on the camshaft
camshaft
sprocket attaching screw (Figs.
(Figs. 9,
9, 10
10 and
and
11).
11). Zero the dial
dial indicator. Position a
large
large screwdriver between the camshaft
camshaft
sprocket or gear and the
the block.
block. Pull the
camshaft
camshaft forward and release it.
it.
Compare the
the dial
dial indicator reading with
specifications. If
If the
the end play isis excessive,
excessive,
replace the
the thrust plate.
plate.
replace
Remove
Remove the
the dial
dial indicator.
indicator.
BACK TO GROUP INDEX
SCREW & WASHER

A3722-A
FIG. 8 Cam Shaft Thrust Plate

Installation2300cc
Installation-2300cc
21-01-6
Hold the gear firmly against the block
block
while making the check. Refer
Refer to the
specifications
specifications for the backlash limits. If
If
backlash exceeds specifications, replace
both gears.
TIMING
TIMING GEAR RUNOUT
Install a dial indicator on the cylinder
block as shown in Fig. 13. Hold the
camshaft
camshaft gear against the camshaft
thrust plate and zero the indicator.
Rotate the crankshaft
crankshaft to turn the
camshaft,
camshaft, while holding the camshaft
gear against the thrust plate. Check the
gear runout
runout through
through one complete
revolution of the camshaft. If
If the gear
runout exceeds specifications, remove it
and check for burrs or foreign particles
on or between the camshaft
camshaft and gear
joiningflanges.
flanges. Recheck the runout; if it
still exceeds specifications, replace the
gear.
TOOL-4201-C
OO/-6565
A1374-B
11 Checking Camshaft End

FIG. 11
Play1-6 Engine
Play-I-6
A2988-A
FIG. 9 Checking Camshaft End

Play-V-8
PlayV-8 Engine
FIG. 12
12 Checking Timing
Timing Gear
FIG.
Backlash
Backlash
FIG. 10 Checking Camshaft End

End
FIG.
Play-V-6
PlayV-6 Engine
TIMING GEAR BACKLASH-V-6

BACKLASHV-6
ENGINE
Install aa dial
dial indicator on
on the
the cylinder
block (Fig.
(Fig. 12).
12). Check the backlash
between the camshaft gear and the
dial indicator.
indicator.
crankshaft gear with aa dial
above procedure to check

Follow the above
runout.
crankshaft gear runout.
DEFLECTION
TIMING CHAIN DEFLECTION
1. Rotate
R o t a t e the crankshaft
c r a n k s h a f t in a
1.
(as viewed
viewed
counterclockwise direction (as
the front) to
to take
take up
up the
the slack
from the
on the
the left side
side of the
the chain.
chain.
on
2. Establish aa reference point on
on the
2.
this point to
to
block and measure from this
the chain (Fig.
(Fig. 14).
14).
the
21-01-7
3. Rotate the crankshaft
crankshaft in the opposite
direction to take up 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
difference between
deflection is the difference
the two measurements.
If the deflection
d e f l e c t i o n exceeds
exceeds
If
specifications, replace the timing
chain and sprockets.
CRANKSHAFT END PLAY
1.
1. Force the crankshaft
crankshaft toward the rear
of the engine.
2. Install a dial indicator so that the
contact point rests against the
contact
crankshaft
crankshaft flange and the indicator
crankshaft axis
axis is parallel to the crankshaft
(Fig. 15).
3. Zero the dial indicator. Push the
crankshaft forward and note the
crankshaft
reading on the dial.
4. If the end play exceeds the wear limit,
replace the thrust bearing. If the end
play.is
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,
they probably were not aligned
properly. Install the thrust bearing
and align the faces following the
procedure recommended under Main
Bearing Replacement in the pertinent
engine section. Recheck the end play.
FLYWHEEL
RUNOUT-AUTOMATIC
RUNOUTAUTOMATIC
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
crankshaft
forward or backward as far as possible to
prevent crankshaft
crankshaft end play from being
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.
ADJUSTMENTS
HYDRAULIC VALVE
CLEARANCEEXCEPT 2.3 AND
CLEARANCE-EXCEPT
2.8 ENGINES
The 2.3
2.3 engine is an overhead cam
engine with hydraulic lash adjusters.
Refer to Part 21-05 for adjustment
adjustment
procedures. The 2.8 engine has
mechanical lifters. Refer to Part 21-12 for
adjustment procedures.
adjustment
The valve arrangement on the left
bank is E-I-E-I-E-I-E-I and on the right
BACK TO GROUP INDEX
21-01-7
FLYWHEEL CLUTCH FACE

RUNOUT-MANUAL-SHIFT
RUNOUTMANUAL-SHIFT
TRANSMISSIONS
Install a dial indicator so that the
indicator point bears against the flywheel
(Fig. 16).
16). Turn the flywheel making
face (Fig.
sure to hold it in the full forward or
rearward position so that crankshaft
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 the flywheel and
the face of the crankshaft
crankshaft mounting
flange. If no burrs exist, check the runout
crankshaft mounting flange.
of the crankshaft
flange.
Replace the flywheel or machine the
crankshaft-flywheel
crankshaft-flywheel mounting face
sufficiently
sufficiently to true up the surface if the
mounting flange runout
runout exceeds
specifications. Replace it or reinstall it on
the flywheel. Refer
Refer to Ring Gear
Replacement in this Part for the proper
procedure.
Tool -4201-
FIG. 13 Checking Timing Gear

Runout
REFERENCE
POINT
FIG. 14 Checking Timing Chain

DeflectionTypical
Deflection-Typical
Tool -4201 -C
A1408-C
FIG. 16 Checking Flywheel Face

Runout
Tool
UC
A2987-B
FIG. 15 Checking Crankshaft End

Play
bank is I-E-I-E-I-E-I-E. For the

6-cylinder engine, the valve arrangement
1- E-I-E-E-I-E-I -1- E.
is E-IE-M-E-I-E-E-I-E-I-l-E.
A O.060-inch
0.060-inch shorter push rod or a
0.060-inch longer push rod are available
O.060-inch
for service to provide a means of
compensating for dimensional changes in
mechanism. Refer to
to the
the Master
the valve mechanism.
Parts List for the pertinent color code.
Valve stem to valve rocker arm
specifications
clearance should be within specifications
with the hydraulic lifter
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
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:
check:
following
1. Connect an auxiliary starter switch in
1.
the starting circuit. Crank the engine
with the ignition switch OFF until the
No. 1 piston is on TDC after
after the
compression stroke.
21-01-8
Tool - 6513-AC
FIG. 17 Checking Valve

Clearance-Hydraulic
ClearanceHydraulic Valve
Lifters
2. With the crankshaft

crankshaft in the positions
designated in Steps 3, 4 and 5 position
lifter compressor tool
the hydraulic lifter
on the rocker arm. Slowly apply
pressure to bleed down the hydraulic
lifter until the plunger is completely
lifter
bottomed (Fig. 17). Hold the lifter
lifter in
this position and check the available
With No.
With
No.11 at TDC at end
end of compression stroke
and 3 approximately
make aa chalk mark at points 2 and
apart.
90 degrees aport.
21-01-8
clearance between the rocker arm and

the valve stem tip with a feeler gauge.
The feeler gauge width must not
exceed 3/8-inch. If
If the clearance is
specifications, install a
less than specifications,
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'
end of
of the compression
compression stroke,
stroke,
(POSITION NO.
NO.11 in Fig. 18) check
the following valves:
302
302 and 460 Engines
No. 1 Intake No. 1 Exhaust
No.
No.77 Intake No.
No.55 Exhaust
No.
No.88 Intake No.
No.44 Exhaust
351-JJ;
351- W,351-M
351-Mand
and400
400Engines
Engines
No.
No.44 Intake No. 3 Exhaust
crankshaft to POSITION
NO. 2 in Fig. 18 and check the
following valves:
302
302 lind
and 460 Engines
No.22 Exhaust
No. 5 Intake No.
No.44 Intake No.
No.66 Exhaust
No.
351-Jt;
351- W,351M
351-Mand
and400
400Engines
Engines
No.
No.33 Intake No.
No.22 Exhaust
5. Rotate'
NO. 3 in Fig. 18 and check the
following valves:
3(J2
302 and 460 Engines
No.22 Intake No.
No.77 Exhaust
No.
No.33 Intake No.
No.33 Exhaust
No.
No.
351- W,351M
351-MIlnd
and400
400Engines
Engines
351Jt;
No.22 Intake No.
No.44 Exhaust
No.

No.66 Intake No.
No.88 Exhaust
No.
Positive Stop
Engines With
With Positive
Stop Rocker
Rocker
Arm Studs
Arm
Studs
The positive stop rocker arm stud
eliminates the necessity of adjusting
adjusting
the valve clearance. However, to
obtain the specified
specified valve lash, it is
important that all valve components
be in a serviceable condition and
installed and torqued properly. Each
stud nut should be removed and
inspected for conditions shown in Fig.
19 when adjusting valve clearance.
6. With the crankshaft
crankshaft in the positions
designated in Steps 2, 3 and 4 remove
the stud nut and inspect
inspect it for
for
conditions shown in Fig. 19.
Install the stud nuts on the stud and
turn the nut clockwise
clockwise until it
turn
contacts the stop. Torque the stud nut
to specifications.
7. With the No.
No.11 piston on TDC at the
end of
of the compression
compression stroke,
POSITION NO. 1 in Fig 18, inspect
the stud nut and install the stud nut
on the following valves:
302 and 460 Engines
No.11 Intake No.
No.11 Exhaust
No.
No.44 Exhaust
No. 8 Intake No.
351.Jt;
351- W,351M
351-Mand
and400
400Engines
Engines
No.
NO. 2 in Fig. 18.
18. Inspect and install
the stud nut on the following valves.
~ CD
end of compression stroke.

POSITION 1 - No.
No.11 at TDC at end
POSITION 2 - Rotate the crankshaft 180 degrees (one half
revolution) clockwise from
1..
from POSITION 1
POSITION 3 - Rotate the crankshaft 270 degrees (three
3 )
clockwise
from
quarter revolution) clockwi
se from
POS'ITION
POSITION 2.
..--:.~-
A3234C
A3234-C
Adjusting Valve Clearance

FIG. 18 Position of Crankshaft for Checking and Adiusting
BACK TO GROUP INDEX

21-01-9

302 and 460 Engines
Engines
No.
No.44 Intake No.
No.66 Exhaust
Engines
351-W, 351-M and 400 Engines
No.33 Intake No.
No.22 Exhaust
No.
No.66 Exhaust
No. 7 Intake No.
crankshaft to
9. Rotate the
the crankshaft
to POSITION
NO. 3 in
18. Inspect and
and install
in Fig. 18.
on the
the stud nut
nut on
GOOD
21-01-9
302 and 460 Engines
Engines
No.
No.33 Intake No.
No.33 Exhaust
No.
No. 8 Exhaust
No. 6 Intake No.
351W,351-M
351-M and
and400
400Engines
Engines
351~
No. 2 Intake No.
No.44 Exhaust
No. 6 Intake No.
No. 8 Exhaust
POOR A3193-C
POOR
A3193-C
FIG. 19
Arm
19 Inspection of Rocker Arm
Stud Nut
Nut

NUT
ROCKER ARM
ARM STUD NUT
REPLACEMENT302 and
and 351-W
REPLACEMENT-302
V-8
If the rocker arm stud nut
If
nut breakaway
torque is less than specified, install a new
standard stud nut
and recheck the
standard
nut and
bbreaking
r e a k i n g torque.
t o r q u e . Refer
Valve
Refer to Valve
Clearance Adjustment
the applicable
Adjustment in the
Part for
for the
the torque procedure.
ROCKER ARM
ARM STUD
REPLACEMENT302 AND
REPLACEMENT-302
AND 351-W
V-8
If it is
is necessary to
to remove a rocker
arm stud, tool kit
kit T62F-6A527-B is
available which contains the following: a
stud remover, a 0.006-inch
0.006-inch oversize
reamer and a 0.015-inch oversize reamer.
For O.OIO-inch
0.010-inch oversize studs, use reamer
T66P-6A527-B. To
To press in replacement
use stud replacer T69P-6049-D.
studs, use
Rocker arm
arm studs that are
are broken or
may be
be replaced
have damaged threads may
the
with standard studs. Loose studs in
in the
may be
be replaced with 0.006, 0.010
0.010
head may
are
or O.OIS-inch
0.015-inch oversize studs which are
available for
for service.
Standard and
be
and oversize studs can
can be
identified
identified by measuring the stud diameter
within 1-1/8
1-1/8 inch from the
the pilot end
end of
of
the stud. The
are:
The stud diameters are:
Standard... 0.3714-0.3721
0.3714-0.3721
0.006 oversize
oversize... 0.3774-0.7781
0.3774-0.7781
0.010 oversize
oversize... 0.3814-0.3821
0.3814-0.3821
0.015 oversize
oversize... 0.3864-0.3871
0.3864-0.3871
standard size
When going from a standard
to a 0.010 or 0.0
0.015-inch
rocker arm stud to
IS-inch
0.006-inch
oversize stud, always use
use the
the 0.OO6-inch
oversize reamer before finish reaming
with the
the 0.010
0.010 or 0.015-inch
0.015-inch oversize
reamer.
BACK TO GROUP INDEX
1. Position the
arm
the sleeve of the rocker arm
stud remover (Tool T62F-6A527-B)
the bearing end
over the
the stud with the
end
351down. When working on a 302 or 351CID cylinder head, cut
cut the
W CID
the
the stud off with aa
threaded part of the
hack saw. This is necessary due to the
for 3/8-inch
puller being designed for
studs and
not grip the
and it will not
the 5/16
5/16inch thread on
CID
on aa 302
302 or
or 351-W CID
cylinder head stud. Thread the
the puller
into the sleeve and over the stud until
is fully bottomed. Hold the
it is
the sleeve
the puller
with a wrench, then rotate the
clockwise to
to remove the
the stud (Fig.
(Fig.
20).
If the rocker arm
arm stud was broken
off
the stud boss, use
an
off flush with the
use an
easy-out to
to remove the
the broken stud
following the
the instructions of the tool
manufacturer.
If a loose rocker arm
arm stud is
is being
2. If
replaced, ream the stud bore using the
pproper
r o p e r rreamer
e a m e r (or rreamers
e a m e r s in
sequence) for
for the
the selected oversize
stud (Fig. 21).
21). Make sure the
the metal
not enter the
particles do
do not
the valve area.
the end
end of the
the stud with
Coat the
the stud
stud and
Lubriplate. Align the
and
the stud
installer T69P-6049-D with the
bore, then tap
tap the
the sliding driver until
it bottoms
bottoms (Fig.
(Fig. 22).
22). When the
the
the stud boss, the
installer contacts the
the
is installed to
to its
its correct height.
stud is
A2912 A
A1653-B
FIG. 20
20 Removing Rocker Arm Stud
21 Reaming Rocker Arm Stud

FIG. 21
Bore
21-01-10
21-01-10
General
General Gasoline
Gasoline Engine
Engine Service
Service
CORE PLUGS
PLUGS
CORE
Removal
Removal
To remove
remove aa large
large core
core plug,
plug, drill
drill aa
To
1/2-inch hole
hole in
in the
the center
center of
of the
the plug
plug
1/2-inch
and remove
remove with
with aa clutch
clutch pilot
pilot bearing
bearing
and
puller (Tool
(Tool T59L-1OO-B
TS9L-IOO-B and
and T58L-1OOTS8L-lOOpuller
A) or
or pry
pry itit out
out with
with aa large
large drift
drift punch.
punch.
A)
On aa small
small core
core plug,
plug, drill
drill aa 1/4-inch
1/4-inch hole
hole
On
in the
the center
center of
of the
the plug
plug and
and pry
pry itit out
out
in
with aa small
small pin
pin punch.
punch. Clean
Clean and
and inspect
inspect
with
the plug
plug bore.
bore.
the
Prior to
to installing
installing aa core
core plug
plug the
the plug
plug
Prior
bore should
should be
be inspected
inspected for
for any
any damage
bore
that would
would interfere
interfere with
with the
the proper
proper
that
sealing of
ofthe
the plug.
plug. If
Ifthe
the bore
bore is
is damaged
damaged
sealing
true the
the surface
surface by
by
will be
be necessary
necessary to
to true
itit will
boring for
for the
the next
next specified
specified oversize
boring
plug.
Oversize (OS) plugs
plugs are identified
identified by
by
Oversize
the OS stamped
stamped in the
the flat
flat located
located on
on the
the
of the plug.
cup side of
Coat the
the plug
plug and/or
and/or bore
bore lightly
Coat
oil-resistant (oil galley) or
or waterwith an oil-resistant
resistant (cooling
(cooling jacket)
jacket) sealer
sealer and
resistant
following the procedure
procedure for cup
install it following
type or expansion
expansion type below:
Installation
Cup-Type
Cup-Type
, Cup-type
Cup-type core
core plugs
plugs (Fig.
(Fig. 23)
23) are
are
installed with the flanged edge outward.
The maximum
maximum diameter
diameter of
of this
this plug
plug is
is
The
located at the outer edge of the flange.
The flange on cup-type plugs flares
flares
outward with the largest diameter at the
outer (sealing) edge.
It is imperative to install the plug in
the machined
machined bore using a properly
designed tool. Under no circumstances is
the plug to be driven into the bore using
aa tool that contacts
contacts the flange.
flange. This
This
method will damage the sealing edge and
will reslllt
result in leakage and/or plug blow
out. The flanged (trailing) edge must be
below the
the chamfered
chamfered edge
edge of
of the
the bore
bore to
to
below
the
effectively seal
seal the
the plugged
plugged bore.
bore. IfIf the
effectively
core plug
plug replacing
replacing tool
tool',has
depth
core
has aa depth
seating surface,
surface, do
do riot
tiot seat
seat, the
the tool
tool
seating
against aa non-machined
non-~achined(castJng)
~urface.
against
(casting) surface.
Expansion-Type
Expansion-Type
'
Expansion-type core
core plugs
plugs (Fig.
(Fig. 23)
23)
Expansion-type
are installed
installed with
with the
the flanged
flanged edge
edge
are
inward. The
The maximum
maximum diameter
diameter of
of this
this
inward.
plug is
is located
located at
at the
the base
base of
of the
the flange
flange
plug
with the
the flange flaring
flaring inward.
with
It is
is imperative
imperative to
to push
push or
or drive
drive the
the
It
plug into
into the
the machined
machined bore
bore by
by using
using aa
plug
properly designed
designed tool.
tool. Under
Under no
n9
properly
circumstances is
is the
the plug
plug to
to be
be driven
driven
circumstances
that contacts
contacts the
the crowned
using a tool
tool that
using
portion of
of the
the plug.
plug. This
This method
method will
will
portion
expand the
the plug
plug prior
prior to
to installation
installation and
and
expand
may damage the plug and/or
and/or plug bore.
bore.
trailing (maximum)
When installed, the trailing
diameter must be below the chamfered
21-01-10
21-01-10
edge
edge of
of the
the bore
bore to
to effectively
effectively seal
seal the
the
plugged
the core
core plug
plug replacing
replacing
plugged bore.
bore. IfIf the
tool
tool has
has aa depth
depth seating
seating surface,
surface, do
do not
not
seat
seat the
the tool
tool against
against aa non-machined
non-machined
(casting)
(casting) surface.
surface.
'
FLYWHEEL
FLYWHEEL RING
RING
GEARMANUAL-SHIFT
GEAR-MANUAL-SHIFT
TRANSMISSION
TRANSMISSION
Removal
Remf)'vai
To
To replace
replace aa damaged
damaged or
or worn
worn ring
ring
gear,
gear, heat
heat the
the ring
ring gear
gear with
with aa blow
blow torch
torch
on
on the
the engine
engine side
side of
of the
the gear,
gear, and
and knock
knock
ofT the
the flywheel.
flywheel. Do
Do not
not hit
hit the
the flywheel
fly'wheel
itit off
~hen removing
removing the
the ring
ring geaf.
geat.
when
Installation
InstalJ/(tlon
Heat
the new
Heat,the
new ring
ring gear
gear evenly
evenly until
the
gear expands
the.gear
expands enough
enough to
to slip
slip onto
onto the
flywheel. Make
Make sure
sure the
the gear
gear is seated
seated
properly
properly against
against the
the shoulder.
shoulder. Do not
not
heat
heat any
any portion
portion of
of the
the gear
gear to aa
SEALING
SEALING
EDGE
BEFORE
BEFORE
INSTALLATION
INSTAL LA TION
CUP TYPE CORE

PLUG REPLACER TOOL
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
CUP TYPE
PLUG
SEALING
EDGE
BEFORE
INS'T ALLATION
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
EXPANSION TYPE
TYPE CORE
CORE
EXPANSION
PLUG REPLACER
REPLACER TOOL
TOOL
PLUG
POSITIVE STOP TYPE S T U D * ^
FIG.
FIG. 22
22 Installing
Installing Rocker
Rocker Arm
Arm Stud
Stud
BACK TO GROUP INDEX
A3217-E
A3217
-B
FIG. 23
23 Typical
Typical Core
Core Plugs
Plugs and
and Installation
Installation Tools
Tools
FIG.
21-01-11
21-01-11
than 500 degrees F.
F.
temperature higher than
the temper
temper will
If this limit is exceeded, the
be removed
removed from
from the
the ring gear
gear teeth.
teeth.
be
CRANKSHAFT REAR OIL

SEALEXCEPT 2800cc ENGIHi
ENGINE
SEAL-EXCEPT
A split-lip type
type crankshaft rear oil
A
seal isis provided for servicing 1975
1975 car
seal
engines except the
the above.
above. The complete
engines
seal may be
be replaced without removing
seal
(Fig. 24).
the crankshaft (Fig.
24).
Removal
Removal
1. Remove
Remove the oil pan and the oil pump
1.
required).
(if required).
2. Loosen all the main bearing cap bolts,
bolts,
2.
crankshaft
thereby lowering the crankshaft
inch.
slightly but not to exceed 1/32 inch.
3. Remove the rear main bearing cap,
3.
and remove the oil seal from the
block. On
bearing cap and cylinder block.
use a seal
the block half of the seal use
tool, or install a small metal
removal tool,
seal, and pull
screw in one end of the seal,
on the screw to remove the seal.
prevent
Exercise caution to prevent
scratching or damaging the
scratching
crankshaft seal surfaces.
the oil
oil seal
sealretaining
retaining pin
pinfrom
from
4. Remove the
the bearing cap if so equipped. The
pin is not used with the split-lip seal.
Installation
Installation
1. Carefully
Carefully clean the seal grooves in the
1.
brush and
cap and block with a -brush
solvent such as lacquer thinner,
chlorothane or tri-chlor-ethylene.
Also clean the area where sealer is
later to be applied (Fig.
(Fig. 25).
25). Dry the
so no solvent
area thoroughly, s6
touches the seal.
2. Dip the split lip-type seal halves in the
clean engine oil. 3. Carefully
Carefully install the upper seal
(cylinder block) into its groove with
undercut side of seal toward the
FRONT of the engine (Fig. 24), by
rotating it on the seal journal of the
crankshaft
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. 25).
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. 24). Allow the seal to protrude
approximately 3/8-inch
3/8-inch above the
parting surface
surface to mate with the
upper seal when the cap is installed.
On 2300cc
2300cc engines,
engines, install
install the
theseals
seals
so that the locating tab faces the rear
of the engine (Fig. 26).
26). .
6. Apply an even 1/16
RTV
1/16 inch bead of
ofRTV
silicone rubber sealer to the areas
BACK TO GROUP INDEX
21-01-11
21-01-11
General Gasoline Engine

Engine Service
Service
shown in
in Fig.
Fig. 25,
25, following the
the
given in
in the
the illustration.
illustration.
procedure given
NOTE: This
This sealer sets
sets up
up in
in 15
15
NOTE:
minutes. Install the rear main bearing
minutes.
to
cap. Torque the cap bolts to
specifications.
7.
7. Install the
the oil
oil pump
pump and oil
oil pan.
pan. Fill
the
the crankcase
crankcase with
with the
the proper amount
and viscosity oil.
oil.
8.
8. Operate the
the engine
engine and check for oil
leaks.
leaks.
INSTALL
INSTALL SEAL
SEAL WITH
WITH LIP
LIP
TOWARDS
TOWARDS FRONT
FRONT OF
OF ENGINE
ENGINE
I
I
-+-
3/8"
FRONT
FRONT OF ENGINE
ENGINE
SEAL HAL
VES TO
RTING FACES
HALVES
TO PROTRUDE BEYOND
BEYOND PA
PARTING
THIS
THIS DISTANCE TO
TO ALLOW FOR
FOR CAP TO
TO BLOCK ALIGNMENT
_L
-----r
3/8"
REAR FACE OF
OF REAR MAIN
BEARING CAP AND
AND CYLINDER BLOCK
VIEW LOOKING AT PARTING FACE

OF
OF SPLIT,
SPLIT, L1PTYPE
LIP-TYPE CRANKSHAFT
CRANKSHAFT SEAL
SEAL
A2639C
A2639-C
fiG.
FIG. 24 Installing Crankshaft Rear Oil Seal
FROM FORWARD FACE

OFSLINGER GROOVE
TO REAR FACE OF
BLOCK.
REAR FACE
REAR
FAC_E_~~...
OF BLOCK
APPLY 1/16"
1/16" DIA BEAD OF
C3AZ19526A(OR-B) SEALER IN
C3AZ-19526-A(OR-B)
SHADED AREA OF CYLINDER
CYLINDER BLOCK
PRIOR TO ASSEMBLY OF BEARING
CAP- (BOTH SIDES)
CAP
DO NOT PERMIT SEALER
1.0. OF SPLIT LIP
TO GET ON I.D.
SEAL
C3AZ19526A(ORB)--r-~~~""
APPLY 1/16"
1/16' DIA
DIA BEAD OF C3AZ-19526-A(OR-B)
SEALER AS INDICATED ON BEARING
CAP - (BOTH SIDES)
CAP-
1/8" GAP
LEAVE 1/8"
FOR SEALER
EXPANSION
~.-........
I
----=--
SEALER
SEALER APPLICATION SKETCH
SPLIT LIP TYPE SEAL SHOWN
BASIC APPLICATION AREAS FOR
OTHER
OTHER SEAL
SEAL INSTALLATIONS
ARE THE SAME.
SAME.
A3724-B
A3724B
25 Applying RTV Sealer

Sealer To Main Bearing Cap and BlockTypical
Block-Typical for 6
FIG. 25
and 8-Cylinder
a-Cylinder Engines
21-01-12
21-01-12
CRANKSHAFT REAR
REAR OIL
OIL
CRANKSHAFT
SEAL-2800cc ENGINE
ENGINE
SEAL2800cc
RemoyaJ
Removal
Remove the
the transmission
transmission assembly.
assembly.
1.1. Remove
Remove clutch
clutch pressure
pressure plate
plate and
and
Remove
clutch disc,
disc, ifif so
so equipped.
equipped.
clutch
Remove the
the flywheel
flywheel and
and rear
rear plate.
plate.
2.2. Remove
Use an
an awl
awl to
to punch
punch two
two holes
holes in
in the
the
3.3. Use
crankshaft rear
rear oil
oil seal.
seal. Punch
Punch the
the
crankshaft
holes on
on opposite
opposite sides
sides of
of the
the
holes
crankshaft and
and just
just above
above the
the bearing
bearing
crankshaft
cap to
to cylinder
cylinder block
block split
split line.
line. Install
Install
cap
sheet metal
metal screw
screw in
in each
each hole
hole (Fig.
(Fig.
aa sheet
27). Use
Use two
two large
large screwdrivers
screwdrivers or
or
27).
small pry
pry bars
bars and
and pry
pry against
against both
both
small
screws at
at the
the same
same time
time to
to remove
remove the
the
screws
crankshaft rear
rear oil
oil seal.
seal. It
It may
maybe
crankshaft
be
necessary to
to place
place small
small blocks
blocks of
of
necessary
wood against
against the
the cylinder
cylinder block
block to
wood
General
General Gasoline
Gasoline Engine
Engine Service
Service
21-01-12
21-01-12
provide
provide aa fulcrum
fulcrum point
point for
for the
the pry
pry
caution throughout
throughout this
this
bars. Use
Use caution
bars.
procedure
procedure to
to avoid
avoid scratching
scratching or
or
otherwise
otherwise damaging
damaging the
the crankshaft
crankshaft
oil
oil seal
seal surface.
surface.
4.4. Clean
Clean the
the oil
oil seal
seal recess
recess in
in the
the
cylinder
cylinder block
block and
and main
main bearing
bearing cap.
cap.
Inspect
Inspect and
and clean
clean the
the oil
oil seal
seal contact
contact
surface
surface on
on the
the crankshaft,
crankshaft, following
following
the
the procedure
procedure in
in this
this Part.
Part.
Installation
Installation
1. Coat
Coat the
the oil
oil seal
seal to
to cylinder
cylinder block
block
1.
of the
the oil
oil seal
seal with
with oil.
oil. Coat
Coat
surface of
surface
of the
the oil
oil seal
seal
the seal
seal contact
contact surface
surface of
the
and crankshaft
crankshaft with
with" Lubriplate.
Lubriplate. Start
Start
and
the seal
seal in
in the
the recess
recess and
and install
install itit with
with
the
the tool
tool as
as shown
shown in
in Fig.
Fig. 28.
28. Drive
Drive the
the
the
seal into
into position
position until
until itit is
is firmly
firmly
seal
seated.
seated.
2.2. Install
Installthe
therear
rearplate
plateand
andthe
theflywheel.
flywheel.
TTighten
i g h t e n fflywheel
l y w h e e l bbolts
o l t s tto
o
specification.
specification..
3. Install
Install the
the clutch
clutch disc
disc and
and clutch
clutch
pressure
pressure plate,
plate, ifif so
so equipped.
equipped. Align
Align
clutch
clutch disc
disc before
before tightening
tightening pressure
pressure
plate
plate attaching
attaching screws.
screws.
4. Install
Install the
the flywheel
flywheel housing.
housing.
5. Install
Install the
the transmission.
transmission.
REAR BEARING
BEARING CAP
CAP
REAR
_ '--
'---
DIP SEALS
SEALS IN
DIP
IN ENGINE
ENGINE
OIL BEFORE
BEFORE INSTALLING
OIL
INSTALLING
'~
-4~1~
A3574-A
FIG. 27 Removing Crankshaft Rear

Oil
Seal2800cc Engine
OilSeal-2800cc
REAR OIL SEAL
FRONT OF ENGINE
/'
UPPER
UPPER AND
AND LOWER
LOWER SEAL
SEAL
ENDS
ENDS TO
TO BE
BE FLUSH
FLUSH IN
IN
BLOCK
BLOCK ANDCAP
AND CAP
SEALER
SEALER NOTE:
NOTE:CLEAN
CLEANTHE
THE AREA
AREA WHERE
WHERESEALER
SEALER
ISISTO
TOBE
BEAPPLIED
APPLIEDBEFORE
BEFORE INSTALLING
INSTALLINGTHE
THESEALS.
SEALS.
USE
USEFORD
FORDSPOT
SPOTREMOVER
REMOVER B7A-19521-A
B7A-19521-A OR
OREQUIVALENT.
EQUIVALENT.
AFTER
SEALS ARE
ARE IN
IN PLACE,
PLACE,APPLY
APPLY AA 1/161NCH
1/16 INCH
A F T E R THE
T H E SEALS
BEAD
BEADOF
OFC3AZ-19562-A
C3AZ-19562-A OR
OR-B-BSEALER
SEALER AS
ASSHOWN.
SHOWN.
SEALER
SEALERMUST
MUSTNOT
NOTCONTACT
CONTACTSEALS.
SEALS.
A3575-B
A3761-B
A3761-B
FIG.
FIG. 26
26 Rear
Rear Oil
Oil Seal
Seal Installation-2300cc
Installation2300cc Engine
Engine
BACK TO GROUP INDEX
FIG. 28
28 Installing
Installing Crankshaft
Crankshaft Rear
Rear
FIG.
Oil Seal-2800cc
Seal2800cc
Oil
21-01-13
21-01-13
General
General Gasoline
Gasoline Engine
Engine Service
Service
OVERHAUL
OVERHAUL
VALVES
VALVES
Minor
Minor pits,
pits, grooves,
grooves, etc.,
etc., may
may be
be
removed.
removed.Discard
Discard valves
valvesthat
that are
areseverely
severely
damaged,
damaged, ifif the
the face
face runout
runout cannot
cannot be
be
corrected by
by refinishing
refinishing or
or stem
stem
corrected
clearance exceeds
exceeds specifications.
specifications. Discard
Discard
clearance
any excessively
excessively worn
worn or
or damaged
damaged valve
valve
any
train parts.
parts.
train
CYLINDER HEAD
HEAD
CYLINDER
Replace the
the head
head ifif itit isiscracked.
cracked. Do
Do
Replace
not plane
plane or
orgrind
grind more
more than
than 0.010
0.010 inch
inch
not
from the
the cylinder
cylinder original
original head
head gasket
gasket
from
surface. Remove
Remove all
all burrs
burrs or
or scratches
scratches
surface.
with an
an oil
oil stone.
stone.
with
Reaming Valve
Valve Guides
Guides
Reaming
becomes necessary
necessary totoream
ream a
IfIf itit becomes
valve
valve guide
guide (Fig.
(Fig. 29)
29) to
to install
install aa valv~
valve
with
with an
an oversize
oversize stem,
stem, aa reaming
reaming kit
kit isis
available
available which
which contains
contains the
the following
following
reamer
reamer and
and pilot
pilot combinations:
combinations: aa 0.0030.003inch
inch OS
OSreamer
reamer with
with aa standard
standard diameter
diameter
pilot,
pilot, aa 0.015-inch
0.015-inch OS
OS reamer
reamer with
with aa
0.003-inch OS
OS pilot,
pilot, and
and aa 0.030-inch
0.030-inch
0.003-inch
reamer with
with aa 0.015-inch
0.015-inch OS
OS pilot.
pilot.
reamer
When going
going from
from aa standard
standard size
size
When
valve to
to an
an oversize
oversize valve
valve always
always use
use the
the
valve
reamer in
in sequence.
sequence. Always
Always reface
reface the
the
reamer
valve seat
seat after
after the
the valve
valve guide
guide has
has been
been
valve
reamed, and
and use
use aa suitable
suitable scraper
scraper to
to
reamed,
break the
the sharp
sharp corner
corner (lD)
(ID) at
at the
the top
top of
break
the valve
valve guide.
guide.
the
Refacing Valve
Valve Seats
Seats
Refacing
Refacing of
of the
the valve
valve seat
seat should
should be
Refacing
closely coordinated
coordinated with
with the refacing of
closely
the valve
valve face
face so
so that the finished seat and
the
valve face
face will be
be concentric and the
the
valve
interference angle will be
specified interference
is important so
so that the
maintained. This is
valve and seat will have a compressioncompressionfit. Be
Be sure that the refacer grinding
tight fit.
wheels are properly dressed.
Grind the valve seats of all engines to
45 degree angle (Fig.
(Fig. 30).
30). Remove
a true 45
only enough stock to clean up pits and
grooves or to correct the valve seat
runout. After
seat has been refaced,
refaced,
runout.
After the seat
use a seat width scale or a machinist scale
to measure the seat width (Fig. 31).
Narrow the seat, if necessary to bring it
within specifications.
If
If the valve seat width exceeds the
maximum
maximum limit,
limit, remove
remove enough
enough stock
stock
from
and/or bottom
bottom edge
edge of
of
from the
the top
top edge
edge and/or
the
e d u c e the
the seat
seat to
to rreduce
the width
width to
to
specifications.
specifications.
On the valve seats of
of all engines, use
use
a 60 degree angle grinding
grinding wheel
wheel to
remove
remove stock
stock from
from the
the bottom
bottom of
of the
the
seats
seats (raise
(raise the
the seats)
seats) and
and use
use aa 30
30 degree
degree
angle
angle wheel
wheel to
to remove
remove stock
stock from
from the
the top
top
of
of the
the seats
seats (lower
(lower the
the seats).
seats).
The
The finished
finished valve
valve seat
seat should
should contact
contact
the
of the
the valve
valve face.
face.
the approximate
approximate center
center of
ItIt is
is good
good practice
practice to
to determine
determine where
where the
the
valve
valve seat
seat contacts
contacts the
the face.
face. To
To do
do this,
this,
coat
coat the
the seat
seat with
with Prussion
Prussion blue
blue and
and set
set
the
the valve
valve in
in place.
place. Rotate
Rotate the
the valve
valve with
with
light
light pressure.
pressure. IfIf the
the blue
blue isis transferred
transferred
to
ofthe
the valve
valve face,
face, the
the contact
contact
to the
the center
centerof
isis satisfactory.
If
the
blue
is
transferred
satisfactory. If the blue is transferred
to
of the
the valve
valve face,
face, lower
lower
to the
the top
top edge
edge of
the
valve
seat.
If
the
blue
is
transferred
the valve seat. If the blue is transferred
to
ofthe
thevalve
valveface,
face, raise
raise
to the
thebottom
bottom edge
edgeof
the
the valve
valve seat.
seat.
BACK TO GROUP INDEX
Refacing
Refacing Valves
Valves
The
The valve
valve refacing
refacing operation
operation should
should
be
beclosely
closely coordinated
coordinated with
with the
the valve
valve seat
seat
refacing
refacing operations
operations so
so that
that the
the finished
finished
angles
angles of
of the
the valve
valve face
face and
and of
of the
the valve
valve
seat
seat will
will be
be to
to specifications
specifications and
and provide
provide
compression-tight fit.
fit. Be
Be sure
sure that
that the
the
aa compression-tight
refacer grinding
grinding wheels
wheels are
are properly
properly
refacer
dressed.
dressed.
If
If the
the valve
valve face
face runout
runout isis excessive
excessive
and/or
and/or to
to remove
remove pits
pits and
and grooves,
grooves, reface
reface
the
the valves
valves to
to aa true
true 44
44 degree
degree angle.
angle.
Remove
Remove only
only enough
enough stock
stock to
to correct
correct the
the
run
out or
runout
or to
to clean
clean up
up the
the pits and
and
grooves.
grooves. If
If the edge
edge of
of the valve
valve head is
is
less
less than
than 1/32
1/32 inch
inch thick after grinding
grinding
(Fig. 32),
32), replace the valve as
as the valve
(Fig.
will run too hot in the engine. The
and seat
interference angle of the valve and
be lapped out. Remove all
should not be
or score marks from the end of
grooves or
valve
the val
ve stem, and chamfer it as
necessary. Do not remove more than
the valve stem.
0.010 inch from the end of the
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.
21-01-13
21-01-13
Select
Select Fitting
Fitting Valves
Valves
If
If the
the valve
valve stem
stem to
to valve
valve guide
guide
clearance
clearance exceeds
exceeds the
the wear
wear limit,
limit, ream
ream
the
thevalve
valveguide
guidefor
for the
the next
next oversize
oversize valve
valve
stem.
stem. Valves
Valves with
with oversize
oversize stem
stem
diameters
diameters of
of 0.003,
0.003, 0.015
0.015 and
and 0.030
0.030 inch
inch
are
are available
available for
for service
service for
for all
all engines
engines
except
except 2300cc
23OOcc and
and 2800cc.
28OOcc. For
For these
these
engines,
engines, oversize
oversize valve
valve stems
stems are
are
available
available in
in diameters
diameters of
of 0.008,
0.008, 0.016,
0.016,
and
and 0.032
0.032 inch
inch oversize.
oversize. Always
Always reface
reface
the
the valve
valve seat
seat after
after the
the valve
valve guide
guide has
has
been
been reamed.
reamed. Refer
Refer to
to Reaming
Reaming Valve
Valve
Guides.
Guides.
TO
TO REMOVE
REMOVE STOCK
STOCK
FROM
FROM TOP
TOP OF
OF SEAT,
SEAT,
0
USE
USE 30
30 WHEEL
WHEEL
TO
TO REMOVE
REMOVE
STOCK
STOCK FROM
FROM
BOTTOM
BOTTOM0 OF
OF SEAT,
SEAT,
USE
60
USE 6 0 WHEEL
WHEEL
A2897-B
FIG.
FIG. 30 Refacing
Refacing Valve Seat
FIG. 31
31 Checking
Checking Valve
Valve Seat
Seat Width
Width
FIG.
Ui ~ CHECK FOR
FOR DIMENSIONS
DIMENSIONS
FOR
REFER TO
TO
REFER
SPECIFICATIONS
SPECIFICATIONS
II-;:;~:::~
ANGLE
1/32" M I N I M U M
THIS LINE
PARALLEL
WITH
VALVE HEAD
A2910-B
A 3453-A
A3453-A
FIG.
FIG. 29
29 Reaming
Reaming Valve
Valve Guides6
Guides-6
Cylinder
Cylinder Shown
Shown
FIG. 32
32 Critical
Critical Valve
Valve Dimensions
Dimensions
FIG.
21-01-14
21-01-14
CAMSHAFT REPAIR
REPAIR
CAMSHAFT
Remove light
light scuffs,
scuffs, scores
scores or
or nicks
nicks
Remove
from the
the camshaft
camshaft machined
machined surfaces
surfaces
from
with aa smooth
smooth oil
oil stone.
stone.
with
PISTONS, PINS
PINS AND
AND RINGS
PISTONS,
Fitting Pistons
Fitting
for service in
in
Pistons are available for
standard sizes and the
the oversizes
oversizes shown in
in
standard
Specification section at the end of
of each
each
Specification
engine Part.
standard size pistons are color
color
The standard
coded red or blue, or
or have 0.003 OS
as
coded
stamped on the dome. Refer
Refer to the
stamped
Specifications for standard
standard size piston
Specifications
dimensions.
Measure the cylinder
cylinder bore and select
select
the piston to assure the proper clearance.
When the bore diameter is in the lower
of the specified
specified range, a red
one third of
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
specified clearance is
obtained. It may be necessary
obtained.
necessary
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
When aa piston
has been fitted, mark it for assembly in
the cylinder to which it was fitted. If the
taper,
taper, out-of-round
out-of-round and
andpiston
pistonto
tocylinder
cylinder
bore clearance conditions of the cylinder
bore are within specified limits, new
piston rings
rings will
will give
give satisfactory
satisfactory service.
service.
If new
new rings
rings are
are to
to be
be installed in
in aa used
used
cylinder that has
has not been refinished,
remove
remove the
the cylinder wall glaze (Refer to
Cylinder Block, Refinishing Cylinder
Walls).
Walls). Be
Besure
suretotoclean
cleanthe
thecylinder
cylinderbore
bore
thoroughly.
thoroughly.
1.
1. Calculate the size
size piston to be
be used by
by
taking aa cylinder bore check.
check. Follow
the procedures outlined under
under
Cleaning and Inspection.
Inspection.
2.
2. Select the proper size piston to
to
provide
provide the
the desired clearance (refer to
to
the specifications). Measure the
the
piston diameter in line with the
the
centerline of the
the piston pin
pin and
and at 90
90
degrees
degrees to
to the
the piston pin
pin axis.
axis.
3.
3. Make
Make sure
sure the
the piston and
and cylinder
cylinder
block are
are at
at room
room temperature
temperature (70
(70
degrees
degrees F.).
F.). After any
any refinishing
refinishing
operation
operation allow
allow the
the cylinder
cylinder bore
bore to
to
cool,
cool, and
and make
make sure
sure the
the piston
piston and
and
bore
bore are
are clean
clean and
and dry
dry before
before the
the
piston
piston fit
fit isis checked.
checked.
Fitting
Fitting Piston
Piston Rings
Rings
1.1. Select
Select the
the proper
proper ring
ring set
set for
for the
the size
size
cylinder
cylinder bore.
bore.
2.
2. Position
Position the
the ring
ring in
in the
the cylinder
cylinder bore
bore
in
in which
which itit isis going
going to
to be
be used.
used.
BACK TO GROUP INDEX
General
General Gasoline
Gasoline Engine
Engine Service
Service
21-01-14
21-01-14
3. Push
Push the
the ring
ring down
down into
into the
the bore
bore area
area
3.
where
where normal
normal ring
ring wear
wear is
is not
not
encountered.
encountered.
4. Use
Use the
the head
head of
of aa piston
piston to
to position
position
4.
the ring
ring in
in the
the bore
bore so
so that
that- the
the ring
ring
the
is square
square with
with the
the cylinder
cylinder wall.
wall. Use
Use
is
caution to
to avoid
avoid damage
damage to
to the
the ring
ring
caution
bore.
or cylinder bore.
betwen
of
5. Measure the gap bet
wen the ends of
feeler gauge (Fig. 33).
33).
the ring with a feeler
If
If the
the ring gap is
is less or greater
greater than
than
the specified
specified limits, try another
another ring
set.
Refinishing Journals
Journals
Refinishing
Refinish
Refinish the
the journals
journals to
to give
give the
the
proper
proper clearance
clearance with
with the
the next
next undersize
undersize
bearing.
If the
the journal
journal will
will not
not clean
clean up
up
bearing. If
to
to maximum
maximum undersize
undersize bearing
bearing available,
available,
replace
replace the
the crankshaft.
Always
Always reproduce
reproduce the
the same
same journal
journal
shoulder
shoulder radius that existed originally.
Too small a radius will result in fatigue
failure
failure of
of the crankshaft.
crankshaft. Too large aa
radius will
will result in
in bearing
bearing failure
failure due
due
to radius ride of
of the bearing.
bearing.
After
After refinishing
refinishing the
the journals,
chamfer
chamfer the oil holes; then polish
polish the
journal
journal with a No. 320 grit polishing
cloth and engine oil. Crocus cloth may
may
also be used as a polishing agent.
A2902-B
FIG. 33 Checking Piston Ring Gap
6. Check the ring side clearance of the

compression rings with a feeler gauge
inserted between the ring and its
lower land (Fig. 34). 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.
A1020-B
FIG.
FIG. 34
34 Checking
Checking Piston
Piston Ring
Ring Side
Side
Clearance
Clearance
Fitting
Fitting Piston
Piston Pins
Pins
Install
Install the
the piston
piston pin,
pin, following
following the
the
procedure
procedure under
under Piston
Piston Assembly
Assembly in
in the
the
applicable
applicable engine
engine part.
part.
CRANKSHAFT
CRANKSHAFT
Dress
Dress minor
minor scores
scores with
with an
an oil
oil stone.
stone.
If
If the
the journals
journals are
are severely
severely marred
marred or
or
exceed the
the wear
wear limit,
limit, they
they should
should be
be
exceed
refinished to
to size
size for
for the
the next
next undersize
undersize
refinished
bearing.
bearing.
FITTING MAIN
MAIN OR CONNECTING
ROD BEARINGS WITH
PLASTIGAGE
1. Clean crankshaft
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,
bearings,
it is good practice to fit the bearing
to minimum specified clearance. If
If
the desired clearance
clearance. cannot be
obtained with a standard bearing, try
one half
half of a 0.001 or 0.002 inch
undersize in combination with a
standard bearing to obtain the proper
clearance.
clearance.
2. If fitting a main bearing in the vehicle,
vehicle,
under counterweight
position aa jack under
adjoining bearing which is being
checked. Support crankshaft with
jack so its weight will not compress
and provide an
an erroneous
Plastigage and
reading.
reading.
3. Place a piece of Plastigage on bearing
3.
surface across full width of bearing
inch off center
cap and about 1/4 inch
(Fig. 35).
(Fig.
4. Install cap and torque bolts to
4.
Do not turn crankshaft
crankshaft
specifications. Do
while Plastigage isis in
in place.
place.
while
5. Remove
Remove cap.
cap. Using
Using Plastigage scale,
scale,
5.
check width of Plastigage at widest
to get minimum clearance.
clearance.
point to
to get
Check at narrowest point to
Difference
maximum clearance. Difference
readings isis taper of journals.
journals.
between readings
6. If
If clearance
clearance exceeds
exceeds specified
specified limits,
limits,
6.
try 0.001
0.001 or
or 0.002
0.002 inch
inch undersize
undersize
try
in combination
combination with the
the
bearings in
standard bearings.
bearings. Bearing
Bearing clearance
clearance
standard
must be
be within
within specified
specified limits.
limits. If
must
0.002 undersize
undersize main
main bearings
bearings are
are
0.002
used on
on more
more than
than one
one journal,
journal, be
be
used
sure they
they are
are all
all installed
installed in
in cylinder
cylinder
sure
block side
side of
of bearing.
bearing. If
If standard
standard and
and
block
0.002 inch
inch undersize
undersize bearings
bearings do
do not
not
0.002
bring clearance
clearance within
within desired
desired limits,
limits,
bring
refinish crankshaft
crankshaft journal,
journal, then
then
refinish
install undersize
undersize bearings.
bearings.
install
21-01-15
PLACE Plastigage FULL CHECK WIDTH OF

WIDTH OF JOURNAL , ^ . ^ , Plastigage
ABOUT VA INCH "'
OFF CENTER
\
MEASURING
INSTALLING
Plastigage
0.0015"
Plastigage
CLEARANCE
A2868-A
FIG. 35
35 Installing and
and Measuring
Plostigoge
Plastigage
7.
7. After bearing has
has been fitted, apply
light coat of engine oil to journal and
cap. Torque
bearings. Install bearing cap.
cap-bolts
to specifications.
cap
bolts to
8.
8. Repeat procedure for remaining
bearings that require replacement.
CYLINDER BLOCK
Refinishing Cylinder Walls
Honing
Honing is recommended
recommended for
refinishing cylinder walls only when the
the
walls have minor scuffs or scratches, or
or
to the
the specified
specified
for fitting pistons to
to be
be used
used
clearance. The grade of hone to
is determined by
by the
the amount of metal to
the instructions of
be removed. Follow the
of
the hone manufacturer. If coarse stones
to start the
the honing operation,
are used to
leave enough material so
so that all
all hone
marks can be removed with the finishing
hone which is
is used to
to obtain the
the proper
piston clearance.
Cylinder walls that are
are severely
marred and/or worn beyond the specified
limits should be
any
be refinished. Before any
cylinder is refinished, all
all main bearing
caps must be in place and tightened to the
the crankshaft
crankshaft
proper torque so that the
not become distorted
bearing bores will not
the refinishing operation. Refinish
Refinish
from the
only the cylinder or cylinders that require
All pistons are
are the
the same weight, both
it. All
and oversize; therefore, various
standard and
be used without
can be
sizes of pistons can
upsetting engine balance. Refinish the
the
the most wear first to
cylinder with the
determine the
the maximum oversize. If the
cylinder will not clean up
up when
cylinder
refinished for
for the
the maximum oversize
piston recommended, replace
replace the
the block.
piston
Refinish the
the cylinder to
to within
Refinish
approximately
approximately 0.0015 inch of the
required oversize diameter. This will
allow enough stock for
final step of
of
for the
the final
honing so
so that the
the correct surface finish
and pattern are obtained. For
For the
the proper
proper
BACK TO GROUP INDEX
21-01-15
the refinishing equipment follow

use of the
the instructions of the
the manufacturer.
manufacturer.
Only experienced personnel should be
be
to perform this work. Use
Use a
allowed to
motor-driven, spring pressure-type hone
at aa speed of 300-500 rpm. Hones of grit
sizes 180-220 will normally provide the
the
desired bore surface finish of 15/32 RMS.
RMS.
the cylinder bores use
When honing the
use
a lubricant mixture of equal parts of
SAE No.
20 motor oil.
kerosene and
and SAB
No. 20
oil.
the hone in
in such aa way
way to
Operate the
on the
produce aa cross-hatch finish on
the
cylinder bore. The
The cross-hatch pattern
be at
at an
an angle of approximately
should be
30 degrees to the cylinder bore. After the
in either of the
the two
final operation in
two
refinishing methods described and
and prior
to checking the
the piston fit,
fit, thoroughly
clean and
and oil
oil the
the cylinder
cylinder walls.
walls. Mark
Mark the
the
to correspond to
to the
the cylinders in
pistons to
in
which they are to
to be installed. When the
the
refinishing of all cylinders that require it
has been completed and
and all
all pistons are
are
the entire block
fitted, thoroughly clean the
and oil
oil the
the cylinder walls.
Repairing Sand Holes or Porous
Engine Castings
Porosity or
or sand hole(s) which will
cause oil
oil seepage or leakage can
can occur
with modern casting processes. A
A
complete inspection of engine and
and
transmission should be made.
made. If the leak
is attributed to
of
to the
the porous condition of
hole(s), repairs
the cylinder block or sand hole(s),
can be
be made with metallic plastic (part
No. C6AZ-19544-A).
C6AZ-19544-A). Do
Do not
not repair
cracks with this material. Repairs with
this metallic
metallic plastic
plastic must
must be
be confined
confined to
those cast iron engine component
surfaces (Fig.
(Fig. 36)
36) where the
the inner wall
surface is
is not
not exposed to
to engine coolant
pressure or
or oil
oil pressure, for
for example:
1.
1. Cylinder block surfaces extending
along the length of the block, upward
from the
the oil
oil pan
pan rail to
to the
the cylinder
water jacket but not
not including
machined areas.
2.
2. Lower rear face of the cylinder block.
3. Intake manifold casting. Repairs are
are
not recommended to
to the
the intake
manifold exhaust crossover section,
since temperatures can
the
can exceed the
recommended temperature limit of
of
500 degrees F.
4. Cylinder front cover on engines using
cast iron material.
5.
arm
5. Cylinder head, along the
the rocker arm
cover gasket surface.
The following procedure should be
be
holes
used to repair porous areas or sand holes
in cast iron.
1.
by
1. Clean the
the surface to
to be
be repaired by
grinding or
or rotary filing to
to aa clean
bright metal surface. Chamfer
Chamfer or
undercut the
the hole or porosity to
to aa
the
greater depth than the
the rest of the
cleaned surface. Solid metal must
surround the
the hole.
hole. Openings larger
than 1/4 inch should not
not be
be repaired
using metallic plastic. Openings in
in
excess of 1/4 inch can
can be
be drilled,
tapped and
and plugged using common
tools. Clean the repair
repair area
area
thoroughly. Metallic plastic will not
not
to aa dirty or
or oily surface.
stick to
2.
and
2. Mix
Mix the
the metallic plastic base and
hardener as directed on the container.
Stir thoroughly until uniform.
SHADED AREAS MAY

MAY BE
BE REPAIRED WITH EPOXY
FRONT AND
AND LEFT
LEFT SIDE
AND LEFT
LEFT SIDE
FRONT AND
TYPICAL FOR
FOR 6-CYLINDER ENGINE
TYPICAL FOR
FOR V8
V-8 ENGINE
AND RIGHT SIDE

REAR AND
R~EAR
REAR AND
AND RIGHT SIDE
A2386-C
FIG. 36
36 Typical Cast Iron Cylinder Block Areas Repairable with Metallic Plastic
21-01-16
3.
3. Apply the
the repair mixture with a
suitable clean tool,
tool, (putty knife, wood
spoon,
spoon, etc.) forcing the epoxy into the
hole
hole or
or porosity.
porosity.
4.
4. Allow the
the repair mixture to
to harden.
This can
two
can be
be accomplished by
by two
methods,
methods, heat cure with aa 250
250 degree
watt lamp placed 10
10 inches from the
or air
air dry
dry for
for 10-12
10-12
repaired surface, or
at temperatures above 50
hours at
degrees F.
degrees
F.
5.
5. Sand or
or grind the
the repaired area to
blend with the
the general contour of the
surrounding surface.
surface.
6.
6. Paint the surface to
to match the rest of
the block.
block.
CLEANING AND
AND INSPECTION
The cleaning and
and inspection
inspection
procedures are
are for
for aa complete engine
overhaul;
overhaul; therefore, for
for partial engine
overhaul or parts replacement, follow the
inspection
pertinent cleaning or inspection
procedure.
procedure.
Intake Manifold
Manifold
Clesning
Cleaning
Remove all
all gasket material from the
machined surfaces of the manifold. Clean
the manifold in
in a suitable solvent and dry
it with compressed air.
air.
Inspection
Inspection
Inspect the
the manifold for
for cracks,
damaged gasket surfaces, or other defects
that would make it unfit for
for further
further
service. Replace all
all studs that are
stripped or otherwise damaged.
damaged. Clean the
EG
R exhaust passages. Remove all
EGR
filings and
and foreign
foreign matter that may
may have
entered the
the manifold as
as aa result of
repairs.
repairs. Check the
the baffle plate on
on the
the
underside
underside of the
the manifold if so
so equipped.
equipped.
The
The baffle
baffle should
should be
be securely
securely fastened
fastened at
at
all attaching points.
Exhaust Manifolds
Manifolds
Cleaning
Clesning
Remove all
all gasket material from the
manifolds.
On the
the right exhaust manifold of the
V-8
V-8 engines,
engines, make sure the
the automatic
choke air
air inlet and
and outlet holes are
completely open and
not
and the
the cover does not
leak (if so
so equipped).
equipped).
Inspection
Inspection
the cylinder head joining
Inspect the
the exhaust manifold(s) for
flanges of the
gas leaks.
leaks.
evidence of exhaust gas
Inspect the
the manifolds for
for cracks,
damaged gasket surfaces, or other defects
for further
further
that would make them unfit for
service.
service.
Arm and/or Shaft
Valve Rocker Arm
Assembly
Cleaning
Clesning
all the
the parts
parts thoroughly.
thoroughly. Make
Make
Clean all
all oil
oil passages are
are open.
open.
sure all
in the push
Make sure the oil passage in
end of the rocker arm
arm is
is open.
rod end
BACK TO GROUP INDEX
21-01-16

Inspection
Inspection
Inspect the
arm
the shaft and
and the
the rocker arm
bore for
for nicks, scratches, scores or scuffs.
Replace any
any damaged parts.
Inspect the pad at
at the valve end of the
rocker arm
arm for
for indications of scuffing
scuffing or
abnormal wear. If the
pad is
the pad
is grooved,
replace the
not attempt
the rocker arm. Do
Do not
to
to true this surface by grinding~
grinding. On studstudmounted rocker arms,
the rocker
arms, check the
arm
pad, side rails and
for
arm pad,
and fulcrum seat for
excessive wear,
wear, cracks, nicks or
or burrs.
Check the
nut for
the rocker arm
arm stud and
and nut
for
stripped or
or broken threads.
threads. On
On positive
stop rocker arm
the
arm stud nuts, check the
shoulder for damage as shown in Fig. 37.
37.
Replace all
all damaged nuts.
GOOD
Dial Indicator
Ho/d/noRxfure
Holding Fixture
'PUSH ROD
A1003-B
FIG. 38
38 Checking Push Rod
Rod Runout
Inspection
Inspection
the cylinder head for cracks
Check the
and inspect the
the gasket surface for burrs
is
and nicks. Replace the head if it is
cracked.
The following inspection procedures
are for a cylinder head that is to be
be
completely overhauled. For individual
repair operations, use
use only the
the pertinent
inspection procedure.
When a cylinder head is removed
because of gasket leaks, check the flatness
(Fig.
of the cylinder head gasket surface (Fig.
If
39) for conformance to specifications. If
necessary to refinish the
the cylinder head
gasket surface, do not
not plane or
or grind off
more than 0.010 inch.
POOR A3193.C
POOR
A3193-C
37 Positive Stop Rocker Arm

FIG. 37
Arm
Stud Nut
On pedestal mounted rocker arms,
check the
pad and
the rocker arm
arm pad
and fulcrum
fulcrum
for excessive wear, cracks, nicks or
seat for
all damaged rocker arms.
burrs. Replace all
Push Rods
Push
Cleaning
Clesning
Clean the
the push rods in
in a suitable
solvent. Blowout
the
Blow out the
the oil
oil passage in
in the
push rod
air.
rod with compressed air.
Inspection
Inspection
the ends of the push rods for
Check the
nicks, grooves, roughness or excessive
wear. Replace damaged push rods.
The push rods can be visually checked
are installed
for straightness while they are
in the
the
the engine by
by rotating them with the
valve closed. They also can
be checked
can be
with aa dial indicator (Fig. 38).
38).
If the
the push rod
rod is
is bent beyond
specifications, it should be
be replaced.
Cylinder Heads
Cleaning
Clesning
With
to protect
With the
the valves installed to
the
the valve seats, remove deposits from the
and valve heads
combustion chambers and
and aa wire brush. Be
with aa scraper and
Be
to damage the
the cylinder head
careful not to
After the
gasket surface. After
the valves are
bores. Use
Use
removed, clean the valve guide bores.
to remove dirt, grease
cleaning solvent to
deposits. Clean all
all bolt holes.
and other deposits.
Remove all deposits from the valves with
or buffing wheel.
a fine wire brush or
HECK DIAGONALLY
CHECK ACROSS CENTER
A 2895-A
FIG. 39 Typical Cylinder Head

Flatness
Check the
the valve seat runout with an
an
accurate gauge (Fig.
(Fig. 40).
40). Follow the
the
instructions of the
the gauge manufacturer.
If
If the
the runout exceeds the wear limit,
reface the
the valve and
and valve seat. Measure
the valve seat width (Fig. 30). Reface any
valve seat whose width is not
not within
specifications.
The critical inspection points of the
the
valves are
are illustrated in Fig. 32. Refer to
to
the specifications for wear limits.
Inspect the
the stem for a bent condition
and the
the end
end of the
the stem for grooves or
or
scores. Check the
the valve head for signs of
burning, erosion, warpage and
and cracking.
Minor
Minor pits, grooves etc.,
etc., may be
be
removed. Discard valves that are severely
damaged.
Inspect the
the valve spring, valve spring
retainers, locks and
and sleeves for wear or
or
damage. Discard any
any visually damaged
parts.
Check the
the valve stem to valve guide
clearance of each valve in its respective
valve guide with the
Fig.
the tool shown in Fig.
41
41 or its equivalent. Use
Use a flat end
end
indicator point.
Install the tool on the valve stem until
it is fully seated, and
and tighten the knurled
set screw firmly. Permit the valve to drop
21-01-17
21-01-17
away from
from its
its seat
seat until
until the
the tool
tool contacts
contacts
away
the upper
upper surface
surface of
of the
the valve
valve guide.
guide.
the
Position the
the dial
dial indicator
indicator with
with its
its flat
flat
Position
tip against
against the
the center
center portion
portion of
of the
the tool's
tool's
tip
spherical section
section at
at approximately
approximately 90
90
spherical
degrees to
to the
the valve
valve stem
stem axis.
axis. Move
Move the
the
degrees
tool back
back and
and forth
forth in
in line
line with
with the
the
tool
indicator stem.
stem. Take
Take aa reading
reading on
on the
the dial
dial
indicator
indicator without
without removing
removing the
the tool
tool from
from
indicator
the valve
valve guide
guide upper
upper surface.
surface. Divide
Divide the
the
the
reading by
by two,
two, the
the division
division factor
factor for
for the.
the,
reading
tool.
tool.
APPLY TORQUF.
TORQUE UNTI
UNTIL
APPLY
L
CLICK ISIS HEARD,
HEARD, READ
READ
CLICK
Torque Wrench
Wrench AND
AND
Torque
MULTIPLY READING
READING
MULTIPLY
BY TWO
TWO (2).
(2).
By
Tool-6513-DD
VALVE SPRING
SET K N O B T O
COMPRESSED
LENGTH OF
SPRING
A2917-C
FIG. 42
42 Checking
Checking Valve
Valve Spring
Spring
FIG.
Pressure
Pressure
Runout Gauge
Check
Check each
each spring
spring for
for squareness,
squareness,
using aa steel
steel square
square and
and aa flat
flat surface
surface
(Fig.
(Fig. 43).
43). Stand
Stand the
the spring
spring and
and square
square on
on
flat surface. Slide
Slide the spring
spring
end on the flat
square. Revolve the spring
spring
up to the square.
the
slowly and observe the space between the
square. The
The
top coil of the spring and the square.
5/64-inch.
out-of-square limits are 5/64-inch.
NOT MORE
THAN 5/64"
FIG. 40 Checking Valve Seat Runout
A 2900- B
FIG. 43 Checking Valve Spring

Squareness
TOOL
M AND 400 CID
TOOL 6505-E
6505-E 302,
302, 351
351 M
TOOL6505-F
TOO L 6505-F 460
460 CID
CID
TOOL
TOOL 6505-G
6505-G 200
200 AND
AND 250
250 CID
CID
A3131-D
A3131-D
FIG.
FIG. 41
41 Checking
Checking Valve
Valve Stem
Stem
Clearance
Clearance
Check
Check the
the springs
springs for
for proper
proper pressure
pressure
(Fig.
(Fig. 42)
42) at
at the
the specified
specified spring
spring lengths
lengths
(Tool-6513-DD).
(Tool-6513-DD). Manually
Manually rotating
rotating the
the
valve
valve spring
spring assemblies
assemblies while
while installed
installed in
in
the
the engine,
engine, must
must not
not be
be used
used to
to determine
determine
good
good and/or
and/or bad
bad valve
valve springs.
springs. Weak
Weak
valve
valve springs
springs cause
cause poor
poor engine
engine
^performance.
performance. Replace
Replace any
any spring
spring not
not
Vithin
Gwithin specifications.
specifications.
BACK TO GROUP INDEX
21-01-17
21-01-17
General
General Gasoline
Gasoline Engine
Engine Service
Service
Follow the same procedure

procedure to check
Follow
new valve springs
sp-rings before
before installation.
certain the proper spring (Color
Make certain
coded) is installed. Visually
Visually inspect the
valve spring retainer to determine if
if the
damper spring coil
coil has been hitting the
retainer. This interference
interference will also cause
a clicking
clicking noise when the engine
engine is
operating.
operating. The
The damper
damper spring
spring is
is properly
properly
installed
installed in
in the
the valve
valve spring
spring when
when
positioned
positioned so
so that
that the
the end
end of
of the
the damper
damper
spring
spring bottom
bottom coil
coil is
is 135
135 degrees
counterclockwise
counterclockwise from
from the
the end
end of
of the
the
valve
valve spring
spring lower
lower coil.
coil.
Hydraulic Valve
Valve Lifters
Lifters and
and
Hydraulic
Hydraulic Lash
Lash Adjusters
Adjusters
Hydraulic
The valve
valve lifter
lifter (or
(or lash
lash adjusters)
adjusters)
The
assemblies
should be
be kept
kept in
in proper
proper
assemblies should
sequence
sequence so
so that
that they
they can
can be
be installed
installed in
in
their
their original
original position.
position. Inspect
Inspect and
and test
test
each lifter
lifterseparately
separately so
so as
as not
not to
to intermix
intermix
each
the
the internal
internal parts.
parts. If
Ifany
any part
part of
ofthe
the lifter
lifter
assembly
assembly needs
needs replacing,
replacing, replace
replace the
the
entire
entire assembly.
assembly.
Cleaning
Cleaning
Thoroughly
Thoroughly clean
clean all
all the
the parts
parts in
in
clean
clean solvent
solvent and
and wipe
wipe them
them with
with aaclean,
clean,
lint-free
lint-free cloth.
cloth.
Inspection
Inspection
Inspect
Inspect the
the parts
parts and
and discard
discard the
the
entire
entire lifter
lifter assembly
assembly ifif any
any part
part shows
shows
pitting,
pitting, scoring,
scoring, galling,
galling, excessive
excessive wear
wear or
or
evidence
evidence of
of non-rotation.
non-rotation. Replace
Replace the
the
entire
entire assembly
assembly ifif the
the plunger
plunger isis not
not free
free
in
in the
the body.
body. The
The plunger
plunger should
should drop
drop to
to
the
the bottom
bottom of
of the
the body
body by
by its
its own
own weight
weight
when
when assembled
assembled dry.
dry.
Assemble
Assemble the
the lifter
lifter assembly
assembly and
and
check
check for
for freeness
freeness of
of operation
operation by
by
pressing
pressing down
down on
on the
the push
push rod
rod cup.
cup. The
The
lifters
lifters can
can also
also be
be checked
checked with
with aa
hydraulic
hydraulic tester
tester to
to test
test the
the leakdown
leakdown rate.
rate.
Follow
Follow the
the instructions
instructions of
of the
the test
test unit
unit
manufacturer
manufacturer or
or the
the procedure
procedure under
under
Diagnosis
Diagnosis and
and Testing.
Testing.
Timing
Timing Chain
Chain and
and Sprockets
Sprockets
Cleaning
Cleaning
Clean all parts in solvent and dry
dry
them with compressed air.
air.
Lubricate the timing chain with
with
engine oil before installing it on the
the
sprockets.
Inspection
Inspect the chain for broken links.
Inspect the sprockets for cracks and worn
or damaged
damaged teeth. Replace all the
the
components of
of the timing chain and
sprocket
sprocket assembly,
assembly, if
if anyone
any one item
item needs
needs
replacement.
replacement.
Fuel Pump Eccentric
Cleaning
Cleaning
Clean the fuel pump eccentric in
solvent and
and dry
dry with
with compressed
compressed air.
solvent
air.
Inspection
Inspection
Inspect the fuel pump drive eccentric
for scores, nicks and excessive wear. If
If
for
the eccentric surface
surface is scored, nicked
nicked or
worn, replace it.
On two-piece designs, inspect
inspect inner
and outer
outer rings for
for scoring, nicks, and
and
excessi ve wear.
wear. Replace
Replace any
any part
excessive
part
indicating scoring
scoring or
or excessive
excessive wear.
indicating
Camshaft
Camshaft
and Inspection
Cleaning and
Clean the
the camshaft
camshaft in
in solvent
solvent and
and
Clean
wipe itit dry.
dry. Inspect
Inspect the
the camshaft
camshaft lobes
lobes for
for
wipe
scoring and
and signs
signs of
ofabnormal
abnormal wear.
wear. Lobe
Lobe
scoring
wear characteristics
characteristics may
may result
resul~ in
in pitting
pitting
wear
of the
the lobe
lobe toe.
toe. This
This
in the
the general
general area
area of
in
is not
not detrimental
detrimental to
to the
the operation
operation
pitting is
pitting
of the
the camshaft;
camshaft; therefore,
therefore, the
the camshaft
camshaft
of
should not
not be
be replaced
replaced unless
unless the
the lobe
lobe lift
lift
should
loss
loss has
has exceeded
exceeded 0.005
0.005 inch.
inch.
The lift
lift of
of the
the camshaft
camshaft lobes
lobes can
can be
be
The
checked with
with the
the camshaft
camshaft installed
installed in
in
checked
the engine
engine or
or on
on centers.
centers. Refer
Refer to
to
the
Camshaft Lobe
Lobe Lift.
Lift.
Camshaft
Check the
the distributor
distributor drive
drive gear
gear for
for
Check
broken or
or chipped
chipped teeth.
teeth. Replace
Replace the
the
broken
camshaft ifif this
this condition
condition exists.
exists.
camshaft
21-01-18
21-01-18
OilPan
Pan
Oil
Cleaning
Cleaning
Scrape any
anydirt
dirt or
or metal
metal particles
particles
Scrape
from the
theinside
insideof
ofthe
thepan.
pan.Scrape
Scrapeall
allold
old
from
gasket material
material from
from the
thegasket
gasket surface.
surface.
gasket
Wash the
thepan
paninin aa solvent
solvent and
and dry
dry itit
Wash
thoroughly. Be
Besure
sure all
allforeign
foreign particles
particles
thoroughly.
are
areremoved
removedfrom
from below
belowthe
thebaffle
baffle plate.
plate.
Inspection
Inspection
Check the
the pan
pan for
for cracks,
cracks, holes,
holes,
Check
damaged drain
drain plug
plug threads,
threads, and
andaaloose
loose
damaged
baffle or
oraadamaged
damaged gasket
gasket surface.
surface.
baffle
Inspect for
for damage
damage (uneven
(uneven surface)
surface)
Inspect
thebolt
bolt holes
holescaused
caused by
by over-torquing
over-torquing
atat the
thebolts.
bolts.Straighten
Straighten surfaces
surfaces as
asrequired.
required.
the
Repair
Repair any
any damage,
damage, or
orreplace
replace the
the pan
pan if
repairs
repairs cannot
cannot be
be made
made satisfactorily.
satisfactorily.
Oil Pump
Pump
Oil
Caution: Oil
Oil Pump
Pump with
with outboard
outboard
Caution:
bearingsin
inpump
pumpcover
coverfor
for2300cc
2300ccengine
engine
bearings
must not
not be
bedisassembled.
disassembled. Pump
Pump with
with 44must
bolt cover
cover may
may be
be serviced
serviced as
as follows:
follows:
bolt
Cleaning
Cleaning
Wash all
all parts
parts in
in aa solvent
solvent and
and dry
dry
Wash
them thoroughly
thoroughly with
with compressed
compressed air.
air.
them
Use aa brush
brush to
to clean
clean the
the inside
inside of
of the
the
Use
pump housing
housing and
and the
the pressure
pressure relief
pump
valve chamber.
chamber. Be
Be sure
sure all
all dirt
dirt and
and metal
metal
valve
particles are
are removed.
removed.
particles
Inspection
Inspection
to the
the specifications
specifications for
Refer to
clearances and
and wear limits.
limits.
Check the inside of the pump housing
and the
the outer race and
and rotor for
for damage
wear.
or excessive wear.
Check the mating surface of the pump
cover for wear. If the
the cover mating
surface is
is worn, scored or grooved,
replace the
the cover.
Measure the
the outer race to housing
clearance (Fig. 44).
44).
A1026-C
FIG.
FIG. 44
44 Checking
Checking Outer
Outer Race
Race to
to
Housing
Housing Clearance
Clearance
With
With the
the rotor
rotor assembly
assembly installed
installed inin
the
thehousing,
housing, place
placeaastraight
straightedge
edgeover
overthe
the
rotor
rotor assembly
assembly and
and the
thehousing.
housing. Measure
Measure
the
the clearance
clearance (rotor
(rotor end
end play)
play) between
between
the
the straight
straight edge
edgeand
and the
therotor
rotorand
and outer
outer
race
race (Fig.
(Fig. 45).
45). The
The outer
outer race,
race, shaft
shaftand
and
rotor
rotor are
are replaceable
replaceable only
only as
as an
an
assembly.
assembly. Check
Check the
the drive
drive shaft
shaft to
to
housing
housing bearing
bearing clearance
clearance by
by measuring
measuring
BACK TO GROUP INDEX
21-01-18
21-01-18
General
General Gasoline
Gasoline Engine
Engine Service
Service
the
the OD
ODof
ofthe
theshaft
shaft and
andthe
theID
IDof
ofthe
the
housing
housingbearing.
bearing. Inspect
Inspect the
therelief
relief valve
valve
spring
springfor
foraacollapsed
collapsedor
orworn
worncondition.
condition.
Check
Check the
therelief
relief valve
valve spring
spring tension.
tension. If
If
the spring
spring tension
tension isis not
not within
within
the
specifications
specifications and/or
and/or the
thespring
spring isisworn
worn
or
ordamaged
damagedreplace
replacethe
thespring.
spring.Check
Checkthe
the
relief
relief valve
valve piston
piston for
for scores
scores and
and free
free
operation ininthe
thebore.
bore.
operation
Straight Edge
Feeler Gauge
specifications,
specifications, install
install aa 0.001
0.001 inch
inch
oversize
oversize piston
piston pin.
pin. First,
First, prefit
prefit the
the
oversize
oversizepiston
pistonpin
pintotothe
thepiston
piston pin
pinbore
bore
by
by reaming
reaming or
or honing
honing the
the piston
piston to
to
provide
provide 0.0002-0.0004
0.0002-0.0004 inch
inch clearance
clearance
(light
(lightslip
slipfit).
fit).Then,
Then,assemble
assemblethe
the piston,
piston,
piston
piston pin
pinand
andconnecting
connecting rod
rodfollowing
following
the
the procedures
procedures for
for the
the specific
specific engine
engine
being
being worked
worked on.
on. ItIt isis not
notnecessary
necessary to
to
ream
ream or
or hone
hone the
the pin
pin bore
bore in
in the
the
connecting
connecting rod.
rod. Replace
Replace damaged
damaged
connecting
rod
nuts
and
connecting rod nuts andbolts.
bolts. Check
Check the
the
connecting
connecting rods
rods for
for bend
bend or
or twist
twist on
on aa
suitable
the
suitable alignment
alignment fixture.
fixture. Follow
Follow the
instructions
instructions of
ofthe
the fixture
fixture manufacturer.
manufacturer.
If
If the
the bend
bend and/or
and/or twist
twist exceeds
exceeds
specifications,
specifications, the
the connecting
connecting rod
rod must
must
be
be straightened
straightened or
or replaced.
replaced.
Pistons,
Pistons, Pins
Pins and
and Rings
Rings
Cleaning
Cleaning
Remove
Remove deposits
deposits from
from the
the piston
piston
surfaces.
the
surfaces. Clean
Clean gum
gum or
or varnish
varnish from
from the
piston
piston skirt,
skirt, piston
piston pins
pins and
and rings
rings with
with
solvent.
solvent. Do
Do not
not use
use aa caustic
caustic cleaning
cleaning
solution
solution or
or aa wire
wire brush
brush to
to clean
clean pistons.
pistons.
Clean
Clean the
the ring
ring grooves
grooves with
with aa ring
ring
groove
the
groove cleaner
cleaner (Fig.
(Fig. 46).
46). Make
Make sure
sure the
oil
oil ring
ring slots
slots (or
(or holes)
holes) are
are clean.
clean.
FIG. 45
45 Checking
Checking Rotor End
End Play
FIG.
Connecting Rods
Connecting
Cleaning
Cleaning
Remove the
the rod
rod
the bearings from the
cap. Identify the bearings if they are
are
and cap.
to be
be used again. Clean the
the connecting
rod in solvent, including the rod bore and
the back of the
the inserts. Do
Do not
not use
use aa
caustic cleaning solution. Blow
out all
Blowout
all
air.
passages with compressed air.
Inspection
Inspection
The connecting rods and related parts
should
should be carefully
carefully inspected
inspected and
and
cchecked
h e c k e d ffor
o r cconformance
o n f o r m a n c e tto
o
specifications.
specifications. Various forms
forms of
of engine
engine
wear
wear caused
caused by
by these
these parts
parts can
can be
be readily
readily
identified.
identified.
A
A shiny
shiny surface
surface on
on either
either pin
pin boss
boss side
side
of
of the
the piston
piston usually
usually indicates
indicates that
that aa
connecting
is bent.
bent.
connecting rod
rod is
Abnormal
Abnormal connecting
connecting rod
rod bearing
bearing
wear
can be
be caused
caused by
by either
either aa bent
bent
wear can
connecting
connecting rod,
rod, worn
worn or
or damaged
damaged
crankpin,
crankpin, or
or aa tapered
tapered connecting
connecting rod
rod
bore.
bore.
Twisted
Twisted connecting
connecting rods
rods will
will not
not
create
create an
an identifiable
identifiable wear
wear pattern,
pattern, but
but
badly
badly twisted
twisted rods
rods will
will disturb
disturb the
the action
action
of
ofthe
the entire
entire piston,
piston, rings
rings and
and connecting
connecting
rod
of
rod assembly
assembly and
and may
may be
be the
the cause
cause of
excessive
excessive oil
oil consumption.
consumption.
Inspect
Inspect the
the connecting
connecting rods
rods for
for signs
signs
of
offractures
fracturesand
andthe
thebearing
bearingbores
boresfor
foroutoutof-round
of-round and
and taper.
taper. IfIf the
the bore
bore exceeds
exceeds
the
the recommended
recommended limits
limits and/or
and/or ififthe
the
connecting
fractured, itit should
shouldbe
be
connecting rod
rod isis fractured,
replaced.
replaced.Check
Checkthe
theID
IDofofthe
theconnecting
connecting
rod
thepin
pinbore
borein
in the
the
rodpiston
pistonpin
pinbore.
bore.IfIfthe
cconnecting
o n n e c t i n g rrod
o d isis l larger
a r g e r tthan
han
Ring Groove C/eone
A2918-B
46 Cleaning Piston Ring

Ring
FIG. 46
Grooves
Grooves
Inspection
Carefully inspect
inspect the
the pistons
pistons for
for
Carefully
fractures at
at the
the ring
ring lands,
lands, skirts
skirts and
and pin
pin
fractures
or scored
scored
bosses, and
and for
for scuffed,
scuffed, rough
rough or
bosses,
If the
the lower
lower inner
inner portion
portion of
of the
the
skirts. If
skirts.
ring grooves
grooves has
has aa high
high step,
step, replace
replace the
the
ring
piston. The
The step
step will
will interfere
interfere with
with ring
ring
piston.
operation and
and cause
cause excessive
excessive ring
ring side
side
operation
clearance.
clearance.
Spongy, eroded
eroded areas
areas near
near the
the edge
edgeof
of
Spongy,
the top
top of
of the
the piston
piston are
are usually
usually caused
caused
the
or pre-ignition.
pre-ignition. A
A shiny
shiny
by detonation
detonation or
by
surface on
on the
the thrust
thrust surface
surface of
of the
the
surface
piston, offset
offset from
from the
the centerline
centerlinebetween
between
piston,
the piston
piston pin
pin holes,
holes, can
can be
be caused
caused by
by aa
the
bentconnecting
connectingrod.
rod. Replace
Replacepistons
pistonsthat
that
bent
ofexcessive
excessive wear,
wear, wavy
wavy ring
ring
show signs
signs of
show
lands or
or fractures
fractures or
or damage
damage from
from
lands
detonation or
or pre-igniton.
pre-igniton.
detonation
Check the
the piston
piston to
to cylinder
cylinder bore
bore
Check
clearance by
by measuring
measuring the
the piston
piston and
and
clearance
bbore
o r e ddiameters.
i a m e t e r s . RRefer
e f e r t to
o t the
he
specifications for
for the
the proper
proper clearance.
clearance.
specifications
Refer to
to Cylinder
Cylinder Block
Block Inspection
Inspection for
for
Refer
the bore
bore measurement
measurement procedure.
procedure.
the
Measure the
the OD
OD of
of the
the piston
piston with
with
Measure
micrometers at
at the
the centerline
centerline of
ofthe
the
micrometers
at90
90degrees
degreesto
to the
the
pistonpin
pinbore
boreand
andat
piston
pin bore
bore axis.
axis. Check
Check the
the ring
ring side
side
pin
21-01-19
clearance following the procedure under

Fitting Piston Rings in this section.
Replace piston pins showing signs of
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.
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 pistOll
piston to
another regardless of mileage.
Main and
and Connecting Rod
Rod
Bearings
Cleaning
Clean the bearing inserts and caps
thoroughly in solvent, and dry them with
compressed air. Do not scra~
scrape gum or
varnish deposits from tM
the bearing shells.
Inspection
Inspect each bearing carefully.
carefully.
Inspect
chipped or
Bearings that have a scored, chipPed
worn surface should be replaced. Typical
examples of unsatisfactory
unsatisfactory bearings and
their causes are shown in Fig. 47.
47. 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
satisfactory with
Plastigage as detailed under Main and
Connecting Rod Bearings.
Inspection
Inspect the main and connecting rod
jpurnals for cracks, scratches, grooves or
journals
crankshaft oil seal
scores. Inspect the crankshaft
surface for nicks, sharp edges or burrs
that might damage the oil seal during
installation or cause premature seal wear.
Measure the diameter of each journal
in at least four places to determine an
out-of-round,
out-of-round, taper
taper or undersize
undersize
condition (Fig. 48).
Crankshaft
Cle/llling
Cleaning
Handle the crankshaft
crankshaft with care to
avoid possible fractures or damage to the
crankshaft
finished surfaces. Clean the crankshaft
blow out all oil
with solvent, then blowout
passages with compressed air.
AVS
B = VERTICAL TAPE
TAPER
A
VS B
R
CVS
C VS D=HORIZONTAL
D
HORIZONTAL TAPER
A
VS C
OUT.OFROUND
AVS
C AND
AND B
B VS
VS 0D =
OUT-OF-ROUND
FOR OUT-OF.ROUND
OUT-OF-ROUND AT
CHECK FOR
EACH END
END OF
OF JOURNAL
EACH
Lii..i . . . . . . ;.i...il!ii.i . . i.. I;;. ,..7 I
,"
-.....!.""""...L.---~=_-=_.o!..;'_
.... -.....::'-/
FIG. 48 Crankshaft Journal

HG.
Measurement
CAl
Inspect the pilot bearing (roller

bearing)
b e a r i n g ) when so equipped,
e q u i p p e d , for
for
roughness, evidence of overheating or
loss of lubricant. Replace it if any of these
conditions are found.
found.
Crankshaft Vibration
Vibration Damper
Damper
Crankshaft
and Sleeve
and
Cleaning
Cleaning
Clean the oil seal contact surface on
the crankshaft
crankshaft damper or sleeve with
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
installation or
or cause
cause premature
premature seal
seal wear.
wear.
-:~
SCRATCHES
BY DIRT
~RLAYGO~
FROM ENTIRE SURFACE
TAPERED JOURNAL
.:
IWJ
4.
~~~:~7~L
A 2901- B
SCRATCHED
./
LACK OF
OF OIL
RADIUS RIDE
RADIUS RIDE
"
/t:
"
. ;.:.,. . .
.'
B;'IGH~
(POLISHED)
SECTIONS
IMPROPER SEATING
CRATERS OR POCKETS
FATIGUE
FAILURE
A2903-A
A2903A
FIG. 47 Typical Bearing Failures
BACK TO GROUP INDEX
;'
'"
21-01-19
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
crankshaft damper seal
Inspect the crankshaft
surface for nicks, sharp edges or burrs
that might damage the oil seal during
installation or cause premature seal wear.
FlywheelManual-Shift
Flywheel-Manual-Shift
Transmission
Transmission
Inspection
Inspect the flywheel for cracks, heat
check, or other damage that would make
it unfit for further
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
If the teeth are
damaged, replace the ring gear.
With the flywheel installed on the
crankshaft,
face
crankshaft, check the flywheel face
runout, following the procedure under
Diagnosis and Testing.
Flywheel-Automatic
FlywheelAutomatic
Transmission
Transmission
Inspection
Inspect the flywheel for cracks or
other defects that would make it unfit for
further service. Inspect the flywheel ring
further
gear for worn, chipped or cracked teeth.
If the teeth are damaged, replace the ring
If
gear and flywheel assembly.
With the flywheel installed on the
crankshaft,
crankshaft, check the gear face runout.
Cylinder Block
Cleaning
Cleaning
After
After any cylinder
cylinder bore repair
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
If the engine is disassembled,
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
Blow out all passages,
all the passages. Blowout
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 trueup threads and to remove all deposits.
Thoroughly clean the grooves in the
crankshaft bearings
bearings and bearing
bearing
crankshaft
retainers.
21-01-20
Inspection
After
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
of 25 percent kerosene
with a mixture of
and 75 percent light engine oil. Wipe the
part dry and immediately apply a coating
oxide dissolved in wood alcohol.
of zinc oxjde
If cracks are present, the coating will
If
become discolored at the defective area.
Replace the block if it is cracked.
Check all machined gasket surfaces
surfaces
for burrs, nicks, scratches and scores.
Remove minor imperfections
oi}"'
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
out-of-round and
the cylinder bore for out-of-round
BACK TO GROUP INDEX
21-01-20
taper. Measure the bore with an accurate

of
bore gauge following the instructions of
the manufacturer. Measure the diameter
of each cylinder bore at the top, middle
and bottom with the gauge placed at right
th
angles and parallel to the centerline of th~
e n g i n e (Fig.
( F i g . 49).
4 9 ) . Use
U s e only
only the
engine
measurements obtained at 90 degrees to
the engine centerline when calculating
the piston to cylinder bore clearance.
Refinish cylinders that are deeply
Refinish
out-of-round and/or
and/or
scored and/or when out-of-round
taper exceed the wear limits. If
If the
cylinder walls have minor
minor surface
surface
cylinder
out-of-round and
imperfections, but the out-of-round
taper are within limits, it may be possible
to remove the imperfections
imperfections by honing
the cylinder walls and installing new
service piston rings providing the piston
clearance is within specified
specified limits.
"'-CENTER
- CENTER LINE OF ENGINE
ENGINE ~
A
AT
RIGHT
ANGLE
TO
CENTER
LINE OF
ENGINE
B
PARALLEL
TO
CENTER
LINE OF
ENGINE
1. OUT-OF-ROUND
DIFFERENCE
BETWEEN
OUT-OF-ROUND =
A AND B
A
2. TAPER = DIFFERENCE BETWEEN THE A
MEASUREMENT AT TOP OF
A
CYLINDER BORE AND THE A
MEASUREMENT AT BOTTOM OF
2905-A
A 290SA
CYLINDER BORE
FIG. 49 Cylinder Bore Out-of-Round

and Taper

21-01-21
21-01-21
21-01-21
SPECIAL SERVICE TOOLS
Application Engine Size
Description
Hydraulic Lifter Remover
Crankshaft Front Seal InstallinQ
Installing Tool
Crankshaft Front Seal
Seal RemovinQ
Removing Tool
Impact Hammer
Puller Attachment Use
Use with
T50T100-A
or T59L-100-B
T50T-100-AorT59L-100-B
Handle Adapter
Differential Backlash and
Runout Gauge,
Gauge, with Universal
Bracket and Dial Indicator
(1-1/4 inch range).
range). Includes
Indicator TOO
L-6565
TOOL-6565
Engine Lifting Hook
Engine Lifting Hook
Engine Lifting Brackets
Cam
Cam Bearing Bore Plug Installing Tool
Core Plug Replacer
Cylinder Front Cover Pilot
Front Cover Alignment Tool
Cylinder Front Cover Pilot
Valve Spring Compressor, on Engine
Valve Guide Reamer Kit
Engine Lifting and
**
and Head
Head Holding Brackets
Brackets**
Piston Pin Remover and Replacer Kit
Camshaft Bearings Remover and
Replacer Adapters
Camshaft Rear Bearing Bore
Replacer-Adapter-Use
Plug Replacer-Adapter-Use
T53L-200-A
with T53L200-A
Cylinder Block Core Plug Replacer
Core Plug Replacer
Crankshaft Damper Replacer
Camshaft Timing Gear Replacer
Screw Adapter
Crankshaft Damper Installer
Camshaft Gear Installer
Crankshaft Damper Remover
Cylinder Block Core Ptug
Plug Replacer
Valve Guide Reamer Kit
Seal Replacer
Cam Bearing Remover and Replacer Adapter Tube
Cam
Cam
Cam Bearing Bore Plug Replacer
Cover Plate Retaining Studs
Seal Replacer and
Front Cover Aligner, Seal
Timing Gear Replacer
Piston Pin Remover and Replacer/Adapter
Crankshaft Timing Gear Remover Adapter
Damper Pulley Remover and Replacer
Crankshaft Dar:nper
Crankshaft Damper Pulley Replacer
Valve Spring Compressor Lever
Valve Spring Compressor Bar
Front Cover Seal
Seal Remover
Pilot Bearing Replacer Adapter*
Pilot Bearing Replacer Adapter*
Ford Tool
No.
No.
2300
CC
CC
Four
T70P-14151
T70P-14151
T70P-6B070-A
T70P-6B070-B
T50T-100-A
2800
CC
CC
Y-a
V6
200/
200/
250 Six
X
X
X
X
T58Ll0l-A
T58L-101-A
T53L-200-A
TOOL-4201-C
T60K-6000-A
T65L-6000-A
T58P-6000-A
T70P6001-A
T70P-6001-A
T54L-6015A
T54L-6015-A
T61
P60 19-B
T61P-6019-B
T61
K-6019-A
T61K-6019-A
T68P-6019-A
T70P-6049-A
T70P6049A
T52L6085AEE
T52L-6085-AEE
T62F6085A
T62F-6085-A
T68P-6135-A
T65L-6250-A
T65L-6250A
T65L-6306-A
T52L-6306-AEE
T65L-6306-A
T58P-6316-B
T72C-6015
T72C-6085
T72C-6165
6005-BDA
6005BDA
T52L-6261-CEE
460
V-a
V-8
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X+
x+
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
200
200
T72C~6250
T72C-6250
X
X
X
X
X
X
X
X
T72C-6266
T72C-7007
X
X
T74P-6019-A
T74P-6135-A
T74P-6136-A
T74P6136-A
T74P-6316-A
T74P-6316-B
T74P-6565-A
T74P-6565-B
T74P-6700-A
T74P-7137-A
T74P-7137-B
X
200
200
302-351-W 351
351M&
M&
Y-8
400 V-a
V-8
V-8
200
200
200
200
X
6059-F
T62F-6266-A
T62
F6266-A
T68P-6266-A
T52L-6266-BGD
T64T-6306-A
*Use
with TOOL T71 P-7137-H or T74P-7137-H
'UsewithTOOLT71P-7137-HorT74P-7137-H
**When
**When Removing Engine with Exhaust Manifolds Attached
BACK TO GROUP INDEX
Former
No.
No.
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
+
+Use
Use with TOOL T68P-6135-A
CA1327-E

21-01-22
21-01-22
SPECIAL SERVICE TOOLS (Continued)

Application Engine Size
Description
Camshaft Damper Remover
Adapter Screw
Crankshaft Damper Remover
Upper Main Bearing Insert
Remover and Replacer
Upper Main Bearing Remover
and Replacer
Hydraulic Tappet Leakdown Tester
Hydraulic Tappet Plunger
Remover and Replacer
Valve Stem Deburring Tool
Valve Stem Clearance Checking Tool
Valve Stem Clearance Checking Tool
Valve-Gauge
Valve Gauge
Valve Spring Compressor
Air Adapter and Hose-Valve Holdup
Compressor-Tappet Bleed-Down
Valve and Clutch Spring Tester
Rocker Arm Stud Kit
Rocker Arm Stud Installer
(Supplements T62F-6A527-B)
Hydraulic Tappet Bleed-Down Tool
Cup Shaped Adapter to TOO
L-6565
TOOL-6565
Crankcase Ventilation System
Tester (Kit)
Cylinder Block Front Cover
Oil Seal
Seal Replacer Adapter
Cylinder Block Front Cover
Seal Replacer-Adapter
Oil Seal
UsewithT53L-200-A
Use
with T53L-200-A
Seal Replacer
Front Cover Oil Seal
Seal Forming Tool
Crankshaft Rear Seal
Seal Replacer
Seal Replacer
Seal Replacer
6701 Tools
Fibre Block for 6701
Clutch Disc Pilot
Clutch Pilot Bearing Replacer
Clutch Pilot Bearing Replacer
Rocker Arm Stud Driver
Clutch Disc Aligner
Clutch Disc Aligner
Clutch Disc Aligner
*Mustang Only
BACK TO GROUP INDEX
Ford Tool
No.
Former
No.
T64T-6316-A
T52L-6316-FEE
6316-FF
2300
CC
CC
Four
2800
CC
CC
V-6
V6
200
250 Six
302-351-W 351M&
351 M &
302351W
V-8
400 V-8
V8
460
V-8
X
X
TOOL-6331
TOOL-6331
T00L-6331-E
TOOL-6331-E
TOOL-6500-E
X
X
TOOL-6500-F
T70P-6505-A
TOOL-6505-E
TOOL-6505-F
T64L-6507-A
T65P-6513-A
T71P-6513-A
T71
P-6513-A
T00L-6513-ABA
TO
0 L-6513-ABA
TOOL-6513-AC
T00L-6513-AC
T00L-6513-DD
TOOL-6513-DD
T00L-6513-H
TOOL-6513-H
T62F-6A527-B
X
X
200
200
X
X
200
200
X
X
6513-AB
X
X
X
X
X
X
X
X
X
X
X
X
X
T65P-6A527-A
T70P-6564-A
T00L-6565-AB
TOO
L-6565-AB
X
X
C8AZ-6B627-A
X
X
T60K-6700-A
T58P-6700-B
T68P-6700-A
T60K-6701-A
T62F-6701-A
T65P-6701-A
T68P-6701-A
T58P-6701-AC
T58P-7563-A
TOOL-7600-H
T65L-7600-A
T69
P-6049-D
T69P-6049-D
T71P-7137-H
T71
P-7137-H
T74P-7137-H
T74P-7137-K
6700-C
200
200
250
250
200
200
X
X
200
200
7600-H
X
X
X
X
X
351W
X
X*
'X
X
CA1327-E 1

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

Cylinder Engine
Pinto, Bobcat and Mustang
COMPONENT INDEX
COMPONENT INDEX
Page
DESCRIPTION
,.
05-1
05-1
Cylinder Front Cover, Camshaft
05-3
05-3
And Auxiliary Shaft Seals

Seals..
Exhaust Emission Control System

05-3
ADJUSTMENTS
Valve Clearance - Hydraulic Valve
Page
05-11
Sprocket
Sprocket
05-11
05-11
Seal
Seal
05-11
05-11
Camshaft
Timing Belt
Camshaft Timing
Belt
05-11
05-11
05-12
05-12
Lash
justGrs
Lash Ad
Adjusters
05-4
Timing Belt Tensioner
Camshaft Timing
05-4
Auxiliary Shaft And Bearings .
05-12
05-12
Cylinder Front Cover
05-12
Flywheel
05-12
Clutch Pilot Bearing
05-12
05-9
Pan
Oil Pan
05-12
05-12
05-9
Oil Pump
05-12
05-12

INSTALLATION
Engine
05-8
Engine Front Supports - Pinto, Bobcat

Or Mustang
Engine Rear Support - Pinto and Bobcat

Engine Rear Support - Mustang
05-9
05-12
05-12
05-10
Main Bearings
05-12
Valve Rocker Arm Cover
05-10
Connecting Rod Bearings
05-13
Pistons And Connecting Rods . .
05-13
Oil Filter
05-13
05-13
Valve Rocker Arm (Cam Follower)

05-10
And Hyd
Hydraulic
Lash Ad
Adjuster
And
rau Iic Lash
j uster
DISASSEMBLY AND ASSEMBLY
Valve Spring,
Spring, Retainer And
.
05-10
Cylinder Head
05-29
Intake Manifold
05-10
Pump . . . . . . . . . . . . . . . . . . . . .
Oil Pump.
05-29
Exhaust Manifold
05-11
05-11
Piston And Connecting Rod
05-30
Head
Cylinder Head
05-11
05-11
Adjuster . . . . . . . . . . .
Hydraulic Lash Adjuster.
05-30
Seal . . . .. .
Stem Seal.
Special Tools
05-36
Tools. . . . . . . . . . . . . . . . . . . . . . .
Water Pump
.
05-11
05-11
Specifications . . . . . . . . . . . . . . . . . . . .--l_.:..:....:..:..----I
Specifications.
.
05-37
05-37
'-------,------------L------L--L----=-
information in this Part applies to both 1975 and 1976 model year vehicles unless otherNOTE: The infonnation
wise specified.
CR1966-A
CR1966-A
DESCRIPTION
4 - c y l i n d e r 2300cc
23OOcc (2.3L)
(2.3L)
The 4-cylinder
overhead cam engine is of lightweight
crankshaft is
iron construction. The crankshaft
supported on five
five main bearings and the
camshaft by four. Main, connecting rod,
camshaft and auxiliary shaft bearings are
camshaft
replaceable.
all replaceable.
camshaft is driven from the
The camshaft
crankshaft by a cogged belt, which also
crankshaft
BACK TO GROUP INDEX
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.
Water pump and fan are separately
driven
driven from
from the crankshaft
c r a n k s h a f t by a
conventional V-belt, which also drives
the alternator.
Hydraulic valve lash adjusters

adjusters are
used in the valve train. These units are
placed at the fulcrum
fulcrum point of
of the cam
followers (or rocker arms). Their
Their action
is similar to the hydraulic valve lifters
used in push-rod
push-rod engines and they are
constructed
constructed and serviced
serviced in the same
manner. The cylinder
cylinder head has drilled oil
passages to provide engine oil pressure to
the lash adjusters
adjusters (Fig. 3).
21-05-2
21-05-2
2300cc
2300cc Four
Four Cylinder
Cylinder Engine
Engine
21-05-2
21-05-2
A3727-B
A3727-B
FIG.
FIG. 11 Left
Left Front
Front View-2300cc
View-2300cc (2.3L)
(2.3L) Engine
Engine
BACK TO GROUP INDEX

21-05-3
21-05-3
2300cc
2300cc Four
Four Cylinder
Cylinder Engine
Engine
21-05-3
21-05-3
A
A set
set of
of metric
metric wrenches
wrenches is
is required
required
to
to service
service the
the 23OOcc
2300cc (2.3L)
(2.3L) engine.
engine.
EXHAUST
EXHAUST EMISSION
EMISSION CONTROL
CONTROL
SYSTEM
SYSTEM
Operation,
Operation, removal,
removal, installation
installation and
and
required
required maintenance
maintenance of
of the
the exhaust
exhaust
emission
emission control
control devices
devices used
used on
on this
this
engine
engine are
are covered
covered in
in Group
Group 29
29 of
of this
this
Volume,
Part 50-29
50-29 of
of Volume
Volume 5.
5.
Volume, and
and Part
CRANKCASE
SYSTEM
SYSTEM
This
This engine
engine is
is equipped
equipped with
with aa
positive,
positive, closed-type
closed-type crankcase
ventilation
ventilation system
system re-cycling
re-cycling crankcase
crankcase
vapors
vapors to
to the
the intake
intake manifold.
A3730-A
FIG. 2 2300cc Engine With Optional Belt-Driven Accessories
FIG.
FIG. 33 Valve
Valve Train
Train Lubrication
Lubrication System
System
BACK TO GROUP INDEX

21-05-4
21-05-4
ADJUSTMENTS
VALVE CLEARANCE-HYDRAULIC
CLEARANCEHYDRAULIC
LASH ADJUSTERS
VALVE LASH
1. Position the camshaft
camshaft so that the base
1.
circle of the lobe is facing the cam
follower of the valve to be checked
(Fig. 2).
2. Using the tool shown in Fig. 4, slowly
apply pressure to the cam follower
until the lash adjuster
adjuster is completely
collapsed. Hold the follower in this
position and insert the proper size
feeler gauge between the base circle of
of
the cam and the follower.
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,
measure the valve spring assembled
height to be sure the valve is not
sticking.
5. If
If the valve spring assembled height
is correct, check the dimensions of the
cam shaft
shaft following the procedure
under Checking Cam Shaft Lobe Lift
in Part 21-01.
6. If the camshaft
camshaft dimensions are to
specifications, remove, clean and test
the lash adjuster,
adjuster, following the
procedures given in Part 21-01.
7. Re-install the lash adjuster
adjuster and check
the clearance. Replace damaged or
worn parts as necessary.
NOTE: For any repair that

requires the removal of the camshaft
follower (rocker arm), each affected
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
camshaft timing
can be checked without removal of the
cover or any other parts.
1.
1. Remove the access plug (Fig. 5) from
the cam drive belt cover.
2. Set the crankshaft
crankshaft to TDC by aligning
the timing pointer on the belt cover
O mark on the crankshaft
crankshaft
with the 0
the
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.
5) is lined up with the pointer on the
inner belt cover.
4. Remove the distributor cap and check
that the distributor rotor is facing the
No.
position on
on the
thedistributor
distributor cap.
cap.
No.11 position
5. Install the distributor cap.
6. Install the belt cover access plug.
Adjusting Timing
1.
1. Refer to Fig. 6 and remove the timing
belt outer cover.
2. If the belt timing is incorrect, loosen
adjustment screw
the belt tensioner adjustment
adjusting
(Fig. 7), position the tension adjusting
tool shown on the tension spring
rollpin and release the belt tensioner.
adjustment screw to hold
Tighten the adjustment
the tensioner in released position.
crankshaft damper and

3. Remove the crankshaft
belt guide (Fig. 6).
4. Remove the drive belt and inspect it
for wear or damage. If
If the belt is
damaged, replace it.
crankshaft sprocket and
5. Position the crankshaft
camshaft sprocket as shown in
the camshaft
5. Remove the distributor cap
Fig. 5.
and set the distributor rotor to No. 11
firing position
turning the
firing
position by turning
auxiliary shaft.
shaft.
auxihary
6. Install the timing belt over the
crankshaft
crankshaft sprocket
sprocket and then
counterclockwise over the auxiliary
and camshaft
camshaft sprockets. Align the
belt fore and aft on the sprockets.
7.
7. Loosen the tensioner adjustment
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.
crankshaft two complete
8.
turns in normal rotation to remove
the slack from the belt. Torque
CAM ON
ON BASE CIRCLE
FEELER GAUGE
FIG. 44 Checking Hydraulic Valve lash

Lash Adjuster
BACK TO GROUP INDEX

21-05-5
tensioner adjustment
adjustment and pivot bolts
to specifications. Re-check the
alignment of the timing marks (Fig.
5).
5).
9. Install the crankshaft

crankshaft damper and
9.
belt guide (Fig.
(Fig. 6).
10. Install
Install the
the timing
timing belt
belt outer
outer cover
cover and
and
10.
the spark plugs.
21-05-5
11.Start
11.
Start the engine and check the
ignition timing. Adjust the ignition
specification as required.
timing to specification
TIMING POINTER MUSI

INDEX WITH TIMING
MARK ON SPROCKET
ACCESS
"
DISTRIBUTOR ROTOR MUST

ALIGN WITH NO. 1 FIRING
POSITION
TIMING POINTER
MUST ALIGN WITH
TDC MARK ON DAMPER
A3373-B
FIG. 5 Camshaft Drive Train Installation
BACK TO GROUP INDEX

21-05-6
21-05-6
BELT OUTER
COVER 6E004
BELT INNER COVER
A3735-C
FIG. 66 Timing Belt Outer Cover, Crankshaft Belt Guide and Pulley Installation
BACK TO GROUP INDEX

21-05-7
21-05-7
2300cc Four
Four Cylinder
Cylinder Engine
Engine
2300cc
21-05-7
21-05-7
BELT TENSIONER
ADJUSTING TOOL
TI4P-6254A
A3734B
A3734-B
FIG. 7 Releasing Belt Tension
BACK TO GROUP INDEX

21-05-8
21-05-8
N602569-S100*
N602569-S100
REQ'D.
3 REO'D.
~~ (
'
/
n
35-60 FT-LB
FT-LB
35-60
ENGINE SUPPORT -6C010
(R.H.)
6C010(R.H.)
c~
ENGINE SUPPORT
SUPPORT (REAR(REAR 34794 S2~""---- ENGINE
6D089
2 REO'D.
;I;
60089
*382802-S2
20-30 FT-LB
304726-S2*
2 REO'D.
40-60 FT-LB
TRANSMIT
TRANSMISSI~N
386321-S2*
~r'"
~~
20-30 FT-L
FT-LB""
~ _
N-800005-S101
*56753-52~
I~/
~~
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~_.,7
*56753-S2
40-60
FT-LB
ENGINE
SUPPORT---------------......,
/
ENGINESUPPORT-'
40-60FT-LB
-,:::e
6C060(L.H.)
56748-S2
01_
6C060
(L.H.)
I
56748-,S2
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*
VIEW X
2030 FT-LB
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56753-S2
382802-52*......~ ,
IEW Y::-::;
I
W/AUTOMATIC 2 REO'D.
"ADAPTER ~
TRANSMISSION
5059 ASSY
.......
(SAME AS MANUAL 5059 ASSY.
(SAME AS MANUAL
34670-S2 .
~
ADAPTER 6A069
~"'"
_ TRANSMISSION
34670-S2
6043
2 REQ'D.
---6043
56740-S2
EXCEPT AS SHOWN)
2
REO'D.
30-45 FTLB
FT-LB
---382802-S2*
4 REO'D
30-45
(CRIMP
AFTER
VIEW Z
VIEW
X
4
REO'D
.
~}iJ
.
REQ'D.
VIEWX
382802-S2
20-30
FT~LB
56740-S2
_~
---4 _ . . . . . . . 382802-52
INSTALLATION
382873-5100
382873-S100
20-30 FT-LB
V
I E W X
---.l
4REO'D.~-VIEWY
4REO'D.
TO
LOCK)
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2REO'D.
4
REQ'D.
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2
REQ'D.
c-.\
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..
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VIEWW
VIEW
W
VIEW
X
VIEWX
VIEWY
VIEW
Y
MAIN VIEW
.~
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~
20-30 FT-LB
FT-LB
20-30
PINTO/BOBCAT
INSTALLATION
PINTO/BOBCAT INSTALLATION
38280~-52*..~!
W/MANUAL
TRANSMISSION
W/MANUAL TRANSMISSION
57481-S2 ASSY.*
4 REQ'D.
REO'D.
35-50 FT-LB
FT-LB
3550
&
382802-S2*
6.A024 ASSY.
386454-S2
6A088 ASSY. (L.H.)
/ 2 REQ'D.
/2REOD.
~~_
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20-30
FT-LB
'
~20-30
FT'-LB
f 20-30 FT-LB /
~
. I
LA1l
34794-S2
. \
2
---2 REO'D.I
REQ'D.
304688-S2
,
p
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REO'D.
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REO'D.
40-60 FT-LB
40-60FT.LB
ADAPTOR
/'
*
382802-S2*
- 66A069
382802S2
.
~
A 0 6 9 ( L(L.H.)
.H.)
4 REQ'D.
386099-S2
57057-S2 ASSY.
20-30 FT-LB
4 REQ'D.
REO'D.
382802-S2*
6Aoaa
4 REO'D.
368041-S100
(NOTE: THESE BOLTS
385759-52
2 REQ'D.
REO'D.
ASSY.
REF. 20-30 FT-LB
385759-S2
ASSY.REF.
2 REQ'D.
4 REO'D.
REQ'D.
20-30 FT-LB
FT-LB
MUST BE
BE INSERTED
85-110 FT-LB
MUST
INSERTED
4
20-30
VIEW W
3860405100
VIEWW
AS SHOWN
2030 FT-LB
2 REO'D.
20-30
SHOWN BOTH
AND L.H. SIDES).
VIEWY
VIEW
Y
85-110 FT-LB VIEW X
R.H. AND
56747-S2
4 REO'D.
56753 S2
-
---
1,-
:!J.... ~
-.
N60.2569-5100*
ENGINE SUPPORT
SUPPORTN602569-S100*
6C060 (l.H.)
- . // 6
REO'D.
(L.H.)
6 REQ'D.
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~
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35-60 FT-LB
VIEW
VIEWZZ
VIEWZZ
VIEW
j'
~~
ENGINE SUPPORT
~ ENGINE
SUPPORT
( R E A R )-- 66068
068
......
(REAR)
(SAME AS VIEW Y EXCEPT AS SHOWN)
..,
VIEWY
VIEWZZ
VIEW
ENGINE SUPPORT
-6C010(R.H.)
~~..
I\
MAIN VIEW
ti
I'~~--GO
I'
-f--
N602569-S100*
N6025?9-S100*
3 REO
REQ'D.
D.
35-60 FT-LB
35-60~-LB
/-
I~'
__
I'
~~;OO~~'_LB
MUSTANG INSTALLATION
A3729-B
FIG. 8 Engine Supports-2300cc

Supports2300cc Engine
REMOVAL AND
AND INSTALLATION
When installing nuts or bolts (refer to
torque specifications), oil
oil the
the threads
with light-weight engine oil.
oil. Do
not oil
Do not
oil
threads that require oil-resistant or
or
water-resistant sealer.
ENGINE
ENGINE
Removal
Removal
1.
1. Raise the
the hood and
and secure it in
in the
vertical position.
2.
2. Drain the
the coolant from the
the radiator
oil from the
and the
the oil
the crankcase.
3. Remove the
the air cleaner and the
exhaust manifold shroud.
4. Disconnect the ground cable from the
the
battery.
5.
5. Remove the radiator upper and lower
hoses.
hoses.
6.
and fan.
fan.
6. Remove the
the radiator and
7.
7. Disconnect the
the heater hose from the
water pump and
and carburetor choke
fitting.
8.
8. Disconnect the
the alternator wires from
the alternator, the
the starter cable from
the starter, and
and the
the accelerator cable
from the
the carburetor.
On aa vehicle
from
carburetor. On
vehicle
the
with
with air
air conditioning,
conditioning, remove
remove the
BACK TO GROUP INDEX
compressor from the mounting

bracket, and
and position it out of the
way, leaving the
the refrigerant
refrigerant lines
attached.
9.
9. Disconnect the flexible fuel line at the
the
fuel pump line and
and plug the
the fuel line.
10.
10. Disconnect
Disconnect the
the coil
coil primary
primary wire
wire at
at
the coil. Disconnect the
the oil
oil pressure
the water temperature sending
and the
unit wires from the
the sending units.
Remove the
the starter.
starter.
11. Remove
12.
12. Raise
Raise the
the vehicle.
vehicle. Remove
Remove the
the
flywheel or converter housing upper
attaching bolts.
13. Disconnect
Disconnect the
the muffier
muffler inlet
inlet pipe
pipe at
at
the exhaust manifold. Disconnect the
and left mount at the
engine right and
underbody bracket. Remove the
flywheel or converter housing cover.
On a vehicle with a manual-shift
manual-shift
the flywheel
transmission, remove the
housing lower attaching bolts.
automatic
On a vehicle with automatic
transmission,
transmission, disconnect
disconnect the
the flywheel. Remove
converter from the
the converter housing lower attaching
bolts.
14.
14. Lower
Lower the
the vehicle.
vehicle. Support
Support the
the
transmission
transmission and flywheel
flywheel or
converter housing with a jack.
15. Attach
Attach the
the engine
engine lifting
lifting hooks
hooks to
to the
the
existing lifting brackets. Carefully lift
engine
the engine out of the engine
the engine on
on aa
compartment. Install the
work stand.
Installation
Installation
1.
per
1. If clutch was
was removed, re-install per
Group 16.
16. Carefully
Carefully lower the
the engine
engine
into the
the engine compartment.
2.
2. Make sure the
the studs on
on the
the exhaust
manifold are aligned with the holes in
in
the muffier
muffler inlet pipe.
automatic
transmission, start the converter pilot
into the
the crankshaft.
crankshaft.
manual-shift
the transmission
transmission, start the
main drive gear into the
the clutch disc.
may be
be necessary to
to adjust the
It may
position of the transmission in
relation to the engine if the input shaft
will not
not enter the
the clutch disc.
disc. If the
the
engine hangs up after the shaft enters,
the crankshaft in
in the
the clockwise
turn the
21-05-9
direction slowly (transmission in
gear),
gear), until the shaft splines mesh
with
with the
the clutch disc splines.
3.
3. Install the flywheel
flywheel or converter
housing upper attaching bolts.
Remove the engine lifting sling hooks.
hooks.
4.
h e j a cc kk fr
0 m the
4. Rem
R e m o0 vvet
e the
from
the
transmission. Raise the vehicle.
5.
On aa vehicle with automatic
automatic
transmission, attach the converter to
the flywheel and torque the attaching
nuts to specifications.
specifications.
6.
housing dust cover.
cover.
7.
7. Install the engine left and right mount
to
to the underbody bracket.
8.
8. Remove the plug from the fuel line
and connect the flexible fuel line to
the fuel pump line.
line. Install the exhaust
manifold to muffier
muffler inlet pipe nuts.
Torque the nuts to specifications.
specifications.
9.
9. Lower the vehicle.
vehicle. Connect the oil
pressure and the engine temperature
sending unit wires.
wires. Connect the coil
wires. Connect the accelerator cable.
wires.
10.
10. Install
Install the
the starter
starter motor.
motor. Connect
Connect the
the
starter cable.
cable. Connect the alternator
wires.
wires. Connect the heater hose to the
water pump and the carburetor choke
housing.
housing.
11.
11. Install the pulley, fan, and drive belt.
tension. On a
Adjust the drive belt tension.
vehicle with air conditioning, install
the compressor on the mounting
bracket, and adjust the belt tension to
specification. Install the fan and the
radiator. Connect the radiator upper
hoses. Fill and bleed the
and lower hoses.
system. Fill the crankcase
cooling system.
with the proper grade and quantity of
oil.
engine oil.
12. Connect
Connect the
the battery
battery ground
ground cable.
cable.
12.
13. Operate
Operate the
the engine
engine at
at fast
fast idle
idle and
and
13.
check all gaskets
g a s k e t s and hose
hose
check
connections for leaks.
automatic
transmission, adjust the transmission
17, Throttle
control linkage (Group 17,
Linkage).
Linkage).
14. Install
Install the
theair
air cleaner
cleaner and
and connect
connect the
the
14.
crankcase
positive closed type crankcase
ventilation hose.
hose.
ENGINE FRONT SUPPORTS
Mustang
Pinto, Bobcat or Mustang
Removal
1. Remove the fan shroud attaching
1.
screws.
screws.
2. Support the engine using a wood
2.
block and jack placed under the oil
pan.
pan.
3. Remove the through bolt and lock nut
3.
insulator to the
attaching the insulator
(Fig. 8).
insulator support bracket (Fig.
4. Remove the support bracket (between
4.
front engine mount and side rail)
bolts and nuts.
nuts.
attaching boIts
BACK TO GROUP INDEX
21-05-9
21-05-9

5.
5. Raise the engine sufficiently
sufficiently to
remove the support bracket from the
vehicle.
vehicle.
6.
6. Remove the engine insulator
insulator
assembly to cylinder block attaching
bolts and lockwashers. Remove the
engine mount assembly.
Installation
Installation
1.
1. Position the engine mount assembly
to the cylinder block. Install the
bracket bolts and lockwashers and
torque the bolts to specifications.
2.
2. Install the support bracket to the
frame side rail with attaching bolts
boIts
and nuts. Torque the nuts to
specifications.
3.
3. Lower the engine until the engine
mount insulator assembly lines up
with the support bracket to allow
installation of the through bolt.
Install the through bolt and locknut
and torque to specifications.
4.
4. Remove the jack and wood block
from the engine pan.
5.
5. Install the fan shroud attaching
screws and torque the screws to
specifications.
2. Support the transmission with a block

of wood and a jack.
3. Remove the bolt or bolts attaching
the rear support to the transmission.
4. Raise the transmission slightly and
remove the support.
Installation
Installation
1.
Position the
the ssupport
1. Position
u p p o r t to the
transmission and install the attaching
bolt or bolts. Torque the bolts to
specifications.
2. Lower the transmission until the
support seats on the crossmember.
Remove the jack and block of wood.
3. Install and torque the attaching nuts.
Mustang
Removal
Removal
1.
1. Place a block of wood and a jack
under the transmission to remove the
weight
supporting
weight from
from the
the supporting
crossmember.
2. Remove the two nuts holding the
insulator bracket to the crossmember.
3. Remove the crossmember-attaching
through-bolts and the two bolts
holding
holding the insulator
insulator to the
transmission.
sufficiently to
4. Raise the transmission sufficiently
slide the crossmember and insulator
rearward.
S. Remove both the crossmember and
5.
the insulator.
ENGINE REAR SUPPORT

Pinto and Bobcat
Removal
Removal
1.
1. Remove the engine rear insulator
attaching nuts at the crossmember
(Fig.
(Fig. 8).
FILTER
FILTER PACK
RETAINER~
FILTER RETAINER.
FILTER
(REF.)~f:~<: ./::?
AIR CLEANER
SH. ELL
ELB~W'O:'
.....
~ ,
~~~
~
::::'"
CLIP
...........:..:.::.:o:::.:.:.:.. . .
j::.
...
GROMMET//://?~'ftjf ,,--~j
{:'So::
FILLERCAP-6789
"'-'''':'_
.../
~~.
. J.
/~."
~..
CLOSURE HOSE
"""-1"'-
\--.,~ .)- -Ui),;:;",?

<-~-
.../')
ELBOW
'c
'~r - ,?':
'-~)
.-'
HOT
HOT IDLE
IDLE COMPENSATOR
COMPENSATOR -- 9E890
9E890
.r" ~
UPPER VENT
HOSE -6853
-6853
STRAP
HOSE - 6A886
LOWER
VENT
HOSE 6A886
WITH AIR CONDITIONING
FRONT OF ENGINE
A3736-C
A3736C
FIG. 99 Positive Crankcase Ventilation System

21-05-10
Installation
Installation
1.
1. Position
Position the insulator
insulator to the
crossmember and loosely install the
two attaching nuts. Do not tighten.
2. Slide the crossmember and insulator
2.
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.
4. In
Inss e q
que
u e nnc
c ee - tor
t o r qque
u e the
the
crossmember through-bolts and then
the insulator
insulator attaching nuts to
specifications.
5.
from the transmission.
SYSTEM
The positive crankcase ventilation
system components are shown in Fig. 9.
Disconnect and connect points are shown
on
the illustration.
on the
illustration.
VALVE ROCKER ARM COVER
Instructions
Instructions for removal and
installation of the rocker arm cover and
gasket are given in Fig. 10.
VALVE ROCKER ARM (CAM
(CAM
FOLLOWER) AND HYDRAULIC
LASH ADJUSTER
Removal
Removal
1.
1. Remove the valve rocker arm cover
and associated parts as required.
2. Rotate the camshaft

camshaft so that the base
circle of the cam is facing the
applicable cam follower.
follower.
3. Using the tool shown in Fig. 4,
collapse the lash adjuster
adjuster and/or
depress the valve spring if necessary
and slide the cam follower over the
lash adjuster
adjuster and out.
4.
the hydraulic
hydraulic lash
4. Lift
Lift out
out the
lash adjuster.
adjuster.
Installation
Installation
1.
the camshaft
that the
the base
base
1. Rotate
Rotate the
camshaft so
so that
circle
the cam
circle of
of the
cam is
is facing
facing the
the
applicable
applicable cam
cam follower.
follower.
2. Place
the hydraulic
hydraulic lash
lash adjuster
in
2.
Place the
adjuster in
position in
in the
the bore.
bore.
position
3. Using
Using the
the tool
tool shown
shown in
4,
3.
in Fig.
Fig. 4,
collapse
the lash
lash adjuster
adjuster as
as necessary
collapse the
necessary
to position
position the
the cam
the
to
cam follower
follower over
over the
lash
the valve
valve stem.
lash adjuster
adjuster and
and the
stem. It
It
may also
be necessary
may
also be
necessary to
to compress
compress the
the
valve spring,
using the
tool shown
in
valve
spring, using
the tool
shown in
11.
Fig.
Fig. 11.
4. Before rotating the camshaft
camshaft to the
next position, be sure the lash
adjuster
just installed
installed is fully
adjuster just
fully
compressed and released.
5. Clean the gasket surfaces of the valve
cover and cylinder head.
6.
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
INSTALL AND TORQUE THESE 8 SCREWS
"V
ROCKER ARM COVER
GASKET
A3737-C
A3737 -c
FIG. 10 Installing Valve Rocker Arm Cover
BACK TO GROUP INDEX
21-05-10
positioned in slots in cover (Fig. 10).
7.
7. Install 8 screws and torque to
specification.
8.
8. Install the air cleaner and all other
hardware removed.
9.
9. Run the engine at fast idle and check
for oil leaks.
VALVE SPRING, RETAINER AND
STEM SEAL
If the valve or valve seat has not been
damaged; valve springs, seals and
retainers may be replaced by holding the
affected valve against its seat using
affected
compressed air. Use the tool shown in
Fig. 11
11 installed in the spark plug hole.
A minimum of 140 PSI line pressure is
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
Removal
1.
1. Remove the valve rocker arm cover
and associated parts as required.
2.
2. Remove the cam follower.
follower.
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
around the end of the valve stem will
prevent this condition and will still
allow enough travel to check the valve
for binds.
5. Inspect the valve stem for damage.
Rotate the valve and check the stem
tip for eccentric movement. 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 and repair
as outlined in Part 21-01.
Installation
Installation
1.
1. Install a new valve stem seal using a
plastic installation cap.
cap. Use the tool
shown in Fig. 12 and the procedure
given in Fig.
Fig. 13.
13. Install the valve
spring, retainer and locks.
locks. Turn off
off
the air and remove the air line and
adapter.
2.
2. Apply Lubriplate to all contact
surfaces of the cam follower and
install in position. Install the spark
plug. Be sure that the affected
affected lash
adjuster
adjuster has been collapsed and
released before rotating the camshaft.
3. Install the rocker arm cover following
the information given in Fig. 10.
INTAKE MANIFOLD
Information
Information necessary to properly
remove and install the intake manifold is
given in Figs.
Figs. 15,
15, 16
16 and 17.
21-05-11
21-05-11
21-05-11
21-05-11
2300cc
2300cc Four
Four Cylinder
Cylinder Engine
Engine
TOOL
TOOL T73P-6571-A
T73P6571A SHOULD
SHOULD
CONTACT
CONTACT SHOULDER
SHOULDER
PLASTIC
PLASTIC INSTALLATION
INSTALLATION CAP
CAP
(OIL
(OIL SURFACE
SURFACE OF
OF CAP
CAP
TO
TO FACILITATE
FACILITATE
SEAL
SEAL INSTALLATION)
INST ALLATION)
SEAL JACKET
VALVE GUIDE
A3739- B
STEP #1
ffi
2
STEP' ##2
STEP
3
STEP #
#3
FIG. 11
11 Removing Valve Spring
Retainer
TOOL
T73P--6571--A
STEP
S
TEP
#\
#1 _
- WITH VALVES IN HEAD. PLACE PLASTIC INSTALLATION
INSTALLATION CAP OVER END OF VALVE STEM.
STEM.
STEP #
2 - START VALVE STEM SEAL CAREFULLY
#2
CAREFULLY OVER CAP. PUSH SEAL DOWN UNTIL
UNTI L JACKET
STEP
S
TEP
TOUCHES TOP
TOP OF
OF GUIDE.
GUIDE.
TOUCHES
#3
- REMOVE PLASTIC INSTALLATION CAP. USE INSTALLATION TOOL- T73P-6571-A
T73p6571A
#
3 _
SCREWDRIVERS TO
TO BOTTOM
BOTTOM SEAL
SEAL ON
ON VALVE
VALVE GUIDE.
GUIDE.
SCREWDRIVERS
OR
A3451-D
A3451D
FIG. 13 Valve Stem Seal Installation
A3299B
FIG.
FIG. 12
12 Valve
Valve Stem
Stem Seal
Seal Installation
Installation
Tool
Tool
The
The special
special tool
tool required
required to
to remove
remove
and
and install
install the
the carburetor
carburetor isis illustrated
illustrated in
in
Fig.
Fig. 14.
14. Carburetor
Carburetor installation
installation isis shown
shown
in
in Fig.
Fig. 15.
15.
EXHAUST
EXHAUST MANIFOLD
MANIFOLD
Information
Information necessary
necessary to
to properly
properly
remove
remove and
and install
install the
the exhaust
exhaust manifold
manifold
isis given
given in
in Fig.
Fig. 18.
18.
CYLINDER
CYLINDER HEAD
HEAD
Information
Information necessary
necessary to
to properly
properly
remove
remove and
and install
install the
the cylinder
cylinder head
head isis
given
given in
in Fig.
Fig. 19.
19. AA disassembled
disassembled view
view of
of
the
the cylinder
cylinder head
head isis given
given in
in Fig.
Fig. 41.
41.
Refer
Refer to
to the
the various
various other
other illustrations
illustrations
covering
covering installation
installation of
of the
the associated
associated
parts.
parts.
WATER
WATER PUMP
PUMP
Provision
Provision for
for wrench
wrench clearance
clearance has
has
been
been made
madeinin the
thetiming
timingbelt
belt inner
inner cover,
cover,
so
soonly
only the
the outer
outer cover
cover must
must be
beremoved
removed
BACK TO GROUP INDEX
in order to replace the water pump.

rssociated parts
parts
Water pump and 4~,ssociated
is illustrated in Fig.
Fig. 20.
installation is
No special
special tool
tool is
is required
required for
for
No
installing the crankshaft sprocket on the
crankshaft.
CYLINDER FRONT COVER,

"\
AUXILIARY
CAMSHAFT AND AUXILIARY
SHAFT SEALS
The cylinder front cover,
cover, camshaft
camshaft
The
and the
the auxiliary shaft seals
seals are
are replaced
in
in the
the same
same manner with
with the
the same
same tools
tools
after the respective gear has been
been
removed.
removed. NOTE:
NOTE: Always
Always use
use aa new
new
attaching
attaching bolt when replacing the
the
camshaft sprocket
sprocket or
or use
use new
new Teflon
Teflon tape
tape
camshaft
on the
the threads
threads of
of the
the old
old bolt.
bolt.
on
Removal
Removal
One common
common seal
seal removal
removal tool
tool is
is
One
used to
to remove
remove all
all the
the seals.
seals.
used
Fig. 24
24 shows
shows the
the tool
tool being
being used
used to
to
Fig.
camshaft seal.
seal. When
When
remove the camshaft
this tool,
tool, be
be sure
sure that
that the
the jaws
jaws
positioning this
are gripping
gripping the
the thin
thin edge
edge of
of the
the seal
seal very
very
are
tightly before operating
operating the
the jack-screw
tightly
of the
the tool.
tool.
portion of
Sprocket
Sprocket Removal
Removal And
And
Installation
Installation
Fig. 21
21 shows
shows the
the multi-purpose
multi-purpose tool
tool
Fig.
being
being used
used to
to pull
pull the
the cam
cam drive
drive sprocket.
sprocket.
This
This same
same tool
tool isis used
usedininexactly
exactly the
thesame
same
manner
manner to
to remove
remove the
the auxiliary
auxiliary shaft
shaft
sprocket.
sprocket.
Fig. 22
22shows
showsthe
thesame
samemulti-purpose
multi-purpose
Fig.
tool with
with the
the 'threaded
threaded puller
puller insert
insert
tool
removed, being
being used
used to
to hold
hold the
the cam
cam
removed,
sprocket while
while the
the attaching
attaching bolt
bolt isis
sprocket
installed and)torqued.
and^torqued. This
This isisalso
also typical
typical
installed
of the
oft
h e aauxiliary
u'X i Ii a r y sshaft
h aft ssprocket
pro c k e t
installation.
installation.
Fig. 23
23 shows
shows the
the multi-piece
multi-piece tool
tool
Fig.
usedto
topull
pullthe
thecrankshaft
crankshaft drive
drivesprocket
sprocket
used
otT
off the
the crankshaft.
crankshaft.
Seal
Fig. 25
25 shows
shows the
the tool
tool being
being used
used to
to
Fig.
remove the
the cylinder
cylinder front
front cover
cover seal.
seal.
remove
Installation
Installation
One common
common tool
tool with
with aa stepped,
stepped,
One
threaded arbor
arbor isis used
used to
to install
install all
all the
the
threaded
seals. The
The tool
tool acts
acts as
as aa press,
press, using
using the
the
seals.
internal threads
threads of
of the
the various
various shafts
shafts as
as
internal
pilot.
aa pilot.
Fig. 26
26 shows
shows the
the special
special tool
tool being
being
Fig.
used to
to install
install the
the camshaft
camshaft seal.
seal. This
This isis
used
typical of
of the
the other
other seal
seal installations.
installations.
typical
CAMSHAFT TIMING
TIMING BELT
BELT
CAMSHAFT
Installation information
information for
for the
the
Installation
complete cam
cam drive
drive mechanism
mechanism isis given
given
complete
inFig.
Fig.29.
29.Associated
Associatedparts
partsare
areillustrated
illustrated
in
in Figs.
Figs. 41
41 and
and 42.
42.
in

21-05-12
21-05-12
TOOLT74P-9510-A
120-168 IN-LB
(4 PLACES)
'\.
1/16"
1/16"
~
------T
1/2"
1/2"
t~
CHOKE HOSE
FIG. 14 Special Carburetor Wrench
TIMING BELT
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
Refer to Fig. 30 for installation
installation
information on the auxiliary shaft.
shaft.
information
If
If necessary, the auxiliary shaft
shaft
bearings can be removed using the slideT58L-1O1-A.
hammer Tool T58L-I0I-A.
Install new bearings using a driver,
T57T-7OO3-A. Be sure to align the
Tool T57T-7003-A.
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
adjusting the cover into
position and torquing the attaching bolts,
use the tool shown in Fig. 32 to position
crankshaft.
the cover in relation to the crankshaft.
Torque the bolts to specifications
specifications with
this tool in place. This will assure that the
timing belt does not interfere with the
front cover when operating.
Fig.
F i g . 33 shows
s h o w s the
t h e method
m e t h o d of
overlapping
overlapping the front
front and side pan
gaskets when assembling.
BACK TO GROUP INDEX
14-21
14-21
FT-LB
(2 PLACES)
A3741-B
FIG. 15 Carburetor Installation
Refer to Fig. 35 as a guide for further

further
assembly information.
information.
FLYWHEEL
Information on installation of both

Information
transmission
automatic and manual transmission
flywheels is given in Fig. 34.
CLUTCH PILOT BEARING
This engine is equipped with a sealed
roller bearing clutch pilot (Fig. 32).
Inspection procedures are outlined
under Flywheel Cleaning and Inspection
in Part 21-01.
Removal
Removal
1.
1. Remove the transmIssIon,
transmission, clutch
pressure plate, and disc following the
procedures in Volume One, Group
16-Clutch.
16Clutch.
2. Using
U s i n g Tools
T o o l s T59L-I00-B
T59L-1OO-B and
and
T58L-IOI-A,
T58L-1O1-A, remove the pilot
bearing (Fig. 27).
Ins/aHa/ion
Installation
1.
1. Using
Using Tool
Tool T71P-7137-C
T 7 1 P - 7 1 3 7 - C and
and
T7IP-7137-M,
T71P-7137-M, install the pilot service
bearing (Fig. 28).
2.
2. Install the clutch pressure plate, disc,
and the transmission following the
Group
procedure in Volume One, Group
16Clutch.
16--Clutch.
OIL PAN
installation
Oil pan removal and installation
instructions are given in Fig. 35.
OIL PUMP
information is
Oil pump installation information
shown in Fig. 36. Prime the oil pump
final
with engine oil when making final
installation.
CRANKSHAFT REAR OIL SEAL
A split lip-type crankshaft

crankshaft rear oil
seal is used on this engine. Installation
information
information is given in Fig. 37.
MAIN BEARINGS
Selective-fit
Selective-fit main bearings are used in
this engine. Number three journal is the
thrust bearing.
Main bearing installation information
information
is given in Fig. 38.
21-05-13
OIL LEVEL
INDICATOR -- 66759
759
84-108 IN-LB
~
EGR PVS-9D473
40 -50 TO COVER
MOUNTING FACE
MANIFOLD COVER 9E434
21-05-13
Check
Check crankshaft
crankshaft end play according
according
to the procedure
procedure given in Part
Part 21-01,
under
Diagnosis
and
under
D i a g n o s i s
and
Testing-Crankshaft
TestingCrankshaft End Play.
Fit
Fit replacement
replacement main
main bearings
bearings
according
procedure given in Part
according to the
the procedure
21-01 under
under Overhaul-Fitting
OverhaulFitting Main or
Connecting
C o n n e c t i n g Rod Bearings
Bearings With
With
Plastigage.
Plastigage.
CONNECTING ROD
ROD BEARINGS
connecting rod bearings
The connecting
bearings are
selective-fit. Refer
Refer to procedures
under
selective-fit.
procedures under
Overhaul-Fitting
And
O v e r h a u l F i t t i n g Main
Main A
nd
Connecting Rods With Plastigage,
Plastigage, Part
Connecting
21-01.
AND CONNECTING
PISTONS AND
RODS
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-B
FIG. 16
16 Water Manifold Installation
Installation
~
~ . ..J
Installation
Installation information
information on the
connecting rods and pistons is given in
Fig.
Fig. 39.
OIL FILTER
Installation information for the oil
filter, oil pressure sender, water
temperature sender and the fuel pump
Fig. 40.
are shown in Fig.
FITTINGS
FITTINGS
FRONT
OF ENGINE
Nil.;ADAPTER
_ _ _ _ _i 0
NUT
VALVE
9K793
TORQUE THE MANI

MANIFOLD
FOLD BOLTS
IN TWO
TO SPECIFICATIONS IN
PROGRESSIVE STEPS IN
IN THE
THE
SEQUENCE SHOWN
A3740-B
FIG. 17
17 Intake Manifold Installation
BACK TO GROUP INDEX

21-05-14
21-05-14
APPLY GRAPHITE
GRAPHITE
APPLY
GREASE LIGHT
LIGHT
GREASE
UNIFORM FILM
FILM
UNIFORM
ON MOUNTING
MOUNTING
ON
SURFACE
SURFACE
APPLY
APPLY SEALER
SEALER TO
TO THREADS-BOTH
THREADS-BOTH ENDSPRIOR
PRIOR TO
TO INSTALLATION
INSTALLATION
t - ' 4 M M SPARK PLUG
~~~
THERMACTOR
CHECr VALVE
~~65J
f\:$g . +0
\
3'
Oo~
~/-'I4
1 '-,
-~II
1
_____
IfC'}j 'n I
~.
~-!!(
OF
FRONT OF
ENGINE \ .
ENGINE
"Yf./(/~J..
"Ij~
(!f.
-~
HEX SHOULDER
STUD
"\~ ~ "Jdf/AI
()).V~-
"oJ i>~AUSTMANIFOLO
LIFTING EYE
EXHAUST MANIFOLD
".
. . . ,,, -'" l
'))
........::
TORQUE THE MANIFOLD BOLTS TO SPECIFICATIONS IN

TORQUETHEMANIFOLDBOLTSTOSPECIFICATIONSIN
TWO PROGRESSIVE STEPS IN THE SEQUENCE SHOWN
A3743-B
FIG. 18 Exhaust Manifold Installation
TORQUE THE CYLINDER HEAD BOLTS TO SPECIFICATIONS

IN TWO PROGRESSIVE STEPS IN THE SEQUENCE SHOWN.
WHEN INSTALLING CYLINDER

HEAD, POSITION THE CAMSHAFT
AS SHOWN TO AVOID DAMAGE
TO PROTRUDING VALVES.
If~
PIN
~~~744-A
A3744-A
Fig. 19
19 Cylinder
Cylinder Head
Head Installation
BACK TO GROUP INDEX

21-05-15
85940UTLET CONNECTION
8594-OUTLET
2300cc Four Cylinder

Cylinder Engine
2300cc
8575-THERMOSTAT-OUTLET
SIDE TO RADIATOR
8255-GASKET
21-05-15
FRONT
OF
FRONTOF
'ENGINE
ENGINE
:;.;
6E009-SEALS TO
BE FLUSH WITH
TOP OF COVER
STUD AND WASHER

SEALING TYPE
6E005-BELT
COVER INNER
A3745-A
FIG. 20
20 Water Pump,
Pump, Thermostat and
and Inner Timing Belt Cover Installation
T74P-6256-A
A3746-B
FIG.
FIG. 21
21 Removing
Removing Cam
Cam or
or Auxiliary Shaft Sprocket
Sprocket
BACK TO GROUP INDEX

21-05-16
21-05-16
2300cc Four
Four Cylinder
Cylinder Engine
Engine
2300cc
21-05-16
21-05-16
NOTE: CENTER
CENTER
NOTE:
ARBOR REMOVED
REMOVED
ARBOR
A3747B
A3747-B
Cam or
or Auxiliary Shaft Sprocket
FIG.22 Installing Cam
A3748-A
FIG.
FIG. 23
23 Removing
Removing Crankshaft
Crankshaft Sprocket
Sprocket
BACK TO GROUP INDEX

21-05-17
21-05-17
2300cc
2300cc Four
Four Cylinder
Cylinder Engine
Engine
21-05-17
21-05-17
"*t0fa'y
A3749-B
24 Removing Cam
Cam or
or Auxiliary Shaft Seal
FIG. 24
\ A3750-A
FIG.
FIG. 25
25 Removing
Removing Cylinder
Cylinder Front
Front Cover
Cover Seal
Seal
BACK TO GROUP INDEX

21-05-18
21-05-18
21-05-18

Engine
FIG. 26 Installing Camshaft Seal-Typical

Shaft Seal Installation
SealTypical of Crankshaft and Auxiliary Shaft
PILOT BEARING
TOOLT71P-7137-C
'" PILOT
PILOT BEARING
BEARING
Tool TSBL707A
TS8L-101.A or
600-E .
A3430-B
* ft
^ '
Tool
T59L-7OO-S
or 7600-E
FIG. 28 Installing Clutch Pilot

BearingTypical
Bearing-Typical
FIG.
FIG. 27 Removing
Removing Pilot
Bearing-Typical
BearingTypical
BACK TO GROUP INDEX

21-05-19
21-05-19
BELT
GUIDE-6B260
BELTGUIDE-6B260
CAMSHAFT
SPROCKET -6256
CAMSHAFT
TIMING MARK
USE A NEW BOLT OR
NEW TEFLON TAPE
ON BOLT THREADS
WHEN INSTALLING
INSTALLING
WASHER
BELT-6268
CRANKSHAFT 90 0
TO PAN RAIL
VIEW FOR
CRANKSHAFT ALIGNMENT
ALIGNMENT
..
CRANKSHAFT
SPROCKET6306
WASHER
C1?~.AUXILLIARY
AUXILLIARY SHAFT
SPROCKET-6256
TIMING BELT
BELT GUIDE
SPROCKET
BELT GUIDE
CRANKSHAFT
RECESS IN SPROCKET
CAMSHAFT
CRANKSHAFT
SECTIONAL VIEW FOR

SPROCKET INSTALLATION
INSTALLATION
SECTIONAL VIEW FOR

CRANKSHAFT BELT GUIDE
INSTALLATION
SECTIONAL VIEW FOR

CAMSHAFT BELT GUIDE
INSTALLATION
A3752-A
FIG. 29 Installing Cam Drive Belt, Sprockets and Tensioner
BACK TO GROUP INDEX

21-05-20
2300 cc Four
Four Cylinder
CYin
1 der Engine
2300cc
21-05-20
'
GEAR AND
AND FUEL PUMP
GEAR
ECCENTRICFUEL
PUMP
ECCENTRIC
ALLOWED TMUST
MUST NOT
NOTBE
BE
ALLOWED
BEARING TO0 TOUCH
TOUCH
BEARING
SURFACES
DURING I~~RFACES
TALLATION
DURING INSTALLATION
.....
. .
'\'
~ i\
"-:
!! I
~ ~~~~I"
.
AUXILLIARY SHAFT6K230
r}
RETAINING PLATE-6A222
PLATE6A222
RETAINING
P|IN
P
N
--,
DIP SHAFT COMPLETELY IN ENGINE

OIL BEFORE
BEFOR~~~;T~~CI~~IN
ENGINE
OIL
INSTALLING
NOTE:CU
NOTE: CUT GASKET
FOR
GASKET
FOR SEPA~
SEPARATE
REMOVAL
ATE
REMOVAL OR
INSTAL
OR OF
INSTALLATION
COVERSLATION OF
COVERS
AUXILLIARY
AUXILLIARY
SHAFT
COVE
SHAFT
R6E007
COVER-6E007
COVER
AL
COVER
PADS _3ALIGNMENT
piLGNMENT
ACES
PADS -3 PLACES
FRONT COVER
ALIGNMENT TOOL
(T74P-6019-B)
A3754-A
A3754A
FIG.
..
a f t and
.
9 AuxIliary
Sh
earmgs
d Cylinder
an
FIG. 30
30 Installin
Installing
Auxiliary
Shaft
and BBearings
and
Cylinder Front
Front Cover
Cover
BACK TO GROUP INDEX

21-05-21
21-05-21
2300cc
2300cc Four
Four Cylinder
Cylinder Engine
Engine
21-05-21
21-05-21
FIG.
31 Timing Belt Tensioner
FIG.31
BACK TO GROUP INDEX

21-05-22
21-05-22
21-05-22
21-05-22
2300cc
2300cc Four
Four Cylinder
Cylinder Engine
Engine
TOOL-T74P-6019-B
FIG.
FIG. 32
32 Positioning
Positioning Front
Front Cover
Cover
A3756-A
FIG.
FIG. 33
33 Gasket
Gasket Installation
Installation
BACK TO GROUP INDEX

21-05-23
21-05-23'
21-05-23
Engine
APPLY LUBRIPLATE
LUBRIPLATETO
APPLY
TO
CRANKSHAFT PILOT
PILOT HOLE
HOLE
CRANKSHAFT
AUTOMATIC
AUTOMATIC TRANSMISSION
TRANSMISSION
FLYWHEEL-6375
REFINFORCING PLATE - 6A366
REAR COVER PLATE-6A373
SHIELD-6C509
ROCKER ARM COVER SHIELD6C509
NOTE: TRANSMISSION CLUTCH
HOUSING ATTACHES TO
ENGINE WITH METRIC BOLTS
FLYWHEEL AND PRESSURE PLATE
FRICTION SURFACES MUST BE
ANDOIL
FREE OF DIRT, GREASE AND
OIL
INSTALLATION
PRIOR TO INSTALLATION
REAR COVER PLATE - 6A373

FLYWHEEL-6375
MANUAL TRANSMISSION
CLUTCH DISC - 7550
PRESSURE PLATE
P L A T E-- 77563
563
ROLLER PILOT BEARING - 7600
INSTALL
INSTALL WITH SEAL
TOWARD TRANSMISSION
(
~DDWEL
A3757C
A3757-C
FIG. 34
34 Flywheel Installation
BACK TO GROUP INDEX

21-05-24
21-05-24
Engine
2-1-05-24
21-05-24
DRAIN PLUG
730
PLU,'3 -- 66730
--~~~T---"'"
M6X
M6X 16.0 MM LONG SCREW
SCREW
AND WASHER-18 PLACES
OIL PAN-6675
OILPAN-6675
M8X 20.0 LONG

SCREW AND WASHER
4 PLACES ---~t--------I~~
-4
PAN GASKET
GASKET (R)
(Rl
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
BLOCK
FRONT
SEAL TAB
1. APPLY GASKET ADHESIVE EVENLY TO OIL PAN

PAN FLANGE AND TO PAN
PAN SIDE
GASKETS.
GASKETS. ALLOW ADHESIVE TO DRY PAST WET STAGE,
STAGE, THEN INSTALL
INSTALL
GASKETS TO OIL PAN.
2.
2. APPLY SEALER TO
TO JOINT OF
OF BLOCK AND FRONT COVER.
COVER. INSTALL SEALS TO
FRONT COVER AND REAR BEARING CAP
CAP AND PRESS
PRESS SEAL TABS FIRMLY INTO
INTO
BLOCK. BE
BE SURE
SURE TO
TO INSTALL THE REAR SEAL BEFORE THE REAR MAIN
MAIN
BEARING CAP
CAP SEALER HAS
HAS CURED.
CURED.
3.
3. POSITION 22 GUIDE PINS
PINS AND INSTALL THE
THE OIL PAN.
PAN. SECURE
SECURE THE PAN
PAN WITH
WITH
THE
THE FOUR M8
M8 BOLTS SHOWN
SHOWN ABOVE.
ABOVE.
4. REMOVE THE GUIDE PINS
PINS AND INSTALL AND TORQUE THE EIGHTEEN M6 BOLTS,
BOLTS,
" A " AND WORKING CLOCKWISE AROUND THE PAN.
PAN.
BEGINNING AT HOLE "A"
A3759-B
A3759B
FIG.
FIG. 35 Oil
Oil Pan
Pan Installation
Installation
BACK TO GROUP INDEX

21-05-25
21-05-25
SCREW AND WASHER
~(
SHAFT
SHAFT ASSY.
ASSY. OIL PUMP
PUMP
INTERMEDIATE-6A618
INTERMEDIATE-6A618
A3760-B
FIG.
Typical
FIG. 36 Oil Pump Installation -Typical
BACK TO GROUP INDEX

21-05~26
21-05-26
2300cc
Cylinder Engine
21-05-26
21-05-26
REAR BEARING CAP

SEALS IN ENGINE
DIP SEALS
OIL BEFORE INSTALLING
OIL
REAR~LSEAL----~~~
REARfRLSEAL
UPPER AND LOWER SEAL

UPPER
ENDS TO BE FLUSH IN
BLOCK
ANDCAP
BLOCK AND
CAP
APPLY
APPLY SEALER
SEALER AS SHOWN
SEE NOTE BELOW
BELOW
SEALER NOTE: CLEAN THE AREA

AREA WHERE SEALER
SEALER
IS TO BE APPLIED BEFORE INSTALLING
INSTALLING THE SEALS.
USE FORD SPOT REMOVER
REMOVER B7A-19521-A
B7A-19521-A OR EQUIVALENT.
AFTER
INCH
AFTER THE SEALS ARE IN PLACE, APPLY A 1/16
1/161NCH
BEAD OF C3AZ-19562-A
C3AZ-19562-A OR -B SEALER AS SHOWN.
SHOWN.
SEALER MUST NOT CONTACT SEALS.
FRONT OF ENGINE
/
LOCATING TAB
A3761-B
FIG. 37 Rear Oil Seal Installation
BACK TO GROUP INDEX

21-05-27
21-05-27

Cylinder Engine
2300cc
OIL PRIOR TO ASSEMBL y---~
REAR CAP - 6325
CRANKSHAFT JOURNALS
OIL- CRANKSHAFT
THRUST FACES- AFTER
AND THRUST
INSTALLATION TO BLOCK
INSTALLATION
CAP REAR
INTMDT. - 6327
CENTER CAP 6330
CRANKSHAFT - 6303
REAR FACES OF THRUST

BE FLUSH,
BEARINGS MUST BE
PRIOR TO
TO FINAL
FINAL TORQUE
TORQUE
PRIOR
OF BOLTS
NOTE:
-CAPS MUST BE
BE SEATED PRIOR TO BOLT RUNDOWN
-DO
- D O NOT ALLOW CRANKSHAFT TO ROTATE BEARINGS
-TORQUE ALL MAIN BEARING CAP BOLTS TO SPECI
FICATION
SPECIFICATION
CAP
JOURNAL
1+tt 3 JOURNAL
BEARING)
(THRUST BEARING)
PRESS
PRESS PINS
PINS TO
TO BOTTOM-3 PLACESPLACESPRIOR TO CRANKSHAFT INSTALLATION
INSTALLATION
BEARING
THRUST BEARING
LOWER-6A339
BEAR ING - 6333
THRUST BEARING
BEARING
-THRUST
UPPER-6337
UPPER6337
FRONT OF
*"NGINE
BEARING - 6333
APPLY
OIL-TO
APPL
Y 01
L- TO UPPER
BEARING THRUST
THRUST
BEARING
FACES IN
IN BLOCK
BLOCK
FACES
SECTION
SECTION A
A
VIEW
VIEW FOR
FOR PCV
PCV BAFFLE
BAFFLE INSTALLATION
INSTALLATION
A3762-B
A3762-B
FIG. 38 Installing Crankshaft and Main Bearings

Bearings
BACK TO GROUP INDEX

21-05-28
21-05-28
2300cc Four
Four Cylinder
Cylinder Engine
Engine
2300cc
21-05-28
21-05-28
HAND
HANDSTART
STARTUNTIL
UNTILFLUSH
FLUSHWITH
WITH
TOP
TOPOF
OF BOLT,
BOLT,THEN
THENTORQUE
TORQUE
IN
IN22STEPS
STEPS-AS
-AS DETAILED
DETAILED
IN
IN SPECIFICATIONS
SPECIFICATIONS
OIL ROD AND CAP BEARINGS

AFTER BEARING ASSEMBLY
ROD BEARING
BEARING - 6211
ROD
OILOIL- ALL
ALL CRANKSHAFT
CRANKSHAFT
PIN JOURNALS
PIN JOURNALS
r< 'J.
\,-t;O
I
'\
ROD C A P - 6 2 1 0
PISTON AND
AND ROD
ROD -- 6100
6100
PISTON
BLOCK FACE
OPTIONALOPTIONAL- OIL
OIL PISTON
PISTON RINGS
RINGS
PRIOR
TO PISTON
PISTON
PRIOR TO
INSTALLATION
INSTALLATION
OIL-COAT ALL CYLINDER BORE SURFACES

PRIOR TO INSTALLATION OF PISTON
AND ROD ASSEMBLY
SEGMENT
SEGMENT GAPS
GAPS TO
TO BE
BE APPROXIMATELY
APPROXIMATELY
80
80 AWAY
AWAY FROM
FROM EXPANDER
EXPANDER GAP
GAP AND
AND
NOT
IN
AREA
OF
SKIRT
NOT IN AREA OF SKIRT
PISTON NOTCH
NOTCH TO
TO FRONT
FRONT
PISTON
OF ENGINE
ENGINE AT
AT INSTALLATION
INSTALLATION
OF
<tC_EXPANDER
EXPANDER
<tC_SEGMENT
SEGMENT
INSTALL
INSTALLPISTON
PISTONINTO
INTOBLOCK
BLOCK
WITH
WITHRING
RINGGAPS
GAPSAS
ASFOLLOWS
FOLLOWS
EXPANDER-TO
EXPANDER-TO FRONT
FRONTOF
OFPISTON
PISTON
SEGMENT-TO
SEGMENT-TO REAR
REAROF
OFPISTON
PISTON
A3763C
A3763-C
FIG.
FIG. 39
39 Installing
Installing Pistons,
Pistons, Rings
Rings and
and Connecting
Connecting Rods
Rods
BACK TO GROUP INDEX

21-05-29
21-05-29
FRONT OF ENGINE
9278-OIL SENDER-SEALING TYPE

TYPE
97DER_SEALING
10883-TEMP INDICATOR OR
10B843-TEMP SWITCH
SEALING TYPE
6714-FIL TER
HAND TIGHTEN 1/2
1/2 TURN
AFTER GASKET CONTACT
9350-FUELPUMP
APPLY CHASSIS GREASE
AS SHOWN PRIOR TO FUEL
INSTALLATION
PUMP INSTALLATION
A3771-A
FIG. 40 Installing Oil Filter, Sending Units and Fuel

Fuel Pump

CYLINDER HEAD
Information for disassembly

disassembly and
Information
assembly of
of the cylinder
cylinder head
head is
assembly
41 and 42.
contained in Figs. 19, 41
When disassembling, mark the cam
adjusters and valves so
followers, lash adjusters
that they can be installed in the original
positions.
If
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
If necessary
necessary to replace the cam
bearings, use the tool system shown in
Fig. 43.
The assembled height of the valve
spring can be checked as shown in Fig.
44.
If the assembled height is greater than
If
specified, install the necessary 0.030 inch
thick spacer(s) between the cylinder head
spring pad and the valve spring to bring
t h e assembled
a s s e m b l e d height
h e i g h t to
t o the
the
the
recommended dimension. Do not install
spacers unless necessary. Use of spacers
BACK TO GROUP INDEX
in excess of recommendations will result

in overstressing the valve springs and
camshaft lobes. This
overloading the camshaft
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
followers.
surfaces of the cam and cam followers.
OIL PUMP
Under no circumstances should the
oil pump be disassembled if it is the
three-bolt type where the outboard
bearing is in the cover (Fig. 45). If found
out of specification, replace as a unit.
A new 4-bolt oil pump is also used,
follows:
and can be serviced as follows:
Disassembly
Disassembly
1.
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
shaft assembly, then
remove the outer race.
3. Drill a small hole and insert a selfthreading sheet metal screw of the
proper diameter into the oil pressure
relief valve chamber cap and pull the
relief
cap out of the chamber. Remove the
spring and plunger.
Assembly
Assembly
The oil pump assembly is shown in
Fig. 46.
1. Oil all parts thoroughly.
1.
2. Install the oil pressure relief
relief valve
plunger, spring and a new cap.
3. Install the outer race and the inner
shaft assembly. Be sure the
rotor and shaft
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
ccover
o v e r aattaching
t t a c h i n g screws
s c r e w s to
to
specifications.
21-05-30
4. Position a new gasket and the oil inlet
tube on the oil pump and install the
attaching bolts.
PISTON AND CONNECTING ROD
Disassembly
Disassembly
1.
1. Remove the bearing inserts from the
connecting rod and cap.
2. Mark the piston and pins to assure
assembly with the same rod and
installation in the same cylinders
installation
from which they were removed.
3. Press the piston pin from the piston
and connecting rod. Remove the
piston rings.
Assembly
Assembly
Check the fit of a new piston in the
cylinder bore before
before assembling the
cylinder
piston and pin to the connecting rod.
The piston pin bore of a connecting
rod and the diameter of the piston pin
specifications.
must be within specifications.
BACK TO GROUP INDEX

1.
1. Apply a light coat of engine oil, SE,
to all parts. Assemble the piston to the
connecting rod with the boss on the
side of the connecting rod and the
arrow in the piston positioned as
shown in Fig. 47.
2. Start the piston pin in the piston and
connecting rod (this may require a
very light tap with a mallet). Press the
piston pin through the piston and
connecting rod until the pin is
connecting
centered in the piston.
3. Check the end gap and spacing (Fig.
39) of all piston rings. They must be
specifications.
4. Check the ring side clearance as
outlined in Part 21-01.
5. Be sure the bearing inserts and the
bearing bore in the connecting rod
and cap is clean. Foreign material
under the inserts will distort the
21-05-30
bearing and cause a failure. Install the
bearing inserts in the connecting rod
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
journals during rod installation.
HYDRAULIC LASH ADJUSTER
Two types of hydraulic lash adjusters

adjusters
48. Type
are used. Type I is shown in Fig. 48.
II in Fig. 49.
Both lash adjusters
adjusters are assembled
with a simple crimped collar which snaps
into a groove on the outside body. This
collar can be removed and re-installed as
necessary without damaging it.
Use the hydraulic
h y d r a u l i c valve lifter
lifter
leakdown tester (Part 21-01) to fill
fill the
fluid.
lash adjusters with test fluid.

21-05-31
21-05-31
21-05-31
21-05-31
FOLLOWER-6564
CAM FOLLOWER-6564
CLIP
DIP IN ENGINE OIL
PRIOR TO INSTALLATION
APPLY LUBRIPLATE TO VALVE

TIPS PRIOR TO ARM INSTALLATION
CYLINDER HEAD-6049
-,
/"
CAMSHAFT C
_
ADJUSTER
~t
--
FRONT OF ENGINE
/'
~~
BE INSTALLED WITH
TO BE
GAP AWAY FROM CAMSHAFT C_
VIEW FOR CLIP

INSTALLATION
COMPLETELY DIP CAMSHAFT

IN ENGINE OIL PRIOR TO
INSTALLATION
...- - - - SEAL-6700
RETAINING PLATE-6A222
A3764-B
FIG. 41 Installing Camshaft
BACK TO GROUP INDEX

21-05-32
21-05-32
21-05-32
21-05-32
2300cc Four
Four Cylinder
Cylinder Engine
Engine
2300cc
KEYS - 6518
RETAINER - 6514
INSTALL SEAL AFTER VALVE
AND PRIOR TO SPRING INSTALLATION
-SEAL MUST BE BOTTOMED ON
VALVE GUIDE
SPRING - 6513
ADJUSTER - 6C50
- 6A517
.-....~~----SEAL
SEAL-6A517
NOTE: LASH
LASH ADJUSTERS
ADJUSTERS MUST
MUST
NOTE:
NOT BE
BE ALLOWED
ALLOWED TO
TO LEAK
LEAK
NOT
OIL PRIOR
PRIOR TO,
TO, DURING,
DURING, OR
OR
OIL
AFTER INSTALLATION
AFTER
INSTALLATION
~ONT OF ENGINE
(APPLY LUBRIPLATE
LUBRIPLATE OR
OR
EQUIVALENT
EQUIVALENT TO VALVE
STEMS AND GUIDES
BEFORE INSTALLING
VALVES)
SECTION OF
INSTALLED SEAL
SEAL
INSTALLED
6-
NOTE: VALVE SPRING MUST

NOT BE COMPRESSED BEYOND
A HEIGHT OF 1.06
1.06 INCHES
DURING ASSEMBLY
-t~
SEE
SEE
SPECI
FICATION
SPECIFICATION
V A L V E-- 66505
505
-..... . - - - - EXHAUST VALVE
L~
~
-6507
INTAKE VALVE -6501
SPRING SEAT MAINTAIN SPECIFIED

~SPRING
./ -
/AND
SPRING INSTALLED HEIGHT lAND
OR LOAD BY
BY VARYING THIS DIMENSION.
DIMENSION.
OR
'----~
A3765-C
A376S-e
FIG. 42 Installing Valves,

Valves, Springs,
Springs, Seals,
Seals, Retainers and Lash
Lash Adjusters
Adjusters
BACK TO GROUP INDEX

21-05-33
21-05-33
21-05-33
2300cc Four
Four Cylinder
Cylinder Engine
Engine
2300cc
Tool-71P-6250-A
OIL HOLES MUST

BE ALIGNED AT
TIME OF INSTALLATION
CAMSHAFT
BEARING
REMOVAL
REMOVAL
INSTALLATION
A3419-A
A3419A
FIG. 43
or Installing Camshaft Bearings-Typical
43 Removing or
BearingsTypical
44 Checking Valve Spring

FIG. 44
Assembled Height
BACK TO GROUP INDEX

21-05-34
21-05-34
2300cc
2300ccFour
FourCylinder
CylinderEngine
Engine
21-05-34
21-05-34
ARROW POINTING TOWARD

ARROW POINTING TOWARD
FRONT OF ENGINE
FRONT OF ENGINE
~tICATlON
IDENTIFICATION
MARKS
BOSS
NUMBER ON LEFT SIDE OF ROD

NUMBER ON LEFT SIDE OF ROD
A 3428-B
A3428-B
A3766-B
FIG.
FIG. 47
47 Correct
Correct Piston
Piston and
and Rod
Rod
Position
Position
A4093-A
FIG. 45
45Oil
OilPump-1975
Pump1975
FIG.
FIG. 46
46 Oil
OilPump-1976
Pump1976
FIG.
RETAINING RING
FOLLOWER ARM
FOLLOWER
ARM
FULCRUM
PLUNGER
PLUNGER RETURN
SPRING
BODY
A3767-C
A3767-C
FIG. 4 8 Type I Lash Adjuster
FIG. 48 Type I Lash Adjuster
BACK TO GROUP INDEX

2300cc
2300ccFour
FourCylinder
CylinderEngine
Engine
21-05-35
21-05-35
21-05-35
RETAINING RING
FOLLOWER ARM
FULCRUM
PLATE~;
METERING
METERINGPLATE
PLUNGER
PLUNGER
PLUNGER RETURN
SPRING
BODY
A3768-C
A376H-C
FIG. 49
49 Type
Type IIII Lash
Lash Adjuster
Adjuster
FIG.
BACK TO GROUP INDEX

en
....
'.
........
T74P-6150-A
NO
CJ
O
O
n
o
n
T74P-6000-LB
O
c
n
5"
NOTE: CRANKSHAFT
NOTE: CRANKS HAFT
PULLEY REMOVER
PULLEY REMOV
ALSO
REQUIRED
ALSO REQUI
REDER
Q_
0
m
eg
T74P-6565-B
CD
T74P-6254-A
T74P-7137-H
2300cc MUSTANG
ONLY
J.\
T74P-9510-A
T74P-6700-B
T74P-6015-A
T74P-6015-A
~il"
...:..;.;.;.:.;::;;::::..
A3769S
FIG.
FIG. 50
50 Special
Sp eClo
. ITools2300cc
Engine
Tools-2300ccEngine
BACK TO GROUP INDEX
A3769 B

21-05-37
21-05-37
SPECIFICATIONS-1975
SPECIFICATIONS1975
SPECIFICATIONS
GENERAL SPECIFICATIONS
Drive Belt Tensions (Ibs.)
(lbs.)
Compression Pressure
PSI (Sea Level) @
@
Oil Pressure-Hot
Engine
Bore and Stroke
Cranking Speed
@2000
RPM
@2000RPM
Firing Order
2300cc
3.126
3.78 x 3.126
Reading ':Jithln
within 75%
Lowest R.eading
75"u of highest
40-60
1-3-4-2
Used
Newly Installed
Size
(1)
(1)
50-80
1/4"
1/4"
Except
1/4"
120-160
1/4"
Mm.
Up to 10 Min.
OveriOMin.
Over
10 Min.
(21
40-80 (2)
40-60 (2)
(31
90-160 (3)
75-120 (4)
(1) Read tension immediately after belt ISis Illstalled,

installed, before it stretches or sec1!S
seats IIIn pulley grouves
grooves.
(3)
120 pounds.
Iff less than 90
90-120
90 pounds, readjust
readiust to 90-
(2) If less than 40

40 pounds, readjust
40-[30 pounds.
readiust to 40-60
(4)
20 pounds.
I f less than 75
90-120
75 pounds, readjust
readiust to 90-
CYLINDER
HEAD
CYLINOERHEAO
Virve
Vltvl Guide
Guidi
Combustion
Comburtion
Bon Oiimtttr
80rlDilmlt.r
(Stlndard
(Stmdird
Vllv.
Valva
Chamber
Chamb.r
Intake and
Intlknd
St Width
Saat
Voluml
Volume
Exhlult)
Exhaust)
Engirt*
Engin.
Vilve
Vllve
Valve
Gasket
Seat
Arrangement
Surface
St
Saat
Runout
(Frantto
(Front
to
Flatn'ess
Flatrfess
Angl.
Angla
(Maximum)
Rear)
Valv.
Valve
In tiki
Intlk.
Exhaust
Exhlust
(j)
0.003 in any
any
0.3433-0.3443
0.3433-0.3443
63.7-66,7
63.
766.7
2300cc
OU7!Ju
o.u7!)-i! ,)l]!
;icjiii
U.0600.090
0.060-0.090
45
6 inches,
E-I-E-I-E-I-E-I
E-l-E-l-E-l-E-l
0.0016
0.006 overall
CD
HHead
ead
Gasket Surface Finish

Fm.sh R.MS
R.M.S.
60
150
60-150
VALVE SPRINGS
Engme
Engine
Valve Sprmg
Spring Free
Specified Length Pressure
Length (Approximate)
(Approximate)
71-79@1.56
71-79 @ 1.56
180-198@
180-198 @ 1.16
1.16
230Ucc
2300cc
Wear Limit
Limit
@
Valve Spring Pressure Lbs
Lbs@
Valve Spring Assembled

Height Pad to Retainer
1.824
1.824
Valve Spring
Out of Square (MaXimum)
(Maximum)
OutofSquare
5/64 (G078)
(0.078)
117/32
1-17/32 - 1-17/32
10% Pressure Loss.
VALVES
Clearance
CltI"nce
Rocker
Valve
V.IV!
Valve
Stem
V.lve St.m
Follower to Cam Clearance
To Valve
Guide
V.ln Guidi
CD
Engin.
Engme
Intake
Int.ke
Exhaust
hhlust
2300cc
0.0010
00010
0.0027
UOOl
0.0015S
0.0032
Intake
0.008 Cold
V.lve Head
Valve
Fece
Face
Arm
Diameter
Ollmeter
Angle
Angle
Follower
Ratio
RltID
Exhlust
Exhaust
Intake
Exhlust
Exhaust
0.010 Cold
1.728
1.725
1.744
1.744
1.492
1.492
1.508
1.508
44
44 0
1.64:1
1.64:1
^ W L.m.t
0 0055
CDwear
Limit 00051J
Max
,rT'urr
00020
MdXifT,
0020
u rr 0
(2>Valve face runouT

runout
(Z)Valve
VALVES (Continu.d)
VALVES
(Continued)
V.lve Stem 0Diameter
i.meter
Valve
0.008 Oversize
St.nd.rd
Standard
0.016 Oversize
0.032 Oversize
Engine
Entin.
Intake
Int.ke
Exhaust
Exh.ust
Intake
Intlke
Exhaust
Exhlust
Intlke
Intake
Exh.ust
Exhaust
Int.ke
Intake
2300cc
0.34160.3416
0.3423
0.3411
U3411
U3<118
0.3418
0.3446O.344G0.3453
(J3441
0.34410344tJ
0.3448
0.35660.3573
0.35610.3568
0.37160.3723
Exhaust
Exh.ust
0.37110.3718
CYLINDER BLOCK
Cylinder
Cylind.r
En,,n
En,ine
Bora
80rt
DiametarCD
Oi.m.t.rCD
2300cc
3.7795-3.7831
3.7795-3.7831
Cylinder
Bore
Cylinder Sore
Mlin
Main SllrlOg
Bearing
Diameter
Oi.met.r
Bore
0.003 OS
Diameter
Ojlm.ter
3.7825-3.7861
2.5902
2.5910
CD
v i / MaXimum
Maximum out-ai-round
out-of-round ...
LimiT ........
Wear Limit
Head Gasket
Surface
Flatness
(J)
'1l
0.003 in 6"
6"
0.006 overall
Taper Wear Limit .... ... ... 0.010
....
0.001
....0.001
.0.005
...0.005
o Head gasket surface finish RMS ... 60-150
r
Cylinder bore surface finish RM
RM;,.
, 18.88
\D
Head gasket surface " inish RMS. . .60-150
CAMSHAFT
Theoretical Valve Lift
Lobe Lift (D
Engin.
Engine
Intake
231)Ocl
23f)0(x
CD
CD Maximum allowable lobe lift lossloss - 0.005
BACK TO GROUP INDEX
Intake
Exhaust
0.3997
U.2437
0.2437
CD Wear Limit
0.009
(@
D
@ Zero Lash
Exhaust
Camshaft
Cemsh.tt
Journ.1 To
Camshaft Journal
Bearing Clllrinci
Clearance
Be.ring
()
End' Play
End
Play ~
(2)
Clearance
Clllrinc.
0.001-0.007
0.001-0.0030
Wear Limit - 0.006
CA
1355-Bl
CA1355-B1
21-05-38
21-05-38

CAMSHAFT DRIVE
DRIVE MECHANISM
CAMSHAFT
CAMSHAFT
CAMSHAFT (Continued)
(Continued)
Item
2300
cc
2300 cc
Bearing
Camshaft Journal
Journal
Diameter
Standard<D
Standard
Engine
Engine
ALL
1.7713-1.77:0
1.7713-1.7720
CAMSHAFT GEAR
CRANKSHAFT GEAR
CRANKSHAFT
OR SPROCKET
OR SPROCKET
SPROCKET
OR
Assembled
Assembled
Assembled
Max
Face Runout TIR Max
Face Runout
Runout TIR
TI RMax
Max
Face
0.007
0.005
0.005
2300cc
Camshaft Bearings
Bearings
Inside Diameter
Diameter
ALL
Camshaft Bearing
Bearing
1.7730-1.7742
Location ~
Q)
Tappet Gap @ Cam

Cam
Clearance Hydraulic Leak- Collapsed Tappet
Allowable
Desired
To Bore Down Rate (Sec.) Allowable
Standard
Diameter
.000-.010
(No.1)
(No. 1)
VALVE TAPPET/ADJUSTER
VALVE
TAPPET/ADJUSTER
0.84220.8427
<J)Camshaft
^Camshaft journal maximum runout 0.005. Camshaft journal maximum outofround
out-of-round 0.0005.
(2)Distance
^Distance in
in inches that the
the front edge of the
the bearing ISis Installed
installed towards the
the rear
from the
the tower front su:tace.
suitace.
0.00070.0027
22-8(1)
-8(1)
0.010-0.070
0.010-0.070
0.0400.050
0.040-0.050
1 - Time required for plunger to leak down 1/8" of travel.
AUXILARY SHAFT
Bearing Clearance
End Play
.001-.007
.001-.0028
.001-.0028
CRANKSHAFT AND
VWHEEL
AND Fl
FLYWHEEL
Main Bearing
Journal
Diameter (J)
Engine
2.398223990
2.3990
2300cc
^
CD
Main Bearing
Journal Runout
Maximum ())
(J)
0.002 (Max.)
Main Bearing
Journal
Thrust Face
Runout
0.0010 (MAX.)
Thrust
Main Bearing
Bearing
Surface Finish
Main Bearing
Journal
Taper Max
Max
Journal
Length
Journal
Thrust Face
Thrust
0.0006 Per
Per Inch
1.1991.201
1.201
12
12
2J Re.ir
Reel[
25
35 Frllllt
Front
RMS maximum
(2)
Wear Limit 0.005
0.00b
Connecting rod
rod and
and main
main bearing Journal
journal out-ot-round
out-of-round maximum 0.0004.
Connecting
CRANKSHAFT AND
AND FLYWHEEL (Continued)
(Continued)
Connecting
Rod Journal
Diameter
Engine
(D
CD
CD
2.04642.0472
2300cc
Crankshaft
Free End
End
Play CD
(2)
Connecting Rod
Bearing Journal
Maximum Taper
Per Inch
0.0006 Per
0.004-0.008
0.004-0.008
Wear
~e8r Limit
rod bearing journal out-of-round maximum 0.0006

Connecting rod
Flywheel
Gea, Lateral Runout

Flywheel Ring Gear
Clutch Face
Runout
Standard
0.0030
0.008
Automatic
Automatic
0.060
0.012
0.012
BEARINGS
CRANKSHAFT BEARINGS
Rod Bearings
Connecting Rod
To Crankshaft Clearance
Desired
Allowable
Engine
0.0008-0.0015
2300cc
0.0008-0.0026
Main Bearings
Wall Thickness
(
Standard <))
Desired
Allowable
0.0619-0.0624
0.0008-0.0015
0.0008-0.0026
0.0008-0.0026
Wall Thickness
Standard ~
$
0.09510.0951
0.0,956
~.002
Add 0.001
a to Standard Thickness.
^ . 0 0 2 U.S.
U.S. Thickness Add
0.0010
^ 0 . 0 0 2 U.S.
U.S. Thickness Add
Add 0.001
0.001 to
to Standard Thickness.
<Do.OO2
CONNECTING ROD
ROD
Connecting Rod
Rod
Piiton Pin
Piston
Pin
Connecting Rod,
Rod.
Connecting
CORllleting
Alignment
Alignm.nt
Aieambly
Alllmbly
Maximum
Total
MlXimum Totll
(Asstmbltd
(Alllmbltd To
Engine
Bore Or
Bustling
Bushing
ID
10
Connecting
Blaring
Rod Bnring
Bora Diameter(])
OiameteKD
BOrl
Rod Length
Center
Center
To Centlr
Twist
2300cc
0.9104-0.9112
2.1720-2.1728
5.2031-5.2063
0.024
^Connecting rod
rod beartng
bearing bore maximum out-of-round and
and taper ..... .. .. 0.0004 (Max.)
CDConnect,ng
<D
Differenced)
Difference<%)
a>
Crankshaft)
Crenksh.ft) < D
Bend
.012
,na
Side Clearance
CI
0.0035-0.0105
0.0035-0.0105
(^) Wear
Wear Limit
Limit -- 0.014
0.014
(2)Prn bushing and

and crankshaft bearing bore must be
be parallel and
and in
in the
the same vertical plane
~In
withm the
the spec1fted
specified total difference at
at ends of B-inch
8-inch long bar
bar measured 4 Inches
inches on each Side
side of rod.
Within
rod
CA1355-B2
CA 1355-82
BACK TO GROUP INDEX

21-05-39
21-05-39
2300cc Four CyJinder

Cylinder Engine
PISTON
CD
Diameter ( T )
Engine
2300cc
CD
(T)
Standard
Coded Blue
3.77803.7786
3.77923.7798
Piston
Piston To
To
Cylinder
Cylinder Bore
Bore Clearance
Clearance
.003 Oversize
3.78043.7810
Piston Pin
Pin
Piston
Bore Diameter
Bore
Diameter
0.91230.9126
0.00140.0022
Ring Groove
Groove Width
Width
Ring
0.0800-0.0810
0.0800-0.0810
0.1880-0.1890
Upper Compression Ring

Lower Compression Ring
Oil Ring
0 to the pin bore.

Measured
Measured at
at the
the piston pin
pin bore centerline at
at 90
90
the pin
PISTON PIN
PIN
Engine
Engine
Diameter
Diameter
Length
Standard
Standard
2300cc
3.010-3.040
0.9120-0.9123
.001
.001 Oversize
Oversize
0.9130-0.9133
To Connecting
Connecting Rod
Rod
To
To Piston
Piston Clearance
To
Clearance
.002 Oversize
.002
Oversize
0.9140-0.9143
Bushing Clearance
Clearance
Bushing
Interference Fit
Interference
0.0002-0.0004
0.0002-0.0004
PISTON RINGS
RINGS
Ring
Ring Width
Width
Side Clearance
Engine
2300cc
CD
(T)
Top
Ring Gap Width
CD
Compfession
Compression Ring
Ring
Compression Ring (T)
Top
Bottom
0.0770-0.080
Compression Ring
Oil Ring
Snug
0.002-0.004
Top
Bottom
Oil Ring
Bottom
0.010-0.020
0.010-0.020
0.015-0.055
0.015-0.055
Wear
. . . . 0.006
0.006
Wear Limit ..........
OIL PUMP
Engine
Rotor Type Oil

Oil Pump
Relief Valve Spring Tension
lbs
Lbs @
@ Specified
Specified length
Length
Shaft
Drive Shah
To Housing
Clearance
2300cc
7.54-8.33 @
@ 1.53
1.53
0.0015-0.0029
Relief Valve
Relief
Clearance
0.0015-0.0029
0.0015-0.0029
Rotor Assembly
Rotor
End Clearance
End
Outer Race
Race To
To
Outer
Housing (Radial
Housing
Clearance)
Clearance)
0.001-0.004
0.001-0.004
0.001-0.007
0.001-0.007
APPROXIMATE Oil
OIL PAN
PAN CAPACITIES
CAPACITIES
Engine
(T)
CD
I,
U.S. Measure
2300cc
5Qt.
at.
5
CD
I mperial Measure
Imperial
4-1/8
CD
Includes one quart with filter replacement.

replacement.
TORQUE SPECIFICATIONS
SPECIFICATIONS
Camshaft Gear Bolt

Camshaft Thrust Plate Bolt
Carb. To
To Carbo
Carb. Spacer Stud
Stud
Carbo
Carb. To
To Spacer Nut
Carbo
Carb.
Spacer
To
Manifold
Bolt
Carbo
To
Rod Nut
Connecting Rod
Crankshaft Damper Bolt
Head Bolt
Bolt
Cylinder Head
Decel Valve Nut
Decel
Decel Valve To
To Intake Manifold - Adapter
Decel
Bolt
Distributor Clamp Bolt
Dist. Vacuum Tube To
To Int.
Int. Manifold - Adapter
Dist.
To Cvlinder
Cylinder Head
Head Nut
Nut or Bolt
Exhaust Manifold To
To Crankshaft Bolt
Flywheel To
Fuel Pump To
To Cylinder Block Bolt
Fuel
Intake Manifold To
To Cylinder Head
Head Nut
Nut or
or Bolt
Intake
Main Bearina
Bearing Cap
Cap Bolt
Bol-t
Main
Oil Pressure
Pressure Sending Unit To
To Cyl.
Cyl. Block
Oil
Oil Pump
Pum Pick-Up Tube To
To Oil
Oil Pump
Oil
Oil Pump
Pump Pick-Up Tube To
To Cylinder Block
Oil
Ml0
M10
M6
M6
Pivot M10
Ml 0
Adj. M8
M8
M12
M6
M6
M8
M8
M8
M8
M8
M8
M9
M9
M14
M14
M12
--M10
Ml0
-_
M10
M10
M8
M8
M8
M8
M12
M12
M8
M8
M8
M8
Component
28-40
6-9
6-9
28-40
14-21
14-21
50-71
50-71
6-9
6-9
7.5-15
10-14
14-21
14-21
30-36 (5)
80-114
(D
80-90 (2)
10-15
22-28
20-28
5-8
5-8
16-23 (5)
(3)
54-64
14-21
14-21
14-21 (4)
14-21
80-90 (2)
8-18
14-21
14-21
14-21
14-21
Oil Pan
Plug
Pan Drain Plufl.
Oil Pan To Cylinder Block Bolts
Torque
(ftlb)
(ft-lb)
15-25
7-9
11-13
20-25
Fastener
Size
M14
M14
M6
M8
CO
Auxiliary Shaft Gear Bolt

Bolt
Auxiliary Shaft Thrust Plate Bolt
Bolt
Belt Tensioner Bolt
Torque
(ftlb)
(ft-lb)
OO
Fastener
Size
Component
Oil Filter Insert To Block

Oil Filter
Rocker Arm
Arm Cover Bolt
Sparkk Plug To Cylinder
Spar
Cyl inder Head
Timing Belt Cover Bolt
Temperature Sending Unit To Cylinder Head
Water Jacket Drain Plug
Water Pump To
To Cylinder Block Bolt
Exhaust Manifold To EGR
EGR Pipe - Connector
EGR Valve To Spacer Bolt
EGR
EGR Tube To Exhaust Manifold (Connector) ..
.
EGR Tube Nut
Auxiliary Shaft Cover Bolt
Cylinder
Cvlinder Front Cover Bolt
Water Outlet Connection Bolt
Inner Timinq
Timing Belt Cover Stud
Outer Timinq
Rocker Arm
Arm Cover Shield Bolt
Thermactor Check Valve to Manifold
Fuel Filter To Carburetor
--
(1)
(i)
4-7
10-15
8-18
23-28
14-21
25-35
14-21
8-12
8-12
6-9
6-9
14-21
14-21
6-9
28-40
25-35
80-100 in-lb
in-Ib
M6
M14
M6
-M8
-M8
~.
M6
M6
M8
M8
M6
M10
Ml0
CD
oil or
or grease
grease on
on the
the gasket surface hand-tighten until
With oil
gasket contacts adapter face,
face, then tighten 1/2
112 turn more.
(T)
CD
Step one
in sequence
one in
in sequence
Step two in
8 Ft-Lbs
16-23 Ft-Lbs
16-23
Step one
one
Step two
two
(2)
one in
in sequence
Step one
Step two
two in
in sequence
Step
(4)
Step
Step
8 Ft-Lbs
16-23 Ft-Lbs
16-23
Step one:
one: 8 vertical screws
Step two:
two: 22 angled screws
60 Ft-Lbs
Ft-Lbs
60
80-90 Ft-Lbs
NOT SPECIFIED ABOVE:

ABOVE:
IF NOT
Component
Note:
(ft-lb)
Torque (ft-Ib)
[;9
(i-9
MB
MFi
M8
M8
M10
Ml0
M12
M12
--
14-21
1!J-71
-2H-40
2H-!J()
!J(l11
I
one in
in sequence
one
two in sequence
Component
M1!]
MM
IHPipe
Pipe
1/4 lH
3/8 1
1H
JIB
H PIPipe
Pf~
25-30 ft-lbs
ft-Ibs
30-36 ft-lbs
ft-Ibs
4-7
4-7
ft-lbs
ft-Ibs
ft-lbs
ft-Ibs
Torque (ft-lb)
(h/b)
80-114
130-114
12-18
1218
23-33
2J33
All viJlv8s
valves iJrf-:
are In
in fl,
It. Ills.
lbs. 1.
11 essf)lhfifWISf?
otherwise'1111!~rJ
noiei
All
IHi/P',S
Oil thr8iJrJs
threads With
with r~n4lne
engine (rlilwilr!',:,
I unless 1~1f!
thii rhrp,;lfls
tlneads fl!qlllrl! IJIIII!W,ldlll
ant [II
111 wdlf!r
watei IPSls1d111
lesislant sealei.
011
srdcr
Standard trHljlJP,
torque lirTIlfS
limits ;Jtj()Vf~
a oveaie
applicable fiJi
li ;ilIIJIIII!1 fIIIWIIIJlI:;
tions 11111
not :,llIIWII
shown III
in Ilw
the Spf?f'l<i1
Special 1
1 IJllill(!
uiqui!
StilndiJrd
;UP, dppllr:iJIJir~
BACK TO GROUP INDEX
chat I,
I.
Chill
CA1355-B3
CA1J55BJ

21-05-40
21-05-40
SPECIFICATIONS-1976
SPECIFICATIONS1976
Engine
Bore and Stroke
PSI (Sea Level @
@
Cranking Speed
2300cc
3.78 x 3.126
3.78x3.126
Lowest Reading within 75% of highest
Oil Pressure - Hot

@2000RPM
40-60
Drive Belt Tensions (lbs.)

Used
Newly Installed
(1)
Over 10 Min.
Up to 10 Min.
Min.
(1)
(2)
(2)
40-60 (2)
50-80
40-80 (2)
40-8Q
Size
1/4"
1/4"
Except
1-3-4-2
90-160 (3)
(3)
1/4"
1/4"
120-160
(3)
(3) If less than 90 pounds, readjust to 90-120 pounds.
(4)
Firing Order
(1) Read tension immediately after belt is installed, before it stretches or seats in pulley grooves.
(2) IIff less than 40 pounds.
pounds, readjust to
to 40-60 pounds.
(4)
75-120 (4)
CYLINDER HEAD
Engine
Combustion
Chamber
Volume
Valve Guide
Bore Diameter
(Standard
Intake and
Exhaust)
Lash Adjuster
Bore Diameter
2300cc
63.7-66.7
0.3433-0.3443
0.8439-0.8449
Valve
Seat Width
Intake
Exhaust
0.070-0.090
0.060-0.080
Valve
Seat
Angle
Valve
Seat
Runout
(Maximum)
Valve
Arrangement
(Front to
Rear)
45 0
45
0.0016
E-I-E-I-E-I-E-I
E-l-E-l-E-l-E-l
Gasket
Surface
Flatness
(1)
(1)
0.003 in any
6 inches,
0.006 overall
(1) Head Gasket Surface Finish R.M.S. 60-150

VALVE SPRINGS
Valve Spring Pressure Lbs @
@
71-79
@ 1.56
71-79@
1.56
2300cc
180-198 @
@ 1.16
Wear Limit
L i m i t ...
. . . 10% Pressure Loss.
Engine
free
Valve Spring Free
Length (Approximate)

Height Pad to Retainer
Valve Spring
Out-of-Square (Maximum)
1.82
1-17/32-1-19/32
5/64 (0.078)
~--
VALVES
Valve Stem
To Valve Guide
Clearance (1)
(1)
Engine
Intake
2300cc
0.0010-0.0027
Valve Head Diameter
Follower to Cam Clearance
Exhaust
Intake
0.0015-0.0032
0.008 Cold
Exhaust
Intake
0.010 Cold
1.73-1.74
I
I
Exhaust
1.49-1.51
1.49-1.51
Valve
Face
Angle
(2)
(2)
440
44 0
Rocker
Arm
Follower
Ratio
1.64:1
1.64:1
(1)
(I) Wear Limit 0.0055
(2) Valve face runout.
runout ..... Maximum 0.0020
VALVES (Continued)
Valve Stem Diameter
0.015 Oversize
0.003 Oversize
Exhaust
Intake
Exhaust
Intake
0.35610.34410.35660.34460.3568
0.3573
0.3453
0.3448
Standard
Engine
2300cc
Intake
0.34160.3423
Exhaust
0.34110.3418
0.030 Oversize
Exhaust
Intake
0.37110.37160.3718
0.3723
CYLINDER BLOCK
Engine
Cylinder Bore
Diameter 1
Cylinder Bore
Diameter
0.003 OS
Main Bearing
Bore
Diameter
Distributor
Shaft Bearing
Bore Diameter
2300cc
3.7795-3.7831
3.7825-3.7861
2.5902-2.5910
0.5155-0.5170
(1)
Maximum bore out-of-round ..' ..... 0.001

0.0015E
Taper Wear Limit .............. ,0.010

0.010
Wear Limit .................. 0.005

Cylinder bore surface finish RMS ... 18-38
(2) Head gasket surface finish RMS .. 60-150
Head Gasket
Surface
Flatness (2)
(2)
0.003 in 66""
0.006 overall
CAMSHAFT
Lobe lift
Lift (1)
(1)
Engine
Intake
2300cc
Theoretical Valve Lift @Zero

@ Zero Lash
Lash
Exhaust
0.2437
(1) Maximum allowable lobe lift loss -- 0.005
Intake
I|
Exhaust
0.3997
(2) Wear Limit -- 0.009
Camshaft
End Play (2)
(2)
0.001-0.007
Camshaft Journal To
Bearing Clearance (3)
(3)
Clearance
0.001-0.0030
(3) Wear Limit - 0.006

CA1355-C1
BACK TO GROUP INDEX

21-05-41
21-05-41
21-05-41
21-05-41
CAMSHAFT DRIVE MECHANISM
Item
Bearing
2300 cc
cc
All
1.7713-1.7720
All
1.7730-1.7742
(No.1)
(No. 1)
.000-.010
000-.010
CAMSHAFT GEAR
OR SPROCKET
CRANKSHAFT GEAR
OR SPROCKET
Engine
Ass6fnbi6d
Assembled
Face Runout TIR Max
Max
Assembled
Face Runout TIR Max
Max
2300cc
0.007
0.005
Camshaft Journal
Diameter
Standard (1)
Camshaft Bearings
Inside Diameter
VALVE TAPPET/ADJUSTER
Camshaft Bearing
Location (2)
(1) Camshaft journal maximum runout 0.005. Camshaft journal maximum
(2) Distance in inches that the front edge of the bearing is installed towards
Standard
Diameter
Clearance
To
To Bore
Bore (2)
(2)
Hydraulic LeakDown Rate (Sec.)
0.84220.8427
0.0007
0.0027
2 -- 8 8( 1(1)
)
Collapsed Tappet Gap @ Cam

Cam
Allowable
Desired
I Desired
0.035-0.055
@Cam
0.040-0.050
@Cam
(1) Time required For plunger to leak down 1/8"

1/8" of travel
the rear from the tower front surface.
(2) Wear Limit

- 0.005
Limit-0.005
AUXILIARY SHAFT
End Play
Bearing Clearance
.001-.007
0.0006-0.0026
CRANKSHAFT AND FLYWHEEL
Engine
Main Bearing
Journal
Diameter (1)
Main Bearing
Journal Runout
Maximum (2)
Main Bearing
Journal
Thrust Face
Runout
Main Bearing
Journal
Taper Max
Max
Thrust
Bearing
Journal
Length
2300cc
2.3982-2.3990
0.002 (Max.)
0.0010 (Max,)
(Max.)
Per Inch
0.0006 Per
1.199-1.201
1.199-1.201
Main Bearing Journal

Surface Finish
RMS Maximum
Journal
Thrust Face
25 Rear
12
35 Front
(2) Wear Limit 0.005
(1) Connecting rod and main bearing journal out-of-round maximum 0.0006
CRANKSHAFT AND FLYWHEEL (Continued)

Connecting
Rod Journal
Diameter (1)
(1) (3)
Engine
2300cc
Crankshaft To
Rear Face Of
Block Runout T.I.R.
Connecting Rod
Rod
Bearing Journal
Maximum Taper
Crankshaft
Free End
End
Play (2)
Flywheel
Clutch Face
Runout T.I.R.
0.005 Max
0.0006 Per
Per Inch
0.004-0.008
0.005
2.0464-2.0472
(1) Connecting rod and main bearing journal out-of-round max

maximum
imum 0.0006
(2) Wear L
Limit
mit 0.012
Flywheel Ring Gear

Lateral Runout T.I.R.
Standard
I Automatic
0.025
0.060
(3) Rod Journal Finish RMS

2
RMS Maximum - 112
CRANKSHAFT BEARINGS
Engine
2300cc

Desired
Allowable
0.0008-0.0015
0.0008-0.0026
(1) 0.002 U.S. Thickness. Add 0.001

0.001 to Standard Thickness.
Wall Thickness
Standard
Standard (1)
0.0619-0.0624
Main Bearings
Desired
Allowable
0.0008-0.0015
0.0008-0.0026
Wall Thickness
Standard
Standard (2)
(2)
0.0951-0.0956
(2) 0.002
D.002 U.S.
U.S. Thickness. Add
Add 0.0010 to Standard Thickness.
CONNECTING ROD
Engine
Piston Pin
Bore Or
Bushing
ID
10
2300cc
0.9104-0.9112
Connecting
Rod Bearing
Bore Diameter (1)
2.1720-2.1728
Connecting
Rod Length
Center
To Center
5.2031-5.2063
Connecting Rod
Rod
Alignment
Maximum Total
Difference (2)
Twist
Bend
I
0.024
.012
Connecting
Rod Assembly
(Assembled To
Crankshaft)
Crankshaft) (3)
(3)
Side Clearance
0.0035-0.0105
(1) Connecting rod

rod bearing bore maximum out-of-round and
and taper ..... 0.0004 (Max,)
(Max.)
(3) Wear Limit - 0.014
0.014
(2)
bore and
and crankshaft
crankshaft bearing
bearing bore
must be
be parallel
parallel and
and in
in the
same vertical
plane within
within
(2) Pin
Pin bore
bore must
the same
vertical plane
on each side of rod
rod centerline.
the specified total difference when measured at ends of 8-inch long bar, 4 inches on
CA1355-C2
BACK TO GROUP INDEX

21-05-42
21-05-42
PISTON
Diameter (1)
Engine
Standard (2)
2300cc
Coded Blue
3,77803.77803,7786
3.7786
3,77923.77923.7798
Piston Pin
Bore Diameter
Piston To
Cylinder Bore Clearance
.003 Oversize
3.78043.7810
0.91230.9126
0.0010.002
(1) Measured at the piston pin bore centerline at 90

900 to the pin bore.
Ring,
Ring Groove Width
Oil Ring
0.0800-0.0810
0.0800-0.0810
0.1880-0.1890
(2) Coped Red
PISTON PIN
Diameter
Engine
Length
Standard
2300cc
3.010-3.040
0.9120-0.9123
I
I
.001 Oversize
0.9130-0.9133
I
I
.002 Oversize
To Piston Clearance
Clearlnce
To Connecting Rod
Bushing Clearance
0.9140-0.9143
0.0002-0.0004
Interference Fit
PISTON RINGS
Compression Ring
Top
2300cc
Compression Ring (1)

Top
Bottom
0.077-0.078
(1) Wear Limit.

Limit ... ..0.006
0.006
Ring Gap Width
Side Clearance
Ring Width
Width
Engine
Oil Ring
Top
Bottom
I
|
Bottom
0.010-0.020
Snug
0.002-0.004
Oil Ring (2)
Compression Ring
0.015-0.055
(2) Steel Rail
APPROXIMATE OIL PAN CAPACITIES
Engine
U.S. Measure
2300cc
Imperial Measure
MelSUre
4
Qt. (1)
(1)
4Qt.
3-1/2 Qt. (1)
(1) Add one quart with filter replacement.
Component
Auxiliary Shaft Gear Bolt
Auxiliary Shaft Thrust Plate Bolt
Belt Tensioner Bolt

Camshaft Gear Bolt
Camshaft Thrust Plate Bolt
Carbo
Carb. to Carbo
Carb. Spacer Stud
Carb. to Spacer Nut
Carbo
Carbo
Carb. Spacer to Manifold Bolt
Connecting
Rod Nut
ConnectingJ-lod
Crankshaft Damper Bolt
Cylinder Head Bolt
Decel Valve Nut
Decel Valve to Intake Manifold - Adapter
Distributor Clamp Bolt
Dis!.
Dist. Vacuum Tube to Int. Manifold - Adapter
Exhaust Manifold to Cylinder Head Nut or Bolt
Flywheel to Crankshaft Bolt
Fuel Pump to Cylinder Block Bolt
Intake Manifold to Cylinder Head Nut or Bolt
Main Bearing Cap Bolt
Oil Pressure Sending Unit to Cyl.
Cyj. Block
Oil Pump Pick-Up Tube to Oil Pump
Oil Pump Pick-Up Tube to Cylinder Block
Fastener
Size
Torque
(ft-Ib)
(ft-lb)
M10
Ml0
M6
M6
Pivot M10
Adj. M8
Adi.
M12
M6
M6
M8
M8
M8
M8
M9
M14
M12
28-40
Ml0
M10
j
j
M10
Ml0
M10
Ml0
M8
M8
M8
M8
M12
-_
M8
M8
M8
6-9
28-40
14-21
14-21
50-71
50-71
6-9
7.5-15
10-14
14-21
14-21
30-36 (5)
100-120
80-90 (2)
10-15
31-38
14-21
14-21
5-8
16-23 (3)
54-64
14-21
14-21
14-21
14-21 (4)
80-90 (2)
8-18
14-21
14-21
14-21
14-21
Oil Pan Drain PluQ

Plus
Pan to Cylinder Block Bolts
Oil Pan
Oil Filter Insert to Block
Oil Filter
Rocker Arm Cover Bolt
Spark Plug to Cylinder Head
Timing Bolt Cover Bolt
Temperature Sending
Unit to Cylinder Head
SendingJJnit
Water Jacket Drain Plug
Water Pump to Cylinder Block Bolt
Exhaust Manifold to EGR Pipe - Connector
EGR
EG
R Valve to Spacer Bolt
EGR Tube to Exhaust Manifold (Connector)
EGR Tube Nut
Auxiliary Shaft Cover Bolt
Cylinder Front Cover Bolt
Water Outlet Connection Bolt
Inner Timing Belt Cover Stud
Outer TiminQ
Rocker Arm Cover Shield Bolt
Thermactor Check Valve to Manifold
Fuel Filter to Carburetor
(2)
Step one
one in
in sequence
sequence
Step
Step two in sequence
(4)
Step one
one in
in sequence
sequence
Step
5-7 Ft-Lbs
16-23 Ft-Lbs
(6)
14-21
14-21
28-40
50-71
50-71
80-114
U.S. Thread Sizes

1/4-20
5/16-18
511618
5/16-24
3/8-16
Note:
Torque (ft-Ib)
(ft-lb)
6-9
12-18
14-20
22-32
U.S. Thread Sizes

3/8-24
7/16-14
7/16-20
1/2-13
All values are in ft. Ibs.

lbs. unless otherwise noted.
Oil threads with engine oil unless the threads require oil resistant or water resistant sealer.
sealer.
Standard torque limits above are
are applicable for all other functions not shown in the Special
Special Torque chart.
chart.
BACK TO GROUP INDEX
8-18
23-28
14-21
14-21
25-35
14-21
14-21
9-11
9-11
9-11
9-11
6-9
6-9
14-21
14-21
14-21
14-21
6-9
17-20
17-20
80-100 in-Ib
in-lb
M6
M6
M8
M8
M6
M10
MlO
(5)
(6)
M8
Ml0
M10
M12
M14
--
5-7 Ft-Lbs
16-23 Ft-Lbs
1/8
- 18 Pipe
1/8-18
1/4
- 18 Pipe
1/4-18
3/8-18Pipe
3/8-18 Pipe
1/2
- 18 Pipe
1/2-18
4-7
5-10
M8
Step one in sequence

Metric Thread Sizes
(1)
(1)
(3)
Torque (ft-Ib)
(ft-lb)
6-9
--
M6
M6
M14
M6
M8
M8
With oil or grease on the gasket surface hand-tighten until

gasket contacts adapter face,
face, then tighten 1/2 turn more.
IF NOT SPECIFIED ABOVE:

Metric Thread Sizes
M6
M6
15-25
6-8
8-10
20-25
M6
M8
(1)
60 Ft-Lbs
Ft-Lbs
60
80-90 Ft-Lbs
Torque
(ft-Ib)
(ft-lb)
Fastener
Fls1Imer
Size
M14
Component
Step one
Step two
Step one:
one:
Step two:
25-30 ft-Ibs
ft-lbs
30-36 ft-Ibs
ft-lbs
8 vertical screws
2 angled screws
4-7 ft-Ibs
ft-lbs
ft-lbs
4-7 ft-Ibs
Torque (ft-Ib)
(ft-lb)
5-8
12-18
23-33
25-35
Torque (ftlb)
(ft-lb)
27-38
40-55
40-60
55-80
CA1355-C3

21-10-1
21-10-1
21-10-1
200 and 250 CID Six-Cylinder

Six-Cylinder Engines
PART
PART 21-10 200 and 250 CID
Applies to fMaverick,
Maverick, Comet,
1hornet, Granada and Monarch
COMPONENT INDEX
INDEX
CAMSHAFT
Rpmnv/al and
anrl Installation
Installation .............
Removal
CAMSHAFT BEARING
BEARING
Removal and
and Installation .............
CAMSHAFT REAR BEARING BORE
PI 11n
PLUG
r LU u
Removal and Installation .............
Removal and Installation
CLUTCH PILOT BEARINGS
BEARINGS
Removal and
CONNECTING ROD
ROD BEARINGS
BEARINGS
Removal and
CRANKCASE VENTILATION SYSTEM
SYSTEM
Description ........................
Removal and
CRAN
KSHAFT
CRANKSHAFT
Removal and
CRANKSHAFT
SEAL
Removal and
CYLINDER ASSEMBLY
ASSEMBLY
Disassembly and
and Assembly ............
CYLINDER BLOCK
BLOCK
Disassembly and
CYLINDER FRONT COVER AND
TIMING CHAIN
CHAIN
Removal and
HEAD
CYLINDER HEAD
Disassembly and
Removal and
ASSEMBLY
ENGINE ASSEMBL
Y
Description ........................
Removal and
SUPPORTS
Removal and
SUPPORT
ENGINE REAR SUPPORT
Removal and
Page
10-9
10-15
10-11
10-10
10-12
10-2
10-5
10-13
10-11
10-18
10-18
10-8
10-16
10-6
10-2
10-3
10-4
10-5
COMPONENT INDEX
COMPONENT
Page
EXHAUST
CONTROL SYSTEM
EXHAUST EMISSION CONTROL
Description ........................
EXHAUST
EXHAUST MANIFOLD
MANIFOLD
Removal and
FL
YWHEEL
FLYWHEEL
Removal and
FRONT OIL SEAL
Removal and
HYDRAULIC
VALVE
HYDRAULIC V
A L V E CLEARANCE
CLEARANCE
Adjustments .......................
HYDRAULIC
VALVE
HYDRAULIC V
A L V E LIFTERS
LIFTERS
oDisassembly
isassemb Iy and
and Assembly
Assemb Iy ............
Removal and
MAIN BEARINGS
BEARINGS
Removal and
OIL FILTER
FILTER
Removal and
01
PAN
OILL PAN
Removal and
o n D111\/iD
OIL
PUMP
UIL rUMr
Disassembly
and Assembly
Assembly ............
Disassembly and
Removal
and
Installation
PISTONS AND
AND CONNECTING
CONNECTING RODS
oDisassembly
isassemb Iy and
and Assembly
Assemb Iy ............
Removal and
SPECIFICATIONS ....................
SPECiFiCATIONS
V
A L V E ROCKER ARM
VALVE
ARM COVER
COVER AND
AND
ROCKER ARM
Removal and
V
A L V E ROCKER ARM
VALVE
ARM
SHAFT ASSEMBL
ASSEMBLY
SHAFT
Y
oDisassembly
isassemb Iy and
and Assembly
Assemb Iy ............
VALVESPRING,
RETAINER AND
VALVE SPRING, RETAINER
AND
STEM
STEM SEAL
SEAL
Removal and
WATER PUMP
WATER
Removal and
and Installation
Installation .............
10-2
10-7
10-10
10-10
10-9
10-2
10-16
10-16
10-7
10-11
10-15
10-15
10-11
10-17
10-17
10-11
10-17
10-12
10-12
10-19
10-19
10-5
10-16
10-16
10-6
10-7
10-7
NOTE: The information in this Part applies to both 1975 and 1976 model year vehicles unless otherNOTE:
specified.
wise specified.
CR1966-A
CR1966-A
BACK TO GROUP INDEX

21-10-2
21-10-2
21-10-2
21-10-2
200 and
and 250
250 CID
CID Six-Cylinder
Engines
200
DESCRIPTION
DESCRIPTION
sectional view
view of
of aa typical
typical six
six
AA sectional
shown in
in Fig.
Fig. 1.1.
cylinder engine
engine isis shown
cylinder
engines
engines are
are covered
covered inin Group
Group 29
29 and
and
Group
Group 50
50 of
ofthis
this Manual.
Manual.
ENGINE
ENGINE
The 200
200 and
and 250
250 CID
CID six
six cylinder
cylinder
The
engines are
are in-line,
in-line, overhead
overhead valve
valve design
design
engines
of lightweight
lightweight cast
cast iron
iron construction.
construction.
of
Adjustment and
and repair
repair procedures
procedures for
for
Adjustment
the two
two engines
engines are
are basically
basically the
the same.
same.
the
EXHAUST EMISSION
EMISSION CONTROL
CONTROL
EXHAUST
SYSTEM
SYSTEM
Operation, removal,
removal, installation
installation and
and
Operation,
maintenance of
of the
the exhaust
exhaust
required
emission control
control devices
devices used
used on
on these
these
emission
CRANKCASE
VENTILATION
SYSTEM
SYSTEM
These
These engines
engines are
are equipped
equipped with
with aa
positive,
closed-type ventilation
ventilation system
system
re-cycling
re~cycling the
the crankcase
crankcase vapors
vapors to
to the
the
intake
intake manifold.
manifold.
A2748-F
A2748-F
FIG.
FIG. 11 Typical In-Line Six-Cylinder Engine
ADJUSTMENTS
HYDRAULIC
HYDRAULIC VALVE
VALVE CLEARANCE
CLEARANCE
A
0.060-inch
shorter
A 0.060-inch shorter than
than standard
standard
push
push rod
rod and
and aa O.060-inch
0.060-inch longer
longer than
than
standard
standard push
push rod
rod are
are available
available for
for
service
service to
to provide
provide aa means
means of
of
compensating
compensating for
for dimensional
dimensional changes
changes in
in
the
thevalve
valvemechanism.
mechanism. Refer
Refer to
tothe
the Master
Master
Parts
Parts List
List or
or the
the specifications
specifications for
for the
the
pertinent
pertinent color
color code.
code.
Valve
Valve stem
stem to
to valve
valve rocker
rocker arm
arm
clearance
clearance should
should be
be within
within specifications
specifications
with
with the
the hydraulic
hydraulic lifter
lifter completely
completely
collapsed.
collapsed. Repeated
Repeated valve
valve reconditioning
reconditioning
operations
operations (valve
(valve and/or
and/or valve
valve seat
seat
refacing)
refacing) will
will decrease
decrease the
the clearance
clearance to
to
the
thepoint
pointthat,
that,ififnot
notcompensated
compensated for,
for, the
the
hydraulic
hydraulic valve
valve lifter
lifter will
will cease
cease to
to
function
function and
and the
thevalve
valvewill
willbe
beheld
held open.
open.
To
To determine
determine whether
whether aa shorter
shorter or
or aa
longer
longer push
push rod
rod isis necessary,
necessary, make
make the
the
following
following check:
check:
1.1. Connect
Connectan
anauxiliary
auxiliarystarter
starterswitch
switchinin
the
thestarting
startingcircuit.
circuit. Crank
Crankthe
theengine
engine
with
withthe
theignition
ignitionswitch
switchOFF
OFFuntil
untilthe
the
No.1
No. 1 piston
piston isis on
on TDC
TDC after
after the
the
compression
compressionstroke.
stroke.
BACK TO GROUP INDEX
2. With the
the crankshaft in
in the position
2.
in Steps
Steps 33 and 4,
4, position
designated in
the hydraulic lifter compressor tool
the
on the rocker arm.
arm. Slowly apply
on
pressure to
to bleed down the hydraulic
lifter until
until the
the plunger
plunger isis completely
completely
lifter
bottomed (Fig.
(Fig. 2).
2). Take
Take care
care to
to avoid
bottomed
excessive pressure
pressure that
that might
might bend
bend
excessive
the push
push rod.
rod. Hold
Hold the
the lifter
lifter in
in this
this
the
position and
and check
check the
the available
available
position
clearance between
between the
the rocker
rocker arm
arm and
clearance
the valve
valve stem
stem tip
tip with
with aa feeler
feeler gauge.
gauge.
the
If the
the clearance
clearance isis less
less than
than
If
specified, install
install an
an under-size
under-size push
push
specified,
rod. If
If the
the clearance
clearance isis greater
greater than
than
rod.
specified, install
install an
an oversize
oversize push
push rod.
rod.
specified,
With the
the No.
No. 11piston
piston on
on TDC
TDC after
after
3.3. With
the compression
compression stroke,
stroke, use
use the
the
the
procedure inin Step
Step 22 and
and check
check the
the
procedure
following valves:
valves:
following
No.1
No. 1Intake
Intake
No. 1Exhaust
No.1
Exhaust
No. 2 Intake
Intake
No.2
No. 3 Exhaust
No.3
Exhaust
No. 4 Intake
Intake
No.4
No. 55 Exhaust
Exhaust
No.
the
Now rotate
Irotate the
the crankshaft
crankshaft until
until the
4.4. Now
the
No. 66 piston
piston isis on
on TDC
TDC after
after the
No.
compression stroke
stroke (l
(1 revolution
revolution of
compression
of
the crankshaft).
crankshaft). By
By using
using the
the
the
procedure in
in Step
Step 2,
2, check
check the
the
procedure
following valves:
valves:
following
No. 22 Exhaust
Exhaust
No.
No. 3 Intake
Intake
No.3
No. 4 Exhaust
No.4
No. 5 Intake
Intake
No.5
Feeler Gauge
Gauge
Feeler
Tool-6513-K
Too/-6513-K
FIG. 22 Check
Check Valve
Valve Clearance
Clearance
FIG.
21-10-3
21-10-3
200
200 and
and 250
250 CID
CID Six-Cylinder
Engines
No. 6 Intake
Intake
No.6
No. 66 Exhaust
Exhaust
No.
When compressing
compressing the
the valve
valve spring
spring to
to
5.5. When
remove the
the push
push rods,
rods, be
be sure
sure the
the
remove
piston in
in the
the individual
individual cylinder
cylinder isis
piston
below TDC
TDC to
to avoid
avoid contact
contact between
between
below
the valve
valve and
and the
the piston.
piston. To
To replace
replace
the
aa push
push rod,
rod, itit will
will be
be necessary
necessary to
to
remove
remove the
the valve
valve rocker
rocker arm
arm shaft
shaft
assembly.
assembly. Upon
Upon replacement
replacement of
of aa
valve
valve push
push rod,
rod, valve
valve rocker
rocker arm
arm shaft
shaft
assembly
assembly or
or hydraulic
hydraulic valve
valve lifter,
lifter, the
the
engine
engine should
should not
not be
be cranked
cranked or
or
rotated
rotated until
until the
the hydraulic
hydraulic lifters
lifters have
have
21-10-3
21-10-3
had
had an
an opportunity
opportunity to
to leak
leak down
down to
to
their
their normal
normal operating
operating position.
position. The
The
leak
leak down
down rate
rate can
can be
be accelerated
accelerated by
by
using
using the
the tool
tool shown
shown in
in Fig.
Fig. 22 on
on the
the
valve
valve rocker
rocker arm
arm and
and applying
applying
pressure
pressure in
in aa direction
direction to
to collapse
collapse the
the
lifter.
lifter.
INSTALLATION
When installing
installing nuts
nuts or
or bolts
bolts that
that
When
t o r q u e d (refer
(refer to the
the
must be torqued
Specification Section
Section at
at the
the end
end of this
this
Specification
Part). Oil
Oil the
the threads
threads with
with light-weight
light-weight
Part).
engine oil.
oil. Do
Do not
not oil
oil threads
threads that
that require
require
engine
or water-resistant sealer.
sealer.
oil-resistant or
to Part 21-01
21-01 for cleaning and
Refer to
inspection and
and engine
engine test
test procedures.
procedures.
inspection
ENGINE ASSEMBLY
is equipped with the
If the engine is
Thermactor system, remove or
or
Thermactor
will interfere with
disconnect parts that will
removal or installation of the engine.
Removal
Removal
1. Remove the hood.
hood.
1.
2. Drain the cooling system and the
2.
crankcase.
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
automatic transmission
transmission
disconnect
disconnect the
the transmission
transmission oil
oil cooler
cooler
lines
lines from
from the
the radiator.
radiator.
4. Remove the radiator. Remove the
fan, spacer, belt and pulley.
5. Disconnect the heater hoses from the
water pump and cylinder
cylinder block.
Disconnect the alternator wires from
the alternator, the starter cable from
the starter and the accelerator control
cable from
from the carburetor. On aa
vehicle with air conditioning, remove
the compressor from the mounting
bracket, and position it out of
of the
way, leaving the refrigerant
refrigerant lines
attached.
attached.
6. Disconnect the flexible fuel line at the
the
fuel pump line and plug the fuel line.
line.
7. Disconnect
Disconnect the coil wires from the
coil. Disconnect
Disconnect the
the oil pressure and
and
the water temperature
temperature sending unit
unit
wires from
from the sending units.
units.
8. Remove the starter.
On
On aa vehicle
vehicle with
with aa manual-shift
manual-shift
transmission,
disconnect the
the clutch
clutch
retracting
retracting spring. Disconnect
Disconnect the
clutch
clutch equalizer
equalizer shaft
shaft and
and arm
bracket
bracket at
at the
the underbody
underbody rail
rail and
and
remove
remove the
the arm
arm bracket
bracket and
and equalizer
equalizer
shaft.
shaft.
BACK TO GROUP INDEX
9.
9. Raise
Raise the
the vehicle.
vehicle. Remove
Remove the
the
flywheel
flywheel or
or converter
converter housing
housing upper
bolts.
attaching bolts.
10.
10. Disconnect
Disconnect the
the muffler
muffler inlet
inlet pipe
pipe atat
the
the exhaust manifold. Loosen the
the
inlet pipe
pipe clamp
clamp and slide
slide itit off the
the
support bracket on the engine.
engine.
Disconnect the
the engine
engine right and
and left
left
bracket.
mounts at the underbody bracket.
Remove the flywheel or converter
housing cover.
cover.
On
On aa vehicle with aa manual-shift
manual-shift
transmission, remove the flywheel
flywheel
automatic
disconnect the
the
converter from the flywheel.
flywheel. Remove
the converter housing lower attaching
bolts.
bolts.
11. Lower the vehicle. Support the
transmission
transmission and flywheel or
converter housing with a jack.
12.
12. Attach
Attach the
the engine
engine lifting
lifting hook
hook (Fig.
(Fig.
3). Carefully
Carefully lift the engine out of the
engine compartment. Place the engine
on a work stand (Fig. 4).
Tool-T60K-6000A
TOOI-T6OK-6OOOA
FIG.
FIG. 33 Engine
Engine Lifting
lifting Hook
Hook
Installation
Instal/ation
1. If
If the
the clutch
clutch was
was removed,
removed, install
install as
as
1.
Group 16. Install
Install guide
guide
detailed in
in Group
detailed
pins
pins in
in the
the flywheel
flywheel or
or converter
converter
housing
housing bolt
bolt holes
holes in
in the
the rear
rear of
of the
the
engine.
engine.
2. Carefully
Carefully lower
lower the
the engine
engine into
into the
the
2.
engine compartment.
engine
3.
3. Make
Make sure
sure the
the guide
guide pins
pins in
in the
the block
engage
engage the
the holes
holes in
in the
the flywheel
flywheel
housing.
housing.
automatic
transmission,
transmission, start
start the
the converter pilot
into
into the
the crankshaft.
crankshaft.
On
On aa vehicle
vehicle with aa manual-shift
manual-shift
transmission,
transmission, start the
the transmission
main
main drive
drive gear into
into the
the clutch disc.
disc.
It may be
be necessary to
to adjust the
relation to
to the
the engine
engine if the
the input shaft
shaft
will
will not enter the clutch disc.
disc. If the
engine hangs
hangs up
up after
after the
theshaft
shaft enters,
enters,
turn the crankshaft
crankshaft slowly
slowly
(transmission in
in gear)
gear) until the
the shaft
splines mesh
mesh with the clutch disc
splines.
splines.
4.
4. Remove the engine lifting hook.
hook.
Install the flywheel or converter
housing upper attaching bolts.
5.
5. Remove
R e m o v e tthe
h e jjack
a c k from
from the
the
transmission. Raise the vehicle.
6.
6. Remove the guide pin and install the
flywheel or converter housing lower
attaching bolts.
transmission, attach the converter to
the flywheel and torque the attaching
7. Install the flywheel or converter
housing dust cover.
transmission, install the clutch
equalizer shaft
shaft and arm bracket.
equalizer
Connect the clutch retracting spring.
8. Install the engine left
left and right mount
to the underbody bracket.
9. Remove the plug from the fuel pump
line and connect the flexible fuel line
to the fuel pump line. Using a new
new
manifold to
gasket, install the exhaust manifold
muffler inlet pipe with lockwashers
muffler
and nuts. Torque
Torque the
the nuts
nuts to
and
pipe
specifications. Position the inlet pipe
support bracket on the
clamp on the support
clamp.
engine and tighten the clamp.
vehicle. Connect the oil
pressure and
and the
the engine
engine temperature
pressure
Connect the coil
coil
sending unit wires. Connect
wires. Connect
Connect the
the accelerator
accelerator
wires.
control cable.
cable.
control
Install the
the starter
starter motor.
motor. Connect
Connect the
the
11. Install
starter cable.
cable. Connect
Connect the
the alternator
alternator
starter
wires. Connect
Connect the
the heater
heater hose
hose at
at the
the
wires.
water pump
pump and
and cylinder
cylinder block.
water
Connect the
the battery
ba.ttery ground
ground cable.
cable.
Connect
21-10-4
200 and 250 CID Six-Cylinder Engines
12. Install the pulley, fan, and drive belt.

Adjust
Adjust the drive belt tension. On aa
vehicle with air conditioning, install
compressor on
on the
the mounting
mounting
the compressor
adjust the belt tension to
bracket, and adjust
the radiator.
specifications. Install the
Connect the radiator upper and lower
hoses. Fill and
and bleed the
the cooling
system. Fill the crankcase with the
the
proper grade and quantity of
of engine
oil.
13. Install and adjust the hood.
14. Operate the engine at
at fast idle and
check
c h e c k all
a l l gaskets
g a s k e t s and
a n d hose
hose
connections for leaks.

automatic
transmission, perform
perform aa transmission
kickdown linkage adjustment
adjustment (Part
24-60).
15. Install the air cleaner and connect the
positive closed-type
crankcase
ventilation hose.
21-10-4
replaced with new self-locking bolts and
nuts.
Granada, Monarch, Maverick

and Comet 200 and 250 CID
Engines
Removal
Removal
1.
the insulator
insulator to
to support
1. Remove the
support
bracket nuts and washers from both
insulators (Fig. 5).
2. Raise the
the engine with aa jack and
wood block placed under the oil pan.
3. Remove the insulator-to-engine bolts
and
and washers
w a s h e r s and
a n d remove
r e m o v e tthe
he
insulator.

The procedures given apply to either
a right or
or left installation.
installation.
The engine front supports are located
on each side of
of the cylinder
cylinder block.
self-locking mounting bolts
Whenever self-locking
and nuts are removed, they must be
be
Too/_
T64L.6001.B
Tool-T64L-600UB
A2842A
A2842-A
FIG. 4
4 Engine Mounted on Work StandTypical
StandTypical
BRACKETUPPER BRACKET
6043 R.H.
6A069 L.H.
250 ENGINE ONLY
386242-5100
4 REO'D.
1737 FTLB
INSULATOR -6038
ASSY.
6038 ASSY.
2REO/D.
2 REO'D.
~
LOWER
BRACKET BRACKET6061 L.H.
6061
6037 R.H.
~~
\
UPPER BRACKET AND INSULATOR -6C010 ASSY. R.H.

6C060 ASSY. L.H.
MAIN VIEW
VIEWY
VIEW Y
~
_
INSULATOR -- 6068
386242-S100
2 REQ'D.
17-32 FT-LB
3 SPD. STD. TRANS.
FLOORSHIFTONLY
LOWER
LOWER BRACKET
BRACKET -6061
6061 L.H.
L.H. oREF
c c
EF
6037
R
H
.
6037 R.H.. R
EXHAUST
EXHAUST SYSTEM
SYSTEM
BRACKETBRACKETIFOR CATALYTIC
CATALYTIC
(FOR
SYSTEM ONLY)
,.
200 ENG. ONLY

~~OH~~~I~~~~ME
OTHERWISE SAME
383421-S2
2
2 REO'D.
REQ'D.
' ~ ~.
SHOWN GRANADA/MONARCH
SIMILAR)
UPPER BRACKET
AND INSULATOR -6043 R.H.
R.H.
6043
6A069 L.H.
6A069L.H.
3862425100
6 REO'D.
LOWER
LOWER BRACKET
BRACKET _6061 L.H.
REF.
6037 R.H. REF.
J~
~....f$C*
~-
;;;(
~
;;-'
2 REO'D.
~
-~,9
~~
-~ ~_~
\~
~~
200 ENGINE ONLY

OTHERWISE SAME
ASVIEWY
AS VIEWY
382400-S2
2 REO'D.
REQ'D.
30-50 FT-LB
FT-LB
30-50
LOWER
~
6K013
LOWER
BRACKET
_
~ \
'"
AS5Y.
BRACKET6061 L.H.
VIEW Y
6061
6037 R.H.
R.H.
I
~""""'---- 34978-S2
250 ENG.
6037
TYPICAL 1976
38606952
2 REO'D.
ONLY
2649
386069-S2
2
(GRANADA/MONARCH SHOWN -_
2 REQ'D.
REO'D.
;8~;~~~2
40-60 FTLB
\e;
56748-52
2 REO'D.
ATAMPED
STAMPED
"R"
LETTER "R"
6E046 L.H.
~;~:~
6A060 ~'~'.
R.H.
17_32FT.LB 383421S2
---...r--nr-_,,,,,
;O~;OOF~'_LB
2 REO'D.
3050 FT-LB
~:~~A/MONARCH ~~/~j~'.~'.
34977-S2
4 REQ'D.
20-32 FT-LB
3824~-S2
34978-S2
BRACE -BRACE
TYPICAL 1975
ALL EXCEPT
3-SPD. STD.
TRANS. FLOOR
SHIFT.
INSULATOR ,",,,,_~__=--"". _
6038 ASSY. R.H. '""""'... _~
6B032 ASSY. L.H
VIEWZ
TYPICAL 1975176
VIEW
Y
VIEWY
250 ENG.
ENG. ONLY
(MAVERICK/COMET
(MAVER
ICK/COMET
UPPER BRACKET -6043 R.H.

6A069 L.H.
382802-52
2 REO'D.
__
I\i
y--
383421-S2~lil--
~~~
~
AS
Y
AS VIEW
VIEWY
INSULATOR
- 6068
34977-S2
4 REO'D.
REQ'D.
2032
.
()
20-32 FTLB
FT-LB
386454-S2
~.-"(6 REQ'D.-
6
R E O ' D . p............... ~~
382802-52
382802-S2
6
REQ'D.
6REO'D.
20-37 FT-LB
Jh.
1
MAVERICK/COMET
MAVERICK/COMET SIMILAR)
A4059B
A4059-B
FIG. 5
5 Granada, Monarch,
Monarch, Mayerick
Maverick and Comet-Front
CometFront and Rear Supports 200 and 250 CIO
CID Engines
BACK TO GROUP INDEX

21-10-.$
21-10-5
200 and
and 250 CID
CID Six-Cylinder Engines
Installation
Installation
1.1. Position
Position the
the insulator
insulator assembly
assembly on
on the
the
engine
engine and
and install
install the
the insulatorinsulator- totoengine
engine bolts
bolts and
and washers
washers finger-tight.
finger-tight.
2.
2. Lower
Lower the
the engine
engine carefully
carefully to
to make
make
sure
sure the
the insulator
insulator stud
stud engages
engages the
the
hole
hole in
in the
the support
support bracket.
bracket.
3.
3. Install
Install the
the insulator
insulator to
to support
support
bracket
bracket washer
washer and
and nut
nut on
on bolt engine
engine
front
front mounts.
mounts. Tighten
Tighten the
the insulator
insulator
bolts
bolts and
and nuts
nuts to
to specification.
specification.
REAR SUPPORT
SUPPORT
ENGINE REAR
The
The rear support
support isis located at the
the
transmission
transmission extension
extension housing (Fig.
(Fig. 5).
5).
Whenever selflocking
self-locking mounting
mounting bolts
Whenever
and nuts
nuts are
are removed,
removed, they
they must
must be
and
replaced with
with new
new self.locking
self-locking bolts
bolts and
replaced
nuts.
nuts.
Granada, Monarch,
Monarch, Maverick
Maverick
Granada,
and
and Comet
Removal
Removal
1. On
On automatic transmISSIon
transmission models,
models,
1.
support the
the engine
engine with aa jack and
support
wood block under the oil pan and
insulator to
remove the rear insulator
nuts.
crossmember attaching nuts.
2. Remove the rear insulator
insulator to
2.
transmission extension housing bolts
washers.
and lock washers.
3. On
On all
all models
models except those with floor
3.
manual
shift man
ual transmissions, raise the
transmission and remove the rear
insulator.
4. On floor shift manual transmission
4.
models, support the transmission
models,
with aa floor jack and remove the
frame
frame crossmember from the frame
and from
from the
the rear
rear insulator;
insulator; then
then
and
remove the
the rear
rear insulator
insulator from
from the
remove
the
transmission. Do not apply upward
transmission.
pressure on
on the transmission with the
jack as
as damage
damage to
to the
the transmission
transmission
jack
shift lever
lever console
console or
or mounting
mounting plate
shift
plate
will result.
will
result.
Installation
Installation
1. Position the rear insulator on the
1.
transmission extension housing.
2. On all models except those with floor
2.
shift, install the rear insulator to
and lock-washers. Torque the bolts to
specification. Lower the transmission.
Install the two insulator
3. Install
insulator to
crossmember attaching
attaching nuts and
crossmember
torque to
specification.
torque
to specification.
4. On models with floor shift manual
transmission, position
rear
transmission,
position the
the rear
insulator to
insulator
to the
the transmission
transmission and
and
install and
and torque
install
torque the
the attaching
attaching bolts.
bolts.
5. Position the removable crossmember
5.
to the frame and install the through
bolts. Remove the supporting jack,
install
install the
the nuts
nuts and
and washers
washers attaching
attaching
the
the support
support to
to the
the crossmember
crossmember and
and
torque
specification.
torque the
the nuts
nuts to
to specification.
6. Remove the jack. Disconnect all
6.
necessary vacuum components and
BACK TO GROUP INDEX
21-10-5
ELBOW 3829565
ELBOW
382956-S
CRANKCASE CLOSURE
HOSE 6853
ELBOW GROMMET 3821565
OIL FILLER CAP 6766

CRANKCASE VENT
HOSE
HOSE 6A664
FRONT OF VEHICLE
A3414-C
FIG. 6 Closed Crankcase Ventilation System Components

FIG.
identify
lines for accessibility and identify
them for proper connection.
SYSTEM
The closed crankcase ventilation
system components are shown in Fig. 6.
Removal
Removal
1. Remove the inlet hose from the air
1.
cleaner and the oil filler cap. Remove
the fresh air intake tube and the heat
shroud tube.
2. Remove the air cleaner.
2.
3. Grasp the crankcase vent hose near
the rocker arm cover grommet and
pull the regulator valve from the
rocker arm cover.
4. Remove the regulator valve from the
vent hose and remove the vent hose
from the hose fitting in the carburetor
spacer.
Installation
Insta//ation
1.
1. Install the vent hose on the fitting in
in
the
the carburetor
carburetor spacer
spacer and
and the
the
regulator
regulator valve
valve in
in the
the hose.
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.

lOCKER ARM
AND ROCKER
Removal
Removal
1.
cleaner and the
1. Remove the air cleaner
crankcase ventilation
ventilation system.
crankcase
Remove the accelerator control cable
bracket.
rarm cover
2. Remove the valve rocker .arm
and discard the gasket.
shaft support
3. Remove the rocker arm shaft
bolts by loosening the bolts two turns
at a time in sequence. Remove the
7).
shaft assembly (Fig. 7).
rocker arm shaft
Make
Remove the valve push rods. Make
sure the push rods are identified
before
before removal so they can be
be
returned to the same location when
when
they are installed.
A3165-A
A316SA
FIG. 7 Valve Rocker Arm

Arm Shaft
Shaft
Removal
Installation
Installation
1. Apply Lubriplate
Lubriplate or equivalent
equivalent to
to
both ends of
of the push rods and to
to the
the
valve stem tip.
tip.
21-10-6
21-10-6
200
200 and
and250
250CIO
CIDSix-Cylinder
Engines
Install the
thevalve
valve push
push rods.
rods. Position
Position
2.2. Install
the valve
valve rocker
rocker arm
armshaft
shaft assembly
assembly
the
on the
thecylinder
cylinder head.
head.
on
Install and
and tighten
tighten all
all valve
valve rocker
rocker
3.3. Install
armsupport
supportbolts,
bolts,two
twoturns
turnsatataatime
time
arm
in sequence,
sequence, until
until the
thesupports
supports fully
fully
in
contact the
thecylinder
cylinder head.
head.Torque
Torque the
the
contact
bolts toto specifications.
specifications.
bolts
If finy
any part
part which
which could
could affect
affect the
the
4.4. If
valve clearance
clearance has
has been
been changed,
changed,
valve
check the
the valve
valve clearance
clearance following
following
check
the procedure
procedure outlined
outlined under
under
the
Hydraulic Valve
Valve Lifter
Lifter Adjustment.
Adjustment.
Hydraulic
Clean the
the valve
valve rocker
rocker arm
arm cover
cover and
and
5.5. Clean
cylinder head
head gasket
gasket surfaces.
surfaces. Install
Install
cylinder
the gasket
gasket in
in the
the cover
cover making
making sure
sure
the
that all
all of
of tangs
tangs of
of the
the gasket
gasket are
are
that
engaged in
in the
the notches
notches provided
provided in
in
engaged
the cover.
cover. Connect
Connect all
all vacuum
vacuum lines
lines
the
and components
components using previous
previous
and
identification for
for proper
proper connection.
connection.
identification
Tighten the
the cover
cover attaching
attaching bolts
bolts in
Tighten
in
two steps.
steps. First,
First, torque
torque the
the bolts
bolts to
to
two
specifications; then,
then, retorque
retorque to
to the
specifications;
the
same specifications
specifications two
two minutes
minutes after
after
same
initial tightening.
tightening. Install
Install the
the
initial
accelerator control
control cable
cable bracket.
bracket.
accelerator
6. Install
Install the
the crankcase
ventilation
6.
system and
and the
the air
air cleaner.
cleaner.
system
VALVE SPRING,
SPRING, RETAINER AND
AND
STEM SEAL
STEM
SEAL
Broken valve
valve springs
springs or
or leaking
leaking valve
Broken
valve
stem seals
seals and
and retainer
retainer may
may be
bereplaced
replaced
stem
without
cylinder head
without removing
removing the
the cylinder
head
provided
damage to
or valve
provided damage
to the
the valve
valve or
valve
seat
occurred.
seat has
has not
not occurred.
Removal
Removal
1.
1. Remove the
the air cleaner. Remove the
the
crankcase
ventilation regulator
regulator valve
valve
from
the valve
valve rocker
rocker arm
arm cover.
cover.
from the
Remove
Remove the
the valve
valve rocker
rocker arm
arm cover.
cover.
Remove
Remove the
the applicable
applicable spark
spark plug.
plug.
2.
2. Loosen
Loosen the
the valve
valve rocker
rocker arm
arm shaft
shaft
support bolts two
two turns at a time, in
in
sequence, until the valve spring
pressure is relieved. Remove both
valve
be
valve push
push rods
rods of the
the cylinder
cylinder to
to be
serviced.
3.
3. Install
Install an
an air
air line
line with
with an
an adapter
adapter in
in
the
the spark
spark plug
plug hole.
hole.
4.
4. Tighten
Tighten the
the attaching
attaching bolts
bolts just
just
enough
enough to
to seat
seat the
the rocker
rocker arm
arm shaft
shaft
supports
supports on
on the
the cylinder
cylinder head.
head. Push
Push
the
the rocker
rocker arm
arm to
to one
one side
side and
and secure
secure
itit in
8). To
To move
move
in this
this position
position (Fig.
(Fig. 8).
the
the rocker
rocker arm
arm on
on either
either end
end of
of the
the
shaft,
shaft, itit will
will be
be necessary
necessary to
to remove
remove
the
and spring
spring washer
washer
the retaining
retaining pin
pin and
and
and slide
slide the
the rocker
rocker arm
arm off
offthe
the shaft.
shaft.
Turn on
on the
the air
air supply.
supply. Air
Air pressure
5.5. Turn
may turn
turn the
the crankshaft
crankshaft until
until the
the
may
the bottom
bottom of
of the
the
piston reaches
reaches the
piston
stroke.
stroke.
Usingthe
the valve
valvespring
springcompression
compression
Using
tool shown
shown in
in Fig.
Fig. 8,
8, compress
compress the
the
tool
valve
valve and
and remove
remove the
the valve
valve spring
spring
retainer
retainer locks,
locks, the
the sleeve,
sleeve, spring
spring
retainer
retainer and
and the
the valve
valve spring.
spring. IfIfair
air
BACK TO GROUP INDEX
Air Line And Adapter
Tool- T65P-65 73- A
4.4.
5.5.
FIG. 88 Compressing
Compressing Valve
Valve Spring-In
SpringIn
FIG.
Chassis
Chassis
pressure fails
fails to
to hold
hold the
the valve
valve in
in the
the
pressure
closed position
position during
during this
this operation,
operation,
closed
can be
be presumed
presumed that
that the
the valve
valve is
is
itit can
not seating
seating or
or is
is damaged.
damaged. If
If this
this
not
condition occurs,
occurs, remove
remove the
the cylinder
cylinder
condition
head for
for further
further inspection.
inspection.
head
6. Remove
Remove the
the valve
valve stem
stem seal
seal (Fig.
(Fig. 9).
6.
9).
If air
air pressure
pressure has
has forced
forced the
the piston
piston
If
to the
the bottom
bottom of
of the
the cylinder,
cylinder, any
to
any
removal of
of air
air pressure
pressure will
will allow
allow the
the
removal
valve(s) to
to fall
fall into
into the
the cylinder.
cylinder. A
valve(s)
A
rubber band,
band, tape
tape or
or string
string wrapped
wrapped
rubber
around the
the end
end of
of the
the valve
valve stem
stem will
will
around
prevent this
this condition
condition and
and will
will still
still
prevent
allow enough
enough travel
travel to
to check
check the
the valve
valve
allow
for binds.
for
binds.
AirLine
SEAL
A3134-A
FIG. 9
9 Removing Valve
Valve Stem
Stem Seal
Seal
Installation
Installation
1.
1. Install
Install aa new
new valve
valve stem
stem seal.
seal. Position
Position
the
the spring
spring over
over the
the valve.
valve. Install
Install the
the
spring
spring retainer
retainer and
and sleeve.
sleeve. Compress
Compress
the
the valve
valve spring
spring and
and install
install the
the valve
spring
spring retainer
retainer locks.
locks.
2.
2. Apply
Apply Lubriplate
Lubriplate or
or equivalent
equivalent to
to
both
both ends
ends of
of the
the push
push rod,
rod, the
the valve
valve
and
and push
push rod
rod ends
ends of
of the
the rocker
rocker arm,
arm,
and
and the
the valve
valve stem
stem tip.
tip. Remove
Remove the
the
rocker
rocker arm
arm shaft
shaft and
and install
install the
the push
rod(s),
rod(s), making
making sure
sure the
the lower
lower end
end of
the rod
rod isis positioned
positioned in
in the
the valve
valve lifter
lifter
the
push
push rod
rod cup.
cup.
3.3. Remove
Remove the
the wire
wire securing
securing the
the valve
valve
rocker
rocker arm
arm and
and slide
slide the
the rocker
rockerarm
arm
into
into position.
position. If
If an
an end
end valve
valve rocker
rocker
arm
arm was
was removed,
removed, slide
slide itit into
into
position
position on
on the
the shaft
shaft and
and install
install the
the
spring
Turn
spring washer
washer and
and retainer
retainer pin.
pin. Turn
6.
6.
21-10-6
21-10-6
off
offthe
theair
airand
andremove
removethe
theair
airline
lineand
and
adapter.
adapter. Install
Install the
the spark
spark plug
plug and
and
spark
spark plug
plug wire.
wire.
Install
Install the
the rocker
rocker arm
arm shaft
shaft by
by
following
following the
the instructions
instructions under
under
Rocker
Rocker Arm
ArmInstallation.
Installation.
Clean
Clean the
the valve
valverocker
rocker arm
arm cover
coverand
and
cylinder
cylinder head
head gasket
gasket surfaces.
surfaces. Install
Install
aanew
newgasket
gasketininthe
thecover
covermaking
makingsure
sure
the
the gasket
gasket tangs
tangs are
are securely
securely engaged
engaged
with
with the
thenotches
notchesin
inthe
thecover.
cover.Position
Position
the
the cover
cover on
on the
the head.
head. Install
Install and
and
tighten
tighten the
the cover
cover attaching
attaching bolts
bolts in
in
two
two steps.
steps. First,
First, torque
torque the
the bolts
bolts to
to
specifications.
specifications. Two
Two minutes
minutes later,
later,
torque
torque the
the bolts
bolts to
to the
the same
same
specifications.
specifications.
Insert
Insert the
the regulator
regulator valve
valve (with
(with the
the
vent
vent hose
hose attached)
attached) into
into the
the valve
valve
rocker
rocker arm
arm cover
cover mounting
mounting grommet.
grommet.
Install
Install the
the air
air cleaner.
cleaner.
CYLINDER
CYLINDER HEAD
HEAD
RemoJ'al
Removal
1.1. Drain the
the cooling
cooling system.
system. Remove
Remove
the air
the
air cleaner. Disconnect the
radiator upper hose
hose at
at the
the engine.
engine.
2.
2. Disconnect the
the muffler inlet pipe
pipe at
the exhaust manifold. Pull the muffler
muffler
inlet pipe down.
down. Remove the
the gasket.
gasket.
3.
3. Disconnect the
the accelerator retracting
spring.
spring. Disconnect the
the accelerator
control cable at
at the
the carburetor.
4.
con n e c t the
I' a n s m iss ion
4. Dis
Disconnect
the ttransmission
kickdown rod.
rod. Disconnect
Disconnect the
accelerator linkage at
the bellcrank
at the
assembly.
the fuel inlet line at the
the
5. Disconnect the
filter hose. Disconnect
Discon nect the
the
fuel filter
distributor vacuum lines. Disconnect
as
vacuum lines and components as
necessary for accessibility
accessibility and
and
necessary
iidentify
d e n t i f y tthem
h e m for proper
proper
re-connection.
carburetor fuel inlet
inlet
6. Disconnect the carburetor
the
line at the fuel pump. Remove the
lines as an assembly.
Disconnect the
the spark
spark plug
plug wires
wires at the
the
7. Disconnect
spark plugs
plugs and the
the temperature
spark
sending unit
unit wire
wire at
at the
the sending
sending unit.
unit.
sending
8. Remove
Remove the
the crankcase
ventilation
8.
system. Remove
Remove the
the accelerator
accelerator
system.
control cable
cable bracket.
bracket.
control
9. Remove
Remove the
the valve
valve rocker
rocker arm
arm cover.
cover.
9.
10. Remove the
the valve rocker arm
arm shaft
10.
assembly. Remove
Remove the
the valve
valve push
push
assembly.
rods in
in sequence
sequence (Fig.
(Fig. 10).
10).
rods
A2224-A
A2224-A
FIG. 10
10 Valve
Valve Push
Push Rod
Rod Removal
Removal
FIG.
11.Remove
Remove the
the remaining
remaining cylinder
cylinder head
head
11.
bolts and
and remove
remove the
the cylinder
cylinder head.
head.
bolts
Donot
notpry
prybetween
betweenthe
the cylinder
cylinder head
head
Do
21-10-7
200 and
and 250 CID
200
and block as the gasket surfaces may

become damaged.
Installation
1. Clean the head and block gasket
21-01 for
surfaces. (Refer to Part 21-01
cleaning and inspection procedures).
If the cylinder head was removed for
If
a gasket change, check the flatness of
the cylinder head and block. Install
the cylinder
guide studs at each end of the
block (Fig. 11).
7/16"-14
7 / 1 6 " - 1 4 xx6"
6 " BOLT. CUT
CUT OFF
OFF HEAD, TAPER
END AND
AND SLOT FOR
FOR SCREWDRIVER.
rEND
~;
f. . . . .
A2790-t
A2790-/
FIG. 11
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
of
the muffler
muffler inlet pipe.
4. Lift the cylinder head over the guides
and slide it down carefully, connect
the muffler
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
6.
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
after extended
retorque the bolts after
operation. However, on cylinder
heads with composition gaskets, the
bolts may be checked and retorqued,
if desired. Tighten the exhaust
if
manifold flange attaching nuts to
manifold
specification.
A1369-A
12 Cylinder Head Bolt Torque

FIG. 12
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.
8. Install the valve rocker arm shaft
shaft
assembly following procedures under
BACK TO GROUP INDEX
Valve Rocker Arm Shaft Installation.

Check the valve clearance,
clearance,
Check
following the procedure outlined
under Valve Clearance Adjustment.
Adjustment.
9.
9. Install the muffler
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. Connect the transmission
kickdown rod.
13. Connect the accelerator control cable
retracting spring. Connect
Connect the
retracting
accelerator control cable at the
carburetor.
14. Connect the distributor vacuum line
at the distributor. Connect the
carburetor fuel inlet line at the fuel
pump.
p u m p . Connect
C o n n e c t all vacuum
vacuum
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.
wires. Be sure the wires
are forced all the way down into their
sockets.
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
lifter for noisy operation, be sure the
improperly
noise is not caused by improperly
adjusted valve clearance or by worn
adjusted
rocker arms or push rods.
Removal
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).
13). Place the lifters in a
rack so they can be installed in the
original positions.
If
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
If the
valve lifters
lifters are to be tested or
disassembled and cleaned, follow the
procedures in Part
Part 21-01. If
If a
lifter has been
disassembled and cleaned, be sure to
fill it with test fluid before installing
21-10-7
Magnet
Magnet
A3135-A
A3135A
FIG. 13
13 Removing
Removing Valve Lifter
it in the engine. New valve lifters

lifters
already contain test fluid.
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
Removal
1. Remove the air cleaner and related
parts. Disconnect the muffler
muffler 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
muffler inlet pipe.
2. Position the exhaust manifold on the
cylinder
cylinder head and install
install the
attaching bolts and tab washers.
Torque the bolts and studs in
sequence shown in Fig. 14.
14. Refer to
specifications.
muffler
3. Place a new gasket on the muffler
muffler inlet
inlet pipe. Position the muffler
pipe to the manifold. Install and
ttorque
o r q u e the attaching
a t t a c h i n g nuts to
specifications. Install the automatic
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
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
21-10-8
200
200 and
and 250
250 CID
CID Six-Cylinder
Engines
21-10-8
21-10-8
INSTRUCTIONS:
INSTRUCTIONS:
INSTALL 3/8-16
3/8-16STUD
STUD&&WASHER
WASHER ASSEMBLY
ASSEMBLY - - HOLES
HOLESNUMBERED
NUMBERED44&&55TORQUE
TORQUETO
TO18-24
18-24FT-LB.
FT-LB.
INSTALL
.3/8-16XX2.62
2.62BOLT
BOLT- - HOLES
HOLES3-6-7-83-6-7-8-TORQUE
TORQUETO
TO18-24
18-24FT-LB.
FT-LB.
,3/8-16
3/8-16 XX1.12
1.12 BOLT
B O L T- - HOLES
HOLES1-2-9-10-11
1-2-9-10-11TORQUE
TORQUETO
TO18-24
18-24FT-LB
FT-LB
FRONT
FRONT
~
3/8-16
OF
OFENGINE
ENGINE ....,...
TIMING
MARKS
A2791.B
A2791-B
FIG.
FIG. 15
15 Aligning
Aligning Timing
Timing Marks
Marks
VIEW LOOKING
LOOKING AT
AT RIGHT
RIGHT
VIEW
SIDE OF
OF ENGINE
ENGINE
SIDE
EXHAUST
EXHAUST MANIFOLD
MANIFOLD (9430)
(9430)
A4081-B
A4081-B
FIG. 14
14 View
View Looking
Looking at
at Right
Right Side
Side of
of Engine
Engine
FIG.
pump. Remove the drive
drive
the water pump.
belt, fan,
fan, or fan and drive clutch, and
and
belt,
water pump
pump pulley.
pulley.
water
3. Disconnect the heater hose at the
the
3.
pump.
water pump.
4. Remove the water pump.
pump.
4.
Installation
1. If a new water pump is to be installed,
1.
remove the heater hose fitting
fitting from
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
of the cylinder
front cover. Use a water pump service
gasket to replace it
2. Coat
Coat the new gasket
gasket on both
both sides
with
with water-resistant
water-resistant sealer
sealer and
position
position it on
on the
the cylinder
cylinder block.
3. Position
Position the water
water pump
pump and
and install
the
the lockwashers
lockwashers and
and attaching
attaching bolts
(the
(the alternator
alternator adjusting
adjusting arm
arm is
secured
secured by
by one
one water
water pump
pump bolt).
bolt).
Torque
Torque the
the bolts
bolts to
to specifications.
4.
4. Connect
Connect the
the radiator
radiator lower
lower hose
hose and
and
the
the heater
heater hose
hose to
to the
the water
water pump.
pump.
5.
5. Install
Install the
the water
water pump
pump pulley
pulley and
and fan.
TTorque
o r q u e tthe
h e bbolts
o l t s eevenly
v e n l y and
and
alternately
alternately to
to specifications.
specifications.
6.
6. Install
Install the
the air
air pump,
pump, power
power steering
steering
and
and air.
air.'conditioner
conditioner drive
drive belts,
belts, ifif so
so
equipped
equipped and
and adjust
adjust the
the tension
tension to
to
specifications.
specifications.
7.
7. Fill
Fill and
and bleed
bleed the
the cooling
cooling system.
system.
Operate
Operate the
the engine
engine until
until normal
normal
operating
operating temperature
temperature isis reached.
reached.
Check
Check for
for leaks
leaksand
and check
check the
the coolant
coolant
level.
level.
CYLINDER
CYLINDER FRONT
FRONT COVER
COVER AND
AND
TIMING
TIMING CHAIN
CHAIN
Removal
Removal
1.1. Drain
Drain the
the cooling
cooling system
system and
and the
the
BACK TO GROUP INDEX
2.
3.
4.
4.
5.
5.
6.
6.
7.
7.
8.8.
crankcase. Disconnect the radiator

radiator
upper hose at the coolant outlet
outlet
housing and the radiator lower hose
at the water pump.
pump. On a vehicle with
disconnect
automatic transmission, disconnect
the transmission oil cooler lines from
from
radiator.
the radiator.
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.
compressor drive belt. If
If
Remove the compressor
so equipped, remove the accessory
drive pulley. Using Tool T-58P-6316B, remove the crankshaft
crankshaft damper.
CID engine, remove the
On a 200 CID
cylinder
cylinder front
front cover
cover attaching
attaching screws
from
from the cover
cover and
and from
from the oil pan.
Pry
Pry the top of
of the
the front
front cover
cover away
from the
the block
block slightly
slightly and, using aa
from
thin
thin bladed
bladed knife,
knife, cut
cut the
the oil
oil pan
pan
gasket
gasket flush
flush with
with the
the front
front face
face of
of the
cylinder
cylinder block.
On aa 250
250 CID
CID engine,
engine, remove
remove the
the oil
oil
On
pan. Remove
Remove the
the cylinder
cylinder front
front cover.
cover.
pan.
Clean any
any gasket
gasket material
material from
from the
the
Clean
surfaces.
surfaces.
Rot
ina
R
o t aate
t e tthe
h e ccrran
a n kksshhaft
a f t in
a
counterclockwise direction
direction (as
(as viewed
viewed
counterclockwise
from
from the
the front)
front) to
to take
take up
up the
the slack
slack
on
on the
the left
left side
side of
of the
the chain.
chain.
Check
deflection
Check timing
timing chain
chain deflection
following
following the
the procedures
procedures given
given in
in Part
Part
21-01.
21-01. IfIf the
thedeflection
deflection exceeds
exceeds 1/2
1/2
inch,
inch, replace
replace the
the timing
timing chain
chain and
and
sprockets.
sprockets.
Crank the
the engine
engine until
until the
the timing
timing
Crank
15.
marksare
arealigned
alignedas
asshown
shown in
in Fig.
Fig. 15.
marks
Remove the
the camshaft
camshaft sprocket
sprocket
Remove
attaching bolt
bolt and
and washer.
washer. Slide
Slide both
both
attaching
sprockets and
and timing
timing chain
chain forward
forward
sprockets
andremove
removethem
themas
asan
anassembly
assembly(Fig.
(Fig.
and
16).
16).
A2792.B
A2792-B
FIG. 16 Timing Chain and Sprockets

Removal
Installation
Installation
1. Clean
Clean and inspect
inspect all parts before
chain after
installation. Oil the timing chain
installing it on the camshaft
camshaft and
installing
crankshaft. Be sure the timing marks
crankshaft.
on the sprockets
sprockets are positioned
positioned as
on
shown in Fig. 15. Install
Install the camshaft
shown
camshaft
sprocket attaching
attaching bolt
bolt and
and washer.
sprocket
Torque the
the bolt
bolt to
to specifications.
Torque
2. Apply
Apply oil-resistant
oil-resistant sealer
sealer to
to aa new
new
2.
cylinder front
fran t cover
cover gasket
gasket and
and
cylinder
position the
the gasket
gasket on
on the
the cylinder
cylinder
position
front cover.
cover. Apply
Apply sealer
sealer to
to the
the
front
exposed area
area of
of the
the gasket.
gasket. On
On aa 200
200
exposed
CID engine,
engine, coat
coat the
the gasket
gasket surface
surface
CID
of the
the oil
oil pan
pan with
with oil
oil resistant
resistant sealer.
sealer.
of
Cut and
and position
position the
the required
required
Cut
portions of
of aa new
new gasket
gasket on
on the
the oil
oil
portions
pan. Apply
Apply sealer
sealer to
to the
the exposed
exposed areas
areas
pan.
of the
the gasket,
gasket, including
including the
the corners
corners
of
where they
they contact
contact the
the front
front cover
cover
where
gasket. On
On aa 250
250 CID
CID engine,
engine, install
install
gasket.
the timing
timing chain
chain snubber
snubber in
in the
the front
front
the
cover (Fig.
(Fig. 17).
17).
cover
Install the
the cylinder
cylinder front
front cover
cover using
using
3.3. Install
18. On
On aa 250
250
the tool
tool shown
shown in
in Fig
Fig 18.
the
CID engine,
engine, no
no adjustment
adjustment isis needed
needed
CID
on the
the chain
chain snubber
snubber (Fig.
(Fig. 17)
17)as
as this
this
on
automaticallyobtained
obtainedduring
during front
front
isisautomatically
ccover
o v e r aalignment.
l i g n m e n t . TTorque
o r q u e tthe
he
attaching bolts
bolts toto specifications.
specifications.
attaching
21-10-9
f
^ C Y L I N D F R FRONT
COVER
7. Disconnect the spark plug wires from

from
the spark plugs and the coil high
tension lead at the coil. Remove the
distributor cap and spark plug wires
Disconnect the
as an assembly. Disconnect
primary
from the coil and
primary wire from
remove it from the retaining clip on
the cylinder head.
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
following
steps 8 thru 11
11 under Cylinder Head
Removal.
lifters and keep them in order so that
they can be installed in their original
locations (Fig. 14). If
If the valve lifters
lifters
are stuck in the bores by excessive
varnish, etc., it may be necessary to
use a claw-type tool to remove the
lifters.
2. Replace the cylinder front cover.
OIL SEAL
T o o / - T53L-200-A
TS3L-200-A
Tool-
TIMING CHAIN SNUBBER
A 3222-A
FIG. 17 Timing Chain Snubber

Installation-250
Installation250 CIO
CID Six
IMLK-6O79-A
OIL SEAL
A2808-A
A2808A
FIG. 19 Crankshaft Front Oil Seal

Replacement
CAMSHAFT
The camshaft
camshaft and related parts are
shown in Fig. 20.
BEARINGS
6263~'7m\""-"""--
---;:;;:--:::::::~'-
6263*
FIG. 18 Aligning Cylinder Front

Cover
4. Lubricate the hub of the crankshaft
crankshaft
damper with Lubriplate or equivalent
to prevent damage to the seal during
installation or initial engine start.
Using Tool T52L6306-AEE, install
crankshaft damper. Torque the
the crankshaft
specifications.
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 under
u n d e r Oil
Oil Pan
Pan
instructions
Installation.
6. Install the fan, pulley and drive belt.
Adjust
Adjust the drive belt.
7. Install the radiator. Connect
Connect the
radiator upper and lower hoses. Refill
the crankcase with the proper grade
and quantity of engine oil before
starting the engine.
9. Start
Start the engine and check
check the
ignition timing. Operate the engine at
fast
fast idle
i d l e and
a n d check
c h e c k all hose
hose
connections and gaskets for leaks.
FRONT OIL SEAL

Remoyal
Removal
1. Remove the cylinder front cover.
1.
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
1.
install the seal. Drive the seal in until
it is fully seated in the recess (Fig. 19).
after installation to be
Check the seal after
sure the spring is properly positioned
in the seal.
BACK TO GROUP INDEX
21-10-9
6261,
.......,,~~
.. :.....
".j
i'
SPACER
WASHER
6278
....
~l
~}T3
CAMSHAFT REAR BEARING
BORE PLUG
CAMSHAFT
6266
6250
6250
371643
s
371643-S
TIMING CHAIN -^6260~626G

AND CAMSHAFT SPROCKET -625<<
-625f1
A2804-A
FIG. 20 Camshaft and Related Parts
Removal
Removal
1.
crankcase. Remove the air cleaner.
from
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 conditioning,
c o n d i t i o n i n g , remove
r e m o v e the
the
air
condenser attaching
attaching bolts, and
condenser
position the condenser to one side. Do
disconnect the condenser
condenser
not disconnect
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
Disconnect the muffler
muffler inlet pipe
from the exhaust manifold. Pull the
muffler
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.
11. Loosen and remove the drive belt, fan

crankshaft
and pulley. Remove the crankshaft
T58P-6316-B.
damper using Tool T58P-63I6-B.
12.Remove
dipstick.
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.
camshaft toward the rear of
14. Push the camshaft
of
the engine. Install a dial indicator so
that the indicator point is on the
camshaft
camshaft sprocket cap screw (Fig.
21). Zero the dial indicator. Position
a large screw driver between the
camshaft
camshaft sprocket and the block. Pull
camshaft forward and release it.
the camshaft
Compare the dial indicator reading
If the end play is
with specifications. If
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.
camshaft thrust plate.
16. Remove the camshaft
Carefully remove the camshaft
camshaft by
Carefully
pulling it toward the front of the
engine. Use
Use caution to
to avoid
damaging the journals and
and lobes.
TOOL-4201-C
A1374-B
FIG. 21
21 Checking Camshaft End
End Play
Installation
Installation
1.
1. Clean the oil passage at the rear of the
cylinder block that feeds the rocker
arm shaft by blowing compressed air
into the
the opening in
in the
the block.
Camshaft
Camshaft lobes are to be coated with
Lubriplate or
the
or equivalent and the
journals lubricated with heavy oil SE
before installation. Carefully
Carefully slide the
camshaft through the bearings.
2.
2. Install the thrust plate with the oil
groove toward the rear of the engine
and torque the attaching bolts to
to
crankshaft
specifications. Replace the crankshaft
front oil seal.
3. Install the
the sprockets and timing
chain, cylinder front
front cover and
crankshaft
crankshaft damper as detailed under
Cylinder Front Cover and Timing
Chain Installation.
4.
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.
oil pump and oil
oil pan.
Install the oil
Install the oil level dipstick.
5.
5. Install the fan, fan pulley and drive
belt. Adjust the belt tension. Install
the radiator and the grille.
6.
6. Dip the base of the valve lifter body
in Lubriplate or
or equivalent. Tappets
or lifters
lifters and
and bores are
are to
to be
be
lubricated with heavy oil SE before
installation. Install the valve lifters in
their original bores.
7.
7. Install the cylinder head, push rods
the val
valve
shaft
and the
ve rocker arm shaft
assembly by following the procedure
under Cylinder Head Installation.
8.
8. Using aa new gasket, install the fuel
pump and connect the flexible fuel
line.
line. Install the oil filter.
filter.
9.
No. 11 piston at
9. Position the No.
at TDC
after the compression stroke. Position
the distributor in the block with the
rotor at the No.
No. I1 firing
firing position
positionand
and
BACK TO GROUP INDEX
21-10-10
21-10-10
the breaker points open. Install the

distributor hold-down clamp.
10. Connect
Connect the
the engine
engine temperature
temperature
10.
wire. Connect the coil
sending unit wire.
primary wire.
wire. Install the distributor
cap. Connect the spark plug wires and
the coil high tension lead.
11. Install the carburetor fuel inlet line,
new clarp.p
clamp on
on the
the filter tubing.
tubing.
using a new
Connect the distributor vacuum line
to the carburetor.
12.
12. On
On aa vehicle
vehicle with
with air
air conditioning,
conditioning,
position the condenser and install the
attaching bolts.
bolts. Install the radiator
and connect the radiator upper and
lower hoses.
13. Connect the
the accelerator control
cable retracting spring. Connect
the accelerator control cable at the
carburetor.
14.
the
14. Fill
Fill the
thecooling
cooling system.
system. Fill
Fill the
crankcase.
15.
15. Start the engine and check and adjust
the ignition timing. Connect the
the
distributor
distributor vacuum line to
to the
the
distributor. Check for coolant and oil
leaks.
leaks. Adjust the engine idle speed
and the idle fuel mixture.
FLYWHEEL
Removal
Removal
1.
1. On
On aa manual-shift
manual-shift transmission,
remove the
the transmission, clutch
pressure plate and disc,
disc, following the
procedures in
in Volume One.
One. Group
16-Clutch.
the
16Clutch. Do
Do not
not drain the
transmission.
On aa vehicle with an
an automatic
transmission,
t r a n s m i s s i o n , re.move
r e m o v e tthe
he
transmission and converter housing
following the procedure in
in Volume
One, Group
G r o u p 17-Automatic
17 A u t o m a t i c
Transmission. Do
the
Do not
not drain the
transmission.
2. Refer to
to Part 21-01, Cleaning and
2.
for flywheel
flywheel face
face runout
runout
Inspection, for
Remove the
checking procedure. Renlove
the
flywheel attaching bolts and remove
flywheel.
the flywheel.
Installation
Installation
1.
1. Clean and inspect all
all parts before
installation. Position the flywheel on
crankshaft flange. Apply
the crankshaft
to the attaching
oil-resistant sealer to
to
bolts. Install and torque the bolts to
sequence across from each other to
to
specifications.
2.
2. On
On aa manual-shift
install the clutch pressure plate, disc,
the
procedures in
in Volume One, Group
16Clutch.
16-Clutch.
automatic
transmission, install the converter
housing and transmission following
the procedure in Volume One,
One, Group
17-Automatic
17Automatic Transmission. It
It isis
not necessary
the
necessary to
to adjust
adjust the
transmission linkage when it has been
been
removed
r e m o v e d only
only for
for flywheel
flywheel
replacemen
1.
replacement.
Inspection procedures are outlined

under Flywheel Cleaning and Inspection
in Part 21-01.
Removal
Removal
1.
1. Remove the
the transmIssIon,
procedures in
16-Clutch.
16Clutch.
2.
59 L-l OO-B and
and
2. Using Tools T
T59L-100-B
T58L-I01-A, remove the
T58L-1O1-A,
the pilot
Bearing (Fig.
(Fig. 22) and adapter.
Too/-T58L- 70 7-A
Too/-T59L-700-B
A2837-A
A2837A
FIG. 22 Removing Clutch Pilot

Bearing
Installation
Installation
1.
1. A new clutch pilot bushing normally
does not
not require lubrication.
lubrication.
However, due to long storage periods,
it may lose some of
of the lubricant
pressed into the
bushing in
in
pressed
the bushing
manufacture.
manufacture. It
It is
is therefore
therefore
recommended that the new bushing
be soaked in
in SAE-30 non-detergent
type motor oil for a minimum of onehalf hour before installation. Do not
of any type.
lubricate with grease of
2. Using Tool T65L-7600-A, install the
pilot service bushing (Fig. 23).
A2838-A
FIG. 23
23 Installrng
Installmg Clutch Pilot Service
Bushing
3. Install the clutch pressure plate, disc,

the
procedure in
16Clutch.
16-Clutch.
21-10-11
21-10-11
200
200 and
and 250
250 CID
CID Six-Cylinder
Engines
CAMSHAFT REAR
REAR BEARING
BEARING BORE
BORE
CAMSHAFT
PLUG
PLUG
Removal
Remoyal
On aa vehicle
vehicle with
manual-shift
1.1. On
transmission, slide
slide the
the transmission
transmission
transmission,
to the
the rear
rear and
and remove
remove the
the 'clutch
clutch
to
pressure plate
plate and
and disc
disc following
following the
the
pressure
procedure in
in Volume
Volume One,
One, Group
Group
procedure
16Clutch.
16-Clutch.
On aa vehicle
vehicle with
with automatic
automatic
On
t r a n s m i s s i o n , remove
r e m o v e the
the
transmission,
transmission and
and converter
converter housing
housing
transmission
following the
the procedure
procedure in
in Volume
Volume
following
O n e , Group
G r o u p 17-Automatic
17 A u t o m a t i c
One,
Transmission.
Transmission.
2. Remove
Remove the
the flywheel
flywheel attaching
attaching bolts
bolts
2.
and remove
remove the
the flywheel
flywheel and
and engine
engine
and
rear cover
cover plate.
plate.
3. Remove
Remove the
the plug
plug as
as detailed
detailed in
in Part
Part
3.
21-01.
21-01.
Installation
InstaJ/ation
new plug as
as det~ed
detailed in
in Part
Part
1.1. Install aa new
21-01.
21-01.
2. Install the engine rear cover plate,
plate,
2.
apply oil-resistant sealer to the
the
the
flywheel bolts and install the
flywheel.
manual-shift
On aa vehicle with aa manual-shift
clutch
disc, and transmission
pressure plate, disc,
following the procedure in Volume
16Clutch.
One, Group 16-Clutch.
automatic
transmission install the transmission
and converter housing following the
procedure in Volume One, Group
17Automatic Transmission.
17-Automatic
OIL PAN
Removal
Remoyal
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
gasket surfaces
surfaces of
of the block
block
and oil
oil pan.
pan. Be sure to
to clean the
the seal
retainer
retainer grooves in the cylinder
cylinder block
block
and
and oil
oil pan.
pan. The
The oil
oil pan
pan has
has aa twotwopiece
piece gasket.
gasket. Coat
Coat the
the block
block surface
surface
and
and the
the oil
oil pan
pan gasket
gasket surface
surface with
with oil
oil
resistant
resistant sealer.
sealer. Position
Position the
the oil
oil pan
pan
gaskets
gaskets on
on the
the cylinder
cylinder block
block (Fig.
(Fig.
25).
25).
2.
2. Position
Position the
the oil
oil pan
pan front
front seal
seal on
on the
the
cylinder
cylinder front
front cover.
cover. Be
Be sure
sure the
the tabs
tabs
on
on the
the seal
seal are
are over
over the
the oil
oil pan
pan gasket.
gasket.
3.
3. Position
Position the
the oil
oil pan
pan rear
rear seal
seal on
on the
the
rear
rear main
main bearing
bearing cap.
cap. Be
Be sure
sure the
the
tabs
tabs on
on the
the seal
seal are
are over
over the
the oil
oil pan
pan
gasket.
gasket.
4.
4. Hold
Hold the
the oil
oil pan
pan in
in place
place against
against the
the
block
block and
and install
install aa bolt,
bolt, finger
finger tight,
tight,
on
on each
each side
side of
ofthe
the oil
oil pan.
pan. Install
Install the
the
remaining
remaining bolts.
bolts. Torque
Torque the
the bolts
bolts
from
from the
the center
center outward
outward in
in each
each
direction
direction to
to specifications.
specifications.
BACK TO GROUP INDEX
5.5. Install
Install the
the oil
oil level
level dipstick.
dipstick. Fill
Fill the
the
crankcase
crankcase with
with the
the proper
proper grade
grade and
and
quantity of
of engine
engine oil.
oil. Operate
Operate the
the
quantity
engine and
and check
check for
for oil
oil leaks.
leaks.
engine
A3169A
FIG. 24
24 200
200 CID
CID Six
Six Oil
Oil Pump
Pump Inlet
FIG.
Tube Installed
Installed
Tube
OIL PAN GASKET
FRONT SEAL
A3168-A
-200 CID
CID Six
Six Oil
Oil Pan
Pan
FIG. 25
25 200
FIG.
Gaskets and
and Seals
Seals Installed
Installed
Gaskets
OIL
OIL PUMP
PUMP
Removal
Removal
1. Remove
Remove the
the oil
oil pan
pan and
and related
related parts
parts
1.
as
as outlined
outlined under
under Oil
Oil Pan
Pan Removal.
Removal.
2. Remove
Remove the
the oil
oil pump
pump attaching
attaching bolts
bolts
2.
and
and remove
remove the
the oil
oil pump,
pump, gasket,
gasket, and
and
intermediate drive
drive shaft.
shaft.
intermediate
21-10-11
21-10-11
Installation
Installation
1.1. Prime
Prime the
the oil
oil pump
pump by
by filling
filling the
the inlet
inlet
port
port with
with engine
engine oil.
oil. Rotate
Rotate the
the pump
pump
shaft
shaft to
to distribute
distribute the
the oil
oil within
within the
the
pump
pump body.
body.
2.2. Position
Position the
the intermediate
intermediate drive
drive shaft
shaft
into
into the
the distributor
distributor socket.
socket.
3.3. Position
Position aa new
new gasket
gasket on
on the
the pump
pump
housing.
housing. Insert
Insert the
the intermediate
intermediate drive
drive
shaft
shaft into
into the
the ojl
oil pump.
pump. Install
Install the
the
pump
pump and
and shaft
shaft as
as an
an assembly.
assembly. Do
Do
not
not attempt
attempt to
to force
force the
the pump
pump into
into
position
position ifif itit will
will not
not seat
seat readily.
readily. The
The
drive
drive shaft
shaft hex
hex may
may be
be misaligned
misaligned
with
with the
the distributor
distributor shaft.
shaft. To
To align,
align,
rotate
rotate the
the intermediate
intermediate drive
drive shaft
shaft
into
into aa new
new position.
position. Torque
Torque the
the oil
oil
pump
p u m p attaching
a t t a c h i n g screws
s c r e w s to
to
specifications.
specifications.
4.
4. Install
Install the
the oil
oil pan
pan and
and related
related parts
parts as
as
outlined under Oil
Oil Pan Installation.
Installation.
CRANKSHAFT
CRANKSHAFT REAR
REAR OIL
OIL SEAL
A
A split-lip type
type crankshaft rear oil
seal is
is used for replacement on all
all
engines.
engines. If replacement is necessary, this
type
type of seal must
must be
be used.
used. The complete
seal can be replaced without removing
the crankshaft. Refer to Part 21-01
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
journals that
that have been
for use on journals
refinished.
Removal
Remoyal
1. Drain the crankcase. Remove the oil
level dipstick. Remove the oil pan and
related parts.
2. Remove the oil pump
pump inlet tube and
pump.
the oil pump.
3. Replace
Replace one
one bearing
bearing at a time,
time, leaving
3.
other bearings securely
securely fastened.
the other
Remove the
the main
main bearing
bearing cap
cap to
to
Remove
which new
new bearings
bearings are
are to
to be
which
installed.
installed.
Insert the
the upper
upper bearing
bearing removal
removal tool
tool
4. Insert
4.
(Tool 6331)
6331) in
in the
the oil
oil hole
hole in
in the
the
(Tool
crankshaft.
crankshaft.
5. Rotate
Rotate the
the crankshaft
crankshaft in
in the
the direction
direction
5.
ofengine
engine rotation
rotation to
to force
force the
the bearing
bearing
of
out of
of the
the block.
block.
out
InstaJ/ation
Installation
1. Clean
Clean crankshaft
crankshaft journals.
journals. Inspect
Inspect
1.
journals and
and thrust
thrust faces
faces (thrust
(thrust
journals
bearing) for
for nicks,
nicks, burrs
burrs or
or bearing
bearing
bearing)
pickup that
that would
would cause
cause premature
premature
pickup
bearing wear.
wear. When
When replacing
replacing
bearing
standard bearings
bearings with
with new
new bearings,
bearings,
standard
fit bearings
bearings to
to minimum
minimum specified
specified
fit
clearance. IfIf the
the desired
desired clearance
clearance
clearance.
cannot be
be obtained
obtained with
with aa standard
standard
cannot
21-10-12
21-10-12
2.
3.
4.
4.
5.
5.
6.
6.
7.
7.
8.8.
21-10-12
21-10-12
200 and
and 250
250 CID
CID Six-Cylinder
Engines
200
bearing, try one half

half of
of aa 0.001
0.001 or
or
combination
0.002 inch undersize in combination
with a standard
standard bearing
bearing to
to obtain
obtain the
the
proper clearance. Be certain
certain that
proper
bearings and that the bearing bore
bore in
in
Foreign
the block or cap are clean. Foreign
material under a bearing insert can
can
cause bearing failure.
To install
!nstall the upper main bearing,
of the bearing over
over
place the plain end of
the shaft
shaft on the locking tang side of
of
the block and partially install the
bearing so that Tool 6331 can be
be
inserted in the oil hole in the
inserted
crankshaft. With
With Tool
Tool 6331
crankshaft.
positioned in the oil hole in the
'crankshaft,
crankshaft in
in
crankshaft, rotate the crankshaft
of engine
the opposite direction of
rotation until the bearing seats itself.
Remove the tool.
Install the cap bearing.
Select fit the bearings for proper
clearance following procedures under
Fitting Main and Connecting Rod
Bearings in Part 21-01.
If the rear main bearing is replaced,
replace the oil seal in the rear main
bearing cap as described under
Crankshaft
Crankshaft Rear Oil Seal in Part
21-01.
21-01.
Afte,r
After the bearing has been fitted,
fitted,
apply aa light coat of engine oil to the
journal and bearings,
bearings, then install the
bearing cap.
cap. Torque the cap bolts to
specifications. Repeat the procedure
for the remaining bearings that
require replacement.
replacement.
If the
the thrust bearing cap (No.5
(No. 5 main
main
bearing)
bearing) has
has been removed,
removed, install it
as
as follows:
follows:
Install the
the thrust bearing cap
cap with
the bolts finger-tight. Pry the
the
crankshaft forward against the
the thrust
surface
surface of the upper half of the
bearing
bearing (Fig.
(Fig. 26).
26). Hold the
the crankshaft
crankshaft
forward
forward and
and pry
pry the
the thrust bearing
cap
cap to
to the
the rear.
rear. This
This will
will align
align the
the
thrust
thrust surfaces
surfaces of
of both
both halves
halves of
of the
the
bearing.
bearing. Retain
Retain the
the forward
forward pressure
pressure
on
on the
the crankshaft.
crankshaft. Torque
Torque the
the cap
cap
bolts
bolts to
to specification.
specification.
Clean
Clean the
the oil
oil pump
pump inlet
inlet tube
tube screen.
screen.
Prime
Prime the
the oil
oil pump
pump by
by filling
filling the
the inlet
opening
opening with
with oil
oil and
and rotating
rotating the
the
pump shaft
shaft until
until oil emerges
emerges from
from the
the
pump
outlet opening.
opening. Then
Then install
install the
the oil
oil
outlet
pump and
and the
the inlet
inlet tube,
tube, following
pump
Oil Pan
Pan
iinstructions
n s t r u c t i o n s uunder
n d e r Oil
Installation.
the gasket
gasket surfaces
surfaces of
of the
the block
block
9. Clean the
Be sure to
to clean
clean the
the seal
seal
and oil pan. Be
of the
the block and oil
oil pan.
pan. The
The
grooves of
oil pan has a two-piece gasket. Coat
Coat
the block side of
of the gasket with
with an
an
oil resistant sealer. Position
Position the oil
oil
pan gasket on the block, then install
the oil pan and related parts following
iinstructions
n s t r u c t i o n s uunder
n d e r Oil
Oil Pan
Pan
Installation. Install
Install the oil level
dipstick.
10. Fill
Fill the
the crankcase to
to the
the proper level
recommended engine oil.
oil.
with the recommended
Start the engine and check for oil
pressure. Operate the engine at fast
idle and check for oil leaks.
IEARINGS
CONNECTING ROD BEARINGS
Removal
Removal
1.
1. Follow steps 1 and 2 under Main
Bearing Replacement.
crankshaft until the
2. Turn the crankshaft
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
Installation
1.
and cap are clean. Foreign material
failure.
bearing and cause a failure.
2. Clean crankshaft
crankshaft journal. When
2.
replacing standard bearings with new
bearings,
bearings, fit the bearing to minimum
specified clearance.
3.
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
4.
crankshaft
down firmly on the crankshaft
journal.
journal.
5. Select
Select fit the bearings for proper
5.
Bearings in
in Part 21-01.
21-01.
Bearings
6. After
After bearing
bearing has
has been
been fitted, clean
6.
and apply
apply light coat of engine
engine oil
oil SE
and
to journal and bearings.
bearings. Install
Install
to
connecting
connecting rod
rod cap.
cap. Be
Be sure
sure
connecting
connecting rod
rod bolt
bolt heads
heads are
are
properly
properly seated
seated in
in connecting
connecting rod.
rod.
Torque
Torque nuts
nuts to
to specifications.
specifications.
7. Repeat
Repeat the
the procedure
procedure for
for the
the
7.
remaining connecting
connecting rods
rods that
that
remaining
require
require new
new bearings.
bearings.
8.
8. Install
Install the
the oil
oil pump
pump assembly
assembly and
and oil
oil
pan
pan following
following the
the procedure
procedure under
under
Main
Main Bearings.
Bearings.
PISTONS
PISTONS AND
AND CONNECTING
CONNECTING
RODS
RODS
Removal
Removal
Drain the cooling
cooling system
system and
and the
the
1. Drain
crankcase.
2. Refer
Refer to Cylinder
Cylinder Head
Head Removal
Removal and
and
remove the cylinder
cylinder head
head and
and related
related
parts.
3. Remove the oil pan and related
related parts.
parts.
Remove the oil pump inlet tube and
and
the oil pump.
pump.
crankshaft until the piston
piston
to be removed is at the bottom of
of the
stroke, then place a cloth
cloth on the
piston head to collect the cuttings.
Remove any ridge and/or
and/or deposits
from the upper end of
of the cylinder
bores. Remove the cylinder ridge with
a ridge cutter. Follow the instructions
furnished
furnished by the tool manufacturer.
Never cut into the ring travel area in
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
6.
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
Installation
1. Clean the oil pump inlet tube screen,
1.
and the oil pan and block gasket
surfaces.
2. Oil
Oil the
the piston
piston rings,
rings, pistons
pistons and
and
2.
cylinder walls
walls with
with light
light engine
engine oil.
cylinder
oil.
3. Be
Be sure
sure to
to install
install the
the pistons
pistons in
in the
3.
same cylinders
cylinders from
from which
which they
they were
same
removed, or
or to
to which
which they
they were
were fitted.
fitted.
removed,
The connecting
connecting rod
rod and
and bearing
bearing caps
caps
The
THRUST
BEARING
PRY CRANKSHAFT FORWARD
PRY CAP BACKWARD
TIGHTEN CAP
A2795-A
A2795-A
FIG. 26
26 Typical
Typical Thrust
Thrust Bearing
Bearing Alignment
Alignment
FIG.
BACK TO GROUP INDEX

21-10-13
21-10-13
21-10-13
21-10-13
200 and
and 250
250 CID
CIO Six-Cylinder
Engines
200
are numbered
numbered from
from 11 to
to 6,
6, beginning
beginning
are
at the
the front
front of
of the
the engine.
engine. The
The
at
numbers on
on the
the connecting
connecting rod
rod and
and
numbers
bearing cap
cap must
must be
be on
on the
the same
same side
side
bearing
when installed
installed in
in the
the cylinder
cylinder bore.
bore. If
If
when
connecting rod
rod is transferred
transferred from
aa connecting
one block
block or
or cylinder
cylinder to
to another,
another, new
new
one
bearings should
should be
be fitted
fitted and
and the
bearings
connecting rod
rod should
should be
be numbered
numbered
connecting
to correspond
correspond with
with the
the new
new cylinder.
to
Make sure
sure the
the ring
ring gaps are
are properly
properly
4. Make
spaced around
around the
the circumference
circumference of
of
spaced
the piston
piston (Fig. 27). Install
Install a piston
piston
the
ring compressor
compressor on
on the
the piston
piston and
ring
push the piston
piston in with
with a hammer
push
handle until it is slightly
slightly below the top
handle
of the cylinder
cylinder (Fig. 28). Be sure to
of
connecting rods to avoid
guide the connecting
damaging the crankshaft
damaging
Install the piston with the notch in the
dome of
of the piston toward the front
of the engine (Fig. 30).
of
crankshaft jjournal.
Install the
the
crankshaft
o u r n a l . Install
connecting rod
rod cap.
cap. Torque
Torque the
the nuts
nuts
connecting
to
to specifications.
8. After
After the
the piston
piston and
and connecting
connecting rod
rod
assemblies
assemblies have
have been
been installed,
installed, check
check
the
the connecting
connecting rod
rod side
side clearance
clearance on
on
each
each crankshaft
crankshaft journal
journal (Fig.
(Fig. 29).
29).
5.
6.
6.
A2806-A
FIG.
FIG. 29
29 Typical Connecting Rod Side
Clearance
Clearance
7.
8.
FRONT OF ENGINE
OIL RING SPACER

OIL
OIL RING
OIL
RING
SEGMENT
SEGMENT
OIL RING
OIL
SEGMENT
SEGMENT
INDENTATION
NOTCH
A1392-A
A1392-A
FIG.
FIG. 30 Typical Piston and
Connecting Rod Assembly
PIN GORE
C PISTON
COMPRESSION RING
RING
FRONT OF
OF ENGtNE
ENGINE
Cf.
~ COMPRESSION
COMPRESSION
RING
RING
A2811-A
A2811-A
FIG. 27 Piston Ring

Ring Gap Spacing
NOTCH
NOTCH TO
TO FRONT
FRONT OF
OF E~GINE
ENGINE
FIG.
FIG. 28
28 Piston
Piston Installation
Installation
5.
5. Check
Check the
the clearance
clearance of
of each
each bearing,
bearing,
following
following the
the procedure
p r o c e d u r e under
under
Connecting
Connecting Rod
Rod Bearings.
Bearings.
6.
6. After
After the
the bearings
bearings have
have been
been fitted,
fitted,
apply
apply aa light
light coat
coat of
of engine
engine oil
oil to
to the
the
journals
journals and
and bearings.
bearings.
7.
7. Turn
Turn the
the crankshaft
crankshaft throw
throw to
to the
the
bottom
bottom of
of the
the stroke,
stroke, then
then push
push the
the
piston
piston all
all the
the way
way down
down until
until the
the
connecting
connecting rod
rod bearing
bearing seats
seats on
on the
the
BACK TO GROUP INDEX
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
following
the instructions under Cylinder Head
Installation.
11. Fill the crankcase with proper grade
oil.
of oil.
12. Start the engine and check for oil
pressure. Operate the engine at fast
fast
idle and check for oil and coolant
coolant
leaks.
leaks.
13. Check and adjust the ignition timing,
timing,
13.
fuel
engine idle speed and the fuel
mixture.
mixture.
14.
cleaner.
CRANKSHAFT
A2796-A
A2796-A
4.
4.
Removal
Removal
The
The crankshaft
crankshaft and
and related
related parts
parts are
are
shown
31.
shown in
in Fig.
Fig. 31.
With engine
engine removed
removed from
from vehicle
vehicle
1.1. With
and
and placed
placed on
on aa work
work stand,
stand, remove
remove
the oil
oil level
level dipstick.
dipstick.
the
2.
2. Remove
Remove the
the accessory
accessory drive
drive pulley
pulley (if
(if
so equipped).
equipped). Remove
Remove the
the crankshaft
crankshaft
so
damper
damper attaching
attaching bolt
bolt and
and washer.
washer.
Remove the
the crankshaft
crankshaft vibration
vibration
Remove
damper using
using Tool
Tool T58P-6316-B.
T58P-6316-B.
damper
3.
3. Remove
Remove the
the cylinder
cylinder front
front cover
cover and
and
air
air conditioning
conditioning idler
idler pulley
pulley assembly
assembly
(if
(if so
so equipped).
equipped). Remove
Remove the
the cover
cover
gasket.
gasket.
Check
Check the
the timing
timing chain
chain deflection;
then
then remove
remove the
the timing
timing chain
chain and
and
sprockets
sprockets as
as detailed
detailed under
under Cylinder
Cylinder
Front
Front Cover
Cover and
and Timing
Timing Chain
Chain
Removal.
Removal.
Invert
Invert the
the engine
engine on
on the
the work
work stand.
Remove
Remove the
the flywheel. Remove
Remove the
the oil
oil
pan
pan and
and gasket.
gasket. Remove
Remove the
the oil
oil pump.
pump.
Make
Make sure
sure all
all bearing
bearing caps
caps (main
(main and
and
connecting
connecting rod) are
are marked
marked so that
they
they can
can be installed
installed in their
their original
locations. Turn
Turn the
the crankshaft
crankshaft until
the connecting
connecting rod
rod from
from which
which the
cap
cap is being
being removed
removed is down.
Remove the connecting
connecting rod cap. Push
the
the connecting
connecting rod
rod and
and piston
assembly up in the cylinder. Repeat
for the remaining caps.
Remove the main bearing
bearing caps.
Carefully
Carefully lift
lift the crankshaft
crankshaft out of
of the
block
block so that
that the thrust
thrust bearing
surfaces
surfaces are not damaged. Handle the
crankshaft
crankshaft with care to avoid possible
fracture
fracture or damage to the finished
surfaces.
Installation
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.
Clean the rear
rear journal
journal oil seal
4. Clean
grooves. Install a new rear journal oil
seal in the block and rear main
bearing cap.
oil-resistant
5. Apply a thin coating of oil-resistant
sealer to the rear main bearing cap at
the rear of the top mating surface. Do
forward
not apply sealer to the area forward
groove.
of the oil slinger groove.
6. If the crankshaft
crankshaft main bearing
bearing
6.
journals have been refinished to a
correct
definite undersize, install the correct
the
undersize bearings. Be sure the
are
bearing inserts and bearing bores are
the
clean. Foreign material under the
and
inserts will distort the bearing and
failure.
cause aa failure.
7. Place the upper main bearing inserts
inserts
7.
in position in
in the bores with the tang
tang
in
fitting the
the slot
slot provided.
provided.
fitting
8. Install
Install the
the lower
lower main
main bearing
bearing inserts
inserts
8.
in the
the bearing
bearing caps.
caps.
in
9. Carefully
Carefully lower
lower the
the crankshaft
crankshaft into
into
9.
place. Be
Be careful
careful not
not to
to damage
damage the
the
place.
bearing surfaces.
surfaces.
bearing
10. Check
Check the
the clearance
clearance of
of each
each main
main
10.
bearing. Select
Select fit
fit the
the bearings
bearings for
for
bearing.
p r o p e r clearance
c l e a r a n c e following
following
proper
procedures under
under Fitting
Fitting Main
Main and
and
procedures
Connecting Rod
Rod Bearings
Bearings in
in Part
Part
Connecting
21-01.
21-01.
11. After
After the
the bearings
bearings have
have been
been fitted,
fitted,
11.
apply aa light
light coat
coat of
of engine
engine oil
oil to
to the
the
apply
21-10-14
21-10-14
21-10-14
21-10-14
200
200 and
and 250
250 CID
CID Six-Cylinder
Engines
CLUTCH
CLUTCHPILOT
PILOTBEARING
BEARING
7600
7600
RING
RINGGEAR
GEAR
THRUST BEAR ING-6342
BEARING INSERTS
6333
FRONT
FRONT
KEY -372854.S
\,:::::?
WASHER
WASHER
6378
6378
"'~.
~'
/~
REAR SEAL
6701 (2)
CRANKSHAFT
6303
\
CRANKSHAFT GEAR-6306
THRUST BEARING-6342
SCREW-6A340 /
SCREW-6A340
MAIN
MAIN BEARING
BEARING CAPS
CAPS
DAMPER-6312
DAMPER-6312
FRONT~:::
6700
6700
BOLT-6345SOL
T- 6 3 4 5 - - '
A2230-E
A2230-E
31 -200
2 0 0 CID
CID Six Crankshaft and
and Related Parts
FIG. 31
journals and bearings. Install all the

bearing caps, except the thrust
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.
specifications.
12. Install the thrust
thrust bearing cap with the
bolts finger-tight.
13. Pry
Pry the crankshaft
crankshaft forward
forward against
the thrust
of the upper
upper half
half of
of
thrust surface
surface of
the bearing
bearing (Fig. 26).
26).
14. Hold
Hold the
the crankshaft
crankshaft forward
forward and
and pry
pry
the
the thrust
thrust bearing
bearing cap
cap to
to the
the rear.
This
of
This will
will align
align the
the thrust
thrust surfaces
surfaces of
both
both halves
halves of
of the
the bearing.
bearing.
15.
15. Retain
Retain the
the forward
forward pressure
pressure on
on the
the
crankshaft.
crankshaft. Torque
Torque the
the cap
cap bolts
bolts to
to
specifications.
specifications.
16.
16. Force
Force the
the crankshaft
crankshaft toward
toward the
the rear
rear
of
of the
the engine.
engine.
17.
17. Install
Install aa dial
dial indicator
indicator so
so that
that the
the
contact
contact point
point rests
rests against
against the
the
crankshaft
crankshaft flange
flange and
and the
the indicator
indicator
axis
parallel to
to the
the crankshaft
crankshaft axis
axis
axis isis parallel
(Fig.
(Fig. 32).
32).
18.
18. Zero
Zero the
the dial
dial indicator.
indicator. Push
Push the
the
crankshaft
crankshaft forward
forward and
and note
note the
the
reading
reading on
on the
the dial.
dial.
19.
19. IfIfthe
the end
end play
play exceeds
exceeds specifications,
specifications,
replace
the end
end
replace the
the thrust
thrust bearing.
bearing. IfIfthe
play
less than
than the
the minimum
minimum limit,
limit,
play isis less
inspect
inspect the
the thrust
thrust bearing
bearing faces
faces for
for
scratches,
scratches, burrs,
burrs, nicks
nicks or
or dirt.
dirt. IfIfthe
the
thrust
thrust faces
facesare
arenot
notdamaged
damagedor
ordirty,
dirty,
BACK TO GROUP INDEX
Too/ T53L-200-A
OIL SEAL
A2808.A
A2808-A
FIG.
FIG. 32
32 Crankshaft
Crankshaft End
End Play
Play
they probably
probably were
were not
not aligned
aligned
they
properly. Install
Install the
the thrust
thrust bearing
bearing
properly.
and align
align the
the faces
faces following
following the
the
and
recommended
recommended procedure
procedure (steps
(steps 12,
12,
13,
13, 14
14 and
and 15).
15). Check
Check the
the end
end play
play
which
which should
should be
be within
specifications.
20.
20. Install
Install new
new bearing
bearing inserts
inserts in
in the
the
connecting
connecting rods
rods and
and caps.
caps. Check
Check the
the
clearance
of each
each bearing
bearing following
following
clearance of
the
the procedure
procedure under
under Connecting
Connecting Rod
Rod
Bearings.
Bearings.
21.
21. IfIf the
the bearing
bearing clearances
clearances are
are to
to
specifications, apply
apply aa light
light coat
coat of
of
specifications,
engine oil
oil to
to the
the journals
journals and
and
engine
bearings.
bearings.

crankshaft throw to the
bottom of the stroke. Push the piston
all the way down until the rod bearing
crankshaft journal.
seats on the crankshaft
23. Install
Install the connecting
connecting rod cap.
24. After
After the piston and connecting rod
assemblies have been installed, check
the connecting
connecting rod side clearance on
each connecting
connecting rod
rod crankshaft
each
crankshaft
journal.
journal.
25. Turn
Turn the engine on the work
work stand
stand so
so
is up.
up. Install
Install the
that the
the front
front end
end is
that
timing chain
chain and
and sprockets, cylinder
cylinder
timing
front cover
cover and
and crankshaft
crankshaft pulley
pulley or
or
front
damper, as
as detailed
detailed under
under Cylinder
Cylinder
damper,
Front Cover
Cover and
and Timing
Timing Chain
Chain
Front
Installation.
Installation.
26. Clean
Clean the
the oil
oil pan,
pan, oil
oil pump,
pump, and
and oil
oil
26.
pump screen.
screen.
pump
27. Prime
Prime the
the oil
oil pump
pump by
by filling
filling the
the inlet
inlet
27.
opening with
with oil
oil and
and rotating
rotating the
the
opening
pump shaft
shaft until
until oil
oil emerges
emerges from
from the
the
pump
outlet opening.
opening. Install
Install the
the oil
oil pump
pump
outlet
1, 22 and
and 33 under
under Oil
Oil
following steps
steps 1,
following
Pump Installation.
Installation. Install
Install the
the oil
oil pan
pan
Pump
following steps
steps 22thru
thru 55under
under Oil
Oil Pan
Pan
following
Installation.
Installation.
28.Position the
the flywheel
flywheel on
on the
the
28.Position
crankshaft. Apply
Apply oil-resistant
sealer
crankshaft.
to the
theflywheel
flywheel attaching
attachingbolts.
bolts. Install
Install
to
and torque
torque the
the bolts
bolts to
to specifications.
specifications.
and
On aa flywheel
flywheel for
for aa manual-shift
manual-shift
On
transmission, locate
locate the
the clutch
clutch disc
disc
transmission,
and install
install the
the pressure
pressure plate.
plate.
and
21-10-15
21-10-15
200 and 250 CtD

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
(if
adjust the
so equipped). Install and adjust
drive belt and accessory belts to
specifications.
30. Remove the engine from the work
stand and install it in the vehicle,
f o l l o w i n g engine
e n g i n e installation
installation
following
instructions.
UfcTAIL-l,-2or -3
UI::TAIL.l,2or3
EXPANDING COLLET
THRUST BEARING
DETAIL-1,-2 or -3
BACK-UP NUT
EXPANDING MANDREL
DETAIL
PULLING NUT
CAMSHAFT BEARING
camshaft bearings are available

The camshaft
pre-finished to size and require no
pre-finished
reaming for standard
standard and 0.015 inch
undersize journal diameters.
Removal
Removal
1. Remove the engine following the
1.
procedures under Engine Removal
and Installation. Place the engine on
a work stand and remove the flywheel
flywheel
and the camshaft. Remove the rear
bearing bore plug.
camshaft bearings with
the tool shown in Fig. 33.
3. Select the proper size expanding collet
On the
and back-up nut and assemble on
expanding
e x p a n d i n g mandrel.
m a n d r e l . With
With the
expanding collet collapsed, install the
collet assembly in the camshaft
camshaft
bearing, and tighten the back-up nut
on the expanding mandrel until the
camshaft bearing.
collet fits the camshaft
Assemble the puller
puller screw and
4. Assemble
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
front
bearing or journal. Tighten
bearing
Tighten the
pulling nut against the thrust bearing
and pulling plate to remove the
camshaft
camshaft bearing. Be sure to hold a
wrench on the end of the puller screw
to prevent it from turning.
procedure for each
5. Repeat
Repeat the procedure
bearing. To remove the front bearing,
install the puller screw from the rear
of the cylinder block.
Installation
Installation
1. Position the new bearings at the
1.
bearing bores, and press them in place
DETAIL-5
PULLER SCREW
CAMSHAFT BEARING ( LOOSE )

DETAII.4
DETAII -4
PULLING PLATE
DETAIL-6 or
or -77
DETAIL6
PULLER SCREW EXTENSION
ITool-T65L-6250-A I
T001- T6SL.62S0.A
A2813-A
FIG. 33 Typical Camshaft Bearing Replacement
33. Be
with the tool shown in Fig. 33.
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.
camshaft, crankshaft,
crankshaft,
3. Install the camshaft,
flywheel and related parts, following
following
the appropriate procedures. Do not
check connecting
connecting rod and main
bearing
clearances as a part
of
bearing clearances
part of
Camshaft Bearing Replacement.
Replacement.
Camshaft
Install the engine in the vehicle.
OIL FILTER
Removal
Removal
1.
1. Place a drip pan under the filter.
filter.
Unscrew the filter from the adapter
fitting. Clean the adapter filter recess.
Installation
Installation
1.
1. Add one quart of the proper type 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,
1/2 turn.
then advance it 1/2
2. Operate the engine at fast idle, and
If oil leaks are
check for oil leaks. If
evident, perform
perform the necessary repairs
to correct the leakage. Check the oil
level and fill the crankcase
c r a n k c a s e if
if
necessarv.
necessary.

When installing nuts or bolts that
m u s t be torqued
t o r q u e d ((refer
r e f e r to the
the
must
Specification at the end of this Part for
Specification
BACK TO GROUP INDEX
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 and inspection
procedures.
21-10-16
VALVE ROCKER ARM SHAFT

ASSEMBLY
Disassembly
Disassembly
1.
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
off the shaft. Be sure to
identify
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
to knock out the plug on the
opposite end. Working from the open
end, knock out the remaining plug.
Assembly
Assembly
1.
1. All rocker arms and rocker arm shafts
shafts
are to be lubricated with heavy oil SE
before assembly.
.before
2. If
If the plugs were removed from the
ends of the shaft, use aa 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.
shaft.
one'end
4. IInstall
n s t a l l the valve rrocker
o c k e r arms,
arms,
in the order
supports, and springs in
shown in Figure 34. Be sure the oil
holes in
in the shaft
shaft are facing
facing
downward. Complete the assembly by
installing the remaining spring
washer and pin.
2. Remove the push rod cup, plunger

and spring.
3. Invert the plunger
plunger assembly and
remove the check valve retainer by
carefully prying up on it with a screw
carefully
driver. Remove the check valve and
spring. Refer
for
Refer to
to Part
Part 21-01 for
Cleaning, Inspection and Testing
Procedures.
Assembly
Assembly
A typical hydraulic valve lifter
lifter
assembly is shown in Fig. 35.
SPRING
VALVE DISC RETAINER
VALVE DISC
LOCK RING
BODY
PUSH
ROD
CUP
PLUNGER
SPRING
\
LIFTER ASSEMBLY
-6500
ASSEMBLY-6500
A1835-B
A
18358
FIG. 35 Typical Valve Lifter Assembly
1.
1. Place the plunger in
in the inverted
position on aa clean work bench.
2. Place the check valve in position over
of the
the oil hole on the bottom of
~BOLT--6A527
'*~
,ij
1/1 j:"OJA/; 370347S

../11 /II);!".
t
.
~
FRONT OF ENGINE
SUPPORT -6531
4'zJII
ROCKER ARM-6564
a . ".. /.
1IJ:h Jllt:,:
'.!
SPRING-6587
" - OJJJ:JII
SHAFT
-6563
SHAFT-6563
PLUG-6572
t ,;) .
.4..
21-10-16
body groove. Release the plunger;
then depress it again to fully seat the
lock ring.
CYLINDER HEAD
Disassembly
Disassembly
1.
1. Remove
R e m o v e deposits
d e p o s i t s from
f r o m t the
he
combustion chambers and valve
combustion
heads with a scraper and a wire brush
before removing the valves. Be
before
Be
careful not to
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
1/2 inch ID and 33
inches long) over the end of the valve
stem squarely against the sleeve
surface. Tap the tube with aa steel
hammer to disengage the locks.
3. Remove the sleeve, spring retainer,
stem seal, and valve. Discard the
valve stem seals. Identify
Identify all valve
If the cylinder head is
is to
to be
be
parts. If
manifold
replaced, remove the manifold
assembly.
Assembly
Assembly
1.
1. Clean, inspect and repair all parts
before assembly. If
If the cylinder head
is being replaced, install the manifold
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
in the
valve guide from
from which it
it was
removed or
or to
it was fitted.
fitted.
to which it
Install aa 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
Spring Compressor
Valve
Compressor
i(]~
~f~~~~~AU' r:"~%~:<'
I
6598
"4
"
SUPPORT BOLT HOLES
.::;;;;'
PIN-372929-S
PIN-372929S
A3172-A
A3172A
FIG. 34 Valve Rocker Arm Shaft Assembly
VALVE LIFTER-HYDRAULIC
LIFTERHYDRAULIC
Disassembly
Disassembly
Each
Each valve lifter
lifter is
is aa matched
matched
assembly; therefore, the parts are not
interchangeable. Disassemble
Disassemble and
and
lifter carefully, keeping the
assemble each lifter
assemblies in proper sequence so they will
be installed in the original bores.
1. Grasp the lock ring with needle nose
1.
pliers to release it from the groove. It
be necessary to
to depress the
may be
plunger to fully release the lock ring.
BACK TO GROUP INDEX
3.
4.
5.
6.
plunger. Set the check valve spring on

top of the check valve.
Position the check valve retainer over
the check valve and spring and push
the retainer down into place on the
plunger.
Place the plunger spring and then the
plunger (open end up) into the tappet
body.
Place the push rod seat in the plunger.
Depress the plunger and position the
closed end of the lock ring in the lifter
A2799-A
FIG. 36 Compressing Valve

SpringOn Bench
Spring-On
5. Measure the assembled height of the

valve spring from the surface of the
cylinder head spring pad to
to the
cylinder
underside of the spring retainer with
dividers (Fig. 38).
6. Check the dividers against aa scale. If
If
the assembled height is greater than
21-10-17
21-10-17
21-10-17
200
200and
and250
250CIO
CIDSix-Cylinder
Six-CylinderEngines
Engines
LOCKS-6518
LOCKS-6518
);S
SLEEVE-6517,
SLEEVE-6517
:::~~:~::,6:'4~J:
RETAINER-6514,
VALVE
VALVE SPRING-6513
installation
installationin inthe
thesame
samecylinders
cylinders
from
fromwhich
whichthey
theywere
wereremoved.
removed.
3. 3.Using
Usingananarbor
arborpress
pressand
andthethetool
tool
shown
shownin inFig.
Fig.39,39,press
pressthe
thepiston
pistonpin
pin
from
fromthethepiston
pistonand
andconnecting
connectingrod.
rod.
Remove
Removethe
thepiston
pistonrings.
rings.
UPPER
COMPRESSION
RING
6148
Lrp,essRam
OILSEAL-6571
Press Ram
EXHAUST
EXHAUST
VALVE
VALVE
-6505
-6505
\:iB:;11I
621:0LTi
INTAKE
VALVE-6507
CONNECTING ROC
,..;:ttR
INSERT
INSERT
TAPERED
TAPERED PILOT
PILOT
ININ PISTON
PISTON PIN
PIN
FOR
FOR PIN
PINREMOVAL
REMOVAL
A2800-B
A2800-B
FIG. 37
37 Typical
Typical Valve
Valve Assembly
Assembly
FIG.
INSERT
INSERT THIS
THIS END
END
IN
IN PISTON
PISTON HOLE
HOLE
OR INS
TAL
LA
T
ION
FFOR
INSTALLATION
~
-
6200
6200
62111:p~~~R~~~
BEARING
MSERTS
Ii
Adaptor DetaH
Detail A-3
A-3
Adapto,
T68P-6135-A
T68P-6I35-A
Cup
Cup Detail
Detail A-7
A-l
/f
A2802 -A
A2802-A
FIG.
FIG. 40
40 Typical
Typical Piston,
Piston, Connecting
Connecting
Rod and Related Parts
Rod and Related Parts
A2374-C
A2374-C
FIG. 39
39 Removing
Removing or
or Installing
Installing Piston
Piston
FIG.
Pin
Pin
SURFACE OF
SURFACE OF
SPRING PAD
UNDERSIDE OF
UNDERSIDE OF
SPRING RETAINER
SPRING PAD
SPRING RETAINER
A2801-A
A2801-A
FIG.
38 Checking Valve Spring
FIG. 38 Checking Valve Spring
Assembled
Height
Assembled Height
specifications,
install the
the necessary
necessary
0.030
0.030inch
inchthick
thickspacer(s)
spacer(s)between
betweenthe
the
cylinder head spring pad and the
cylinder head spring pad and the
valve spring to bring the assembled
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
height to the recommended
dimension. Do not install spacers
dimension. Do not install spacers
unless necessary. Use of excess
unless necessary. Use of excess
spacers will result in overstressing the
spacers will result in overstressing the
valve springs and overloading the
and overloading
the
valve springs
camshaft
lobes which
would lead to
camshaft
lobes and
which
would
lead to
spring
breakage
worn
camshaft
spring breakage and worn camshaft
lobes.
lobes.
PISTON
PISTONAND
ANDCONNECTING
CONNECTINGROD
ROD
Disassembly
Disassembly
1. 1. Remove
the bearing inserts from the
Remove the bearing inserts from the
2. 2.Mark
the pistons and pins to assure
Mark the pistons and pins to assure
BACK TO GROUP INDEX
Assembly
Assembly
The piston,
piston, connecting
connecting rod
rod and
and
The
related
related parts
parts are
are shown
shown in
in Fig.
Fig. 40.
40. Check
Check
the
ofaanew
new piston
pistoninin the
thecylinder
cylinderbore
bore
thefit
fit of
before
before assembling
assembling the
the piston
piston and
and piston
piston
pin
Part
pin toto the
the connecting
connecting rod.
rod. Refer
Refer toto Part
21-01
21-01 for
for fitting
fitting pistons
pistons procedure.
procedure.
The piston
piston pin
pin bore
bore ofofaa connecting
connecting
The
rod
and the
the diameter
diameter ofofthe
the piston
piston pin
pin
rod and
must
must be
be within
specifications. Refer
Refer toto
specification
specification atat the
the end
end Section
Section ofofthis
this
part.
part.
1.1. Apply
Applya alight
lightcoat
coatofofengine
engineoiloiltotoallall
parts.
parts. Assemble
Assemble the
the piston
piston toto the
the
connecting
connectingrod
rodwith
withthe
theoiloilsquirt
squirthole
hole
inin the
the connecting
connecting rod
rod and
and the
the
indentation
indentation inin the
thepiston
piston dome
dome
positioned
positionedasasshown
shownininFig.
Fig.30.
30.
2.2. Start
Startthe
thepiston
pistonpin
pinininthe
thepiston
pistonand
and
connecting
connectingrod
rod(this
(thismay
mayrequire
requirea a
very
verylight
lighttap
tapwith
witha amallet).
mallet).Using
Usinganan
arbor
arborpress,
press,press
pressthe
thepiston
pistonpin
pin
through
throughthe
thepiston
pistonand
andconnecting
connecting
rod
centeredin inthethe
roduntil
untilthethepinpinis iscentered
piston
piston(Fig.
(Fig.39).
39).
3. 3.Check
and
(Fig.
Checkthetheend
endgap
gap
andspacing
spacing
(Fig.
27)27)of of
allallpiston
pistonrings.
rings.They
Theymust
mustbebe
within
withinspecifications.
specifications.
4. Follow the man u fa c t u r e r ' s

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
(included with
with the
the piston
piston
instructions
ring
package)
and
install
the
piston
ring package) and install the piston
rings.
rings.
5.
Check
the ring
ring side
side clearance
clearance of
of the
the
5. Check the
compression rings
rings with
with aa feeler
feeler gauge
gauge
compression
the ring
ring and
and the
the
inserted between
between the
inserted
lower land
land (Part
(Part 21-01).
21-01). The
The gauge
gauge
lower
should slide
slide freely
freely around
around the
the entire
entire
should
ring circumference
circumference without
without binding.
binding.
ring
Anywear
wearthat
thatoccurs
occurswill
willform
formaastep
step
Any
thelower
lowerland.
land.
theinner
innerportion
portionofofthe
atatthe
thelower
lowerlands
landshave
havehigh
highsteps,
steps,the
the
IfIfthe
pistonshould
shouldbe
bereplaced.
replaced.
piston
Be sure
sure the
the bearing
bearing inserts
inserts and
and the
the
6.6. Be
bearing bore
bore inin the
the connecting
connecting rod
rod
bearing
and cap
capare
areclean.
clean. Foreign
Foreign material
material
and
under the
the inserts
inserts will
will distort
distort the
the
under
bearing
and
cause
a
failure.
Install
the
bearinginserts
insertsininthe
theconnecting
connectingrod
rod
bearing
andcap
capwith
withthe
thetangs
tangsfitting
fittingininthe
the
and
slotsprovided.
provided.
slots
OILPUMP
PUMP
OIL
Disassembly
Disassembly
Removethe
theoiloilinlet
inlettube
tubefrom
fromthetheoiloil
1. 1. Remove
pumpand
andremove
removethethegasket.
gasket.
pump
Removethethecover
coverattaching
attachingscrews,
screws,
2. 2.Remove
andremove
removethethecover.
cover.Remove
Removethethe
and
innerrotor
rotorand
andshaft
shaftassembly,
assembly,and
and
inner
outerrace.
race.
removethetheouter
remove
Drilla small
a smallhole,
hole,then
theninsert
inserta selfa self3. 3.Drill
threadingsheet
sheetmetal
metalscrew
screwof ofthethe
threading
proper
diameter
into
pressure
proper
diameter
into
thethe
oiloilpressure

200
200 and
and 250
250 CID
CIO Six-Cylinder
Engines
21-10-18
21-10-18
relief valve
valve chamber
chamber cap
cap and
and pull
pull the
the
relief
cap out
out of
of the
the chamber.
chamber. Remove
Remove the
the
cap
spring and
and plunger.
plunger.
spring
Assembly
Assembly
The oil
oil pump
pump assembly
assembly isis shown
shown in
in
The
Fig. 41.
Fig. 41.
6600
BODY
ASSEMBLY
Install the
the outer
outer race,
race, and
and the
the inner
inner
3.3. Install
rotor and
and shaft
shaft assembly.
assembly. Be
Be sure
sure the
the
rotor
identification
identification mark
mark on
on the
the rotor
rotor isis on
on
the
the same
same side
side as
as the
the identification
identification
mark
mark on
on the
the outer
outer race.
race. The
The inner
inner
rotor
rotor and
and shaft,
shaft, and
and the
the outer
outer race
race are
are
serviced
One part
part
serviced as
as an
an assembly.
assembly. One
should
should not
not be
be replaced
replaced without
without
replacing
replacing the
the other.
other. Install
Install the
the cover
cover
and
and torque
torque the
the cover
cover attaching
attaching screws
screws
to
to specification.
4. Position
Position aa new
new gasket
gasket and
and the
the oil
oil inlet
inlet
4.
tube
tube on
on the
the oil
oil pump
pump and
and install
install the
the
attaching bolts.
bolts.
attaching
5. Prime
Prime the
the oil
oil pump
pump by
by filling
filling the
the inlet
inlet
5.
port
port with
with oil.
oil. Rotate
Rotate the
the pump
pump shaft
shaft
until
until oil
oil flows
flows from
from the
the outlet
outlet port.
ASSEMBLY
CYLINDER ASSEMBLY
INLET TUBE
ASSEMBLY 34806.$
6622
6622
(.~:';itt:'%~""':;';;'" GASKEt
6626
~\.-:::~8~36;:
204260S<:'::::::::::::;:'::
20426-S"
A2803-B
FIG. 41
41 Oil PumpDisassembled
Pump-Disassembled
inspect and oil all parts
1. Clean, inspect
thoroughly.
relief valve
plunger, spring, and a new cap.
BACK TO GROUP INDEX
Disassembly
Disassembly
Mount the old engine in a work stand
1. Mount
and remove all parts not furnished
cylinder assembly,
with the new cylinder
following the procedures given in the
Removal and Installation Section of
of
this Part.
2. Remove the old cylinder assembly
from the work stand.
Assembly
Assembly
1.
of
1. Clean the gasket and seal surfaces of
all serviceable parts and assemblies.
2. Position the new cylinder assembly in
21-10-18
21-10-18
aa work
work stand
stand and
and transfer
transfer all
all
serviceable
serviceable parts
parts removed
removed from
from the
the
old
old cylinder
cylinder assembly,
assembly, following
following the
the
procedures
procedures given
given in
in the
the Removal
Removal and
and
Installation
Installation Section
Section of
of this
this Part.
Part.
3.
3. Check
Check all
all assembly
assembly clearances
clearances and
and
correct
correct as
as necessary.
necessary.
CYLINDER
CYLINDER BLOCK
BLOCK
Before
Before replacing
replacing aa cylinder
cylinder block,
block,
determine
determine ifif itit is
is repairable.
repairable. If
If so,
so, make
make
the
the necessary
necessary repairs,
repairs, following
following the
the
procedures
procedures given
given in
in Part
Part 21-01.
21-01.
Disassembly
Disassembly
1. M
o u n t in
o r k sstand
t a n d and
Mount
in aa w
work
and
completely
completely disassemble
disassemble the
the old
old
engine, following
foilowing the
the procedures
given
given in
in the
the Removal
Removal and
and Installation
Installation
Section
Section of
of this Part.
2. Remember
Remember to ridge-ream
ridge-ream the cylinder
cylinder
bores
bores before
before removing
removing piston
assemblies.
Assembly
Assembly
1. Clean the gasket and seal surfaces
surfaces of
of
2. Position the new cylinder block in the
w
o r k sstand
t a n d aand
n d ttransfer
r a n s f e r all
work
serviceable parts removed from the
old cylinder
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
21-10-19

Engines
200
SPECIFICATIONS-1975
SPECIFICATIONS1975
GENERAL
Drive
Oriv~ Belt Tensions (lbs.)
(Ibs.)
Pressure
Bore
Bore
Engine
Engine
and Stroke
Stroke
and
200
33.68
. 6 8 xx33.13
.13
PSI (Sea
(Sea Level)
level) @
@Cranking
PSI
Cranking
Oil Pressure-Hot
Speed
@2000 RPM
@2000RPM
check ing compression,

When checking
30-50
30-50
3.68 xx 3.91
3.68
250
reading and compare it to the

the
(1)
(1)
Order
Firing Order
1-5-3-
the highest
highest compression
take the
5-2-4
6-2-4
40-60
Used
Newly
NeVl/ly Installed '
Size
Up to 10 Mm.
Min.
Over 10
10 Min.
Min.
1/4"
1/4"
50-80
40-80 (2)
40-80
(2)
(2)
40-60
40-60 (2)
Exc.1/4"
Exc.
1/4"
120-160
120-160
90-160 (3)
(3)
75-120 (4)
(4)
lowest reading. The lowest

lowest
within 75%
reading must be within
of the
the highest.
(1)
immediately after
after belt
belt is
is installed, before it stretches or seats
secUs in
in pulley
pulley grooves.
Read tension immediately
(2) If less than 40

40 pounds, readjust to 40-60 pounds.
(2)
(3)
If less than 90
90 pounds, readjust
readiust to
to 90-120 pounds.
(4) If less than 75

75 pounds, readjust to
to 90-120 pounds.
(4)
CYLINDER HEAD
HEAD
CYLINDER
Valve Guide
Valve
Guide
Engine
Engine
Combustion
Combustion
Bore
Bore
Valve
Valve
Valve
Valve
Valve
Valve
Gasket
Chamber
Chamber
Diameter
Diameter
Seat Width
Seat
Seat
Seat
Seat
Seat
Arrangement
Arrangement
Surface
Surface
Intake and
and
Intake
59.459.4200, 250
250
200,
CD
Exhaust)
Exhaust)
Intake
Intake
Exhaust
Exhaust
0.3115-0.3125
0.3115-0.3125
0.060-0.080
0.060-0.080
0.070-0.090
0.070-0.090
62.4
62.4
Head
Gasket Surface
R.M.S.
Surface Finish
Finish R.M.S.
Head Gaske
Runout
Runout
(Front to
to
(Front
Flatness
Flatness
(Maximum)
(Maximum)
Rear)
ftear)
C0
0.002
0.002
E-l-l-E-l-E
E-I-I-E-I-E
E-l-E-l-l-E
E-I-E-I-I-E
0.003
0.003
in any
any
6
6 inches
0.006
0.006
overall
overall
Angle
Angle
(Standard
(Standard
Volume
Volume
Intake
Intake
and
and
Exhaust 445
5
60-150
60-150
VALVE ROCKER
ROCKER ARMS,
ARMS, ROCKER
ROCKER ARM
ARM SHAFT, PUSHRODS AND
AND TAPPETS
VALVE
Arm
Rocker
Arm Rocker Arm
Rocker Arm
Shaft
0.0.
Bore
Shaft O.D.
Diameter
Engine
Engine
Rocker
Arm
Lift
Ratio
200
200
1.52:1
1.52:
1
0.7797-0.7807
0.784
0.7797-0.7807 0.783 0.784
250
250
CD
Valve
Push
Push
Rod
(Maximum
(Maximum
Runout)
0.020
0.020
1.50:
1
1.50:1
VALVE TAPPET OR LIFTER

Standard
Diameter
0.87400.8745
Clearance
Clearance
Hydraulic
Hydraulic
To Bore CD
Lifter
lifter
Leakdown Rate
0.00070.0027
5-50 Seconds
MaximumMeasured at 1/16 Inch
plunger travel
Collapsed
Tappet Gap
Gap
Allowable
Desired
0.0790.209
0.0950.195
0.0790.129
0.0950.145
Wear
Wear Limit-0.005
Limit0.005
VALVES
VALVES
Valve Stem
To Valve Guide
Clearance CD
Intake
Exhaust
Exhaust
Intake
II
Engine
Engine
200
200
--
0.00080.00080.0025
0.0025
I
!
0.00100.00100.0027
0.0027
250
250
II
Wear Limit
L i m i t 0.0055
0.0055
CD
Wear
Valve face
face runout
runout ... ............... Maximum
Maximum 0.002
0.002
CD
Valve
Valve
Valve
Face
Angle
Angle
Valve Head
Diameter
II
:
Intake
Exhaust
CD
1.642-1.660
1.381-1.399
1.642-1.660
1.381-1.399
Intake
and Exhaust
and
44
i
i
VALVES
VALVES (Continued)
(Continued)
Engine
Engine
200,
200, 250
250
BACK TO GROUP INDEX
Standard
Intake
Intake
Exhaust
Exhaust
0.31000.31000.3107
0.3107
0.30980.30980.3105
0.3105
Diameter
Valve Stem Diameter
0.003
0.003 Oversize
Oversize
Oversize
0.015 Oversize
Intake
Exhaust
Intake
Exhaust
0.31300.31300.3137
0.31280.3135
0.32500.3257
0.32480.3255
Oversize
0.030 Oversize
Intake
Exhaust
0.34000.3407
0.33980.3405
CA
1265-C
CA1265-C
21-10-20
21-10-20
VALVE SPRINGS
250 Int.
61-67 @1.55
@ 1.55
142-158 @ 1.18
142-158@
51-57 @1.59
@ 1.59
142-1
58 @1.22
142-158
@ 1.22
61-67 @1.55
@ 1.55
142-158 @1.18
@ 1.18
200 Int. & Exh.
I
I
250 Exh.
I
Lobe Lift
CD
5/64 (0.078)
9/16-1-19/64
1 9/16-1-19/64
1.79
I
9/16-1-19/64
1 9/16-1-19/64
Theoretical
Valve lift
lash
Lift @ Zero Lash
Exhaust
Intake
Engine
Intake
CD
0
0
CD
Valve Sprilll
Sprini
Out-ofSq....
Out-of -Square
(Maximum)
(Maximum)
CD
CD Wear Limit: 10% Pressure Loss
CAMSHAFT
200
Valve Spring
Assembled Height
Pad to Retainer
Valve Spring
Free Length
Approximate
Valve Spring Pressure

Specified Length
Length CD0
Lbs @ Specified
Pressure
Engine
Exhaust
0.2450
Camshaft Journal to
Bearing Clearance
Wear limit
Clearance
Limit
----+-i
Wear Limit
End Play
0.3720 ~. 0.0010.007
0.001-0.007
0.3720
0.3720
0.2450
Camshaft CD
-I
250
0.3500
0.3820 --~-o~oo-0.2530
0.2320
Maximum allowable-lobe lift loss ............ 0.005
Chain Deflection (Maximum) .........
.. 0.500
Timing Cnain
0.001-0.003
0.001-0.003
0.009
'0.001-0.007
0.001-0.007
0.006
Item
200,-250
200,250
Bearing
Camshaft Journal
Diameter
Standard CD
I
I
Camshaft Bearings
Inside Diameter
(No. 1)
(No.2)
(No. 2)
(No.3)
(No. 3)
(No.4)
(No. 4)
(No.5)
(No. 5)
~;No.
No. 1)
1.8095-1.8105
1.8095-1.8105
--
'No. 2)
~'NO.2)
(No.3)
(No. 3)
(No.4)
(No. 4)
(No.5)
(No. 5)
1.8115-1.8125
1.8115-1.8125
Camshaft Bearing
Location CD
(No.1)
0.030-0.050
(No. 1)
(T) Camshaft journal maximum run
runout
out 0.005
Camshaft journal maximum out-of-round 0.0005
(2) Distance in inches that the front edge of the bearing is installed
Q)
towards the rear from the front face of the cylinder block.
CD
YWHEEL
CRANKSHAFT AND FL
FLYWHEEL
I
Engine
Main Bearing
Journal
Diameter CD
200
250
250
2.
24ITT2490
2.2482-2.2490
2.3982-2.3990
Main Bearing
RunoutJournal Runout
Maximum
Main Bearing
Journal
Journal
Thrust Face
Runout
0.002
(2)
0.002(2)
Thrust
Bearing
Journal
length
Length
Main Bearing
I Journal
Taper Max.
Max.
I
0.001
0.0006
I
I Per Inch
CD
Main bearing journal out-of-round maximum 0.0006 (2)
3.005
2) Wear Limit -- 0.005
I
I
I
Main Bearing
Surface Finish
R.M.S. Maximum
Journal
I Thrust Face
1.275-1.277
1.199-1.201
1.199-1.201
12
12
-
'-----
35 Front
25 Rear
CRANKSHAFT AND FL
YWHEEl (Continued)
FLYWHEEL
Engine
Connecting
Rod Journal
Diameter CD0
200
2.1232-2.1240
Connecting
Connecting
Rod Bearing
Journal
Journal
Maximum
Taper
0.0003 Per Inch
I
I
Crankshaft
Free End
End
Play
I
I
i
Flywheel Ring Gear

Lateral Runout
lateral
Transmission
Standard
Automatic
0.030
0.060
0.004-0.008
250
CD
(V)
CD
Flywheel
Clutch
Face
Runout
0.010
CD
Connecting rod journal out-of-round maximum 0.0006 (all engines)

Wear Limit
0.012
CA
1265-C1
CA1265-C1
BACK TO GROUP INDEX

21-10-21
21-10-21
21-10-21
21-10-21
200
200 and
and 250 CID
CYLINDER
CYI.INDER BLOCK
BLOCK
Cylinder Bore
Bore I
Cylinder
Diameter
Diameter CD
(D (2)
a>
Engine
Engine
Tappet Bore
Diameter
I
I
200
200
250
250
3.6800-3.6836
L:800.36836
0.8752-0.8767
0.8752-0.8767
2.4012-2.4020
2.5902-2.5910
Crankshaft
Crankshaft
To
Face
To Rear
Rear Face
Of
Of Block
Block Runout
Runout
T.I.R.
T.I.R. Max.
Max.
Head
Head Gasket
Surface
Flatness Q)
(3)
Distributar
Distributor
Shaft Bearing
Bore
Bore Diameter
Main
Main Belrinl
Bearing
Bore
Bore
Diameter
0.5155-0.5170
0.003 inch in
any 6 inches
or 0.006 inch
Overall
0.005
. . . . . . . -.- . ..... U.U01

0.001
Wear Limit ... ......... . . . . . . . . . . . . . . . . 0.010
60-150
(3)
. . . .60-150
<3> Head gasket surface finish RMS ............
(2)
Maximum Taper ...
.. . ......
(2) Maximum
0)
Maximum out-of-round
out-of-round .................... 0.0015
0.0015
0 Maximum
Wear
Wear Limit
Limit ............................
. . . 0.005
Cylinder
Cylinder bore
bore surface
surface finish
finish RMS
RMS ............ 18-38
18-38
CRANKSHAFT BEARINGS
BEARINGS
Engine
Engine
Main Bearings
Allowable
Desired
Connecting
Connecting Rod
Rod Bearings
Wall
Wall Thickness
To
Standard (0
Allowable
Desired
Desired
0.0569-0.0574
200
200
0.0008-0.0026
0.0008-0.0015
0.0008-0.0015
250
250
0.0008-0.0024
10'0.002
0.002 Undersize
Undersize Thickness Add 0.0010 to
to Standard Thickness
0.0008-0.0024
0.0008-0.0024
0.0008-0.0015
:
f
Wall Thickness
Standard (0
--
0.0758-0.0761
0.0954-0.0957
CONNECTING ROD
ROD
Engine
Engine
Piston Pin
Pin
Piston
Bore Or
Bore
Bushing
Bushing
I.D.
1.0.
Connecting
Rod
Rod Bearing
Bore Diameter
Bore
(0
C'lnnecting Rod
Connecting
Assembly
(Assembled To
To
Crankshaft)
Wear
Side
limit
Clearance
Limit
0.0035-0.0105
0.014
0.0035-0.0105
Connecting Rod
Alignment
Maximum Total
Difference CD
Twist
Bend
Connecting
Rod
Rod Length
Center
To Center
4.7135-4.7165
2.2390-2.2398
0.9107-0.9112
0.012
200
0.024
200
0.004
5.8785-5.8815
250
250
(0
Connecting rod
rod bearing bore maximum out-of-round and taper ....... 0.0004
CD
at ends of 8-inch
Pin
Pin bushinq
bushinq and
and c.ankshaft bearing bore must be
be parallel and in
in the same vertical plane within the soecified
specified total difference at
measured 4 inches on
on each
each side of
of rod
rod
long bar measured
CA 1265-A2
CA1265-A2
PISTON
Diameter (0
Piston Pin
Piston To
Ring Groove Width
Bore
Cylinder Bore
lore
0.003
Coded
Engine
Coded
Diameter
Oversize
Clearance
Red
Blue
Red
Oversize
3.68083.6796
200
3.6784
3.6808
3.6802
3.6790
250
I3 3.6814
to the pin bore.
bore
90 to
Measured at
at the
1he piston pin bore centerline at
0)
at 90
0.00130.0021
0.0021
Upper Compression
. . . 0.080-0.081
Compress'ion Ring .....
Lower Compression Ring .....
. . . 0.080-0.081
1880-0. 1890
Oil Ring ............... O.
0.1880-0.1890
0.91240.9127
PISTON PIN
Engine
Length
length
Diameter
Standard
200
250
3.010-3.040
0.9120-0.9123
0.001 Oversize
0.9130-0.9133
0.002 Oversize
0.9140-0.9143
0.9140-0.9143
To Piston
Clearance
To Connecting Rod
Bushing Clearance
0.0003-0.0005
0.0003-0.0005
Interference Fit
Fit
Interference
PISTON RINGS
Ring Width
Side Clearance
Compression
Oil
Compression Ring
R
i n gCD
Ring
Ring
Top
Engine
Top
Bottom
Top
Bottom
20(l
200
0.0020.0020.077-0.078
0.077-0.078
0.004
250
Snug
0.004
Wear Limit (All Engines) .................. 0.006
Steel Rail
CD
CD
OIL PUMP
Rotor Type Oil
Oil
Drive Shaft
Relief
Relief Valve To
Bore Clearance
Pump Relief Valve
To Housing
Engine
Spring Tension
Bearing
Lbs
Specified length
Length
Clearance
lbs @
@ Specified
200
9.0-10.1 @
@ 1.078
250
20.6-22.6
2.49
0.0015-0.0029
20.6-22.6 @
@ 2.49
0.0015-0.0029
0.0015-0.0029
0.0015-0.0029
Ring Gap Width

Compression Ring
Top
Bottom
0.008-0.016
0.008-0.016
0.008-0.016
0.008-0.016
Oil
Ring
Ring CD
0.015-0.055
0.015-0.055
Rotor Assembly
End Clearance
Outer
Outer Race
Race
To Housing
Housing
(Radial
(Radial
Clearance)
Clearance)
00.001-0.004
001-0 004
0.001-0.013
0.001-0.013
CA1265-C22
CA1265-C
BACK TO GROUP INDEX

21-10-22

Engines
21-10-22
APPROXIMATE OIL
Oil PAN
PAN CAPACITIES
CAPACITIES CD
APPROXIMATE
CD
Engine
Engine
200
200
250
Includes one quart
quart with
with filter
filter replacement
Includes
U.S.
U.S. Measure
Measure
Imperial Measure
Measure
Imperial
55 Quarts
Quarts
Quarts
44 Quarts
TORQUE lIMITSFTLBS
TORQUE
LIMITS-FT-LBS
Exhaust
Exhaust Manifold
Manifold To
To
Cylinder Head Bolts

Bolts
Cylinder
Pan To
Oil Pan
Cylinder
Cylinder
Engine
Engine
200
Step 11
Step 22
Step
Step 33
Step
Block
50-55
50-55
60-65
60-65
70-75
7-9
Distributor
Distributor
Cylinder
Cylinder Head
Head
Water
Water
Bolt
Bolt Stud
Stud
Outlet
Outlet
Intake
Exhaust
Exhaust
Integral
Integral
13-18
13-18
18-24
18-24
13-18
13-lB
250
Housing
Vacuum
Flywheel
Control
To
To
Crankshaft
Crankshaft
Valve
75-85
15-18
12-15
12-15
TORQUE
L1MITSFTlBS (Continued)
T
O R Q U E LIMITS-FT-LBS
(Continued)
Oil Pump
Pump
Oil
Oil Filter
Filter
Oil Filter
Filter
Main
Main
Spark Plug
Plug
Spark
Oil Pan
Pan
Oil
To
Insert
Insert To
To
To Adapter
Adapter
Cylinder
Cylinder
Bearing
Bearing
To Cylinder
Cylinder
To
Orain
Drain
Cylinder
Cylinder
Cylinder
Cylinder
Or Cylinder
Cylinder
Front
Front
Engine
Engine
Cap Bolts
Bolts
Cap
Head
Head
Plug
Plug
Block
Block
Block
Block
Cover
200,250
2
00,250
60-70
60-70
15-2~J
15-25
15-25
15-25
10-15
10-15
10-15
10-15
With grease on the
(j-g
gasket
gasket surface,
surface,
hand-tighten until
gasket
gasket contacts
adapter
adapter face,
face, then
then
tighten
tighten %
1/2 turn
more.
TORQUE LIMITS-FT-LBS
L1MITS-FTlBS (Continued)
TORQUE
(Continued)
Camshaft Sprocket
Camshaft
Sprocket
Oamper Or
Or Pulley
Damper
Pulley
Connecting
Connecting Rod
Valve Rocker
Engine
Engine
To Camshaft
To
Camshaft
To Crankshaft
To
Crankshaft
Nuts
Nuts
Arm Cover
200,250
35-45
35-45
85-100
85-100
21-26
3-5
TORQUE
lIMITSFTlBS
T
O R Q U E LIMITS
FT-LBS (Continued)
(Continued)
Engine
Engine
Valve
Valve Rocker
Rocker Shaft
Shaft Support
Support
To
To Cylinder
Cylinder Head
Head
200,250
200,250
30-35
Oil Inlet Tube

To
To Oil
Oil Pump
Pump
10-15
ENGINE SUPPORT TORQUE lIMITSL I M I T S - FTLBS

FT-LBS
FRONT SUPPORTS
Insulator Bracket to Engine
lator
Insulator Bracket to Insu
Insulator
200
200
Insulator to Support Bracket (Maverick)

Mourning
Mounting Bracket to Frame
Insulator to Frame Bracket
Through Bolt (Nut)
250
Damper Bolts
Pulley To Oamper
EGR Valve To
Carburetor Spacer
35-50
12-18
200
l|
17-32
20-32
REAR SUPPORTS
Insulator to TransmissionManual
Automatic
30-50
20-30
Crossmember to Frame
14-24
1424
20-37
Insulator to Crossmember-
30-50
CD
250
40-60 CD
40-60
40-60 CD
40-60
ft-lb. manual floor shift only.

only.
17-32 ft-Ib.
TORQUE LIMITS FOR VARIOUS SIZE BOlT8-FTlBS

BOLTS-FT LBS
Caution: If any of the torque limits listed inn this table disagree with
w i t h any of
of those listed
iisted in
in thr.
the precr.ding
preceding tables, the limits
l i m i t s listed in
in thr.
t h e preceding tables prevail.
prevail.
Size
Size (Inches)
(Inches)
1/4-20
5/16-18
5/16-24
3/8-16
3/8-24
7/16-14
7/16-20
1/2-30
Torque
Torque (Ft-Lbs)
(Ft-Lbs)
6-9
6-9
12-18
12-18
14-20
14-20
22-32
27-38
45-57
40-60
55-80
NOTE:
NOTE:
11
22
Oil
Oil threads
threads with
w i t h engine
engine oil
oil unless
unless the
the threads
threads require
require oil
oil resistant
resistant or
or water
water resistant
resistant sealer.
sealer.
Standard
Standard torque
torque limits
limits listed
listed above
above are
are applicable
applicable for
for all
all other
other functions
functions not
not shown
shown in
in the
the special
special torque
torque chart.
chart.
PIPE
PIPE THREAD
T H R E A D TORQUE
T O R Q U E lIMITS-FTlBS
LIMITS-FT-LBS
Size
Size (Inches)
(Inches)
1/8
1/4
1/4
3/8
3/8
1/2
1/2
Torque
Torque (Ft-Lbs)
(Ft-Lbs)
5-8
5-8
12-18
12-18
22-33
22-33
25-35
25-35
CA1265-C 3
CA1265C3
BACK TO GROUP INDEX

21-10-23
21-10-23
MISCELLANEOUS
MISCELLANEOUS ATTACHING HARDWARE - Torque In Ft-Lb
Ft Lb (Unless Otherwise Specified)
EGR Valve To Carburetor Spacer
12-18
35-50
35-50
24-40
Alternator Bracket to Cylinder Block (Bolt)
Alternator Adjusting Arm to Cylinder Block (Bolt)

Alternator Adjusting Arm to Alternator (Bolt)
Thermactor Pump Bracket to Cylinder Block (Bolt)
Grade 8
Grade 55
Thermactor Pump Pivot Bolt
Thermactor Pump Adjustment Arm to Pump (Bolt)
Thermactor Pump Adjustment Arm to Cylinder Block (Bolt)
Thermactor Pump Pulley to Shaft (Bolt)
Power Steering Pump Pulley to Damper (Bolt)
Fan to Water Pump Hub (Bolts)
Carburetor Mounting Nuts (12-point Nuts)
Carburetor Spacer to Intake Manifold (Bolts)
Carburetor Mounting Stud to Spacer (Stud)
30-45
22-32
30-45
27-37
12-18
80-115 in-Ib
in-lb
35-50
12-18
12-15
12-15
15 Max.
80-100 iin-lb
n-Ib
CA1265-A4
CA1265A4
BACK TO GROUP INDEX

21-10-24

200 and 250 CtO
21-10-24
21-10-24
SPECIFICATIONS-1976
SPECIFICATIONS1976
Engine
Bore
and Stroke
PSI (Sea
(Sea Level) @
@ Cranking
Speed
Oil Pressure-Hot
@2000RPM
.2000
RPM
200
3,68
x 3.13
3.68x3.13
When checking compression,
30-50
Size
Firing Order
(lbs.)
Drive Belt Tension Obs.)
Newly Installed
Used
(1)
Up
Over 10 Min.
Up to 10
10 Min.
(1)
1/4"
50-80
40-80 (2)
(2)
40-60 (2)
(2)
Exc.1/4"
Exc. 1/4"
120-160
90-160
(3)
90-160(3)
75-120
(4)
75-120(4)
the highest compression

take the
and compare it to
to the
the
reading and
250
The lowest
lowest reading. The
3.68 xx 3.91
3.91
1-5-3-6-2-4
40-60
be within 75%
reading must be
75%
of the highest.
(1) Read tension immedi:Jtely
immediately after belt is
is installed, before it stretches or
or seats in pulley grooves.
(2) If less than 40 pounds, readjust to

to 40-60 pounds.

to 90-120 pounds.

to 90120
90-120 pounds.
CYLINDER HEAD
Valve Guide
Bore
Diameter
(Standard
Intake and
and
Exhaust)
Combustion
Chamber
Volume
Engine
Intake
Valve
Seat
Runout
(Maximum)
Valve
Seat
Angle
Valve
Seat Width
SeatWHlth
Valve
Arrangement
(Front to
Rear)
Gasket
Surface
Flatness
(1)
(1)
Exhaust
0.003
Intake
200,250
59.4-62.4
0.3115-0.3125
0.3115-0.3125
0.060-0.080
0.070-0.090
and
0.002
0
45
Exhaust 45
E-I-I-E-I-E
E-l-l-E-l-E
E-l-E-l-l-E
E-I-E-I-I-E
in any
6 inches
0.006
overall
(1) Head Gasket Surface Finish R.M.S.
60-150
VALVE ROCKER ARMS,

ARMS, ROCKER ARM
ARM SHAFT,
SHAFT, PUSHRODS
PUSHRODS AND
AND TAPPETS
TAPPETS
Valve
Rocker
Rocker Arm
Arm
Push
Rocker Arm
Arm
Engine
E!1gine
Bore
Rod
Shaft O.D.
0.0.
Lift
(Maximum
Diameter
Ratio
Runout)
Standard
Diameter
VALVE TAPPET OR LIFTER

Hydraulic
Clearance
Lifter
To Bore (1)
(1)
Leakdown Rate
Collapsed
Tappet Gap
Gap
Allowable
AOowable
Desired
5-50 Seconds
200,250
0.7797-0.7807
0.7797-0.7807
0.7830-0.7845
0.7830-0.7845
1.52:1
1.52:1
0.020
0.8740-0.8745
0.8740-0.8745
0.0007-0.0027
0.0007-0.0027
Maximum
Measured at
at 1/16
1/16 Inch
Measureq
0.079-0.209
0.079-0.129
plunger travel
(1) Wear Limit
L i m i t-- 00.005
.005
VALVES
Valve Stem
To Valve Guide
Clearance (1)
(1)
Engine
Valve
Face
Angle
Valve Head Diameter
Intake
Exhaust
0.0008-0.0025
0.0008-0.0025
0.0010-0.0027
0.0010-0.0027
200
Intake
Exhaust
1.642-1.660
1.381-1.399
(2)
Intake
and Exhaust
250
1.642-1.660
440
44
1.381-1.399
(1) Wear Limit 0.0055

(2) Valve face runout
........... Maximum 0.002
runout..
VALVES (Continued)
Intake
Exhaust
Valve Stem Diameter

0.113
0.015 Oversize
0.803 Oversize
Intake
Exhaust
Intake
Exhaust
0.3100-
0.3098-
0.3130-
0.3128-
0.3250-
0.3248-
0.3400-
0.3398-
0.3107
0.3105
0.3137
0.3135
0.3257
0.3255
0.3407
0.3405
Engine
200,250
200, 250
Standard
0.030 Oversize
Exhaust
Intake
CA1265-D
BACK TO GROUP INDEX

21-10-25
21-10-25
200
200 and
and 250
250 CID
CID Six-Cylinder
Engines
21-10-25
21-10-25
VALVE SPRINGS
VALVE
SPRINGS
Valve Spring
Spring Pressure
Pressure
Valve
Lbs @
@ Specified Length
Lbs
Pressure
Pressure
:
I
I
I
Engine
Engine
250 Int.
Int.
250
200 Int.
Int. && Exh.
Exh.
200
250 Exh.
Exh.
250
Valve
Valve Spring
Spring
Out-of-Square
Out-of-Square
(Maximum)
(Maximum)
61-67 @
@ 1.55
1.55
61-67
142- 158 @
@1.18
142-158
1.18
51-57 @
@1.590
51-57
1.590
142-158 @
@ 1.222
142-158
1.222
61-67@1.55
61-67
@ 1.55
142-158 @
@1.18
142-158
1.18
Valve
Valve Spring
Spring
Assembled
Assembled Height
Height
Pad
Pad to
to Retainer
Retainer
Valve
Valve Spring
Spring
Free
Free Length
Length
Approximate
Approximate
CD0
1-9/16-1-19/32
1-9/16-1-19/32
i
I
1.79
1.79
1-9/16-1-19/32
1-9/16-1-19/32
1-17/32-r-37/64
1-17/32- T-37 /64
CD Wear
Wear Limit:
Limit: 10%
10% Pressure
Pressure Loss
Loss
5/64
5/64 (0.078)
(0.078)
CAMSHAFT
CAMSHAFT
Lobe Lift
Lift CD
Lobe
Camshaft
Camshaft CD
Theoretical
Theoretical
Engine
Engine
Intake
Intake
Exhaust
Exhaust
Valve Lift
Lift @
@ Zero Lash
Valve
Lash
Exhaust
Intake
0.2450
0.2450
0.2450
0.3720
0.3720
0.3720
0.001-0.007
0.001-0.007
250 (Man.)
(Man.)
0.3850
250
0.3850
0.2530
0.2320
CD Maximum
Max imum allowable-lobe
allowable-lobe lift
lift loss ............
.. 0.005
CD Timing Chain Deflection

Deflection (Maximum)
(Maximum) .........
0..500
.. 0.500
0.3530
0.3530
0.001-0.007
200,250
(Auto.)
200,
250 (Auto.)
End Play
Play
Camshaft
Camshaft Journal
Journal to
to
Bearing
Bearing Clearance
Clearance
Wear Limit
Clearance
0.009
0.001-0.003
Wear Limit
0.006
1I
(Continued)
CAMSHAFT
Item
Item
Bearing
Bearing
(No. 1)
1)
(No.
(No.2)
(No.
2)
(No.3)
(No.
3)
(No.4)
(No.
4)
(No.5)
(No. 5)
':No. 1)
(No.
fNo. 2)
r~NO.
(No.3)
(No. 3)
(No.4)
(No. 4)
Camshaft Journal
Camshaft
Journal
Diameter
Diameter
Standard CD
Standard
Camshaft Bearings
Camshaft
Bearings
Inside
Inside Diameter
Diameter
200,250
200,250
--
1.8095-1.8105
1.8095-1.8105
--
1.8115-1.8125
1.8115-1.8125
(No.5)
(No. 5)
Camshaft
Camshaft Bearing
Bearing
(No.
Location
0.030-0.050
Location CD
(No. 1)
(T) Camshaft
Camshaft journal maximum
maximum runout 0.005 Max. T.I.R.
Camshaft
journal maximum
Camshaft journal
maximum out-of-round
out-of-round 0.0005
0.0005 Max.
Max. T.I.R.
T.I.R.
@
(2) Distance in inches that the front edge of the bearing is installed
towards the rear from the front face of the cylinder block.
block.
CD
CRANKSHAFT
VWHEEL
CRANKSHAFT AND FL
FLYWHEEL
Engine
Engine
Main Bearing
Journal
Journal
Diameter
Diameter CD
200
200
250
250
2.2482-2.2490
2.2482-2.2490
2.3982-2.3990
2.3982-2.3990
Main Bearing
Journal
Journal RunoutMaximum
O.002~
0.002 O
Main Bearing
Journal
Thrust Face
Runout
Thrust
Bearing
Journal
Journal
Length
Length
Bearing
Main Bearing
Journal
Journal
Max.
Taper Max.
0.001
0.0006
Inch
Per Inch
<D
naximum 0.0006
0.0006 ~
2) Wear Limit - 0.005
(D Main bearing journal out-of-round
out-of-round rmaximum
Main Bearing
Surface Finish
R.M.S. Maximum
Journal
Thrust Face
1.275-1.277
1.275-1.277
1.199-1.201
1.199-1.201
12
12
35 Front
Front
35
25 Rear
CRANKSHAFT AND FL
VWHEEL (Continued)
FLYWHEEL
(Continued)
Connecting
Connecting
Rod
Rod Journal
Journal
Diameter
Diameter CD
Engine
Engine
200,
200, 250
250
<D
0
2.1232-2.1240
2.1232-2.1240
Connecting
Connecting
Rod
Rod Bearing
Bearing
Journal
Journal
Maximum
Maximum
Taper
Taper
0.006
0.006 Per
Per Inch
Inch
Crankshaft
Crankshaft
Free
Free End
End
Play
Play
Flywheel
Flywheel
Clutch
Clutch
Face
Face
Runout T.I.R.
T.I.R.
Runout
0.004-0.008
0.004-0.008
I
Connecting
Connecting rod
rod journal
journal out-of-round
out-of-round maximum
maximum 0.0006
0.0006 (all
(all engines)
engines)
CD
0
Flywheel Ring
Ring Gear
Gear
Flywheel
Lateral Runout
Runout
Lateral
Transmission
Transmission
0.010
0.010
Manual
Manual
Automatic
Automatic
0.030
0.030
0.060
0.060
(J)
0 Wear
Wear Limit
Limit ...... 0.012
0.012
CA1265-D1
CA1265-D1
BACK TO GROUP INDEX

21-10-26
21-10-26
200
200 and
and 250
250 CID
CID Six-Cylinder
Engines
21-10-26
21-10-26
CYLINDER
BLOCK
.INDER BLOCK
CYI
Cylinder Bore
Bore
Cylinder
Diameter Q Q)
(2)
Diameter
CD
Engine
Engine
200
200
250
250
CD
Tappet Bore
Bore
Tappet
Diameter
Diameter
0.8752-0.8767
0.8752-0.8767
3.6800-3.6848
3.6800-3.6848
out-of-round
Maximum
Wear Limit
Limit
Wear
Cylinder bore
bore surface
surface finish
finish RMS
RMS
Cylinder
Main
Main Bearing
Bearing
Bore
Bore
Diameter
Diameter
Distributor
Distributor
Shaft
Shaft Bearing
Bearing
Bore
Bore Diameter
Diameter
2.4012-2.4020
2.5902-2.5910
0.5155-0.5170
Crankshaft
Crankshaft
To
To Rear
Rear Face
Face
Of
Of Block
Block Runout
Runout
T.I.R.
T.I.R. Max.
Max.
Head
Head Gasket
Gasket
Surface
Surface
Flatness
Flatness Q)
(3)
0.003 inch in
any 6 inches
or 0.006 inch
Overall
0.005
0.005
(2) Maximum Taper
0.0015
0.0015
0.005
Q005
0.001
0.010
60-150
..
Wear Limit
CD Head gasket surface finish RMS
18-38
18-38
CRANKSHAFT BEARINGS
BEARINGS
CRANKSHAFT
Connecting
Crankshaft Clearance
Th ick ness
Wall Thickness
To Crankshaft
Desired
AIIQwable
Standard
Standard CD
Allowable
Engine
Engine
,200,250
.200,250
0.0008-0.0015
0.0008-0.0015
0.0008-0.0026
0.0008-0.0026
Main
Main Bearings
Bearings
To
To Crankshaft
Allowable
Desired
Allowable
0.0008-0.0015
0.0008-0.0015
0.0569-0.0574
0.0569-0.0574
0.0008-0.0024
0.0008-0.0024
Wall Thickness
Standard
Standard CD0
0.0954-0.0957
0.0954-0.0957
CD 0.002 Undersize
Undersize Thickness
Thickness Add 0.0010
0.00 0 to Standard Thickness

CONNECTING ROD
ROD
CONNECTING
Piston Pin
Pin
Piston
Or
Bore Or
Bushing
1.0.
I.D.
Engine
Engine
Connecting
Rod Bearing
Bore Diameter
Connecting
ConnectinQ Rod
Rod
Alignment
Alignment
Maximum Total
Difference
Difference CD
Twist
Bend
Twist
Connecting
Rod Length
Center
Ctlnter
To Center
<D
0
Connecting
Connecting Rod
Rod
Assembly
(Assembled To
To
Crankshaft)
Cranks~aft)
Wear
Side
Limit
Clearance
4.7135-4.7165
4.7135-4.7165
200
0.014
0.~1 07-0.9112
0.024
0.012
2.2390-2.2398
0.0035-0.0105
2.2390-2.2398
0.0035-0.0105
0.9107-0.9112
5.8785-5.8815
5.8785-5.8815
250
CD Connecting rod bearing bore maximum out-of-round and
and taper ....... 0.0004
CD Pin
and crankshaft
crankshaft bearing bore must be
be parallel and
and in the same vertical plane within the specified total difference
difference at ends of 8-inch
Pin bushinQ
bushinq and
long bar measured 4 inches on each side of rod
rod center line.
CA1265-A2
CA 1265-A2
PISTON
PISTON
Diameter CD0
Engine
Coded
Coded
~
Red
Blue
~
Piston To
Cylinder Bore
0.003
Oversize
~~1
Piston Pin
Bore
__
Ring Groove Width
Clearance
Diameter
~_"_r_~_C_e_~~D~~~m~e_~_r~
3.6796
3.67843.68080.00130.0021
3.6814
3.6790
3.6802 ~~_-:-3_.6-:-8_14_--,0_.0_0_21_-----,I __
CD
Measured at the piston pin bore centerline at 90
90(3 to
to the
the pin
pin bore.
bore
200.250
0.9124
0.9127
0.080-0.081
0.080-0.081
0.080-0.081
0.080-0.081
Oil Ring
0.1880-0.1890
---,-_O_i_1R_i
..,..,n9e...---'._._.._._._
. ._._.._._.._0_.
1_88_0_-0_.1_89_0-t
PISTON
PISTON PIN
PIN
Engine
Engine
2,00,250
200, 250
Length
Diameter
Standard
0.001 Oversize
0.002 Oversize
Piston
To Pistpn
Clearance
To Connecting Rod
Rod
Bushing Clearance
3.0
10-3.040
3.010-3.040
0.9120-0.9123
0.9130-0.9133
0.9140-0.9143
0.0003-0.0005
Interference Fit
PISTON
PISTON RINGS
RINGS
Ring
Ring Width
Width
Compression Ring
Ring
Top
Bottom
Top
Engine
Engine
Side
Side Clearance
Compression
Compression
R i n gCD
Ring
Top
Bottom
Top
0.0020.0020.004
0.004
CD
.................. 0.006
Wear
Wear Limit
Limit (All
(All Engines)
Engines)..
0.006
200,250
200,250
0.077-0.078
0.077-0.078
0.077-0.078
0.077-0.078
0.0020.0020.004
0.004
CD
Ring Gap
Gap Width
Width
Ring
Oil
Oil
Ring
Ring
Snug
Snug
Steel Rail
Rail
Steel
Ring
Compression Ring
Top
Top
Bottom
0.008-0.016
0.008-0.0
16
0.008-0.016
0.008-0.016
Oil
Oil
Ring CD
Ring
0.015-0.055
0.015-0.055
OIL
OIL PUMP
PUMP
Engine
Engine
200
200
250
250
Rotor
Rotor Type
Type Oil
Oil
Pump
Pump Relief
Relief Valve
Valve
Spring
Spring Tension
Tension
Lbs
Lbs @
@Specified
Specified Length
Length
Drive
Drive Shaft
Shaft
To "ousing
Housing
To
Bearing
Bearing
Clearance
Clearance
Relief Valve
Valve To
To
Relief
Bore Clearance
Clearance
Bore
9.0-10.1
9.0-10.1 @
@ 1.078
1.078
20.6-22.6
20.6-22.6 @
@2.49
2.49
0.0015-0.0030
0.0015-0.0030
0.0015-0.0030
0.0015-0.0030
Rotor Assembly
Assembly
Rotor
End Clearance
Clearance
End
0.004 Max.
Max.
0.004
Outer Race
Race
Outer
To Housing
Housing
To
(Radial
(Radial
Clearance)
Clearance)
0.001-0.013
0.001-0.0
13
CA1265-D.2
2
CA1265-0
BACK TO GROUP INDEX

21-10-27
21-10-27
APPROXIMATE OIL PAN CAPACITIES (1)

Engine
U.S. Measure
Imperial Measure
4 Quarts
3.5 Quarts
200
250
(1) Add one quart with filter replacement
SPECIAL TORQUE LIMITS

TORQUE (ftlb)
(ft-lb)
ITEM
TO
RQU E (ftlb)
TORQUE
(ft-lb)
ITEM
Camshaft Sprocket to Camshaft
35-45
Rocker Arm Support Shaft to Cylinder Head
30-35
Camshaft Thrust Plate to Block
12-18
20-25
Connecting Rod Nuts or Bolts
21-26
3-5
Valve Rocker Arm Cover Bolts to Cylinder Head
6-9
Cylinder Front Cover Bolts
35-50
Alternator Adjusting Arm to Cylinder Block
12-18
Damper or Pulley to Crankshaft
85-100
Alternator Adjusting Arm to Alternator
24-40
Distributor Vacuum Control Valve (PVS)
15-18
Thermactor Pump Bracket to Cylinder Block
12-18
EGR Valve to Carburetor Spacer or Intake Manifold
12-18
Thermactor Pump Pivot Bolt to Bracket
30-45
(Note
1)
(NoteU
Cylinder Head Bolts
Fuel Pump to Cylinder Block or Front Cover
12-18
Thermactor Pump Adjusting Arm to Pump
22-32
Flywheel to Crankshaft
75-85
Thermactor Pump Adjusting Arm to Cylinder Block
30-38
130-180 (in-lb)
Main Bearing Cap

Cap Bolts
60-70
Thermactor Pump Pulley to Shaft
Manifold to Cylinder Head (Exhaust
18-24
35-50
Oil Filter Insert to Cylinder Block
10-15
Fan to Water Pump Hub (Bolt)
12-18
(Note 2)
Carburetor Mounting Nuts to Spacer
12-15
Oil Inlet Tube to Oil Pump
10-15
Carburetor Spacer to Intake Manifold
12-15
Oil Pan
Pan Drain Plug to Oil Pan
15-25
Carburetor Mounting Studs
Oil Pump to Cylinder Block
10-15
Pulley to Damper (80It)

(Bolt)
35-50
Oil Filter to Cylinder Block or Adapter
Max.
15 Max.
80-100 (in-Ib)
(in-lb)
(1) Torque cylinder head bolts in sequence in three steps:

steps: 1st Step (50-55 ft-Ib),
ft-lb), 2nd Step (60-65 ft-Ib),
ft-lb), 3rd Step (7075
(70-75 ft-Ib).
ft-lb).
(2) 1/2 turn after gasket contacts sealing surface (with oiled gasket).
BOLTS-FT-LBS
TORQUE LIMITS FOR VARIOUS SIZE BOLTS-FTLBS
Caution: If any of the torque limits listed in this table disagree with any of those listed in the preceding tables,
tables, the limits listed in the preceding tables prevail.
Size (I(Inches)
nches)
1/4-20
1/420
5/16-18
5/16-24
3/8-16
3/8-24
7/16-14
7/16-20
1/2-30
Torque (Ft-Lbs)
6-9
6-9
12-18
14-20
22-32
27-38
45-57
40-60
55-80
NOTE:
resistantororwater
waterresistant
resistantsealer.
sealer.
Oil threads
threads with
with engine
engine oil
oil unless
unless the
the threads
threads require
require oil
o 1resistant
Oil
al torque chart.
Standard torque limits listed above are
special
are applicable for aallII other functions not shown in the spec
LIMITS-FT-LBS
PIPE THREAD TORQUE L1MITS-FTLBS
(I nches)
Size (Inches)
1/8
1/4
3/8
Torque (Ft-Lbs)
5-8
5-8
12-18
22-33 .
1/2
25-35
CA1265-D3
BACK TO GROUP INDEX

21-12-1
21-12-1
21-12-1
21-12-1
2800cc V-6
V-6 Engine
Engine
2800cc
PART 21-12
21-12 2800cc V-6 Engine
PART
INDEX
COMPONENT INDEX
Page
Pigi
COMPONENT INDEX
INDEX
,...
CAMSHAFT
CAMSHAFT
Removal and
and Installation
Installation ...............
Removal
12-12
12-12
EXHAUST MANIFOLDS
MANIFOLDS
EXHAUST
Removal
and
12-9
12-9
12-18
12-18
FL
YWHEEL
FLYWHEEL
Removal and
and Installation
Removal
12-14
12-14
SEAL
FRONT OIL SEAL
Removal
Removal and
and Installation ...............
12-11
12-11
MANIFOLD
INTAKE MANIFOLD
Removal and
12-9
MAIN BEARINGS
BEARINGS
Removal and
12-15
FILTER
OIL FILTER
Removal and Installation ...............
12-18
OIL PAN
Removal and Installation . ..............
12-13
OIL PUMP
DisassembIy
Iy ..............
Disassembly and Assemb
Assembly
12-20
12-14
PISTONS AND CONNECTING RODS

Disassembly and Assembly ..............
Removal and Installation . ..............
12-20
12-16
SPECIFICATIONS 1975
SPECIFICATIONS
................
12-22
SPECIFICATIONS 1976
SPECIFICATIONS
................
12-25
.......................
12-13
Pinto,
Pinto, Bobcat
Bobcat and
and Mustang
Mustang
BEARINGS
CAMSHAFT BEARINGS
Removal and
and Installation
Removal
PLUG
CAMSHAFT REAR BEARING BORE PLUG
Removal and
and Installation
12-14
12-14
BEARING
Removal and
12-14
BEARINGS
a n d Installation
Installation .... . . . . . . . . . . . .
Removal and
12-16
SYSTEM
Description ..........................
12-2
12-8
CRANKSHAFT
CRANKSHAFT
Removal and Installation .............. .
12-17

CRANKSHAFT
12-15
CYLINDER ASSEMBL
ASSEMBLY
CYLINDER
Y
12-21
CYLINDER BLOCK
CYLINDER
12-21
CYLINDER
Removal and Installation .............. .
12-11
CYLINDER
CYLINDER HEADS
Removal and Installation ................
12-10
ENGINE
ENGINE
Description ..........................
12-2
12-20
TIMING GEARS
TIMING
Page
VALVE CLEARANCE
CLEARANCE ADJUSTMENT ......
VALVE
12-4
VALVE LIFTERS
VALVE
..............
ARM COVER
VALVE ROCKER ARM
AND ROCKER ARM
ARM
12-10
Disassembly and Assembly

Assembly .........
Disassembly
12-19
12-19

Installation .............. .
ENGINE FRONT
FRONT SUPPORTS
ENGINE
ENGINE
REAR
ENGINE REAR SUPPORT
12-6
12-6
Installation
12-7
12-7
VALVE SPRING, RETAINER

VALVE
AND STEM SEAL
AND
12-7
12-7
..............
12-9
12-9
EXHAUST
EXHAUST EMISSION
EMISSION CONTROL
CONTROL SYSTEM
Description
Description ..........................
Installation
WATER PUMP
WATER
12-2
12-2
and installation
lnstallation
Removal and
. .............
12-10
12-10
BACK TO GROUP INDEX
..............
12-8

21-12-2
21-12-2
2800cc V-6
V-6 Engine
Engine
2800cc
21-12-2
21-12-2
NOTE: The
The information
infonnation in
in this
this Part
Part applies
applies to
to both
both 1975
1975 and
and 1976
1976 model
model year
year vehicles
vehicles unless
unless otherotherNOTE:
wise specified.
specified .
wise
CR1966-A
CR1966-A
DESCRIPTION
DESCRIPTION
ENGINE
ENGINE
The compact
compact Ford
Ford 60-degree
60-degree V-6
V-6
The
of modern
modern lightengine (Figs. 1 and 2) is of
engine
iiron
r o n cconstruction~
o n s t r u c t i o n > IItt hhas
as
precision-molded cast
cast iron
iron crankshaft,
precision-molded
supported on
on four
four replaceable
replaceable copper
supported
alloy bearings. Camshaft
Camshaft and connecting
alloy
rod bearings are
are also replaceable. The
The
rod
connecting rods are made of forged
forged steel.
connecting
Except
Except for the
the 60-degree
60-degree block
block
inclination,
in
inclination, it is similar
similar to a V-8
V-8 in
construction
construction and service
service accessibility.

EXHAUST
SYSTEM
Operation
Operation and required
of
of the exhaust
exhaust emission
emission control
control devices
used
used on
on this
this engine
engine are
are covered
covered in
in Groups
29 and 50 of this Manual.
CRANKCASE
SYSTEM
The engine
engine is equipped
equipped with
with aa
positive,
ventilation
ventilation system
system re-cycling
re-cycling the
the
crankcase vapors to the
the intake manifold.
A3717-C
A3717-C
FIG.
FIG. 11 2800cc
2800cc V-6
V-6 Engine-With
EngineWith Thermactor
Thermactor and
and Ale-Left
A/CLeft Front
Front View
View
BACK TO GROUP INDEX

to
!IV
(X)
00
o
o
n
n
<
I
:::s
ceo
:::s
CD
to
FIG. 2 2800cc V-6 Engine-With

EngineWith Thermactor and Ale-Right
A/CRight Front View
BACK TO GROUP INDEX
A3718-B
A3718B

21-12-4
21-12-4
21-12-4
2800cc V-6 Engine

2800cc
A3541A
A3541-A
FIG.
FIG. 3 V-6 Engine Full
Full Pressure Lubrication System
ADJUSTMENTS
VALVE CLEARANCE
CLEARANCE
If some
some component of the valve
valve train
is
is replaced,
replaced, i.e.,
i.e., rocker arm,
arm, push rod,
rod,
camshaft, etc.,
etc., it will
will be
be necessary to
camshaft,
make aa valve
valve lash adjustment before
the engine.
engine. If the valve lash
starting the
adjustment isis made
made for an engine tuneup, on
on aa 1975
1975 engine
engine only,
only, follow the
up,
(hot) adjustment procedure.
procedure.
(hot)
Cold
Cold Adjustment-1975 Engines
Engines
1. Remove
Remove the rocker arm covers.
covers.
1.
Before adjusting the
the valves,
valves, torque
torque
Before
the rocker
rocker arm
arm support
support bolts to
to
the
specification.
specification.
2. The
The val
valves
are ad
a d jjus
u s tted
e d by
by
2.
v e s are
positioning each
each piston at
at TDe
TDC on
on the
the
positioning
compression stroke
stroke in
in the
the firing order
compression
sequence.
sequence.
3. Rotate
Rotate the
the crankshaft
crankshaft clockwise
clockwise when
3.
viewed from the
the front until
until No.
No. 1
viewed
piston isis on
on TDC
TDC at
at the
the end
end of
of the
the
piston
compression
compression stroke
stroke (Fig.
(Fig. 6).
6).
BACK TO GROUP INDEX
4.
4. Set the valve lash to specification with
gage (go
(go and no
no go).
go).
a step-type feeler gage
adjusting nuts are
The valve adjusting
self-locking and will remain at the set
(Fig. 4).
position (Fig.
5. Adjust the valves in the remaining
5.
cylinders following the firing order
sequence. This can be accomplished
sequence.
by removing the distributor cap and
rotating the engine in 120 degree
increments (the spokes on the
distributor armature are 60 degrees
apart). After
After one
one complete
complete distributor
distributor
apart).
revolution, all
all cylinders
cylinders will
will have
have
revolution,
been at
at their
their TDC
TDC position
position at
at the
the top
top
been
of the
the compression
compression stroke.
stroke.
of
Cold Adjustment-1976
Adjustment1976 Engines
Cold
FIG. 4 Adjusting Valve Lash

FIG.
1. Remove
Remove air cleaner assembly.
assembly.
1.
2. Disconnect negative battery cable
2.
battery.
from battery.
hose between thermactor
3. Disconnect hose
3.
dump valve
valve and check valve
valve at check
dump
valve.
valve.
hose between thermactor
4.
4. Disconnect hose
air pump
pump and dump valve
valve at dump
valve.
valve.
5. Disconnect thermactor dump valve

5.
mounting bracket
bracket from
from engine
engine and
mounting
remove thermactor
thermactor dump
dump valve,
valve,
remove
mounting bracket
bracket and
and hose
hose to
to check
check
mounting
valve.
valve.
6. Remove and discard both lifting eyes.
6.
7. Remove
Remove alternator
alternator drive
drive belt
belt from
from
7.
alternator
alternator and rotate alternator
fender.
outward toward fender.
A3542-B

21-12-5
8.
8. Disconnect spark plug wires from
spark plugs and rocker arm covers.
9.
9. Remove electric assist choke wire
from choke cap.
10.
10. Remove
Remove wiring
wiring harnesses
harnesses from
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.
12. Disconnect
Disconnect vacuum
vacuum hose
hose to
to exhaust
exhaust
heat control valve at PVS.
13. Reposition
Reposition vacuum
vacuum hoses
hoses as
as required
required
to facilitate
facilitate rocker arm cover
removal.
14.
14. Remove
Remove rocker
rocker arm
arm cover
cover attaching
attaching
screws.
screws.
15.
15. Remove
Remove rocker
rocker arm
arm covers.
covers.
16.
16. Torque
Torque rocker
rocker arm
arm support
support bolts
bolts to
to
43-49ft-lbs. Reconnect battery cable.
17.
17. Make
Make sure
sure transmission
transmission isis in
in Neutral
Neutral
(manual transmission), or in Park (P)
(automatic transmission), and that
parking brake is applied.
18.ADJUST
18.ADJUST VALVE
VALVE LASH AS
FOLLOWS:
FOLLOWS:
a. Place a finger on adjusting screw of
for
intake valve rocker arm for
cylinder No.
No.5.
5. The slightest
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
camshaft
position to adjust the valves on No.
1 cylinder.
cylinder.
c.
No. 1 intake valve so
c. Adjust the No.
that a 0.014" feeler has a light to
moderate drag and a 0.015" feeler
is very tight. (Turn adjusting screw
clockwise to decrease lash and
counterclockwise to increase lash).
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
not
centerline of the crankshaft. Do not
insert feeler at outboard edge and
move inward toward carburetor
(perpendicular to the crank
(perpendicular
centerline). This will produce an
erroneous "feel" that will result in
excessively tight valves.
d. Using the same method, adjust the
No. 1 exhaust valve lash so that a
feeler has a light to
0.018" feeler
moderate drag and a 0.019" feeler
is very tight.
BACK TO GROUP INDEX
2800cc V-6 Engine
21-12-5
e.
e. Adjust
Adjust the remaInIng
remaining valves, in
firing order (1-4-25- 3-6) by
(1-4-2-5-3-6)
positioning the cam according to
the following chart:
To adjust both valves
for cylinder 4P
:#
1 4 2 55 3 6
The intake valve just

be opening for
cylinder 4P
#
5 3 6 1 4 2
CA4094-A
19. Clean
Clean all
all gasket
gasket material
material from
from
19.
cylinder heads and rocker arm cover
gasket surfaces.
20.
20. Disconnect
Disconnect negative
negative battery
battery cable
cable
from battery.
21. Reinstall rocker arm covers using
new gaskets and torque attaching
ft-lbs.
screws to 3-5 ft-Ibs.
22. Reposition vacuum hoses to their
22.
original positions.
23. Reconnect vacuum hose from exhaust
heat control valve to PVS.
24. Reinstall
Reinstall PCV
PCV valve
valve in
in rocker
rocker arm
arm
24.
cover.
25. Replace wiring harnesses on rocker
arm covers.
26.
26. Reinstall electric choke assist wire to
choke cap.
27. Reinstall
Reinstall spark
spark plug
plug wires
wires on
on spark
spark
plugs and attach to retaining clips on
rocker arm covers.
Reinstall alternator
alternator drive
drive belt
belt and
and
28. Reinstall
specification.
tighten to specification.
29. Reinstall thermactor components.
29.
30.
30. Reconnect
Reconnect battery
battery cable.
cable.
31. Reinstall air cleaner assembly and
specification.
torque wing nut(s) to specification.
(15-20 in-lb.).
32. Start
Start engine
engine and
and check
check for
for oil
oil and
and
vacuum leaks.
Hot Adjustment-1975
Adjustment-1975 Engine Only
1. Remove the air cleaner assembly.

1.
2.
the spark plugs.
3. Remove electric terminal from choke
cap.
4. Remove the alternator belt from the
4.
alternator.
5. Rotate the alternator toward the right
5.
fender.
6. Remove both engine lifting eyes and
discard.
7.
7. Disconnect
Disconnect vacuum line from
from
thermactor bypass vacuum control
solenoid at 4-way tee.
8. Remove wiring harness from
from
8.
left-hand
attaching bracket on rear of left-hand
rocker arm cover.
9.
9. Remove clips holding wiring loom
along inside edge of right-hand rocker
arm cover.
10.
10. Remove
Remove adjustable
adjustable vacuum
vacuum hose
hose
straps as required to reposition hoses
for rocker arm cover removal. Note
location of straps removed and proper
hose routing through straps for later
reinstallation.
11. Remove thermactor dump valve if
if
required during removal of rocker
arm cover.
12.
12. Remove
Remove the
the attaching
attaching screws
screws from
from
the rocker arm covers.
13. Remove
Remove the
the rocker
rocker arm
arm covers.
covers.
14.
14. Install
Install Slave
Slave Rocker
Rocker Arm
Arm covers
covers
T75L-658O-A or
(Rotunda Tool Kit T75L-6580-A
equivalent) to prevent excess engine
oil from being thrown onto the
exhaust manifold while the engine is
running (Fig.
(Fig. 5).
If
If Slave Rocker Arm covers (as
above) are not available, fabricate
slave covers by cutting the tops off
off a
pair of production rocker arm covers.
Cut covers parallel to the mounting
surface 1.25 inches up from the
flange.
attaching bolt flange.
A4068-A
A4068A
FIG. 5 Slave Rocker Arm

Cover-2800cc
Cover2800cc V-6
15.
15. Reinstall
Reinstall the
the alternator
alternator belt
belt and
and
specification.
16.
16. Reinstall
Reinstall the
the spark
spark plug
plug wires
wires on
on the
the
spark plugs.
plugs. Start engine.
17.
17. Bring
Bring engine
engine to
to normal
normal operating
operating
temperature. Torque the rocker arm
support bolts to specification.
specification.
18. With
With the
the engine
engine idling,
idling, set
set the
the valve
valve
18.
lash to specification, using a step-type
go). The
feeler gage only (go and no go).
valve adjusting nuts are self-locking
and will remain at the set position.
19. Stop
Stop the
the engine.
engine. Remove
Remove alternator
alternator
19.
belt from the alternator and rotate
fender.
alternator toward right fender.
20.
20. Disconnect
Disconnect the
the spark
spark plug
plug wires
wires from
from
the spark plugs.
21. Remove -the
the slave rocker arm covers.
22.
22. Clean
Clean all
all gasket
gasket material
material from
from the
the
cylinder heads and rocker arm covers.
23. Install new gaskets on the original
rocker arm covers.
24. Reinstall the original rocker arm
24.
covers and torque attaching screws to
specification.
21-12-6
2800cc V-6 Engine
NO. 2
A3543-A
25. Reinstall thermactor dump valve it

if
removed in previous steps.
adjustable vacuum hose
26. Reinstall adjustable
straps removed above, taking care to
reposition hoses and straps as nearly
as possible to the configuration
configuration noted
during removal.
27. Reattach wiring harness to bracket on
rear of left hand rocker arm cover.
28. Reinstall clips holding wiring loom
along inside edge of right hand rocker
arm cover.
29.
Reconnect vacuum
29.Reconnect
vacuum line from
from
thermactor bypass vacuum control
solenoid to 4-way tee.
21-12-6
alternator belt and
30. Reinstall the alternator
specification.
31. Reinstall the electric terminal on the
choke cap.
32. Install the spark plug wires on the
spark plugs.
33. Install the air cleaner assembly.
T o r q u e air
a i r cleaner
c l e a n e r nut
n u t to
to
Torque
specification.
34. Start the engine and check for leaks.
FIG. 6 Position of Crankshaft for

Adjusting Valve Lash
lash
REMOVAL AND
AND INSTALLATION
ENGINE ASSEMBLY
Removal
Remove or disconnect Thermactor
interfere with
system parts that will interfere
1. Disconnect the battery, drain the
1.
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.
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.
alternator ground
Disconnect the alternator
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.
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. Disconnect transmission
downshift linkage, if so equipped.
downshift
10. Disconnect the engine wire from the
ignition
Disconnect brake
igni
tion coil. Disconnect
booster line.
11. Raise the vehicle and secure with
safety stands.
12. Disconnect the muffier
muffler inlet pipes at
the exhaust manifolds.
13. Disconnect the starter cable and
remove the starter.
14. Remove the engine front
front support
through bolts.
15.If
15.If equipped
e q u i p p e d with
w i t h automatic
automatic
transmission, remove the converter
inspection cover and disconnect the
flywheel from the converter.
downshift rod.
Remove the downshift
BACK TO GROUP INDEX
Remove the converter housing-tocylinder block bolts and the adapter

plate-to-converter housing bolt.
plate-to-converter
On vehicles equipped
equipped with a
manual transmission, remove the
clutch linkage.
17. Attach engine lifting sling, Tool No.
T53L-3OO-A and hoist to lifting
lifting
T53L-300-A
brackets at exhaust manifolds.
1 8 .PP0osit
s i t iion
o n a j aa cckk un
u n dd eerr the
the
18.
transmission.
slightly and carefully
carefully
19. Raise the engine slightly'
pull it from
transmission.
Carefully
engine compartment so that the rear
cover plate is not bent or components
damaged. Install the engine on a work
stand.
Installation
Installation
If clutch pressure plate and disc have
following
been removed, install by following
procedures in Group 16.
1.
1. Attach engine lifting sling (Tool No.
T53L-300-A)
T53L-3OO-A) and hoist to lifting
lifting
exhaust manifolds.
manifolds.
brackets at exhaust
Remove engine from work stand.
2. Lower the engine carefully
carefully into the
engine compartment. Make sure the
exhaust manifolds
manifolds are properly
properly
exhaust
muffler inlet pipes.
aligned with the muffier
manual-shift
transmission, start the transmission
main shaft into the clutch disc. It may
adjust the position of
of
be necessary to adjust
the transmission in relation to the
shaft will not enter
engine if the input shaft
the clutch disc.
disc. If the engine hangs up
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

t h e converter
converter p
i l o t into
i n t o the
the
the
pilot
crankshaft.
3. Install
I n s t a l l the clutch
clutch housing
housing or
converter
converter housing upper
upper bolts,
making sure that the dowels in the
cylinder block engage the flywheel
flywheel
housing. Remove the jack from under
the transmission.
4. Remove the lifting sling.
5. On automatic transmission equipped
vehicles, position the downshift
downshift rod
on the transmission and engine.
6.
safety stands.
7. On a vehicle with an automatic
automatic
transmission,
position
transmission, p
o s i t i o n the
the
transmission linkage bracket and
install the remaining
remaining converter
converter
housing bolts. Install the adapter
plate-to-converter housing bolt.
plate-to-converter
converter-to-flywheel nuts
Install the converter-to-flywheel
and install the inspection cover.
downshift rod on the
Connect the downshift
transmission.
manual
On a vehicle with a manual
transmission, remove the pilot studs,
then install the clutch lower housing
bolts and connect the clutch linkage
to the cylinder block.
8. Install the starter and connect the
8.
cable.
9. Connect the muffier
muffler inlet pipes at the
exhaust manifolds.
10. Install the engine front
front support
support
through bolts.
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.
21-12-7
21-12-7
2800cc V-6 Engine
13. Install
Install the
the accelerator
accelerator linkage
linkage and
and
downshift rod, if so
connect the downshift
equipped. Connect the vacuum lines.
Connect the fuel tank line at the fuel
pump.
pump.
14.
14. Connect
Connect the
the ground
ground wire
wire at
at the
the
cylinder block. Connect the heater
hoses to the water pump and cylinder
block.
15. Install the alternator and bracket.
to
Connect the alternator ground wire to
the cylinder block. Install the drive
belt and adjust the belt tension to
specifications.
16.
16. Position
Position the
the fan
fan shroud
shroud over
over the
the fan.
fan.
Install the radiator and connect the
hoses. Install the fan
upper and lower hoses.
shroud attaching bolts.
17. Fill
Fill and
and bleed
bleed the
the cooling
cooling system.
system. Fill
Fill
17.
of oil. Adjust
Adjust the
and quantity of
transmission downshift linkage, if so
equipped. Connect the battery.
18. Operate
Operate the
the engine
engine at
at fast
fast idle
idle until
until itit
reaches
r e a c h e s normal
n o r m a l operating
operating
temperature and check all gaskets and
hose connections for leaks. Adjust
'ignition
ignition timing and idle speed.
19.
19. Install
Install the
the air
air cleaner
cleaner and
and intake
intake duct.
duct.
Install and adjust the hood.
Removal
Removal
1.
screws.
screws.
2.
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
4.
front engine mount and frame side
rail) attaching bolts and locknuts.
5.
5. Raise the engine sufficiently
sufficiently to
remove the support bracket from the
vehicle.
vehicle.
6. Remove the engine ins
insulator
6.
ula tor
bolts and lockwashers. Remove the
engine mount assembly.
Installation
Installation
1. Position the engine mount and heat
shield to the cylinder block. Install
the bracket bolts and lockwashers
specifications.
and torque to specifications.
2. Install the support bracket to the
frame side rail with attaching bolts
a n d locknuts.
l o c k n u t s . Torque
T o r q u e to
to
and
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.
ENGINE FRONT
SUPPORTS-(FIGS.
SUPPORTS(FIGS. 7 AND 8)
The procedures given apply to either
a right or left installation.
installation.

from the engine oil pan.
5.
5. Install the fan shroud attaching
screws and torque to specifications.
ENGINE REAR SUPPORT-(FIGS.

SUPPORT(FIGS. 7
AND 8)
Removal
Removal
1.
1. Place a block of wood and a jack
under the transmission to relieve the
weight
weight from
from the supporting
supporting
crossmember.
2. Remove the two (2) locknuts holding
insulator bracket
bracket to the
the
the insulator
crossmember.
3. Remove the two bolts and locknuts
attaching the crossmember to the
rails, along with the two
frame side rails,
bolts attaching the insulator to the
transmission.
4. Raise the transmission enough to
slide the crossmember and insulator
rearward.
5. Remove the crossmem
crossmember
5.
ber and
insulator as an assembly.
Installation
Installation
1.
1. Position
Position the insulator
insulator to the
crossmember and loosely install the
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
INSULATOR ASSY. 6C010R.H.
INSULATOR ASSY. - 6068

6A088 - ASSEMBLY (L.H.)
368041-S100
(2 REQ'D.) \
85-110 FT-LBTN^
CROSSMEMBER
- 6A024
INSULATOR ASSY.6C060 L H
N602569-S100 *
. .
(6 REO'D.)
35-60 FT-LB
g... -, ~~
yg....., ,\
r--
~~,,~ 382802-S2 *
.~W).<~.t5)~(2REO'D.. )
~......-:.; ) '. ;'/J

,
~/J. 1\
/~tr.:l
56753-S2
56753-S2
L.H. SHOWN, R.H. SYMETRICALLY

OPPOSITE
20-30 FT-LB
'
"'" '" ,_
386099-52
386099-S2
(4
(4 REO'D.)
REQ'D.)
~ ~;'
\1.
~~ '""----
--..,"
"'----
(2 REQ'D.) V
(2REO'D.)~
~. rl.t'"'~
NOTE:THESEBOLTS----~-JIi1
NOTE: THESE BOLTS
7' . / I/'-I~r.\ ~ MUST BE INSERTED
AS
L.H
\\~~\ f) ':t: -0 AS
SHOWN BOTH L.H.
~I
l~ "'---\" AND R.H. SIDES
56747-S2
/
/S;\
/')
(2 R EO'D.)
BRACKET ASSEMBLY
A 0 6 9 (L.H.) 38579-S2....Y~
- 66A069
(4 R EO'D.)
382802-S2
(4 REO'D.)
20-30 FT-LB
30-40 FT-LB
*NOTE:
NOTE: WHENEVER SELF-LOCKING BOLTS AND
NUTS ARE REMOVED.
REMOVED, THEY MUST BE
REPLACED WITH NEW SELF-LOCKING
SELF-LOCKING
BOLTS AND NUTS.
A3725-B
FIG. 7 Engine Supports-Mustang

SupportsMustang with 2800cc V-6 Engine
BACK TO GROUP INDEX

21-12-8
~ 6C010ASS~:BL.Y~J
tJ
382802-S2
(4 REO'O.)
t
\
6043ASSEMBLY
rr
6C060 ASSEMBL Y L.H.
N602569-S100
ASSEMBLY
(6 REQ'D.)
35-60 FT-LB
56740-S2
MAIN
VIEW
56753-S2
VIEW
N800005_S101~
56748-S~
~
3(278R4E809-,S02.)
MUST BE
BE REPLACED
REPLACED
MUST
WITH NEW
NEW SELFSELFWITH
~~~K~~~:OLTS
AND NUTS.
........
6068 ASSEMBLY
::t- ,\
'~
-'0
XX
~
34670-S2
3(246R7EOO-~20.)
CRIMPED
CRIMPED
AFTER ASSEMBLY
ASSEMBLY
AFTER
TO LOCK
TO LOCK
40-60 FT-LB
~~~8;~~~~~O
(2 REQ'D.)
30-45 FT-LB
FT-LB'
MANUAL TRANSMISSION
TRANSMISSION
VIEW
VIEW
304726-S2
(2 REO'D.)
382873-S100
(2
(2 REO'D.)
REQ'D.) - - - - " ' "
LOCKING BOLTS
~
~
57211-S2
.I
- ,
~ n\
W ~)
~ / )
~ 1~\
5059
5059 ASSEMBLY
ASSEMBLY
LOCKING BOLTS
BOLTS
LOCKING
OR
OR NUTS ARE REREMOVED,
THEY
MOVED,
60089 ASSEMBLY
40-60 FT-LB
20-30 FT-LB
WHENEVER SELF-
12AEQ'0Y"
386321-S2
20-30 FT-LB
(2 REO'D.)
*#
__
v!'z -~,~~
~'
,,'
~(4REO'O')
SAME AS VIEW Y
EXCEPT AS SHOWN
NOTE:
NOTE:
v"wy
~-~-~~
~ . ~\V~~'"
21-12-8
2800cc V-6 Engine
AUTOMATIC
5 6353-S2
(2 REO'D.)
AUTOMATIC
TRANSMISSION
TRANSMISSION
(SAME
(SAME AS
AS MANUAL
MANUAL
TRANSMISSION
VIEW X
X
;~~~;~~SsS~~~~~EW
EXCEPT AS SHOWN
382802-52
382802-S2
(4
(4 REO'O.)
REQ'D.)
20-30 FT-LB
FT-LB
VIEW
Y
A4069-B
FIG..8
SupportsPinto and Bobcat with 2800cc V-6 Engine
FIG..
8 Engine Supports-Pinto
the insulator to the transmission
a t t a c h i n g bolts.
b o l t s . Torque
T o r q u e to
to
attaching
specifications.
4. In sequence, torque the crossmember
4.
bolts and then the engine mount-tocrossmember attaching locknuts to
specifications.
5.
from under the transmission.
3. Remove rocker arm cover attaching

screws. Tap rocker arm cover lightly
screws.
with a plastic hammer to break gasket
seal. Lift otT
off rocker arm cover.
seal.
4.
4. Remove rocker arm shaft
shaft stand
attaching bolts by loosening the bolts
two turns at a time, in sequence. Lift
off
otT rocker arm and shaft assembly and
baffle (Fig.
(Fig. 9).
oil baffie
SYSTEM
Removal
Removal
1. Remove the inlet hose from the air
1.
cleaner. Disconnect the carbon
canister hose.
3. Remove the crankcase vent hose and
regulator valve from the rocker cover.
Installation
Installation
1. Install the vent hose and the regulator
valve in the valve cover.
3. Connect the inlet hose to the air
cleaner. Connect the carbon canister
caniste'r
hose.
4. Operate the engine and check for
leaks.

AND ROCKER ARM
Removal
Removal
Remove emission control equipment
as necessary to remove cover.
1. Disconnect
Disconnect spark plug wires from
spark plugs and rocker arm cover,
using the proper plier-type tool to
remove the boots from the plugs.
plugs.
2. Disconnect
Disconnect throttle
throttle linkage
linkage to
carburetor
carburetor if
if it interferes
interferes with
removal operation.
BACK TO GROUP INDEX
FIG. 9 Removing or Installing Rocker

Arm Assembly
Installation
Installation
1. Loosen the valve lash adjusting
1.
adjusting
screws a few turns.
2. Apply SE-type engine oil to the
assembly
initial
assembly to provide
provide initial
lubrication.
3. Install oil baffle
baffie and rocker arm shaft
assembly to the cylinder head and
guide adjusting
adjusting screws on to push
9).
rods (Fig. 9).
4.
4. Install and tighten rocker arm stand
attaching bolts to specifications, two
time, in sequence.
turns at a time,
5.
5. Adjust valve lash to cold specified
setting.
6.
6. Clean the valve rocker arm cover and
cylinder head gasket surfaces. Coat
one side of a new gasket with an oilresistant sealer and lay cemented side
of gasket on the cover. Install the
cover, making sure the gasket seats
evenly around the head. Tighten the
ccover
o v e r attaching
a t t a c h i n g bbolts
o l t s to
to
specifications.
spceifications.
7. Install parts removed to gain access
to rocker arm and shaft assemblies.
8.
Connect spark
8. Connect
spark plug wires and
accelerator control cable. Connect
throttle return spring.
9. Start engine and run until normal
Adjust valve
temperature is reached. Adjust
lash to hot specified setting.
10. Run
Run the
the engine
engine at
at fast
fast idle
idle and
and check
for oil leaks.

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
Removal
1. Remove the air cleaner. Remove the
valve rocker arm cover. Remove the
applicable spark plug wire and spark
plug. Remove the spark plug wire cap
from the spark plug by using the
proper plier-type tool.
2. Remove the valve rocker arm shaft.
Remove both valve push rods of the

21-12-9
3.
3.
4.
4.
21-12-9
2800cc V-6 Engine
cylinder to be serviced. (Procedures

given under
u n d e r Cylinder
C y l i n d e r Head
Head
Removal.)
Install an air line with an adapter in
the spark plug hole.
hole.
Turn on the air supply.
supply. Air pressure
may
may turn
turn the crankshaft until the
piston reaches the bottom of the
stroke. Using the valve spring
spring
compression tool shown in Fig.
Fig. 10,
compress the valve spring and remove
the valve spring retainer locks,
locks, spring
spring. If air
retainer and the valve spring.
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
inspection.
head for further inslpec:tioln.
A3299B
FIG. 11
11 Removing or Installing Valve
Stem Seal
5.
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
specification.
attaching bolts to specification.
6.
7.
7. Run the engine at fast idle and check
for oil leaks.
A3554-A
FIG. 10 Compressing Valve Spring-In

ChassisTypical
Chassis-Typical
5. Remove the valve stem seal (Fig.

(Fig. 11).
5.
If air pressure has forced the piston
to the bottom of the cylinder, any
removal of air pressure will allow the
around the end of the valve stem will
valve
binds.
for binds.
Installation
I/lsWlstion
1. Install a new
new valve stem seal (Fig.
(Fig. 11).
1.
Position the spring over the valve.
Install the spring retainer. Compress
valve spring and install the valve
the valve
locks.
spring retainer locks.
2. Apply Lubriplate to both ends of the
2.
push rod, the valve tips and both ends
arms. Install the push
of the rocker arms.
rod(s), making sure the lower end of
rod(s),
is positioned in the valve lifter
lifter
the rod is
cup.
push rod cup.
3. Turn off the air and remove the air
3.
line and adapter. Install the spark
plug and spark plug wire.
plug
4. Install the rocker arm shaft
shaft by
4.
following the instructions under
Arm Installation.
Rocker Arm
BACK TO GROUP INDEX
MANIFOLD
INTAKE MANIFOLD
Remoysl
Removal
1.
1. Remove air cleaner. Disconnect
battery negative cable.
2.
2. Disconnect throttle cable.
Disconnect and
3. Drain coolant. Disconnect
remove hose from water outlet to
radiator and bypass hose from intake
manifold to thermostat housing rear
cover.
4. Remove distributor cap and spark
4.
as an
an assembly.
assembly. Disconnect
Disconnect
plug wires as
distributor wire and distributor
vacuum line.
5. Observe and mark the location of the
5.
distributor rotor and housing so
ignition timing can be maintained at
reassembly. Remove distributor holddown screw and clamp and lift out
distributor.
6. Remove fuel line and filter between
6.
fuel pump and carburetor, rocker arm
covers, and EGR tube.
7. Remove intake manifold attaching
7.
nuts. Tap manifold lightly
bolts and nuts.
with a plastic mallet to break gasket
seal. Lift off
off manifold.
seal.
8. Remove all old gasket material and
8.
sealing compound.
Installation
IlIsWllltio.
1. Apply sealing compound to the
1.
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.
compound to the
2. Apply sealing compound
attaching bolt bosses on the intake
manifold and position the intake
manifold
manifold. Tool T72C-6519 is required
to torque one of the intake manifold
bolts. Follow the torque sequence in
Fig. 12 and torque the bolts to
specifications.
3. Install distributor so that rotor and
housing are in same radial position
marked at removal.
Install distributor
distributor clamp
clamp and
4. Install
attaching bolt. Connect distributor
wire and vacuum line.
filter
5. Install carburetor, fuel line and filter
and EGR tube. Replace rocker arm
cover gaskets, and reinstall rocker
arm valve covers using the procedure
gi ven under Rocker Arm Cover
given
Installation.
6. Install distributor cap and wires.
adjust linkage.
7. Install and adjust
8. Install air cleaner and air cleaner tube
at carburetor. Connect
Connect battery
negative cable.
9. Connect hoses from water outlet to
radiator and bypass hose from
radiator
thermostat housing rear cover to
intake manifold.
10. Refill
Refill the
the cooling
cooling system.
system.
11.
Recheck ignition timing and reset
ll.Recheck
engine idle speed to specification.
Run engine
engine at
at fast
fast idle
idle and
and check
check for
for
12. Run
coolant and oil leaks.
EXHAUST MANIFOLD
RemoysJ
Removal
1. Remove the carburetor air cleaner.

1.
2. Remove the attaching nuts from the
exhaust manifold shroud (right side
only).
3. Disconnect the attaching nuts from
the muffler
muffler inlet pipe. Remove
thermactor components as necessary
to allow
allow removal
removal of
of exhaust
manifold(s).
4. Disconnect
Disconnect choke heat tubes at
carburetor.
5. Remove the manifold
manifold attaching nuts.
6. Lift the manifold
manifold from the cylinder
head.
Installation
Instllllstion
1. Position the manifold
1.
manifold on the studs
and install and torque the attaching
bolts in sequence to specification
specification (Fig.
13).
13).
2. Install a new inlet pipe gasket. Install
and torque the inlet pipe attaching
nuts to specification.
3. Position the exhaust manifold
manifold shroud
on the manifold
manifold and install and
torque
torque the attaching
attaching nuts
nuts to
specification
specification (right side). Install
thermactor components that had been
removed.
4. Install the carburetor
carburetor air cleaner.
Reinstall choke heat tube.
21-12-10
2800cc V-6
V-6 Engine
21-12-10
A3551-C
Torque Sequence
FIG. 12 Intake Manifold Torque
CYLINDER HEAD
Removal
Remoylll
1. Remove air cleaner from carburetor.
Disconnect negative battery cable.
linkage. Drain coolant.
Disconnect linkage.
2. Remove distributor cap and wires as
an assembly. Remove distributor
vacuum line, distributor, coolant
from
outlet hose, coolant hose from
thermostat housing rear cover to
intake manifold,
manifold, rocker
rocker arm
arm covers,
intake
fuel line and filter,
filter, carburetor and
intake manifold.
rocker arm shaft
shaft (by
3. Remove rocker
timein
loosening two bolts at a time-in
sequence) and oil baffles. Remove
push rods and keep in sequence for
proper assembly.
4.
4. Remove exhaust manifold, following
procedure under Exhaust ManifoldManifold
Removal.
5. Remove cylinder head attaching bolts
and lift off
off heads. Remove head
gaskets.
Instlll/stion
Installation
1. Clean cylinder head, intake manifold,

manifold,
1.
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
different.
head gaskets are different.
2. Install cylinder head assemblies on
2.
time. Guide
cylinder block one at a time.
carefully over positioning studs (Fig.
Tighten
14). Tigh
ten attaching bolts in
sequence shown in Fig. 15 to
specifications.
sure to
to use
use
3. Install intake manifold. Be sure
sealing compound on gasket surfaces
and to position gasket correctly.
Torque attaching bolts in sequence
(Fig. 12).
4. Install exhaust manifold, following
pprocedures
r o c e d u r e s uunder
n d e r Exhaust
Exhaust
ManifoldInstallation
Manifold-Installation
RIGHT SIDE
5.
5. Apply Lubriplate or equivalent
equivalent
lubricant to
to both ends
ends of the
the push
rods.
rods. Install valve push rods,
rods, oil
shaft
baffles and rocker arm and shaft
assemblies.
assemblies. Adjust (cold)
(cold) valve
valve lash.
lash.
6.
6. Install distributor hold-down bolt and
clamp.
clamp.
7.
7. Install rocker arm covers
covers with new
gaskets.
gaskets.
8.
8. Install carburetor and distributor cap
with spark plug wires.
wires. If necessary,
adjust linkage.
linkage.
9.
9. Install fuel line with filter and
vacuum line.
line.
10.
10. Install
Install air
air cleaner
cleaner and
and air
air cleaner
cleaner tube
tube
at carburetor. Connect battery
battery
negative cable.
11.
11. Refill and bleed cooling system.
12.
12. Re-check
Re-check ignition
ignition timing
timing and
and check
check
idle speed.
13.
13. Perform
Perform final
final (hot)
(hot) valve
valve lash
lash
adjustment as
as outlined in Part 29-02.
14.
14. Operate
Operate the
the engine
engine at
at fast
fast idle
idle speed
speed
and check for coolant and oil leaks.
VALVE LIFTERS
Remoys/
Removal
1.
1. Remove the cylinder head and related
parts following the procedure under
Cylinder Head Removal.
2.
2. Remove the valve lifters with a
magnet. Place them in a rack in
sequence. If the lifters are stuck in
bbores,
o r e s , use pplier-type
l i e r - t y p e Tool
Tool
(T70P-14151) to remove them (Fig.
16).
16). Rotate lifters back and forth to
loosen them from gum or varnish
deposits.
deposits.
Instlll/stion
Installation
1.
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. 16). Check any new
lifter for free fit in bore to which it is
to be installed.
2. Install the cylinder head and related
parts, following the procedures given
under Cylinder Head Installation.
GUIDE STUDS
1 REQUIRED
A 3552-A
FIG. 14 Cylinder Head Guide Studs
5 REQUIRED
A4083-A
A4083-A
FIG. 13 Exhaust Manifold Torque PatternPinto/Bobcat

Pattern-Pinto/Bobcat 2.8L
2.8l
ShownMustang
Shown-Mustang Same Pattern
BACK TO GROUP INDEX
WATER PUMP
Remoys/
Removal
Drain the coolant. Detach
Detach the
1. Drain
radiator lower hose and the heater
return hose from
from the water inlet
housing.
2. Loosen the alternator mounting bolts
and remove the belt. (With A/C,
A/e,
remove alternator
and
bracket.)
21-12-11
21-12-11
21-12-11
21-12-11
V-6 Engine
2800cc V-6
3.
3.
4.
4.
5.
5.
6.
6.
7.
7.
with
with the
the chamfered side
side of the
the sleeve
toward the
the front cover (Fig.
(Fig. 17).
17).
Apply sealing compound to
to front
front
cover gasket surface. Place gasket in
position on
on front cover.
cover.
Place front cover on
on engine
engine and start
all retaining screws two
two or three
turns.
turns. Center cover by
by inserting tool
in
in oil
oil seal
seal (Fig.
(Fig. 20).
20).
Tighten front cover attaching screws
to specifications.
specifications.
Install belt drive pulley and tighten
attaching bolt to specification.
specification.
Install oil pan following Oil Pan
Installation procedure.
procedure.
A3553-B
A3553-B
FIG. 15 Cylinder Head Bolts Torque Sequence
3. Remove the fan and pulley.

3.
4. Remove the water pump assembly
4.
attaching bolts and remove water
pump assembly, water inlet housing
and thermostat from the front cover.
Installation
Installation
1. Remove all gasket material from the
1.
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
2.
the front cover with two bolts finger
tight. Remove all gasket material
from the water inlet housing sealing
surfaces. Appply 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
flange to the
water pump and install the attaching
bolts. Torque all water pump
assembly
t t a c h i n g bolts
assembly aattaching
bolts to
specification. Note the different
different
length bolts.
4. Install fan and pulley. (With A/C,
AIC,
install bracket and alternator.) Install
belt
d j u s t ttension
e n s i o n to
belt and
and aadjust
specification. Reconnect both hoses
to water inlet housing and tighten
hose clamps. Fill and vent cooling
system.
5. Start the engine
eng~ne and check for leaks.
Removal
RemoyaJ
1. Remove oil pan as described under
Oil PanRemoval.
Pan-Removal.
2. Drain
Drain the coolant. Remove the
radiator
radiator and any other
other parts to
provide necessary clearance.
3. Remove
Remove A/C
AIC compressor
compressor and
bracket, ifif equipped.
4. Remove alternator, thermactor pump
and drive belt(s). Remove water
pump and water lines.
5. Remove fan.
BACK TO GROUP INDEX
MAGNET
A3557-A
FIG. 17 Removing or Installing Guide

Sleeves
A3556-A
FIG. 16 Removing or Installing Valve

LiftersTypical
Lifters-Typical
6. Remove the drive pulley from the
crankshaft.
If
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. 18).
18). If necessary, remove guide
sleeves from cylinder block (Fig. 17).
Installation
Installation
1.
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. 18).
Temporarily install four front cover
screws to position gasket and cover
plate in place. Install and tighten two
cover plate attaching bolts (Fig. 19),
19),
then remove four screws that were
temporarily installed.
2. If
If removed, fit new seal rings
rings to the
guide sleeves and, with no sealer used,
insert the sleeves in the cylinder block
8.
8. Install water pump, water hose,
hose, AIC
A/C
compressor, alternator, thermactor
pump and drive belt(s). Adjust drive
belt tension to specifications.
9.
9. Fill the cooling system to the proper
level with the specified coolant.
10.
10. Operate
Operate the
the engine
engine at
at fast
fast idle
idle speed
speed
and check for coolant and oil leaks.
FRONT OIL SEAL
In-Chassis
RemoyaJ
Removal
1.
1. Drain the coolant. Remove the
crankshaft pulley and
radiator and crankshaft
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
21.
the tools shown in Fig. 21.
Installation
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. 22).
22).
crankshaft pulleys and bolt.
2. Replace crankshaft
Torque bolt to specifications, then
radiator and drive belt.
replace radiator
Adjust
Adjust belt tension to specification
using Tool T63L-862O-A.
T63L-8620-A.
3. Fill the cooling system to the proper
specified coolant.
level with the specified
4. Operate the engine at fast idle speed
and check for coolant leaks.
21-12-12
21-12-12
2800cc V-6 Engine
A3558-A
FIG. 18 Removing or Installing Front

Cover Plate
Removal
Removal
1. Drain
Drain the coolant. Remove the
1.
radiator, fan, spacer, water pump
pulley and drive belt.
2. Remove distributor cap with spark
plug wires as an assembly. Remove
distributor vacuum line, distributor,
alternator, thermactor pump, rocker
filter,
arm covers, fuel line and filter,
carburetor, and intake manifold. Use
the proper plier-type tool to remove
the spark plug wire boots.
3. Drain the crankcase. Refer to Rocker
Arm Removal and remove rocker
shaft assemblies. Lift
Lift out
arm and shaft
push rods and place in a marked rack
so they can be reinstalled in the same
location.
Installation
Installation
1.
1. Oil the camshaft
camshaft journals with heavy
SE engine oil and apply Lubriplate or
equivalent lubricant to the cam lobes.
2. Install the camshaft
camshaft in the block,
carefully
carefully avoiding damage to the
bearing surfaces.
3. Install the spacer
spacer ring with the
chamfered
chamfered side toward the camshaft.
camshaft.
Insert camshaft
camshaft key. Install thrust
plate so that it covers the main oil
gallery (Fig. 26). Torque attaching
specifications.
screws to specifications.
TOOL171 P-7137-H
TOOL-T71P-7137-H
Tool-1175-AB
A3595-B
A3595-8
FIG. 23 Removing Front Oil

Seal-Front
SealFront Cover Removed
-
A3559-A
FIG. 19 Torquing Front Cover Plate

Attaching Bolts
Front Cover Removed

Removal
Removal
1.
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. 23.
Installation
Installation
1.
1. Support
Support front
front cover
cover to prevent
prevent
damage while installing seal.
2. Coat the new front cover oil seal with
Lubriplate or equivalent. Install the
new seal in the front cover as shown
in Fig. 24.
CAMSHAFT
The camshaft
camshaft and related parts are
shown in Fig. 25.
Tool-T50T100A
"TOOI-T50T-100-A
or T59L-100-B
A3561-A
A3561A
FIG. 21
21 Removing Front Oil Seal-In
SealIn
Chassis
4. Remove oil pan, as described under

Oil Pan Removal.
5. Remove drive sprocket attaching bolt
and slide sprocket otT
off end of shaft.
shaft.
6. Remove engine front cover and water
pump as an assembly.
7. Remove camshaft
camshaft gear attaching bolt
off camshaft.
camshaft.
and slide gear otT
8. Remove camshaft
camshaft thrust plate and
screws.
9. Remove the valve lifters, following
following
Valve Lifter
Lifter Removal procedure.
10. Carefully
Carefully pull the camshaft
camshaft from the
block, avoiding any damage to the
camshaft bearings. Remove camshaft
camshaft
camshaft
gear key and spacer ring.
TOOL-T74P 6700-A
TOOL-T74P 6019-A
A3560-C
FIG. 20 Aligning Front Cover
BACK TO GROUP INDEX
A3562-C
SealIn
FIG. 22 Installing Front Oil Seal-In
Chassis
4. Check the camshaft

camshaft for the specified
specified
end play. The spacer ring and thrust
plate are available in two thicknesses
adjusting the end play.
to permit adjusting
camshaft and crankshaft
crankshaft as
5. Turn camshaft
necessary to align timing marks as
camshaft
shown in Fig. 28 and install camshaft
TOOL-T71P-7137-H
A3596-B
FIG. 24 Installing Front Oil

Seal-Front
SealFront Cover Removed
attaching bolt and

gear. Install attaching
washer and tighten to specifications.
specifications.
6. Position the valve lifters
lifters in their
original locations, following Valve
Lifter
Lifter Installation procedure.
7. Install engine front cover and water
pump as an assembly.
8. Install belt drive pulley and secure
with washer
washer and attaching
attaching bolt.
Tighten bolt to specifications.
specifications.
9. Install oil pan, as described under Oil
Pan Installation.
both ends of the push rods. Install
valve push rods in same location as
removed.
21-12-13
CAMSHAFT SPROCKET-6256
BEARINGS
6263
.1
. . M
,,~
~.:.k ~p.'.'. '.
CAMSHAFT
REAR
REAR BEARING
BEARING
BORE
BORE PLUG-6266
PLUG-6266
21-12-13
2800cc V-6 Engine

I
7. Drain the crankcase. Remove the

splash shield.
8. Remove the starter and disconnect
the electrical lead.
front support
nuts.
10. Raise
Raise the
the engine
engine and
and place wood
blocks between the engine front
supports and chassis brackets.
11. Remove the oil pan attaching bolts
and remove the oil pan.
,)70 .)62
I
""'$7
.:
..; .
CAMSHAFT-6250
SPACE R-6278
BOLT
Tool-T71P-19703-B
THRUST PLATE-6279
SCREW-388379-GS
A3563A
A3563-A
FIG.
11.
11. Install intake manifold, as described
under Intake Manifold Installation.
12.
12. Install
Install oil
oil baffles
baffles and
and rocker
rocker arm
arm and
and
shaft assemblies.
assemblies. Tighten rocker arm
Adjust
stand bolts to specifications. Adjust
valves to specified cold setting (Part
valyes
29-02).
29-02).
13.
13. Install water pump pulley, fan spacer,
fan, and drive belt. Adjust
Adjust belt
tension to specifications. Install
carburetor, fuel line and filter,
filter,
alternator, thermactor
thermactor pump,
distributor, distributor vacuum line,
wires. Install
and distributor cap and wires.
the radiator. Fill the cooling system
to the proper level with the specified
coolant. Adjust ignition timing as
described in Group 29.
14. Install
Install valve
valve covers
covers following
following Valve
Valve
14.
Cover Installation procedures.
15. Run
Run the
the engine
engine and
and check
check the
the idle
idle
15.
speed. Perform final
speed.
final (hot) valve lash
adjustment (Part 29-02).
16. Run
Run the
the engine
engine at
at fast
fast idle
idle speed
speed and
and
16.
check for coolant and oil leaks.
TIMING GEARS
Removal
Remoylll
1. Drain the cooling system and
1.
crankcase. Remove oil pan and
radiator.
2.
pump, drive belt, and camshaft
camshaft
water pump,
following the procedures in this
section.
section.
3. Use
Use the gear pullers as shown in Fig.
3.
27 and remove the crankshaft gear.
27
crankshaft.
Remove the key from the crankshaft.
Installation
IRstlll/lltion
1. Place the spacer and thrust plate on
1.
camshaft.
the camshaft.
2. Install the key in the camshaft. Align
2.
the keyway in the gear with the key,
shaft,
then slide the gear onto the shaft,
making sure that it seats tight against
the spacer.
spacer.
the
3. Check the camshaft end play.
play. If not
3.
within specifications, replace the
thrust plate.
BACK TO GROUP INDEX
i
Tool T71P-7137-H
A3565-C
FIG. 27 Removing Crankshaft

Crankshaft Gear
A3564-A
FIG. 26 Camshaft Thrust Plate

Installed
4.
4. Position the key in the crankshaft.
crankshaft.
Align the keyway and install the gear,
using the tool shown in Fig. 28.
5. Install the cylinder front
front cover
5.
following the procedures in this
section. Install the oil pan and
radiator.
6. Fill the cooling system and crankcase.
6.
adjust the
Start the engine and adjust
ignition timing. Operate the engine at
fast idle and check
check all hose
fast
connections and gaskets for leaks.
PAN
OIL 'AN
Remoylll
Removal
1.
1. Remove the oil level dipstick.
2.
2. Remove the radiator pressure cap and
drain the cooling system. Disconnect
the radiator upper and lower hoses at
the radiator.
attaching the fan
3. Remove the bolts attaching
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
5.
power steering hoses, if equipped) and
position the gear out of the way (see
Group 13).
6. Disconnect the sway bar at the ends
6.
and rotate to allow clearance to
remove pan.
Installation
Instlll/stion
1.
1. Clean the gasket surfaces of the block
and oil pan.
2. Coat both pieces of the oil pan gasket
block surfaces
surfaces with oil resistant
sealer. Position the oil pan gaskets on
the cylinder block (Fig. 30).
3. Position the oil pan front seal on the
cylinder cover. Make sure the tabs on
the seal are over the oil pan gasket.
4. Place end seals in position, flush
flush with
the cylinder
cylinder block oil pan rail.
Position the oil pan rear seal on the
rear main bearing cap (Fig. 30). Be
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. 31,
31, to secure the front and rear
of the oil pan. Install the remaining
bolts and torque to specification
specification in the
sequence shown.
6. Reinstall
(or
Reins tall the clutch
cl u tch cover
cover (or
converter housing).
7. Raise the engine and remove the
wood blocks. Lower the engine and
install the engine support
support nuts.
Torque to specification.
8. Install the starter and reconnect the
electrical lead.
9. Install the splash shield.
Reconnect the
the sway
sway bar.
bar. Install
Install the
the
10. Reconnect
steering gear and power steering
equipment disconnected following
13.
11. Connect the automatic transmission
oil cooler lines at the radiator and
reconnect the radiator lower cooling
hose.
Lower the
the vehicle.
vehicle. Connect
Connect the
the
12. Lower
21-12-14
2800cc V-6 Engine
21-12-14
21-12-14
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.
3. Install oil pan as described in this
Section.
4.
4. Operate the engine at fast idle speed
and check for oil leaks.
A3566-C
FIG.
FIG. 28 Installing Crankshaft Gear
2. Install the clutch pressure plate and

disc, and the transmission following
16--Clutch.
the procedure in Group 16Clutch.
FLYWHEEL
ARROWS MUST POINT X

TOWARD FRONT
Removal
Removal
1.
1. On a manual-shift
remove the transmission, clutch
pressure plate and disc, following the
16-Clutch.
procedures in Group 16Clutch.
On a vehicle with an automatic
ttransmission,
r a n s m i s s i o n , rremove
e m o v e the
the
transmission and converter housing
following the procedure in Group
17-Automatic Transmission.
17Automatic
21-01 for flywheel face
2. Refer to Part 21-01
runout. Remove the flywheel
flywheel
attaching bolts and remove the
flywheel.
.
Installation
Installation
1. Clean and inspect all parts before
1.
installation. Position the flywheel on
the crankshaft
crankshaft flange. Apply
oil-resistant sealer to the attaching
in
bolts. Install and torque the bolts in
sequence across from each other to
specifications.
2. On a manual-shift
install the clutch pressure plate, disc,
following the
and the transmission following
procedures in Group 16Clutch.
16-Clutch.
transmission, install the converter
housing and transmission following
tthe
h e pprocedure
r o c e d u r e in
Group
in Group
17Automatic Transmission. It is
17-Automatic
not necessary
necessary to adjust
adjust the
transmission, when it has been
removed only for flywheel removal.
Pan Gaskets and Seals

FIG. 30 Oil Pan
Installed
CAMSHAFT
CAMSHAFT REAR BEARING CORE
PLUG
Removal
Removal
1. On a vehicle with a manual-shift
manual-shift
1.
transmission, slide the transmission
to the rear and remove the clutch
pressure plate and disc following the
procedure in Group 16Clutch.
16-Clutch.

Inspection procedures are outlined in
Part 21-01.
Removal
Removal
1.
1. Remove the transmission, clutch
procedures in Group 16-Clutch.
16Clutch.
2.
T59L-IOO-B and
2. Using Tools T59L-100-B
T58L-I0I-A,
T58L-1O1-A, remove the pilot
bearing (Fig.
(Fig. 33).
Installation
Installation
1.
1. Using Tools T74P-7137-A and
T74P-7137-H install the pilot service
bearing.
bearing, with the seal facing the
transmission (Fig.
(Fig. 34).
FRONT SEAL
V
A3567-A
FIG. 29 Aligning Timing

Timing Marks
FIG.
hose. Position the

radiator upper hose.
radiator shroud forward over the fan
and install the attaching bolts.
Maintain radial clearance shown in
Group 27.
27.
13.
13. Connect the battery ground cable.
cable. Fill
following
the cooling system following
instructions in Group 27.
14. Install
Install the
theoil
oillevel
leveldipstick
dipstick and
and fill
fill the
the
14.
crankcase with the proper grade and
engine oil.
oil. Start the engine
amount of engine
and check for oil or coolant leaks.
Correct as
as necessary.
PUMP
OIL PUMP
Removal
Removal
1. Remove oil pan as
as described under
1.
Oil Pan Removal.
Removal.
2. Remove bolt that attaches oil pick-up
2.
screen to main bearing cap.
cap. Remove
oil pump
pump attaching
attaching bolts
bolts (Fig.
(Fig. 32).
oil
Lift off
off oil
oil pump
pump and
and withdraw
withdraw oil
oil
Lift
pump drive
drive shaft.
shaft.
pump
Installation
Installation
1. Prime the oil
oil pump by filling either
1.
oil.
the inlet or outlet port with engine oil.
Rotate the pump shaft to distribute
oil within the pump body.
the oil
2. Insert oil
oil pump drive shaft into block
2.
with the pointed end facing inward.
BACK TO GROUP INDEX
66
~:(
~_O
""'l'"0....;.....-
10
11
12
o..:...-_ _....:o_
13
L5
100
14
INSTALL THESE BOLTS FIRST

INSTALL
FRONT OF ENGINE
~.-O
O
o
24
23
22
21
21
20
19
19
18
17
A3721-A
FIG. 31
31 Oil
Oil Pan
Pan Installation
Installation and
and Bolt
Bolt Torque
FIG.
Torque Sequence
Sequence
21-12-15
21-12-15
2800cc
2800cc V-6
V-6 Engine
Engine
21-12-15
21-12-15
the
the tool
tool as
as shown
shown in
in Fig.
Fig. 37.
37. Drive
Drive the
the
seal
seal into
into position
position until
until itit isis firmly
firmly
seated.
seated.
A3573-B
A3573B
FIG. 32
32 Oil
Oil Pump
Pump and
and Inlet
Inlet Tube
Tube
FIG.
Installed
Installed
A3574-A
Tool T72C-6266
T72C-6266
Tool
A 3570-A
3570-A
A
FIG. 35 Installing Camshaft Rear

Plug
Bearing Core Plug
Too/ T58L-7O7-A
T59L-7OO-B
Tool T59L-700-B
A 3568-A
A3569-C
FIG. 34
34 Installing Clutch Pilot Bearing

ttransmission,
e m o v e the
the
transmission and converter
converter housing
following
17Automatic
17-Automatic Transmission.
2. Remove the flywheel
flywheel attaching bolts
and remove the flywheel and engine
rear cover plate.
plate.
3. Remove the core plug as detailed in
in
Part
Part 21-01.
21-01.
Installation
Instlll/stion
1. Install a new plug
plug with the tool shown
shown
in Fig. 35 using the procedure
procedure given
given
in
in Part
Part 21-01.
21-01.
2.
2. Install
Install the
the engine
engine rear
rear cover
cover plate,
plate,
apply
apply oil-resistant
sealer to
to the
flywheel
flywheel bolts
bolts and
and install
install the
the
flywheel.
Torque the
the attaching
attaching bolts
bolts
flywheel. Torque
to
to specifications.
BACK TO GROUP INDEX
vehicle with a manual-shift

manual-shift
On a vehicle
clutch
plate, disc,
disc, and transmission
pressure plate,
16Clutch.
16-Clutch.
automatic
transmission, install the transmission
procedure in Group 17-Automatic
17Automatic
Transmission.
CRANKSHAFT
FIG. 33 Removing Clutch Pilot

Bearing
FIG. 36 Removing Crankshaft Rear

Oil Seal
Seal
Removal
Remoys/
1. Remove the transmission. Remove
1.
clutch pressure plate and clutch disc,
if so equipped. Follow the procedures
given in Group 16.
2. Remove flywheel,
flywheel, flywheel
flywheel housing
and rear plate.
3. Use an awl to punch two holes in the
crankshaft
crankshaft rear oil seal. Punch the
holes on opposite sides of
of the
crankshaft
crankshaft and just above the bearing
cap to cylinder block split line. Install
a sheet metal screw in each hole (Fig.
36). Use two large screwdrivers or
small pry bars and pry against both
screws at the same time to remove the
crankshaft
crankshaft rear oil seal. It may be
necessary to place small blocks of
of
wood against the cylinder block to
provide a fulcrum
fulcrum point for the pry
bars. Use caution throughout this
procedure to avoid scratching or
or
otherwise damaging the crankshaft
oil seal surface.
Clean the
the oil seal recess in the
4. Clean
cylinder block
biock and main bearing cap.
cap.
cylinder
Inspect and clean the oil seal contact
contact
surface on the crankshaft,
the procedure in Part 21-01.
21-01.
Installation
Instlll/stion
Coat the
the oil
oil seal
seal to
to cylinder
cylinder block
block
1. Coat
surface
of the
the oil
oil seal
seal with
with oil.
oil. Coat
Coat
surface of
the
of the
the oil
oil seal
seal
the seal
seal contact
contact surface
surface of
and
and crankshaft
crankshaft with
with Lubriplate.
Lubriplate. Start
Start
the
the seal
seal in the recess and install it with
A3575-B
FIG. 37 Installing Crankshaft Rear

Oil Seal
2. Install rear plate, flywheel

flywheel housing,
flywheel. Tighten flywheel
flywheel bolts
and flywheel.
to specifications.
3. Install clutch disc and clutch pressure
plate, if so equipped.
equipped. Align clutch disc
disc
before tightening pressure plate
before
attaching screws.
4. Install transmission.
MAIN BEARINGS
The main and connecting rod bearing
fit. Do not file or lap
inserts are selective fit.
lap
the
bearing caps or use shims to obtain the
proper bearing clearance. Selective fit
main bearings are
are available for
for service in
standard and undersizes. Refer to the
Parts Catalog for the available sizes.
Undersize bearings which are not
Undersize
on
selective fit, are available for use on
journals that have been refinished.
journals
If the rear
rear main bearing is to be
be
If
replaced, remove the engine and place itit
in a work stand.
Removal
RemoysJ
Drain the crankcase. Remove the oil
oil
1. Drain
pan and oil pump.
pump.
pan
2. Replace
Replace one bearing at aa time,
2.
time,leaving
leaving
the other
other bearings
bearings securely
securely fastened.
fastened.
the
Remove the
the main
main bearing
bearing cap
cap to
Remove
which new
new bearings
bearings are
are to
to be
which
installed.
installed.
3. Insert
Insert the
the upper
upper bearing
bearing removal
removal Tool
Tool
3.
(Tool 6331)
6331) in
in the
the journal
journal oil
oil hole.
hole.
(Tool
21-12-16
21-12-16
2800cc V-6 Engine
crankshaft slowly in the

direction of engine rotation to force
the bearing insert out of the block.
Installation
InsWlation
1.
1. Clean each crankshaft
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.
No. 3 main bearing.
2. To install the upper main bearing,
lubricate the bearing with heavy
then place
place the
the end
end of
of the
the
engine oil SE then
bearing over the shaft on the locking
tang side of the block and partially
6331
install the bearing so that Tool 6331
hole.
can be inserted in the journal oil hole.
6331 installed, rotate the
With Tool 6331
crankshaft slowly in the opposite
crankshaft
direction of engine rotation until the
bearing tang is seated. Remove the
bearing tool.
3. Select fit the bearing for proper
4. Coat the bearing insert and journal
with heavy engine oil SE and install
cap. Tighten the cap bolt
the bearing cap.
to specification.
5. Install the remaining bearings in the
same manner. If servicing the rear
main bearing, apply sealer to the cap
38. If necessary,
as shown in Fig. 38.
align the thrust bearing as shown in
Fig. 39.
2.
2.
3.
4.
5.
t A3577-A
6.
6.
FIG. 39 Aligning Thrust Bearing
9. Position the gaskets on the block. See

9.
Fig. 40 for installation of the rear
seals. Install
main bearing cap wedge seals.
one end seal in the rear main bearing
cap and the other in the cylinder
block front cover.
cover. Be
Besure
sureends
endsengage
engage
oil pan side gaskets properly.
7.
7.
8.
8.
9.
9.
WEDGE SEALS
PISTONS AND CONNECTING

RODS
RemoyaJ
Removal
1.
2.
A3578-A
FIG. 40 Replacing Rear Main Bearing

Cap Wedge Seals
APPLY SEALER TO THESE SURFACES
A3576-A
FIG. 38 Sealer Application to Rear

Main Bearing Cap
6.
6. Clean all oil pan gasket surfaces
surfaces
thoroughly. Straighten the oil pan
f l a n g e if
if deformed
d e f o r m e d due to
to
flange
overtorquing the bolts.
7.
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
screen and torque
torque
attaching bolts to specifications.
8.
8. Coat the cylinder block oil pan
surfaces and oil pan gasket surface
with oil-resistant sealer.
BACK TO GROUP INDEX
clean. Foreign material under inserts

or between rod and cap will distort
the bearing and cause premature
failure.
Clean the crankshaft
crankshaft journal.
Install the bearing inserts in the
fitted in the slots provided.
Pull the connecting rod assembly
crankshaft
journal.
following
Select fit the bearing following
procedures in Part 21-01.
fitted,
After
clean and apply a light coat of engine
oil to the journal and bearings. Install
cap. Tighten the
the connecting rod cap.
specification.
nuts to specification.
Clean the oil pump inlet tube screen.
Prime the pump by filling the inlet
opening with oil while rotating the
opening. Install the pump with a new
gasket and torque the attaching bolts
to specification.
Install the oil pan.
Fill the crankcase to the correct level
with the specified oil.
and check for leaks.
10. Position
Position the
the oil
oil pan
pan and
and install
install the
the
10.
attaching bolts. Torque the bolts to
specification.
11. Fill the crankcase to the correct level
with the specified oil. Start the engine
CONNECTING
The connecting rod bearings are
selective fit. Refer to procedures under
Bearing with Plastigage, Part 21-01.
RemoysJ
Removal
1.
pan and related parts.
2.
2. Remove the oil pump.
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
Installation
1.
1. Make sure bearing inserts and bearing
bore in connecting rod and cap are
3.
4.
5.
5.
6.
6.
intake
crankcase. Remove the intake
manifold, cylinder heads, oil pan and
oil pump, following the procedures in
this Section.
Remove any ridges and/or deposits
from the upper end of the cylinder
bores as follows:
follows:
Turn the crankshaft
piston to be removed is at the bottom
of its travel and place a cloth on the
Remove any ridge and/or deposits
furnished by the tool manufacturers.
excess of 1/32 inch when removing
ridges.
ridges.
Make sure all connecting rod caps are
marked so that they can be installed
in their original positions.
Turn the crankshaft
connecting rod being removed is
down.
Remove the connecting rod nuts and
cap.
Push the connecting rod and piston
Avoid damage to the crankshaft
journal or the cylinder wall when
removing the piston and
and rod.
21-12-17
21-12-17
2800cc V-6 Engine

2800cc

8. Install the cap on the connecting rod
from which it was removed.
Feeler Gauge
Installation
Installation
1.
1. If new piston rings are to be installed,
remove the cylinder wall glaze.
Follow the instructions of the tool
manufacturer.
2.
2. Oil the piston rings, pistons and
cylinder walls with light engine oil
(SE). 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 toto
3 in the right bank and from 4 to 6
in the left bank, beginning at the front
of the engine.
engine. The numbers on the
connecting rod and bearing cap must
be on the same side when installed in
the cylinder bore (Fig. 41). If a
connecting rod is ever transposed
to another,
another,
from one block or cylinder to
new bearings should be fitted and the
connecting rod should be numbered
to correspond with the new cylinder
number.
3.
3. Make sure the ring gaps are properly
spaced around the circumference of
the piston (Fig.
(Fig. 42).
4.
4. Install aa piston ring compressor on
the piston and push the piston in with
aa hammer handle
handle until it isis slightly
below the top of the cylinder (Fig.
(Fig. 43).
43).
Be sure to guide the connecting rods
Be
crankshaft
to avoid damaging the crankshaft
journals. Install the
the piston with
with the
journals.
notch in
in the
the piston head
indentation notch
toward
toward the
the front
front of the
the engine (Fig.
%, A3579-A
FIG. 41 Connecting Rod and Cap

Numbering
"- OIL RING SPACER
A
OIL RING
SEGMENT
OIL RING
SEGMENT
SEGMENT
\1,/
J~
)K
/ \
, I '
"
C PISTON
r ~
COMPRESSION RING I COMPRESSION RING

FRONT OF ENGiNE'
ENGINE
fRONT
A2811-A
FIG. 42 Piston Ring Gap Spaci~g

Spacing
i
44).
44).
5.
5. Check the clearance of each bearing
following the procedure under Fitting
Main and Connecting Rod Bearings
in'
in Part 21-01.
21-01.
6.
6. After the bearings have
have been fitted,
fitted,
apply
apply aa light coat of engine oil
oil (SE)
to the
the journals and bearings.
bearings.
to
7.
7. Turn the
the crankshaft throw to the
bottom of its
its stroke.
stroke. Push the
the piston
all the
the way
way down
down until the
the connecting
all
crankshaft
rod bearing seats
journal.
journal.
8. Install the connecting rod cap.
cap.
8.
Tighten the
the nuts
nuts to
to specifications.
specifications.
Tighten
9.
9. After
After the
the piston and
and connecting rod
assemblies have
have been
been installed,
installed, check
assemblies
the side
side clearance
clearance between the
the
the
connecting rods
rods on
on each
each crankshaft
crankshaft
connecting
(Fig. 45).
45).
journal (Fig.
10. Disassemble,
Disassemble, clean,
clean, and
and assemble
assemble the
the
10.
oil pump.
pump. Clean
Clean the
the oil
oil pump
pump inlet
oil
tube screen
screen and
and the
the oil
oil pan
pan and
and block
tube
gasket surfaces.
surfaces.
gasket
11. Prime
Prime the
the oil
oil pump
pump by
by filling
filling either
11.
the inlet
inlet port
port or
or outlet
outlet port with
the
engine oil
oil and
and rotating
rotating the
the pump
pump shaft
shaft
engine
BACK TO GROUP INDEX
A3581-A
FIG. 43 Installing Piston

RIGHT BANK
RIGHT
LEFT BANK
NOTCHES
FRONT
ENGINE
NUMBERED SIDE
SIDE TO
TO LEFT
LEFT
NUMBERED
A3580-A
A3580.
FIG. 44 Correct Piston

Piston and Rod
Rod
FIG.
Positions
to distribute the oil within the
housing. Install the oil
oil pump and the
housing.
oil pan.
pan.
oil
A 3594-A
45 Checking Connecting
Connecting Rod
Rod
FIG. 45
Side Clearance
12. Install the

the cylinder heads following
Cylinder Head
procedures under Cylinder
Installation.
13. Install the intake manifold following
procedures under Intake Manifold
Installation.
14. Fill
Fill and bleed the
the cooling system.
system. Fill
and quantity of engine oil.
Start the
the engine
engine and check and adjust
adjust
15. Start
the ignition timing. Connect
Connect the
distributor
distributor vacuum hoses at the
carburetor.
Operate the
the engine
engine at
at fast idle
idle and
16. Operate
check for oil and coolant leaks. When
the engine temperature has stabilized,
adjust
adjust the engine idle speed and idle
fuel mixture.
Install the
the air
air cleaner
cleaner and
and intake
intake duct
17. Install
assembly.
CRANKSHAFT
Removal
Removsl
crankshaft and related parts are
The crankshaft
shown in Fig. 46.
1. Remove engine from the vehicle and
1.
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
4.
of
engine and front cover.
5. Invert engine and remove oil pump
5.
and inlet tube assembly. Leave oil
pump drive shaft in position.
6. Make sure all main and connecting
6.
bearing caps are marked so they can
be installed in their original locations.
7. If crankshaft
crankshaft is being replaced,
7.
remove gear as shown in Fig. 27.
8. Remove connecting rod nuts and lift
8.
off rod cap with bearing insert.
off
Carefully push piston and rod
Carefully
assemblies down in cylinders.
9. Remove main bearing bolts and lift
9.
off main bearing caps with inserts.
otT
Discard rear oil seal.
10. Carefully
Carefully lift
lift crankshaft
crankshaft out
out of
of
10.
cylinder block, being careful not to
damage the thrust bearing surfaces.
21-12-18
2800cc V-6 Engine
21-12-18
MAIN BEARING L1NERS-6333

LINERS-6333
& PULLEY
DAMPER &
ASSEMBLY-6B321AA
ASSEMBL
Y-6B321AA
FLYWHEEL ASSEMBLY-6375
ASSEMBLY-6375
6384 (RING GEAR)
SCREWS
jII"r
CRANKSHAFT GEAR-6306
I I\
.
~I
BOLT-6345
MAIN BEARING CAP BOLT-6345/
~uSTl
IB~:~~~G. ~
I
-.
r 1
BOLT-6379
MAIN BEARING LINERS

-6333
Installation
InstaHation
*,~
*, 1 ,*
MAIN BEARING CAPS
* SERVICED IN 6010 BLOCK ASSY.

ASSY.
A3582-B
46 Crankshaft and Related Parts

FIG. 46
Remove bearing inserts from block

and identify for position if they are to
be re-used.
Installation
InstJd/ation
1.
1. If crankshaft
crankshaft gear was
was removed,
install it
it as shown in
in Fig.
Fig. 28.
2.
2. Clean the bearing bores in
in the block
and caps and the bearing inserts on
on
both sides.
sides. Foreign material under the
inserts or on the bearing surfaces may
the insert and
and cause bearing
distort the
failure.
3. Assemble main bearing inserts in
in
their correct location in bearing caps
and cylinder block. Check alignment
of oil holes in inserts with oil holes in
block. Apply aa liberal coating of SEtype engine oil to the bearing surfaces.
Carefully
Carefully lower crankshaft
crankshaft into
position. Check gear timing marks for
(Fig. 29).
correct positioning (Fig.
4.
4. Apply aa thin even coating of
of sealing
sealing
compound to the rear sealing surface
of the rear main bearing cap as shown
Fig. 38.
38. Install main bearing caps
in Fig.
in their correct location. The arrows
on the front and center main bearing
to the
the front of
of the
caps must point to
engine.
engine.
5. Install and
and tighten all
all main bearing
5.
bolts finger tight. Then tighten all
all
bolts, except for center thrust bearing,
in steps to
to specifications.
6.
6. Align the thrust bearing surfaces by
the crankshaft
crankshaft forward and
forcing the
and
cap rearward.
While holding in this position, tighten
cap bolts
bolts totospecifications
specifications (Fig.
(Fig.
the cap
39).
7.
lip of aa new
7. Coat the
the sealing lip
new
crankshaft oil
oil seal with SE-type
crankshaft
oil. Slide seal over end
end of
of
engine oil.
crankshaft
and drive into position
crankshaft and
(Fig. 35).
35). Be sure the seal bottoms in
(Fig.
groove.
groove.
BACK TO GROUP INDEX
4. Assemble the
the puller screw and
4.
and
on the
the expanding mandrel.
install on
of
Wrap aa cloth around the threads of
the puller screw to
to protect the front
or journal. Tighten the
bearing or
the
to remove the
and pulling plate to
the
camshaft bearing. Be sure to
to hold aa
to prevent itit from turning.
5. Repeat the
the proced
procedure
for each
5.
ure for
bearing. To remove the front and rear
special adapter tube
bearings, use the sp~cial
Tool T72C-6250.
8. Using a flat tool such as a large blunt

8.
wedgeend screwdriver, push the two wedgethe cylinder
shaped seals between the
block and
cap.
and rear main bearing cap.
Position the seals with the round side
facing the main bearing cap (Fig. 40).
9.
9. Pull connecting rods up one at a time
and install rod caps.
caps. Be sure to apply
a liberal coating of SE-type oil to the
bearing surfaces. Tighten cap nuts to
specifications.
10.
10. Install
Install oil
oil pump
pump and
and pick
pick up
up tube
tube as
as
an assembly.
11. Install front cover.
12.
12. Install
Install rear
rear cover
cover plate,
plate, flywheel
flywheel
housing and
and flywheel. Tighten
flywheelbolts
boltstotospecifications.
specifications.
flywheel
Install clutch
clutch disc
disc and
and clutch
clutch pressure
pressure
13. Install
plate, if so equipped.
14.
14. Install
Install oil
oil pan
pan as
as described
described under
under Oil
Oil
Pan-Installation.
PanInstallation. Be
Be sure gaskets
and seals are installed as directed.
15. Install
Install the
the front
front cover
cover and
and previously
previously
removed components.
16.
16. Install
Install the
the engine
engine in
in the
the vehicle.
vehicle.
CAMSHAFT BEARING
camshaft bearings are
are availbale
The camshaft
pre-finished
no
pre-finished to
to size and
and require no
reaming for
for standard and
and undersize
journal diameters.
Removal
RemoJ'al
1.
1. Remove the engine from the vehicle
and place in
in aa work stand. Remove
the flywheel and
and the
the camshaft.
camshaft.
Remove the rear bearing bore plug.
2. Remove the
the camshaft bearings with
the tools shown in
in Fig.
Fig. 47.
and back-up nut and assemble on the
expanding
the
expanding mandrel. With the
collet assembly in
in the
the camshaft
camshaft
bearing. Tighten the back-up nut on
the expanding mandrel until the collet
fits the camshaft
camshaft bearing.
1. Position the
the new
new bearings at
at the
1.
the
bearing bores, and press them in place
in Fig.
Fig. 47.
47. Be
Be
with the tools shown in
sure to
to center the
the pulling plate and
to avoid damage to
to the
the
puller screw to
to use
use the
the correct
bearing. Failure to
can cause severe
expanding collet can
damage. Align
Align the
the oil
oil holes
holes in
in
bearing damage.
in the
the
the bearings with the oil holes in
cylinder block when the bearings are
installed. Check oil hole alignment of
of
Nos. 2 and 3 bearings with aa welding
welding
rod or slightly smaller diameter than
holes. Insert the rod into the
the
the oil holes.
(Fig. 48).
48). The rod will pass
pass
oil passage (Fig.
into the camshaft bore when the holes
are properly aligned.
2.
2. Install aa new bearing bore plug.
the camshaft, flywheel and
3. Install the
and
related parts,
p a r t s , following
following the
related
the
appropriate procedures. Do not check
rod and
and main bearing
connecting rod
as aa part of Camshaft
Camshaft
clearances as
Bearing Replacement. Install the
the
in the vehicle.
engine in
OIL FILTER
Removal
RemoJ'al
1.
a drip pan
pan under the
the filter.
1. Place a
filter.
the filter
filter from the
the adapter
Unscrew the
fitting. Clean the filter adapter recess.
InstaHation
Installation
1.
1. Coat the
the gasket on
on the
the replacement
oil. Position the
the filter
filter on
filter with oil.
on
the adapter fitting. Hand tighten the
the gasket contacts the
filter until the
the
it 1/2
adapter face, then advance it
turn.
2.
of
2. Add one quart of the proper grade of
engine oil to
to the crankcase.
3. Operate the
the engine at
at fast idle, and
and
for oil
oil leaks.
leaks. If oil leaks are
are
check for
evident, perform the necessary repairs
leakage. Check the oil
to correct the leakage.
and fill
fill the
the crankcase to
to the
the
level and
recommended level if necessary.
21-12-19
2800cc V-6 Engine
21-12-19
Tool T71P-6250-A
A3585-B
FIG. 47 Typical Camshaft Bearing Replacement
A3586-A
Alignment-Nos. 2 and 3 Camshaft Bearings

FIG. 48 Checking Oil Hole AlignmentNos.

must be torqued
t o r q u e d (refer
(refer to the
the
must
Specification at the end of this Part for
torque specifications), oil the threads
oil. Do not
with light weight (SE) engine oil.
oil threads that require oil-resistant or
water-resistant sealer. Refer to Part
inspection
21-01 for cleaning and inspection
procedures.
R M ASSEMBLY
VALVE ROCKER A
ARM
Refer to Fig. 49 for component parts.
Dissssembly
1. Remove the spring washer and pin
from each end of the valve rocker arm
shaft.
BACK TO GROUP INDEX
2. Slide the rocker arms, springs and

shaft supports off
off the
rocker arm shaft
shaft. Be sure to mark the parts for
re-assembly in the same locations.
If it is necessary to remove the plugs
3. If
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
Assembly
1.
1. The oil holes in the rocker arm shaft
shaft
must point down when the shaft
shaft is
installed. This position of the shaft
shaft
can be recognized by a notch on the
shaft (Fig. 49).
front face of the shaft
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
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.
21-12-20
21-12-20
CYLINDER HEAD
HEAD
CYLINDER
overstressing
overstressing the
the valve
valve springs
springs and
and
overloading
overloading the
thecamshaft
camshaft lobes
lobeswhich
which
would lead
lead to
to spring
spring breakage
breakage and
and
would
worn camshaft
camshaft lobes.
lobes.
worn
Disassembly
Disassembly
R e m o v e deposits
d e p o s i t s from
from the
the
1.1. Remove
combustion chambers
chambers and
and valve
valve
combustion
heads with
with aascraper
scraper and
and aa wire
wirebrush
brush
heads
before removing
removing the
the valves.
valves. Be
Be
before
careful not
not to
to scratch
scratch the
the cylinder
cylinder
careful
head gasket
gasket surfaces.
surfaces.
head
Compress the
the valve
valve springs.
springs. Remove
Remove
2.2. Compress
the valve
valve retainer
retainer locks
locks and
and release
release
the
the springs.
springs.
the
3. Remove
Remove the
thespring
springretainer,
retainer, stem
stemseal,
seal,
3.
and valve
valve (Fig.
(Fig. 50).
50). Discard
Discard the
the valve
valve
and
stem seals.
seals. Identify
Identify all
all valve
valve parts
parts for
for
stem
re-assembly. Remove
Remove the
the manifold
manifold
re-assembly.
assembly and
and spark
spark plugs.
plugs.
assembly
Clean, inspect and repair all
all parts
parts
1.1. Clean,
before assembly.
assembly. Install
Install the
the manifold
manifold
before
assembly and spark plugs.
plugs. Torque the
the
spark plugs
plugs and
and manifold
manifold attaching
attaching
spark
parts to
to specifications.
specifications. Lubricate
Lubricate the
the
parts
valve guides
guides and
and valve
valve stems
stems with
with
valve
engine oil.
oil. Apply
Apply Lubriplate
Lubriplate to
to the
the
engine
tips of
of the
the valve
valve stems.
stems.
tips
2. Install each valve in the valve guide
2.
from which
which itit was
was removed
removed or
or to
to
from
which itit was
was fitted.
fitted. Install
Install aa new
new stem
stem
which
seal on
on the
the valve.
seal
valve.
3. Inst~ll
Install the valve spring assembly over
the valve,
valve, close
close coils
coils toward
toward the
the
the
cylinder head. Install the spring
retainer.
4. Compress the spring and install the
cylinder head spring pad to the
dividers (Fig. 51).
51).
6. Check the dividers against a scale. If
If
the
the assembled
assembled height
height is
is greater
greater than
than
specifications,
install the
the necessary
necessary
spacer(s)
spacer(s) between
between the
the cylinder
cylinder head
head
spring
pad and
and the
the valve
valve spring
spring to
to
spring pad
bring
bring the
the assembled
assembled height
height to
to the
the
recommended
recommended dimension.
dimension. Do
Do not
not
install
install spacers
spacers unless
unless necessary.
necessary. Use
Use
of
of excess
excess spacers
spacers will
will result
result in
in
RETAINER_6514~
~;
~\ ~\::~~PRING
AND CONNECTING
CONNECTING ROD
PISTON AND
Disassembly
connecting
cap.
ROCKER
ROCKER ARM-6564
ARM-6564
PIN-72034-S
PI N-72034-5
"
V
~\.r. \(,,;\..i
SPRING
SPRING
6587
6587
2.2. Mark
Mark the
the pistons
pistons and
and pins
pins to
to assure
assure
assembly
assembly with
with the
the same
same rod
rod and
and
installation
installation in
in the
the same
same cylinders
cylinders
from
from which
which they
they were
were removed.
removed.
3.3. Using
Using an
an arbor
arbor press
press and
and the
the tool
tool
shown
shown in
in Fig.
Fig. 53
53 press
press the
the piston
piston pin
pin
from
from the
the piston
piston and
and connecting
connecting rod.
rod.
Remove
Remove the
the piston
piston rings.
rings.
OIL PUMP
PUMP
OIL
Disassembly
DisllSSembly
1.1. Remove
Remove oil
oil pick-up
pick-up tube
tube and
and screen
screen
assembly from
from pump
pump housing.
housing.
assembly
Assembly
Assembly
2.2. Remove
Remove oil
oil pump
pump cover
cover and
and lift
lift out
out
The
The piston,
piston, connecting
connecting rod
rod and
and
two-piece
two-piece rotor
rotor assembly
assembly (Fig.
(Fig. 52).
52).
related
parts
are
shown
in
Fig.
54.
Clean
related
parts
are
shown
in
Fig.
54.
Clean
3.
3. Drill
Drill aa small
small hole
hole in
in the
the center
center of
and
and inspect
inspect the
the piston
piston and
and connecting
connecting rod
rod
pressure
pressure relief
relief valve
valve plug.
plug. Thread
Thread an
an . following
Part
21-01.
procedures
given
in
following
procedures
given
in
Part
21-01.
appropriate
appropriate size
size metal
metal screw
screw in
in the
the
Check
Check the
the fit
fit of
of aa new
new piston
piston in
in the
the
hole
hole and
and pull
pull the
the plug
plug from
from the
the
cylinder
cylinder bore
bore before
before assembling
assembling the
the
housing.
housing.
piston
piston and
and piston
piston pin
pin to
to the
the connecting
connecting
4.
4. Remove
Remove pressure
pressure relief
relief valve
valve spring
spring
rod.
rod.
and valve.
valve.
and
The
The piston
piston pin
pin bore
bore of
of aa connecting
connecting
Assembly
Assembly
rod
rod and
and the
the diameter
diameter of
of the
the piston
piston pin
1.
1. Clean and
and inspect
inspect the
the oil
oil pump
pump
must
must be
be within
specifications.
given in
in Part
Part
following procedures given
21-01. Apply
Apply SE-type
SE-type engine
engine oil
oil to
to the
the
21-01.
LOCKS-6518
LOCKS-6518
valve and relief valve
valve spring.
spring.
relief valve
valve and spring into
Insert relief valve
RETAINER-6514 ...
housing.
housing.
2.
2. Install aa new
new relief valve retaining
INTAKE
~.\f
INTAKE VALVE
VALVE
6W7
f
:.
plug into the oil
oil pump housing.
housing. Place
6507
bottoms.
plug into housing until it bottoms.
\
The plug should be installed with its
VALVE SPRING
6513
out. With aa round
flat side pointing out.
\
OILSEAL-6571
drift of approximately 1/2
1/2 inch
drift
\
EXHAUST
EXHAUST VALVE
VALVE
diameter and a hammer, spread the
6505
6505
plug in the housing to prevent its
A3589-A
accidental removal.
3. Install inner and outer rotors and
FIG. 50 Valve Assemblies
shaft assembly in housing. Make sure
sure
shaft
the dimple
dimple identification
identification marks
markson
onthe
the
outer rotor and inner
inner rotor
rotor are
are on
on the
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
cover in position
position and
and tighten
attaching screws to specifications.
Check for free movement of
of rotor.
Assembly
Assembly
~ 0, ~
21-12-20
21-12-20
2800cc
2800cc V-6
V-6 Engine
Engine
PI N-72034-S
PIN-72034-S
\',rj\J\J \~
SPRING-6587
SPRING-6587
,.
tf.'
SUPPORT
SUPPORT
6531
6531
?'
SPRING WASHER
WASHER
SPRING
6598
6598
A3590-A
FIG. 51 Checking Valve

Valve Spring
FIG.
Assembled Height
Height
Assembled
BODY ASSEMBLY-6600
ASSEMBLY-6600
BODY
ROTOR AND
AND SHAFT
SHAFT
ROTOR
ASSEMBLY-6608
ASSEMBLY-
SUPPORT-6531
SUPPORT-6531
SUPPORT-6531
SUPPORT-6531
SPRING
SPRING WASHER
WASHER
6598
6598
.....~.:.;:.. :
BOLT
: ...
~l ~
SHAFT-6563
SHAFT-6563
JJ'
PLATE-6616
PLATE-6616
A3588-A
A3588-A
FIG.
FIG. 49
49 Rocker
Rocker Arm
Arm Shaft
Shaft Assembly
Assembly
BACK TO GROUP INDEX
BOLT
A3591-A
FIG. 52
52 Oil
Oil Pump
Pump Disassembled
Disassembled
FIG.
21-12-21
1.
1. Apply aa light coat of engine oil to all
parts. Assemble the
the piston and
and the
the
connecting rod
rod as shown in Fig. 44.
connecting rod
rod (this may
may require aa
very light tap with a mallet). Using an
arbor press, press the
the piston pin
pin
through the
the piston and
and connecting
rod until the
the pin
pin is
is centered in
in the
the
piston (Fig.
(Fig. 53).
3. Check the end gap and spacing of all
piston rings following instructions
given in
be
in 'Part
Part 21-01. They must be
4. F o0 l11l o0 w
w the
t h e man
m a nuufa
f accttuurree rr ' s
instructions (included with the piston
ring package) and
and install the
the piston
rings.
rings.
5.
inserted between the
the ring and
and the
the
lower land (Part 21-01).
21-01). The
The gauge
gauge
the
the bearing inserts and
6. Be
Be sure the
and the
the
in the
the connecting rod
bearing bore in
rod
are clean. Foreign material
and cap are
the inserts will distort the
under the
the
in the connecting rod
bearing inserts in
in the
the
and cap with the tangs fitting in
slots provided.
CYLINDER ASSEMBLY
Disassembly
Disassembly
1. Mount the old engine in a work stand
1.
and remove all
not furnished
furnished
all parts not
the new
new cylinder assembly,
with the
and Installation Section of
of
Removal and
this Part.
2. Remove the
the old
old cylinder assembly
2.
Assembly
1.
BACK TO GROUP INDEX
21-12-21
2800cc V-6
V-6 Engine
Engine
UPPER
-'>,..-COMPRESSION
COMPRESSION
~
RING
, _ DRIVER DETAIL A-7

A)
6148
6148
..
LOWER
COMPRESSION
RING
>
-.....-~~~OILRING
ASSEMBLY
.~.
....
...,l
INSERT THIS END

FOR INSTALLATION
a::~::~:::~~::::R
tt
REVERSIBLE LOCATOR
DETAIL A-5
DETAIL
A5
.w~ INSERT THIS END

FOR PIN REMOVAL
;:,t
Tool
Tool T72C.6735
T72C-6135
CONNECTING
ROD ASSEMBLY
BOLT-6214
BOLT-6214
Tool
6735- A
Tool T68PT68P-6135-A
.......".,
ROD B~;'~INGS:<
CONNECTING
CONNECTING
J6200
ROD BEARINGS ^ \
X
6211
CUP
C U P DETAIL
D E T A I L AA1
-l
62121~1
NUT
NUT-6212
A3592A
A3592-A
FIG.
FIG. 53
53 Removing
Removing or
or Installing
Installing Piston
Piston
Pin
Pin
all
a work stand and
and transfer
transfer all
serviceable parts removed from the
the
old cylinder assembly, following the
the
procedures given in the Removal and
Installation Section of this Part.
and
3. Check all
all assembly clearances and
CYLINDER BLOCK
Before replacing aa cylinder block,
determine if it is
is repairable. If so,
so, make
the necessary repairs, following the
the
procedures given in
in Part 21-01.
Disassembly
Disassembly
1. Completely disassemble the
the old
old
1.
engine, following the
the procedures
given in the Removal and Installation
Section of this Part.
A3593-B
A3S93-B
FIG.
FIG. 54
5 4 Piston,
Piston, Connecting
Connecting Rod
Rod and
and
Related
Related Parts
Parts
2. Remember to ridge-ream the cylinder

bores before
before removing piston
assemblies.
assemblies.
Assembly
1. Clean the cylinder block following the

1.
in Part 21-01.
instructions given in
Clean the gasket and seal surfaces of
in aa
2. Position the new cylinder block in
work stand and install all serviceable
parts removed from the old cylinder
block, following the procedures given
in the
and Installation
the Removal and
3. Check all
all assembly clearances and
and

21-12-22
2800cc V-6 Engine
21-12-22
SPECIFICATIONS-1975
SPECIFICATIONS1975
IENERAL
RCIFICATIONS
8ENERAL SPECIFICATIONS
EnpiK
En.
.
Sorl
Bora and Stroke
2800ee
2800.cc
3.66 x 2.79
2.79
Comprlssion
PrlSSurl
PSI (Sea
(See Levll)
Level) @
9 Cranking
Speed
Drive Sitt
Bert Tlnlionl
Tensions (lbl.)
(lbs.)
Oil Pressure-Hot
Lowest Reading within 75%

of highest.
Size
@2000
RPM
@2000RPM
Firing Order
40-55
1-4-2-5-3-6
(1) Read tension immediately after belt is

or seats in
in pulley grooves.
to 90-120 pounds.
Newly Instilled
Installed
U....
Ustd
UptoiOMin.
Up
to 10 Min. DVII'
Over 10 Min.
(1)
(1)
1/4"
1/4"
50-80
Exc. 1/4" 120-160
40-80 (2)
(2)
40-60 (2)
90-160 (3)
75-120 (4)
(2) If less than 40

40 pounds, readjust to 40-60 pounds.
CYLINDER HEAD
CVLlNDER
Valve Guid.
Guide
Va".
Bora Dilmltlr
Diameter
Borl
(Standard
Intake and
In1lke
and
Exhault)
Exhaust)
Combustion
Chamber
Voluml
Volume
Engina
ERline
2800cc
Vaivi
Valve
StltWidth
Seat Width
0.31740.3174
0.3184
42.8-44.3
Head Gasket Surface Finish R.M.S.

CD
Head
I|
Intakl
Intaka
Seat
Slit
Runout
(Maximum)
Valve
Valve
Stet
Seat
Angl.
Angle
Exhaust
Valve
Arrangement
(Front to
Rllr)
Rear)
Gasket
Surface
Flatness
CD
CD
003'nany
o0 003
,n any
45
0.050-0.079
0.0015
inches,
6 Inches.
0.006
0006
overall
IEEIEI (LH)
IEIEEI (RH)
(RH)
60150
60-150
VAL VE SPRINGS
VALVE
Valve Spring Pressure lbs
Lbs @
@
Engine
Valve Spring Free

Length Approximate
66.5-74.5 @
@ 1.585
143.5-156.0 @
@ 1.222
2800cc

Height Pad to
to Retainer
1.99
Valve Spring
OutatSquare
Out of Square (Maximum)
137/64
1-37/64-. 1-39/64
5/64 (.078)
Wear Limit ...... 10% Pressure Loss.
VALVES
To Valve Guide
Clearance CD0
Clearance
Intake
Exhaust
Engine
0
<D
0.00180.0035
0.0008O.OOOS0.0025
2800cc
2S00cc
Rocker Arm
Arm
Bore Diameter Shaft Diameter
Valve Stem To Rocker

Arm Clearance
Intake
Exhaust
Pushrod
Valve Head
Runout
Diameter
T.I.R. (Max.) Intake
Exhaust
Valve
Angle
Rocker Arm
Arm
Follower
Ratio
0.7830-0.7842
0.014 Hot
Hot
0.020
44
44
1.46:11
1.46:
(2)
0.0055
Wear Limit ......0.0055
0.7799-0.7811
Valve face runout
0.016 Hot
Hot
1.5621.577
1.2611.276
... Maximum 0.002
'"
VALVES (Continued)
Valve Stem Diameter
Engine
2800cc
Intake
Exhaust
0.3158-
0.3149-
0.3167
0.3156
0.016 Oversize
Exhaust
Exh.ust
0.008 Oversize
Intake
Exhaust
Intlke
Exh.ust
Intake
Intlke
0.32380.3238
0.3245
0.33170.3324
Standard
Stand.rd
0.3228-
0.3235
Intake
0.032 Oversize
Exhaust
0.34740.3481
0.3481
0.33070.3314
0.34840.3471
0.3471
CYLINDER
CYLINDER BLOCK
Valve Lifter
Engine
Cylinder Bore
Diameter CD0
Main Bearing
Bore Diameter
Distributor Shaft
Bearing Bore Diameter
Head Gasket
Surface Flatness ( 2 )
2800cc
3.6614-3.6630
3.6614-3.6630
2.3866-2.3874
0.4534-0.4549
0.003 in
6", 0.006 overall 0.8736-0.8741
in 6",
0
CD
Cylinder bore surface

RMS ........ 15-38
finish RMS
15-38
Maximum out-of-round ...... 0.0013

Wear Limit . ............... 0.005
0 005
Taper Limit ............... 0.010
0.010
(2)
CD
Standard Diameter
To Bore
Clearance To
CD0
0.0009-0.0024
Head gasket surface

finish RMS
finish
RMS ... ... .60-150
60-150
CAMSHAFT
Theoretical V.lve
Valve Lift @ Zero
Zero Lash
Lash
Lobe lift
Lift (J)
0
Lob.
Ca",sh.ft
Camshaft
Engine
Ellli.
Intake
In~k.
2800cc
O Maximum allowable-lobe lift loss - 0.005.
0.005.
Q)
Exhaust
Intake
0.2555
~
<2> Wear Limit - 0.009.
I
0.3730
Exhaust
Exh.ust
End PI.yOO
Play ( D
0.0008-0.004
Camshaft
Journal To
Camsh.ft Journ.1
SI.ring
~
Bearing CIII,.ncl
ClMranca Q)
Clearance
Ciliranci
0.0010-0.0026
Q) Wear limit
Limit - 00.006.
.006.
~
CA1262-D
BACK TO GROUP INDEX

21-12-23
V-6 Engine
2800cc V-6
21-12-23
CAMSHAFT ORIVE
DRIVE MECHANISM
Item
Bearing
Bearing
2800cc
(No. 1)
11
1.6505
1.63471.6355
1.61971.6205
1.60651.6073
1 6073
1.6515-1.6523
1.6515-1.6523
1.6365-1.6373
1.6365-1.6373
1.6215-1.6223
1.6215-1.6223
1.6065-1.6073
1.6065-1.6073
1.6497Lb48/-
(No.2)
(No.
2)
Camshaft Journal
Diameter
Standard<J)
Standard
(No.3)
(No. 3)
(No
4)
(No. 4)
Mo.
(N'o. 1)
(No.2)
(No.3)
(No. 3)
(No. 4)
(No.4)
camshaft
Bearings
Camshaft Bearings
Inside Diameter
Engine
Entine
CAMSHAFT GEAR CRANKSHAFT GEAR

OR SPROCKETG)
SPROCKET
OR SPROCKET
Autmbled
A-.nbled
HSWmDItu
Auembled
Aunout TI
AM.x
Face Runout TIR
TIR Max
Face Runout
TIR
Max
Flee
MIX Fie.
2800cc
.Q.007
0.007
0.005
(f)
- 0.006-0.010
CD Backlash
Backlash-0.006-0.010
Camshaft Bearing
camshaft
Bearing
(No.
(No.
Q)
Location a>
0.040-0.060
1)
(Dcamshaft
journal maximum
maximum runout
runout 0.005. Camshaft journal
(DCamshaft journal
journal maximum
outotround O.OOOJ.
out-of-round
0.0003.
Distance
in
inches
that
the
front
edge
of
the
bearing
(2) Distance in inches that the front edge of the bearing is
is installed
installed below
below
the front face of the block (towards the rear).
a>
CRANKSHAFT BEARINGS
Bearings
To Crankshaft
Clearance
To
Engine
Desired
2800cc
Standard
Allowable
Allowable
0.0005-0.0015
0.0005-0.0015
Main Bearings
Bearings
Main
Desired
Desired
Allowable
Allowable
Wall
Wall ThicknessThickness-
00005-0.0022
0.0005-0.0022
CI>
(3)
Wall Thickness
Wall
Standard
CDQ
Red 0.0707-0.0710
Red
0.0707-0.0710
Red 0.0548-0.0552
Red
0.0548-0.0552
Blue 0.0552-0.0556
0.0552-0.0556
0.0005-0.0019
0.0005-0.0016
Blue 0.0711-0.0714
0.0711-0.0714
CDo.D02 U.S. Thickness Add 0.001 to

to Standard Thickness.
0.002
CRANKSHAFT AND FLYWHEel
FLYWHEEL
Main Staring
Bearing
M.in
Journal
Journll
Diameter
Di.m.tlr())
Engine
M.in
Btaring
Main Bearing
Journal RunoutRunout
M.ximum(%) <D
@
Maximum
2.2433
2.2441
2800cc
2800cc
Main Bearing
Mlin
Staring
I
I
0002
0.002
CD Connecting rod
rod and main
main bearing
bearing journal
journal out-at-round
maximum 0.0006.
Thrun
Thrust
Staring
Bearing
Journal
Journll
Length
Llngth
Main and Rod

Main
Thrust Face
Thrun
Fie.
Runout
Journal
Taper
rap.r Max
0.0010 Max.
Max.
1.039
1.041
0.0005 Per
Per Inch
Q) Wear
Q)
Wear Limit
Limit - 0.005
M.in
Be.ring
Main Bearing
Surface Finish
Surf.et
RMS
Maximum
AMSMlximum
Journ.1
Thrun
Fie.
Journal
Thrust Face
20
20
12
12
Q)
Crankshaft to
to rear
rear cylinder block
block face
tace runout
runout 1.I.A....
Max.
T.I.R. . . . 0.005 Max.
CRANKSHAFT AND FLYWHEEL (Continu.d)

(Continued)
Connecting
Rod
Rod Bearing
Bearing
Connecting
Rod Journal
Diameter CD0
Engine
2.12522.1260
2800cc
<D
Journal
Maximum
Taper
Crankshaft
Cr.nkshlft
Free End
Fr"
Play
PlIV (2)
<D
0.0006 Inch
0.004-0.008
Flywhtal
Flywheel
Clutch
Face
Fae.
Runout
St.ndlrd
Standard
Automatic
0.005
0005
0.025
0.060
Flywheel
Lateral Runout
Flywheel Ring
Aing Gear
Gear lateral
Runout
T.I.R.
rod bearing
bearing journal
maximum 0.0006.
0.0006.
Connecting rod
Wear limit
Limit....
. . 0.012.
CD
ROD
CONNECTING ROD
Piston Pin
Pin
Bora
Bore
Engine
2800cc
2800ee
(10)
(ID)
0.9450-0.9452
Crankshaft
Bearing
B.aring
Bore Diameter (f)
Bore
(X)
Twist
2.2370-2.2378
5.1386-5.1413
0.006
^Connecting rod bearing bore maximum out-of-round

0.0004
CDConnecting
outof-round and taper ........ ...0.0004
Connecting Rod
Assembly
Assembly
(Assembled
(Assembled To
To
Crankshaft)
Crankshaft) 0)
<$
Connecting Rod
Alignment
Alignment
Maximum
Maximum Total
(?)
Difference <D
Connecting
Rod
Length
Rod length
Center
To Center
I
I
Bend
Side Clearance
Ciliranc.
0004
0.004
0.004-0.011
0.0040.011
Q)
Wear Limit --0.014
0.014
( 2 ) Wea
(2)Pin
in the same vertical plane
~Pin bore and crankshaft bearing bore must be
be parallel and in
within the specified total difference when measured at
at ends of an 8-inch long bar
bar 44
inches on each side of rod.
CA12620
CA1262-D11
BACK TO GROUP INDEX

21-12-24
21-12-24
21-12-24
2800cc V-6
V-6 Engine
PISTON
PISTON
Diameter
Oiamet-CD
Engine
Engine
Piston
To
Pifton To
0.020
0.020 Ovenizi
Ovmiza
Standard
Standard
Pin
Pin
Bore
Bore Diamltt,
Diameter
Bore
Bore CIII,ancl
Clearance
Ai,. Groove
Groove Width
Ring
Width
2800 cc
cc
2800
Upper Compression
CompressIon Ring
Ring
Upper
0.0803
0.0803
0.0811
0.0811
3.68023.68023.6812
3.6812
3.66053.66053.6615
3.6615
2800ce
2800cc
0.00110.00110.0019
0.0019
0.9450
0.9450
0.9452
0.9452
Lower Compression
CompressIon Ring
0.1197
0.1197
Oil
Oil Ring
0.1579
0.1579
0.1587
0.1587
0.1205
0.1205
.... ....
CD
CD Measured
Measured at the piston pin
pin bore centerline at 90
90 to the pin bore.
PISTON
PIN
PISTON PIN
Diameter
Diameter
Length
Length
Engine
Engine
2800cc
2800cc
2.835-2.866
2.835-2.866
Ta Connecting
Connecting Rod
Rod
To
Ta Piston
Piston Cllarance
To
Clearance
Standard
Standard
Bushing Clearance
Clearance
Bushing
Interference Fit
Fit
Interference
0.0003-0.0006
0.0003-0.0006
0.9446-0.9450
0.9446-0.9450
PISTON
PISTON RINGS
RINGS
Compre~sion
Comprersion Ring
Engine
Engine
Top
Top
2800cc
0.0778-0.0783
CD
W Wear
e a r Limit.
L i m i t . .........
.
...
Ri,. Gap
Gap Width
Ring
Width
Side Clearance
Side
Ring
Ring Width
Width
Top
Top
Bottom
0.1172-0.1177
.... 0.006
0.006
Compression Ri",
Compression
Ring
Compression RingeD
Ring
Top
Top
Oil Ring
Oil
Bottom
Oil Ring
Ring
Oil
Bonom
Bottom
Q)
00150- 0.0230
0.0150-0.0230
Snug
0.0020-0.0033
0.015-0.055
0.015-0.055(2)
(VSteel
S t e e l Rail
OIL PUMP
PUMP
Engine
Relief Valve
Spring Tension
Drive
Drive Shaft
Shaft
To
To Housing
Housing
Bearing
Relief Valve
Relief
Rotor AssemblV
Rotor
Assembly
To Bore
End
End Clearance
(RadIal
(Radial
Lbs @ Specified Length
Clearance
Clearance
Clelf.nce
Assembled
Clearance)
Clearance)
0.0014-0.0029
0.0015-0.0030
0.0015-0.0030
13
14 7
13 6
6-14.7
2800cc
@ 1.39
1.39
Outer Race
Race
Outer
..
To Housing
Housing
To
0.006-0.012
0.0011-0.0041
0.0011-0.0041
APPROXIMATE
APPROXIMATE OIL PAN
PAN CAPACITIES
Engine
Engine
2800cc
^
CD
U.S. Measure
Imperial Measure
Measure
Imperial
4.5 Qt.(D
Qt.
3.8 Qt. CD
Add 1/2 quart with filter replacement

replacement
Add
SPECIAL
SPECIAL TORQUE
TORQUE LIMITS
LIMITS
Item
C a m s h a f t G e a - ![b:1
iB;it)
Camshaft
C a m s h a f t Th',lst
T h - u s t Plate
P l a t e IBoltl
(Bolt)
Camshaft
Carbuieto r to Spacer (Stud)
(Stud)
Carburetor:o
Carburetor .Adapter
Adapter to
to Manifold (Stud)
(Stud)
Carburetor
Carburetor to
to Spacer (Nut)
Carburetor
Connecting Rod
Rod (Nut)
(Nut)
Connecting
Crankshaft Damper
Damper (Boltl
(Bolt)
Crankshaft
Valve
Crankcase Vent Valve
Cylinder Head
Head (Bolt)
(Bolt)
Cvlinder
Decel Valve (Nut)
Decel
(Nut)
Decel Valve
Valve to
to Manifold
Manifold (Adapter)
(Adapter)
Decel
Distributor Clamp (Bolt)
(Bolt)
Distributor
EGR Tube Fittings
Fittings
EGR
EGR Valve to
to Spacer (Bolt)
(Bolt)
EGR
Ex. Manifold
Manifold to
to EGR
EGR Tube (Connector)
(Connector)
Ex.
Ex. Manifold
Manifold to
to Cvl.
Cyl. Head
Head (Bolt/Stud)
(Bolt/Stud)
Ex.
Flywheel to
to Crankshaft (Bolt)
(Bolt)
Flywheel
Front Cover
Cover to
to Cvl.
Cyl. Block (Bolt)
(Bolt)
Front
Front Plate
Plate to
to Cvl.
Cyl. Block 1801t)
(Bolt)
Front
Fuel Pump
Pump to
to CVI.
Cyl. Block (Bolt)
(Bolt)
Fuel
Int. Manifold
Manifold to
to CVI.
Cyl. Block (Bolt/Nut)
(Bolt/Nut)
Int.
Int. Manifold
Manifold to
to CVI,
Cyl. Block (Stud)
(Stud)
In\.
Main Bearing
Bearing Cap
Cap (Bolt)
(Bolt)
Main
Pointer to
to Fr.
Fr. Cover 180ltl
(Bolt)
Monolithic Timing Pointer
Oil Pump
Pump Pick-up
Pick-up Tune
TuDe to
to Pump (Bolt)
(Bolt)
Oil
(T)
CD
2.8L Engine
Torque
Metric
Ft Lb
FtLb
Thread Size
M1 [)
M1D
M8
MR
30-36
303li
Pl
12-15
17
1~J
t)
( '
[
:33
MB
M8
M8
M8
M12
MP
~J5
(1
3-5
;110
4-1 B
21-25
21/')
92 ](]3
103
97
1-
>
,\18
Mo
MB
Mf:
M l 13/MS
M1lJ;M8
M10
~.11
[)
MB
Mil
MB
Mll
MB
M8
MB
ME
MB
~'1B
M12
M12
M6
M6
M6
M6
( 1 R
M8
M6
M14
M6
'
Q)
(D
M6
M10
M8
M6
-
1
1 |
1
Gb-BO (T)
27 30
30-34
3D:]4
2-1b
12b
11
; ~)D
5-20
122-15
1~J
5-35
6-23
1673
1)1
il77-51
17215
UJ
2-15:J
121
2-15:J
171
t
11
11-14
111i1
M 12
~,11
2
2.8L Engine
2.8L
Metric
Torque
Torque
Thread Size
Ft-Lb
Ft-Lb
Item
1
1-
i
1
-i
H
i
1
t
1 1
A
\
1
t
1
I
1
0-12
ll
6b-771
bJ
G~
11
1,7
5-7
7-9
lCJ
i
1
(2)
i
1
1/
T.m,
1 P
M8
M12
M8
~18
M8
M10
M8
~18
b l B
Ft-Lhs), 711rJ
2nd stl~P
step
Cylinder Head
Head Bolts in
in sequence In
in 3 steps
steps. 1st step - (29-40 Ft-L!,s),
Torque Cvlinder
(40-51 Ft-Lbs);
Ft-Lbs); 3rd
3rd step -- (65-80 Ft-Lbs)
Ft-Lbs).
(40-51
gasket.
( 3 ) 1/2
1/2 turn
turn after
after gasket
gasket contacts
contactssealing
sealing surface
surface With
with oiled
0 led gaskel
(!)
IH I l l l . l M ! M
i3-(i I t ' L b s ) , 2 n d
Ft 1 1Si. A i l t ' l (!!
1
I
' 1
1 P
1 1
1 r
j |
\
HI
R
untold !n i'\l Bli

,!f'p !(i 11 h - l
inn has Imnn opui
rk H n i i s ; N u s in seqiiencr in 4 steps
s). 3 u i step
12-15
12-15
7-9
7-9
15-20
15-20
5-7
10-15
10-15
Q)
3-b
3-:J
43-49
43-49
14-18
14-18
12-15
12-15
7-9
79
7-11
15-20
15-20
80-100
80-100 in-lbs.
m-Ibs
18-25
45-60
45-60
50-71
24-40
18-25
18-25
14-20
14-20
28-40
28-40
18-25
18-25
22-32
30-45
30-45
1st step -
(1 1 10 Ft-Lbs), 4,th step - (15-18
,'(!, nMo.1,1 ' . i l l h o l t s / n u l s t n 15-18 Ft-Lhs H o t ) .
CA1262-D2
CA126202
BACK TO GROUP INDEX

21-12-25
21-12-25
2800cc V-6 Engine
STANDARD TORQUE LIMITS

Metric Thread Sizes
U.S. Thread Sizes
Pipe Thread Sizes
1/4-20 = 6-9
3/8-24 = 27-38
M6
6-9
M12
50-71
50-71
1/8 = 5-8
3/8 = 22-33
5/16-18 = 12-18
7/16-14 =45-57
= 45-57
M8
14-21
14-21
M14
80-114
1/4=12-18
1/4 = 12-18
1/2 = 25-35
5/16-24 = 14-20
7/16-20 = 40-60
M10
28-40
3/8-16 = 22-32
1/2-13 = 55-80
NOTES:
NOTES:
values shown
shown are
are in
in Ft-Lbs unless
unless otherwise noted.
noted.
i AllAll values
Oil
Oil threads with engine oil unless the threads require oil-resistant or water-resistant sealer.
sealer.
are applicable for all

all other functions not shown
shown in
in the special
special torque charts.
charts.
Standard
Torque
Limits
are
CA1451A
CA1451-A
BACK TO GROUP INDEX

21-12-26
2800cc V-6 Engine
21-12-26
SPECIFICATIONS-1976
SPECIFICATIONS1976
Engine
Bore and Stroke
2800ce
2800cc
3.66 x 2.70
2.70
PSI (Sea
(Sea Level) @Cranking
@ Cranking
Speed

Ubs.)
Oil Pressure-Hot
@2000
@ 2000 RPM
RPM
Size
1-4-2-5-3-6
(3)
Used
Used
(1)
(1)
Firing Order
40-60
Lowest Reading within 75%

75%
of highest.
Newly Installed
1/4"
1/4"
50-80
Exc. 1/4" 120-160
Up to 10 Min.
UptoiOMin.
Mm.
Over 10 Min.
40-80 (2)
90-160 (3)
40-60 (2)
(4)
75-120 (4)
If less than 90 pounds, readjust to 90-120 pounds.
(4)
CYLINDER HEAD
Valve
Valvt Guide
Guidt
Bore Diamtttr
Diameter
80rt
(Standard
(Sttndard
Intake and
Intllcelnd
Exhlust)
Exhaust)
Combuition
Combustion
Chamber
Chamlltr
Volum.
Volume
Engine
Engint
Vtlvt
Valve
V.lve
Valve
St.t
Seat
StitWidth
Seat Width
I|
Intake
Intlkl
Angl.
Angle
Exhaust
Exhlust
Valve
Vllve
Valve
Seat
Selt
Runout
(MlXimum)
(Maximum)
Arrangement
Arrlngement
Gisket
Gesket
Surface
Surflce
Flatness
(Front to
Relr)
Rear)
CD
0
any
00003
003 ,n
many
0.3174-
2800cc
45
450
0.060-0.079
0.3184
42.8-44.3
0.0015
6 Inches,
inches,
IEEIEI (LH)
lEI EEl (RH)
IEIEEI
0.006
overall
<D
Head Gasket Surface Finish R.M.S.
Head
60-150
VALVE SPRINGS
Valve Spring Pressure (Lbs) @
@
Specified Length
Engine
Valve Spring Free

Length Approximate
@ 1.585
60.0-68.0 @
1.585
138.0-149.0 @
@ 1.222
1.222
2800cc

Height (Pad to Retainer)
1.91
1.91
Valve Sp-ring
Spring
OutotSquare
Out-of-Square (Maximum)
1-37/64-- 1-39/64
1-37/64
5/64 (.078)
Wear Limit ...... 10% Pressure Loss.

VALVES
Engine
Eng!ne
Valve
Valvt Stem
To Valve Guide
Clearance CD0
Exhaust
Intake
2800ec
2800cc
0.0008-
0.0018-
0.0025
0.0035
G)
Wear Limit ......0.0055
0
0.0055
Valve Stem To
To Rocker
Rocker Arm
Arm
Bore Diameter Shaft Diameter
0.7830-0.7842
Arm Clearance
Intake
Exhaust
Cold o0 0.018 Cold

0.7799-0.7811 0.015 Cold
Cold o0
0.7799-0.7811
Valve Head
Pushrod
Diameter
Runout
T.I.R. (Max.) Intake
Exhaust
Valve
Angle
Rocker Arm
Arm
Follower
Ratio
0.020
440
44 0
1,46:
1.46:11
1.5621.577
1.2611.276
@
Valve face runout ......Maximum
Maximum 0.002
(f )
VALVES (Continu.d)
(Continued)
Engine
Intake
Intalce
Exhaust
Valve
Valv. Stem Diameter
0.016 Oversize
0.008 Oversize
Overaiz.
Exhaust
Intllce
Intake
Intake
Intllce
Exhaust
2800cc
0.3159
0.3167
0.31490.3156
0.3245
Standard
0.32280.3235
0.3239
0.3318
0.3307-
0.3324
0.3314
Intake
0.032 Oversize
Exhaust
0.3484-
0.3475
0.3481
0.3481
0.3471
0.3471
CYLINDER BLOCK
Valve Lifter
Engine
Cylinder Bore
Diameter 0
Main Bearing
Bore Diameter
Distributor Shaft
Diameter
Bearing Bore 0iameter
Head Gasket
Surface Flatness ( 2 )
2800cc
3.6614-3.6630
2.3866-2.3874
0.4534-0.4549
0.8736-0.8741
0.003 in 6", 0.006 overall 0.8736-0.8741
0G)
CD
Cylinder bore surface

finish RMS
RMS ........ 18-38
18-38
out-of-round ...... 0.0015

Maximum out-af-round
Wear Limit ................ 0.005
Taper Limit ............... 0.010
(2)
Standard
Diameter
Bore Diameter
Clearance
To
^
Clea~~r~e
To (1)
Bore
0
0.8750-0.8760
0.0009-0.0024
Head gasket surface

finish RMS
RMS ....... 60-150
CAMSHAFT
a>
Intake
Intlke
2800cc
2800ee
(1)
Maximum
<D Max
mum allowable-lobe lift loss - 0.005.
Camshaft Journal To
Btaring
~
Bearing CIranct
Clearance
Theoretical Valve
Zero Lash
Lash
Thtoretical
Vllve Lift @ Zero
Lobt
Lobe Lift <D
Engine
Enline
Exhaust
Intake
~ Wear Limit
L i m i t - 00.009.
.009.
I
0.3730
0.2555
Exhaust
End PlavO)
Play ( D
0.0008-0.004
Clearance
Clllr.ne.
0.0010-0.0020
~ Wear Limit
- 0.006.
0
Limit-0.006.
CA1262-E
BACK TO GROUP INDEX

21-12-27
2800cc V-6 Engine
21-12-27
CAMSHAFT DRIVE
ORIVE MECHANISM
Item
Bearing
2800cc
1.6497
1.6505
1.6347
1.6355
1.6197
1.6205
1.60651.6073
1.6515-1.6523
1.6365-1.6373
1.6215-1.6223
1.6065-1.6073
(No. 1)
1)
(No.2)
(No. 2)
Camshaft Journal
Diameter
Standard
Standard<D
(No.3)
(No.
3)
Camshaft Bearings
Inside Diameter
(No.1)
(No. 1)
(No.2)
(No. 2)
(No.3)
(No. 3)
(No.4)
(No. 4)
Camshaft Bearing
Location (2)
(No.1)
(No.
1)
(No.4)
(No. 4)
Enginl
Engine
CAMSHAFT GEAR CRANKSHAFT GEAR

OR SPROCKET
SPROCKET
OR SPROCKETCD
A.mblld
Assembled
Assembled
Face Runout TI
TIR
Max
Facl
R MIx
Face Runout TIR MIX
Max FaCI
2800cc
0.007
Backlash
- 0.006-0.010
Backlash-0.006-0.010
<D
0.005
0.040-0.060
(1)Camshaft
(J)Camshaft journal maximum runout 0.005. Camshaft journal maximum
outotround
(2) Distance in inches that the
the bearing is ir:1stalled
installed below
the front face of the
the block (towards
(!9wards the
the rear).
CRANKSHAFT BEARINGS
Connecting Rod
Rod Bearings
Bearings
Desired
Oesired
Allowable
Engine
2800cc
0.006-0.0015
Main Bearings
Desired
Allowable
Wall ThicknessStandard CD
CD
0.0548-0.0552
Red 0.0548-0.0552
Blue 0.0552-0.0556
0.0005-0.0022
0.0008-0.0015
0.0005-0.0019
Wall Thickness
Standard (T)
CD
Red 0.0707-0.0710
0.0707-0.0710
Blue 0.0711-0.0714
0.0711-0.0714
CDo.OO2
U.S. Thickness Add 0.001 to Standard Thickness.
^ . 0 0 2 U.S.
CRANKSHAFT AND
AND FLYWHEel
FLYWHEEL
Engine
2800cc
<D
Main Bearing
Mlin
BHrin.
Journal
OiameterCD
Diameter<))
JouriMi
Journal Runout"
Runout
2.2433
2.2441
0.002
Main Bearing
Blarin.
Maximum tJ)
Maximum(2)
Thrust
Main Beering
Blaring
Main Beering
M.in
BI.ring
Thrust Face
Runout
Rod
Main and Rod
Bearing
Blaring
Surface Finish
Journal
Taper Max
Tapir
MIX
Journal
0.0010 Max.
Max.
0.0005 Per
Per Inch
Connecting rod
rod and
and main
main bearing
bearing journal out-of-round maximum 0.0006.
i - T i r i i i i r w i i
@ Wear
Wear Limit
Limit - 0.005
a>
Length
Llngth
Journll
Journel
1.039
1.041
12
RMS Meximum
RMSMlXimum
Thrust Face
Flel
20
20
@
T.I.R} ..... 0.005 Max.
Max.
Crankshaft to rear cylinder block face runout T.I.
CRANKSHAFT AND
AND Fl
YWHEEl (Continued)
FLYWHEEL
Connecting
Rod Journal
Diam.t.r
Diameter 0
CD
Engine
2.12522.1260
2800cc
Connecting
Rod Bearing
Journal
Maximum
Taper
Tap.r
Crenk,haft
Crankshaft
Free End
End
Fr.
Play
(1)
Pley
Flywhlll
Flywheel
Clutch
Face
Faci
Runout
0.0006 Per Inch
0.004-0.008
0.005
Flywheel Ring Glar

Gear Lateral Runout
T.I.R.
Autom.tic
Automatic
St.ndard
Standard
0.025
0.060
(T) Connecting rod

CD
rod bearing journal out-of-round
uut-of-round maximum 0.0006.
0 Wear Limit ....
....0.012.
CV
0.012.
CONNECTING ROD
ROD
Pin
Piston Pin
Bore
Bo"
Engine
2800cc
(to)
(ID)
0.9450-0.9452
Connecting Rod
Rod
Alignment
Maximum Total
Difference
Crankshaft
Be.ring
Beering
Diameter ( D
Bore Dineter<J)
Connecting
Length
Rod length
Center
To Center
Twist
2.2370-2.2378
5.1386-5.1413
5.1386-5.1413
0.006
^Connecting rod bearing bore maximum out-at-round

out-of-round and taper ...........0.0004
0.0004
<Dconnecting
I
I
Connecting Rod
Rod
Assembly
(Assembled To
Crankshaft)
<D
Bend
0.002
Side Clearlnc.
Clearance
Sidl
0.004-0.011
Q)
Q) Wear Limit - 0.014
PPin
i n bore and
and in the
(%)
be parallel and
'within
an 8-inch long bar 4
within the specified total difference when measured at ends of an
rod center line.

inches on each side of rod
CA1262-E1
BACK TO GROUP INDEX

21-12-28
2800cc V-6
V-6 Engine
21-12-28
PISTON
Diameter
o
iamet.r(D
Engine
Piston To
To
0.020 Oversize
Ov.rsiz.
Standard
3.68023.6812
3.66053.6615
2800cc
Pin
Pin
Bore Dilmlter
Diameter
Borl
Bora Cluranc.
Clearance
Bore
0.00110.0011-
0.9450
0.9450
0.0019
0.0019
0.9452
0.9452
Groove
Ring G
rooVl Width
2800 cc
cc
Compression Ring
Upper CompreSSion
0.0803
0.0811
0.OS11
Compression Ring
Lower CompreSSion
0.1197
0.1205
Oil Ring
ali
0.1579
0.1579
0.1587
..... " .
\D Measured at the piston

CD
piston pin
pin bore
bore centerline at
at 90
90 0 to
to the
the pin
pin bore.
bore.
PISTON PIN
PIN
Diameter
Diameter
Engine
Length
2800cc
2.835-2.866
To Connecting Rod
Rod
To Pilton
Piston Cllarlnce
Clearance
Standard
Bushing Clearance
Interference Fit
0.0003-0.0006
0.9446-0.9450
PISTON RINGS
Compression
Compre~sion Ring
Engine
Top
2800cc
0.0778-0.0783
Wear Limit.
CD
Limit. .......... ..
Ring Gap Width

Ri",
Clearance
Side CI..rence
Ring Width
Top
Bottom
I 0.1172-0.1177
Bottom
Oil Ring
Ring
Top
Snug
0.0020-0.0033
0.1172-0.1177
.. 0.006
Compression Ring
Compreaion
Ring
Compression RingCD
Oil Ring
Ring
Bottom
Bonom
0.015-0.055
@
0.015-0.055(2)
0.0150-0.0230
0.01500.0230
S t e e l Rail
CDSteel
Rail
OIL PUMP
PUMP
Outer Race
Drive Shaft
To
To Housing
Relief
Valve
Relief Vatve
Relief
R.lief Valve
Vlive
Rotor
Rotor Assembly
To
To Housing
End Clearance
Assembled
Clearance)
Clearance)
Spring Tension
Bearing
To Bore
To
Bore
Engine
Engine
Clearance
Clearance
Clearance
Clearance
2800cc
13 6 14 7 @
@ 1.39
1.39
136147
0.0015-0.0030
0.0015-0.0030
(Radial
0.001-0.013
0.001-0.013
0.004 Max.
Max.
OIL PAN
PAN CAPACITIeS
CAPACITIES
APPROXIMATE OIL
Engine
Engine
U.S. Measure
U.S.
Measure
2800cc
4.5 Qt.
4.50t.CD
Imperial Measure
Measure
CD
3.8 Qt.
3.80t.
^
Add 1/2 quart with
CD
Add
with filter replacement
speCIAL
TORQUE LIMITS
SPECIAL TORQUE
Item
2.8L Engine
Torque
Metric
Ft-Lb
Thread
FtLb
Thread Size
f : Gea,Boltl
Camsha
Camshaft
Gear ^Bolt)
Camshaft Thrust Plate IBolt)
(Bolt)
Carbuietor
:o Spacer (Stud)
Carbuletor:o
IStud)
Carburetor Adapter to
to Manifold (Stud)
to Spacer (Nut)
Carburetor to
(Nut)
Rod (Nut)
(Nut)
Connecting Rod
Crankshaft Damper (Bolt)
Crankcase Vent Valve
Cylinder Head
Head (Bolt)
Decel
Decel Valve (Nutl
(Nut)
Decel
Decel Valve to
to ManifOld
Manifold (Adapter)
Distributor Clamp (Bolt)
EG
R Tube Fittings
EGR
EGR Valve to
to Spacer (Bolt)
Ex.
to EGR Tube (Connector)
Ex. Manifold to
Ex. Manifold to
to Cyl.
Cyl. Head
Head (Bolt/Stud)
Flywheel to
to Crankshaft (Bolt)
Front Cover to
to Cyl
Cyl. Block (Bolt)
Front Plate to
to Cyl.
Cyl. Block (Bolt)
Fuel Pump to
to Cyl.
Cyl. Block (Bolt)
Int. Manifold to
to Cyl.
Cyl. Block (Bolt/Null
(Bolt/Nut)
lnt.
Int. Manifold to
to Cyl.
Cyl. Block (Stud
(Stud)I
Cap (Bolt)
Main Bearing Cap
Monolithic Timing Pointer to
to Fr.
Fr. Cover (Bolt)
Oil Pump
to Pump
Pump Pick-up Tube to
Pump (Bolt)
CD
(T)
(3)
@
M10
MlO
M8
M8
-_
-~
M8
MB
M8
M8
M12
M12
-_
-_
M8
-_
M8
-_
M10/MB
M10/M8
M10
Ml0
M8
M8
M8
M8
MB
M8
MB
M12
M6
M6
2.8L Engine
Torque
Metric
Ft-Lb
Size
Thread Size
M8
M8
M6
M14
M6
-
Tube:o
Brg. Cap
Oil Pump Pick-up Tube
to Main
Mam Brg.
Cap (Bolt)
Gil
Gil Pump Cover (Bolt)
Oil
Gil
Pan
Dra;n
Oil Pan Dra^ Plug
Oil Pan
Panto
Gil
to Cyl. Block (Bolt)
Oil Filter to
to Cyl. Block (Insert!
011
Oil Filter to Engine
Rocker Arm
Aim COVRr
Cover IBoill
(Bolt)
Rocker Arm Shaft Support IBolt)
(Bolt)
WatRr
Water Jacket Drain
Dram Plug
Water
Woter Outlet Connection (Bolt)
Water
Cyl. Block (Bolt)
WiHer Pump
Pump to
to Cvl.
Wiiter Temperature Sending Unit
Water
Spark Plug
Plug to
10 Cyl.
Cy'l Head
Fuel
to Carburetor
Fuel Filter to
to Cvl.
Cvl Heod
Alternator Mounting Bolt to
Head (8olt!
(Bolt!
Alternator Mounting Bracket to
to Cylinder Block (Bult)
(Bull)
Alternator Pivot Bolt
A1ternatur Ad|.
Adl Arm.
Arm to Flont
Alternator
Front Cover IBolt)
(Bolt)
Alternator Adj.
to Alternotor
Alternator
Adl. Aim
AI m to
Crankshaft Pulley to
'Crankshaft
to Damper (Bolt)
Fan
Fan to
to Water Pump H,lb
Hub (Bult)
(Bolt)
Mounting Blk!.
Brkt. to
to CVI
Cyl. Block (Boltl
(Bolt)
Therm. Pump Mountlnq
Therm.
Mounting Brk!.
Brkt. to
to Cvl.
Cyl. Head
Head (Bclt)
(Bolt)
Therm Pump Mountlog
Therm. Pump
Pump Adj.
to Pump
Pump (Bult)
(Bolt)
Adl Arm to
Therm. Pump Pivot Bolt
30-36
12-15
3-5
3-5
4-18
21-25
92-103
11-14
65-80 CD
65-BO
2730
27 30
30-34
1215
12-15
15-20
12-15
25-35
16-23
47-51
47-51
12-15
12-15
12-15
18 0
1515-18
10-12
65-75
5-7
7-9
1st step - (29-40

(2940 Ft-Lbs),
Ft-Lbs). 2nd step -Torque Cylinder Head
in sequence in
in 3 steps
steps: 1st
Head Bolts in
(40-51 Ft-Lbs); 3rd step - (65-80 Ft-Lbs).
Ft-Lbs)
(40-51
1/2 turn after gasket contacts sealing surface with oiled gasket.
gasker.
Item
CD
(2)
M6
M10
M8
M6
--M8
M10
M10Ii
M12
MB
M8
M8
M8
M10
M8
M8
--
12-15
7-9
15-20
5-7
10-15
@
(D
3-b
3-5
43-49
14-18
12-15
7-9
7-11
7-11
10 15
10-15
in-Ibs
80-100 in-lbs.
18-25
28-40
45-60
50-71
50-71
24-40
18-25
14-20
28-40
18-25
22-32
2232
30-45
tD Cyl.
[yl Block Bolts/Nuts
Bolts/NlltS in
In sequence in
in 4 steps:
steps 1st
1st step
step-Torque Intake Manifold to
(3-G Ft-Lhs)
(611 Ft-Lbs); 3rd step - (11-16 Ft-Lbs); 4th step - (15-18
(3-6
Ft-Lbs). 2nd step - (6-11
Ft-Lbsl.
(Hot)
Ft-Lbs). After engine has
has been
been operated,
operated, retorque all
all bolts/nuts to
to 15-18 Ft-Lbs (Hot).
CA1262E2
CA1262E2
BACK TO GROUP INDEX

21-12-29
21-12-29
2800cc V-6 Engine
Metric Thread Sizes
U.S. Thread Sizes

u.S.
1/4-20 = 6-9
5/16-18 = 12-18
5/16-24 =
= 14-20
= 22-32
3/8-16 =
3/8-24 =
= 27-38
7/16-14=45-57
7/16-14
=45-57
= 40-60
7/16-20 =
1/2-13 = 55-80
55~80
M6
M6
M8
M8
M10
Ml0
6-9
14-21
14-21
28-40
Pipe Thread Sizes

M12
M12
M14
M14
50-71
50-71
80-114
1/8 = 5-8
1/4=12-18
1/4 = 12-18
3/8 =
= 22-33
1/2 =
= 25-35
NOTES:
NOTES:
All values shown are
are in Ft-Lbs unless otherwise noted.
noted.
Oil
Oil threads with engine oil unless the threads require oil-resistant or water-resistant sealer.
sealer.
all other functions not shown in the special
special torque charts.
charts.
Standard Torque Limits are applicable for all
CA1451-B
BACK TO GROUP INDEX

302 and 351W

351W CID
CtO V-8
v-a Engines
302
21-21~1
21-21-1
21-21-1
21-21 302 and 351W CID V-8 Engines

PART 21-21
Applies to Granada, Monarch, Mustang, Maverick, Comet, Torino and Montego
COMPONENT INDEX
COMPONENT
CAMSHAFT
CAMSHAFT
CAMSHAFT BEARINGS
CAMSHAFT
CAMSHAFT
VENTILATION SYSTEM
Description ........................
CRANKSHAFT
CRANKSHAFT
CRANKSHAFT REAR OIL
OIL SEAL
CRANKSHAFT
Removal and Installation ..............
Y
CYLINDER ASSEMBL
ASSEMBLY
oDisassembly
isassemb Iy and Assembly
Assemb Iy ............
CYLINDER BLOCK
Disassembly and Assembly ............
AND
TIMING CHAIN
CYLINDER HEAD
Disassemb
Iy and Assemb
Iy ............
Disassembly
Assembly
ENGINE
Description ........................
Removal and
ENGINE REAR SUPPORT
Removal and
EXHAUST EMISSION CONTROL SYSTEM
SYSTEM
Description ........................
BACK TO GROUP INDEX
Page
21-13
21-20
21-14
21-14
21-17
21-2
21-6
21-18
21-16
21-23
21-23
COMPONENT
COMPONENT INDEX
Page
EXHAUST MANIFOLDS
EXHAUST
FL YWHEEL
FLYWHEEL
FRONT OIL SEAL
INTAKE MANIFOLD
MAIN BEARING
OIL FILTER
Removal and Installation ..............
OIL PAN
OILPUMP
OIL PUMP
Disassembly
Disassemb
Iy and Assembly
Assemb Iy ............
21-11
21-14
21-13
21-8
21-16
21-20
21-14
21-22
21-16
21-22
21-18
21-24
SPECIFICATIONS 1975 ............... ' 21-24
SPECIFICATIONS 1976 ...............
21-28
21-11
21-11
21-21
21-21
21-10
21-2
21-3
21-4
21-6
VALVE LIFTER
VALVE ROCKER ARM COVER AND
AND
ROCKER ARM
ARM
AND
STEM SEAL
WATER PUMP
Removal and
21-21
21-21
21-9
21-7
21-7
21-11
21-11
21-2

302 and
and 351W
351W CID
CID v-a
V-8 Engines
21-21-2
21-21-2
21-21-2
NOTE:
to both 1975 and 1976
NOTE: The
The infonnation
information in
in this Part applies to
1976 IlH)del
model year
year vehicles
vehicles unless
unless otherotherwise specified.
specified.
CR1966-A
CR1966A
DESCRIPTION
ENGINE
The 302-2V and
and 351-W
351-W V-8
V-8 engines
(Figs.
(Figs. 1 and
and2)
2)have
haveaapiston
pistondisplacement
displacement
of 302 and
and 351
351 cubic inches respectively.

SYSTEM
Operation, removal, installation and
required maintenance of the
the exhaust
exhaust
emission control devices used on these
engines are
29 and
and
are covered in Group 29
Group 50
50 of this Manual.
SYSTEM
The engine is equipped with a positive
closed-type crankcase ventilation system
re-cycling the
the crankcase vapors to the
manifold.
intake manifold.
A3287-B
A3287B
View302-2V V-8
FIG. 11 3/4 Left Front View-302-2V
v-a
BACK TO GROUP INDEX

302 and
and 351W
351W CID
(to V-8
v-a Engines
Engines
302
21-21-3
21-21-3
21-21-3
21-21-3
A2715-E
FIG. 2
3/4
View-351-W V8-With Thermactor
3/4 Right Front View351-W

must be torqued, oil the threads with
light weight engine oil.
oil. Do not
not oil
oil threads
threads
that
t h a t require
r e q u i r e oil-resistant
o i l - r e s i s t a n t or
or
water-resistant sealer.
Refer to Part 21-01 for Cleaning and
Inspection and Engine test procedures.
procedures.
ENGINE ASSEMBLY
5.
5.
6.
6.
7.
7.
The
The Engine
Engine Removal and Installation
Installation
procedures are for the engine only
without the
the transmission attached.
attached. If the
the
engine
engine isis equipped with
with the
the Thermactor
Thermactor
system,
system, remove
remove or disconnect parts
parts that
will
will interfere with
with removal
removal or installation
installation
of
of the
the engine.
engine.
Removal
RemoyaJ
1.1. Drain
Drain the
the cooling
cooling system
system and
and the
the
crankcase.
crankcase.
2.
2. Remove
Remove the
the hood.
hood. Disconnect
Disconnect the
the
battery
battery and
and alternator
alternator ground
ground cables
cables
from
from the
the cylinder
cylinder block.
block.
3.
3. Remove
Remove the
the air
air cleaner
cleaner and
and intake
intake
duct
duct assembly.
assembly.
4.
4. Disconnect
Disconnect the
the radiator
radiator upper
upper hose
hose
from
from the
the coolant
coolant outlet
outlet housing
housing and
and
the
the radiator
radiator lower
lower hose
hose at
at the
the water
water
pump.
pump.
BACK TO GROUP INDEX
8.
8.

disconnect the
the
transmission oil cooler lines from the
radiator.
Remove the bolts attaching the fan
so equipped.
equipped.
shroud to the radiator, if so
Remove the radiator. Remove the
fan, spacer, belt pulley and shroud.
shroud.
fan,
Remove the alternator bolts and
the alternator out of the
the way.
way.
position the
Disconnect the oil
oil pressure sending
wire from the sending unit,
unit, and
unit wire
the flexible fuel line
line at the
the fuel tank
the
line. Plug
Plug the
the fuel tank line.
line.
line.
Disconnect the
the accelerator rod
rod from
from
the carburetor.
carburetor.
the
On
On aa vehicle
vehicle with an
an automatic
automatic
transmission
transmission disconnect
disconnect the
the throttle
throttle
valve vacuum
vacuum line
line from
from the
the intake
intake
valve
manifold. Disconnect the
the manual
manual
manifold.
shift rod
rod and
and disconnect
disconnect the
the
shift
retracting spring
spring at
at the
the shift
shift rod
rod stud.
stud.
retracting
Disconnect the
the transmission
transmission filler
filler
Disconnect
tube bracket
bracket from
from the
the cylinder
cylinder block.
block.
tube
On aa vehicle
v e h i c l e with
w i t h an
an air
air
On
conditioner, isolate
isolate and
and remove
remove the
the
conditioner,
compressor as
as outlined
outlined in
in Group
Group 36.
36.
compressor
On aa vehicle
vehicle with
with power
power steering,
steering,
On
disconnect the
the power
power steering
steering pump
pump
disconnect
bracket
bracket from
from the
the cylinder
cylinder head.
head.
Remove the drive belt. Position the

power steering pump out of the way
and in a position that will prevent the
out.
fluid from draining out.
On a vehicle with power brakes,
vacuum line
disconnect the brake vacuum
manifold.
from the intake manifold.
9. Disconnect the heater hoses
hoses from the
9.
manifold.
water pump and intake manifold.
temperature
Disconnect the water temperature
wire from the sending
sending unit wire
unit.
unit.
10. Remove
Remove the
the flywheel
flywheel or
or converter
converter
10.
housing to
to engine
engine upper bolts.
bolts.
housing
11. Disconnect the
the primary wire
wire from the
the
11.
coil. Remove the wire
wire
ignition coil.
harness from
from the
the left
left rocker
rocker arm
arm
harness
cover and
and position the
the wires
wires out
out of
ofthe
the
cover
way. Disconnect
Disconnect the
the ground
ground strap
strap
way.
from the
the block.
block.
from
12. Raise
Raise the
the front
front of
of the
the vehicle.
vehicle.
12.
Disconnect the
the starter
starter cable
cable from
from the
the
Disconnect
starter. Remove
Remove the
the starter.
starter.
starter.
13. Disconnect
Disconnect the
the mumer
muffler inlet
inlet pipes
pipes
13.
from the
the exhaust
exhaust manifolds.
manifolds.
from
Disconnect the
the engine
engine support
support
Disconnect
insulators from
from the
the brackets
brackets on
on the
the
insulators
frame.
frame.
v-a
21-21-4
302 and 351W

351 W CID V-8 Engines
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
flywheel
housing to engine bolts.
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
Lower the
the vehicle,
vehicle, and
and then
then support
support
14.
the transmission. Attach the engine
lifting sling, Tool No.
No. T53L-3OO-A
T53L-300-A
and hoist to lifting brackets on intake
manifolds.
Raise the
the engine
engine slightly
slightly and
and carefully
carefully
15. Raise
pull it from the transmission.
transmission.
engine compartment (avoid bending
or damaging the rear cover plate or
other components). Install the engine
on a work stand.
Installation
Installation
1.
1. Attach the engine lifting sling, Tool
No. T53L-300-A,
T53L-3OO-A, and lifting brackets
to intake manifold. Hoist the engine
2. Lower the engine carefully into the
engine compartment. Make sure the
exhaust manifolds are properly
aligned with the muffier
muffler inlet pipes.
transmission, start the converter pilot
into the crankshaft.
crankshaft.
manual-shift
transmission, start the transmission
main drive shaft into the clutch disc.
It may be necessary to adjust the
,p0sition
relation to the engine if the input shaft
will not enter the clutch disc.
disc. If the
hangs up
upafter
afterthe
theshaft
shaftenters,
enters,
engine hangs
crankshaft slowly
slowly
turn the crankshaft
(transmission in gear) until the shaft
splines mesh with the clutch disc
splines.
3. Install the flywheel or.
or converter
housing upper bolts, making sure that
the dowels in the cylinder
cyHnder block
engage the flywheel housing.
4. Install the engine support insulator to
bracket attaching nuts. Disconnect
the engine lifting sling and remove the
lifting brackets.
fron t of
5. Raise the front
of the vehicle.
Connect both mumer
muffler inlet pipes to
the exhaust manifolds. Torque the
6.
6. Install the starter and the starter
cable.
cable.
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 aa vehicle
On
vehicle with
with an
an automatic
automatic
transmission,
transmission, remove
remove the
the retainer
retainer
holding
converter in
in the
housing.
holding the
the converter
the housing.
A
ttach the
verter to
Attach
the con
converter
to the
the
flywheel.
flywheel. Install the
the converter
converter
housing inspection cover. Install the
verter housing
remaining con
converter
housing
attaching bolts.
7.
7. Remove the support
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
9. Connect
the water
water temperature
temperature
sending
unit wire.
heater
sending unit
wire. Connect
Connect the
the heater
hose
to
the
intake
manifold.
hose to the intake manifold.
10.
10. Connect
Connect the
the bellcrank
bellcrank to
to the
the intake
intake
manifold.
manifold.
On
an automatic
On aa vehicle
vehicle with
with an
automatic
transmission,
connect
t r a n s m i s s i o n , c o n n e c t the
the
transmission
transmission filler
filler tube
tube bracket.
bracket.
Connect the
the manual
and
Connect
manual shift
shift rod
rod and
connect
retracting spring.
connect the
the retracting
spring.
Connect
vacuum
Connect the
the throttle
throttle valve
valve vacuum
line.
line.
Connect
rod.
Connect the
the accelerator
accelerator rod.
11.
Remove
the
plug
from
the
tank
11. Remove the plug from the fuel
fuel tank
line and
the fuel
fuel line
line and
the
line
and connect
connect the
and the
oil
pressure
sending
unit
wire.
oil pressure sending unit wire.
12.
12. Install
Install the
the pulley,
pulley, belt,
belt, spacer
spacer and
and fan.
fan.
13.
Position
the
alternator
and
install
13. Position the alternator and install the
the
alternator bolts.
bolts. Connect
alternator
Connect the
the
alternator
the battery
battery ground
alternator and
and the
ground
cables.
belt tension
cables. Adjust
Adjust the
the belt
tension to
to
specifications.
specifications.
On aa vehicle
On
v e h i c l e with
with an
an air
air
conditioner,
install
the
compressor
as
conditioner, install the compressor as
Group 36.
36.
outlined in
in Group
outlined
On
power steering,
steering,
On aa vehicle
vehicle with
with power
install
belt and
and power
install the
the drive
drive belt
power
steering
pump bracket.
bracket. Install
Install the
the
steering pump
bracket attaching
bolts. Adjust
Adjust the
bracket
attaching bolts.
the
drive belt
belt tension
drive
tension to
to specifications.
specifications.
On
power brakes,
brakes,
On aa vehicle
vehicle with
with power
connect
the
brake
vacuum
line.
connect the brake vacuum line.
14.
14. Place
Place the
the radiator
radiator shroud
shroud over
over the
the
fan,
if
so
equipped.
Install
fan, if so equipped. Install the
the
radiator.
upper
radiator. Connect
Connect the
the radiator
radiator upper
On
a
vehicl~
wjth
an
and
lower
hoses.
and lower hoses. On a vehicle with an
automatic transmission,
the
automatic
transmission, connect
connect the
transmission fluid
fluid cooler
cooler lines.
lines. Install
transmission
Install
the
bolts if
the shroud
shroud bolts
if so
so equipped.
equipped.
15.
15. Connect
Connect the
the heater
heater hose
hose at
at the
the water
water
pump. Fill
Fill and
bleed the
pump.
and bleed
the cooling
cooling
system.
Fill the
the
system. Fill
the crankcase
crankcase with
with the
of oil.
oil.
proper grade
grade and
and quantity
quantity of
proper
16.
16. Adjust
Adjust the
the transmission
transmission throttle
throttle
linkage.
linkage.
17.
17. Operate
Operate the
the engine
engine at
at fast
fast idle
idle and
and
check
check all
all ggaskets
a s k e t s and
and hose
hose
connections for
leaks.
connections
for leaks.
18.
18. Install
Install the
the air
air cleaner
cleaner and
and intake
intake duct
duct
assembly.
assembly.
19.
19. Install
Install and
and adjust
adjust the
the hood.
hood.
BACK TO GROUP INDEX
21-21-4
The front supports are located on
each side of the cylinder block (Figs.
(Figs. 3
thru 6).
6). The procedures given apply to
either a right or left
left installation.
installation.
self-locking mounting bolts
Figs. 3-8.
nuts. See (*) in Figs.
30-50 FT-LB ~
~
6046
~~6046
6C101RH.A55EMBLY
6C101 R.H. ASSEMBLY
6038 R.H.
"-
383232-52*
(2 REO'D.)
35-60 FT-LB
382400-52*
RIGHT SIDE
30-50 FT-LB
*383232-52
(2 REO'D.)
i
8
35-OF%"
382400-S2
6B032
68032
LEFTSIDE
LEFT SIDE
386069-52
35-60 FT-LB
A4072-B
FIG. 3 Engine Front

Supports-Granada
SupportsGranada and
Monarch
INSULATOR
ASSEMBLY-6038
6D037 L.H.
SIDE ONLY
~~~.
~
---
*383232-52
I. - . -
.'
382802-52*
20-30 FT-LB
~~:/
REOD.~~ .'.:>
35-60 FT-L8
(2
~~.'~.~.&->.
'~01' ~'"
~---
56354
/~'
: __ < ' ) -
~;~m /~'~"._'(_',;~
~/
56350
l'
6061 L.H.
~~_~.,37R.H.
If,': )
1"~ir:~.~~
-.---
382802-52 *
20-37 FT-LB
A3412-C
FIG. 4 Engine Front

Supports-Comet
SupportsComet and
Maverick
Maverick, Comet, Granada and

Monarch
Removal
Removal
1.
1. Support the engine using a jack and
wood block placed under the oil pan.
2.
2. Remove the nut and through bolt
insulator to the
insulator support bracket (Figs. 3 and
and
4).
3. Raise the engine slighly with the jack.
302
302 and
and 351W
351W CID
CID V-8
v-a Engines
Engines
21-21-5
21-21-5
2. From
From under
under the
the car
car support
support the
the
2.
engine
engine using
using aa wood
wood block
block and
and jack
jack
placed under
under the
the oil
oil pan.
pan.
placed
3. Remove
Remove the
the nut
nut and
and through
through bolt
bolt
3.
attaching
attaching the
the insulator
insulator to
to the
the frame
crossmember
crossmember (Figs.
(Figs. 55 and
and 6).
6).
4. Raise
Raise engine
engine enough
enough to remove
insulator and
and heat
heat shield
shield (if
(if so
insulator
equipped).
equipped).
4. Remove
Remove the
the engine
engine insulator
4.
insulator
assembly to
to cylinder
cylinder block
block attaching
attaching
assembly
bolts. Remove
Remove the
the engine
engine insulator
insulator
bolts.
assembly and
and the
the heat
heat shield,
shield, ifif so
so
assembly
equipped.
equipped.
InstslJstion
Installation
Position the
the engine
engine insulator
1. Position
insulator
the heat
heat shield, ifif so
so
assembly and the
cylinder block
block and
and
equipped, to the cylinder
install the
the attaching
attaching lock
lock bolts.
install
bolts to specifications.
Torque the bolts
2. Lower the engine into position, install
insulator assembly
assembly to
the engine insulator
insulator support
support bracket
bracket through
insulator
wood
bolt and remove the jack and wood
block.
insulator assembly
3. Install the engine insulator
to insulator support bracket lock nut.
Torque the nut to specifications.
Torino, Elite, and Montego, and
Mustang
Mustang
RemoYs}
Removal
screws.
382802-S2*
R.H. SIDE ONLY
20-30 FT-LB
Installation
Instllllstion
1. Position the insulator
insulator assembly and
heat
heat shield, ifif so equipped, to the
engine block and torque the attaching
screws to specification.
2. Lower the engine until the through
bolt can be inserted
inserted through
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.
4. Remove the jack and wood block,
install the fan shroud attaching screw.
21-21-5
21-21-5
INSULATOR
INSULATOR
6B032-LH
6B032LH
6038-RH
6038RH
382400-S2*
(2 REC'O.)
35-50 FT-LB
J.
NO. 2 CROSSMEMBER
A3232-F
FIG. 5 Engine Front

SupportsTorino,
Supports-Torino, Elite and
Montego
383232-S2*
(4 REC'O.)
-{/FT.. LB
~
~\
387125-52
(2 REC'O.)
20-30 FT-LB
~_.
INSULATOR - 6038 R.H.
56347-82
(R REC'O.)
383272-S2
(2REQ'D.)
ASSY. -INSULATOR A5SY.

6B302 L.H.
L.H.
6B302
BRACKET ASSY.ASSY.BRACK"ET
. V1
6A069 LH.
L.H.
6A069
/l ..)
382802-S2
38280252
(4 REQ'O.)
REQ'D.)
(4
20-30 FT.-LB.
FT.-LB.
2030
BRACKET - 6043 R.H.
~ 56340-S2
386099-82
(3 REC'O.)
VIEWW
'~(3._~:Q'D'~
VIEW
VIEWX
;1:'
CR05SMEMBER
CROSSMEMBER
6E034
L.H.
L.H. SlOE
SIDE ONLY
ONLY
385759-52
20-30 FT.-LB.
SAME AS VIEW X
EXCEPT AS SHOWN
6A087 ASSEMBLY R.H
;:
L.H.
6A088 ASSEMBLY L.H.
57481-S2 ASSEMBLY
ASSEMBLY
57481-52
(4 REQ'O.)
REQ'D.)
(4
35-50 FT.-LB.
FT.-LB.
35-50
57057-S2 ASSEMBLY
(4 REQ'D.)
20-30 FT.-LB.
VIEW
^
VIEWZ
.---
V IEWW
6A088
6A088 ASSEMBLY
ASSEMBLY
L.H.
REF.
L.H.REF
-.,-.1---- f:~s:g:~~)
368041-5100*
368041-S100*
(2
(2 REC'O,)
REQ'D.)
85-110
85-110 FT.-LB.
FT.-LB.
VIEW
VIEW
XJ
VIEW
VIEWy
386040-5100'
(2 REC'O.)
85-110 FT.-LB.
VIEWy
VIEW
L.H.
L.H. SHOWN,
SHOWN. R.H.
R.H. SYMMETRICALLY
SYMMETRICALLY
OPPOSITE
OPPOSITE
A4058-B
A4058B
FIG.
FIG. 66 Engine
Engine Supports-Mustang
SupportsMustang
BACK TO GROUP INDEX

21-21-6
21-21-6
302 and
and 351W
351W CID
(ID V-8
v-a Engines
Engines
302
21-21-6
21-21-6
ENGINE REAR
REAR SUPPORT
SUPPORT
ENGINE
RemoJ'sl
Removal
1. Remove
Remove the
the ventilation
ventilation system
system air
air
1.
intake hose
hose from
from the
the air
air cleaner
cleaner and
and
intake
the
the right
right valve
valve cover.
cover.
2. Remove
Remove the
the air
air cleaner
cleaner and
and intake
intake
2.
duct assembly.
assembly.
duct
3. Disconnect
Disconnect the
the crankcase vent hose
hose
3.
from the carburetor
carburetor spacer.
from
4. Pull
Pull the regulator
regulator valve out of
of the oil
oil
4.
filler cap
filler
cap in
in the
the left
left valve
valve cover.
cover.
Installation
Instsllstion
1.
1. Insert
Insert the
the regulator
regulator valve
valve into
into the
the oil
oil
filler
cap on
on the
the left
left valve
valve cover.
cover.
filler cap
2.
2. Connect
Connect the
the vent
vent hose
hose to
to the
the regulator
regulator
valve;
valve; install
install the
the hose
hose on
on the
carburetor
carburetor spacer.
spacer.
3.
3. Install
Install the
the air cleaner and intake
intake duct
duct
assembly.
The rear
rear support
support is
is located
located at
at the
the
The
transmission extension
extension housing
housing (Figs.
(Figs. 66
transmission
and 7).
7).
and
mounting
Whenever
bolts and
and nuts are
bolts
are removed, they must be
be
replaced with new self-locking
self-locking bolts and
and
replaced
nuts.
nuts.
RemoJ'sl
Removal
Elite and
and Montego
1. On Torino, Elite
support the engine with aa
models, support
jack and wood block under the oil pan
jack
and remove the support insulator to
crossmember attaching nuts.
support insulator
insulator to
2. Remove the support
and lockwashers.
floor
shift manual transmissions, raise the
shift
transmission with a floor
floor jack.
transmission
Remove the support insulator and
retainer.
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 engine rear support;
then remove the rear support from the
WASHER34794-S2
CROSSMEM~BER
- 502Q;6~r
~~ .. ~
-.~
6068 ASSEMBLY
~379068-S
~ .
45-60 FT-LB
386242-S100
17-32 FT-LB (2 REQ'D.)
INSULATOR -606
BOLT-304726-S2
40-60 FT-LB
NUT-382400-S2
30-50 FT-LB
2 REQ'D
#3 CROSSMEMBER
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.
Ins/slls/ion
Installation
1.
1. Position the support insulator and
retainer on the transmission extension
housing.
housing.
2.
floor
shift, install the support insulator to
and lockwashers.
lockwashers. Torque the bolts to
specifications.
s p e c i f i c a t i o n s . Lower
L o w e r the
the
transmission.
transmission.
3.
floor shift manual
3. On models with floor
transmission, position the rear
rear
support to the transmission and
install and torque the attaching bolts.
bolts.
Position the
the removable crossmember
to
to the
the frame and
and install the
the throughthroughbolts.
bolts. Remove
Remove the
the supporting jack,
jack,
install the
the nuts
nuts and washers
washers attaching
attaching
the
the support
support to
to the
the crossmember
crossmember and
torque
torque the
the nuts
nuts to
to specifications.
specifications.
4.
4. On Torino,
Torino, Elite and
and Montego
Montego
models,
models, install
install the
the support
support insulator
insulator
to
to crossmember
crossmember attaching
attaching nuts.
nuts.
Tighten
Tighten the
the nuts
nuts to
to specifications.
specifications.
CROSSMEMBER - 5 0 2 6
ALL
ALL EXCEPT
EXCEPT
MANUAL
FLOOR SHIFT
/Jr)
#3
# 3 CROSSMEMBER MUST BE
MOVED TO THIS POSITION
FOR C4
C4 AUTO.
AUTO. TRANS.
TRANS.
NUT-386703-S:
70-100 FT-LB
2REQ'D
A3283-E
FIG. 7 Engine Rear

Supports-Torino,
SupportsTorino, Elite and
and
Montego
*382802-S2
20-30 FT-LB
STAMPED
LETTER "R"
/'
FRONT OF CAR
388400-S2
30-50 FT-LB
(2 REO'D.)
/
A3413-C
FIG. 8 Engine Rear

SupportsComet, Maverick,
Supports-Comet,
Granada and Monarch
CRANKCASE VENT
TUBE EXTENSION HOSE
CRANKCASE
CRANKCASE VENT
VENT
HOSE
HOSE
CRANKCASE VENT
TUBE H O S E 6A664
PCV VALVEVALVE
PCV
6A666
6A666
~:.r400_ _
GROMMET.58 I.D.
.71I.D.
GROMMET
OILFILLER
CAP - 6766
CRANKCASE
VENTILATION
SYSTEM
SYSTEM
The
The positive
positive closed-type
crankcase
ventilation
ventilation system
system components
components are
are
shown
shown in
in Fig.
Fig. 9.
9.
A4070-A
A4070-A
FIG. 99 Typical
Typical Crankcase
Crankcase Ventilation
Ventilation System
System Components
Components
FIG.
BACK TO GROUP INDEX

21-21-7
21-21-7
v-a
4.
4. Install
Install the
the ventilation
ventilation system
system air
air
intake
intake hose
hose to
to the
the air
air cleaner
cleaner and
and the
the
right valve
valve cover
cover fitting.
fitting.
right
5.
5. Start
Start the
the engine
engine and
and check
check for leaks.
leaks.
VALVE
VALVE ROCKER
ROCKER ARM
ARM COVER
COVER
AND
AND ROCKER
ROCKER ARM
ARM
The
The valve
valve rocker
rocker arm
arm assembly
assembly
sequence
sequence isis shown
shown in
in Fig.
Fig. 10.
10.
Remoyal
Removal
1.
1. To
To remove
remove aa valve
valve rocker arm from
from
the right cylinder head,
head, disconnect
the
the automatic choke heat chamber air
the
inlet hose
hose from the
the inlet tube
tube near the
inlet
valve rocker arm cover,
cover, if so
right valve
equipped (302
(302 only).
only).
equipped
Remove the
the air cleaner and intake
Remove
assembly.
duct assembly.
Remove the
the automatic choke heat
Remove
the
tube (302 only). Remove the
crankcase ventilation fresh air tube
cover.
from the valve rocker arm cover.
vacuum
Disconnect the EGR vacuum
hoses.
amplifier hoses.
2. Remove the Thermactor by-pass
2.
valve and air supply hoses.
valve
hoses.
from
3.
No.
the spark plugs using Tool No.
T68P-6666-A. Do not pull on wire.
T68P-6666-A.
Remove the wires
wires from
from the
the bracket
bracket on
on
Remove
valve rocker arm cover(s) and
the valve
wires out of the way.
position the wires
4. On a left side rocker arm cover,
4.
remove the wire harness from the
clips. Remove the valve
retaining clips.
rocker arm cover attaching bolts and
remove the cover.
5. Remove the valve rocker arm stud
5.
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.
21-01.
Installation
Installation
All rocker arms and fulcrum seats are
to be lubricated with heavy engine oil SE
1. Apply Lubriplate, or equivalent, to
1.
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
21-02).
3. Install the rocker arm, fulcrum seat
and stud nut.
and
4. Clean the valve rocker arm cover(s)
and the cylinder
cylinder head gasket
gasket
and
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
BACK TO GROUP INDEX
21-21-7
21-21-7
302
302 and
and 351W CID
CID V-8 Engines
0- \
ROCKER
ROCKER ARM
ARM
STUD
STUD NUT
NUT
6A529
6A529
ROCKER ARM
6564
and push rods fronl

from the applicable
cylinder. On 302 CID engines,
remove the exhaust valve stem caps.
4.
4. Install the stud nut and position the
compressor tool as
11.
as shown in Fig.
Fig. 11.
Compress the valve spring and
remove the retainer locks, sleeve,
spring retainer and valve spring.
1634-C
A 1634C
FIG. 10 Valve Rocker Arm-302

Arm302 and
351-W Engines
or6513-HH
bolts and wire loom clips on left hand

cover.
cover. The cover is
is tightened in two
steps.
s t e p s . Torque
T o r q u e the
t h e bbolts
o l t s to
specifications. Two minutes later,
torque the bolts to the same
EGR
specifications. Install the EG
R
vacuum amplifier hoses.
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
6.
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.
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
Remoyal
1. Make sure the applicable piston is at
the top of
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
of the air pressure
to hold the valve(s) in the closed
position is an indication of
of valve seat
damage and necessitates removal of
of
the cylinder head.
3. Remove the valve rocker arm stud
nuts, fulcrum
fulcrum seats, valve rocker arms
FIG. 11
11 Compressing Valve
Spring-In
SpringIn Chassis
5. Remove and discard the valve stem

seal (Fig. 12).
FIG. 12 Removing or Installing Valve

FIG.
Stem Seal
6. If
If air pressure has forced the piston
to the bottom of
of the cylinder, any
removal of
of air pressure will allow the
A
around the end of
of the valve stem will
will
for binds.
binds.
Installation
Installation
damage.
Rotate the valve and check the valve
valve
stem tip for
for eccentric
eccentric movement
movement
during rotation. Move the valve
valve up
up
and down through normal travel in
in
the valve guide and check
check the stem for
binds. If
If the
the valve
valve has
has been
been damaged,
it will be
be necessary
necessary to remove
remove the
the
cylinder head for repairs as outlined
outlined
in Part 21-01.
21-01.
2. If
If the condition of
of the valve proved
proved
satisfactory,
satisfactory, apply heavy engine oil
oil
21-21-8
3.
4.
S.
5.
6.
6.
7.
8.
9.
9.
SE to the valve stem and hold the

valve in
in the
the closed position.
position. Apply
Apply the
the
air pressure within the cylinder.
Install a new valve stem seal
seal (Fig.
(Fig. 12).
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.
Tum
ofT the air and remove the air
Turn off
line and adapter. Install the spark
plug.
Apply Lubriplate or equivalent on
both ends of the push rod. Install the
push rod. Apply Lubriplate or
equivalent to the tip of the valve stem.
stem.
On exhaust valves,
valves, install the valve
stem cap, if so equipped.
Apply Lubriplate, or equivalent, to
the push rod socket, underside of the
fulcrum seat and the valve pad of the
rocker arm; then install the valve
rocker arms, fulcrum seats and stud
nuts.
Clean and install the rocker arm
cover.
If the right cover was removed
install the automatic choke heat tube
(302 only) and the crankcase
crankcase
ventilation hose and fittings. Connect
inlet hose (302 only).
Install the air cleaner and intake duct
assembly.
Install the valve rocker arm covers
and crankcase ventilation hoses, etc.
INTAKE MANIFOLD
manifold assembly is
The intake manifold
shown in Fig. 13.
13.
RemoysJ
Removal
1.
1. Drain the cooling system. Disconnect
inlet hose at the inlet tube near the
right valve rocker arm cover (302
only). Remove the air cleaner,
crankcase ventilation hose and intake
duct assembly.
2. Disconnect the accelerator rod or
cable from the carburetor and/or
manifold brackets. Remove the
manifold
accelerator retracting spring.
Disconnect automatic transmission
and power brake booster vacuum
lines, if so equipped, at the intake
manifold.
3. Disconnect the high tension lead and
wires from the coil.
4. Remove Thermactor by-pass valve
and air supply hoses.
S. Disconnect the spark plug wires from
5.
the spark plugs using Tool No.
T68P-6666-A. Do not pull on the
wire. Remove the wires from the
BACK TO GROUP INDEX
302 and 351W (10

CID v-a
V-8 Engines
21-21-8
HEATER HOSE FITTING

MANIFOLD-TO-BLOCK
MANIFOLDTOBLOCK
REAR SEAL
9A424
MANIFOLD-TO-HEAD GASKET
9441
>'
K
r"
"
WATER
WATER TEMflUATURf
TEMPERATURE
} SENDING UNIT
10884
SEALING
WASHER
INTAKE MANIFOLD
9424
GASKET 8255
MANIFOLD-TO-HEAD GASKET
9441
MANIFOLD-TO-ILOCK FRONT SEAL'
9A425
THERMOSTAT 8575
COOLANT OUTLET HOUSING
8594
A1589-G
A1589 G
FIG. 13 Typical Intake Manifold Assembly
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.
6. Remove the carburetor fuel inlet line
and the automatic choke heat tube
(302 only).
7.
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
8.
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
Disconnect the
the crankcase
crankcase vent
vent hose
hose
10.
assembly at the valve rocker arm
cover.
11. Disconnect EGR valve and vacuum
hoses from back-pressure transducer.
12. Remove
Remove the
the intake
intake manifold
manifold and
and
12.
be
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.
Discard the intake manifold attaching
bolt sealing washers.
13. If
If the
the manifold
manifold assembly
assembly isis to
to be
be
identify all vacuum
disassembled, identify
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, EGR back-pressure
transducer assembly, and gasket. On
351W
3S1W remove the choke heat stove
cover and tube assembly.
InstsJJstion
Installation
1.
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.
On 351W
351 W remove the choke heat
stove cover and tube assembly. Install
the EGR back-pressure transducer
and the EGR valve using a new
gasket. Position the thermostat in the
coolant outlet housing. Coat the
t h e r m o s t a t ggasket
a s k e t with
with
thermostat
water-resistant sealer and position it
on the coolant outlet housing. Install
the coolant outlet housing. Connect
all vacuum hoses.
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.
21-21-9
Positionnew
newseals
sealson
onthe
thecylinder
cylinder
3.3. Position
blockand
andnew
newgaskets
gasketsononthe
thecylinder
cylinder
block
headswith
withthe
thegaskets
gasketsinterlocked
interlocked
heads
withthe
theseal
sealtabs.
tabs.Be
Besure
surethe
theholes
holes
with
thegaskets
gasketsare
arealigned
alignedwith
withthe
the
ininthe
holes
in
the
cylinder
heads.
holes in the cylinder heads.
1/16inch
inch bead
bead of
ofthe
the
Apply aa 1/16
Apply
above
sealer
to
the
outer
end
of
each
above sealer to the outer end of each
intakemanifold
manifoldseal
sealfor
forthe
thefull
fullwidth
width
intake
of
the
seal
(4
places).
See
Fig.
14.
of the seal (4 places). See Fig. 14.
NOTE: This
This sealer
sealer sets
sets up
up in
in 15
15
NOTE:
minutes,
so
it
is
important
that
minutes, so it is important that
302
302and
and351W
351WCID
CIOV-8
v-aEngines
Engines
21-21-9
21-21-9
assembly
assemblybebecompleted
completedpromptly.
promptly.Do
Do
notdrip
dripany
anysealer
sealerinto
intothe
the engine
engine
not
valley.
valley.
Carefullylower
lowerthe
theintake
intakemanifold
manifold
4.4. Carefully
onthe
thecylinder
cylinderblock
block
intoposition
positionon
into
andcylinder
cylinderheads.
heads.After
Afterthe
theintake
intake
and
run aa finger
finger
manifoldisisin
inplace,
place, run
manifold
aroundthe
theseal
sealarea
areatotomake
makesure
surethe
the
around
sealsare
areininplace.
place.IfIfthe
theseals
sealsare
arenot
not
seals
place,remove
removethe
theintake
intakemanifold
manifold
ininplace,
andposition
positionthe
theseals.
seals.
and
5.5. Be
Be sure
sure the
the holes
holes in
in the
the manifold
manifold
the
thehose
hoseatatthe
theintake
intakemanifold.
manifold.
8.8. Install
Installthe
thecarburetor
carburetorfuel
fuelinlet
inletline
line
and
the
automatic
choke
heat
and the automatic choke heattube
tube
(302
(302only).
only).
9.9. Rotate
Rotatethe
thecrankshaft
crankshaftdamper
damperuntil
until
the
1 piston
No.1
piston isis on
on TDC
TDC at
at the
theend
end
theNo.
ofofthe
thecompression
compressionstroke.
stroke. Position
Position
the
thedistributor
distributorininthe
theblock
blockwith
withthe
the
rotor
1 firing
rotoratatthe
theNo.
No.1
firing position
position and
and
the
thepoints
pointsjust
justopen.
open.Install
Installthe
thehold
hold
down
downclamp.
clamp.
10.
10.Install
Install the
the distributor
distributor cap.
cap. Position
Position
the
the spark
spark plug
plug wires
wires in
in the
the harness
harness
brackets
brackets on
on the
the valve
valve.rocker
rockerarm
arm
covers
the
covers and
and connect
connect the
the wires
wires to
to the
spark
spark plugs.
plugs. Install
Install Thermactor
Thermactorbybypass
pass valve
valve and
and air
air supply
supplyhoses.
hoses.
11.
11.Connect
Connect the
the crankcase
crankcase vent
vent hose.
hose.
Connect
Connectthe
thehigh
hightension
tensionlead
leadand
andcoil
coil
wires.
wires.
12.
12. Connect
Connect the
the accelerator
accelerator rod
rod or
or cable
cable
and
and retracting
retracting spring.
spring.
On
On aa vehicle
vehicle with
with an
an automatic
automatic
ttransmission,
r a n s m i s s i o n , cconnect
o n n e c t tthe
he
transmission
vacuum
line.
transmission vacuum line.
On
On aa vehicle
vehicle equipped
equipped with
with
vacuum-operated
vacu urn-operated accessories,
accessories,
connect
connect any
any vacuum
vacuum lines
lines that
that were
were
disconnected
from
the
intake
disconnected from the intake
manifold
manifold during
during removal.
removal.
13.
Fill
and
bleed
the cooling
cooling system.
system.
13. Fill and bleed the
14. Start
Start the
the engine
engine and
and check
check and
and adjust
adjust
14.
the
ignition
timing.
Connect
the
distributor vacuum
vacuum hoses
hoses to
to the
distributor
the
distributor.
distributor.
15. Operate
Operate the
the engine
engine at
at fast
fast idle
idle and
15.
and
check all
all hose
hose connections
connections and
check
and
gaskets for
for leaks.
leaks. When
When engine
engine
gaskets
temperatures
have
stabilized
adjust
temperatures have stabilized adjust
the engine
engine idle
idle speed
speed and
and idle
idle fuel
fuel
the
mixture. Retorque
Retorque intake
intake manifold
manifold
mixture.
bolts to
to specifications.
specifications.
bolts
16.Connect
Connect the
theautomatic
automatic choke
choke heat
heat
16.
chamber air
airinlet
inlet hose.
hose.
chamber
17.Install
Installthe
theair
aircleaner
cleanerand
andintake
intakeduct
duct
17.
assembly.
assembly.
TYPICALSEALER
SEALERAPPLICATION
APPLICATIONAREAS
AREASFOR
FORINTAKE
INTAKEMANIFOLD
MANIFOLDINSTALLATION
INSTALLATION
TYPICAL
1/8" DIA. BEAD C3AZ-19526-A(OR-B)

1/8"
DIA. BEAD C3AZ-19526-A(OR-B)
SEALER (4-JOINTS)
SEALER (4-JOINTS)
INTAKE
INTAKEMANIFOLD
MANIFOLDGASKET
GASKET
CYLINDER HEAD
HEAD
CYLINDER
INTAKE
INTAKE MANIFOLD
MANIFOLD
SEAL
SEAL
SEAL MOUNTING
MOUNTING SURFACE
SURFACE
SEAL
OF CYLINDER
CYLINDER BLOCK
BLOCK
OF
1/16"
1/16" DIA.
DIA. BEAD
BEAD C3AZ-19526-A(OR-B)
C3AZ-19526-A(OR-B)
SEALER (4-SEALENDS)
(4-SEAL ENDS)
SEALER
A3715-B
A3715-B
FIG.
Typical RTV
Sealer Installation-Intake
FIG. 14
14 Typical
RTV Sealer
Installation-Intake Manifold
Manifold
and manifold
manifold are
are in
gaskets and
the choke heat
alignment. Install the
351W.
stove on the 351
W. Install the intake
and nuts.
nuts.
manifold attaching bolts and
Torque the
the intake
intake manifold bolts
bolts in
Torque
sequence
to
sequence (Figs.
(Figs. 15
15 and
and 16)
16) to
specifications.
specifications.
After completing
completing the
the remaining
remaining
After
assembly steps,
steps, on
on1975
1975 engines
engines only,
only,
assembly
operate the
the engine
engine until
until itit reaches
reaches
operate
normal operating
operating temperature,
temperature, then
then
normal
retorque the
the manifold
manifold bolts
bolts in
in
retorque
sequence toto specifications.
specifications.
sequence
6.6. Install
Installthe
thewater
waterpump
pumpbypass
bypasshose
hoseon
on
the
the coolant
coolant outlet
outlet housing.
housing. Slide
Slide the
the
clamp
clamp into
into position
position and
andtighten
tighten the
the
clamp.
clamp.
7.7. Connect
Connect the
theradiator
radiator upper
upper hose.
hose.
Install
Install the
theheater
heater hose
hose and
andconnect
connect
VALVE LIFTER
LIFTER
VALVE
Before
replacing aa hydraulic
hydraulic valve
valve
Before replacing
lifter
for
noisy
operation,
be
sure
the
noise isis not
not caused
caused by
by improperly
improperly
noise
adjustedvalve
valvetotorocker
rockerarm
armclearance
clearanceor
or
adjusted
byworn
wornrocker
rockerarms
armsororpush
push rods.
rods.
by
A1658.F
A1658-F
FIG.
FIG.1515Intake
IntakeManifold
ManifoldBolts
BoltsTorque
Torque
Sequence-302 (10 (1975),
(1976)
'
302/351W (10 (1976)
BACK TO GROUP INDEX
FRONT OF ENGINE
FIG.1616Intake
IntakeManifold
ManifoldBolts
BoltsTorque
TorqueSequence-351-W
Sequence351-W(10
CID(1975)
(1975)
FIG.
v-a
21-21-10
21-21-10
302
302 and
and351W
351W(10
CID V-8Engines
Engines
Removal
Remoyal
Remove the
the intake
intake manifold
manifold and
and
1.1. Remove
related parts
partsby
byfollowing
following procedures
procedures
related
under Intake
Intake Manifold
Manifold Removal.
Removal.
under
Remove the
the crankcase
ventilation
2.2. Remove
hoses and
and fittings
fittings from
from the
the valve
valve
hoses
rocker arm
armcovers.
covers.
rocker
Remove the
the valve
valve rocker
rocker arm
arm covers.
covers.
3.3. Remove
Loosenthe
thevalve
valverocker
rockerarm
armstud
studnuts
nuts
Loosen
and rotate
rotatethe
therocker
rockerarms
armsto
tothe
theside.
side.
and
Remove the
the valve
valve push
push rods
rods and
and
4.4. Remove
identify them
them so
so that
that they
they can
can be
be
identify
installed in
in their
their original
original positions.
positions.
installed
Using aa magnet,
magnet, remove
remove the
the valve
valve
5.5. Using
lifters and
and place
place them
them in
in aarack
rack so
sothat
that
lifters
they can
can be
beinstalled
installed in
in their
their original
original
they
bores (Fig.
(Fig. 17).
17).
bores
If the
the valve
valve lifters
lifters cannot
cannot be
be
If
removed from
from their
their bores
bores due
due to
to
removed
excessive varnish,
varnish, etc.,
etc., itit may
may be
excessive
be
necessary to
to use
use aa plier-type
plier-type tool
tool
necessary
(T52T-6500-DJD or
or 6500-D)
65OO-D) or
or a
(T52T-6500-DJD
claw type
type tool
tool to
to remove
remove the
the lifters.
lifters.
claw
the lifter back and
and forth to
Rotate the
to
loosen itit from
from the
the gum
gum or
or varnish
varnish that
that
may have
have formed
formed on
on the
the lifter.
lifter.
may
If necessary to
to disassemble aa lifter,
lifter,
Valve Lifter Disassembly and
refer to Valve
Assembly.
Assembly.
SE.Position
Positionthe
therocker
rockerarms
armsover
overthe
the
SE.
push rods
rods and
and install
install stud
stud nuts.
nuts.
push
Perform aavalve
valveclearance
clearanceadjustment
adjustment
Perform
as outlined
outlined under
under Valve
Valve Clearance
Clearance
as
AdjustmentHydraulic Valve
Valve
Adjustment-Hydraulic
Lifters.
Lifters.
Install the
the valve
valve rocker
rocker arm
armcovers.
covers.
4.4. Install
Install the
the crankcase
ventilation
Install
regulator
regulator valve
valve in
in the
the valve
valve rocker
rocker
arm
arm cover.
cover.
Install the
the intake
intake manifold
manifold and
and
5.5. Install
related
related parts
parts by
by following
following procedures
procedures
under Intake
Intake Manifold
Manifold Installation.
Installation.
under
Magnet
A2864-A
FIG.
FIG. 17
17 Removing
Removing Valve
Valve Lifter
lifter
Installation
Installstion
Tappets
Tappets or
or lifters
lifters and
and bores
bores are
are to
to be
be
lubricated
lubricated with
with heavy
heavy engine
engine oil
oil SE
SE
before
installation.
1.
1. Clean
Clean outside
outside of
of lifters
lifters and
and install
install in
in
the
the bores
bores from
from which
which they
they were
were
removed.
If aa new
new lifter(s)
lifter(s) is
is being
being
removed. If
installed,
installed, check
check the
the new
new lifter(s)
lifter(s) for
for aa
free
is to
to be
be
freefit
fit in
in the
the bore
bore in
in which
which itit is
installed.
installed. Lubricate
Lubricate the
the lifter(s)
lifter(s) and
and
bore(s)
bore(s) with
with heavy
heavy engine
engine oil
oil SE
SE
before
before inserting
inserting itit in
in the
the bore.
bore.
2.2. Install
Install the
the push
push rods
rods in
in their
their original
original
position.
position. Apply
Apply Lubriplate
Lubriplate or
or
equivalent
equivalent to
to the
the valve
valve stem
stem tips
tips and
and
the
the push
push rod
rod ends.
ends.
3.3. Lubricate
Lubricate the
the rocker
rocker arms
arms and
and
fulcrum
fulcrum seats
seats with
with heavy
heavy engine
engineoil
oil
BACK TO GROUP INDEX
21-21-10
21-21-10
AI593-C
FIG.
FIG. 18
18 Removing
Removing Valve
Valve Push
Push Rod
Rod
Too/-T62F.6085.A'
CYLINDER HEADS
HEADS
CYLINDER
If aa cylinder
cylinder head
head isis to
to be
be replaced,
replaced,
If
follow the
the procedures
procedures under
under Cylinder
Cylinder
follow
Head
and
Head Disassembly
Disassembly and
and Assembly,
Assembly, and
transfer
transfer all
all valves,
valves, springs,
springs, spark
spark plugs,
plugs,
etc.,
etc., to
to the
the new
new cylinder
cylinder head.
head. Clean
Clean and
and
inspect
inspect all
all parts,
parts, reface the
the valves
valves (refer
(refer
to
to Part
Part 21-01)
21-01) and
and check all
all assembly
assembly
clearances before assembling the
the new
new or
used
used parts
parts to
to the
the new
new cylinder head.
head.
Removal
RemoJ'sJ
1. Remove the
the intake manifold and
1.
and
as an
an assembly following
following
carburetor as
the procedure under Intake Manifold
Removal.
Removal.
2. Remove the
the rocker arm
arm cover(s).
2.
the left cylinder head is
is to
to be
If the
be
on aa vehicle with an
an air
removed on
conditioner, isolate and
the
and remove the
36.
compressor as
as outlined in Group 36.
the left cylinder head is
is to be
be
If the
on a vehicle with power
removed on
disconnect the power
steering, disconnect
the left
steering pump bracket from the
and remove the
the drive
cylinder head and
belt from the
the pump pulley. Position
the
the power steering pump out of the
way and in a position that will
will prevent
the oil from draining out.
out.
3. If the right cylinder
cylinder head is to be
be
removed,
removed, remove
remove the alternator
alternator
mounting
mounting bracket
bracket bolt
bolt and
and spacer
spacer and
and
air
right
air cleaner
cleaner inlet
inlet duct
duct from
from the
the right
cylinder
cylinder head
head assembly.
assembly.
4.
4. Disconnect
Disconnect the
the exhaust
exhaust manifold(s)
from
from the
the muffler
muffler inlet
inlet pipe(s).
pipe(s).
5.
5. Loosen
Loosen the
the rocker
rocker arm
arm stud
stud nuts
nuts so
so
that
that the
the rocker
rocker arms
arms can
can be
be rotated
rotated
to
in
to the
the side. Remove the
the push rods in
sequence
so that they
they may
may
sequence (Fig.
(Fig. 18)
18) so
be
be installed
installed in
in their
their original
original positions.
positions.
On 302-2V
302-2V engines
engines remove
remove the
the
On
exhaust
exhaust valve
valve stem
stem caps.
caps.
6.6. Install
Install the
the cylinder
cylinder head
head holding
holding
fixtures
(Fig. 19).
19).
fixtures (Fig.
Remove
Remove the
the cylinder
cylinder head
head
attaching
attaching bolts
bolts and
and lift
lift the
the cylinder
cylinder
head
head off
off the
the block.
block. If
If required,
required,
remove
remove the
theexhaust
exhaust manifolds
manifolds to
to gain
gain
access
access to
to the
the lower
lower attaching
attaching bolts.
bolts.
Remove
and discard
discard the
the cylinder
cylinder
Remove and
head
head gasket.
gasket.
A2853A
A2853-A
FIG.
FIG. 19
19 Cylinder
Cylinder Head
Head Holding
Holding
Fixture--302
Fixture302 and
and 352-W
352-W
Installstion
Installation
1.
1. Clean the
the cylinder head, intake
intake
manifold, valve rocker arm cover and
the
cylinder head gasket surfaces. If the
cylinder head was
was removed for
for a
cylinder head gasket replacement,
check the flatness
flatness of the cylinder head
and block gasket surfaces.
2. Position the new cylinder head gasket
over the cylinder dowels on the block.
the cylinder head on
on the
the
Position the
block and
and install the
the attaching bolts.
the holding fixtures.
Remove the
fixtures.
all
in three progressive steps. Torque all
(Fig. 20)
20) to
to
the bolts in sequence (Fig.
specifications. When cylinder head
to
retorque the bolts
bolts after
after extended
extended
retorque
be
operation. However, the bolts may be
If
checked and
and retorqued
retorqued if
if desired.
desired. If
checked
removed, install
install the
the exhaust
exhaust
removed,
manifolds and
and retorque
retorque the
the attaching
attaching
manifolds
bolts to
to specification.
bolts
4. Clean
Clean the
the push
push rods
rods in
in aa suitable
suitable
4.
Blowout
the oil
oil passage
passage in
in
solvent. Blow
solvent.
out the
the push
push rod
rod with
with compressed
compressed air.
air.
the
of the
the push
push rods
rods for
for
Check the
the ends
ends of
Check
orexcessive
excessive
nicks, grooves,
grooves, roughness
roughness or
nicks,
wear. Visually
Visuallycheck
checkthe
the push
push rods
rods for
for
wear.
straightness or
orcheck
check push
push rod
rod runout
runout
straightness
with aa dial
dial indicator.
indicator. If
If runout
runout
with
exceeds the
the maximum
maximum limit
limit at
at any
any
exceeds
point, discard
discardthe
therod.
rod. Do
Donot
not attempt
attempt
point,
to straighten
straighten push
push rods.
rods.
to
Apply Lubriplate
Lubriplate or
or equivalent
equivalent to
to
5.5. Apply
ofthe
thepush
push rods.
rods. Install
Installthe
the
bothends
endsof
both
push rods
rods in
in their
their original
original positions.
positions.
push
orequivalent
equivalentto
tothe
the
Apply Lubriplate
Lubriplateor
Apply
valve stem
stem tips.
tips. On
On 3O2-2V
302-2V engines
engines
valve
install the
the exhaust
exhaust valve
valve stem
stem caps.
caps.
install
21-21-11
21-21-11
T
v
"-'
A1594-B
FIG. 20 Cylinder Head Bolt Torque

Sequence
6.
6. Install the rocker arms.
arms. If all original
assembly components are installed, a
valve clearance adjustment
adjustment is not
necessary. If
If any valve train
train
components are replaced, perform a
valve clearance adjustment
adjustment as
Clearance
outlined under Valve Clearance
AdjustmentHydraulic Valve
Adjustment-Hydraulic
Lifters (Part 21-01).
7.
7. Connect the exhaust manifold(s) at
the muffier
muffler inlet pipe(s).
pipe(s). Tighten the
specifications.
8.
8. If the right cylinder head was
removed, install the alternator
alternator
attaching bracket and air cleaner inlet
duct on the right cylinder head
assembly. Install the alternator.
alternator.
Adjust the drive belt tension to
Adjust
specifications.
9. Clean the valve rocker arm cover(s).
9.
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.
steps. Tighten the bolts to
specifications. Two minutes later
r e t i g h t e n bolts to the same
same
retighten
specifications.
10. If
If the
the left
left cylinder
cylinder head
head was
was removed
removed
10.
on aa vehicle with an air conditioner,
as outlined in
install the compressor as
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.
bolts. Adjust
Adjust
specifications.
the drive belt to specifications.
11. Install the intake manifold
manifold and
related parts following the procedure
MANIFOLDS
EXHAUST MANIFOLDS
Removal
Remoysl
1. On aa right exhaust manifold, remove
1.
the air cleaner and intake duct
assembly. Disconnect the automatic
assembly.
choke heat chamber air inlet hose
from the inlet tube near the right
valve rocker arm cover (302
(302 only).
valve
Remove the automatic choke heat
(302 only).
tube (302
Remove the nuts or bolts retaining
exhaust
the heat stove on the exhaust
manifold and remove the heat stove.
2. Disconnect the exhaust manifold
manifold
2.
muffler inlet pipe.
pipe. Remove
from the muffier
BACK TO GROUP INDEX
302 and 351W CID

CIO V-8
v-a Engines
21-21-11
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.
manifold.
hose and water pump by-pass hose at

the water pump.
Install all the accessory brackets
which attach to the water pump.
Place the water pump pulley on the
water pump shaft.
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.
Position the fan shroud,
shroud, if
if so
Position
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
Adjust
specified belt tension.
Fill and bleed the cooling system.
Operate the engine until normal
operating temperatures have been
reached and check for leaks.
InstJI/lstion
Installation
1.
of the
1. Clean
Clean the
the mating
mating surfaces
surfaces of
the
exhaust
head.
exhaust manifold
manifold and
and cylinder
cylinder head.
Clean
of the
the
Clean the
the mounting
mounting flange
flange of
exhaust
muffier inlet
inlet
exhaust manifold
manifold and
and muffler
pipe.
pipe.
2.
manifold on
on the
the
2. Position
Position the
the exhaust
exhaust manifold
cylinder
head
and
install
the
heat
cylinder head and install the heat
shields
bolts and
and tab
tab
shields and
and the
the attaching
attaching bolts
washers.
Working
from
the
center
to
washers. Working from the center to
the
the bolts
bolts to
the ends,
ends, torque
torque the
to
specifications.
the spark
plugs
specifications. Install
Install the
spark plugs
and
plug wires.
wires.
and spark
spark plug
3. Position the muffler
muffler inlet pipe to the
manifold. Install and torque the
attaching nuts to specifications.
4.
4. Install the automatic choke heat tube
and heat stove on the right exhaust
manifold (302 only). Install the air
cleaner and intake duct assembly.
5.
5. Connect the automatic choke heat
chamber inlet hose (302 only).
6.
6. Start the engine and check for exhaust
leaks.
leaks.
WATER PUMP
Remoysl
Removal
1.
1. Drain the cooling system.
On vehicles equipped with a fan
shroud, remove the shroud attaching
fan.
Remove the fan and spacer from
the water pump shaft. Remove the
shroud if so equipped.
2. Remove the air conditioner drive belt
2.
and idler pulley bracket
bracket if
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.
Installation
Instllllstion
1.
cylinder
mounting surfaces of the cyhnder
front cover
cover and
and water
front
water pump.
pump.
2. Position a new gasket, coated on both
2.
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
4.
5.
6.
7.
8.

TIMING CHAIN
Remoysl
Removal
1. Refer
Refer to Water Pump Removal.
1.
of
Perform all steps except removal of
the pump. Leave it attached to the
front cover.
2. Drain the crankcase.
crankshaft pulley from
the crankshaft
crankshaft vibration damper.
Remove the damper attaching screw
and washer. Install the puller on the
crankshaft
crankshaft vibration damper (Fig. 21)
and remove the vibration damper.
UNIVERSAL
PULLER
A3248-A

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 theflexible
flexible fuel
line still attached.
6. Remove the oil pan to cylinder front
cover attaching bolts. Use a thin blade
knife to cut the oil pan gasket flush
flush
21-21-12
v-a
withcylinder
cylinderblock
blockface
faceprior
priortoto
with
specifications
specifications(Fig.
(Fig.25).
25).Tighten
Tightenthe
the
separatingthethecover
coverfrom
fromthethecylinder
cylinder
separating
cover
covertotoblock
blockattaching
attachingscrews
screwstoto
block.Remove
Removethe
thecylinder
cylinderfront
front
block.
specifications.
specifications.Remove
Removethe
thepilot.
pilot.
cover and
and water
water pump
pumpasasanan
cover
assembly.
assembly.
newcylinder
cylinderfront
frontcover
coveris istoto
IfIfa anew
installed,remove
removethe
thewater
waterpump
pump
bebeinstalled,
anddipstick
dipstick tube
tubefrom
from the
theold
old
and
cylinderfront
frontcover
coverand
andinstall
installthem
them
cylinder
thenew
newcover.
cover.
ononthe
7. Discard the cylinder front cover
7. Discard
the cylinder front cover
gasket.Remove
Removethe
thecrankshaft
crankshaftfront
front
gasket.
slinger.
oiloilslinger.
Check the
the timing
timing chain
chain deflection
deflection
8.8. Check
(refertotoPart
Part21-01).
21-01).
(refer
Crank the
the engine
engine until
until the
the timing
timing
9.9. Crank
markson
onthe
thesprockets
sprocketsare
arepositioned
positioned
marks
shownininFig.
Fig.22.
22.
asasshown
10.
Remove
the
camshaft
sprocket cap
cap
10. Remove the camshaft sprocket
screw, washers
washers and
and fuel
fuel pum
pump
screw,
p
eccentric. Slide
Slide both
both sprockets
sprockets and
and
eccentric.
thetiming
timingchain
chainforward,
forward,and
andremove
remove
the
them
as
an
assembly
(Fig.
23).
them as an assembly (Fig. 23).
Installation
Instal/ation
Position the
the sprockets
sprockets and
and timing
timing
1.1. Position
chain
on
the
camshaft
and
crankshaft
chain on the camshaft and crankshaft
simultaneously (Fig.
(Fig. 23).
23). Be
Be sure
sure the
the
simultaneously
timing
marks
on
the
sprockets
are
timing marks on the sprockets are
positioned as
as shown
shown in
in Fig.
Fig. 22.
22.
positioned
TIMING
TIMING MARKS
MARKS
A2731-A
A2731A
2. Install
Install the
the fuel
fuel pump
pump eccentric,
eccentric,
2.
washers
and
camshaft
sprocket
cap
FIG. 22
22 Aligning Timing Marks
Marks
washers and camshaft sprocket cap
FIG.
screw. Torque
Torque the
the sprocket
sprocket cap
cap screw
screw
screw.
to specifications.
Install the
the
to
crankshaft front
front oil
oil slinger
slinger (Fig.
(Fig. 24).
crankshaft
24).
3. Clean
Clean the
the cylinder
cylinder front
front cover,
cover, oil
oil pan
3.
pan
and the
the block
block gasket
gasket surfaces.
surfaces.
and
4. Install
Install aa new
4.
new oil
oil seal
seal in
in the
the cylinder
cylinder
front
front cover
cover following
following the
the procedures
procedures
under
Front Oil
Oil Seal
Seal Removal
Removal and
and
under Front
Installation.
Installation.
5.
5. Lubricate
Lubricate the
the timing
timing chain
chain with
with
engine
engine oil.
oil.
6.
6. Coat
Coat the
the gasket
gasket surface
surface of
of the
the oil
oil pan
pan
with
with sealer,
sealer, cut
cut and
and position
position the
the
required
required sections
sections of
of aa new
new gasket
gasket on
on
the
the oil
oil pan,
pan, apply
apply sealer
sealer at
at the
the
corners.
corners. Install
Install pan
pan seal
seal as
as required.
required.
Coat
Coat the
the gasket
gasket surfaces
surfaces of
of the
the
block
and
cover
with
sealer,
block and cover with sealer, and
and
position
position aa new
new gasket
gasket on
on the
the block.
block.
7.7. Position
the
cylinder
front
Position the cylinder front cover
cover on
on
the
the cylinder
cylinder block.
block. Use
Use care
care when
when
installing
installing the
the cover
cover toto avoid
avoid seal
seal
ddamage
a m a g e or
o s s i b l e ggasket
asket
or ppossible
mislocation.
mislocation.
8.8. Install
Installthe
thecylinder
cylinderfront
frontcover
covertotoseal
seal
alignment
tool
into
proper
alignment tool into properposition.
position.
9.9. ItItmay
maybe
benecessary
necessarytotoforce
forcethe
thecover
cover
downward
to
slightly
compress
the
FIG.
FIG.23
23Removing
RemovingororInstalling
InstallingTiming
Timing
downward to slightly compress the
pan
gasket. This operation can be
Chain
Chain
pan gasket. This operation can be
facilitated by using a suitable tool at
facilitated by using a suitable tool at
the
front cover attaching hole
11.
11.Apply
ApplyLubriplate
Lubriplateororequivalent
equivalenttotothe
the
the front cover attaching hole
locations.
oil
oilseal
sealrubbing
rubbingsurface
surfaceofofthe
the
locations.
10.
vibration
vibrationdamper
damperinner
innerhub
hubtoto
10.Coat
Coat the
the threads
threads ofofthe
the attaching
attaching
screws
with
oil
resistant
prevent
preventdamage
damagetotothe
theseal.
seal.Apply
Applya a
screws with oil resistantsealer
sealerand
and
install
white
whitelead
leadand
andoiloilmixture
mixturetotothe
thefront
front
installthe
thescrews.
screws.While
Whilepushing
pushinginin
ononthe
alignment
tool,
tighten
ofofthe
thecrankshaft
crankshaftfor
for damper
damper
the alignment tool, tightenthe
theoiloil
pan
installation.
installation.
pantotocover
coverattaching
attachingscrews
screwstoto
BACK TO GROUP INDEX
21-21-12
21-21-12
302
302and
and351W
351WCIO
CID V-8Engines
Engines
12.12.
Line
Lineupupthethecrankshaft
crankshaftvibration
vibration
damper
damperkeyway
keywaywith
withthe
thekey
keyononthe
the
crankshaft.
crankshaft. Install
Install the
thevibration
vibration
damper
damperononthe
thecrankshaft
crankshaft(Fig.
(Fig.26).
26).
and
Install
the
cap
screw
Install the cap screw andwasher.
washer.
Tighten
Tightenthe
thescrew
screwtotospecifications.
specifications.
Install
Installthe
thecrankshaft
crankshaftpulley.
pulley.
13.
13.Install
Install the
thefuel
fuel pump
pump using
usinga anew
new
gasket.
Connect
the
fuel
pump
gasket. Connect the fuel pumpoutlet
outlet
line.
line.
14.
14.Install
Installthe
theoiloillevel
leveldipstick.
dipstick.
15.
Refer
to
Water
15. Refer to Water Pump
Pump Installation.
Installation.
Perform
Performallallthe
therequired
requiredsteps
stepsexcept
except
installation
of
the
pump.
installation of the pump.
16.
16.Fill
Fill the
thecrankcase
crankcase with
with the
theproper
proper
of
engine
grade
and
quantity
grade and quantity of engineoil.
oil.
17.
17.Fill
Filland
andbleed
bleedthe
thecooling
coolingsystem.
system.
18.
Operate
the
engine
18. Operate the engineatat fast
fast idle
idle and
and
check
checkfor
forcoolant
coolantand
andoil
oilleaks.
leaks.Check
Check
and
and adjust
adjust the
the ignition
ignition timing.
timing.
TWO PIECE
FUEL PUMP ECCENTRIC
CRANKSHAFT FRONT OIL SLINGER

CRANKSHAFT
FRONT OIL SLINGER
A2733-B
A2733-B
FIG. 24
24 Fuel
Fuel Pump
Pump Eccentric
Eccentric and
and
FIG.
Front
Oil
Slinger
Installed
Front Oil Slinger Installed
T00/-T6 JP-60J9-B or 6059-F
FIG.2525Aligning
AligningCylinder
CylinderFront
Front
FIG.
Cover
Cover
21-21-13
302 and 351W CID V-8 Engines
Tool-T.52L6306AEE or 6306AJ
Too/-T52L-6306-AEE
6306-AJ
FIG. 26 Installing Crankshaft

Vibration Damper
Too/T53L200A
Too/-753L-200-A
Tool
T58P-6700-B
or 6700-6 ,
1
OIL SEAL
A2861A
A2861-A
FIG. 27 Installing Crankshaft Front

Oil Seal
THRUST
PLATE
6269
TIMING CHAIN--6268 AND

CAMSHAFT SPROCKET-6256
C~:~::TSPR\_6256
FRONT OIL SEAL

FIONT
Removal
Removal
1.
1. Remove the cylinder front cover
following the procedure under
Cylinder Front Cover and Timina
Timing
Chain Removal.
2. Drive out the old seal with the pin
punch. Clean out the recess in the
cover.
Installation
Installation
1.
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. 27).
27). Check the seal after
installation to be sure the spring is
properly positioned in the seal.
2. Replace the cylinder front cover
Chain Installation.
CAMSHAFT
The camshaft
camshaft and related parts are,
are..,
shown in Fig. 28.
Removal
Removsl
1.
1. Disconnect the upper and lower
radiator hoses. Disconnect the
transmission oil cooler lines from the
radiator, if so equipped. Remove the
bolts retaining the fan shroud to the
radiator, if so equipped. Remove the
radiator.
radiator.
On vehicles equipped with air
conditioning, remove the bolts which
conditioner and
secure the air conditioner
position the condenser out of the way.
2.
the timing chain following the
procedure under Cylinder Front
Cover and Timing Chain Removal.
3. Remove the intake manifold and
related parts by following procedures
under Intake Manifold Removal.
4. Remove the crankcase ventilation
valve and tubes from the valve rocker
covers. Remove the valve rocker
arm covers.
covers. Loosen the valve rocker
arm covers.
BEARINGS
~6' ci 6b'i-O~,
67
j i~,
~i .
~~
~
TWO PIECE
PIECE
TWO
FUEL PUMP ECCENTRIC-6287
ECCENTRIC-6287
BACK TO GROUP INDEX
CAMSHAFT
REAR BEARING
BORE PLUG
6266
A28638
A2863-B
21-21-13
arm stud nuts and rotate the rocker
arms to the side.
S. Remove the valve push rods and
5.
identify them so that they can be
identify
installed in their original positions.
lifters and place them in
in aa rack so
so that
that
bores
bOres (Fig. 17).
If necessary to disassemble a lifter,
refer to Valve Lifter
Lifter Disassembly and
Assembly.
If the valve lifters are stuck in their
bores by
by excessive
excessivevarnish,
varnish,etc.,
etc.,ititmay
may
be necessary to use a plier-type tool
(TS2T-6,00-OJO
6Soo-0) or a
(T52T-65OO-DJD or 6500-D)
claw. type tool to remove the lifters.
claw
Rotate the lifter back and forth to
loosen it from the gum or varnish that
may have formed at the lifter.
Remove the camshaft
camshaft thrust plate.
7. R.emove
Carefully remove the camshaft
camshaft by
Carefully
pulling toward the front of the engine.
engine.
Use caution to avoid damaging the
camshaft bearings.
camshaft
Installation
In6tll/JiltJon
1.
1. Oil the camshaft journals with heavy
engine oil SE and apply Lubriplate or
equivalent to the lobes.
Carefully slide
lobes. Carefully
the camshaft
camshaft, through the bearings.
Install the camshaft
camshaft thrust plate with
groove towards the cylinder block.
camshaft end play
as shown in
Check camshaft
playas
Part 21-01.
2. Lubricate the lifters and bores with
heavy engine oil SEt
SE. Install the valve
lifters in the bores from which they
were removed.
each end of the push rods and install
the push rods in their original
positions. Apply Lubriplate or
equivalent to the valve stem tips.
and
Lubricate the rocker arms arid
fulcrum seats with heavy engine oil
SE. Position the rocker arms over the
SEt
push rods.
manifold and
related parts by following procedures
5.
5. Connect the water temperature
temperature
sending unit and the engine ground
strap.
6.
6. Connect the accelerator rod and
retracting spring.
7.
7. Connect
Connect the heater hose at the intake
manifold. Position and connect the
fuel line.
8.
8. Replace the crankshaft
crankshaft front oil seal
following procedures under Front Oil
Seal Removal and Installation. Install
the timing chairi,
chain, cylinder front cover
and related
p a r t s following
following
and
related parts
procedures under
undet Cylinder Front
Cover and Timing Chain Installation.
9. On vehicles equipped
equipped with air
conditioning,
conditioning, install
install the air
conditioning condenser.
21-21-14
21-21-14
Position the
thefan
fanshroud,
shroud, ififsoso
Position
equipped, over
over the
thefan.
fan.Install
Install the
the
equipped,
radiatorand
andconnect
connect the
theupper
upperand
and
radiator
lowerradiator
radiatorhoses.
hoses.
lower
On aavehicle
vehicle equipped
equipped with
with an
an
On
automatic transmission,
transmission, connect
connect the
the
automatic
transmissionoil
oilcooler
coolerlines.
lines.
transmission
Install the
thefan
fan shroud
shroud attaching
attaching
Install
screwsififsosoequipped.
equipped.
screws
10.With
WithNo.
No.1 1piston
piston
TDC
end
10.
onon
TDC
at at
thethe
end
of the
thecompression
compression stroke,
stroke, position
position
of
thedistributor
distributor ininthe
theblock
block with
with the
the
the
rotoratatthe
theNo.1
No. 1firing
firingposition
positionand
and
rotor
the points
pointsjust
just open.
open. Install
Install the
thehold
hold
the
down clamp.
clamp.
down
11.IfIf any
any valve
valve train
train components
components have
have
11.
been replaced,
replaced, perfC'rm
perform aa Valve
Valve
been
Clearance Adjustment
Adjustment as
as outlined
outlined
Clearance
under Hydraulic
Hydraulic Valve
ValveLifters
Lifters ininPart
Part
under
21-01.
21-01.
12.Clean
Clean the
thevalve
valve rocker
rocker arm
armcovers
covers
12.
and the
the cylinder
cylinder head
head gasket
gasket surface.
surface.
and
Position the
the valve
valve rocker
rocker cover
cover gasket
gasket
Position
in each
each cover,
cover, making
making sure
sure that
that the
in
the
tabs engage
engage the
the notches
notches in
in the
the cover.
cover.
tabs
13.Position
Position the
the covers
covers on
on the
the cylinder
cylinder
13.
heads. Make
Make sure
sure the
the gasket
gasket seats
seats
heads.
evenly all
all around
around the
the head.
head. Install
Install the
the
evenly
bolts. The
The cover
cover isis tightened
tightened in
in two
two
bolts.
s t e p s . Torque
T o r q u e the
t h e bolts
b o l t s to
to
steps.
specifications. Two
Two minutes
minutes later,
later,
specifications.
torque the
the bolts
bolts to
to the
the same
same
torque
specifications.
specifications.
14. Clean
Clean and
and install
install the
the crankcase
crankcase
14.
ventilation
ventilation system.
system.
15.
Install the
the distributor
distributor cap.
cap. Position
Position
15. Install
the
the spark
spark plug
plug wires
wires in
in the
the harness
harness
brackets
arm
brackets on
on the
the valve
valve rocker
rocker arm
covers
the
covers and
and connect
connect the
the wires
wires to
to the
plugs.
pIugs. Connect
Connect the
the high
high tension
tension lead
lead
at
coil.
at the
the coil.
16.
Fill and
and bleed
bleed the
the cooling
cooling system.
system. Fill
Fill
16. Fill
the
crankcase
with
the
proper
grade
and
of engine
engine oil.
oil.
and quantity
quantity of
17.
Start
the
engine
and
check and
and adjust
adjust
17. Start the engine and check
the
the ignition
ignition timing.
timing. Connect
Connect the
the
distributor
distributor vacuum
vacuum line
line at
at the
the
carburetor.
carburetor.
18.
18. Operate
Operate the
the engine
engine at
at fast
fast idle
idle and
and
check
check all
all hose
hose connections
connections and
and
gaskets
gaskets for
for leaks.
leaks. When
When the
the engine
engine
temperature
temperature has
has stabilized
stabilized adjust
adjustthe
the
engine
engine idle
idle speed
speed and
and idle
idle fuel
fuel
mixture.
mixture. Retorque
Retorque intake
intake manifold
manifold
bolts
bolts and
and nuts.
nuts.
19.
19. Adjust
Adjust the
the transmission
throttle
linkage.
linkage. Install
Install the
the air
air cleaner
cleanerand
and
intake
intakeduct
duct assembly.
assembly.
20.
20.Connect
Connect the
the automatic
automatic choke
choke heat
heat
chamber
chamberair
airinlet
inlethose.
hose.
FLYWHEEL
FLYWHEEL
Removal
RemoJ'al
1.1. On
On aa vehicle
vehicle with
manual-shift
t transmission,
r a n s m i s s i o n , r remove
emove th
e
the
transmission,
clutch pressure
pressure plate
plate
and
anddisc
discfollowing
followingthe
theprocedures
proceduresinin
Group
Group16.
16.
BACK TO GROUP INDEX
v-a
302and
and351W
351W CID
CID V-8Engines
Engines
302
On
On a avehicle
vehicle with
with automatic
automatic
transmission,
t r a n s m i s s i o n , remove
r e m o v e the
the
transmission and
andconverter
converter housing
housing
transmission
followingthe
theprocedure
procedureininGroup
Group17.
17.
following
Tocheck
check flywheel
flywheel face
face runout
runout or
or
2.2. To
replaceflywheel
flywheelring
ringgear
gearfor
formanualmanualreplace
shift transmissions,
transmissions, refer
refer toto Part
Part
shift
21-01.
21-01.
3.3. Remove
attaching
Removethe
theflywheel
flywheel
attachingbolts
bolts
andremove
removethe
theflywheel.
flywheel.
and
Installation
Installation
1.1. Coat
Coat the
the threads
threads of
of the
the flywheel
flywheel
attaching bolts
bolts with
with oil-resistant
oil-resistant
attaching
sealer. Position
Position the
theflywheel
flywheelon
on the
the
sealer.
crankshaft flange.
flange. Install
Install and
andtorque
torque
crankshaft
thebolts
boltsininsequence
sequenceacross
acrossfrom
from each
each
the
other totospecifications.
specifications.
other
2.2. On
On aa vehicle
vehicle with
manual-shift
transmission,
transmission, check
check the
the flywheel
flywheel
runout,
runout, following
following the
the procedure
procedure in
in
Part
Part 21-01
21-01 and
and install
install the
the clutch
clutch
pressure
pressure plate,
plate, disc
disc and
and the
the
transmission
t r a n s m i s s i o n following
following the
the
procedures in
in Group
Group 16.
procedures
16.
On
On aa vehicle
vehicle with
with an
an automatic
automatic
transmission, check
check the
the flywheel
flywheel
transmission,
runout, following
following the
the procedure
procedure in
runout,
21 and
and install
install the
the transmission
transmission
Part 21
in Group 17.
17.
procedure in
21-21-14
21-21-14
Installation
Installation
1.1. Install
Install the
thebore
boreplug
plugasasdetailed
detailed inin
Part
Part21-01.
21-01.
2.2. Coat
Coatthe
theflywheel
flywheelattaching
attachingbolts
boltswith
with
oil-resistant
oil-resistant sealer.
sealer. Position
Position the
the
engine
enginerear
rearcover
coverplate
plateon
onthe
thecylinder
cylinder
block
block dowels.
dowels. Position
Position the
theflywheel
flywheel
on
onthe
thecrankshaft
crankshaft flange.
flange.Install
Installand
and
torque
torquethe
theattaching
attachingbolts
boltsininsequence
sequence
across
a c r o s s from
from each
e a c h other
o t h e r to
to
specifications.
specifications.
On
ic Ie wi
t ham
anuaI
On aa veh
vehicle
with
a manual
transmission,
transmission, install
install the
the clutch
clutch
pressure
pressure plate,
plate, disc
disc and
and the
the
transmission
t r a n s m i s s i o n following
following the
the
procedures
procedures ininGroup
Group 16.
16.
On
On aa vehicle
vehicle with
with an
an automatic
automatic
transmission,
transmission, install
install the
the transmission
transmission
and
and converter
converter housing
housing following
following the
the
17.
procedure
procedure inin Group
Group 17.
OIL
PAN
OIL PAN
Ford
Ford
RemoJ'al
Removal
1.1. Remove
Remove the
the oil
oil level
level dipstick.
dipstick.
2.
2. Remove
Remove the
the bolts
bolts attaching
attaching the
the fan
fan
shroud
shroud to
to the
the radiator
radiator and
and position
position
the
the shroud
shroud over
over the
the fan.
fan.
3.
3. Raise
Raise the
the vehicle.
vehicle.

Removal
RemoJ'al
1.
the transmission, clutch
1. Remove the
pressure plate and disc, following the
16. It is
is not
not
necessary to
flywheel.
to remove the
the flywheel.
2. Remove the pilot bearing and adapter
as shown in Fig. 29.
29.
Installation
Installation
1. Install
Install the
the pilot
pilot service
service bearing
bearing as
as
shown
shown in
in Fig.
Fig. 30;
30; using tool, install
adapter so
so the
the
new bearing
bearing and
and adapter
new
adapter is
is not
not cocked.
adapter
2. Install
Install the
the clutch
clutch pressure
pressure plate,
plate, disc
disc
2.
and the
the transmission,
transmission, following
following the
the
and
16.
procedures in
in Group
Group16.
procedures
ToolZ58L-10\-4
or7600-E\
Tool 759L-100-B
or 7600-E
A2874-A'
FIG. 29
29 Removing
Removing Clutch
Clutch Pilot
Pilot
FIG.
Bearing
Bearing
CAMSHAFT REAR
REAR BEARING
BEARING BORE
BORE
CAMSHAFT
PLUG
PLUG
Removal
RemoJ'al
1.1. On
On aa vehicle
vehicle with
with aa manual
manual
ttransmission,
e m o v e t the
he
transmission,
clutch pressure
pressure plate
plate
and
and disc
disc following
following the
the procedures
proceduresinin
Group
16.
Group16.
On aa vehicle
vehicle with
with an
an automatic
automatic
On
t transmission,
r a n s m i s s i o n , r remove
e m o v e t the
he
transmission and
and converter
converter housing
housing
transmission
17.
followingthe
theprocedure
procedureininGroup
Group17.
following
2.2. Remove
Removethe
theflywheel
flywheel attaching
attaching bolts
bolts
and
andremove
removethe
theflywheel.
flywheel.Remove
Removethe
the
engine
enginerear
rearcover
coverplate.
plate.
3.3. Remove
Removethe
thebore
boreplug
plugasasdetailed
detailedinin
Part
Part21-01.
21-01.
Tool-7600-H
Tool-7600-H
A3262-A
A3262-A
FIG.30
30Installing
InstallingClutch
ClutchPilot
PilotBearing
Bearing
FIG.
21-21-15
302 and 351W

351W CID V-8
v-a Engines

5. Remove the bolts and nuts retaining
front supports
supports to the
the engine front
chassis.
6. Raise the engine and place wood
stabilizer from the
7. Disconnect the stabilizer
lower control arms and pull ends
down.
and position
position the
the pan
pan on the
and
crossmember.
Position the stabilizer
stabilizer bar
bar for
9. Position
clearance and remove the oil pan.
Instal/ation
Installation
and oil pan. The oil pan has a twopiece gasket. Coat the block surface
and the oil pan gasket with sealer.
Position the oil pan gaskets on the
cylinder block (Fig. 31).
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
31). Be
rear main bearing cap (Fig. 31).
oil pan gasket.
4. Position the oil pan against the block
and install a bolt,
bolt, finger-tight, on
on each
each
side of the oil pan. Install the
remaining bolts. Tighten the bolts.
bolts
from the center outward in each
direction to specifications.
specifications.
5.
5. Connect the stabilizer
stabilizer to lower
control arms.
6.
wood blocks from between the engine
support and chassis bracket. Lower
the engine.
7.
7. Install the bolts and nut attaching the
engine supports to the chassis.
Tighten the nuts to specifications.
8.
9.
9. Install the bolts attaching the shroud
to the radiator.
radiator.
10.
10. Install
Install the
the oil
oil level
level dipstick.
dipstick. Fill
Fill the
the
quantity of engine oil.
and check for oil leaks.
Mustang
RemoJ'sJ
Removal
1.
1. Disconnect battery cable.
cable.
2.
2. Remove 44 bolts attaching fan shroud
to radiator and position shroud over
fan.
fan.
3.
3. Raise vehicle on hoist.
hoist.
4.
4. Drain crankcase.
crankcase.
5.
5. Remove the 44 attaching bolts and
remove the
the 2a
2a crossmember.
crossmember.
remove
6.
6. Remove
Remove the
the attaching screw from flex
flex
joint to
to release
release steering pinion shaft.
shaft.
Remove
Remove 33 nuts
nuts and bolts attaching
crossmember.
steering gear to crossmember.
Remove 44 bolts attaching sway
sway bar to
to
Remove
chassis and move
move sway bar down.
down.
7. Disconnect battery cable from starter,

starter attaching bolts and
remove 2 starter
remove starter.
attaching bolts,
8. Remove oil pan attaching
loosen oil pan from block and remove.
Instal/ation
Installation
gasket surface
surface of
of
1. Clean oil pan gasket
cylinder block. Clean and inspect oil
pan.
2. Position oil pan gasket and seals to
cylinder block using contact cement
31).
(Fig. 31).
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
flex coupling to
specification. Install flex
shaft attaching bolt.
steering gear stub shaft
7. Position the 2a crossmember to the
vehicle and install the 4 attaching
bolts.
8.
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.
BACK TO GROUP INDEX
REAR SEAL
FRONT SEAL
01
L PAN
OIL
PAN GASKET
GASKET
A2876-A
A2876 A
FIG.
FIG. 31
31 Oil Pan
Pan Gaskets and
and Seals
Installed302 and
and 351-W
351-W
Installed-302
Engines
Engines
21-21-15
Torino, Elite and Montego
RemoJ'al
Removal
Remove the bolts attaching the fan

shroud to the radiator. Position the
shroud over the fan.
2. Raise the vehicle.
4. Remove the stabilizer bar from the
chassis.
front support
through bolts.
If equipped
equipped with an automatic
7. If
disconnect the oil
cooler lines at the radiator.
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
crankshaft
the oil pan.
Installation
Instal/ation
1.
and oil pan. The oil pan has a twopiece 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. 34).
(Fig.
5.
(Fig. 34).
34). Be
rear main bearing cap (Fig.
oil pan gasket.
6. PPosition
thee
6.
0 sit ion the 0oil
i I pan 0onnth
crossmember. Install a new gasket on
the oil pump and install the oil pump
pick up tube.
7.
bolt, finger tight,
tight, on
on each
and install a bolt,
the
side of the block. Install the
bolts. Tighten the bolts
remaining bolts.
specifications.
direction to specifications.
8. If equipped with an automatic
automatic
8.
transmission, connect the oil cooler
lines at the radiator.
radiator.
lines
9.
brackets. Lower
the engine
engine and
and install
install the
the engine
engine
the
support through bolts.
bolts. Tighten the
bolts to
to specifications.
specifications.
boIts
10. Install
Installthe
thestabilizer
stabilizerbar
barto
tothe
thechassis.
chassis.
10.
11. Lower the
the vehicle.
vehicle.
11.
12. Install
Install the
the fan
fan shroud.
shroud.
12.
13. Install
Install the
the oil
oil level
level dipstick.
dipstick. Fill
Fill the
the
13.
engine oil.
oil. Start the
the engine
engine
quantity of engine
and check for oil
oil leaks.
leaks.
21-21-16
21-21-16
302 and 351W

351W CID
CtO V-8 Engines
Engines
21-21-16
Maverick, Comet, Granada and

"onarch
Monarch
RemoYal
Removal
InstJll/ation
Installation
1. Prime the oil pump by filling either
shaft to distribute
Rotate the pump shaft
the oil within the pump body.
2. Position the intermediate drive shaft
into' the
the. distributor socket. With the
into
shaft firmly seated in the distributor
shaft
shaft should
socket, the stop on the shaft
roof of
of the crankcase.
touch the roof
Remove' the shaft
shaft and position the
Remove
stop as necessary.
3. With the stop properly positioned,
insert the intermediate drive shaft
into' the oil pump. Install the pump
into
shaft as an assembly. Do not
and shaft
attempt to force the pump into
position if it will not seat readily. The
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
4. Clean and install the oil pump inlet
tube and screen assembly (Fig. 32).
5. Install the oil pan and related parts as
outlined under Oil Pan Installation.
crankshaft rear oil
Replacement of a crankshaft
s~al because of oil leakage requires
seal
replacement of both the upper and lower
seals.
seals. Refer to Crankshaft
Replacement
Replacement in Part
Part 21-01 for
for
replacement procedures.
MAIN BEARING
HARING
The main bearing inserts are selective
fit. Refer to procedures under Fitting
Main and Connecting Rod Bearings in
Part 21-01.
Removal
Rellloval
1.
level dipstick.
dipstick. Remove
Remove the
the oil
oil pan
pan and
related parts.
2.
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
which new bearings
bearings are to be
installed.
4. Insert the upper bearing removal Tool
(Tool 6331) in the oil hole in the
crankshaft.
crankshaft.
crankshaft in the direction
of
of the engine rotation to force the
bearing out of the block.
6. Clean the crankshaft
Inspect the journals and thrust faces
(thrust bearing) for nicks, burrs or
bearing pick-up that would cause
premature bearing wear.
7. If
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
Removal in Part 21-01.
9. Repeat the above procedure (Steps 3
thru 8) for the remaining bearings to
be replaced.
Installation
Installation
1. If the rear main bearing is being
1.
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
Installation in Part 21-01.
place the plain end of the bearing over
the shaft on the locking tang side of
of
bearing so that Tool 6331
6331 can be
crankshaft. With Tool 6331
6331
crankshaft.
positioned in the oil hole in the
crankshaft in
crankshaft, rotate the crankshaft
the opposite direction of engine
rotation until the bearing seats itself.
Remove the tool.
4. Replace the bearing in the cap.
4.
5.
6. If the bearing is
is being replaced on
6.
journal number 1,
1, 22or
or4,4,apply
applyaalight
light
oil to the journal and
coat of engine oil
cap.
bearings and install the bearing cap.
T i g h t e n the
t h e cap
c a p bolts
b o l t s to
to
Tighten
specifications.
7. If the rear main bearing is
is being
7.
oil seal groove in
replaced, clean the oil
t h e cap,
c a p , with aa brush
b r u s h and
and
the
recommended solvent (Part 21-01).
21-01).
Remove the
the oil
oil seal
seal retaining pin
Remove
the bearing cap,
cap, if so
so equipped.
equipped.
from the
The pin
pin is
is not
not used
used with
with the
the split lip
lip
The
seal.
seal.
8. Install the
the lower seal
seal in
in the
the rear main
8.
cap with undercut side
side of seal
bearing cap
drain the
1. Raise the vehicle and cjrain
crankcase.
2. Remove the stabilizer bar from the
chassis.
engipe front
front support
3. Remove the engine
through bolts
bolts and
and remove the
through
If so equipped, remove the
supports. If
bolt and nut retaining the power
steering lines to the rear side of the
lower arm.
idler arm bracket
4. Remove the idler
retaining bolts and pull the linkage
of the way.
down and out of
and remove the pan.
6. Remove the oil pump pick-up tube
and screen assembly.
InstJll/ation
Installation
1.
1. Clean the oil pan and inspect for
damage. Clean the oil pump pick-up

tube and screen.
and oil pan. Position the oil pump
pick-up tube and screen with gasket.
b~lts and torque to
Install the two bolts
specifications.
3. Coat the block surface and oil pan
gaskets with sealer. Position the oil
(Fig.
(Fig. 31).
5. fosition
s~l on the
position the oil pan rear seal
rear main bearing cap (Fig.
(Fig. 31).
31). Be
sure the tabs on the seal ar~
are over the
oil pan gasket.
6.
6. Position the oil pan to the cylinder
block. Install the
the attaching bolts and
torque to specifications.
specifications.
7.
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.
"
rear.
8.
8. Position the engine supports to the
chassis side rails and install the
reattaching bolts. Torque to
specifications.
9.
9. Install the stabilizer bar.
bar.
10.
10. Lower
Lower the
the vehicle.
vehicle. Fill
Fill the
the crankcase.
crankcase.
Start the engine a'nd
and check for oil
leaks.
leaks.
OIL
OIL PUMP
Removal
Removal
1.
1. Remove the oil pan and related
related parts
as
as outlined under Oil Pan'
Pan Removal.
Removal
2.
2. Remove
Remove the
the oil pump inlet tube
tube and
screen assembly.
.
assembly.
3.
3. Remov~
Remove the oil
oil pump
pump attaching
attaching bo~ts
bolts
and remove
remove the oil pump,
pump, gasket
gasket and
and
intermediate drive
',
drive shaft:
shaft.
BACK TO GROUP INDEX
A3142-A
FIG.
FIG. 32 Oil Pump
Pump and
and Inlet Tube
Installed
Installed

21-21-17
the FRONT of the
the engine
engine
toward the
(Fig. 33);
33); allow
allow the
the seal
seal to
to protrude
protrude
(Fig.
above the
the
approximately 3/8 inch above
parting surface to mate with the
seal when the cap
cap is
is installed.
installed.
upper seal
9. Refer to
to Crankshaft Rear
Rear Oil Seal
9.
Installation Part 21-01 for
for
Installationon use of sealer in
instructions on
main bearing cap.
installing the main
Lubricate the journal with engine oil
and install the rear main bearing cap.
cap.
Torque the cap bolts to specifications.
specifications.
10. If
If the
the thrust
thrust bearing
bearing cap
cap (No.3
(No. 3main
main
10.
removed, install it
bearing) has been removed,
as follows:
follows:
as
Lubricate the journal with engine
oil and install the thrust bearing cap
with the bolts finger-tight. Pry the
crankshaft forward against the thrust
302 and
and 351W CID
CID v-a
V-8 Engines
Engines
21-21-17
surface of the upper half of the

the
bearing (Fig.
(Fig. 34).
34). Hold the
the crankshaft
crankshaft
cap to
to the
the rear.
rear. This
This will
will align
align the
the
cap
thrust surfaces of both halves
halves of the
bearing.
bearing. Retain the forward pressure
on
on the crankshaft. Torque the cap
cap
to specifications.
specifications.
bolts to
11.
11. Clean the
the oil
oil pump inlet tube
tube screen.
screen.
Prime by
by filling
filling the
the inlet
inlet opening
opening with
with
oil
oil and rotating the
the pump
pump shaft until
until
oil emerges from the outlet opening.
opening.
Install the oil pump and the inlet tube
assembly.
assembly.
12.
12. Position
Position the
the oil
oil pan
pan gaskets
gaskets on
on the
the oil
oil
pan.
pan. Position the oil pan front seal on
cover. Position the
the cylinder front cover.
oil pan rear seal
seal on the rear main
oil
cap. Install the oil pan and
bearing cap.
parts. Install the oil level
related parts.
dipstick.
13.
13. Fill
Fill the
the crankcase.
crankcase. Start
Start the
the engine
engine
and
and check
check for oil
oil pressure.
pressure. Operate
the
the engine
engine at fast idle
idle and check
check for
for
oil
oil leaks.
leaks.
BEARINGS
are
selective fit.
fit. Refer to
to procedures under
Bearings in
in Part 21-01.
21-01.
Removal
Removal
1.
crankcase. Remove the oil
level dipstick.
dipstick. Remove the oil pan and
related parts.
parts.
2.
2. Remove the oil pump inlet tube
assembly and the oil pump.
pump.
3.
the
connecting rod to which new
new bearings
are to be fitted is
is down.
down. Remove the
connecting rod cap.
cap. Remove the
Installstion
Installation
1.
1. Be
Be sure the bearing inserts and the
and cap are clean.
clean. Foreign material
failure.
2.
crankshaft journal.
fitting in the slots provided.
4.
crankshaft
journal.
5.
5. Select fit the bearing following
following
procedures under Fitting Main and
Connecting Rod Bearings in Part
21-01.
6.
6. After the bearing has been fitted,
fitted,
the connecting rod cap. Tighten the
7. Clean the oil pump inlet tube screen.
7.
opening. Install the oil pump and the
inlet tube assembly.
INSTALL SEAL WITH

WITH LIP
LIP
TOWARDS
TOWARDS FRONT OF
OF ENGINE
ENGINE
3/8"
I
I
FRONT OF ENGINE
-+I
PARTING
SEAL HALVES TO PROTRUDE BEYOND PA
RTING FACES
THIS DISTANCE TO
TO ALLOW FOR CAP TO BLOCK ALIGNMENT
__L
---r3/8"
3/8'
REAR FACE OF REAR MAIN

BEARING CAP AND CYLINDER BLOCK

TYPE CRANKSHAFT SEAL
OF SPLIT, LIP
LIP-TYPE
A
26 39- C
A2639-C

PRY FORWARD
THRUST BEARING
PRY CRANKSHAFT PORWAR
HOLD
CRANKSHAFT
FORWARD
PRY CAP
BACKWARD
BACKWARD
THRUST BEARING
PRY CAP BACKWARD
HOLD CRANKSHAFT
FORWARD
THRUST BEARING
A2879-A
34 Aligning Thrust Bearing

FIG. 34
BACK TO GROUP INDEX

v-a
21-21-18
302
W CIO
302 and
and 351
351W
CID V-8 Engines
8. Position the
the oil
oil pan gaskets
gaskets on
on the
the oil
8.
pan. Position the
the oil
oil pan front seal
seal on
on
pan.
the cylinder front cover.
cover. Position the
the
the
oil pan
pan rear seal on
on the
the rear main
oil
cap. Install the
the oil
oil pan
pan and
bearing cap.
parts. Install the
the oil
oil level
related parts.
dipstick.
dipstick.
9. Fill the
the crankcase.
crankcase. Start the
the engine
9.
for oil
oil pressure.
pressure. Operate
and check for
the engine
engine at
at fast idle
idle and
and check for
the
oil leaks.
leaks.
oil
The
rod
The numbers
numbers on
on the
the connecting rod
and
and bearing cap
cap must be
be on
on the
the same
same
when installed in
in the
the cylinder
cylinder
side when
rod is
is ever
bore. If aa connecting rod
from one block or
or cylinder
cylinder
transposed from
new bearings should be
to another, new
and the
the connecting rod
rod should
fitted and
to correspond with the
be numbered to
number.
new cylinder number.
3. Make
Make sure
sure the
the ring gaps
gaps are
are properly
3.
the circumference of
spaced around the
(Fig. 35).
35).
the piston (Fig.
AND CONNECTING
CONNECTING
PISTONS AND
RODS
Removal
Remoyal
1. Drain the
the cooling system and
and the
1.
the intake
intake
crankcase. Remove the
heads, oil
oil pan
pan and
and
manifold, cylinder heads,
pump, following the procedures in
in
oil pump,
this Section.
2. Remove any
any ridges and/or deposits
2.
the upper end
end of the
the cylinder
from the
as follows:
follows:
bores as
the crankshaft
Turn the
to be removed is at
at the bottom
piston to
and place aa cloth on
on the
the
of its travel and
to collect the
the cuttings.
piston head to
any ridge and/or deposits
Remove any
the upper end
end of the
the cylinder
from the
bores.
ridge cutter.
cutter. Follow the instructions
a ridge
by the
the tool manufacturers.
furnished by
in
when removing
excess of 1/32 inch when
ridges.
ridges.
3. Make sure all connecting rod caps are
so that they can
can be
be installed
marked so
down.
5. Remove the
and
5.
the connecting rod
rod nuts and
cap.
6. Push the
the connecting rod
rod and
and piston
assembly out the
the top
top of the cylinder
with the
the handle end
end of a hammer.
Avoid damage to the
the crankshaft
journal or
or the
the cylinder wall when
the piston and rod.
removing the
rod.
the
connecting rod
cap.
rod and
and cap.
8. Install the
the cap on the connecting rod
rod
from which it was
was removed.
Installation
Installation
1. If new piston rings
rings are to be installed,
remove the cylinder
cylinder wall glaze.
manufacturer.
and
cylinder walls with light engine oil.
oil.
Be sure to install the pistons in the
the
same cylinders from which they were
removed or to which they were fitted.
The connecting rod and
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.
BACK TO GROUP INDEX
OIL RING
RING SPACER
A
__-*U___
OIL RING
SEGMENT
OIL RING
RING
SEGMENT
\1,/
)1&
, I \
/
"i
PINl30RE
PISTON
FRONT OF ENGiNE
ENGINE
A?Rll~A
A9R11-A
21-21-18
engine
engine oil
oil and
and rotating
rotating the
the pump
pump shaft
shaft
to distribute the
the oil
oil within the
the
housing.
housing. Install the
the oil
oil pump
pump and
and the
the
oil
oil pan.
pan.
12.
12. Install
Install the
the cylinder
cylinder heads
heads following
following
procedures under Cylinder Head
Installation.
Installation.
13.
13. Install
Install the
the intake
intake manifold
manifold following
following
Manifold
Installation.
Installation.
14.
14. Fill
Fill and
and bleed
bleed the
the cooling
cooling system.
system. Fill
Fill
the crankcase with the
the proper grade
oil.
15.
15. Start
Start the
the engine
engine and
and check
check and
and adjust
adjust
distributor vacuum hoses at
at the
carburetor.
16.
16. Operate
Operate the
the engine
engine at
at fast
fast idle
idle and
and
check for
for oil and coolant leaks.
leaks. When
the engine temperature has
has stabilized
adjust the
the engine idle speed and
and idle
fuel mixture.
mixture.
17.
17. Install
Install the
the air
air cleaner
cleaner and
and intake
intake duct
duct
assembly.
assembly.
18.
18. Connect
Connect the
the automatic
automatic choke
choke heat
heat
chamber air
air inlet hose.
CRANKSHAFT
The crankshaft
crankshaft and
and related parts are
shown in
in Fig.
Fig. 38.
38.
FRONT
Piston
Ring
Compressor
FIG. 35 Piston Ring Spacing
4. Install a piston ring compressor on

4.
on
a hammer handle until it is
is slightly
(Fig. 36).
36).
below the top of the cylinder (Fig.
to guide the
the connecting rods
Be sure to
the crankshaft
crankshaft
to avoid damaging the
journals. Install the
the piston with the
the
indentation notch in
in the
the piston head
toward the
the front of the engine.
5.
the clearance of each bearing
5. Check the
and Connecting Rod
Rod Bearings
Main and
in Part 21-01.
6. After
After the
the bearings have been fitted,
apply a light coat of engine oil to the
the
journals and
and bearings.
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
connecting rod cap.
cap.
Tighten the nuts to specifications.
9. After
rod
clearance between
between the
the side clearance
connecting rods on each crankshaft
journal (Fig. 37).
37).
10. Disassemble,
Disassemble, clean,
clean, and
and assemble
assemble the
the
oil pump. Clean the oil pump inlet
tube screen and the
the oil
oil pan
pan and
and block
block
gasket surfaces.
the inlet port or outlet port with
NOTCH TO FRONT OF ENGINE
A2870-A
A2871-A
Rod
FIG. 37 Checking Connecting Rod
Side Clearance
21-21-19
Removal
RemoysJ
1. With engine
engine removed from vehicle
vehicle
1.
stand,
and placed on aa work stand,
wires at the
disconnect the spark plug wires
wires
spark plugs and remove the wires
the ignition harness brackets on
from the
covers.
the valve rocker arm covers.
distributor
Disconnect the coil to distributor
coil. Remove
high tension lead at the coil.
the distributor cap and spark plug
assembly. Remove the spark
wire assembly.
plugs to allow easy rotation of the
crankshaft.
2. Remove the fuel pump and oil filter.
filter.
2.
Slide the water pump by-pass hose
pump.
clamp toward the water pump.
Remove the alternator and mounting
brackets.
brackets.
3. Remove the crankshaft pulley from
3.
the crankshaft vibration damper (if so
equipped). Remove the cap screw and
equipped).
washer from the end of
of the
the
washer
crankshaft. Install the pulley on the
crankshaft vibration damper (Fig. 21)
damper.
and remove the damper.
water pump as an assembly.
crankshaft front oil
5.
slinger. Check the timing chain
deflection, then remove the timing
chain and sprockets as detailed under
Chain Removal.
6. Invert the engine on the work stand.
6.
Remove the clutch pressure plate and
(manual-shift transmission).
disc (manual-shift
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
locations.
Turn the crankshaft
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
all the connecting rod bearing caps
are removed.
8. Remove the main bearing caps.
9. Carefully
Carefully lift the crankshaft
crankshaft out of the
block so that the thrust bearing
the
crankshaft
surfaces.
To refinish journals, dress minor
imperfections, etc., refer to Part 21-01
for instructions.
Installation
InstsJllltion
caps.
BACK TO GROUP INDEX
302 and
and 351W CID
CID v-a
V-8 Engines
Engines
4.
bearing
journals have
have been refinished to
to a
undersize, install
install the
the correct
definite undersize,
Be sure the
the
undersize bearings. Be
bores are
bearing inserts and bearing bores
clean.
will distort the bearing and
inserts will
cause aa failure.
failure.
cause
5.
5. Place the
the upper main bearing inserts
in position in
in the bores with the tang
in
fitting in the slot provided.
provided.
6.
6. Install the lower main bearing inserts
caps.
in the bearing caps.
7.
7. Clean the rear journal oil seal groove
and the mating surfaces of the block
cap. Remove
the oil seal retainer pin from the rear
main bearing seal groove, if so
The retainer
retainer pin
pin isis not
not used
used
equipped. The
with aa split lip
lip seal.
with
8.
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
(Fig.
(Fig. 33)
33) and approximately 3/8 inch
protruding above the partial surface.
9.
9. Carefully lower the crankshaft
crankshaft into
,lace.
place. Be careful not to damage
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.
After the
the bearings
bearings have
have been
been fitted,
fitted,
11. After
21-21-19
journals and
and bearings.
bearings. Install
Install the
the rear
main
main bearing cap
cap by
by following steps
steps
77 thru
thru 99 under
under Main
Main Bearing
Bearing
Installation. Install all the bearing
caps, except the thrust bearing cap
caps,
(No.3
(No. 3 bearing).
bearing).Be
Besure
surethat
thatthe
themain
main
bearing caps
caps are
are installed in
in their
original locations.
locations. Torque
Torque the bearing
cap
cap bolts
bolts to
to specifications.
specifications.
12.
12. Install the thrust bearing cap
cap with the
bolts finger-tight.
finger-tight.
13.
13. Pry
Pry the
the crankshaft
crankshaft forward
forward against
against
the thrust surface of the upper half of
the bearing (Fig.
(Fig. 34).
14.
14. Hold the crankshaft forward and pry
the thrust bearing cap to the rear.
rear.
This will
will align the thrust surfaces of
halves of the bearing.
both halves
15.
15. Retain
Retain the
the forward
forward pressure
pressure on
on the
the
crankshaft. Tighten the cap bolts to
specifications.
16.
16. Force the crankshaft toward the rear
of the engine.
17.
17. Check the crankshaft end play (refer
to Part 21-01).
18.
18. Install new bearing inserts in the
connecting rods and caps.
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.
FLYWHEEL
MAIN
M
A I N BEARING INSERTS.....
INSERTS ~~ _ _
CRANKSHAFT SPROCKET
66306
306\
MAIN BEARING
INSERTS
KEY
372890
CRANKSHAFT
FRONT OIL SLINGER*

6310
6333
~~~,
::t\:_J)
~.:)::
BOLT
BOLT
.~
MAIN BEARING
MAIN
CAPS
2878.E
A 2878-E
FIG.
FIG. 38
38 Crankshaft
Crankshaft and Related Parts
21-21-20
seats on
on the crankshaft
crankshaft journal.
21. Install the
cap.
the connecting rod
rod cap.
Torque the nuts to
to specifications.
22.
22. After
After the
the piston
piston and
and connecting
connecting rod
the side clearance between the
the
connecting rods and each connecting
rod crankshaft
crankshaft journal (Fig.
(Fig. 37).
37).
23.
Install the
and
23.Install
the timing chain and
sprockets, cylinder front cover and
and
crankshaft pulley and
and adapter,
adapter,
crankshaft
following Steps 11 thru 99 under
and Timing
Cylinder Front Cover and
Chain Installation.
24. Coat
Coat the
the threads
threads of
of the
the flywheel
flywheel
attaching bolts with oil-resistant
sealer. Position the
flywheel on
the flywheel
on the
the
crankshaft
flange. Install and
and torque
crankshaft flange.
the bolts to
to specifications.
flywheel for
for aa manual-shift
On aa flywheel
manual-shift
transmission, use
use Tool 6392-N to
the clutch disc.
disc. Install the
locate the
the
plate. Tighten the attaching
pressure plate.
bolts.
25. Clean the
the oil
oil pan, oil
oil pump and
and oil
oil
pump screen. Prime the oil pump by
the inlet or
or outlet port
filling either the
with engine oil and rotating the pump
shaft
to distribute oil
the
shaft to
oil within the
housing. Install the oil pump and oil
oil
pan by
by following the
the procedures
under
Oil Pan
Oil Pump
under Oil
Pan and
and Oil
Pump
Installation.
26. Install the
and
the oil
oil filter, fuel pump and
the
connect the
the fuel lines. Install the
and mounting
alternator, shield and
bracket.
27. Install
Install the
the spark
spark plugs,
plugs, distributor
distributor
302 and
W CID v-a
and 351
351W
V-8 Engines
21-21-20
cap and spark plug wires.

wires. Connect the
spark plug wires and
and high tension
lead.
in the
the vehicle.
vehicle.
28. Install the engine in
0.0
IS-inch undersize journal diameters.
0.015-inch
The bearings are
are not
not interchangeable
from one bore to
to another.
1.
the
1. Position the
the new
new bearings at
at the
bearing bores with the
oil holes
the oil
aligned, and press them in
in place with
the tool shown in
to
in Fig.
Fig. 39.
39. Be sure to
and puller
center the
the pulling plate and
screw to avoid damage to the bearing.
to use the correct expanding
Failure to
collet can
can cause severe bearing
damage. Be sure the front bearing is
damage.
is
installed the specified distance below
the front face of the cylinder block
(Fig. 40).
CAMSHAFT BEARINGS
Remoyal
Removal
1.
flywheel and
and
1. Remove the
the camshaft, flywheel
crankshaft, following the appropriate
procedures in
in this Section. Push the
the
pistons to
to the
the top
top of
ofthe
the cylinders.
cylinders.
2.
2. Remove the
the camshaft
camshaft rear bearing
bore plug. Remove the
the camshaft
camshaft
bearings (Fig.
(Fig. 39).
39).
the
collet assembly in
in the
the camshaft
camshaft
nut
on the
the
the expanding mandrel until the
fits the camshaft bearing.
collet fits
the puller screw and
4. Assemble the
and
install on
the expanding mandrel.
on the
the threads of
Wrap aa cloth around the
of
to protect the
the front
the puller screw to
bearing or
or journal. Tighten the
the
to remove the
and pulling plate to
the
camshaft bearing. Be sure to
to hold a
5.
5. Repeat the
the procedure for
for each
install the puller screw from the rear
Installation
Installation
Camshaft
Camshaft bearings are
are available
prefinished to
to size for
for standard and
prefinished
and
INSTALL FRONT BEARING

DIMENSION BELOW FRONT FACE OF BLOCK
A2880-A
FIG. 4
0 Camshaft Front Bearing
FIG.
40
Measurement
in
2. Install the
the bore plug as
as detailed in
Part 21-01.
3. Install the
the camshaft,
crankshaft,
flywheel
andrelated
relatedparts,
parts,following
following
flywheel and
the appropriate procedures in
in this
except do
do not
not check
Section, except
rod and
and main bearing
connecting rod
Camshaft
clearances as
the
vehicle.
engine in
in the
the vehicle.
OIL FILTER
The oil
in
oil filter assembly is
is shown in
Fig. 41.
41.
DETAIL
-1, -2 or-3
or-3
DETAIL-1,-2
EXPANDING COLLET
DETAIL-1,-2 or-3
BACK-UP NUT
EXPANDING MANDREL
RARING
THRUST BiARING
FILTER ELEMENT
6731
6731
DETAIL-8
PULLING NUT
D;
I'
ADAPTER FITTING
6890
A3704- B
B
FIG.
FIG. 41 Cartridge-Type Oil Filter
DETAIL -5
PULLER SCREW
\
DETAIL -4
PULLING PLATE
CAMSHAFT BEARING (LOOSE)
-6 or
or -7
-7
DETAIL -6
PULLER SCREW
SCREW EXTENSION
EXTENSION
PULLER
ToolT65L-6250-A
Tool-T65L-6250-A
A2813A
A2813-A
FIG. 39 Camshaft Bearing Replacement

FIG.
BACK TO GROUP INDEX
RemoYal
Removal
1. Place a
1.
a drip pan
pan under the
the filter.
Unscrew the
the filter
filter from the
the adapter
fitting and clean the
the adapter recess
fitting
and the filter gasket sealing surface.
Installation
Installation
1. Coat the
the gasket
gasket on
onaa new
new filter
filter with
with
1.
oil. Place the new filter in position on
the
302 and
and 351W CID v-a
V-8 Engines
Engines
21-21-21
21-21-21
filter until the
the
the gasket contacts the
adapter face, and then advance it
it 1/2
turn.
2. Operate the
and
the engine at fast idle, and
check for
are
for oil
oil leaks. If oil
oil leaks are
evident, perform
21-21-21
to correct leakage. Check the oil level
add oil
oil as
as required to bring to
to
and add
specified level.
specified

When installing nuts or
or bolts that
must be torqued (refer to
to Specifications),
Specifications),
oil the
the threads with light weight engine
oil.
oiloil. Do
Do not
not oil
oil threads that require oilresistant or
Refer to
to Part 21-01
21-01 for
for Cleaning and
Inspection procedures.
VALVE LIFTER
The internal parts of each hydraulic

valve lifter assembly are
are matched sets.
Do not
the
not intermix the
the parts. Keep the
assemblies intact until they are
be
are to
to be
cleaned. Valve lifters should always be
be
to the
tested after assembly; refer to
the
cleaning, inspection and test procedures
in Part 21-01.
covered in
DisllSsembly
Disassemble and assemble each lifter
separately. Identify the lifter assemblies
so they can be installed in their original
bores.
1.
pliers to
to release it
it from the groove. It
may be
the
be necessary to
to depress the
plunger to
to fully release lock ring.
2.
2. Remove the
the push rod
rod cup, metering
valve (disc) plunger and
and spring.
3.
the
3. Remove the
the plunger assembly, the
check valve and
and the
the check valve
retainer and plunger spring. Carefully
Carefully
remove the plunger spring, the check
valve retainer and,
and, the
the check valve
the plunger.
plunger.
disc from the
Assembly
Assembly
is shown in
Hydraulic lifter assembly is
in
Fig. 42.
42.
Fig.
PUSH ROD
ROD SOCKET
SOCKET
PUSH
METERING VALVE
VALVE
"'""". /
METERING
)/ :}',)J.~..., . /
~'4 itii.,
' \{ ' ' -
CHECK VALVE
VALVE
CHECK
SPRING
CHECK VALVE SPRING

jCHECK VALVE
RINGp~l::{%'\~"
PLUNGER SPRING
BODY
LOCK
PLUNGER
VALVE
CHECK VALVE
RETAINER
A2867-B
A2867B
FIG. 42
42 Hydraulic Valve Lifter
FIG.
Assembly
1. Place the
the plunger upside down on
on a
1.
clean work bench.
2. Place the
the check valve (disc or
or ball
2.
check) in
in position over the oil hole on
the plunger. Set
Set the
the
the bottom of the
check valve spring on top of the check
or ball check).
valve (disc or
BACK TO GROUP INDEX
3. Position the check valve retainer over

the check valve and
and spring and
and push
the retainer down into place on
on the
the
plunger.
4. Place the plunger spring, and then the
plunger (open end
the lifter
end up)
up) into the
body.
5. Position the
in
the metering valve (disc) in
the plunger, and
and then place the push
rod cup in
in the
the plunger.
6. Depress the plunger, and position the
the lock ring in
in the
the
closed end
end of the
the
groove of the
the lifter
lifter body. With the
the
plunger still depressed, position the
in the
the
open ends of the
the lock ring in
groove. Release the plunger, and then
to fully seat the lOCK
lock
depress it again to
ring.
7. Use
Use the
t h e hydraulic
h y d r a u l i c valve lifter
lifter
leakdown tester (Part 21-01) to fill the
lifters with test fluid.
against a scale. If the

the assembled
against
height is
is greater than specifications,
install the necessary 0.030 inch thick
the cylinder
cylinder head
spacer(s) between the
pad and
and the
the valve spring to
to
spring pad
the assembled
assembled Jieight
\leight to the
the
bring the
recommended height.
recommended
Do not
not install the
the spacers unless
of spacers in excess of
of
necessary. Use of
recommendations will result
result in
in
recommendations
the valve springs and
and
overstressing the
CYLINDER HEAD
DisllSsembly
Disassembly
1.
the
1. On
On 302-2V engines, remove the
exhaust valve stem caps.
2. Remove the
manifolds (if
(if
the exhaust manifolds
required) and
and the
the spark plugs.
3. Clean the
the carbon out
out of the cylinder
head combustion chambers before
the valves.
removing the
Remove the spring retainer locks and
release the
the spring.
the sleeve, spring retainer,
5. Remove the
and valve. Discard
spring, stem seal and
Identify all valve
the valve stem seals. Identify
parts.
6. Clean, inspect and repair the cylinder
transfer all usable
head as required, or transfer
parts to
to a new cylinder head.
Assembly
Assembly
and valve
All valves, valve stems and
guides are to be lubricated with heavy oil
SE. The valve tips are to have Lubriplate
to
or equivalent applied. The lubricant is
is to
be applied before installation.
1. Install each valve (Fig. 44) in
in the
the port
port
1.
was removed or to
to
from which it was
fitted.
which it was fitted.
the valve stem seal and
and valve
2. Install the
spring over the valve and then install
the spring retainer. Compress the
the
and install the
spring and
the sleeve, if so
so
equipped, and retainer locks (Fig. 44).
the assembled height of the
3. Measure the
the surface of the
the
valve spring from the
cylinder head spring pad
cylinder
pad to
to the
the
dividers (Fig. 45). Check the dividers
A2855-B
FIG. 43
43 Compressing Valve Spring
EXHAUST
VALVE
STEM ^
CAP
6550
OIL SEAL
6571
$i
~I{
EXHAUST
VALVE
6506
:.;::"
INTAKE
:(
:.;;,_ VALVE
VALVE
6507
.',,: !
A3307-A
A 3307A
Assembly302-2V
FIG. 44
44 Valve Assembly-302-2V
and 351-W engines
v-a
21-21-22
302 and 351

W CIO
351W
CID V-8 Engines
overloading the camshaft lobes which

could lead to spring breakage and/or
worn camshaft lobes.
4. Install the exhaust
exhaust manifolds
manifolds (if
(if
removed) and the spark plugs.
1. Oil all parts thoroughly.

relief valve
plunger, spring and a new cap.
3. Install the outer race and the inner
shaft assembly. Be sure the
rotor and shaft
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 torque the
cover
c o v e r attaching
a t t a c h i n g screws
s c r e w s to
to
specifications.
4. Position a new gasket and the oil inlet
tube on the oil pump and install the
attaching bolts.
UNDERSIDE OF SPRING RETAINER
SURFACE OF SPRING PAD
A2857-A
FIG. 45 Valve Spring Assembled

Height
OIL PUMP
Disassembly
Disassembly
1.
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
shaft assembly, then
inner rotor and shaft
remove the outer race.
3. Drill a small hole and insert a se1fselfthreading sheet metal screw of the
proper diameter into the oil pressure
relief
relief valve chamber cap and pull the
cap out of the chamber. Remove the
spring and plunger.
u-1-4---
Driver
Detail A-7
INSE
RT
INSERT
TAPERED PILOT
IN PISTON PIN
FOR PIN REMOVAL
I ~ F~~ ~II~T~~:~~AL
Reversible
Lo~ator
Delod A-5
INSERT
INSERT THIS
THIS END
END
IN PISTON HOL E
HOLE
INSTALLATION
~ FORIN PISTON
INSTALLATION
Adapter
A-3
Adopter Detail
Detail A-3
T68P-6I35-A
T68P-6135-A
Cup
Detail
Cup D
e t a i l A-I
A-l
IDENTIFICATION MARKS
PLATE
6616
FIG. 46 Oil Pump Assembly
BACK TO GROUP INDEX
LOWER
COMPRESSION
ING
6106
A2872-A
Press Ram
P,e"
Rom
GASKET-6626
ROTOR AND SHAFT

ASSEMBLY
6608
UPPER
COMPRESSION^.
RING
{
1.
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. 47, press the piston pin from the
piston and connecting rod.
The oil pump assembly is shown in

Fig. 46.
6622
Assembly
Assembly
The piston, connecting
connecting rod and
related parts are shown in Fig. 48.
48. Check
the fit of a new piston in the cylinder bore
before assembling the piston and piston
pin to the connecting rod.
PISrONS
RODS
Disassembly
Disassembly
Assembly
Assembly
INLET TUBE
ASSEMBLY
21-21-22
A3705-A
A1643-F
FIG. 47 Removing or Installing Piston

Pin
Pin
FIG. 48 Piston,
Rod and
Piston, Connecting Rod
Related Parts
The piston pin bore of a connecting
rod and the diameter of the piston pin
must be within specifications. Refer to
specification
specification at end of this part.
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 indentation notch in the piston
positioned as shown in Fig. 49.
On replacement connecting rods,
install the large chamfered
chamfered side of the
connecting rod bearing bore towards
crankshaft check; facing towards
the crankshaft
front of engine on right bank rods,
and facing towards rear of engine on
left bank rods.
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. 47).
3. Check the end gap of all piston rings
(Part
(Part 21-01). It
It must be within
specifications. Follow the instructions
contained on the piston ring package
and install the piston rings.
21-21-23
lower land (Part 21-01). The gauge
302 and 351W

351W CID V-8
v-a Engines
21-21-23

bearing inserts in the connecting rod
and cap with the tangs fitting in the
slots provided.

CYLINDER ASSEMBLY
LEFT BANK
BANK
LEFT
RIGHT BANK
BANK
RIGHT
NOTCH OR
ARROW TOWARD
FRONT OF ENGINE
OF ROD
ROD
NUMBERED SIDE OF
DisllSsembly
Disassembly
A3706-B
Rod
FIG. 49 Correct Piston and Rod
Positions-302-2V and
Positions302-2V
351-W Engines

BACK TO GROUP INDEX

and remove all parts not furnished
with the new cylinder assembly;
of
this Part.
2. Remove the 4 cylinder head locating
dowels and the block drain plugs.
Assembly
of
1.
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,
of
this Part.
CYLINDER BLOCK
Before replacing a cylinder block,
determine if it is repairable. If
If so, make
necessary
necessary repairs, following
following the
Disassembly
Disassembly
1. Completely
Completely disassemble the old
engine, following the procedures
before removing
removing piston
bores before
assenlblies.
assemblies.
3. Remove the cylinder head locating
Assembly
1.
of
2. Position the new cylinder block in a
work stand and install the cylinder
head locating dowels and the block
drain plugs.
from the old cylinder block, following
the procedures given in the Removal
Renloval
and Installation Section of this Part.

302 and 351

W CID v-a
351W
V-8 Engines
21-21-24
21-21-24
21-21-24
SPECIFICATIONS-1975
SPECIFICATIONS1975
GENERAL
G E N E R A L SPECIFICATIONS
SPECIFICATIONS
Eiqme
Bore
Bore ....
and Stroke
Stroke
Compression
Pressure
PSI
PSI (Sea
(Sea level)
Level) @
@ Cranking
Cranking
Speed
Speed
302-2V
4.00
4.00 x 3.00
3.00
The
The lovvest
lowest reuding
reading must
must be
be
E.._
351-W
351-W
(1)
(1)
Drive Belt
Belt Tensions
Tensions (lbs.)
(Ibs.) (5)
(5)
Drive
Firing Order
Firing
Order
4060
40-60
1S-4-2-G-3-7-8
l-b-4-2-6-3-7-8
1-37-2-6-5-4-8
1-3-7-2-6-5-4-8
40-65
40-65
within
w i t h i n 75%
75% of
of the
the highest
highest
4.00
4.00 x
x 3_50
3.50
Newly Installed
Newly
Installed
Size
Size
Oil
Oil Pressure-Hot
Pressure-Hot
@2000
@ 2 0 0 0 RPM
RPM
1/4"
1/4"
Used
Used
Up to
to 10
10 Mm.
Min.
Up
(1)
(1)
(2)
(2)
5080
50-80
40-80
40-80
120-160
120-160
(3)
90-160 (3)
90-160
Exc. 1/4"
Exc.
1/4"
Over 10
10 Mm.
Min.
Over
40-60
40-60
(2)
(2)
(4)
(4)
75120
75-120
(2)
less than
than 40
40 pounds,
pounds, readjust
readjust to
to 40-60
4060 pounds.
pounds.
(2) If
If less
(4)
If less
less than
than 75
75 pounds,
pounds, readjust
readjust to
to 90-120
90-120 ppounds.
(4) If
ound!
R8Bd
grooves.
Read tension
tension immediately
immediately after
after belt
belt is
is installed,
installed, before
before it
it stretches
stretches or
or seats
seats in
in pulley
pulley grooves.
(3)
(3) If
If less
less than
than 90
90 pounds,
pounds, readjust
readjust to
to 90-120
90-120 pounds.
pounds.
(5)
(5) A
A used
used belt
belt is
is any
any in
in operation
operation for
for 10
10 minutes.
minutes.
CYLINDER
C Y L I N D E R HEAD
HEAD
Engine
Engine
3022V
302-2V
Valve
Valve
Seat
Seat Width
Width
Valve
Valve Guide
Guide
Diameter
Bore Diameter
(Standard
Intake and
Exhaust)
Combustion
Chamber
Chamber
Volume
Exhaust
Intake
351-W
0.0600.0600.080
Valve
Valve
Seat
Runout
Runout
(Maximum)
(Maximum)
Arrangement
Arrangement
Arm
Arm
Surface
Surface
(Front to
to
(Front
Stud Bore
Bore
Stud
Flatness
Flatness
Rear)
Rear)
Dia. Std.
Std.
Dia.
(i)
0
inch
0.0020
0.0020
Left
Left
0.0600.090
CDHeadGasket
H e a d Gasket Surface Finish A.M.S.
R.M.S.
0.003
Right
Right
I-E-I-E-I-E-I-E
I-E-I-E-I-E-I-E
45
450
589-619
58.9-61.9
Gasket
Gasket
Rocker /,{.
Rocker
Valve
Valve
0.0600.0600.080
56.7-59.7
0.3433
0.34330.3443
0.3443
Valve
Valve
Seat
Seat
Angle
0.36800.3680-
In Any
0.3695
0.3695
Inches
66 Inches
0.006
E-I-E-I-E-I-E-I
E-l-E-l-E-l-E-l
Overall
60150
60-150
VALVE ROCKER
ROCKER ARMS
ARMS, PUSH
PUSH RODS
RODS AND
AND TAPPETS
TAPPETS
Valve Push
Rocker
Rocker Arm
Arm
Engine
Engine
Rod (Maximum
(Maximum
Lift
Lift Ratio
Ratio
Runout)
Valve Tappet
Tappet Or
Or lifter
Valve
Lifter
Standard
Diameter
Clearance
To Bore
Bore CD
(!)
0.87400.8745
0.0007-
Collapsed Tappet
Tappet Gap
Gap
Collapsed
Hydraulic
Lifter
Hydraulic lifter
Leakdown Rate
5-50 Seconds
5-50
302-2V
1.61
:1
1.61:1
0.015
351-W
351-W
Allowable
Allowable
Desired
Desired
0.090-0.190
0.090-0.190
0.115-0.130
0.115-0.130
0.106-0.206
0.106-0.206
0.131-0.181
0.131-0.181
Maximum -Maximum
Measured at
Measured
0.0027
1/16 Inch
1/16
plunger
plunger travel
'Wear Limit
Limit-- 0005
0.005
CD'Wear
V A L V E SPRINGS
SPRINGS
VALVE

Engine
Pressure
Wear limit
Limit
1.69
76-84 @ 1.69
190-210 @
@ 1.31
1.31
190210
Intake
Exhaust
@
@
1.22
190-210 @ 1.22
Specified
Length
1.790
71-79 @ 1.790
190-210@
190-210 @ 1.340
1.340
351-W
Valve
Valve Spring
Valve
Valve Spring
Spring
Length
Free length
Assembled
Assembled Height
Height
Out,o',SQuare
O
utofSquare
Approximate
Pad to Retainer
(Maximum)
(Maximum)
1.94
1.94
1-43/64-1
1-43/641 -45/64
1.85
1.85
1-19/32-1-39/64
1-19/32- J -39/64
2.06
1-49/64-113/16
1-49/64-113/16
10% Pressure loss
@ 1.60
1.60
76-84 @
302-2V
Valve Spring
5/64
5/64 (0.078)
VALVES
VALVES
Valve Stem
VatveStem
Engine
Intake
302-2V
L i m i t . 0.005
0.005
Limit.
Valve
Valve
Diameter
Diameter
Exhaust
0.0010-0 0027
00010-00027
351W
(1)
Wear
Valve Head
To Valve Guide
Clearance
ClearanceQ)
Intake
0.0015.0.0032
0.00150.0032
Face
Face
Angle
Angle
1.773-1.791
Exhaust
Exhaust
J:'
1.442-1.460
1.442-1.460
440
44 0
Q) Valve Face Runout

Runout - MaXimum
M a x i m u m 0.002.
0.002.
~
V A L V E S (Continued)
(Continued)
VALVES
Valve
Valve Stem Diameter
Engine
302-2V
351-W
0.003 Oversize
Standard
0.015
0.015 Oversize
0.030
Oversize
0.030 OverSize
intake
Intake
Exhaust
Intake
0.34160.3423
0.34110.3418
0.3446-
0.3441-
0.35660.3566-
0.35610.3561-
0.37160.3716-
0.37110.3711-
0.3453
0.3448
0.3573
0.3568
0.3568
0.3723
0.3718
0.3718
Exhaust
Intake
Exhaust
Exhaust
Intake
Intake
Exhaust
Exhaust
CA1308-B
CA1308-B
BACK TO GROUP INDEX

302 and 351W (10

v-a Engines
CID V-8
21-21-25
Exhaust
Theoretical
Thaoratica!
V.lve
Valve Lift
Exh.ust
Intlka
Exhaust
Intake
Lobe Lift(j)
Lift
Engina
Engim
Intlkl
Intake
302-2V
0.2303
0.2375
0.3707
351-W
0.2600
0.2780
0.4180
D.4180
CD
Maximum allowable lobe lift loss (All engines) ...... 0.005
Maxim,um
Camshaft Journal
Journal
DiameterStandardQ)
Standard
Camshaft Bearing
Bearing
Location~
Location
Beering
Bearing
302-2V
351W
(No l)
1)
(No 2)
(No 3)
3).
(No 4)
(N'o
(No 5)
2.0805-2.0815
2.0655-2.0665
2.0505-2.0515
2.0355-2.0365
2.0205-2.0215
(No 1)
0.0050-0.0200
0.001
0.0010.003
00010007
0,001-0.007
a>
(3) Wear Limit -
Wear Limit - 0009

0.009
Item
Bearing
302-2V
351W
Camshaft
Bearings'
Bearings
Inside
Diameter
(No
1)
(NoD
(No 2)
(No 3)
(No 4)
(No 5)
2.0825-2.0835
2.0825-2.0835
2.0675-2.0685
2.0675-2.0685
2.0525-2.0535
2.0525-2.0535
2.0375-2.0385
2.0375-2.0385
2.0225-2.0235
2.0225-2.0235
OCh
0C 00:
0.006.

CD
APPROXIMATE
CAPACITIES
Mllsure
Engine
U.S. Measure
302-2V,351-W
3-1/2 Quarts
302-2V,351-W
3-1/2
CD
j'.,dd 1/2
ilter repliJcement
replacement
Add
1/2 quart with filter
(Continued)
Item
(%)
(2)
PIIY
End Play
Chlin Deflection
Timing Chain
(Maximum)
Camshaft Journal to
Be.ring Clearance
Clllr.nce
Bearing
e!)
Claarance <3)
Camlhlft
Camshaft
0.3823
0.4480
~
Q)
21-21-25
Imperial Measure
4 Quarts
(DCamshaft
Camshaft journal maximum runout .......... 0.005
Camshaft journal maximum out-of-round .......... 0.0005
<%>
@ Distance
Distance in
in inches
inches that
that the
the front edge
edge of
of the bearing isis installed towards the rear from the front
front
face of
block.
face
CYLINDER BLOCK
<D
Engin.
Engina
Cylind.r
Cylinder Bore Dilmetlr
Diametar <D
CD(3)
(3)
302-2V
4000440052
4.0004-4.0052
351-W
4.0000-4.0048
4.0000-40048
Cylinder Block
M.in
Main Belring
Baaring
Bore Diameter
Lifter Bore
Bora Dilmeter
Diamater
Distributor Shift
Shaft
Beering Bore Oilmeter
Baaring
Diameter
2.4412-2.4420
2.4412-2.4420
0.4525-0.4541
3.1922-3.1930
3.1922-3.1930
0.5155-0.5171
0.8752-0.8767
Maximum out-of-round ......................................... 0.0015

Wear Limit ...................................................., 0.005
0.005
Cylinder Bore Surface Finish RMS ................................. 18-38
Hlld Gasket
Olsklt
Head
(%)
Surface Flatne.
Flatness(2)
Crankshaft To Rear
Relr
Crankshaft
FICI Of Block
Faca
TIR Max
MIx
Runout TIR
0.003 inch in any

66 inches or 0.006
inch overall
0.010
(2)
...60-150
60-150
~ Head Gasket Surface Finish RMS ..................................
. . . . 0 .0.001
001
(3) Maximum Taper ................................................
~
. . . ,. 0.0.010
.010
Wear Limit . .................................................
FLYWHEEL
Engina
Engine
vtBiffi Bllring
DBBriny
M.ln
Journ,1
Journal
Diamatar
Diameter(j)
Main Beering
Bearing
Mlin
RunoutJournal Runout
(2)
Maximum <%>
Main Bllring
Baaring
Mlin
Journll
Journal
Thrust Face
Flee
Runout
Main Bearing
Mlin
Beering
Journal
Journ'l
Taper Max
MIx
Thrust
Baaring
Bearing
Journal
Length
0001
0.0006
Per
~er Inch
,1.137-1.139
.137-1.139
2.2482-2.2490
302-2V
3022V
0.002
2.9994-3.0002
351-W
351W
lCD
Main bearing journal out-of-round maximum 0.0004 (all engines)
(2)
~ Wear Limit --
Main
Mlin Bearing
Bllring
Surface
Surflce Finish
RMS Mlximum
Maximum
Thrust Fece
flee
Journal
Journll
35 Front
12
25 Rear
0.005
FLYWHEEL
(Continued)
CRANKSHAFT AND FL
YWHEEL (Continued)
Engina
Engine
Connecting Rod
Journal Dilmeter
Diametar (%)
(2)
Joumll
302-2V
2.1228-2.1236
Connecting Rod
Bearing Journll
Journal
Beering
Maximum Tlper
Taper
Mlximum
0.0006 Per Inch
351-W
Crankshaft Free
Crlnkshlft
Play <D
0
End PllY
Flywheel Ring Gear

Oelr Lateral
Literal Runout
Transmission
Trensmission
Standard
Automatic
Stlnderd
Automatic
Flywheel Clutch
Faca
Flee Runout
0.010
0.030
--
--
0.004-0.008
0.004-0.008
2.3103-2.3111
00060
060
0 Wear
Wear limit
L i m i t-- 00.012
.012
<D
(2) Connecting rod
rod journal out-of-round maximum 0.0006
0,0006 (all engines).
<%>
OIL PUMP
Engina
Engine
302-2V
351-W
Rotor-Type Oil
Pump Relief Vaivi
Valve
Spring Tension
LbsSpecified
Lbs.
Specified Length
10.6-12.2@
1.704
106-122
@ 1.704
@2.49
2.49
18.2-20.2 @
Shaft
Drive Shift
To Housing
Bearing
Belring
Clearance
Clearence
Relief Valve
Relilf
Vllve
Clearance
Clearence
Rotor Assembly
End Clearance
Clearence
0.0015-0.0029
0.0015-0.0029
0.0015-0.0029
U.001-0.004
Outer Race
Rice
To Housing
(Radial
(Rldill
Clearance)
Clarenc.)
0001-0013
0001-0013
1
CA1308-B
CA1308-Bl
BACK TO GROUP INDEX

302 and
W CIO
v-a Engines
and 351
351W
CID V-8
21-21-26
21-21-26
CRANKSHAFT BEARINGS
BEARINGS
Connecting Rod
Rod Bearings
Engine
302-2V
Main Bearings
o
00080.0015
0.0008-0.0015
0.0008-0.0026
0.0008-0.0026
0.05720.0577
0.0572-0.0577
StandardQ)
Standard
Allowable
Desired
351-W
CD
Wall Thickness
Wall Thickness
Standard 11
Allowable
Desired
No.
No. 1 Bearing
0.0001-0.0005
0.0001-0.0005
All Others
0.0005-0.0015
0.0005-0.0015
NO.11 Bearing
No.
0.0001-0.0020
0.0001-0.0020
All Others *
0.0005-0.0024
0.0005-0.0024
NO.11 Bearing
No.
0.0961-0.0966
0.0961-0.0966
All Others
0.0957-0.0962
0.0957-0.0962
0.00080.0015
0.0008-0.0015
0.0008-0.0026
0.0008-0.0026
0.0957-0.0960
0.0957-0.0960
0.002 Undersize Thickness .......... Add

0.002 Undersize Thickness .......... Add
(l)
CONNECTING ROD
ROD
Rod length
Length
Connecting Rod
Rod
Alignment
Maximum Total
Bore Diameter
Center
Difference
Difference
CD
To Center
Piston Pin
Pin
Engine
302-2V
351-W
Bore Or
Connecting
Rod Bearing
Bushing
ID
0.9104-0.9112
Connecting
5.9545-5.9575
5.9545-5.9575
CD
Connecting rod
Connecting
rod bearing bore maximum out-of-round and
and taper (All
(All Enqines)
Engines)
Assembly
To
(Assembled To
CD
5.08855.0915
5.0885-5.0915
2.2390-2.2398
Rod
Connecting Rod
Crankshaft)
Crankshaft)
Twist
Bend
0.024
0.012
Side
Wear
Clearance
limit
Limit
0.010-0.020
0.010-0.020
0.023
0.0004
(1)
(2) Pm
Pin bushing and
be parallel and
and in
in the
the specified total difference at
at ends of 8-lnch
8-inch long bar
bar measured 4 inches on
on each
within the
side of
rod.
of rod.
PISTON
PISTON
Diameter
Engine
Engine
302-2V
351-W
(?)
J)
Coded
Coded
Red
Red
Coded
Blue
(7)
CD
0.003
Oversize
Coded
Yellow
Piston To
Cylinder Bore
Clearance
Pin
Piston Pin
Bore
Diameter
Diameter
Gmove Width
Ring Groove
3.9984-
3.9996-
4.008-
4.0020-
0.0018-
0.9122-
Upper Compression Ring 0.080-0.081
3.9990
4.0002
4.0014
4.0026
0.0026
0.9126
lower Compression Ring 0.080-0.081

Lower
3.99783.9984
3.99903.9996
4.0002-
4.0014-
0.0018-
0.9124-
4.0008
4.0020
0.0026
0.9127
Oil Ring .......... 0.1880-0.1890
Measured at
at the
t h e piston
p i s t o n pin
p i n bore
b o r e centerline
c e n t e r l i n e at
at gOD
9 0 tu
to the
t h e pill
p i n !Jure.
bore.
PISTON
PIN
PISTON PIN
length
Length
Engine
302-2V
3.010-3.040
351-W
Diameter
To Piston
Standard
0.001 Oversize
0.9120-0.9123
0.9120-0.9123
0.9130-0.9133
0.9130-0.9133
To Connecting
Clearance
Ciearance
Rod Clearance
0.0002-0.0004
0.0002-00004
Interference
Interference Fit
Fit
0.003-0.0005
0.003-0.0005
PISTON RINGS
RINGS
PISTON
Engine
'302-2V
351-W
Ring Width
Compression Ring
Ring
Top
Top
Bottom
0.0770.078
0.0770.078
Wear Limit.
Limit ... .. .. 0.006
0.006
CDWear
Side Clearance
Ring
Compression RingeD
Top
Bottom
0.0020.004
0.0020.004
Ring Gap Width

Oil
Ring
Snug
Oil
Compression Ring
Ring
RingeD
Top
Bottom
0.010-
0.010-
0.015-
0.020
0.020
0.055
Steel Rail
(VSteel
CA130BC22
CA1308-C
BACK TO GROUP INDEX

351W CID v-a

V-8 Engines
302 and 351W
21-21-27
21-21-27
TORQUE LIMITS --FT-LBS

FTlBS
Engine
Item
302-2V
Cylihder
Cylinder Head Bolts
Step 11
Engine
En!i4ne
351-W
351 -W
302-2V
Item
Step 22
to Cylinder
Oil Pan
Panto
Block
Intake Manifold Bolts
Exhaust Manifold Bolts
Distributor Vacuum Control Valve
Distributor
60-70
Main Bearing Cap Bolts

Oil Drain Plug
EGR Valve to Carbu
Carburetor
EGR
retor Spacer
95-105
105-112
9-11 (5/1
6 x 18)
9-11
(5/16x18)
7-9
(1/4 x 20)
7-9(1/4x20)
23-25
18-24
15-18
75-85
95-105
15-25
12-18
10-15
20-30
20-30
Oil Filter to Insert

(Cartridge Type)
With grease on gasket surface,

hand-tighten until gasket contacts adapter face then tighten
1/2 turn more.

Vibration Damper to Crankshaft
Crankshaft Pulley to Vibration Damper
Rocker Arm Stud

Nut
Nut Contacts Shoulder.
45-57
MISCELLANEOUS TORQUE VALUES

Alternator Bracket to Cylinder Block
Thermactor Pump Adjusting Arm to Pump Body
Carburetor Mounting Nuts
Carburetor Mounting Stud to Intake Manifold
19-24
Connecting Rod Nuts
Fuel Pump to Cylinder Front Cover
Fan to Water PLjmp

Pqmp Hub (Bolt)
40-45
9-12
70-90
35-50
351 -W
351W
3-5
19-27
17-23 Ft-Lbs After
55-65
65-72
15-20
45-57
15-20
24-40
15-20
22-32
22-32
15-20
80-115 in-Ib
in-lb
35-50
12-18
12-15
15 max.
in-lb
80-100 in-Ib
40-45

BOLTS-FT-LBS
CAUTION: If any of the torque limits listed in this table disagree with any of those listed in the prece9ing
preceding tables, the limits in the preceding tables prevail.
Size (I(Inches)
nches)
1/4-20
Torque (Ft-Lbs)
6-9
6-9
I
I
5/16-18
3/8-16
7/16-14
1/2-13
12-18
22-32
40-55
55-80
I
I
9/16-18
85-120
Note: Oil threads with engine oil unless the threads require oil resistant or water resistant sealer.
seaier.
CA13O8-B3
CA1308-B3
BACK TO GROUP INDEX

21-21-28
302 and
W CI
D V-8 Engines
and 351
351W
CID
21-21-28
SPECIFICATIONS-1976
SPECIFICATIONS1976
SPECIFICATIONS
(Ibs.) (5)
(5)
E. . .
Bore and
and Stroke
Stroke
PSI
PSI (Sea
(Sea level)
Level) @Cranking
@ Cranking
Speed
J02-7V
3027V
4.00 x 3.00
3.00
The lowest reading must be

be
40-60
1-5-4-2
-6-3-7-8
1-5-4-2-6-3-7-8
1/4"
1/4"
351-W
351 W
4.00)(
4.00 x 3.50
3.50
within 75% 01
of the
the highest
45-65
1-37-2-6-5-4-8
1-3-7-2-6-5-4-8
Exc. 1/4"
(1)
(3)
(5)
(5)
Oil Pressure-Hot
@2000
RPM
@2000RPM
Firing Order
Newly Installed
Size
Read
in pulley grooves.
Read tension immediately after belt isis installed,
installed. before it stretches or seats in
H less
less than 90
90 pounds,
pounds. readilistto
read|iist to 90-120
90 120 pounds.
A used
used bell
belt isis any
any in
in operation for
for 10
10 minutes_
minutes.
(1)
(1)
Used
Osed
Min.
Up to 10 Mm.
Over 10 Min.
Over
Mm.
50-80
(2)
40-80 (2)
(2)
40-60 (2)
120-160
(3)
90-160 (3)
(4)
75-120 (4)
(2)
(2)
(4)
75 pounds, read|ust
read lust to 90-120 pounds.
If less than 75
CYLINDER HEAD
HEAD
Valve Guide
Bore Diameter
Diameter
(Standard
Intake and
and
Exhaust)
Combustion
Chamber
Volume
Engine
302-2V
Valve
Seat Width
Valve
Seat
Runout
(Maximum)
(Maximum)
T.I.R.
Valve
Seat
Angle
Exhaust
Intake
Valve
Rocker
Rocker
Gasket
Arrangement
Arrangement
Arm
Surface
(Front to
(Front
Stud Bore
Flatness
Flatness
Rear)
Dia. Std.
CD
0.3433
0.3443
351-W
0.003
Rlqht
Right
I-E-IEI-E-[t
I-E-I-E-I-E-I-E
56.7-59.7
0.0600.080
0.0600.080
J0
0.002
45
45
Lef I
Left
[-I-E-I-E-IEI
E-l-E-l-E-l-E-l
58.9-61.9
CD
rl ace Finish R.
M.S
HHead
e a d Gaska
Gaskett Su
Surface
R.M.S
inch
368C
0o368C-
In Any
O.369~
0.3695
66 Inches
0.006
Overall
60150
60-150
VALVE ROCKER ARMS, PUSH RODS AND

AND TAPPETS
TAPPETS
Valve Push
Rocker Arm
(Maximum
Engine
Rod (Maximum
lift
Lift Ratio
Runout)
Standard
Diameter
Valve Tappet Or Lifter

Clearance
To Bore (T)
Hydraulic Lifter
Hydraulic
0.87400.8745
0.00070.0027
5-50 Seconds
Maximum -Measured at
at
1/16 Inch
1/16
plunger
plunger travel
302-2V
0.015
1.61:
1.61:11
351-W
Collapsed Ta
Tappet
Gap
ppet Gap
Leakdown Rate
Allowable
Allowable
Desired
0.090-0.190
0.090-0.190
0.115-0.165
0.115-0.165
0.106-0.206
0.106-0.206
0.131-0.181
Wear Limit --0.005

CDWr,m
0.005
VALVE SPRINGS
SPRINGS

@ Specified Length
Length
Lbs @Specified
Engine
Pressure
302-2V
Intake
76-84 @ 1.69
190-210 @ 1.31
1.31
Exhaust
76-84 @ 1.60
1.60
7684@
@ 1.20
190-210 @
@ 1.79
1.79
71-79 @
190-210 @
@ 1.34
351-W
Limit
Wear limit
Valve Spring
Valve Spring
Valve Spring
Free Length
Assembled Height
Out-of-Square
Out-ofSquare
Approximate
Approximate
Pad to Retainer
(Maximum)
(Maximum)
1.94
194
1-21/32-1-23/32
1.87
1-36/64-1-5/8
2.06
1-49/64113/16
1-49/64-1-13/16
10% Pressure loss

@
Specified
Length
5/64
5/64 (0.078)
VALVES
VAL\lES
Valve Stem
To Valve Guide
Clearance
Clearance(D
Engine
302-2V
3022V
351W
W e a r Limit 0.005S
0.0055
Q)WP'ili
Valve Head
Valve
Face
Angle
Diameter
Diameter
Intake
Exhaust
Intake
0.0010-0.0027
0.0015.0.0032
0.0015.0.0032
1.773-1.791
1.773-1.791
Exhaust
Exhaust
zX
1.442-1.460
44
44 0
<2> Valve Face Runout - MaXimum

Maximum 0.002.
(1)
VALVES
(Continued)
VAL
VES (Continued)
Valve Stem Diameter
Engine
302-2V
351-W
0.003 Oversize
Standard
intake
Intake
Exhaust
Intake
0.341603423
0.34110341103418
0.34460.3453
0.030 Oversize
0.015 Oversize
Exhaust
0.34410.3448
Intake
Exhaust
Intake
Exhaust
Exhaust
0.3566-
0.35610.3561-
0.3716-
037110.3711-
0.3575
0.3568
0.3723
0.3718
CA1308-C
CA130BC
BACK TO GROUP INDEX

302 and 351W CtO

CID v-a
V-8 Engines
21-21-29
Intake
Intlkl
Exhaust
Exh.ust
Theoreticel
Thtor.tictl
V.lve
Valve Lift
Exh.ust
Exhaust
Intlkl
Intake
302-2V
0.2373
0.2474
0.3823
351-W
0.2600
0.2600
Lob.
Lobe Lift(D
Lift
Engine
(DMaximum
0 M a x i m u m allowable lobe lift loss (All engines) ...... 0.005
Camshaft Journal
DiameterStandard 0
CD
Camshaft Bearing
Location
LocationQ)
Bearing
302-2V
351W
(No 1)
1)
(No 2)
2)
(No 3)
3)
(No 4)
4)
(No 5)
5)
2.0805-2.0815
2.0655-2.0665
2.0505-2.0515
2.0355-2.0365
2.0205-2.0215
(No 1)
0.0050-0.0200
0.001
0.0010.003
0.001-0.007
00010007
0.4186
0.500
(2) Wear Limit - 0.006.

~
Q) Wear Limit - 0.009.

0 009.
(2)

CD
CAPACITIES0
Engine
I
U.S. Measure
Mllsure
CAMSHAFT (Continu.d)
(Continued)
Item
It""
<2>
~
End Pity
Play
Deflection
Timing Chain D.f1ection
(Maximum)
Camshaft Journal to
BHring Clearance
CIHrance
Baering
Clur.nce
Clearence
($>
~
Camshaft
C.m....ft
0.3884
0.4186
21-21-29
I
I
Item
B.aring
Bearing
302-2V
3022V
3S1W
351W
Camshaft
Bearirigs
Bearings
Inside
Qiameter
(No
1)
(No1)
(No 2)
2)
(No 3)
3)
(No 4)
4)
(No 5)
5)
2.0825-2.0835
2.0675-2.0685
2.0525-2.0535
2.0375-2.0385
2.0225-2.0235
302-2V.351-W
302-2V,351-W
lCD
0
I
I
4 Quarts
Imperial Meesure
Mllsure
3%
31/2 Quarts
Add 1 quart with filter replacement.
0Camshaft journal maximum runout .......... 0.005

<DCamshaft
Camshaft journal maximum out-of-round .......... 0.0005
(%)
Distance in inches that the front edge of the bearing is installed towards the rear from the front
Distance
face of the cylinder block.
CYLINDER BLOCK
Engin.
Ellgin.
CD
Diameter (1)
(D a>
(3)
Cylinder Bore Di.meter
302-2V
4.0004-4.0052
4.0004-40052
351-W
351W
4.0000~40048
4.0000-4.0048
Main Bearing
M.in
Btaring
Bore Diameter
Diam.ter
Cylinder Block
Distributor Shaft
I.aring
Diamlttr
2.4412-2.4420
0.4525-0.4541
3.1922-3.1930
0.5155-0.5171
Di
Lifter Bore Di.m.ter
0.8752-0.8767
Maximum out-of-round ......................................... 0.0015

Wear Limit ...................................................., 0.005
0.005
Cylinder Bore Surface Finish RMS ................................. 18-38
Head Gasket
Surface
~
Surfece Flatn
Flatness
0.003 inch in any
6 inches or 0.006
inch overall
Crankshaft To Rear
Crlnkshlft
Relr
Face Of Block
Fac.
Runout TIR Max
MIX
0.005
(2) Head
60-150
Head Gasket Surface Finish RMS ..................................
...60-150
(3) Maximum Taper ................................................
. . . . 0.001
0.001
~
. . . . 0 0.010
.010
Wear Limit . ...................................................

Engin.
Engine
Main Bearing
B.aring
Journal
Diameter 0
Diameter(J)
Main Beering
B.aring
Journal
Maximum (2)
Main Bearing
B.aring
Journal
Thrust Face
Runout
2.2482-2.2490
0.002
2.9994-3.0002
351-W
0 Main
Main bearing journal out-ofround
out-of-round maximum 0.0004 (all
(all engines)
302-2V
3022V
0.001
0.001
.<0
Main Bearing
luring
Journal
Taper Max
Thrust
Beering
Buring
Journal
Length
L.ngth
0.0006
1.137-1.139
Per Inch
Wear Limit (2)
Mlin
Buring
Main Bearing
Surface Finish
SUrfIC'
RMS Maximum
Thrust Face
Feee
Journal
12
12
35 Front
25 Rear
0.005
CRANKSHAFT AND FLYWHEEL (Continued)

Engine
Connecting Rod
Journal Diam.ter
~
Diameter
302-2V
2.1228-2.1236
Connecting Rod
Bearing Journal
Buring
Maximum Taper
Tlper
0
<D
<D
Flywheel Ring Gllr

Gear Llt.rel
Lateral Runout
Transmission
Automatic
Manual
Flywheel Clutch
Flywhlll
Face Runout
Fact
0.030
0.010
0 0006 Per Inch
0.0006
351-W
Crankshaft
Cranksh.ft Free
Fru
End Play (D
0.004-0.008
0 060
0060
2.3103-2.3111
2.31032.3111
Limit-0.012
Wear Limit
- 0.012
(2) Connecting rod journal out-of-round maximum 0.0006 (all engines).
OIL PUMP
Engin.
Engine
302-2V
351-W
'Rotor-Type
Rotor-Type Oil
Relief Valve
Pump R.Ii.f
Vllve
Spring Tension
Lbs
@Specified Length
LbsSpecified
106122
10.6-12.2 @
@ 1704
<9>2.49
2.49
18.2-20.2 @
Drive Shaft
To Housing
Bearing
Clearance
CI.rlnce
0.0015-0.0030
0.0015-0.0030
Relief Valve
Clearance
CleeranCi
0.0015-0.0030
0.0015-0.0030
Rotor Assembly
A..mbly
End Clearance
Clurance
0.0O4 Max.
0.OG4
Outer Race
RICI
To Housing
(Radial
Clurlncl)
Clearance)
0001-0013
00010013
CA1J08-C1
CA1308-C1
BACK TO GROUP INDEX

302 and 351

welD
v-a Engines
351W
CID V-8
21-21-30
21-21-30
CRANKSHAFT BEARINGS
Main Bearings
Allowable
Desired
Engine
302-2V
Wall Thickness
Standard <D0
Allowable
Desired
0.0008-0.0026
0.0008-0.0015
0.0008-0.0015
No.1
No. 1 BfjiJrlrlfj
Bearing
No. 1 BearlnCj
Bearing
Nu.
0.0001-0.0020
0.0008-0.0015
0.05720.0577
0.0572-0.0577
Wall Thickness
Standard'!)
Standard <])
351-W
009610.0966
0.0961-0.0966
All Others
All Others
0.0005-0.0024
0.0005-0.0024
0.0957-0.0962
0.0008-0.0026
0.0957-0.0960
<D

* 0.002 Undersize Thickness .......... Add 0.0010 to Standard Thickness.
(2)
(2)
0.002 Undersize Thickness .......... Add 0.0010 to Standard Thickness.
CONNECTING ROD
Engine
302-2V
351-W
Piston Pin
Bore Or
Bushing
Bushing
Connecting
Rod Bearing
Bore Diameter
10
ID
CD
o
0.9104-0.9112
2.2390-2.2398
2.4265-2.9273
Connecting Rod
Alignment
Maximum Total
Difference@
Difference
Connecting
Rod length
Length
Center
To Center
5.0885-5.0915
5.9545-5.9575
Connecting Rod
Assembly
(Assembled To
Crankshaft)
Twist
Bend
Side
Clearance
Wear
limit
Limit
0.024
0.012
0.010-0.020
0.023
CDConnecting
Connecting rod bearing bore maximum out-otround
out-of-round and taper (All Enqines)
Engines) .......... 0.0004
CV
(2) Pin bushing and crankshaft bearing bore must be parallel and in the same vertical plane
within the specified total difference when measured at ends of 8-inch long bar, - 4 inches
on each side of rod center line.
PISTON
Diameter
(?)
CD
Engine
Coded
Red
Coded
Blue
0.003
Oversize
Coded
Yellow
Piston To
Cylinder Bore
Clearance
Piston Pin
Bore
Diameter
302-2V
3022V
3.99843.9990
3.99964.0002
4.00084.0014
4.00204.0026
0.00180.0026
0.91220.9126
351-W
3.99783.9984
3.99903.9996
4.00024.0008
4.00144.0020
0.00180,00180.0026
0.002G
0.91240.9127
(7)
'-.0
Ring Groove Width

Upper Compression Ring 0.080-0.081
0.080-0.081
0.080-0.081
Lower Compression Rinq 0.080-0.081
0.1880-0.1890
Oil Ring .............. 0.1880-0.1890
900 to the pin bore.

Measured at the piston pin bore centerline at 90
PISTON PIN
length
Length
Engine
302-2V
351-W
3.010-3.040
Diameter
Standard
0.001 Oversize
0.9118-0.9124
To Piston
To Connecting
Clearance
Rod Clearance
0.0002-0.0004
0.0002
-0 .0004
0.003-0.0005
0.9128-0.9134
Interference Fit
PISTON RINGS
Engine
'302-2V
'3022V
351-W
Ring Width
Compression Ring
Top
Bottom
0.0770.078
W e a r Limit .......... 0.006

CDWear
0.0770.078
Side Clearance
Ring
Compression RingCD
Top
Bottom
0.0020.004
0.0020.004
Ring Gap Width

Oil
Ring
Snug
Compression Ring
Top
Bottom
0.0100.020 '
0.010- '
0.020
Oil
Ring
RingeD
0.0150.055
(l)Steel
S t e e l Rail
CA1308-D-2
CA1308D2
BACK TO GROUP INDEX

302 and 351W

v-a Engines
351W (to
CID V-8
21-21-31
21-21-31
TORQUE LIMITS
- FT-lBS
LIMITS-FT-LBS
Engine
Engine
Item
302-2V
Cylinder Head
Head Bolts
Step 11
Engine
Engine
351-W
351-W
3022V
302-2V
Item
55-65
65-72
Step 2
Oil Pan
to Cylinder
Panto
Cylinder
Block
Distributor Vacuum Control Valve
Crankshaft
60-70
Main
Main Bearing Cap
Cap Bolts
Oil
Oil Drain Plug
Plug
EGR Valve to Carburetor Spacer
Oil
95-105
105-112
9-11
6 x 18)
9-11 (5/1
(5/16x18)
7-9
(1/4 x 20)
7-9(1/4x20)
23-25
18-24
15-18
75-85
95-105
15-25
12-18
10-15
20-30
Oil
20-30
Oil
Oil Filter to Insert
(Cartridge Type)
With oil on gasket surface,

hand-tighten until gasket contacts adapter face then tighten
1/2 turn more.
40-45
9-12
70-90
35-50

Crankshaft
19-24
Rod Nuts
Connecting Rod
40-45
351W
351
-W
Fuel Pump to Cylinder Front Cover
3-5
19-27
Rocker Arm Stud

Nut
17-23 Ft-Lbs After

Nut Contacts Shoulder.
45-57
MISCELLANEOUS TORQUE VALUES

12-18
45-57
15-20
24-40
12-18
22-32
22-32
Thermactor Pump Adjusting Arm to Pump Body
22-32
22-32
12-18
in-Ib
130-180 in-lb
35-50
Fan
Fan to Water Pump Hub (Bolt)
12-18
12-15
15 max.
in-Ib
80-100 in-lb
10-15

BOLTS-FTLBS
CAUTION: If any of the torque limits listed in this table disagree with any of those listed in the preceding tables, the limits in the preceding tables prevail.
Size (I(Inches)
Size
nches)
1/4-20
I 5/16-18 I
5/16-24
5/16-24
3/8-16 I
I 3/8-16
3/8-24
3/8-24
I
I
7/16-14
7/16-14
14-20
22-32 , 27-38
6-9
6-9
12-18
45-57
1 12
-18
1
Note: Oil
Oil threads with engine oil
oi unless the threads require oil resistant or water resistant sealer.
Note:
(Ft-Lbs)
Torque (Ft-Lbs)
7/17-20
7/17-20
40-60
40-60
I
I
1/2-13
55-80
55-80
I 9/16-18
9/16-18
, 85-120
85-120
FT-LBS
TORQUE LIMITS FOR PIPE THREAD - FTLBS
Size (I(Inches)
Size
nches)
1/8
1/4
3/8
1/2
Torque (Ft-Lb)
(Ft-Lb)
5-8
5-8
12-18
22-33
25-35
CA1308-C
CA130BC33
BACK TO GROUP INDEX

351 M and 400

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

PART 21-22 351Mand
Meteor,, Cougar, Torino, Elite and Montego
Applies to Ford, Mercury, Meteor
COMPONENT INDEX
CAMSHAFT
CAMSHAFT BEARING
Page
COMPONENT INDEX
Page
EXHAUST MANIFOLD
EXHAUST
22-11

FL YWHEEL
FLYWHEEL
22-8

22-17

OIL SEAL
FRONT OIL
22-12

ROO BEARINGS
CONNECTING ROD
Ilat ion .............
Removal and Insta
Installation
VE~TILATION SYSTEM
22-12

INTAKE MANIFOLD
22-11
22-14

MAIN BEARING
22-6
Description ........................
CRANKSHAFT
CRANKSHAFT REAR OIL
OIL SEAL
Removal and Insta
Ilation .............
Installation
Y
CYLINDER ASSEMBL
ASSEMBLY
22-2
22-5

OIL FILTER
OIL PAN
OILPUMP
22-13
Disassembly
Assemb Iy ............
Disassemb Iy and Assembly
22-19
22-13
Disassembly
Assembly
Disassemb
Iy and Assemb
Iy ............
22-19
22-14

22-20
22-25
....
VALVE CLEARANCE ADJUSTMENT ....
VALVE LIFTER
Disassembly
Assembly
Disassemb
Iy and Assemb
Iy ............
ROCKER ARM COVER AND
VALVE ROC~ER
AND
22-2
22-15
22-13
Disassemb
Iy and Assembly
Assemb Iy ............
Disassembly
CYLINDER BLOCK
22-20

CYLINDER FRONT COVER PLATE
AND TIMING CHAIN
ANDTIMING
22-20

CYLINDER HEADS
Disassemb
Iy and Assemb
Iy ............
Disassembly
Assembly
22-9

ENGINE
Description ........................
22-18
22-8
22-2
22-3

ENGINE REAR SUPPORT
22-4
Removal
EXHAUST EMISSION CONTROL SYSTEM
Description ........................
22-4
22-2
22-18
22-12
22-18
22-8
ROCKER ARM
ARM
Removal and Installation .......... '"
AND
STEM SEAL
installation .............
Removal
WATER PUMP
Removal
22-5
22-6
22-9
NOTE:
NOTE: The information in
in this Part applies to both 1975 and
and 1976 ITIodel
model year vehicles unless otherwise specified.
specified.
CR1966-A
BACK TO GROUP INDEX

21-22-2
v-a
21-22-2
351M
and 400
400 CIO
CID V-8 Engines
351
M and
NOTE: The
The information in this Part applies to both 1975 and 1976
1976 model year vehicles unless otherwise specified.
CR1966-A
DESCRIPTION
ENGINE
The 351-M and
and 400 CID V-8
V-8 engines
the same design and
are basically of the
structure. Except for a revised crankshaft
crankshaft
damper, the
the differences
differences between the
the 22
is internal and
and consists of the
engines is
the 351M engine has a shorter
following: the
by using a revised
stroke, accomplished by
crankshaft and a piston with an increased
crankshaft
to top
top of
of
compression height (piston pin
pin to
piston). The
The 351M
351M also uses a revised
camshaft for proper valve timing. Both
camshaft
351M and
and400
400CID
CIDV-8
V-8engines
engines are
are
the 351M
equipped with a thermactor air injection
system for reduced engine emissions
(Fig. 1).

SYSTEM
and
the exhaust
on these
emission control devices used on
are covered in Group 29
29 and
engines are
Groupp 50 of this Manual.
Grou
SYSTEM
The engine is equipped with a positive
the crankcase vapors to
to the
re-cycling the
intake manifold.
ADJUSTMENTS
VALVE CLEARANCE-HYDRAULIC
CLEARANCEHYDRAULIC
VALVE LIFTERS
on the
the left
The valve arrangement on
bank is
is E-I-E-I-E-I-E-I and
and on
on the
the right
bank is
is I-E-I-E-I-E-I-E.
The 0.060 inch shorter push rod
rod or aa
rod are
are available
0.060 inch longer push rod
for service to provide a means of
of
in
compensating for dimensional changes in
the valve mechanism.
mechanism. Refer to
to the Master
the specification
specification for the
Parts List or the
pertinent color code.
Valve stem to valve rocker arm
be within specification
specification
clearance should be
the hydraulic lifter
lifter completely
with the
collapsed. Repeated valve reconditioning
and/or valve seat
operations (valve and/or
the clearance to
refacing) will decrease the
for, the
the
the point that if not compensated for,
lifter will cease to
and the
the valve will be
function and
be held open.
To determine whether a shorter or a
longer push rod
rod is
is necessary, make the
following check:
BACK TO GROUP INDEX
A4071-A
1 Right Front View-351-M

View351-M and
and 400
400 Engines (Typical)
FIG. 1
1.
1. Disconnect
Disconnect the brown lead (I
terminal) and the red

red and
and blue
blue lead
lead (S
(S
the starter relay.
terminal) at the
Install an
an auxiliary starter switch
between the
the battery and
and SS terminals
of the Starter relay. Crank the
the engine
engine
with the ignition switch OFF until the
No. 11 piston is on TDC
TDC on the
compression stroke.
2. With the
the crankshaft
crankshaft in
in the
the positions
2.
designated in Steps 3,
3, 4 and 5,
position
hydraulic lifter
lifter
position the hydraulic
on the
the rocker arm.
compressor tool on
arm.
to bleed down
Slowly apply pressure to
the plunger
the hydraulic lifter until the
2). Hold
is completely bottomed (Fig. 2).
in this position and
and check
the lifter in
the available clearance between the
arm and
and the
the valve stem tip
rocker arm
with a feeler gauge.
If
If the clearance is less than
specification, install an undersize
rod. If the
the clearance is
is greater
push rod.
an oversize
than specification, install an
push rod.
rod.
3. With the
No.11 piston
the No.
pistonon
onTDC
TDCatatthe
the
end of the compression
compression stroke,
POSITION 11 in Fig.
Fig. 3,
3, check the
following valves:
T71P-6513-A
if - m
JHS:"% MHMU3235.B
FIG. 2
2 Checking Valve Clearance
21-22-3
No.1
No. 1 Intake No.1
No. 1 Exhaust
No.4
No. 4 Intake No.3
No. 3 Exhaust
No.8
No. 8 Intake No.7
No. 7 Exhaust
351M and 400 CIO

v-a Engines
CID V-8
21-22-3
2 in Fig.
Fig. 3,
3, and check the following
valves:
valves:
No.
No. 22 Exhaust
No. 33 Intake
Intake No.
Exhaust
No.7
No.66 Exhaust
Exhaust
No. 7 Intake
Intake No.
3 in Fig.
Fig. 3 and check the following
valves:
valves:
No.4
No. 2 Intake No.
4 Exhaust

4.
4. After these valves have been checked,
rotate the crankshaft to POSITION
5.
c~ecked,
5. After these valves have been checked,
rotate the crankshaft
With
With No.1
No. 1 at
at TDC
TDC at
at end
end of compression
compression stroke
make
make aa chalk mark
mark at points 22 and
and 33 approximately
90
90 degfees
degrees apart.
apart.
/
"-----.-/ /
--:=:.-----..
~ntake No. 8 Exhaust

No. 6 Intake
No.11 at TDC at end of compression stroke.

POSITION 1 - No.
crankshaft 180 degrees (one half
half
POSITION 2 - Rotate the crankshaft
revolution) clockwise from POSITION 11..
crankshaft 270 degrees (three
POSITION 3 - Rotate the crankshaft
quarter revolution) clockwise from
3 )
POSITION 2.
.
eD3
A
3234-CC
A3234-
FIG. 3 Position of Crankshaft for Checking Valve Clearance and Installing Rocker Arms

must be
be torqued (see Specifications),;
Specifications), oil
oiL
the threads with light weight engine oil.
Do not oil threads that require
oil-resistant or
ENGINE
Remof'al
Removal
Remove or disconnect Thermactor
system parts that will interfere with
1. Disconnect the battery, drain the
1.
cooling system and remove the hood.
2. Remove the air cleaner and intake
2.
assembly.
duct assembly.
3. Disconnect the radiator upperhose
upper hose at
3.
the engine and the lower hose at the
radiator. Disconnect the oil cooler
radiator.
lines at the 'radiator.
4. Remove the'
the fan shroud attaching
4.
fan. Remove the radiator and shroud.
fan.
5. Remove the fan and spacer.'
spacer.
5.
6. On vehicles equipped with air
6.
conditioning, loosen the idler pulley
and remove the drive belt.
7. Loosen the alternator and remove the
7.
belt.
drive belt.
8. Loosen and remove the power
8.
belt.
steering pump drive belt.
9. Remove the water pump pulley.
9.
10. Remove
Remove the
the power
power steering
steering pump
pump
10.
brackets and position the pump out of
upright position to
the way in an uprig~t
prevent fluid
fluid loss.
BACK TO GROUP INDEX
11.
On vehicles equipped
11.On
equipped with air
conditioning, isolate and remove the
compressor as outlined in Group 36.
12. Remove
Remove the
the alternator
alternator and
and bracket.
bracket.
12.
way.
Position the alternator out of the way.
Disconnect the alternator ground
wire from the cylinder block.
13. Disconnect
Disconnect the
the heater
heater hoses
hoses at
at the
the
13.
block and water pump.
14. Remove
Remove the'
the gro~nd
ground wires
wires from
from the
the
14.
cylinder block and right cylinder
head.
15. Disconnect
Disconnect the
the f~el
fuel line
line at
at the
the fuel
fuel
15.
pump. Plug the fuel tank line.
Disconnect the vacuum lines at the
rear of
of the intake
manifold.
rear
intake manifolq.
Disconnect vacuum control valve
hoses and wires on engines so
equipped.
16. Disconnect
Disconnect the
the accelerator
accelerator cable
cable or
or
16.
linkage at the carburetor and intake
manifold. Disconnect transmission
downshift linkage, if so equipped.
17. Disconnect
Disconnect the
the engine
engine wire
wire harness
harness at
at
17.
the ignition coil, water temperature
sending unit and oil pressure sending
unit. Remove the wire harness from
the hold down clips.
18. Raise
Raise the
the vehicle
vehicle and
and secure
secure with
witji
18.
safety stands.
19. Disconnect
Disconnect the
the exhaust
exhaust system
system at
at the
the
19.
exhaust manifolds and remove the
control valve (if
exhaust heat contrpl
(if so
equipped) or the exhaust manifold-topipe spacer.
starter cable and

20. Disconnect the starter
remove the starter.
front support
through bolts and the starter cable
clamp at the engine right front
suppqrt.
support.
22. Remove the converter
converter inspection
cover and disconnect the flexplate
from the converter. Remove the
downshift
downshift rod.
Remove the four converter lower
housing-to-engine block bolts and the
adapter plate-to-converter
plate-to-converter housing
bolt.
24. Remove the two converter housing
upper bolts.
25. Attach engine lifting sling (Tool No.
T53L-3OO-A),
T53L-300-A), and hoist, to lifting
brackets at exhaust manifolds.
26. P o0 ssit
i t iion
o n a j aacckk u n dd eerr the
the
transmission.
27. Raise
Raise the
the engine slightly and carefully
carefully
pull it from
Carefully
engine compartment so that the rear
cover plate
pl~te is not bent or components
damaged. Install the engine on a work
stand.
Installation
Installation
\.
t. Attach
Attac~ engine lifting sling, Tool No.
T53L-3OO-A,
T53L-300-A, and hoist to lifting
brackets at exhaust
exhaust manifolds.
Remove engine from work stand.
v-a
21-22-4
351M and 400 (10

CID V-8 Engines
2.
2. Lower the engine carefully
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.
5. Position the downshift
downshift rod on the
transplission
transmission and engine.
safety stands.
7. Position the transmission linkage
bracket and install the remaining
converter housing bolts.
bolts. Install the
adapter plate-to-converter housing
bolts. Install the converter-toflywheel nuts and install the inspection cover. Connect the downshift rod to the transmission.
8.
cable.
cable.
9. Install the exhaust heat control valve
9.
(if so equipped) or manifold-to-pipe
manifold-to-pipe
spacer and connect the exhaust
system to the exhaust manifolds.
10.
10. Install
Install the
the engine
engine front
front support
support
through bolts and install the starter
cable clamp at the engine right front
support.
12.
12. Connect
Connect the
the ground
ground wire
wire at
at the
the right
right
cylinder head. Install the engine wire
harness and connect it to the ignition
n s t a l l the water
water
coil, then iinstall
temperature sending unit and oil
pressure sending unit.
Install the
the accelerator
accelerator linkage
linkage and
and
13. Install
connect the downshift rod.
14.
14. Connect
Connect the
the vacuum
vacuum lines
lines at
at the
the rear
rear
of the intake manifold. Connect the
fuel tank line at the fuel pump.
15. Connect
Connect the
the ground
ground wire
wire to
to the
the right
right
front of cylinder block. Connect the
heater hoses to the water pump and
cylinder block.
16. Install
Install the
the alternator
alternator and
and bracket.
bracket.
16.
to
Connect the alternator ground wire to
the cylinder block.
17. On
On aa vehicle
vehicle with
with air
air conditioning,
conditioning,
17.
install
install the air
air conditioning
conditioning
compressor and brackets as outlined
in Group 36.
21. Fill and bleed the cooling system. Fill

Adjust the
and quantity of oil. Adjust
downshift linkage.
transmission downshift
Connect the battery.
22.
22. Operate
Operate the
the engine
engine at
at fast
fast idle
idle until
until itit
reaches
operating
temperature and check all gaskets and
hose connections for leaks.
leaks. Adjust
ignition timing and idle speed.
23. Install the air cleaner and intake duct.
Install and adjust the hood.
18. Install
Install the
the power
power steering
steering pump
pump and
and
18.
brackets. Install all parts of the
Thermactor System that were
Thermactor
disconnected and/or removed.
19.
19. InstaH
InstaH the
the water
water pump
pump pulley,
pulley, fan
fan and
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.

fan.
20.
Install the radiator and connect the
radiator upper and lower hoses.
Install the fan shroud attaching bolts.
BACK TO GROUP INDEX
21-22-4
385759-S2"
383232-52'
35-60 FT-LB
INSULATOR ASSY. (6B032 L.H.)

L.H.)
(6038 R.H.J
R.H.)
378489-S2'
378489-S2*
20-35 FT-LB
Whenever self-locking mounting

be
bolts and
new self-locking bolts and
replaced with new
Figs. 4 and 5.)
nuts. (Marked * in Figs.
The front supports are located on
(Figs. 4
each side of the cylinder block (Figs.
5). The procedures given apply to
and 5).
either a right or left installation.
INSULATOR
iN
SU LA TOR ASSEMBLY
ASS EM Bl_ Y
6C060 L.H. /
6(060
6C010 RR.H~_4.---=::-~~~"RT
6(010
\.
383232-52*
35-60FT-~
567~~
DIREC~NJ
OPTIONAL
'\
I ""-\I' \
'-t), e;5Q...
.
\
2'
A3701-D
FIG. 4 Engine Front

SupportsTorino, Elite
Supports-Torino,
Montego and Cougar
Removal
Removal
1.
bolts. On Ford, Meteor and Mercury
400 CID, remove the transmission oil
cooler inlet
inlet and
and outlet
outlet lines
lines from
from the
cooler
the
retaining bracket
bracket on
on the
the block.
retaining
block.
2.
2. Remove the through bolt and lock nut
insulator to the
insulator support bracket (No. 2
crossmember on Torino, Elite,
crossmember
(Fig. 4).
4). On
Montego and Cougar) (Fig.
Ford, Meteor and Mercury 400 CID,
(Fig. 5) remove the nut and through
bolt on the opposite mount to prevent
distortion of the insulator.
385637-S2
DIRECTION OF BOLT OPTIONAL
A 3700-8
3700-B
A
SupportFord,
FIG. 5 Engine Front Support-Ford,
Mercury and Meteor
3. Raise the engine slightly with a jack
and a wood block placed under the oil
pan.
4.
4. Remove the engine insulator
insulator
bolts. Remove the engine insulator
assembly and heat shield, if so
equipped.
Installation
Instal/ation
1. Position
Position the engine insulator
insulator
1.
assembly
assem
bly and heat shield, if so
equipped, to the cylinder block and
install the attaching bolts. Tighten the
specification.
bolts to specification.
2. Lower the engine into position, install
2.
the engine insulator assembly to the
support bracket (No.2
(No. 2 crossmember
on Torino, Elite, Montego and
Cougar).
Cougar). Install the through bolt and
remove the jack and wood block.
3. Install the engine insulator assembly.
Tighten the nut to specification. On
Ford, Meteor and Mercury 400 CID,
install the transmission oil cooler
lines in the retaining bracket on the
cylinder block.
4.
4. Install the fan shroud attaching bolts.
ENGINE REAR SUPPORT
The rear support is located at the

transmission extension housing (Figs.
(Figs. 6
and 7). Whenever self-locking mounting
bolts and nuts are removed, they must be
Figs. 6 and 7.)
nuts. (Marked * in Figs.
Removal
Removal
1. Support the transmission with a floor
1.
jack to remove weight from the
supporting crossmember.
2.
2. Remove the nuts attaching the
i n s u l a t o r assembly
a s s e m b l y to the
the
insulator
crossmember.
3. Remove or loosen the bolts attaching
the supporting crossmember for
repositioning or removal as necessary
to remove the insulator assembly.
351
M and 400
D V-8
351M
400 CI
CID
V-8 Engines
21-22-5
WASHER-
~6068
6068
34794-S2
34794-S2
I~
~
I::J?
ASSEMBLY
~
~\.~~~~~
~~
~~\
ID\ti
"
!",I
CRANKCASE VENT
TUBE EXTENSION HOSE
..
BOLT-304726-S2
BOLT-304726-S;~~
r-
40-60
40-60 FT-LB
FT-LB
NUT-382400-S2
NUT
-382400-S2
30-50
30-50 FT-LB
FT-LB
~
.
21-22-5
CRANKCASE VENT
TUBE HOSE 6A664
CRANKCASE VENT
HOSE
HOSE
PCV VALVE 6A666
#33 CROSSMEMBE
CROSSMEMBER
#
R
2
REO'O
2REQ'D
_ _ .71 1.0.
~,...
A3283-E
FIG. 66 Engine Rear Support-Torino,

SupportTorino,
E|ite, Montego and Cougar
Elite,
INSULATOR
ASSEMBLY 6068
GROMMET
GROMMET.58 I.D
OIL FILLEF
CAP - 6766
..;
~6l'S2"
RETAINER 6054
CRANKCASE
VENT T U B E - 6 7 5 9
A4070B
A4070-B
386454-S2
25-40
~~::;~;:~:r:~~y;.;.;,;~".
25^40 FT-LB
FT-LB
(DIRECTION
(DIRECTION OF
OF
BOLT
BOLT OPTIONAL)
OPTIONAL)
.,.,.v"""
34794-S2
(2 REO'O.)
FIG. 88 Typical Crankcase Ventilation System Components

.. ..
; ;
A3138-C
FIG. 77 Engine Rear SupportFord,

Support-Ford,
Meteor and Mercury
the bolts and

and washers that
4. Remove the
attach the engine rear insulator to the
transmission.
5.
5. Remove the insulator assembly.
Installation
Installation
1.
1. Position
Position the
the engine
engine rear
rear insulator
insulator
assembly
the
assembly in
in place
place beneath
beneath the
transmission.
transmission. Install
Install the
the attaching
attaching
bolts and
and washers and
and torque to
to
specification.
2.
2. Position the supporting crossmember.
Install/tighten the
the bolts to
to proper
torque specification.
specification.
3. Install the
the
the nuts attaching
attaching the
iinsulator
n s u l a t o r assembly
a s s e m b l y to
to tthe
he
crossmember.
4.
floor jack.
4. Remove the floor
SYSTEM
The crankcase ventilation system
Fig. 8.
components are shown in
in Fig.
8.
Removal
Removal
1. Remove the
1.
the ventilation system air
air
intake hose from the air
air cleaner.
2. Remove the crankcase vent hose from
the regulator valve located in
oil fill
in oil
cap.
BACK TO GROUP INDEX
----
the air
3. Remove the
air cleaner and
and intake
duct assembly.
4. Disconnect the
the crankcase vent hose
from the carburetor.
5. Pull the regulator valve out of the oil
fill cap.
6. Remove the
the crankcase ventilation
filter
air cleaner
body.
filter from
from the
the air
cleaner body.
Installation
Installation
1.
1. Install the crankcase ventilation filter
in the air
air cleaner
cleaner body.
body.
2. Insert the PCV valve into the oil fill
cap mounting grommet.
3. Connect
the
Connect the
the vent hose to
to the
carburetor.
4. Install the air cleaner and intake duct
assembly.
5.
air
5. Install the
the ventilation system air
intake hose to the air cleaner and the
regulator valve.
for leaks.
6. Start the engine and check for
leaks.
ARM
AND ROCKER A
RM
The valve rocker arm is shown in Fig.
9.
9.
Removal
Removal
1.
1. Remove the
the air
air cleaner and
and intake
duct assembly. Remove appropriate
crankcase ventilation hose(s) at
the
at the
valve rocker arm cover(s).
2.
the spark plugs by grasping, twisting
and pulling the molded cap only with
the wires
the proper tool. Remove the
from the bracket on the valve rocker
arm cover(s) and
and position the
the wires
out of the way.
arm
3. Remove the
the valve rocker arm
cover(s).
cover(s).
4.
4. Remove the valve rocker arm bolt, oil
deflector, fulcrum seat and
and rocker
arm.
Installation
Installation
All rocker arms and fulcrum seats are
to be lubricated with heavy engine oil SE
1.
1. Apply Lubriplate or equivalent to the
of the valve stem. Lubricate the
top of
the
arm and
and fulcrum seat with
rocker arm
heavy engine oil SE.
2. Position the No.
at
No. 1 piston on TDC at
end of the
the compression stroke,
the end
POSITION 1 ininFig.
Fig.3,3,and
andinstall
installthe
the
rocker arm,
arm, fulcrum
fulcrum seat, oil
oil
and fulcrum bolts on
on the
the
deflector, and
following valves:
No.11 Intake No.
No.11 Exhaust
No.
No.
No.44 Intake No.
No.33 Exhaust
No. 77 Exhaust
No. 88 Intake No.
Position the
the crankshaft
crankshaft in
Position
in
POSITION 2 in Fig. 3 and install the
rocker arm, fulcrum seat, oil deflector
on the
the following
and fulcrum bolts on
valves:
valves:
No. 33 Intake No.
No.22 Exhaust
No.
No.77 Intake No.
No.66 Exhaust
Position the
crankshaft in
Position
the crankshaft
in
in Fig.
Fig. 33and
and install
install the
the
POSITION 3 in
--'---'" .----
21-22-6
21-22-6
rockerarm,
arm,fulcrum
fulcrumseat,
seat,oil
oildeflector
deflector
rocker
and fulcrum
fulcrum bolts
bolts on
on the
the following
following
and
valves:
valves:
No.2
Intake No.
No.4
Exhaust
No.
2 Intake
4 Exhaust
No. 55kitake
Iiltake No.
No. 55Exhaust
Exhaust
No.
No. 66 Ritake
Intake No.
No. 88 Exhaust
Exhaust
No.
Besure
surethat
thatthe
the fulcrum
fulcrum seat
seatbase
base
Be
seated in
in its
its slot
slot on
on the
the cylinder
cylinder
isis seated
head before
before tightening
tightening the
the fulcrum
fulcrum
head
Tighten the
the fulcrum
fulcrum bolt
bolt to
to
bolts. Tighten
bolts.
specification. Check
Check the
the valve
valve
specification.
clearance following
following the
the procedures
procedures
clearance
under Valve
Valve Clearance
Clearance Adjustment.
Adjustment.
under
Clean the
the valve
valve rocker
rocker arm
arm cover(s)
cover(s)
3.3. Clean
and the
the ccylinder
head gasket
gasket
and
y l i n d e r head
surface(s). Apply
Apply oil-resistant
sealer
surface(s).
to one
one side
side of
of new
new cover
cover gasket(s).
gasket(s).
to
ofthe
the gasket(s)
gasket(s)
Lay the
the cemented
cemented side
side of
Lay
in place
place in
in the
the cover(s).
cover(s).
in
4. Position
Position the
the cover(s)
cover(s) on
on the
the cylinder
cylinder
4.
head(s). Make
Make sure
sure the
the gasket
gasket seats
seats
head(s).
around the
the head.
head. Install
Install the
the
evenly all
all around
evenly
bolts. The
The cover
cover is
is tightened
tightened in
in two
two
bolts.
Tighten
ssteps.
teps. T
i g h t e n tthe
h e bbolts
o l t s to
specification. Two
Two minutes
minutes later,
specification.
tighten the
the bolts
bolts to
to the
the same
tighten
same
specification.
specification.
Reconnect
R
e c o n n e c t tthe
h e crankcase
crankcase
hose(s).
ventilation hose(s).
and intake
intake
Install the air cleaner and
duct assembly.
assembly.
duct
5. Install
Install the
the spark
spark plug
plug wires
wires in
in the
the
5.
bracket on
the valve
valve rocker
rocker arm
bracket
on the
arm
wires.
wires.
6.
6. Start
Start the
the engine
engine and
and check
check for
for leaks.
leaks.
VALVE
VALVE SPRING,
SPRING, RETAINER
RETAINER AND
AND
STEM
STEM SEAL
SEAL
Broken
Broken valve
valve springs
springs or
or damaged
damaged
valve
valve stem
stem seals
seals and
and retainers
retainers may
may be
be
replaced
replaced without
without removing
removing the
the cylinder
cylinder
head,
head, provided
provided damage
damage to
to the
the valve
valve or
or
valve
valve seat
seat has
has not
not occurred.
occurred.
Remoyal
Removal
1.1. Remove
Remove the
the required
required rocker
rocker arm(s)
arm(s)
following
the
instructions
following the instructions given
given in
in
Rocker
Rocker Arm
Arm Removal.
Removal.
2.2. Install
Install an
an air
air line
line with
with an
an adapter
adapter in
in
the
the spark
spark plug
plug hole
hole and
and turn
turn on
on the
the
air
air supply.
supply.
3.3. Install
Install the
the compressor
compressor tool
tool as
as shown
shown
inin Fig.
Fig. 10.
10.Compress
Compress the
the valve
valvespring
spring
and
and remove
remove the
the retainer
retainer locks,
locks,spring
spring
retainer
retainer and
and valve
valve spring.
spring.
4.4. Remove
Remove and
and discard
discard the
the valve
valve stem
stem
seal
seal (Fig.
(Fig. 11).
11).
5.5. IfIf air
air pressure
pressure has
has forced
forced the
the piston
piston
toto the
the bottom
bottom of
of the
the cylinder,
cylinder, any
any
removal
removalofofair
airpressure
pressurewill
willallow
allowthe
the
valve(s)
valve(s) toto fall
fall into
into the
the cylinder.
cylinder. AA
rubber
rubber band,
band, tape
tapeororstring
string wrapped
wrapped
around
aroundthe
theend
endofofthe
thevalve
valvestem
stemwill
will
prevent
prevent this
this condition
condition and
and will
will still
still
allow
allowenough
enoughtravel
traveltotocheck
checkthe
thevalve
valve
for
forbinds.
binds.
BACK TO GROUP INDEX
351M
351M and
and 400
400 CID
CID V-8
v-aEngines
Engines
~
or~
....
. .
FULCRUM
FULCRUM
BOLT-6A529
BOLT-6A529
OIL DEFLECTOR
OIL OEFLECTOR
FULCRUM
SEAT -6A528
ROCKER
ARM-6564
A3236-B
A3236 6
FIG. 9 Rocker Arm and Related Parts

Parts
Installation
1.
Rotate the valve and check the valve
stem tip for eccentric movement
during rotation. Move the valve up
the valve guide and
and check the stem for
binds. If the valve has been damaged,
binds.
it will be
be necessary to
to remove the
head for
for repairs
repairs as
as outlined
cylinder head
in Part
Part 21-01.
21-01.
in
2. If
If the
the condition
condition of
of the
the valve
valve proved
proved
2.
satisfactory, hold
hold the
the vaive
vaive in
in the
the
satisfactory,
closed position
position and
and apply
apply the
the air
air
closed
pressure
pressure within
within the
the cylinder.
cylinder.
3.
3. Lubricate
Lubricate the
the valve
valve stem
stem with
with heavy
heavy
engine
engine oil
oil SE.
SE.
21-22-6
21-22-6
4.4. Install
Installaanew
newvalve
valvestem
stemseal
seal(Fig.
(Fig.11).
11).
Place
Placethe
thespring
springinin position
positionover
overthe
the
valve
and install
install the
the valve
valve spring
spring
valve and
retainer.
retainer. Compress
Compress the
the valve
valve spring
spring
and
and install
install the
the valve
valve spring
spring retainer
retainer
locks.
locks. Remove
Remove the
the compressor
compressor tool
tool
and
and stud
stud nut.
nut. Turn
Turn off
off the
the air
air and
and
remove
remove the
the air
air line
line adapter.
adapter.
5.5. Lubricate
Lubricate and
and install
install the
the push
push rod.
rod.
Apply
Apply Lubriplate
Lubriplateor
orequivalent
equivalentto
to the
the
tip
of the
the valve
valve stem.
stem.
tip of
6.6. Install
Install the
the required
required rocker
rocker arm(s)
arm(s)
following
following the
the instructions
instructions given
given inin
Rocker
Arm Installation.
Installation.
Rocker Arm
7.7. Check
Check the
the rocker
rocker arm
arm to
to valve
valve stem
stem
clearance
clearance and
and install
install the
the related
related parts
parts
as
outlined in
in Valve
Valve Rocker
Rocker Arm
Arm
as outlined
Cover
Cover and
and Rocker
Rocker Arm
Arm Installation.
Installation.
INTAKE
INTAKE MANIFOLD
MANIFOLD
A
typical
A typical intake
intake manifold
manifold assembly
assembly isis
shown
shown in
in Fig.
Fig. 12.
12.
Removal
Remoyal
1.
1. Remove
Remove the
the air
air cleaner
cleaner and
and intake
intake
duct.
On Ford,
Ford, Meteor
Meteor and
and Mercury
Mercury
duct. On
vehicles,
with Frigidaire
Frigidaire A/C
Ale comvehicles, with
pressor,
pressor, isolate
isolate and
and remove
remove the
compressor,
compressor, following
following procedure
procedure in
in
Group
Group 36.
2. Disconnect the high tension lead and
wires from the coil. Disconnect
Disconnect the
engine wire harness and position it
out of the way.
the spark plugs by grasping, twisting
and pulling
pulling the
the molded
molded cap
cap only
only
and
(use Tool T75P-6666-A).
Remove the wires from the harness
brackets on the valve rocker arm
covers. Remove
Remove the
the distributor
distributor cap
cap
covers.
and spark
spark plug
plug wire
wire assembly.
assembly.
and
Remove the
the Thermactor
Thermactor by-pass
by-pass
Remove
valve and
and hose
hose from
from the
the check
check valve.
valve.
valve
4. Remove
Remove the
the carburetor
carburetor fuel
fuel inlet
inlet line.
line.
4.
5. Remove
Remove the
the heater
heater hoses
hoses from
from the
the
5.
retainers and
and position
position the
the hoses
hoses out
out of
of
retainers
the way.
way.
the
Remove the
the ignition
ignition coil,
coil, vacuum
vacuum
6.6. Remove
solenoid valve,
valve, and
and bracket.
bracket.
solenoid
Disconnect the
the crankcase
crankcase emission
emission
7.7. Disconnect
hose at
at the
the left
left rocker
rocker arm
arm cover.
cover.
hose
Disconnect the
thevacuum
vacuum lines
linesfrom
from the
the
8.8. Disconnect
intake manifold.
manifold.
intake
A3245-A
FIG. 10
10Compressing
CompressingValve
ValveSpring
Springinin
FIG.
Chassis
Chassis
FIG. 1111Removing
RemovingororInstalling
InstallingValve
Valve
FIG.
StemSeal
Seal
Stem
21-22-7
21-22-7
351M
and 400
400 (10
CID V-8
V-8 Engines
Engines
351
M and
Disconnect the
the distributor
distributor vacuum
vacuum
9.9. Disconnect
hoses from
from the
the distributor.
distributor. Remove
Remove
hoses
the distributor
distributor hold
hold down
down bolt
bolt and
and
the
clamp and
and remove
remove the
the distributor.
distributor.
clamp
Block the
the distributor
distributor hole
hole with
with aa rag
rag
Block
to prevent
prevent entry
entry of
of foreign
foreign material
material
to
into the
the crankcase.
crankcase.
into
10.Disconnect
Disconnect the
the accelerator
accelerator linkage
linkage
10.
and transmission
downshift linkage,
linkage,
and
soequipped,
equipped, and
and position
position out
out of
of the
the
ifif so
way.
way.
11.Remove
Remove the
the carburetor.
carburetor.
11.
12.Remove
Remove the
the manifold
manifold attaching
attaching bolts.
bolts.
12.
Remove the
the manifold.
manifold. Remove
Remove and
and
Remove
discard the
the intake
intake manifold
manifold gasket
gasket
discard
and seals.
seals.
and
13. If
If the
the manifold
manifold assembly
assembly isis to
to be
be
13.
disassembled, disconnect
disconnect vacuum
vacuum
disassembled,
hoses.
hoses.
Installation
Installation
Clean the
the mating
mating surfaces
surfaces of
of the
the
1.1. Clean
intake manifold,
manifold, cylinder
cylinder heads
heads and
and
intake
cylinder block.
block. Use
Use aa solvent
solvent such
such as
as
cylinder
lacquer thinner,
thinner, chlorothane
chlorothane or
or
lacquer
tri-chlor-ethylene. Apply
Apply aa 1/8
1/8 inch
inch
tri-chlor-ethylene.
bead of
of silicone
silicone rubber
rubber sealer
sealer at
at the
the
bead
points shown
shown in
in Fig.
Fig. 13.
13. Caution:
Caution: Do
Do
points
not apply
apply sealer
sealer to
to waffle
waffle section
section of
of
not
end seals
seals as
as the
the sealer
sealer will
will rupture
rupture the
the
end
seal material.
material.
seal
2. Position new seals on the cylinder
2.
block and press the seal locating
locating
extensions into
into the
the holes
holes in
in the
the mating
mating
extensions
surface.
surface.
21-22-7
21-22-7
TYPICAL
TYPICALSEALER
SEALERAPPLICATION
APPLICATIONAREAS
AREASFOR
FORINTAKE
INTAKEMANIFOLD
MANIFOLDINSTALLATION
INSTALLATION
SEAL MOUNTING SURFACE

OF CYLINDER BLOCK
, CYLINDER HEAD
INTAKE MANIFOLD SEAL
1/8" DIA. BEAD C3AZ-19526-A(OR-B)

SEALER (4-JOINTS)
1/16"
1/16" DIA.
DIA.BEAD
BEAD C3AZ-19526-A(OR-B)
C3AZ-19526-A(OR-B)
SEALER
ENDS)
SEALER (4-SEAL
(4-SEALENDS)
A3716-B
A3716-B
FIG.
FIG. 13
13 Typical
Typical RTV
RTV Sealer
Sealer Installation-Intake
Installation-Intake Manifold-351-M
Manifold351-M and
and 400
400
Engines
Engines
CD CD 0<D CD
~
.:;:-.,
..
FRONT
FRONT
OF
ENGINE
Q)@0
A3237.A
A3237-A
FIG. 14 Intake Manifold Torque Sequence

CHOKE
CHOKE HEATER
HEATER
ASSEMBLY
ASSEMBLY
INTAKE
INTAKE MANIFOLD
MANIFOLD
GASKET-9441
GASKET-9441
SEAL 9A425
_ _. ~ ; ~ ~
~ -
~~
SEAL-9A424
~
-..,r
A3238-C
A3238-e
FIG.
FIG. 12
12 Intake
Intake Manifold
Manifold Assembly
Assembly
BACK TO GROUP INDEX
1/16 inch bead of

of the above
3. Apply a 1/16
sealer to the outer end of
of each intake
manifold
manifold seal for the full width of
of the
seal (4 places). See Fig. 13. Caution:
Do not apply sealer to waffle
waffle section
of
of end seals as the sealer will rupture
rupture
the seal material. NOTE: This sealer
sealer
sets
sets up
up in
in 15 minutes,
minutes, so
so it
it is
iimportant
m p o r t a n t tthat
h a t aassembly
s s e m b l y be
completed
completed promptly.
promptly. Do
Do not
not drip
drip any
any
sealer
sealer into
into the
the engine
engine valley.
valley. Position
Position
the
the intake
intake manifold
manifold gasket
gasket onto
onto the
the
block
block and
and cylinder
cylinder heads
heads with
with the
the
alignment
alignment notches
notches under
under the
the dowels
dowels
on
on the
the cylinder
cylinder heads.
heads. Be
Be sure
sure the
the
holes
holes in
in the
the gasket
gasket are
are aligned
aligned with
with
the
the holes
holes in
in the
the cylinder
cylinder head.
head.
4. Carefully
Carefully lower
lower the
the intake
intake manifold
manifold
4.
into
into position
position on
on the
the cylinder
cylinder block
block
and
and cylinder
cylinder heads.
heads.
5. Be
Be sure
sure the
the holes
holes in
in the
the manifold
manifold
ggaskets
a s k e t s and
a n i f o l d are
and m
manifold
are in
in
alignment.
alignment. Install
Install the
the intake
intake manifold
manifold
attaching
attaching bolts.
bolts. Tighten
Tighten the
the intake
intake
manifold
14).
manifold bolts
bolts in
in three
threesteps
steps(Fig.
(Fig. 14).
Tighten all
all bolts
bolts in
in sequence
sequence to
to
Tighten
specification.
specification.
After completing
completing the
the remaining
remaining
After
assembly steps,
steps, operate
operate the
the engine
engine
assembly
until
until itit reaches
reaches normal
normal operating
operating
temperature then re-tighten the

temperature
manifold bolts
bolts in sequence
sequence to
manifold
specification.
specification.
carburetor and gasket.
7. Rotate
crankshaft damper
damper until
the No. 1 piston
piston isison
on TDC
TDC atat the
the end
end
of the
the compression
compression stroke. Position
Position
of
the distributor
distributor in
in the
the block
block with
with the
the
No.11 firing
firing position
position and
and
rotor at
at the
the No.
rotor
the points
points just
just open.
open. Install
Install the
the hold
hold
the
down clamp.
clamp.
down
8. Install
Install the
the accelerator
accelerator linkage
linkage and
and
8.
downshift rod,
rod, ifif so
so
transmission
equipped.
equipped.
9. Install
Install the
the vacuum
vacuum solenoid
solenoid valve
valve and
and
9.
the ignition
ignition coil.
coil.
the
10. Connect
Connect the
the vacuum
vacuum lines
lines at
at the
the
10.
manifold. Install
Install the
the Thermactor
Thermactor bybymanifold.
pass air
air supply
supply hose.
hose.
pass
11. Position
Position the
the engine
engine wire
wire harness
harness
11.
under the
the hold
hold down
down clips
c1 ips on
on the
the left
left
under
rocker arm
arm cover
cover and
and connect
connect the
the
rocker
wires at
at the
the ignition
ignition coil,
coil, water
water
wires
temperature sending
sending unit
unit and
and throttle
throttle
temperature
solenoid.
solenoid.
12.Connect
Connect the
the crankcase
crankcase emission
emission line
line
12.
the left
left hand
hand rocker
rocker arm
arm cover.
cover.
atat the
13. Install
Install the
the heater
heater hoses
hoses in
in the
the
13.
retainers.
retainers.
21-22-8
21-22-8
351 M and
and 400
400 CID
(ID V-8
v-a Engines
Engines
351M
21-22-8
21-22-8
14. Connect the fuel pump to carburetor

14.
fuel line
line at
at the
the carburetor.
fuel
15. Install
Install the
the distributor
distributor cap.
cap. Position
Position
15.
the spark
spark plug
plug wires
wires in
in the
the harness
harness
the
the valve
valve rocker
rocker arm
arm
brackets on
on the
brackets
covers and
and connect
connect the
the wires
wires to
to the
the
covers
spark plugs.
plugs. On
On Ford,
Ford, Meteor
Meteor and
and
spark
Mercury vehicles
vehicles equipped
equipped with
Mercury
Frigidaire A/C
AIC compressor,
compressor, install
Frigidaire
compressor following
following procedure
procedure in
in
compressor
36.
Group 36.
leaks.
Adjust the
the ignition
ignition timing
timing and
Adjust
distributor vacuum lines.
lines.
connect the distributor
17. When engine temperature has
has
adjust idle mixture and
stabilized, adjust
speed. Retorque the intake manifold
to specification.
18. Install the air cleaner and re-check
idle speed.
lifter through
through adjacent
adjacent lifter
lifter hole,
hole, use
use
lifter
light to aid in transferring
aa small light
lifter into
into position
position for
for lifting
lifting out
out
lifter
with T70P-14151 Tool.
withT70P-14151Tool.
4. Instructions
Instructions for
for disassembling
disassembling and
and
4.
assembling the
the lifters
lifters are
are given
given in
in
assembling
Valve LifterDisassembly
Lifter-Disassembly and
Valve
Assembly.
Instlll/stion
Installation
lifters and bores
bores are to be
be
Tappets or lifters
lubricated with heavy engine oil SE
SE
lubricated
before
surfaces of
of the
1. Clean the external surfaces
valve lifters
lifters and install in the bores
from which they were removed. If
If aa
new lifter(s)
lifter(s) is being installed, check
the new lifter(s)
lifter(s) for a free fit in the
bore in which it is to be installed.
Lubricate the lifter(s)
lifter(s) and bore(s)
with heavy engine oil SE before
inserting it in the bore.
2. Install the push rods in their original
position. Apply
Apply Lubriplate
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
(collapsed tappet
clearance), and install the related
parts as outlined in Valve Rocker
Arm Cover
Cover and Rocker
Rocker Arm
Installation.
catalytic
catalytic converter
converter at
at the
the exhaust
exhaust
manifold.
manifold. Tighten
Tighten the
the attaching
attaching nuts
nuts
to
to specification.
6.
6. If
If aa left
left exhaust
exhaust manifold
manifold is
is being
being
installed,
installed, install
install the
the oil
oil filter.
On
On aa vehicle
vehicle with
with an
an automatic
transmission
column selector,
transmission and column
connect
connect the selector
selector cross shaft
shaft at the
the
chassis and cylinder
cylinder block.
block.
7.
7. If
If a right exhaust manifold
manifold is being
being
replaced, install the air cleaner heat
stove. Install
Install the air cleaner
cleaner and
intake duct.
8. Start the engine and check for exhaust
leaks.
VALVE LIFTER
Before replacing a hydraulic valve
lifter
caused by improperly
noise is not caused
adjusted valve clearance (collapsed
adjusted
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
NOTE:
large enough to permit the removal of the
associated lifter, it may be necessary to
remove the adjacent rocker arm
arm and
pushrod and
and use that pushrod hole for
access.
access.
./1
i A3456-B
A3456-B
FIG.
FIG. 15
15 Removing
Removing Hydraulic
Hydraulic Valve
Valve
Lifter
Lifter
Removsl
Removal
1.
1. Remove
Remove the
the valve
valve rocker
rocker arm
arm
covers.
covers.
2.
2. Remove
Remove the
the valve
valve necessary
necessary rocker
rocker
arm(s)
arm(s) push
push rod(s)
rod(s) and
and identify
identify them
them
so
so that
that they
they can
can be
be installed
installed in
in their
their
original positions.
positions.
original
3.3. Using
Using tool
tool T70P-14151,
T70P-14151, remove
remove the
the
valve
valvelifter(s)
lifter(s) and
and place
placethem
themin
inaarack
rack
so
so that
that they
they can
can be
be installed
installed in
in their
their
original
original bores
bores (Fig.
(Fig. 15).
15). If
If removing
removing
BACK TO GROUP INDEX
EXHAUST MANIFOLD
MANIFOLD
Removs/
Removal
1.
1. If a right exhaust manifold is
is being
removed, remove the air cleaner,
intake duct and heat stove.
stove. If a lefthand exhaust manifold is being
filter.
removed, first remove the oil filter.
2. On vehicles equipped with a column
2.
selector and automatic transmission,
disconnect the selector lever cross
clearance.
shaft for clearance.
3.
3. Disconnect the mumer
muffler inlet pipe or
exhaust
catalytic converter at the exhaust
Remove the spark plug heat
manifold. Remove
shields.
shields.
4.
4. Remove the exhaust manifold
manifold
the
manifold.
Instsl/stion
Installation
1.
the
exhaust
exhaust manifold
manifold and
and cylinder
cylinder head.
head.
Clean
Clean the
the mounting
mounting flange
flange of
of the
the
exhaust
exhaust manifold
manifold and
and mumer
muffler inlet
pipe or
or catalytic
catalytic converter.
converter.
pipe
2.
2. Apply
Apply graphite
graphite grease
grease to
to the
the mating
mating
surface
surface of
of the
the exhaust
exhaust manifold.
manifold.
3.
3. Position
Position the
the exhaust
exhaust manifold on
on the
the
head and
and install
install the
the attaching
attaching bolts.
bolts.
head
Working
Working from
from the
the center
center to
to the
the ends,
ends,
tighten
tighten the
the bolts
bolts to
to specification.
specification.
Install
Install the
the spark
spark plug
plug heat
heat shields.
shields.
4.
4. Install
Install the
the spacer
spacer between
between the
the inlet
inlet
pipe and
and the
the exhaust
exhaust manifold.
manifold.
pipe
5.
5. Connect
Connect the
the muffler
muffler inlet
inlet pipe
pipe or
or
CYLINDER
CYLINDER HEADS
If
If a cylinder head is to be replaced,
follow the procedures under Cylinder
Head Disassembly and Assembly, and
transfer
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
Removs/
1.
1. Remove the intake manifold
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.
is to be
If the left cylinder head is
removed, disconnect the power
steering pump bracket from the left
cylinder head and remove the drive
pulley. Position
belt from the pump pulley.
the power steering pump out of the
will prevent
prevent
way and in a position that will
the oil from draining out.
out.
3. If the right cylinder head isis to be
3.
alternator
removed, remove the alternator
mounting bracket through bolt and
the right
air cleaner inlet duct from the
assembly. Remove
Remove the
cylinder head assembly.
wire at the rear of the
the cylinder
ground wire
head.
head.
4. Disconnect the
the exhaust manifold(s)
manifold(s)
4.
from the muffler inlet pipe(s) or
converter(s).
catalytic converter(s).
5. Remove
Remove the
the rocker
rocker arm bolts,
bolts, oil
oil
5.
deflectors, rocker arms,
arms, and
and push
deflectors,
rods in
in sequence
sequence (Fig.
(Fig. 16)
16) so
sothat
that they
they
rods
may be
be installed in
in their original
original
may
positions.
positions.
6. Remove
Remove the
the cylinder
cylinder head
head attaching
attaching
6.
bolts and
and lift the
the cylinder head
head ofT
off the
the
bolts
block. Remove
Remove and
and discard
discard the
the
block.
cylinder head
head gasket.
gasket.
cylinder
Installation
Instllllstion
Clean the
the cylinder
cylinder head,
head, intake
intake
1.1. Clean
manifold, valve
valve rocker
rocker arm
arm cover
cover and
and
manifold,
cylinder head
head gasket
gasket surfaces.
surfaces. If
If the
the
cylinder
cylinder head
head was
was removed
removed for
for aa
cylinder
21-22-9
FIG. 16 Removing Valve Push

Push Rod
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.
in three progressive steps.
steps. Tighten all
the bolts in sequence (Fig. 17) to 50
ft-Ibs,
ft-lbs, then to 60 ft-Ibs
ft-lbs and finally to
specification. When cylinder head
retorque the bolts after
after extended
operation. However, the bolts may be
checked and retorqued if desired.
A3241-A
FIG. 17 Cylinder Head Bolt Torque

Sequence
4. Clean the push rods in a suitable

solvent. Blowout
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
If runout
with a dial indicator. If
exceeds the maximum limit at any
point, discard
discard the
the rod.
rod. Do
Do not
not attempt
attempt
to straighten push rods.
5.
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.
7. Connect the exhaust manifold(s) at
muffler inlet pipe(s) or catalytic
the mumer
converter(s). Tighten the nuts to
specification.
BACK TO GROUP INDEX
351
M and
351M
and 400 CIO
CID v-a
V-8 Engines
21-22-9
8.
8. If
If the right cylinder
cylinder head was
alternator
removed, install the alternator
mounting bracket through bolt and
air cleaner inlet duct on the right
cylinder head assembly. Connect the
ground wire at
at the rear of the
the cylinder
head. Adjust the drive belt tension to
specification.
specification.
9.
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
If the left cylinder head
head was
removed, install the drive belt and
power steering pump bracket. Install
bolts. Adjust
the bracket attaching bolts.
specification.
the drive belt to specification.
10.
manifold and
related parts following the procedure
compressor);
compressor); then install the pump.
Coat the threads of the attaching
screws with oil-resistant sealer and
install the screws. Tighten the
attaching screws to specification.
specification.
3. Install the air conditioner compressor
to water pump bracket and lower
idler pulley, if so equipped.
4.
4. Position the alternator bracket and
power steering pump bracket on the
water pump and install the bracket
bolts.
5.
5. Position the water pump pulley on the
water pump shaft and install the drive
belts.
belts.
6.
6. Place the fan shroud over the pulley
and install the fan and spacer.
7.
8.
8. Adjust the drive belts to specification.
specification.
9.
9. Connect the radiator lower hose at
the water pump.
10.
10. Connect
Connect the
the heater
heater hose
hose atat the
the water
water
pump.
pump.
11. Connect the battery cable.
cable. Fill and
bleed the cooling system. Operate the
operating
engine until normal operating
temperature has been reached and
check for leaks.
WATER PUMP
Removal
Removal
1.
disconnect the battery.
2.
bolts and position
position the shroud
shroud
rearward.
3. Remove the fan and spacer from the
water pump shaft.
shaft.
4. Remove the air conditioner
conditioner
compressor drive belt lower idler
pulley and compressor mount to
water pump bracket, if so equipped.
5.
5. Loosen the alternator and remove the
drive belt.
6.
6. Loosen the power steering pump and
remove the drive belt.
7.
7. Remove the water pump pulley.
8.
8. Remove the alternator bracket from
water pump and position it out of the
way.
way.
9.
9. Remove the power steering pump
bracket from the water pump and
position it out of the way.
10.
10. Remove
Remove the
the heater
heater hose
hose from
from the
the
water pump.
11. Disconnect the radiator lower hose at
the water pump.
12.
12. Remove
Remove the
the water
water pump
pump attaching
attaching
bolts and remove the water pump.
Installation
Installation
1.
mounting surfaces of the cylinder
front cover and water pump. On
Ford, Meteor and Mercury vehicles
Ale compressors,
with Frigidaire A/C
remove all gasket material from the
water pump spacer.
2.
2. Position a new gasket, coated on both
on the cylinder front
sides with sealer, dn
cover (on spacer for Ford, Meteor and
Mercury vehicles
vehicles with AIC
A/C
Mercury
CYLINDER FRONT COVER PLATE

AND TIMING CHAIN
Removal
Removal
1.
1. Refer to Water Pump Removal.
Perform Steps 11 thru
thru 9,9,but
but leave
leavethe
the
water pump attached to the front
front
cover plate.
2.
2. Remove the heater hose and lower
radiator hose from the water pump.
the crankshaft
Remove the vibration
vibration damper
damper
attaching screw.
screw. Install the puller on
the crankshaft
crankshaft vibration damper (Fig.
18) and
and remove
remove the
the vibration
vibration damper.
damper.
UNIVERSAL
PULLER

Vibration Damper
4.
4. Remove the timing pointer.
351M
CID v-a
V-8 Engines
351
M and 400 CIO
21-22-10
21-22-10
TWO PIECE FUEL

PUMP ECCENTRIC
DOWEL
A3250-A
A3252-B
FIG. 19 Aligning Timing Marks
FIG. 21 Fuel pump

Pump Eccentric Installed
5.
5. Remove the bolts attaching the front
cover plate and water pump to the
front
cylinder block. Remove the front
cover plate and water pump assembly.
6.
pump. Remove the fuel
from the fuel pump.
pump attaching bolt and nut and lay
flexible
the pump to one side with the flexible
fuel line still attached.
7. Discard the cylinder front cover
plate gasket and oil pan seal.
s.eal.
8.
8. Check the timing chain deflection
deflection
(refer to Part 21-01).
9.
9. Crank the engine until the timing
marks on the sprockets are positioned
as shown in Fig.
Fig. 19.
10.
10. Remove
Remove the
the camshaft
camshaft sprocket
sprocket cap
cap
screw, washer and two piece fuel
pump eccentric. Slide both sprockets
and the timing chain forward, and
remove them as an
an assembly (Fig.
(Fig. 20).
20).
FIG. 20 Removing or Installing Timing

Chain
BACK TO GROUP INDEX
Installation
InstslJation
1. Position the sprockets and timing
1.
chain on the camshaft
crankshaft
camshaft and crankshaft
(Fig. 21). Be sure
sure the
the timing
timing marks
marks on
on
(Fig.
the sprockets are positioned as shown
Fig. 19.
in Fig.
2.
2. Install the two-piece fuel pump
eccentric, washers and camshaft
camshaft
sprocket cap screw (Fig. 21).
21). Torque
the
t h e sprocket
s p r o c k e t cap screw
screw to
specification. Be sure the outer
eccentric sleeve rotates freely.
3. Coat a new fuel pump gasket with oilresistant 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
crankshaft seal
from the cylinder front cover plate
22. Clean
with the tool shown in Fig. 22.
the cylinder front cover plate and the
engine block gasket surfaces.
5.
5. Coat the gasket surfaces of the block
and cover with sealer, and position a
new gasket on the cylinder block
alignment dowels.
A3 249-A
FIG. 22 Removing Crankshaft Front

Seal
6.
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
7.
with oil-resistant sealer and install the
timing pointer and attaching bolts.
specification.
Torque the bolts to specification.
crankshaft seal into
8. Install the front crankshaft
the cylinder front cover plate with the
tool shown in Fig. 23.
9.
oil seal rubbing surface
surface of the
vibration damper inner hub to
TlOP-6B070-A
T70P-6B070-A
FIG. 23 Installing Front Crankshaft

Seal
21-22-11
21-22-11
prevent damage
damage toto the
the seal.
seal. Apply
Apply aa
prevent
whitelead
leadand
andoil
oilmixture
mixturetotothe
thefront
front
white
of the
the crankshaft
crankshaft for
for damper
damper
of
installation.
installation.
10.Line
Line up
up the
the crankshaft
vibration
10.
damper keyway
keyway with
with the
the key
key on
on the
the
damper
crankshaft. Install
Install the
the vibration
vibration
crankshaft.
damper on
on the
the crankshaft
crankshaft using
using Tool
Tool
damper
T52L-6306-AEE (or
(or 6306-AJ)
6306-AJ) (Fig.
(Fig.
T52L-6306-AEE
24). Install
Install the
thecap
cap screw
screw and
and washer.
washer.
24).
T i g h t e n the
t h e cap
c a p screw
s c r e w to
to
Tighten
specification. Install
Install the
the crankshaft
crankshaft
specification;
pulley.
pulley.
Tool-T52L-6306-AEE or
or 6306-AJ
6306-AJ
Tool-T52L-6306-AEE
A2862-B

Vibration Damper
11. Connect the heater hose and the

the
11.
radiator
radiator lower
lower hose
hose at
at the
the water
water
pump.
pump.
12. Refer to
to Water Pump Installation and
complete Steps 3 thru
thru 11
11totoinstall
installthe
the
necessary parts, fill and bleed the
cooling
cooling system,
system, etc.
etc.
vehicle. Remove the oil pan
and install new gaskets and seals
following procedures under Oil Pan
Pan
Removal and Installation.
14. Lower
Lower the
the vehicle.
15. Fill
Fill the
the crankcase
crankcase with
with the
the proper
proper
grade
of engine
engine oil.
oil. Fill
Fill
grade and
and quantity
quantity of
and
and bleed
bleed the
the cooling
cooling system.
system.
16. Connect
Connect the
the battery. Operate
Operate the
the
engine
engine until
un til normal
normal operating
operating
temperature
temperature has
has been
been reached
reached and
and
check
check for
for leaks.
leaks.
FRONT
FRONT OIL
OIL SEAL
SEAL
Removal
RemoJ'm
1.1. Remove
Remove the
the bolts
bolts attaching
attaching the
the fan
fan
shroud
shroud to
to the
the radiator.
radiator.
2.2. Remove
Remove the
the fan
fan and
and spacer
spacerbolts
bolts from
from
the
the water
water pump
pump shaft.
shaft. Remove
Remove the
the
fan,
fan, spacer
spacer and
and shroud.
shroud.
3.3. Loosen
~oosen the
thealternator,
alternator, power
powersteering,
steering,
Thermactor
Thermactorand
and air
airconditioner
conditionerdrive
drive
belts,
so equipped.
equipped. Remove
Remove the
the
belts, ifif so
drive
drive belts.
belts.
4.4. Remove
Remove the
the crankshaft
crankshaft pulley
pulley from
from
the
the vibration
vibration damper.
damper. Remove
Remove the
the
BACK TO GROUP INDEX
351
M and
351M
and 400
400 CIO
CID v-a
V-8 Engines
Engines
21-22-11
21-22-11
damper
damper attaching
attaching screw
screw and
and washer.
washer.
Install the
the puller
puller on
on the
the crankshaft
crankshaft
Install
vibration damper
damper (Fig.
(Fig. 18)
18) and
and
vibration
remove the
the vibration
vibration damper.
damper.
remove
5.5. Place
Place the
the front
front seal
seal removing
removing tool
tool
onto the
the front
front cover
cover plate
plate over
over the
the
onto
front seal
sealas
asshown
shownininFig.
Fig.22.
22.Tighten
Tighten
front
thetwo
twothrough
through bolts
boltsto
toforce
force the
theseal
seal
the
puller under
under the
the seal
seal flange.
flange.
puller
6.6. Alternately
Alternately tighten
tighten the
the four
four puller
puller
bolts
bolts aa half
half tum
turn at
at aa time
time as
as shown
shown
in
in Fig.
Fig. 22
22 to
to pull
pull the
the oil
oil seal
seal from
from the
the
front cover.
cover.
front
Installation
Ins/mIs/ion
1.1. Coat
Coat aa new
new front
front cover
cover plate
plate oil
oil seal
seal
with
with Lubriplate
Lubriplate or
or equivalent
equivalent and
and
place
place itit onto
onto the
the front
front oil
oil seal
seal
alignment and
and installation
installation sleeve
sleeve as
as
alignment
shown in
in Fig.
Fig. 23.
23. Place
Place the
the sleeve
sleeve and
and
shown
seal onto
onto the
the end
end of
of the
the crankshaft
crankshaft
seal
and push
push itit toward
toward the
the engipe
engine until
until
and
the seal
seal starts
starts into
into the
the front
front cover.
cover.
the
2.
2. Place
Place the
the installation
installation screw,
screw, washer
onto
the
and nut on
to the end of the
the screw
screw into
into the
the
crankshaft. Thread the
crankshaft. Tighten the nut against
the washer and installation sleeve
sleeve to
the
force the seal into the front cover
plate. Remove the installation tool
plate.
crankshaft.
from the crankshaft.
oil seal rubbing surface
surface of the
vibration damper inner hub to
prevent damage to the seal.
seal. Apply a
white lead and oil mixture to the front
of the crankshaft
crankshaft for damper
of
installation.
4. Line up the crankshaft
damper keyway with the key on the
crankshaft.
crankshaft. Install the vibration
damper on the crankshaft
crankshaft (Fig. 24).
24).
Install the cap screw and washer.
Torque the screw to specification.
Install the crankshaft
crankshaft pulley.
pulley.
5. Install the alternator, power steering
Thermactor
and air
ppump,
ump, T
h e r m a c t o r and
air
conditioner
conditioner belts,
belts, ifif so equipped.
6.6. Position
Positionthe
thefan
fanshroud
shroudover
overthe
thewater
water
pump
pump pulley.
pulley. Install
Install the
the fan
fan and
and
spacer.
spacer. Install
Install the
the fan
fan shroud
shroud
attaching
attaching screws.
screws.
7.7. Adjust
Adjust the
thedrive
drivebelts
beltstotospecification.
specification.
THRUST
THRUST
PLATE
PLATE
6269
6269
TIMING CHAIN - 6268 AND
CAMSHAFT SPROCKET - 6256
CAMSHAFT
CAMSHAFT
The
The camshaft
camshaft and
and related
related parts
parts are
are
shown
shown inin Fig.
Fig. 25.
25.
RemoJ'sl
Removal
1.1. Drain
Drain the
the cooling
cooling system.
system. Disconnect
Disconnect
the
the upper
upper and
and lower
lower radiator
radiator hoses
hoses at
at
the
the radiator.
radiator. Disconnect
Disconnect the
theoil
oilcooler
cooler
lines
lines at
at the
the radiator.
radiator. If
If equipped
equipped with
with
air
air conditioning,
conditioning, remove
remove the
the
condenser.
condenser.
2.
2. Remove
Remove the
the cylinder
cylinder front
front cover
cover
plate,
plate, fuel
fuel pump
pump and
and the
the timing
timing chain
chain
following
following the
the procedure
procedure under
under the
the
Cylinder
Cylinder Front
Front Cover
Cover Plate
Plate and
and
Timing
Timing Chain
Chain Removal.
Removal.
3.
take manifold
3. Remove
Remove the in
intake
manifold
following
following the
the procedure under Intake
Intake
Manifold Removal.
Removal.
4.
4. Remove
Remove the
the valve
valve rocker arm covers.
covers.
Loosen the valve
valve rocker arm fulcrum
fulcrum
bolts and rotate the rocker arms
arms to
to the
side.
side.
5.
5. Remove the valve push rods and
identify them so that they can be
6.
remove the valve lifters and place
them in a rack so that they can be
installed in their original bores.
Rotate the lifter back and forth to
loosen it from the gum or varnish that
may have formed at the lifters.
7. Be sure the Number 1 piston
piston isisinin the
the
TDC position. Remove the camshaft
thrust plate. Carefully
Carefully remove the
thrust
camshaft by pulling toward the front
camshaft
of the engine. Use caution to avoid
of
camshaft bearings.
bearings.
damaging the camshaft
Ins/mIs/ion
Installation
Camshaft lobes
lobes are to
to be
be coated
coated with
with
Camshaft
Lubriplate or equivalent
equivalent and the journals
journals
Lubriplate
A
6261
BEARINGS
BEARINGS
6267
6263
6263.
~""1\ ~
~I
0U
<-6270
6262
?<:~
,~l&
>~.
X'"
~$>'
.,
'.
CAMSHAFT
REAR BEARING
BORE PLUG
6266
CAMSHAFT
6250
BOLT
BOLT
\~
Ii
TWO PIECE
PIECE FUEL
FUEL
TWO
PUMP ECCENTRIC
ECCENTRIC -6287
- 6287
PUMP
A3253A
A3253-A
FIG.
FIG. 25
25 Camshaft
Camshaft and
and Related
Related Parts
Parts
21-22-12
lubricated with heavy engine oil SE
installation.
1.
1. Oil the camshaft journal and apply
Lubriplate to the lobes.
lobes. Carefully
Carefully
slide the camshaft
camshaft through the
bearings.
bearings. Install the camshaft thrust
plate onto the cylinder block. Install
the timing sprockets and timing
chain.
chain. Check camshaft end playas
play as
shown in Part 21-01.
2.
2. Install the valve lifters in the bores
from which they were removed.
removed.
3.
3. Install fuel pumps cylinder front
front
cover plate and related parts
parts
following steps 11 thru 13
13 under
Cylinder Front Cover Plate and
Timing Chain Installation.
4.
4. Adjust the drive belts to specification.
specification.
S.
5. Install the push rods in their original
positions.
positions.
6.
6. Install the rocker arms following the
procedure given in Rocker Arm
Installation.
7.
7. Install the rocker arm covers
covers
following the procedure given in
Rocker Arm Cover Installation.
8.
8. Install the intake manifold,
manifold,
distributor and related parts by
following procedures under Intake
Manifold Installation.
9.
9. Connect the accelerator cable and
retracting spring. Connect the
downshift rod if 'so
so
equipped. Install the vacuum lines
that were disconnected from the
intake manifold during removal.
removal.
10.
10. Clean
Clean and
and install
install the
the crankcase
crankcase
system.
ventilation system.
cap. Position
11.
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
plugs.
coil.
at the coil.
12. If
If equipped
equipped with
with air
air conditioning,
conditioning,
12.
condensor.
install the condensor.
13. Place
Place the
the radiator
radiator shroud
shroud over
over the
the
13.
fan. Install the radiator and connect
fan.
the hoses.
hoses. Connect the transmission
the
oil cooler lines at the radiator. On
vehicles so equipped, install the
radiator shroud attaching bolts.
14. Raise
Raise the
the vehicle.
vehicle. Remove
Remove the
the oil
oil pan
pan
14.
and install new gaskets and seals
following procedures under Oil Pan
Removal and Installation.
vehicle. On vehicles so
Lower the vehicle.
equipped, install the fan shroud
attaching bolts.
bolts.
attaching
system. Fill
15.
and quantity
quantity of
of engine
engine oil.
and
16. Start
Start the
the engine
engine and
and check
check and
and adjust
adjust
16.
distributor vacuum lines.
17. Operate
Operate the
the engine
engine at
at fast
fast idle
idle and
and
17.
check all hose connections and
leaks. When the engine
gaskets for leaks.
BACK TO GROUP INDEX
351M and
v-a Engines
and 400 CIO
CID V-8
21-22-12
temperature has stabilized adjust

adjust the
engine idle speed and idle fuel
mixture.
mixture.
18.
18. Adjust
Adjust the
the transmission
throttle
linkage.
linkage. Install the air cleaner and
intake duct assembly.
6. Remove the sway bar attaching bolts

from the chassis and lower the sway
bar for clearance (Torino, Elite,
Montego and Cougar).
front support
through bolts.
blocks between the engine supports
and chassis brackets.
bolts.
9. Remove the oil pan attaching bolts.
10. If
If equipped
equipped with
with an
an automatic
automatic
transmission, position the oil cooler
lines out of the way.
11. Remove the oil pan.
Installation
Installation
1.
and oil pan. The oil pan has a twopiece 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
(Fig. 26).
cylinder front cover plate. Be sure the
tabs on the seal are over the oil pan
gasket.
rear main bearing cap (Fig. 26). Be
Be
oil pan gasket.
and install a bolt, finger tight, on each
FLYWHEEL
Removal
Removal
1.
transmission and
1. Remove the transmission
converter housing following the
procedure in Group 17.
2.
2. To check ring gear for lateral run-out,
refer to Part 21-01.
3. Remove the flywheel attaching bolts
and remove the flywheel.
Instal/ation
Installation
1.
1. Coat the threads of the flywheel
sealer. Position the flywheel on the
crankshaft
crankshaft flange. Install and torque
the bolts in sequence across from each
other to specification.
specification.
2.
2. Check the flywheel lateral runout,
following the procedure in Part 21-01,
and install the transmission and
CAMSHAFT REAR BEARING BORE
PLUG
Removal
Removal
1.
transmission and
2.
2. Remove the flywheel attaching bolts
and remove the flywheel.
flywheel. Remove the
engine rear cover plate.
3. Remove the core plug as detailed in
3.
Part 21-01.
FRONT SEAL
Installation
Installation
1.
1. Using Tool T70P-6011-A, install the
core plug as outlined in Part 21-01.
2. Coat the flywheel
with
2.
flywheel attaching bolts with
oil-resistant sealer. Position the
oil-resistant
engine rear cover plate on the cylinder
dowels. Position the flywheel
block dowels.
flywheel
crankshaft flange.
on the crankshaft
flange. Install and
torque the attaching bolts in sequence
a c r o s s from
from each
e a c h other
o t h e r to
across
specification.
transmission and
Install the transmission
converter
con
verter housing following the
OIL PAN
OIL
Ford, Mercury, Meteor, Torino,
Ford,
Elite, Montego and Cougar
Removal
Removal
1.
2.
bolts and position the fan shroud over
fan.
the fan.
4.
5. Disconnect the starter cable and
5.
remove the starter.
REAR SEAL
A3263-A
FIG. 26 Oil Pan Gasket and Seals

InstalledTypical
Installed-Typical
21-22-13
351
M and 400 CID v-a
351M
V-8 Engines
21-22-13
side of the block. Install the

the
remaining bolts.
bolts. Tighten the bolts
direction to
to specification.
specification.
7.
brackets. Lower
the engine and install the engine
support through bolts.
bolts. Tighten the
specification.
8.
8. Install the sway bar to chassis
attaching bolts (Torino, Elite,
Montego and Cougar).
Cougar).
9.
starter cable.
cable.
10.
10. Lower
Lower the
the vehicle.
vehicle.
11.
12.
12. Install
Install the
the oil
oil level
level dipstick.
dipstick. Fill
Fill the
the
quantity of engine oil.
and operate at idle speed until it
reaches
operating
temperature.
temperature. Check for oil leaks.
4.
4. With the stop properly positioned,
insert the intermediate drive shaft
into the oil pump.
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
shaft hex may be
misaligned with the distributor shaft.
To align, rotate the intermediate
drive shaft into aa new position.
Tighten the oil pump attaching
screws to specification. Be sure
sure the
the oil
oil
pick up screen is parallel with the oil
pan mounting surface.
5.
5. Install the oil pan and related parts as
outlined under Oil Pan Installation.
Installation
Installation
1.
If the rear main bearing is being
1. If
OIL
OIL PUMP
Removal
Removal
1.
1. Remove the oil pan and related parts
as
as outlined under Oil Pan Removal.
Removal.
2.
2. Remove the oil pump attaching bolts
and remove the oil pump with pick up
and
tube and screen, gasket and
intermediate drive shaft.
shaft.
Installation
Installation
1.
1. Clean and install the oil pump inlet
tube and screen assembly (Fig.
(Fig. 27).
3264-B
A 3264-8
FIG. 27 Oil Pump and Inlet Tube

Installed
2. Prime the oil pump by

by filling either
2.
oil.
Rotate the pump shaft to distribute
oil within the pump body.
the oil
3. Position the intermediate drive shaft
shaft
3.
into the distributor socket.
socket. With the
illto
shaft firmly seated in the distributor
socket, the stop on the shaft should
touph the roof of the crankcase.
touch
Remove the shaft and position the
stop as
as necessary.
necessary.
stop
BACK TO GROUP INDEX
CRANKSHAFT
Replacement of a crankshaft
crankshaft rear oil
seal because of oil leakage requires
replacement of both the upper and lower
seals.
seals. Refer to Crankshaft
Replacement in Part
for
Replacement
Part 21-01 for
MAIN BEARING
Main bearing inserts are selective
or lap
lap bearing
bearingcaps
capsororuse
use
fits. Do not file or
clearance.
bearing shims to obtain proper clearance.
Selective fit bearings are
are available
availablefor
for
and 0.002
service in standard size, 0.001 and
inch undersize. Undersize bearings
(0.010, 0.020, 0.030 and 0.040 inch)
are not selective fit, are available
which are
on crankshaft journals that have
for use on
been refinished.
Removal
Removsl
1.
level dipstick. Remove the oil pan and
related parts.
2. Remove the oil pump and inlet tube
2.
assembly.
3. Replace one bearing at a time,
time, leaving
the other bearings securely fastened.
which new bearings are to be
installed.
4. Insert the upper bearing removal tool
4.
(Tool 633 P iin
n the
the oil
oil hole
hole in
in the
the
(TooI6331"
crankshaft.
5.
of the engine rotation to force the
bearing out of the block.
6.
replaced, remove and discard the rear
oil seal from the bearing cap.
Loosen all main bearing bolts,
thereby lowering the crankshaft
crankshaft
slightly but not to exceed 1/32 inch.
Remove the block half of the rear oil
seal. Use a seal removal tool or install
seal.
a small metal screw in one end of the
seal, and pull on the screw to remove
the seal.
seal. Be careful not to burr the
crankshaft seal
seal rubbing
rubbing surface.
crankshaft
replaced, clean the rear oil seal groove

in the block with a brush and solvent.
Carefully install the upper seal
Carefully
(split lip type) into its groove with the
undercut side of the seal toward the
FRONT of the engine (Fig. 30) by
by
rotating it on the seal journal of the
crankshaft until approximately 3/8
crankshaft
inch protrudes below the parting
been
surface. Be sure no rubber has been
shaved from the outside diameter of
of
the seal by the bottom edge of the
groove. Tighten the bolts on main
bearings 1, 2, 3 and 4,
4, thereby
thereby raising
the crankshaft to its original position.
Torque the bolts to specification.
Inspect the journals and thrust faces
(thrust bearing) for nicks, burrs or
bearing pick-up that would cause
place the plain end of the bearing over
the shaft on the locking tang side of
of
bearing so that Tool
6331 can be
Tool6331
inserted
crankshaft. WithTool 6331
6331 positioned
in the oil hole in the crankshaft,
crankshaft, rotate
the crankshaft
opposite
crankshaft in the opposi
te
direction of engine rotation until the
bearing seats itself. Remove the tool.
4. Replace the cap bearing.
6. If the bearing is being replaced on
journal number 1, 22or
or4,4,apply
applyaalight
light
coat of engine oil to the journal and
bearings and install the bearing cap.
Tighten the cap bolts to specification.
replaced, clean the oil seal groove
with a brush and solvent.
8. Install the lower seal in the rear main
bearing cap with undercut side of seal
(Fig. 28), allow the seal to protrude
approximately 3/8 inch above the
parting surface
surface to mate with the
upper seal when the cap is installed.
9. Refer
Refer to Part
Part 21-01 for special
instructions in applying sealer to the
rear main bearing cap. Lubricate the
journal with engine oil and install the
rear main bearing cap. Tighten the
cap bolts to specification.
If the
the thrust
thrust bearing
bearing cap
cap (No.
(No. 33 main
main
10. If
bearing)
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
crankshaft forward against the thrust
surface
surface of the upper half
half of
of the
351 M and 400 CID V-8

v-a Engines
Engines
351M
21-22-14
INSTALL
INSTALL SEAL
SEAL WITH
WITH LIP
TOWARDS FRONT
FRONT OF
OF ENGINE
ENGINE
TOWARDS
I
3/8"
FRONT OF ENGINE
FRONT
-+-
I
SEAL HALVES TO PROTRUDE BEYOND PARTING FACES
THIS DISTANCE TO ALLOW FOR CAP TO BLOCK ALIGNMENT

L1PTYPE CRANKSHAFT SEAL
OF SPLIT, LIP-TYPE
A2639-C
A2639C
REAR FACE OF REAR MAIN

BEARING CAP AND CYLINDER BLOCK
FIG. 28 Installing Crankshaft Rear Oil Seal

crankshaft cap to
bearing. Hold the crankshaft
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.
shaft
opening. Install the oil pump and the
inlet tube assembly.
12. Position the oil pan gaskets on the oil
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.
oil. Start the engine and check for
for
oil pressure. Operate the engine at fast
idle and check for oil leaks.

selective fit.
fit. Refer to
to procedures under
Bearings in
in Part 21-01.
21-01.
Removal
Removal
1.
1. Drain the crankcase oil.
oil. Remove the
oil level dipstick. Remove the oil pan
and related parts.
parts.
2.
2. Remove the oil pump and inlet tube
tube
assembly.
assembly.
3.
3. Turn
T u r n the crankshaft
c r a n k s h a f t until the
the
connecting rod to which new bearings
bearings
are to be fitted
fitted is
is down.
down. Remove the
connecting rod cap. Remove the
the
cap.
BACK TO GROUP INDEX
InstlllJation
Installation
failure.
crankshaft journal.
fitting in the slots provided.
firmly on the' crankshaft
crankshaft
down firmly
journal.
5. Select fi
fitt the bearing following
following
procedures under Fitting Main and
Connecting Rod Bearings in .Part
Part
21-01.
6.
6. After
fitted,
the connecting rod cap. Torque to
specification.
7.
Prime by filling the inlet opening with
oil and rotate the pump shaft until oil
emerges from the outlet opening.
opening.
Install the oil pump and the inlet tube
assembly.
8. Position the oil pan gaskets on the oil
8.
cylinder front
front cover plate.
plate.
the cylinder
Position the oil pan rear seal on the
cap. Install the oil
rear main bearing cap.
parts. Install the oil
pan and related parts.
dipstick.
level dipstick.
9.
9. Fill the crankcase. Start the engine
engine
and check for oil pressure.
pressure. Operate
Operate
for
the engine at fast idle and check for
oil leaks.
leaks.
21-22-14
21-22-14
RODS
Removal
Removal
1. Drain
Drain the cooling
cooling system
system and
and the
ccrankcase.
r a n k c a s e . Remove
Remove the
the intake
manifold,
manifold, cylinder
cylinder heads, oil pan and
oil pump, following
following the procedures
procedures in
this section.
2. Remove any ridges and/or
and/or deposits
from
of the cylinder
bores as follows:
Turn the crankshaft
crankshaft until
until the
Turn
piston to be removed is at the bottom
of its travel and place a cloth on the
of
and/or deposits
Remove any ridge and/or
of the cylinder
from
furnished by the tool manufacturers.
furnished
excess of 1/32
1/32 inch when removing
ridges.
3. Make sure all connecting rod caps are
marked so that they can be installed
Turn
until the
4. T
u r n the ccrankshaft
r a n k s h a f t until
connecting
down.
5. Remove the connecting rod nuts and
cap.
6. Push the connecting rod and piston
Avoid damage to the crankshaft
crankshaft
journal or the cylinder wall when
removing the piston and rod.
8.
8. Install the cap on the connecting rod
from which it was removed.
Installation
InstalJation
1. If
If new piston rings are to be installed,
1.
cylinder wall glaze.
remove the cylinder
manufacturer.
2.
in the
Be sure to install the pistons in
same cylinders from which they were
fitted.
The connecting rod and bearing caps
are numbered from 1 to 4 in the right
and from
from 5 to 8 in
in the left bank,
bank and
beginning at the front of the engine.
The numbers on the connecting rod
and bearing cap
cap must be
be on
on the same
and
in the cylinder
side when installed in
ever
bore. If aa connecting rod is ever
from one block or cylinder
transposed from
to another, new
new bearings should be
to
and the
the connecting rod
rod should
fitted and
be numbered to
to correspond with
with the
be
new cylinder number.
number.
new
3. Make sure the ring gaps are properly
properly
3.
spaced around the circumference of
(Fig. 29).
29).
the piston (Fig.
v-a
21-22,-15
21-22-15
Oil
OIL RING SPACER
Oil
OIL RING
RING
Oil RING
~SEGMENT
\'~f' B
SEGMENT
SEGMENT
!
~
II
I, /
X
/
I
"
'
PINuORE
!
/
(
~
~
RING ~I COMPRESSION
PISTON
SION
COMPRESSION
FRONT OF ENGiNE
ENGINE T
fRONT
351M and 400 CIO

CID V-8 Engines
21-22-15
6. After
After the bearings have been fitted,
fitted,
journals and bearings.
crankshaft
rod bearing seats on the crankshaft
journal.
8. Install the connecting rod cap and
bearing. Torque the nuts to specifispecification.
9. After
the side clearance
clearance between
between the
crankshaft
journal (Fig. 32).

assembly.
RING
A2811-A
A281l-A
Ring Spacing
FIG. 29 Piston Ring
A3257-D

RIGHT BANK
FIG. 32 Checking Connecting Rod

Side Clearance
LEFT
L E F T BANK
NOTCH OR
ARROW TOWARD
FRONT OF ENGINE ^
OF ROD
NUMBERED SIDE OF
A3706-B
31 Correct Piston and Rod

FIG. 31
Positions-351-C
Positions351-C and 400
CID
CIO
4. Install a piston ring compressor on
a hammer handle until it is slightly
below the top of the cylinder (Fig. 30).
Be sure to guide the connecting rods
to avoid damaging the crankshaft
crankshaft
journals. Install the piston with the
arrow on the piston head toward the
front of the engine (Fig. 31).
of each bearing
5. Check the clearance of
Main and Connecting Rod Bearings
in Part 21-01.
BACK TO GROUP INDEX
10. Disassemble, clean and assemble the

tube screen and the oil pan and block
gasket surfaces.
the inlet port or outlet port with
engine oil and rotating the pump shaft
shaft
to distribute
distribute the oil within
within the
housing. Install the oil pump and the
oil pan.
following
12. Install the cylinder heads following
procedures under Cylinder
Cylinder Head
Installation.
manifold following
following
Manifold
Installation.
14. Fill and bleed the cooling system. Fill
15. Start the engine and check and adjust
adjust
the ignition timing. Connect
Connect the
distributor vacuum hoses at the
distributor
distributor.
16. Operate the engine at fast idle until it
operating
reaches
temperature and check for oil and
coolant leaks. When the engine
engine
coolant
temperature has stabilized adjust
adjust the
speed and idle fuel
fuel
engine idle speed
mixture.
CRANKSHAFT
crankshaft and related parts are

The crankshaft
shown in Fig. 33.
Removal
Removal
1.
1. With engine removed from vehicle
and
and pplaced
l a c e d on a work
w o r k stand,
stand,
disconnect the spark plug wires at the
spark plugs and remove the wires
from the ignition harness brackets on
the valve rocker
r o c k e r arm
arm covers.
covers.
Disconnect the coil-to-distributor
coil-to-distFibutor cap
and spark
spark plug wire assembly.
assembly.
Remove the spark plugs to allow easy
rotation of the crankshaft.
crankshaft.
at the pump. Remove the fuel pump
from the cylinder block. Remove the
alternator and mounting brackets.
the crankshaft
damper.
Remove the cap screw and washer
from the end of the crankshaft. Install
the puller on the crankshaft
damper (Fig. 18) and remove the
damper.
4. Remove the timing pointer. Remove
the water pump and cylinder front
front
cover plate as an assembly. Discard
the gasket.
5. Check the timing chain deflection
deflection
(Refer
(Refer to Part 21-01). Remove the
camshaft
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. 20).
6. Invert the engine on the work stand.
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
locations.
Turn
Turn the crankshaft
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
all the connecting rod bearing caps
are removed.
8.
9. Carefully
block so that the thrust
thrust bearing
surfaces. To refinish
refmish journals, dress
minor imperfections, etc., refer to
Part 21-01.
Instal/ation
Installation
1.
from
21-22-16
and the mating surfaces of the block
caps.
5. If
If the crankshaft
journals have been refinished
refinished to a
undersize bearings. Be sure the
failure.
cause a failure.
in position in the bores with the tang
fitting in the slot provided.
7. Install the lower main bearing inserts
in the bearing caps.
8.
8. Dip the lip seal halves in clean engine
oil. Install the lip seals in the bearing
cap and block with the undercut side
of the seal toward the FRONT of the
engine as shown in Fig. 28.
9. Carefully
Carefully lower the crankshaft
crankshaft into
place. Be careful not to damage the
bearing surface.
10. Check the clearance of each main
bearing following the procedure
under Fitting Main and Connecting
Rod Bearings in Part 21-01.
11. After
After the bearings have been fitted,
apply sealer to the rear main bearing
cap, following the instructions given
in Part 21-01 for use of silicone rubber
sealer in this area.
12. Apply heavy engine oil SE to the
13. Install the rear main bearing cap with
the rear surface flush or slightly ahead
of the rear of the cylinder block.
Install all bearing caps, except the
(No. 3 bearing). Be
thrust bearing cap (No.3
sure that the main bearing caps are
installed in their original locations.
Torque the bearing cap bolts to
specification.
14. Install the thrust bearing cap with the
bolts finger tight.
crankshaft forward against
15. Pry the crankshaft
half of
of
the thrust surface of the upper half
the bearing (Fig. 34).
crankshaft forward and pry
16. Hold the crankshaft
the thrust bearing cap to the rear.
of
This will align the thrust surfaces of
both halves of the bearing.
17. Retain the forward pressure on the
crankshaft. Tighten the cap bolts to
specification.
18. Force the crankshaft
crankshaft toward the rear
of the engine.
crankshaft end play (Refer
19. Check the crankshaft
to Part 21-01).
20.Install
t i m i n g chain
chain and
20.
Install the timing
sprockets, cylinder front cover plate
BACK TO GROUP INDEX
351M and
and 400
400 CID
CID v-a
V-8 Engines
21-22-16
MAIN BEARING INSERTS
6333
6337
OIL SEAL
6701
\c?';
6333
.~~~
\.,..
~).;
6~ ~'
.(>
,1\
CRANKSHAFT SPROCKET
6306
MAIN BEARING
INSERTS
6333
01 L SEAL
DAMPER
6316
WASHE R
6378
6333
BOLT
MAIN BEARING CAPS

A3266-D
and Related Parts

FIG. 33 Crankshaft and
thru
and fuel pump, following steps 1 thru
8 under Cylinder Front Cover Plate
and Timing Chain Installation.
21. Install the engine rear cover plate
onto the alignment dowels at the rear
22. Coat the threads of the flywheel
flywheel
sealer. Position the flywheel on the
crankshaft
crankshaft flange. Install and tighten
the bolts to specification.
specification.
23. Install new bearing inserts in the
connecting rods and caps. Check the
clearance of each bearing following
the procedures under Fitting Main
and Connecting Rod Bearings in Part
21-01.
After the connecting rod bearings
24. After
of
have been fitted, apply a light coat of
engine oil to the journals
journals and
bearings.
crankshaft journal.
26. Install the connecting

connecting rod cap.
specification.
Torque the nuts to specification.
27. After
connecting rods on each connecting
crankshaft journal (Fig. 32).
rod crankshaft
28. Clean the oil pan, oil pump and oil
filling either the inlet or outlet port
with engine oil and rotating the pump
shaft to distribute oil within the
shaft
housing. Install the oil pump and oil
pan by following the procedures
under Oil Pan and Oil Pump
Pump
under
Installation.
29. Install the front oil seal, vibration
damper
damper and crankshaft
crankshaft pulley,
following Steps 10 thru 12 under
Cylinder Front Cover Plate and
Timing Chain Installation.
30. Install the spark plugs, distributor
wires. Connect the
cap and spark plug wires.
spark plug wires and high tension
lead.

21-22-17
351 M and 400 CID V-8

v-a Engines
351M
21-22-17
HOLD CRANKSHAFT
FORWARD
PRY CRANKSHAFT FORWARD
A2879-A
FIG. 34 Aligning Thrust Bearing

31. Install the engine in the vehicle.
CAMSHAFT BEARING
Camshaft bearings are available
Camshaft
prefinished to size for standard and 0.015
inch undersize journal diameters. The
bearings are not interchangeable from
her.
one bore to anat
another.
Removal
Removal
1.
1. Remove the engine from the vehicle.
Remove the camshaft, flywheel and
crankshaft, following the appropriate
procedures in this part. Push the
pistons to the top of the cylinders.
2.
camshaft rear bearing
bore plug. Remove the camshaft
camshaft
bearings (Fig.
(Fig. 35).
3.
collet assembly in the camshaft
camshaft
on the expanding mandrel until the
collet fits
fits the camshaft bearing.
4.
4. Assemble the puller screw and
extension (if necessary) as
as shown and
install on the expanding mandrel.
mandrel.
Wrap aa cloth around the threads of
the puller screw to protect the front
front
bearing or journal. Tighten the
and pulling plate to remove the
bearing. Be
Be sure to
to hold a
camshaft bearing.
wrench on
on the
the end of the
the puller screw
to
turning.
5.
5. Repeat the procedure for each
bearing.
bearing. To
To remove
remove the front bearing,
install the
the puller screw from the
the rear
block.
Instal/ation
Installation
1.1. Position the new
new bearings at the
the
bearing bores with the oil holes
holes
aligned,
aligned, and press
press them in
in place
place with
the
the tool
tool shown in
in Fig.
Fig. 35.
35. Be
Be sure
sure to
to
center the
the pulling plate
plate and
and puller
screw to
to avoid damage
damage to
to the
the bearing.
bearing.
screw
BACK TO GROUP INDEX
DETAIL-1,-2 or -3
DETAILl,2
3
EXPANDING COLLET
THRUST BEARING
C:XPANDING MANDREL
EXPANDING
DETAIL-l,-2or
-3
DETAILl,2
or3
BACK-UP NUT
BACKUP
DETAIL
PULLING NUT
DETAIL-5
PULLER SCREW
DETAIL-4
DETA1L4
PULLING PLATE
CAMSHAFT l3EARING
BEARING (LOOSE)
(LOOSED
DETAIL.6
CAMSHAFT
DETAIL-6 or.
or -77
SCREW EXTENSION
PULLER SCREW
IToolT65L.6250.A I
Tool-T65L.625Q.A
A2813-A
A2813A
FIG. 35 Camshaft Bearing

Bearing Replacement
FIG.
Failure to
to use
use the
the correct expanding
collet can cause severe bearing
damage. Be sure
sure the
the front bearing is
damage.
installed the
the specified distance below
the front
front face
face of the
the cylinder block
the
(Fig.
(Fig. 36).
2.
2. Install the core plug as
as detailed in
Part 21-01.
21-01.
3.
3. Install the camshaft, crankshaft,
crankshaft,
flywheel and related parts,
parts, following
following
in this
this
the appropriate procedures in
section except do not check
check
connecting and main bearing
bearing
clearances as
Camshaft
the
engine
engine in
in the
the vehicle.
vehicle.
INSTALL FRONT BEARING TO SPECIFIED

I DIMENSION BELOW FRONT FACE OF BLOCK:
^X
^278-A
FIG. 36 Camshaft Front

Front Bearing
Bearing
FIG.
Measurement
21-22-18
OIL FILTER
The oil filter assembly is shown in
Fig. 37.
351
M and 400 CID v-a
351M
V-8 Engines
21-22-18

filter until the gasket contacts the
1/2
adapter face, and then advance it 1/2
turn.
to correct leakage. Check the oil level

and fill the crankcase if necessary.
Remoyll1
Removal
filter.
Place a drip pan under the filter.
Unscrew the filter from the adapter
adapter
fitting and clean the adapter recess.
2. Fill the crankcase to the required level

with the proper type and grade of
of
lubricant.
Installation
Installation
1. Coat the gasket on a new filter with
oil. Place the new filter in position on
3. Operate the engine at fast idle, and

If oil leaks are
check for oil leaks. If
evident, perform
FILTER ELEMENT
6731
6731
I~t;
I
ADAPTER FITTING
ADAPTER FITTING
6890
A3704- B
FIG. 37 Oil Filter Installation

FIG.

must
must be torqued
torqued (refer
(refer to torque
torque
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
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
before
removing the valves.
Remove the spring retainer locks and
release the spring.
lubricant
l u b r i c a n t is to be applied
applied before
before
installation.
1. Clean the spring retainer lock grooves
on the valves to remove any loose
material left
left by the valve stem
material
deburring tool.
2. Lubricate the valve guide and valve
stem with heavy engine oil SE.
3. Install each valve (Fig. 40) in the port
from which it was removed or to
which it was fitted. Install a new stem
seal on the valve.
/-J$.l'
LOCKS~
LOCKS.
6518
RETAINER
651-.;
6514
SPRING
OIL SEAL
6571
6571
EXHAUST
VAl.
VE
VALVE
6506
~
T70P-6505-A
s::l:.... . . - -
INTAKE
VALVE
6507
/*"*
A32430
A3243-D
A3247-A
A3242-A
FIG. 38 Compressing Valve Spring
4. Remove the spring retainer, spring

and stem seal. Discard the valve stem
seals. Remove any burrs from the
T70P-6505-A as
valve stem with tool T70P-6S0S-A
shown in Fig. 39 to prevent damage
to the valve guide bore. Remove the
valve. Identify all valve parts.
5. Clean, inspect and repair the cylinder
transfer all usable
head as required, or transfer
parts to a new cylinder head.
Assembly
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
BACK TO GROUP INDEX
FIG.
FIG. 39 Removing Valve Stem Burrs
FIG. 40 Valve and Related Parts
4. Install the valve spring over the valve,

and then install the spring retainer.
trie
Compress the spring and install tlie
cylinder head spring pad to the
cylinder
dividers (Fig. 41). Check the dividers
If the assembled
against a scale. If
specification,
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
will result in overstressing the valve
springs and over-loading the camshaft
lobes which could lead to spring
breakage and/or worn camshaft
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.
Disassembly
Disassembly
Disassemble and assemble each lifter
lifter
separately. Identify
Identify the lifter
lifter assemblies
so they can be installed in their original
bores.
pliers to release it from the groove. It
may be necessary to depress the
plunger to fully release lock ring.
21-22-19
21-22-19
351
M and
351M
and400
400CID
CIDv-a
V-8Engines
Engines
groove.
groove.Release
Releasethe
theplunger,
plunger,and
andthen
then
depress
depressit itagain
againtotofully
fullyseat
seatthe
thelock
lock
ring.
ring.
7.7. Use
Usethe
the hydraulic
hydraulic valve
valve lifter
lifter
leakdown
leakdowntester
tester(Part
(Part21-01)
21-01)totofillfillthe
the
lifters
lifterswith
withtest
testfluid.
fluid.
OILPUMP
PUMP
OIL
FIG.41
41 Valve
Valve Spring
SpringAssembled
Assembled
FIG.
Height
Height
Remove the
the push
push rod
rod cup,
cup, metering
metering
2.2. Remove
valve(disc),
(disc),plunger
plunger and
and spring.
spring.
valve
3.
Remove
the
plunger
assembly,
the
3. Remove the plunger assembly, the
check valve
valve and
and the
the check
check valve
valve
check
retainerand
andplunger
plungerspring.
spring.Carefully
Carefully
retainer
remove the
the plunger
plunger spring,
spring, the
the check
check
remove
valve
retainer
and,
the
check
valve
valve retainer and, the check valve
disc from
from the
the plunger.
plunger.
disc
Assembly
Assembly
Hydraulic lifter
lifter assembly
assembly isis shown
shown in
in
Hydraulic
Fig. 42.
Fig. 42.
Disassembly
Disassembly
1.1. Remove
Removethe
theoil
oilinlet
inlettube
tubefrom
fromthe
theoil
oil
pump.
pump.
2.2. Remove
Removethe
thecover
coverattaching
attachingscrews,
screws,
then
then remove
removethe
thecover.
cover. Remove
Removethe
the
innerrotor
rotorand
andshaft
shaft assembly,
assembly,then
then
inner
removethe
theouter
outerrace.
race.
remove
3.3. Remove
Removethe
thecotter
cotterkey.
key.Drill
Drillaasmall
small
hole
holeand
andinsert
insert aaselfthreading
self-threading sheet
sheet
metal screw
screw of
of the
the proper
proper diameter
diameter
metal
into the
the oil
oil pressure
pressure relief
relief valve
valve
into
chamber cap
cap and
and pull
pull the
the cap
cap out
out of
of
chamber
the chamber.
chamber. Remove
Remove the
the spring
spring and
and
the
plunger.
plunger.
Assembly
Assembly
The
The oil
oil pump
pump assembly
assembly isis shown
shown in
in
Fig. 43.
43.
Fig.
GASKET-6659
GASKET
-6659
OIL
OIL RELIEF
RELIEF VALVE
VALVE
21-22-19
21-22-19
PISTON
PISTONAND
ANDCONNECTING
CONNECTINGROD
ROD
Disassembly
Disassembly
1. 1. Remove
Removethe
thebearing
bearinginserts
insertsfrom
fromthe
the
connecting
rod
and
cap.
2.2. Mark
Markthe
thepistons
pistonstotoassure
assureassembly
assembly
with
the
same
rod
and
with the same rod andinstallation
installationinin
the
thesame
samecylinders
cylindersfrom
from which
whichthey
they
were
removed.
were removed.
3.3. Remove
Removethe
thepiston
piston rings.
rings. Using
Using anan
arbor
press
and
the
tool
shown
arbor press and the tool shownininFig.
Fig.
44,
44, press
press the
the piston
piston pin
pin from
from the
the
piston
pistonand
andconnecting
connectingrod.
rod.
L,j_p,eHRam
Press Ram
::I .....
~--
6A616
6A616
A~)o
ASSEMBLY
6670
PUSH ROD SOCKET

PUSH ROD
SOCKET
/
JVIETERING VALVE
CHECK VALVE
\~',~~"
'~t,
LOCK RING
LOCK RING
Reversible
Lo~ator
CHECK VALVE SPRING
De'a,' A-S
BODY
IDENTIFICATION
MARKS
PLUNGER
PLUNGER
A2867-B
A2867-B
FIG.
FIG. 42
42 Hydraulic
Hydraulic Valve
Valve Lifter
Lifter
Assembly
Assembly
1.1. Place
Place the
the plunger
plunger upside
upside down
down on
on aa
clean
clean work
work bench.
bench.
2.2. Place
Place the
the check
check valve
valve (disc
(disc or
or ball
ball
check)
on
check)ininposition
positionover
overthe
theoil
oilhole
holeon
the
the bottom
bottom of
of the
the plunger.
plunger. Set
Set the
the
check
thecheck
cl)eck
checkvalve
valvespring
springon
ontop
topofofthe
valve
(disc
or
ball
check).
valve (disc or ball check).
3.3. Position
Positionthe
thecheck
checkvalve
valveretainer
retainerover
over
the
check
valve
and
spring
the check valve and springand
andpush
push
the
placeon
onthe
the
theretainer
retainerdown
downinintotoplace
plunger.
plunger.
4.4. Place
Placethe
theplunger
plungerspring,
spring,and
andthen
thenthe
the
plunger
(open
end
up)
into
the
plunger (open end up) into thelifter
lifter
body.
body.
5.5. Position
Positionthe
themetering
meteringvalve
valve(disc)
(disc)inin
the
theplunger,
plunger,and
andthen
thenplace
placethe
thepush
push
rod
rodcup
cupininthe
theplunger.
plunger.
6.6. Depress
Depressthe
theplunger,
plunger,and
andposition
positionthe
the
closed
end
of
the
lock
ring
the
closed end of the lock ringininthe
groove
thelifter
lifterbody.
body.With
Withthe
the
grooveofofthe
plunger
still
depressed,
position
plunger still depressed, positionthe
the
open
thelock
lockring
ringininthe
the
openends
endsofofthe
BACK TO GROUP INDEX
..
..
t:::..J'
1.'i\~.
\~p{l~
CHECK
VALVE
CHECK VALVE
RETAINER
RETAINER
TAPERED PILOT
FOR PIN REMOVAL
CHECK VALVE
. .1
,:, /.:,: : :. .PLUNGER
CHECK VALVE
SPRING
SPRING
~
~..
INSE RT
INSERT
TAPERED
PILOT
IN ~i~T~~J6~Al
PISTON PIN
J ~ F6~
METERING VALVE
/2"d~
/
Driver
Detail A-7
INSERT THIS END

INSERT
THIS
END
IN PISTON
HOl
E
IN PISTON HOLE
FOR INSTALLATION
Adopter Detail A-3
Adapter Detail A-3

T68P-6135-A
T68P-6I35-A
Cup Detail A-l
Cup Detail
PLATE
PLATE---'"
6616
6616
Al
A3705-A
A3705-A
A 3493-A
FIG.
FIG. 43
43 Oil
Oil Pump
Pump Assembly
Assembly
1.1. Oil
Oil all
all parts
parts thoroughly.
thoroughly.
2.2. Install
Install the
the oil
oil pressure
pressure relief
relief valve
valve
plunger,
plunger, spring,
spring, aa new
new cap
cap and
and the
the
cotter
cotterkey.
key.
3.3. Install
Install the
the outer
outer race
race and
and the
the inner
inner
rotor
Besure
surethe
the
rotorand
andshaft
shaftassembly.
assembly.Be
dimple
dimple (identification
(identification mark)
mark) on
on the
the
outer
outer race
race isis on
on same
same side
side as
as
identification
identificationmark
markon
onrotor.
rotor.The
Therace
race
rotor
rotorand
andshaft
shaftand
andthe
theouter
outerrace
raceare
are
serviced
servicedasas an
an assembly.
assembly. One
Onepart
part
should
should not
not bebe replaced
replaced without
without
replacing
replacingthe
theother.
other.
Install
Installthe
thecover
coverand
andtighten
tightenthe
the
c cover
o v e r a attaching
t t a c h i n g s cscrews
r e w s t oto
specification.
specification.
4.4. Install
Installthe
theoiloilinlet
inlettube
tubeand
andscreen
screen
assembly
assemblyononthe
theoiloilpump.
pump.
5.5. Prime
Primethe
thepump
pumpbybyfilling
fillingeither
eitherthe
the
inlet
inletororoutlet
outletport
portwith
withengine
engineoil.
oil.
Rotate
Rotatethe
thepump
pumpshaft
shafttotodistribute
distribute
the
thepump
pumpbody.
body.
theoiloilwithin
withinthe
FIG. 44
44 Removing
Removing or
or Installing
Installing Piston
Piston
FIG.
Pin
Pin
Assembly
Assembly
Thepiston
pistonconnecting
connectingrod
rodand
andrelated
related
The
Checkthe
thefit
fit
partsare
areshown
shownininFig.
Fig.45.
45.Check
parts
new piston
piston inin the
the cylinder
cylinder bore
bore
ofof aa new
beforeassembling
assemblingthe
thepiston
pistonand
andpiston
piston
before
pintotothe
theconnecting
connectingrod.
rod.
pin
Thepiston
pistonpin
pinbore
boreofofaaconnecting
connecting
The
thepiston
pistonpin
pin
rodand
andthe
thediameter
diameterofofthe
rod
mustbebewithin
withinspecification.
specification.
must
Applya alight
lightcoat
coatofofengine
engineoiloiltotoallall
1.1. Apply
thepiston
pistontoto the
the
parts. Assemble
Assemblethe
parts.
connectingrod
rod with
withthe
thecylinder
cylinder
connecting
numberside
sideofofthe
theconnecting
connectingrod
rod
number
and the
the a rarrow
the ppiston
and
r o w onon the
iston
positionedasasshown
shownininFig.
Fig.31.
31.On
On
positioned
replacementconnecting
connectingrods,
rods,install
install
replacement
thelarge-chamfered
large.chamferedside
sideofofthe
the
the
connectingrod
rodbearing
bearingbore
boretowards
towards
connecting
thecrankshaft
crankshaftcheek;
cheek;facing
facingtowards
towards
the
frontofofengine
engineononright
rightbank
bankrods,
rods,
front
engineonon
andfacing
facingtowards
towardsrear
rearofof
and
engine
bankrods.
rods.
leftleftbank
21-22-20
UPPER
COMPRESSION
RING
PISTON
PISTON
PIN
6135
CONNECTING
ROD
'\
6200
A3259-A
FIG. 45 Piston,
Piston, Connecting Rod
Rod and
Related
Related Parts

mallet). Using an
very light tap with a mallet).
arbor press and the tool shown in Fig.
44, press the piston pin through the
piston and connecting rod until the
is centered in the piston.
pin is
3. Check the end gap of all piston rings
rings
21-01). It must be within
(Part 21-01).
specification. Follow the instructions
contained on the piston ring package
and install the piston rings.
351M and 400 CIO

CID V-8 Engines
21-22-20

lower land (Part 21-01).
21-01). The gauge
the
5.
5. Be sure the bearing inserts, the
bearing bore and the mating surfaces
on the connecting rod and cap are
cause a failure. Install the bearing
inserts in the connecting rod and cap
with the tangs fitting in the slots
provided.
Transfer all serviceable parts removed

3. Transfer
cylinder assembly,
from the old cylinder
following the installation procedures
section of this Part.
CYLINDER ASSEMILY
ASSEMBLY ('009)
(6009)
Disassembly
1.
1. Remove the intake manifold, cylinder
heads, front cover (with water pump
attached), thermostat and
aiid housing, oil
oil
pressure and temperature sending
units, fuel pump, flywheel, oil pan, oil
pump and associated attaching parts
from the old engine, using the
Installation section of this Part.
2. Remove the dipstick tube, oil filter
2.
adapter and fuel pump retaining stud
from the old block. Remove fasteners
and components not received with the
replacement cylinder block.
Assembly
Assembly
1.
of
all parts and assemblies.
2. Position the replacement cylinder
2.
assembly in a work stand. Install the
cylinder block drain plugs, cylinder
head locating dowels, front and rear
cover plate locating dowels, dipstick
tube, oil filter adapter and fuel pump
retaining stud.
CYLINDER BLOCK (6010)

If so, make
determine if it is repairable. If
Disassembly
Disassembly
1. Disassemble the engine completely,
following the various procedures
section of this Part. Remember to
remove any ridge or carbon deposit
bores before removing pistons.
2. Remove the temperature
temperature and oil
pressure sending units from the old
block, dipstick
dipstick tube,
tube, oil
oil filter
filter adapter
adapter
block,
and fuel
fuel pump
pump retaining
retaining stud.
stud.
and
3. Remove the old cylinder block from
the work stand.
Assembly
1. Install the replacement cylinder block
on the work stand. Install
Install the
temperature and oil pressure sending
units, dipstick tube, oil filter adapter
and fuel pump retaining
retaining stud.
Remove fasteners and components
not received with the replacement
cylinder block.
2. Clean all the gasket and seal surfaces
of all parts and assemblies before
installing on the replacement cylinder
block.
3. Transfer
from the old cylinder block to the
replacement
replacement unit,
unit, using
using the
Installation section of this Part.
SPECIFICATIONS1975
SPECIFICATIONS-1975
Drive Belt Tensions (lbs)
Ubs)
Engine
351M2V
4UU2V
4UU
2V
and Stroke
Bore and
3.50
4.00 x 3.50
4.00 x 4.00
4.00
(Sea level)
Level) @Cranking
@ Cranking Speed
PSI (Sea
Oil Pressure-Hot
@2000RPM
@2000
RPM
Firing Order
When checking compression, take the

highest compression reading and
the lowest reading.
reading. The
compare it to the
be at least 75%
lowest reading must be
the highest.
of the
50-75
1-3-7-2-6-5-4-8
(1) Read
Read tension immediately after belt is
is installed, before it stretches or seats in
in pulley grooves.
(1)
less than 40
40 pounds,
pounds, readjust to 40-60 pounds.
(2) If less
Size
Used
Over 10 Min.
Mm.
Newly Installed
(1)
U
O MMin.
in.
Upp ttoo i10
%"
V*"
50-80
40-80 (2)
(2)
40-60 (2)
Except V*"
%"
120-160
90-160 (3)
(3)
75-120 (4)
(4)

(3)
CA1309-C1
BACK TO GROUP INDEX

351
M and
351M
and 400 CIO
CID v-a
V-8 Engines
21-22-21
21-22-21
CYLINDER HEAD
Vllve
Valve Guide
Diameter
Bore Dilmeter
(Standard
(Stlndlrd
Intake Ind
and
lntlke
Exhaust)
Combustion
Chlmber
Chamber
Volume
Engine
351-M 2V
2V
& 400 2V
Vllve
Valve
Seat Width
Intlke
Intake
0.3433
0.34330.3443
76.9
79.9
76.9-79.9
CD
..........
Head Gasket Surface Finish R.M.S............
R.M.S
Valve
Selt
Seat
Angle
Exhaust
0.0600.080
0.060
0.0600.090
45
45
Vllve
Valve
Seat
Selt
Runout
(Maximum)
Vllve
Valve
Arrangement
Arrlngement
(Front to
Rear)
Rllr)
0.002
Right
I-E-I-E-I-EIEI-EIE
I-E
IE
Left
E-I-EJEE-l-E-l-EI-EJ
I-E-I
Glsket
Gasket
Surface
Surflce
Flltness
Flatness
<D
0.003
inch
in any
6 inches,
0.006
overall
60-150.

AND TAPPETS
Engine
351-M,400
351-M,
400
Valve Push Rod

Rod
(Maximum Runout)
Rocker Arm
Arm
Lift Ratio
1.731
1.73:1
0.015
~tlndard
Standard Diameter
0.8740-0.8745
Vllve
Valve Tippet
Tappet or Lifter
Clearance to Bore (1)0
Hydraulic Lifter Leakdown Rate
5-50 Seconds MaximumMeasured
Maximum-Measured
at 1/16 inch plunger travel
0.0007-0.0027
Collipsed
Gap
Collapsed Tippet
Tappet Gap
Desired
Allowable
0.100-0.200
0.125-0.175
.005.
CD Wear Limit - 00.005.
VALVE SPRINGS
Vllve
Lb.
Lbs Specified Length
Engine
<D
Pressure
35H!12V
351-M 2V
2V
& 400 2V
Valve Spring
Free Length
Approx.
76-84 @
@ 1.820
1.820
215-237 @
@ 1.390
1.390
2.06
Vllve
Valve Spring
Assembled Height
Pad to Retliner
Retainer
Pld
Valve Spring
Out-ofSquare
Out-of-Square
(Maximum)
113/16-127/32
1 13/16-1 27/32
5/64 W.078)
(0.078)
CD
(T)
Wear Limit
Limit: 10%
10% pressure loss @ speciflod
specified length.
length.
VALVES
Valve Stem To Valve Guide Clearance <D0
Intake
Exhaust
Engine
2V
351-M 2V
& 400 2V
<D
Wear Limit - 0.0055.
0.0010-0.0027
Valv.
Valve Hlld
Head Oilmeter
Diameter
0.0015-0.0032
Intake
Intlke
Exhlust
Exhaust
2.032-2.050
1.650-1.660
Valve Face Angle (>

(%)
440
44
(2) VaJve
Valve Face Runout - Maximum 0.002.
VALVES (Continued)
Valve Stem Diameter
Vlive
Engine
351-M,
400
Standard
0.003 Oversize
0.030 Oversize
0.015 Oversize
Intake
Exhaust
Intake
Exhaust
Exhlust
Intake
Exhaust
Intake
Exhaust
0.3416
0.34160.3423
0.34110.3418
0.34460.3453
0.34410.3441
0.3448
0.35660.3573
0.35610.3568
0.37160.3723
0371103711
0.3718
CA13D9-C2
CA1309-C2
BACK TO GROUP INDEX

V-8 Engines
351M and 400 CID v-a
21-22-22
CAMSHAFT
CAMSHAFT
""-
Theoretical
Valve Lift @ Zero Lash
Lobe Lift CD0
Engine
Intake
Exhaust
0.235
I
I
Exhaust
351M-2V
351
M-2V
0.235
0.4065
0.4065
400-2V
0.2474
0.2500
0.4280
0.4325
Intake
CD
0
21-22...22
21-22-22
Camshaft Journal to
Bearing Clearance
Wear Limit
Clearance
Camshaft
End Play
Wear Limit
0.0010.006
0.001 0.006
(lJ)[Jc:J
0.009
0.006
0.001-0.003
Maximum allowable lobe

lobe lift loss
loss ..... 0.005
Item
Item
Bearing
351M, 400
(No 1)
(No 2)
(No 3)
3)
2.1238-2.1248
2.12382.1248
2.0655-2.0665
2.0505-2.0515
2.05052.0515
(No 4)
4)
2.0355-2.0365
(No 5)
2.0205-2.0215
(No 1)
0.040-0.060
Camshaft Journal
OlameterDiameterQ)
Standard (2)
Camshaft Bearing
Location (J)
(3)
0
CD
APPROXIMATE ENGINE OIL CAPACITIES CD0

Engine
U.S. Measure i Imperial Measure
I
CD0
Camshaft
Bearings
Inside
Diameter
Bearing
351M, 400
(No 1)
2.1258-2.1268
2.0675-2.0685
2.0525-2.0535
(No 2)
(NG
(No 3)
3)
(No 4)
4)
(No 5)
5)
4 Quarrs
Quans
351
M, 400 I
3Y2
31/2 Quarts
351M,
!
CD
0 Add
Add 1/2 quart with filter replacement.
replacement.
2.0375-2.0385
2.0225-2.0235
2.02252. 0235
Cham Deflection (MaXimum)..

(Maximum) ........... . ......0.500
0.500
Timing Chain
|ournal maximum runout.

runout .............. .. .. . .0.005
0.005
(2) Camshaft lournal
Camshaft Journal
0.0005
journal maximum out-of-round...............
out-of-round
(2) Distance in Inches
inches that the
the bearing is
is installed towards the
the rear
~
from the
the front face of the
the cylinder block.
CYLINDER BLOCK
Engine
Cylinder Bore Diameter CD0
351M-2V
4.000-4.0036
400-2 V
400-2V
4.000-4.0048
Main Bearing
Bore Diameter
Tappet Bore Diameter
0.8752-0.8767
3.1922-3.1930
Cylinder Block
Distributor Shaft
Diameter
Bearing Bore Di~meter
Head Gasket
Surface Flatness (2)
(2)
Crankshaft To Rear
Face Of Block
TIR
Runout TI
R Max
Max
0.5160-0.5175
any
0.003 inch in any
6 inches or 0.006
0.005
inch overall
CD
0
(2)
(2) Head
Head gasket surface finish RMS..
RMS ..... . ..
Maxlmum-out-ofround..
Max mum-out-of-round ........... . . . . .. ... .. .. .0.001
0.001
Wear Limit.
Limit ...... ........ ....... ...... ........0.005
0.005
RMS
Cylinder bore surface finish RMS......
... . ..........15-35
15-35
Taper Wear Limit ......
..,
.. 60-150
0.010
. " .0.010
AND FLYWHEEL
CRANKSHAFT ANO
Main Bearing
Journal
Diameter (J)
(])
Engine
351
M-2V
351M-2V
400-2V
400-2 V
0
CD
Main Bearing
Journal Runout
Maximum <2)
(2)
2.9994-3.0002
Main Bearing
Journal
Taper Max
Max
Thrust
Bearing
Journal
Length
Journal
Thrust Face
0.001
Per Inch
0.0006 Per
1.137-1.139
12
I
I
iI
20
20 Rear
25 Front
0.002
Main bearing journal out-ofround

Main Bearing
Surface Finish
RMS Maximum
Main Bearing
Journal
Thrust Face
Runout
Q) Wear Limit - 0.005.

(2)
CRANKSHAFT AND
AND flYWHEEL
FLYWHEEL (Continued)
Engine
Connecting Rod
Rod
Journal Diameter (])0
Connecting Rod
RQd
Bearing Journal
flearing
Maximum Taper
Crankshaft Free
End Play (2)
2.3103-2.3111
0.0006 Per
Per Inch
0.004-0.008
351M-2V,400-2V
351
M-2V, 400-2V
CD
0
Connecting rod
rod outot-round
out-of-round maximum 0.0006
Flywheel Ring Gear Lateral Runout

Transmission
Automatic
0.060
(2) Wear Limit - 0.012.

(2)
CRANKSHAFT BEARINGS
Engine
351M-2V,400-2V
351
M-2V, 400-2V
0
CD
Connecting Rod
Rod Bearings
Desired
Allowable
0.0008-0.0015
0.0008-0.0026
Main Bearings
Wall Thickness
":Standard
Standard CD
Desired
Allowable
0.0622-0.0625
0.0008-0.0015
0.0008-0.0026
Wall Thickness
Standard CD
0.0957-0.0962
0.002 Undersize Thickness ..........Add

Thickness
CA1309-C 3
CA1309C3
BACK TO GROUP INDEX

351
M and
v-a Engines
351M
and 400 CID V-8
21-22-23
21-22-23
CONNECTING ROD
ROO
Piston Pin
Pin
Bore or
Bushing
ID
Engine
CD
Rod
Connectinq Rod
Assembly
Assembly
(Assembled To
To
(Assembled
Crankshaft)
Crankshaft)
Wear Limit
Limit
Side Clearance
I Wear
Connecting Rod
Rod
Alignment
Maximum Total
Difference <Z>
Q)
Connecting
Rod length
Length
Center
To Center
Connecting
Rod Bearing
Bore Diameter
Twist
351M-2V,
6.5785-6.5815
0.9734-0.9742
2.4361-2.4369
2.4361 2.4369
400-2V
CD Connecting rod
bearing
bore
maximum
out-of-round
and
taper
................0.0004
rod
and
0.0004
~ Pin
Pin bushing and
be parallel and
and in
in the
within the
the specified total difference at
at ends of 8-inch long bar
bar measured 4 inches on
on each
side
rod.
side of rod.
0.024
Bend
0.012
0.010-0.020
0.023
PISTON
Diamter
(f) (2)
(%)
Diamterfl)
Engine
351
351 M
M
Coded
Red
Red
0.00140.0022
4.00064.0012
3.99944.0000
3.99823.9988
Pin
Piston Pin
Bore
Diameter
Piston To
Cylinder Bore
Clearance
0.003
Oversize
Coded
Blue
0.9754-0.9757
400
0 to
CD
0 Measured
Measured at
at the
the piston
piston pin
pin bore
bore centerline at
at 90
90
to the
the pin
pin bore.
bore.
(2)
(2) Coded yellow -
Ring Groove Width

Ring..
..
Ring. ..... ..
Oil Ring
Ring........ .. ... . .......
,
,
. .0.080-0.081
0.080-0.081
. ... 0.080-0.081
0.1880- 0.1890
0.1880-0.1890
4.0018-4.0024
PISTON RINGS
RINGS
Side Clearance
Ring Width
Engine
Top
Top
351
M, 400
351M,
400
0.077-0.078
Wear
CD
Wear
Limit .. ........... 0.006

limit.
Ring Gap Width
Compression Ring (T)

<D
Compression Ring
Bottom
Top
0.077-0.078
0.002-0.004
Compression Ring
Bottom
Oil
Ring
Top
0.002-0.004
Snug
0.010-0.020
Oil Ring
Bottom
0.010-0.020
(2)
(2)
0.015- 0.055
0.015-0.055
(2)
SSteel
t e e l Rail
PISTON PIN
PIN
Diameter
Engine
Length
Standard
0.001 Oversize
351
M-2V
351M-2V
400-2V
3.150-3.170
0.9749-0.9754
0.9130-0.9133
To Piston
Clearance
To Connecting
Rod Clearance
0.0003-0.0005
Interference Fit
Fit
Rotor Assembly
End Clearance
Outer
Outer Race
To Housing
(Radial
Clearance)
0.001-0.004
0.001-0.013
OIL PUMP
Drive Shaft
To Housing
Bearing
Clearance
Relief Valve
Clearance
Engine
Rotor-Type Oil
RotorType
Oil
Pump Relief Valve
Spring Tension
Lbs @ Specified
Specified
Lbs
Length
351M,
400
351
M, 400
20.6-22.6@
20.622.6 @ 2.49
0.0015-0.0029
0.0015-0.0029
CA1309-C44
CA1309-C
BACK TO GROUP INDEX

351
M and
v-a Engines
351M
and 400 CID V-8
21-22-24
21-22-24
21-22-24
TORGUE
TORQUE LIMITS
LIMITS -- FTLBS
FT-LBS
Engine
Engine
351M2V,4002V
351M-2V.400-2V
Item
Cylinder Head
Head Bolts
Item
Engine
Engine
351M2V,400-2V
351M-2V,
400-2 V
9-12
Step 11
75
75
7CJ-90
70-90
Step
Step 2
95-105
35-50
11-13 (5116
(5/16 x 18)
Connecting Rod Nuts
40-45
7-9
7 - 9 ((1/4
1 / 4 xx220)
0)
Valve Rocket Arm Cover
3-5
21-25 (5/16 Bolt)
Fuel Pump to Cylinder Block
Nut 14-20
Bolt 10-15
Oil
to Cylinder Block
Oil Pan
Panto
27-33 (3/8 Bolt)

18-24

Water Outlet Housing
12-18
Distributor Va~uum
Vacuum Control Valve
10-15
Rocker Arm Bolts to Cylinder Head
18-25
Water Pump Bolts to Cylinder Block
12-18
EGR
reto r Spacer
EGR Valve to Carbu
Carburetor
12-18
Crankshaft
75-85
MISCELLANEOUS TORQUES - FTLBS

FT-LBS
Main
Main Bearing Cap
Cap Bolts
1/2-13,
95-105
1/2-13,95-105
10-15
Oil
Oil Pan
Pan Drain
Dram Plug
Plug
15-25
15-20
Oil
Oil Pump Cover Plate
9-12
Alternator
45-57
Alternator
24-40
Oil
20-30
Thermactor Pump Bracket to Cylinder

Cylinder Block
15-20
Oil
Oil Filter to Block Cartridge Type
With grease on
gasket surface,
hand tighten until gasket contacts
face, then
adapter face,
tighten 1/2 turn
more.
35-45
27-37
Thermactor Adjusting Arm to Cylinder

Cylinder Block
15-20
80-115 in-Ib
m-lb
Fan to Water Pump Hub

Power Steering Pump Pulley to Damper
35-50
12-18
Cylinder Front Cover
12-18
Water Pump Bolts to Front Cover
12-18

Carburetor Mounting
Mounting Stud
Intake Manifold
Manifold
Carburetor
Stud to
to Intake
4-7
40-45
Fuel Filter
Filter to
Carburetor
Fuel
to Carburetor
in-Ib
80-100 in-lb
12-15
CA1309-C
CA1309C 55
TORQUE LIMITS - FT-LBS

FT -LBS
STANDARD TORGUE
U.S. Thread Sizes

6-9
1/4 - 20 -== 6-9
Pipe Thread Sizes

= 27-33
3/8 - 24 =
12-18
5/16 - 18 == 12-18
7 / 1 6 --114
4 =
= 45-57
7/16
14-20
5/16 - 24 == 14-20
7/16-20 =
= 40-60
7/16-20
22-32
3/8 - 16 == 22-32
1/2-30
1/2
- 30 = 55-80
1/8 == 5-8
1/4 == 12-18
3/8
3/8 -= 22-33
1/2
1/2 = 25-35
Standard ttorque
o r q u e llimits
i m i t s listed
o r all other
other
Standard
listed in this
this chart
chart are applicable
applicable ffor
ffunctions
u n c t i o n s not
n o t sshown
h o w n in tthe
h e special ttorque
o r q u e charts.
CA1449-A1
CA1449A1
BACK TO GROUP INDEX

351
M and 400 CID v-a
351M
V-8 Engines
21-22-25
21-22-25
SPECIFICATIONS-1976
SPECIFICATIONS1976
Engine
PSI (Sea Level @Cranking
Cranking Speed
Bore and Stroke

4.00 x
x 3.50
3.50
351M
400
4.00 x 4.00
PressureHot
Oil Pressure-Hot
@2000
@ 2000 RPM
RPM
Firing Order
50-75
1-3-7-2-6-5-4-8
1-3726548
When checking compression,

compression, take the
highest compression reading and
compare it to the lowest reading.
reading. The
The
lowest reading must be at least 75%
of the highest.

Used
Newly Installed
(1)
Up to 10 Min. Over 10 Min.
Size
~"
5080
50-80
40-80 (2)
(2)
4060
(2)
40-60 (2)
Except 1~"
/*"
120-160
90160
(3)
90-160(3)
75120
(4)
75-120(4)
(3)
(2) If less than 40 pounds, readjust to 4060
40-60 pounds.
(4)
(4) If less than 75 pounds, readjust to 90120
90-120 pounds.
CYLINDER HEAD
Engine
351-M 2V
&
& 400 2V
Valve Guide
Bore Diameter
(Standard
Intake and
Exhaust)
Combustion
Chamber
Volume
76.9-79.9
Valve
Seat Width
Intake
0.3433-0.3443
0.060.. 0.080
0.0600.080
Valve
Seat
Angle
Exhaust
45
45
0.060-0.080
0.0600.080
Valve
Seat
Runout
(Maximum)
Valve
Arrangement
(Front to
Rear)
0.002
Right
I-E-I-E-I-E-I-E
IEIE'EIE
Left
E-l-E-l-E-l-E-l
EIEIEI-E'
Gasket
Surface
Flatness
(1)
(1)
0.003 inch
in any
6 inches,
0.006
overall
(1) Head Gasket Surface Finish R.M.S.........

60-150.
R.M.S
VALVE ROCKER ARMS, PUSH RODS AND TAPPETS

Valve Push
Rocker Arm
Push Rod
Engine
Lift Ratio
(Maximum Runout)
351-M,
400
351M,400
1.73:1
1.73:1
0.015
Standard Diameter
0.8740-0.8745
Valve Tappet or Lifter

Clearance to Bore
(1)
Bore(i)
Hydraulic Lifter Leakdown Rate
5-50 Seconds Maximum - Measured
at 1/16 inch plunger travel
0.0007-0.0027
Collapsed Tappet Gap

Allowable
Desired
0.1000.200
0.100-0.200
0.1250.175
0.125-0.175
(1) Wear Limit

L i m i t- 00.005.
.005.
VALVE SPRINGS
Engine

Lbs. @ Specified
Specified Length
Length
Pressure (1)
Valve Spring
Free Length
Approx.
351-M 2V
351M
& 400 2V
&
7680
76-80 @1.820
@ 1.820
215237 @
@1.390
215-237
1.390
2.06
Valve Spring
Assembled Height
Pad to Retainer
Valve Spring
Out-of-Square
OutofSquare
(Maximum)
1-13/16-1-27/32
113/16
1-27/32
5/64 (0.078)
(1) Wear Limit: 10% pressure

pressure loss@specified
loss @ specifiedlength.
length.
VALVES
Engine
351-M 2V
& 400 2V
(1) Wear Limit - 0.0055.
Valve Stem to Valve Guide Clearance (1)

Intake
Exhaust
0.001
0-0.0027
0.0010-0.0027
Valve Head Diameter
0.0015-0.0032
Intake
Exhaust
2.0322.050
2.032-2.050
1.6501.660
1.650-1.660
Valve Face Angle (2)

440
0
44
(2)
(2) Valve Face Runout - Maximum 0.002.
VALVES (Continued)
Intake
Exhaust
Valve Stem Diameter

0.003 Oversize
0.015 Oversize
Intake
Intake
Exhaust
Exhaust
0.34160.3416
0.3423
0.34110.3418
0.34460.3453
Engine
351-M
400
Standard
0.34410.3448
0.35660.3575
0.35610.3568
0.03D
0.030 Oversize
Intake
Exhaust
0.3716
0.37160.3723
0.37110.3718
CA1309D2
CA1309-D 2
BACK TO GROUP INDEX

351M
and 400 CID
CID v-a
V-8 Engines
Engines
351
M and
21-22-26
21-22-26
CAMSHAFT
CAMSHAFT
Theoretical
Theoretical
Valve lift
Lift il
@ Zero
Zero lIsh
Lash
Valve
Lobe lift
Lift CD0
Lobe
Engine
Engine
Intake
Intlke
Exhaust
Exhaust
Intake
Intake
Exhaust
Exhaust
351M
0.235
0.235
0.235
0.235
0.4065
0.4065
400
400
0.2474
0.2474
0.2500
0.2500
0.4280
0.4280
0.4325
0.4325
jrn allowable
allowable lobe
lobe 11ft
lift loss...
loss
(DMaxtrm
CD
Maxlmu~,l
Item
Item
End
End Play
Play
Wear
Wear limit
Limit
Clearance
Clearance
Wear
Wear Limit
Limit
0.0010.006
0.001 0.006
0.009
0.009
0.0010.003
0.001-0.003
0.rJD6
0.00G
.0.005
.0.005
OIL CAPACITIES CD0
APPROXIMATE ENGINE Oil
Imperial
Imperial Measure
Measure
Engine
U.S.
Engine
U.S. Measure
Measure I
CD0
Journal
Camshaft Journal
DiameterDlameterStandard (2)
~
Bearing
Camshaft Bearing
(J)
Location CJ)
Camshaft
Camshaft Journal
Journal to
to
Bearing
Bearing Clearance
Clearance
Camshaft
Camshaft
Item
Item
Bearing
Bearing
400
351M, 400
(No 1)
2.1238-2.1248
(No 2)
2)
(No 3)
2.0655-2.0665
2.0505-2.0515
4)
(No 4)
2.0355-2.0365
(No 5)
5)
2.0205-2.0215
(No
(No 1)
1)
0.040-0.060
Camshaft
Bearings
Inside
InSide
Diameter
Bearing
Bearing
400
351M, 400
(No 1)
2.1258-2.1268
(No 2)
2)
INc
(No 3)
3)
2.0525-2.0535
(No 4)
4)
(No 5)
5)
2.0375-2.0385
2.0225-2.0235
2.067~-2.0685
2.0675-2.0685
3%
4 Quarts
Quarts
31/2 Quarts
Quarts
351M, 400 \
351M,400
\
CD
0 Add
Add 11 quart
quart with
with filter
filter replacement.
replacement.
0 Timing
Timing Chal'l
Chan Deflection
Deflection (MaXimum)..
(Maximum)
0.500
CD
.... .. ....... . .0.500
|ournal maximum runout ..
. .... 0.005
. ....
(2) Camshaft Journal
|ournal maximum out-of-round ........... .. . . 0.0005
Camshaft /ournal
(3) Distance In
in inches that the
the bearing ISis installed towards the
the rear
~
the front face
face of the
the cylinder block.
block.
from the
CYLINDER BLOCK
Cylinder Bore Diameter CD0
Engine
351M
4.000-4.0036
400
4.000-4.0048
0
CD
Max
mum-out-of-round . . . . . . ...
Maxlmum-out-of-round.
Limit .
Wear Limit.
Wear
nder
bore surface finish RMS..
RMS
Cyl
Cylinder
Main Bearing
Bore Diameter
Cylinder Block
Distributor Shaft
Head
Head Gasket
Flatness (2)
7
Surface flatness
Crankshaft To
To Rear
Face Of
Of Block
Runout TI
RMax
Max
TIR
0.8752-0.8767
3.1922-3.1930
0.5160-0.5175
0.003 inch in
in any
any
or 0.006
6 inches or
inch overall
0.005
....
.....
. ...
. ..
. ..
. . ..
0.0015
0.005
0.005
18-38
18-38
Taper Wear Lim

Limitit ................................ 0.010
.60-150
60-150
Q) Head
Head gasket sur
(2)
surface
ace ftnlsh
finish RMS..
RMS . ....
AND FLYWHEEL
CRANKSHAFT AND
Engine
Main Bearing
Journal
Diameter (T)
CD
Main Bearing
Journal Runout
Maximum (2)
<%>
351M
2.9994-3.0002
0.002
400
0CD Main beaflng
bearing lournal
journal ollt-of-round
Main Bearing
Journal
Thrust Face
Runout
Main Bearing
Journal
Taper Max
Max
Thrust
Bearing
Journal
Length
0.001
0.0006 Per
Per Inch
1.137-1.139
Main Bearing
Surface Finish
RMS Maximum
Journal
12
(2) Wear Limit - 0.005.

(2)
Thrust Face
20 Rear
25 Front
CRANKSHAFT
CRANKSHAFT AND
AND FLYWHEEL (Continued)
Engine
Connecting Rod
Rod
Journal Diameter <D
0
Connecting Rod
Rod
Bearing Journal
Maximum Taper
Crankshaft Free
End Play <%>
(2)
2.3103-2.3111
0.0006 Per
Per Inch
0.004-0.008
0.004-0.008
351M,
351 M, 400
0(]) Connecting rod

rod out-ot-round maximum 0.0006

(T.I.R.)
Automatic Transmission
0.060
(2) Wear Limit - 0.012.

(2)
CRANKSHAFT
CRANKSHAFT BEARINGS
Connecting Rod
Rod Bearings
Main Bearings
Engine
Desired
Allowable
Wall Thickness
Standard
351M,
351 M, 400
0.0008-0.0015
0.0008-0.0015
0.0008-0.0026
0.0008-0.0026
0.0622-0.0625
0.0622-0.0625
CD
To Crankshaft
Desired
0.0008-0.0015
0.0008-0.0015
Allowable
0.0008-0.0026
0.0008-0.0026
Wall Thickness
Standard
CD
0.0957-0.0962
0.0957-0.0962
0CD 0.002 Undersize Thickness ...........Add

CA1309D33
CA1309-D
BACK TO GROUP INDEX

351
M and 400 CID v-a
351M
V-8 Engines
21-22-27
21-22-27
CONNECTING ROD
ROD
Piston Pin
Pin
Bore or
Bushing
Engine
0
<D
ID
Connecting Rod
Rod
Assembly
(Assembled To
Crankshaft)
Limit
Side Clearallce
Clearance
I Wear limIt
Connecting Rod
Rod
Alignment
Maximum Totll
Total
Difference ()

Connecting
Length
Rod length
Center
To Center
Connecting
Rod Bearing
Diameter
Bore Dilmeter
(j)
(D
351M
6.5785-6.5815
0.9734-0.9742
2.4361-2.4369
400
rod bearing bore maximum out-of-round and taper .................0.0004
0.0004
Connecting rod
Twist
Bend
0.024
0.012
0.010-0.020
0.023
~
(2) Pin
Pin bushing
bushing and
andcrankshaft
crankshaftbearing
bearingbore
boremust
mustbe
beparallel
paralleland
andininthe
thesame
samevertical
verticalplane
plane
within the
the specified total difference at ends of 8-inch long bar measured 4 inches on
on each
side of rod
rod centerline.
PISTON
< CZ>
Diameter <D
Engine
351M
Coded
Red
3.99823.9988
3.99944.0000
4.00064.0012
400
Piston Pin
Pin
Bore
Diameter
Piston To
Cylinder Bore
Clearance
0.003
Oversize
Coded
Blue
0.0022
Ring Groove Width
0.9754-0.9757
Ring
0.080-0.081
Upper Compression Ring......
.... . ...0.080-0.081
Lower Compression Ring..............0.080-0.081
Ring
0.080-0.081
Ring
0.1880-0.1890
Oil Ring...........................0.18800.1890
<V
0 to
CD Measured at the
the piston pin
at 90
90
to the
the pin
pin bore.
bore.
- 4.0018-4.0024/400
CID Only)
(2) Coded yellow
yellow-4.0018-4.0024
(400 CID
PISTON RINGS
Side ClearallCl
Clearance
Ring Width
Compreaion
<D
Compression Ring (J)
Compression Ring
Engine
Top
Top
351
M, 400
351M,
0.077-0.078
Bottom
Top
Top
0.077-0.078
0.002-0.004
<D Wear Limit .............. 0.006
Ring Gap Width

Compression Ring
Bottom
Oil
Oil
Ring
Top
Top
0.002-0.004
Snug
0.010-0.020
(2) Steel Rail
Bottom
Oil Ring
(2)
(2)
0.01
0-0.020
0.010-0.020
0.015-0.055
0.0150.055
PISTON PIN
Engine
EnliM
Length
length
Diameter
Standard
To Piston
Clearance
Connecting
To Connecti,.
Rod Clearance
351M
400
3.150-3.170
0.9740-0.9754
0.0003-0.0005
Interterence
Interference Fit
OIL PUMP
Oil
Engine
351M,400
RotorType
Rotor-Type Oil
Pump Relief Valve
Spring Tension
Lbs @ Specified
Specified
Lbs.
Length
length
20.6-22.6@ 2.49
2.49
BACK TO GROUP INDEX
Shaft
Drive Sh.h
To Housing
Be.ring
Bearing
Clearance
Cle.rance
Relief V.Iv.
Valve
Clear.nce
Clearance
0.0015-0.0030
0.0015-0.0030
Rotor Assembly
End Clearance
0.004 Max.
Max.
Outer Race
To Housing
(Radial
Clearance)
0.001-0.013
CA1309D4
CA1309D4

351
M and
351M
and 400
400 CID
CID v-a
V-8 Engines
21-22-28
21-22-28
TORQUE LIMITS
L I M I T S-- FFTLBS
T-LBS
Engine
351M-2 V, 400-2V
351M2V,4002V
Item
Engine
351M-2V,
400-2 V
351
M2V, 4002V
9-12
Step 11
75
70-90
Step 22
95-105
Crankshaft Pulley to Vibration Damper (Bolt)
35-50
Item
Cylinder Head Bolts
Panto
Oil Pan
to Cylinder Block
11-13(5/16x
1 1 - l 3 ( 5 / 1 6 x 18)
Rod Nuts
Connecting Rod
40-45
7-9 (1/4
( 1 / 4 x 220)
0)
Valve Rocket Arm Cover
~5
3r5
17-25 (5/16
(5/16 Bolt)
Fuel Pump to Cylinder Block
Nut 14-20
Bolt 10-15
Rocker Arm Bolts to Cylinder Head
18-25
Water Pump Bolts to Cylinder Block
12-18
EGR
EG
R Valve to Carburetor Spacer
12-18
22-32 (3/8 Bolt)

18-24
Water Outlet Housing
12-18
Distributor Vacuum Control Valve (PVS)
10-15
75-85
MISCELLANEOUS TORQUES - FT-LBS
Main Bearing Cap

Cap Bolts
1/2=95-105
1/2=95-105
10-15
3/8=35-45
15-20
45-57
24-40
Oil Pan
Pan Drain Plug
15-25
Oil Pump Cover Plate
9-12
15-20
20-30
35-45
Oil Filter to Block Cartridge Type
With oil on
gasket surface,
hand tighten ununtil gasket contacts
adapter face,
face, then
1/2 turn
tighten 112
more.

Thermactor Adjusting Arm to Cylinder Block
22-32
in-lb
130-180 in-Ib
Fan to
to Water
Water Pump Hub
Hub
Power Steering
Steering Pump
Pump Pulley
Pulley to
to Damper
Damper
Power
35-50
Carburetor Mounting
Mounting Nuts
Nuts
Carburetor
12-15
Water Pump Bolts to Front Cover
12-18
Carburetor Mounting
Mounting Stud
Stud to
to Intake
Intake Manifold
Manifold
Carburetor
4-7
4-7
40-45
Fuel Filter
Filter to
to Carburetor
Carburetor
Fuel
80-100 in-Ib
in-lb
15-20
12-18
CA13090
CA1309-D55
FT-LBS
STANDARD TORQUE LIMITS - FTLBS
Pipe Thread Sizes
U.S. Thread Sizes

1/4
- 20 = 6-9
1/4-20
5/16 - 18
12-18
5/1618 = 12-18
24 = 27-38
3/8 - 24
7/16-14 = 45-57
7/16-14
5/16-24
= 14-20
5/16
- 24 =
14-20
7/16-20
7/16
- 20 = 40-60
1/2
- 13 =
1/2-13
= 55-80
3/8-16
= 22-32
3/8
- 16 =
1/8 = 5-8
1/4 = 12-18
12-18
3/8 = 22-33
1/2 = 25-35
Standard torque limits listed in this chart are

are applicable for all
all other
the special torque charts.
functions not shown in the
1
CA1449-B
CA'449B'
BACK TO GROUP INDEX

21-24-1
21-24-1
21-24-1
21-24-1
460 CIO
CID V-8 Engines
v-a
PART 21-24 460 CID

CIO V-8
Engines
Applies To Ford, Meteor, Mercury, Thunderbird, Torino, Elite, Cougar,
Montego, lincoln
Lincoln Continental and
and Continental Mark IV
COMPONENT INDEX
COMPONENT
CAMSHAFT
CAMSHAFT BEARINGS
CAMSHAFT REAR BEARING
BORE PLUG
CONNECTING ROD BEARING
Description . . . . .. .
Description.
CRANKSHAFT
CYLINDER ASSEMBLY
CYLINDER BLOCK
CYLINDER FRONT COVER .AND
AND
TIMING CHAIN
CYLINDER HEADS
ENGINE
Description
and Installation
Removal and'
nstallation
ENGINE REAR SUPPORTS
SYSTEM
Descriotion
Description
BACK TO GROUP INDEX
COMPONENT INDEX
COMPONENT
Page
Page
24-12
.
24-18
24-13
24-15
.
.
24-2
24-5
EXHAUST MANIFOLDS
FL
YWHEEL
FLYWHEEL
FRONT OIL SEAL
INTAKE MANIFOLD
24-17
24-15
24-21
24-21
24-21
24-21
.
.
.
24-10
OIL
Ul L PAN
rAN
OIL PUMP
24-2
24-19
24-13
24-20
24-14
24-20
SPECIFICATIONS 1976
..
24-26
24-19
24-7
AND ROCKER ARM
SPECIFICATIONS 1975
24-2
24-2
24-4
24-15
24-16
24-22
24-7
HAM
VALVE LIFTER
24-3
24-12
OIL FILTER
FILTER
24-19
24-8
24-13
MAIN BEARING

.
.
24-9
Oil
Page
Page
WATER PUMP
24-5
24-10

21-24-2
v-a
21-24-2
460 (10
CID V-8 Engines
NOTE: The
The infonnation
information in
1976 Illodel
CR1966A
CR1966-A
DESCRIPTION
ENGINE
The 460
460 V-8
V-8 engine (Fig.
(Fig. 1)
1) is
is aa
lightweight
lightweight cast
cast iron
iron design.
SYSTEM
and
the exhaust
on this
emission control devices used on
are covered in
29 and
and
engine are
in Group 29
50 of
of this Manual.
Group 50
SYSTEM
The 460
460 V-8
V-8 engines have aa positive
recycling the
the crankcase vapors to
to the
the
intake manifold.
A2976-B
FIG. 1
1 3/4
3/4 Left Front View-460 CIO
CID Engine

or bolts that
be torqued (refer
(refer to
to torque
must be
specifications), oil the threads with lightDo not oil threads that
weight engine oil. Do
or water-resistant
require oil-resistant or
sealer.
Refer to
to Part 21-01
21-01 for
for Cleaning,
Inspection and
and Test procedures.
ENGINE
The engine removal and
and installation
are for
for the
the engine only
procedures are
the transmission attached.
without the
Remove or disconnect Thermactor parts
interfere with removal or
that will interfere
or
of the
the engine.
engine.
installation of
Removal
1. Raise the hood and mask the edges of
1.
the hood, fenders and cowl to
to protect
the paint. Place fender covers on
on
fenders.
2.
2. Remove the
the hood.
the cooling system at
at the
3. Drain the
the
radiator and
and the
the cylinder block.
4. Disconnect the ground cable from the
battery. Remove the
and
the air
air cleaner and
the
intake duct assembly. Cover the
carburetor air horn with a clean cloth.
cloth.
5.
and
5. Disconnect the
the radiator upper and
BACK TO GROUP INDEX
engine. Disconnect
lower hoses at the engine.
the transmission oil cooler lines at the
radiator.
6.
6. Remove the
the fan
fan shroud attaching
bolts.
7. Remove the
the cooling fan-to-water
fan-to-water
7.
pump hub
hub attaching bolts.
bolts. Remove
the cooling fan
fan and
and the
the shroud.
8.
8. Remove the
the radiator upper support
the radiator.
and the
9.
9. If equipped with air
air conditioning,
purge the
the system of
of freon. Remove
at the
the air
air conditioner
the clamp bolt at
muffier
and
muffler support if so
so equipped and
position the
the refrigerant
refrigerant lines out
out of
of
the way.
Loosen the compressor adjustment
adjustment
and remove the
the drive belt. Remove
the
t h e compressor
c o m p r e s s o r support
support
bracket-to-water pump bolt. Remove
the compressor-to-mounting bracket
the power steering
bolts. Remove the
and position it
it to
to one
one side.
pump and
the compressor clutch
Disconnect the
and remove the
the compressor.
wire and
the compressor mounting
Remove the
and idler pulley.
bracket and
10. Disconnect
Disconnect the
thefuel
fuel inlet
inlet line
line at
at the
the
10.
fuel pump.
to
pump. Plug or
or cap
cap the
the line to
prevent fuel loss.

loss. Disconnect the
the fuel
return line.
11. Loosen the
arm
the alternator adjusting arm
and mounting bolts. Remove the
the
drive belts and
and water pump pulley.
Remove the alternator and
and mounting
brackets and
and position out
out of
of way,
way,
leaving the
the wires connected.
12.
12. Disconnect
Disconnect the
the ground
ground cable
cable at
at the
the
of cylinder block.
right front corner of
hoses. Remove
Disconnect the heater hoses.
the transmission fluid filler tube
the right valve
attaching bolt from the
arm cover, and
and position the
rocker arm
the
transmission filler tube out
out of the
the
way.
way.
13. Disconnect
Disconnect all
all vacuum
vacuum lines
lines at
at the
the
rear of
of intake manifold.
14.
14. Disconnect
Disconnect the
the speed
speed control
control cable
cable atat
carburetor and
and bracket, if so
carburetor
so
equipped. Disconnect the
the accelerator
and secure
and transmission, cable and
way.
out of way.
Disconnect the
the engine
engine wiring
wiring harness
harness
15. Disconnect
at the
the multi-connector on
on dash.
16.
Raise the
16.Raise
the vehicle on
on aa hoist.
hoist.
the inlet pipes at
Disconnect the
at exhaust
manifolds.
17.
17. Disconnect
Disconnect the
the starter
starter cable
cable from
from
21-24-3
starter solenoid or starter. Remove
starter attaching bolts and remove
starter by
by moving starter assembly
forward, rotating it to turn solenoid
outward, then removing it toward
rear of vehicle.
vehicle.
18.
18. Remove
Remove access
access cover
cover from
from converter
converter
housing.
housing. Remove the flywheel to
converter attaching nuts,
nuts, rotating the
flywheel
flywheel as
as necessary. Remove the
converter-to-engine lower rear cover
plate attaching bolts.
19.
19. Remove
Remove the
the nuts
nuts attaching
attaching the
the front
front
support insulators to the underbody
crossmember.
20.
20. Hold the transmission in position
with a support tool.
21.
21. Lower the vehicle on hoist.
hoist. Remove
converter housing to cylinder block
upper attaching bolts (left side).
Disconnect the coil wire,
wire, and remove
the coil and bracket assembly from
manifold.
22.
22. Attach
Attach an
an engine
engine lifting
lifting sling,
sling, Tool
Tool
No.
No. T53L-300-A,
T53L-3OO-A, hoist and lifting
lifting
brackets to intake manifolds.
manifolds.
Carefully remove engine from the
vehicle.
vehicle. Install the engine on a work
stand and remove the lifting sling.
Installation
Installation
1.
1. Attach engine lifting sling,
sling, Tool No.
T53L-300-A,
T53L-3OO-A, hoist and lifting
lifting
brackets to intake manifolds. Remove
engine from work stand.
2.
2. Carefully lower engine into vehicle.
With engine supported by lifting
lifting
sling, align converter- to-flywheel
to-flywheel
mounting studs with flywheel.
flywheel.
Position the engine support insulator
heat shields,
shields, then lower the engine,
guiding the front support insulator
studs into holes in underbody
underbody
crossmember.
3.
3. Install
Install the
the converter
converter housinghousingto-cylinder
to-cylinder block
block upper
upper attaching
attaching
bolts
bolts and
and torque
torque to
to specification.
specification.
Remove
Remove the
the transmission
transmission support.
support.
Position
Position the
the hoist
hoist out
out of
of the
the way
way and
and
remove
remove lifting
lifting sling.
sling.
4.
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.
specification.
5.
5. Install the nuts on covertercoverterto-flywheel mounting studs and
torque nuts to specification. Install
converter access plate.
6.
6. Install the starter and connect starter
cable.
cable.
7.
7. With gaskets in place on inlet pipes,
guide pipe ends into exhaust manifold
flanges.
flange studs
flanges. Install nuts on flange
and torque to specifications:
specifications;
8.
8. Lower the vehicle on a hoist and
connect accelerator and transmission
cable.
cable. Connect engine wiring harness
at multi-connector at dash.
dash.
BACK TO GROUP INDEX
460 CIO
CID v-a
V-8 Engines
9.
of
9. Connect all vacuum lines at rear of
intake manifold. Connect speed
control cable, if so equipped, to
carburetor linkage and bracket.
10.
10. Con
C o n n e c tthe
h e ate
a t e rrho
h o s e s.
s . Set
Set
transmission filler tube in position
and tighten bolt at right valve rocker
arm cover to secure tube.
11. Connect
Connect ground wire
wire to
to right front
front
corner of cylinder block. Install
alternator and mounting brackets.
12.
12. If
If equipped
equipped with
with air
air conditioning,
conditioning,
install the compressor
compressor upper
mounting bracket to left cylinder
head. Position the air conditioner
mumer
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
Connect the
the fuel
fuel inlet
inlet line
line and
and fuel
fuel
return line to the fuel pump. Install
the coil to intake manifold
manifold and
connect wires.
14.
14. If
If equipped
equipped with
with air
air conditioning,
conditioning,
connect
connect the service valves to
compressor and install air conditioner
mumer.
muffler.
15.
15. Set
Set radiator
radiator in
in position
position and
and install
install the
the
radiator upper support. Install the
radiator upper and lower hoses.
Connect the oil cooler lines to
radiator.
16.
16. Fit
Fit the
the water
water pump
pump pulley
pulley in
in position.
position.
Install all drive belts.
17. Place
Place fan
fan assembly
assembly inside
inside radiator
radiator
17.
shroud and position the shroud.
Install fan assembly to water pump
hub and torque bolts to specification.
Install the shroud attaching bolts.
18.
18. Fill
Fill the
the crankcase,
crankcase, cooling
cooling system
system and
and
power steering reservoir to the correct
level with specified lubricants. Adjust
tension of
of drive belts to
the tension
specification.
19.
19. Connect
Connect the
the distributor
distributor and
and vacuum
vacuum
lines.
lines. Install the air cleaner and intake
duct, crankcase ventilation system air
supply hose and oil filler cap.
20.
20. Connect
Connect the
the battery.
battery. Start
Start the
the engine
engine
21. When engine temperature stabilizes,
adjust the ignition timing, engine idle
speed and mixture, and transmission
linkage, as required.
22.
22. If
If equipped
equipped with
with air
air conditioning,
conditioning,
recharge the system
hood. Remove the masking
23. Install the hood.
tape and fender covers.
(Figs. 2 through
through 4)
4) are
are
Front supports (Figs.
located on each side of the cylinder block.
Following procedures apply to either
support.
21-24-3
Ford and Mercury
Removal
Removal
1.
Block rear
rear wheels
wheels and
and set
set parking
parking
1. Block
brake. Raise front of vehicle with aa
floor jack and install safety stands.
floor
of
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
just enough to support
support the
jack
engine.
3. Remove the nut and through bolt that
attaches the front support insulator to
2).
the lower support bracket (Fig. 2).
SHIELD
6C050 L.H.
6D037 L.H. (1976)
6C038 R.H.
'NOTE: WHENEVER SELF-LOCKING

BOLTS AND NUTS ARE REMOVED, THEY MUST BE REPLACED WITH NEW SELFLOCKING BOLTS AND NUTS.
A2979-F
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
Installation
1. Position the support insulator and the
1.
heat shield to cylinder block (Fig. 2).
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
jack and wood block.
Torque
h r o u g h bolt
Torque the
the tthrough
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.
Lincoln Continental
Removal
Removal
1. Block rear wheels and set parking
1.
brake. Raise front
front of vehicle and
install safety stands.
2. Remove through bolts and nuts
which attach insulator assembly to
number 2 crossmember.
v-a Engines
460 CID V-8
21-24-4
UPPER BRACKET ASSEMBLY

/6A069-L.H.l
(6A069-L.H.)
/6043-R.H.)
(6043-R.H.)
383232-S2*
35-60 FT-LB
SHIELD
SHIELD 6C050
6C050
(LEFT SIDE ONLY

/(LEFTSIDEONLY
/, U\
"V
~!~,~ ~5849-S2
j"
'~\\~)
35-50 FT-LB
6C060 L.H.
6C010 R.H.
\),
SUPPORT INSULATOR ASSEMBLY /6B032

(6B032 L.H.)
L.H.)
(6038 R.H.)
R.H.)
/6038
385849-S2
HEAT SHIELD ASSEMBLY

(6D037 L.H.)
(6D036R.H.)
~ ~ 382400-S2*
-'<:J'
\Ni
35-50 FT-LB
NO. 2
CROSSMEMBER REF.
NOTE: WHENEVER SELF-LOCKING

SELF-LOCKING
*NOTE:
BOLTS AND NUTS ARE REMOVED, THEY MUST BE
BE REPLACED WITH NEW SELFLOCKING BOLTS AND NUTS.
*NOTE:
56775-S2
A3281-D
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
1-1
/2 inches) to provide clearance to
remove the support and not damage
the radiator.
4. Remove the bolts that attach the
4.
support bracket to the cylinder block
(Fig. 3).
(Fig.
5. Remove the bracket-to-insulator
bracket-to-insulator
5.
attaching bolt and separate the units.
Installation
InstsJ/ation
1. Position the support bracket on the
1.
support insulator (Fig. 3) and install
and torque the attaching nut to
specifications.
2. Install insulator and bracket assembly
2.
to engine block with three attaching
specification.
bolts and torque to specification.
3. Lower the engine.
4.
4. Install and torque the through bolt
attaching insulator to the number 2
crossmember.
Torino,
Torino, Elite, Montego, Cougar,
Thunderbird and Continental
Mark IV
RemoysJ
Removal
1.
screws.
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
insulator to upper
(Fig. 4).
bracket attaching nuts (Fig.
5.
5. If required, the upper bracket can
now be removed by removal of the
three screws holding the bracket to
the cylinder
cylinder block. Whenever
self-locking mounting bolts and
and nuts
are removed, they must be replaced
with new self-locking bolts and nuts.
Installation
InstlllJstion
1.
1. Position the upper bracket to the
BACK TO GROUP INDEX
21-24-4
THROUGH BOLT
DIRECTION OF BOLT
ODTIONAL
WHENEVER SELFLOCKING
SELF-LOCKING
BOLTS AND NUTS ARE REBE REMOVED, THEY MUST BE
PLACED WITH NEW SELFLOCKING BOLTS AND NUTS.
#2 CROSSMEMBER
A3499-D
FIG. 4 Engine Front Support-Torino, Elite,

Elite, Montego, Cougar, Continental Mark
IV and Thunderbird
2.
2.
3.
4.
5.
5.
cylinder block, install the three

attaching screws and torque to
specification.
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.
Lower the engine until the locator
stud in the insulator engages the
locator
l o c a t o r hhole
o l e in tthe
h e frame
frame
crossmember.
Install the through bolt and locking
nut. Torque the locking nut to
specification.
Remove jack and wood block. Install
fan shroud attaching screws and
specification.
torque to specification.
ENGINE REAR SUPPORT

Meteor and Mercury
Mercury
Ford, Meteor
RemoysJ
Removal
1.
1. Remove the insulator assembly to
crossmember attaching bolt(s) and
nut(s) (Fig.
(Fig. 5).
2. Raise the transmission with a jack to
obtain clearance at the transmission
extension housing. Then, remove the
retainer and insulator assembly
washers. Remove
mounting bolts and washers.
the insulator
insulator assembly and the
retainer.
InstsJ/ation
Installation
1.
1. Position the insulator assembly and
retainer; then install the mounting
bolts and lock washers. Torque the
specification.
2. Lower the transmission. Install the
2.
insulator assembly to crossmember
nut(s). Torque
attaching bolt(s) and nut(s).
them to specification.
Thunderbird and Continental
Mark IV
RemoysJ
Removal
(Fig. 6).
crossmember attaching nuts (Fig.
2. Raise the transmission with a jack to
2.
obtain clearance and remove the
insulator
insulator to extension housing
insulator assembly.
Installation
Insta//ation
1. Position the insulator assembly and
1.
install the insulator to extension
housing
h o u s i n g bolts.
b o l t s . Torque
T o r q u e to
to
specification.
2.
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.
Torino,
Torino, Elite,
Elite, Montego and
Cougar
RemoyBl
Removal
1.
1. Support the transmission with a floor
floor
jack to remove weight from the
INSULATOR
ASSEMBLY6068
386454-S2
25-40 FT-LB
(DIRECTION OF
BOLT OPTIONAL)
34794-S2
(2 REO'D.1
304726-S:L "'.:.
40-60 FT-LB
(2
REO'D:~t:":'"
;.
:_,~,~~\3138~C
A3138-C
FIG. 5 Engine Rear Support Ford,

Meteor and Mercury
v-a
21-24-5
21-24-5
460 CID
CID V-8 Engines
Engines
460
Remove the
the nuts
nuts attaching
attaching the
the
2.2. Remove
a s s e m b l y to
to the
the
insulator
crossmember (Fig.
(Fig. 7).
7).
crossmember
) );J
REAR SUPPORT
SUPPORT
REAR
INSULATOR
INSULATOR
6B002 ASSEMBLY
ASSEMBLY
6B002
386242-S100*
~, 2030 FT-LB
,
~ I~,
~t "'~J,
WASHER T \\~~' 383421-S2
: -i
#3 CROSSMEMBE
CROSSMEMBER
#3
R
382400-S2*
30-50 FT-LB
' '"
~
INSULATOR-6A061
INSULATOR
-6AD6'
SPACER --386510-S2
SPACER
386510-S2 -.;~
*382802-S2 ~
*382802S2
20-35 FT-LB
FT-LB
20-35
~
NOTE: WHENEVER
WHENEVER SELFLOCKING
SELF-LOCKING
*NOTE:
BOLTS AND
AND NUTS
NUTS ARE
ARE REREBOLTS
MOVED,
THEY
MUST BE
BE RE
REMOVED, THEY MUST
PLACED WITH
WITH SELF-LOCKING
SELF-LOCKING
PLACED
BOLTS AND
AND NUTS.
NUTS.
BOLTS
A2980-F
FIG. 6 Engine Rear

Support-Continental Mark IV
Thunderbird
and Thunderbird
'" ,
INSULATOR-6068
INSULATOR
- 6068'
NO. 3 CROSSMEMBER
NO.3
34794-S2
34794-52
&
'\
304726 40-60 FT-LB
&1"---
~\ \.'~:J,~---
~~
"' ....
~-=
.~"~
40-60 FT-LB
45359-S2
(2 REO'O.1
REQ'D.)
45359S212
35-45
3545 FT-LB
FT-LB BEFORE
BEFOR~~
CRIMPING,
40-80 '- " "'
CRIMPING,40-80
AFTER
AFTER CRIMPING.
CRIMPING.
II
56604-S2
56604-S2 REF.
REF.
22 REQ'D.
REO'D.
379297-S2
379297-52 REF.
REF.
22 REQ'D.
REO'D.
~~2,
~
~ ~
NOTE:
'NOTE,
j)
j/
--../''
~"""""""-;2REO'O'
/'
~S(-
70-100 FTLB
WHENEVER
WHENEVER SELFSELF"
LOCKING
LOCKING BOLTS
BOLTS AND
AND
NUTS
ARE
REMOVED,
NuTS ARE REMOVED,
THEY
THEY MUST
MUST BE
BE REREPLACED
PLACED WITH
WITH NEW
NEW
SELF-LOCKING
SELFLOCKING
BOLTS
AND NUTS.
NUTS.
BOLTS AND
A3283-F
A3283F
FIG.
FIG. 77 Engine
Engine Rear
Rear Support-Torino,
Support-Torino,
Elite,
Elite, Montego
Montego and
and Cougar
Cougar
3.
3. Remove
Remove or
or loosen
loosen the
the bolts
bolts attaching
attaching
the
the supporting
supporting crossmember
crossmember for
for
repositioning
repositioning or
or removal
removal as
as necessary
necessary
to
to remove
remove the
the insulator
insulator assembly.
assembly.
4.
4. Remove
Remove the
the bolts
bolts and
and washers
washers that
that
attach
attach the
the engine
engine rear
rear insulator
insulator to
to the
the
transmission.
transmission.
5.S. Remove
Remove the
the insulator
insulator assembly.
assembly.
BACK TO GROUP INDEX
21-24-5
21-24-5
Installation
Instlll/ation
Whenever
mounting
bolts and
andnuts
nuts are
are removed,
removed, they
they must
must be
be
bolts
replaced with
with new
new self-locking
self-locking bolts
bolts and
and
replaced
nuts.
nuts.
1.1. Position
Position the
the engine
engine rear
rear insulator
insulator
assembly
assembly in
in place
place beneath
beneath the
the
transmission.
transmission. Install
Install the
the attaching
attaching
bolts
bolts and
and washers
washers and
and torque
torque to
to
specification.
specification.
2.
2. Position
Position the
the supporting
crossmember.
Install and
and tighten
tighten the
the bolts
bolts to
to proper
proper
Install
torque specification.
specification.
torque
3. Install
Install the
the nuts
nuts attaching
attaching the
the
3.
a s s e m b l y to
to the
the
insulator
crossmember.
crossmember.
4. Remove
Remove the
the floor
floor jack.
jack.
4.
CRANKCASE
VENTILATION
SYSTEM
SYSTEM
Removal
Remoylll
1.1. Remove
Remove ventilation system air intake
hose from air cleaner.
cleaner. Remove
Remove the
the
hose
hose, elbow and grommet from the
hose,
cover.
left rocker arm cover.
2. Remove
Remove air cleaner and intake duct
2.
assembly.
assembly.
3.
3. Disconnect the inlet vent hose
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
filler cap as an
assembly.
assembly.
4. Pull regulator valve out of mounting
grommet in right valve rocker arm
cover.
Installation
Insta//ation
1. Install the oil filler cap. Insert the
1.
regulator (PCV) valve into the right
rocker arm cover grommet. into
2. Position the inlet vent hose and
tube
tu be and connect to carburetor
carburetor and
regulator valve.
3. Install air cleaner and intake duct
assembly.
4. Install ventilation system air intake
hose and elbow to air cleaner
cleaner and oil
oil
filler cap.
filler
cap.
VALVE
VALVE ROCKER
ROCKER ARM
ARM COVER
COVER
AND
RM
AND ROCKER
ROCKER A
ARM
The valve
valve rocker
rocker arm
arm and
and attaching
attaching
The
parts
8.
parts are
are shown
shown in
in Fig.
Fig. 8.
Removal
Remoylll
1. Remove
Remove the
the air
air cleaner
cleaner and
and intake
intake
1.
duct assembly.
assembly.
duct
right cylinder
cylinder head
head rocker
rocker arm
arm
IfIf aa right
is
is to
to be
be removed,
removed, remove
remove the
the
crankcase
ventilation regulator
regulator valve
valve
from
from the
the valve
valve rocker
rocker arm
arm cover.
cover.
2. Disconnect
Disconnect the
the spark
spark plug
plug wires
wires from
from
2.
the spark
spark plugs
plugs by
by grasping,
grasping, twisting
twisting
the
and pulling
pulling the
the moulded
moulded cap
cap only
only
and
with Tool
Tool T74P-6666-A.
T74P-6666-A. Remove
Remove the
the
with
wires from
from the
the bracket
bracket on
on the
the valve
valve
wires
rocker arm
arm cover(s)
cover(s) and
and position
position the
the
rocker
wires
wires out
out of
of the
the way.
way.
A3236-B
FIG.
FIG. 88 Rocker
Rocker Arm
Arm and
and Attaching
Attaching
Parts
Parts
3.
3. Remove the valve rocker arm
arm
cover(s).
cover(s).
4.
4. Remove
Remove the valve
valve rocker arm bolt,
bolt, oil
deflector, fulcrum seat and rocker
arm.
arm.
Instlll/ation
Installation
1.
top of the valve stems,
stems, the rocker arm
and fulcrum seats.
2.
2. Position the No.
No. 1 piston on TDC at
the end of the compression stroke in
position 1 in
in Fig. 9 and install the
rocker arm, fulcrum seat, oil deflector
and bolt on the following valves:
No.
No.44 Exhaust
No. 8 Intake No.
crankshaft in position
Position the crankshaft
2 in Fig. 9 and install the rocker arm,
deflector and bolt on
fulcrum
No.55 Intake No.
No.66 Exhaust
No.
crankshaft in position
Position the crankshaft
3 in Fig. 9 and install the rocker arm,
deflector and bolt on
on
fulcrum
valves:
No.2
No.
2 Intake No. 3 Exhaust
No.33 Intake No.
No.7
Exhaust
No.
7 Exhaust
No.6
No.88 Exhaust
Exhaust
No.
6 Intake No.
Be sure that
that the
the fulcrum seat base
base
Be
is inserted
inserted in
in its
its slot on
on the
the cylinder
cylinder
is
head before
before tightening
tightening the
the fulcrum
fulcrum
head
bolts. Tighten
Tighten the
the fulcrum
fulcrum bolt
bolt to
to
bolts.
specification. Check
Check the
the valve
valve
specification.
clearance following
following the
the procedures
procedures in
in
clearance
Part 21-01
21-01 under
under Valve
Valve Clearance
Clearance
Part
Adjustment.
Adjustment.
Clean the
the valve
valve rocker
rocker arm
arm cover(s)
cover(s)
3.3. Clean
and the
the cylinder
cylinder head
head gasket
gasket
and
surface(s). Position
Position the
the new
new gasket
gasket in
in
surface(s).
the cover,
cover, making
making sure
sure that
that the
the gasket
gasket
the
tangs are
are secured
secured in
in the
the notches
notches in
in the
the
tangs
cover.
cover.
4. Position
Position the
the cover(s)
cover(s) on
on the
the cylinder
cylinder
4.
head(s). Make
Make sure
sure the
the gasket
gasket seats
seats
head(s).
evenly all
all around
around the
the head.
head. Install
Installthe
the
evenly
21-24-6
21-24-6
With No.1
No. 1 at
at TOC
TDC at
at end
end of
of compression
compression stroke
stroke
With
make aa chalk
chalk mark
mark at
at points
points 22 and
and 33 approximately
approximately
make
90 degrees
degrees apart.
apart.
90
v-a
21-24-6
21-24-6
460
460 CIO
CID V-8 Engines
Engines
\
\.
POSITION
POSITION 11 -- No.1
No. 1 at
at TOC
TDC at
at end
end of
of compression
compression stroke.
stroke.
POSITION
POSITION 22 -- Rotate
Rotate the
the crankshaft
crankshaft 18.0
180 degrees
degrees (one
(one half
half
revolution)
clockwise
from
POSITION
revolution) clockwise from POSITION 1.
1.
{ ; \ POSITION
POSITION 33 -- Rotate
Rotate the
the crankshaft
crankshoft 270
270 degrees
degrees (three
(three
quarter
se from
3 )
quarter revolution)
revolution) clockwi
clockwise
from
~:;.---POSITION
POSITION 2.
2.
/.
~ ~
\.!J
A
3234- C
A3234-C
FIG. 99 Position
Position of Crankshaft for Installing Valve Rocker Arms
Arms
FIG.
bolts. The cover is

is tightened in two
bolts.
e n the b 0o lIts
t s to
to
s t e p ss.. T i g h tten
later,
specification. Two minutes later,
same
tighten the bolts to the same
specification.
was removed,
If the right cover was
ventilation
install the crankcase ventilation
regulator valve.
Install the air cleaner and intake
duct assembly.
5. Install the spark plug wires in the
5.
bracket on the valve rocker arm
wires.
wires.
6.
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
seat isis not
not damaged.
damaged.
Removal
RemoysJ
1. If
If defective spring, retainer, or seal is
on right side of engine, remove air
Remove crankcase ventilation system
regulator valve and hose from right
right
valve rocker arm cover.
If
If spring, retainer, or seal to be
removed is on left
left side of
of engine,
remove oil filler cap and ventilation
hose from left
left valve rocker arm cover
and position out of
of way.
way.
2. Remove valve rocker
rocker arm cover(s)
and applicable spark plug(s).
plug(s).
3. Remove valve rocker arm bolts, oil
oil
deflectors,
deflectors, fulcrum
fulcrum seats, rocker
arms, and push
affected
push rods from
from affected
cylinder(s).
4. Install air line with adapter
adapter in spark
spark
plug
plug hole.
hole. Turn
Turn on
on air
air supply
supply to
to hold
hold
valves
valves closed.
closed.
5.
5. Install
Install Tool
Tool T70P-6049-A
T70P-6049-A (Fig.
(Fig. 10)
10)
and
and compress
compress valve
valve spring.
spring. Remove
Remove
retainer
retainer locks,
locks, spring
spring retainer,
retainer, and
and
spring.
spring. Remove
Remove and
and discard
discard valve
valve
stem
If air
air pressure
pressure
stem seal
seal (Fig.
(Fig. 11). If
BACK TO GROUP INDEX
fails to
to hold
hold valve
valve in
in closed position,
fails
valve damage
damage affecting sealing is
inspect
indicated. Remove and inspect
head assembly.
cylinder head
FIG. 10 Compressing Valve

SpringIn
Spring-In Chassis
A3246-A
FIG.
Removing or
or Installing
Installing Valve
Valve
FIG. 11 Removing
Stem
Stem Seal
Seal
6. Wrap
Wrap rubber
rubber band,
band, tape
tape or
or string
string
6.
around end
end of
of valve
valve stem
stem to
to prevent
prevent
around
valve from
from dropping
dropping into
into cylinder
cylinder
valve
is shut
shut
when air
air pressure
pressure in
in cylinder
cylinder is
when
off if piston is
is at bottom of cylinder.
cylinder.
Shut off air pressure.
pressure.
7.
7. Inspect valve stem for damage.
damage.
Rotate valve, checking tip for
for
eccentric movement. Move valve up
valve guide and check for binding.
binding. If
valve is damaged, cylinder head must
be removed for repairs.
Instlll/ation
Installation
1.
1. If valve proves satisfactory, hold
valve closed and turn on air pressure
in cylinder.
2. Lubricate the valve stems with heavy
engine oil SE.
SE. Install new valve stem
seal (Fig. 11).
11). Set spring and retainer
over valve stem. Compress valve
spring (Fig. 10) and install retainer
locks. Release spring and remove tool
and stud nut.
off air pressure and remove air
3. Shut off
line and adapter. Install spark plug.
4. Apply Lubriplate to tip of valve stem
and each end of push rod. Install push
rod. Be sure lower end of push rod is
seated in valve lifter.
fulcrum seats and sockets
5. Lubricate fulcrum
with Lubriplate or equivalent.
Lubricate the push
push rod socket,
6. Lubricate
fulcrum seat and the valve pad of
of the
fulcrum
SE.
rocker arm with heavy engine oil SE.
7. Install the rocker arms using the
procedure and sequence given under
Rocker Arm Installation.
from rocker
8. Clean gasket material from
cylinder head and
arm cover and cylinder
install the rocker arm cover, using aa
new gasket.
If the right
right cover
cover was removed,
If
install the
the crankcase
ventilation
install
regulator valve.
valve.
regulator
9. Install
Install the
the spark
spark plug
plug and
and connect
connect the
the
9.
spark plug
plug wires.
wires.
spark
assembly.
assembly.
Connect the
the automatic
automatic choke
choke heat
heat
11. Connect
chamber air
air inlet
inlet hose.
hose.
chamber
21-24-7
INTAKE MANIFOLD
RemovsJ
Removal
1.
1. Drain cooling system. Remove air
2.
2. Disconnect radiator upper hose at
engine.
engine.
3.
3. Disconnect heater hoses at intake
manifold and water pump, and
position out of way.
way. Loosen water
pump by-pass hose clamp at intake
manifold.
4.
ti ve crankcase
4. Disconnect posi
positive
crankcase
ventilation valve and hose at right
valve
cover. Disconnect
all vacuum lines at rear of intake
manifold
manifold and tag for proper
proper
installation.
5.
5. Disconnect wires at spark plugs by
twisting and pulling moulded caps
with Tool T74P-6666-A (see Part
23-01).
23-01). Remove wires from brackets
on valve rocker arm covers.
covers.
Disconnect coil high tension lead at
coil and remove distributor cap and
wires
wires as
as an assembly.
assembly.
6.
6. Disconnect all distributor vacuum
lines at carburetor and vacuum
control valve and tag for proper
installation. Remove distributor and
as an assembly.
assembly.
vacuum lines as
7. Disconnect accelerator linkage at
7.
carburetor. Remove speed control
linkage bracket, if so equipped, from
intake manifold and disconnect it
from the carburetor. Remove bolts
holding accelerator cable bracket and
way.
position cable out of way.
8. Disconnect fuel line at carburetor.
8.
9. Disconnect wiring harness at coil
9.
temperature
terminals, engine temperature
sending unit, oil pressure sending
unit, and other connections as
necessary. Disengage wiring harness
necessary.
from three clips at left valve rocker
bolts, and position wiring
arm cover bolts,
way.
harness out of way.
10. Remove
Remove coil
coil and
and bracket
bracket assembly.
assembly.
10.
Remove the Thermactor air supply
tubes and check valve from the rear
heads.
of the cylinder heads.
11. Remove attaching bolts and nuts and
11.
manifold and
and
remove intake manifold
as an assembly (Fig.
(Fig. 12).
carburetor as
to pry manifold away
If necessary to
from cylinder heads,
heads, do
do not damage
from
gasket sealing surfaces.
12. Remove
Remove and
and discard
discard intake
intake manifold
manifold
12.
seals. (See
(See Fig.
Fig. 14.)
gaskets and seals.
13.If
manifold is to be further
further
13.
If manifold
disassembled (Fig. 15), remove
coolant outlet housing, gasket, and
coolant
thermostat. Remove automatic choke
tubes, vacuum hoses,
hoses, carburetor,
heat tubes,
spacer, EGR valve and gaskets.
Remove the thermostatic choke
heater tube. Remove engine
engine
heater
unit. Discard all
temperature sending unit.
gaskets.
gaskets.
BACK TO GROUP INDEX
460 CID V-8 Engines
STANDARD EYF
BOLT 5/16-18
THREAD
A2986B
A2986-B
FIG. 12 Removing or Installing Intake

Manifold
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
manifold for cracks,
damaged gasket surfaces, or other
damage that would make it unfit for
service. Replace all studs that are
stripped or otherwise damaged. Remove
all filings and foreign matter that may
have entered the manifold as a result of
of
repairs.
repairs.
Installation
Instal/ation
1. If intake manifold
manifold assembly was
1.
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
temperature sending unit.
2. Clean mating surfaces of intake
2.
manifold, cylinder
cylinder heads, and
manifold,
cylinder block. Use a solvent such as
lacquer thinner, chlorothane,
chlorothane,
lacquer
tri-chlor-ethylene or similar
similar
tri-chlor-ethylene
degreasing agent.
3. Apply a 1/8 inch diameter bead of
of
silicone rubber sealer in and along the
joint, the full width of the cylinder
surface (4
block seal mounting surface
corners) as shown in Fig. 13.
4. Install the cylinder head to manifold
4.
gaskets and valley baffle assembly
(Fig. 14), and the front and rear
intake manifold to cylinder block
seals. Apply a 1/16 inch bead of sealer
seals.
at the outer end of each intake
manifold seal for the full width of the
(Fig. 13).
seal (Fig.
NOTE: This sealer sets up
NOTE:
up within
15 minutes after application, so
assembly should proceed promptly.
5. Carefully lower intake manifold into
5.
position over four (4) studs in ends of
heads. When
When intake
intake manifold
manifold
cylinder heads.
in place,
place, run
runfinger
fingeraround
aroundseal
sealarea
area
is in
to be sure seals are in place. If seals
have shifted, remove manifold and
reposition seals.
reposition
21-24-7
6. Install attaching bolts and nuts snugly
to manifold. Torque bolts and nuts in
specification to
sequence (Fig. 16) to specification
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.
radiator upper hose to
8. Connect radiator
coolant outlet housing.
crankshaft damper until No.
9. Rotate crankshaft
1 piston
piston is
is at
at TDC
TDC at end of
compression stroke. Position
compression
distributor in block with rotor at No.
1 firing
firing position.
position. Install hold-down
clamp.
10. Connect
Connect heater
heater hose
hose at
at intake
intake
manifold and water pump.
I1.Connect positive
positive crankcase
11.Connect
crankcase
ventilation valve and hose to right
rocker arm
arm cover
cover and
valve rocker
carburetor.
12. Connect
Connect fuel
fuel line
line to
to carburetor.
carburetor.
13. Install
Install coil
coil and
and bracket assembly to
to
intake manifold.
14. Fit
Fit wiring
wiring harness
harness into
into three
three (3)
(3) clips
clips
at inboard edge of left valve rocker
cover and connect
connect to all
arm cover
terminals.
Position accelerator
accelerator cable
cable bracket on
15. Position
manifold. Attach
Attach speed control
linkage bracket to intake manifold, ifif
so equipped. Install attaching bolts
and connect linkage to carburetor.
16. Connect
Connect the
the vacuum
vacuum lines
lines to
to their
their
respective ports on the intake
Thermactor air
manifold. Install Thermactor
supply tubes and check valve to rear
of cylinder heads.
Secure distributor
distributor cap
cap to
to distributor.
distributor.
17. Secure
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.
Fill the
the cooling
cooling system.
system.
18. Fill
19. Fill
Fill the
the power
power steering
steering reservoir.
reservoir.
20. Start engine. Check and adjust
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
normal
operating temperature, then retorque
the manifold attaching nuts and bolts
to specification.
23. Check and adjust
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
v-a
21-24-8
21-24-8
CID V-8 Engines

460 CIO
C3AZ-19526-A (OR -B) SEALER
CYLINDER
HEAD
PRESS FIRMLY
INTO BLOCK
C3AZ-19526-A (OR -B) SEALER
APPROXIMATELY .12 BEAD
2. Install push rods in original positions.

2.
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
Adjust
Rocker Arm Installation. Adjust
valve clearance.
4. Clean gasket material from rocker
arms and cylinder head and install
valve rocker arm covers.
5.
5. Install
Install intake
intake manifold
manifold and
carburetor, following the instructions
under Intake Manifold.
CYLINDER BLOCK
INTAKE MANIFOLD SEAL
A4073-A
FIG. 13 Sealing Intake Manifold with RTV Sealer

(T70P
.. 14151) to remove them.
not caused by improper valve clearance
(T70P-14151)
or by worn rocker arms and/or push
Rotate lifter back and forth to loosen
them from gum or varnish deposits.
rods.
Refer to Part 21-01
21-01 for cleaning,
Removal
RemoysJ
inspection and testing procedure.
1.
1. Remove intake manifold
manifold and
liftIf necessary to disassemble Iiftcarburetor as an assembly, following
Lifter Diser(s), refer to Valve Lifter
instructions under Intake Manifold.
assembly and Assembly in this Part.
2.
2. Remove the valve rocker arm covers.
Installation
Instlll/stion
Loosen the rocker arm bolts and tum
turn
1.
1. Clean the outside of valve lifters.
rocker arms to one side.
3. Remove the push rods in sequence.
Lifters and bores are to be lubricated
with heavy oil SE before installation.
4. Remove the valve lifters
lifters with a
Install the lifters in their original
magnet. Place them in a rack in
sequence. If the lifters are stuck in
bores. Check any new lifter for free fit
fit
in bore to which it is to be installed.
bbores,
o r e s , use pplier-type
l i e r - t y p e Tool
Tool
VALLEY COVER AND
GASKET ASSEMBLY - -
90440
9D440
MANIFOLD
. . . . - _ - - INTAKE MANIFOLD
SEAL
S E A L -- 99A425
A425
INTAKE MANIFOLD
MANIFOLD
SEAL
S E A L - 99A425
A425
-----:n~_e;~~:r;~~iil
FRONT OF ENGINE
\
FIG. 14 Installing Intake Manifold Gaskets and End
End Seals
BACK TO GROUP INDEX
A4074-A
A4074A
CYLINDER HEADS
RemoysJ
Removal
1. Remove intake manifold
manifold and
1.
carburetor as an assembly, following
procedure under Intake Manifold
Removal.
2. Disconnect muffler
muffler inlet pipe at
exhaust manifold.
3. Loosen air conditioning compressor
drive belt, if so equipped.
4. Loosen alternator attaching bolts and
remove bolt attaching alternator and
air pump bracket to right cylinder
head.
5.
5. If equipped with air conditioning
purge the system of freon. Remove
nuts attaching compressor support
bracket to water pump. Remove bolts
compressor to upper
attaching compressor
mounting bracket
bracket and remove
compressor. Remove compressor
upper mounting bracket from cylinder head.
inderhead.
If not
If
not equipped
e q u i p p e d With
w i t h air
air
conditioning, remove bolts attaching
power steering reservoir bracket to
left cylinder head. Position reservoir
and bracket out of way.
6.
6. Remove valve rocker arm covers.
Remove rocker arm bolts, rocker
arms, oil deflectors, fulcrums and
push rods in sequence (Fig. 17) so
positions.
7. Remove cylinder head attaching
7.
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
If disassembly or machining of
8.
of
cylinder head is required, remove
exhaust manifold.
Installation
InstsJ/stion
1.
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
of
v-a
21-24-9
21-24-9
21-24-9
21-24-9
460 CIO
CID V-8 Engines
Engines
460
COOLANT OUTLET
HOUSING-8594
THERMOSTAT
8575
A3241-A
INTAKE
MANIFOLD
FIG.
FIG. 18
18 Cylinder
Cylinder Head
Head Bolt
Bolt Torque
Torque
Sequence
Sequence
,t
"
WATFR TEMPERATURE
TEMPERATURE
SENDING UNIT
-10884
UNIT-10884
A2944E
A2944E
FIG. 15 Intake Manifold Disassembled
1?JL
WP
J15
7
Jfc
FIG. 17 Removing Valve Push Rod
Rod
A2932B
FIG. 16 Intake Manifold Torque

Sequence
cylinder
cylinder head
head and
and block
block gasket
surfaces. If
If exhaust
exhaust manifold
manifold was
was
removed, coat
coat cylinder
cylinder head
head and
manifold
manifold port
port areas with film
film of
of
graphite grease and install manifold
manifold
to cylinder
cylinder head.
head.
2. Place
Place two (2) long cylinder
cylinder head
head
attaching
attaching bolts
bolts in
in two
two rear
rear lower
lower bolt
bolt
holes
of left
left cylinder
cylinder head.
head. Place
Place aa
holes of
long
long cylinder
cylinder head
head attaching
attaching bolt
bolt in
in
rear
of right
right cylinder
cylinder
rear lower
lower bolt
bolt hole
hole of
head.
head. Use
Use rubber
rubber bands
bands to
to retain
retain bolts
bolts
in
in position
position until
until cylinder
cylinder heads
heads are
are
installed.
installed.
BACK TO GROUP INDEX
3. Position new cylinder head gaskets on

block over dowels. Do not apply
sealer to head gasket surfaces. Place
cylinder heads on block, guiding
cylinder
manifold studs into inlet pipe
exhaust manifold
connections. Install
Install remaining
attaching bolts (longer bolts in lower
lower
row of
of bolt
bolt holes). Tighten
Tighten all
cylinder
cylinder head
head attaching
attaching bolts in
sequence (Fig. 18) to specification.
procedure is used, it is not
not
When this procedure
necessary to retorque bolts
bolts after
necessary
extended operation.
operation.
4.
4. Clean
Clean and
and inspect
inspect push
push rods,
rods, one
one at
at
aa time. Clean the oil passage in the
push
push rods
rods with
with aa suitable
suitable solvent,
solvent, and
and
blow
out with
blowout
with compressed
compressed air.
air.
5. Install
Install push
push rods
rods in
in original
original positions.
positions.
5.
Apply Lubriplate
Lubriplate or
or equivalent
equivalent to
to
valve
valve stem
stem tips
tips and
and push
push rod
rod ends.
ends.
6.
6. Lubricate
Lubricate and
and install
install the
the rocker arms
arms
following the
the procedure under Valve
Valve
Rocker Arm installation. Be
Be sure
lower
lower ends
endsof
ofpush
pushrods
rodsremain
remainseated
seated
in
in valve
valve lifters.
7.
7. Torque catalyst or muffler inlet pipe
stud nuts to
to specification.
specification.
8.
tall intake man
ifold and
8. Ins
Install
manifold
and
carburetor assembly, following
following
procedure under Intake Manifold
Manifold
Installation.
9.
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'
upper mounting
bracket to left cylinder ,head.
head. Attach
compressor to upper mounting
mounting
bracket. Attach power steering
reservoir and compressor mounting
bracket to left cylinder head and
water pump. Connect hoses to
compressor.
If not
not eequipped
with air
If
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
to one
one side
side
of new valve rocker arm cover
of
gaskets. Lay cemented side of gaskets
in place in covers. Install covers.
12. Install bolt attaching alternator and
air pump bracket to right cylinder
Adjust alternator and air pump
head. Adjust
specification and
drive belt tension to specification
tighten attaching bolts.
If equipped with air conditioning,
13. If
adjust compressor drive belt tension
adjust
specification and tighten attaching
to specification
bolts.
radiator and power
power steering
14. Fill radiator
reservoir, as necessary.
Start engine and check for leaks.
leaks.
15. Start
Check and adjust
adjust carburetor
carburetor idle
16. Check
speed and mixture (Group 24 and
Group 29) as required.
If equipped
equipped with air
air conditioning,
17. If
and charge
charge system
system with
evacuate and
evacuate
refrigerant (Group
(Group 36).
36).
refrigerant
EXHAUST MANIFOLDS
MANIFOLDS
EXHAUST
RemoJ'sJ
Removal
removing right
right exhaust
exhaust manifold,
1.1. IfIf removing
remove air
air cleaner
cleaner and
and intake
intake duct
duct
remove
assembly.
assembly.
v-a
21-24-10
21-24-10
CID V-8 Engines

460 CID
2.
2. Disconnect exhaust manifold(s) at
catalyst or
or muffier
3.
3. Remove attaching bolts and washers,
and remove exhaust manifold(s) and
and
spark plug wire heat shields.
the cylinder head joining
Inspect the
flanges
flangesofofthe
theexhaust
exhaustmanifold(s)
manifold(s)for
for
gas leaks.
leaks.
evidence of exhaust gas
Inspect the
the manifold(s) for
for cracks,
damaged gasket surfaces, or other
defects that would make them unfit
for service.
Installation
Installation
1.
1. Clean mating surfaces of exhaust
manifold(s) and
and cylinder head(s).
Clean mounting flange
flange of manifold(s)
and inlet
inlet pipe(s).
pipe(s). Apply
Apply light
light
catalyst and
film of graphite grease to
to exhaust
film
manifold(s).
2. Position spark plug wire heat shields
2.
on cylinder
and exhaust manifold(s) on
head(s). Install attaching bolts and
and
head(s).
at fourth bolt hole
washers, starting at
from front of each manifold. Position
at third
lifting bracket under bolts at
exhaust port from front of engine. On
On
manifold, install
right exhaust manifold,
for air
air intake heat
shoulder stud(s) for
at first
and sixth bolt holes
shroud at
first and
manifold (Fig.
(Fig. 19).
from front of manifold
19).
Torque bolts to specification, working
from center
center of
of manifold
manifold to
to both
both ends.
ends.
from
new gasket(s) on
on resonator or
3. Place new
or
pipe(s). Position inlet
muffler
pipe(s) to manifold(s). Install
Install
attaching nuts and
and torque to
attaching
specification.
4. Install air
air cleaner and
and intake duct
4.
assembly, if removed.
5. Start engine and
and check for
for exhaust
S.
leaks.
leaks.
WATER PUMP
Removal
Removal
1. Drain cooling system and
and remove the
the
1.
fan shroud attaching bolts.
2.
2. Remove bolts attaching fan
fan assembly
and remove shroud

to water pump and
and fan.
fan.
3. Loosen the
the power steering pump
attaching bolts.
4.
4. If vehicle is
is equipped with air
conditioning, loosen compressor
attaching
attaching bolts. Remove the
compressor and power steering pump
drive belts.
S.
5. Loosen the
the alternator pivot bolt.
Remove the
and
the two
two attaching bolts and
spacer. Remove the
the belt, then rotate
out of the way.
way. Remove
the bracket out
air pump pulley and
and
the Thermactor air
the air
air
air pump pivot bolt. Remove the
pump adjusting bracket at
at the pump.
the upper bracket attaching
Remove the
bolt and
and swing bracket out
out of way.
6.
6. Remove the
the three air
air conditioning
compressor attaching bolts and
compressor
and
the compressor to
to the
the left
secure the
fender brace.
7. Remove the
7.
attaching bolts and position the pump
one side.
side.
to one
8.
8. Remove the
the air
air conditioner bracket
and remove the
attaching bolts and
bracket.
9. Disconnect the
the radiator lower hose
9.
the heater hose from the
the water
and the
pump.
10.
10. Loosen
Loosen the
the by-pass
by-pass hose
hose clamp
clamp at
at the
the
pump.
11. Remove remaining water pump
and remove water
attaching bolts and
pump from cylinder front cover.
Remove cover plate from water
pump. Discard gaskets.
Installation
Installation
1.
1. Remove any
any gasket material from
water pump, cylinder front cover and
pump cover.
2.
2. Position new
new gaskets coated on
on both
sides with water-resistant sealer.
3. Position water pump on
on cylinder
front cover and
and install only those
bolts not
not used to
to attach compressor
bracket (if installed) and
and alternator
HEAT SHROUD
HEAT SHROUD
FRONT-
A2945-C
19 Right Exhaust Manifold Installation

FIG. 19
BACK TO GROUP INDEX
bracket to
to water pump. Torque bolts
specification. Install
Install the
to specification.
Thermactor parts removed or
Thermactor
in Step 55 of Removal.
loosened in
4.
4. Connect radiator lower hose,
hose, heater
return hose,
hose, and by-pass hose to water
pump.
S.
5. Position
Position the
the air conditioner
conditioner
compressor bracket and
and
and install and
and
torque the
the attaching bolts, stud and
nuts.
nuts.
6.
6. Secure the compressor to the bracket.
7. Position the
7.
bracket and install the three attaching
bolts and
and the
the nut.
nut.
8.
8. Rotate the
the alternator bracket into
position and install the
two attaching
attaching
the two
and spacer. Adjust
Adjust the
the belt
bolts and
tension and torque the attaching bolts
specification.
to specification.
9. Place the
the water pump pulley on
on the
9.
the
pump. Position the
the power steering
on their
and compressor drive belts on
respective pulleys.
10. Lower
Lower the
the fan
fan and
and radiator
radiator shroud
shroud
10.
into position. Install the fan attaching
bolts and
and the
the shroud attaching bolts.
Torque the
the bolts to
to specification.
specification.
11. Adjust the power steering, alternator
and air
air pump belt
and compressor and
the compressor
tension. Torque the
to specification.
specification.
attaching bolts to
12.
12. Fill
Fill the
the cooling
cooling system.
system.
13. Start the
the engine and
and check for
for leaks.

AND
TIMING CHAIN
Removal
Removal
Cylinder front cover oil seal
is recommended whenever
replacement is
the cover has
has been removed.
1. Drain cooling system and
and crankcase.
1.
2.
2. Remove screws attaching radiator
shroud to
to radiator. Remove bolts
attaching fan
hub.
fan to
to water pump hub.
Remove fan
fan and
and radiator shroud.
3. Disconnect radiator upper and
and lower
hoses at
at engine.
engine. Disconnect oil cooler
lines at
at radiator.
4.
and
4. Remove radiator upper ,-,..pport
support and
remove radiator.
5. Loosen alternator and
and air
air pump
S.
attaching bolts to
on
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).
equipped).
7.
7. Remove the
the crankshaft
the vibration damper.
8. Remove bolt and
and washer attaching
8.
crankshaft damper. Remove
Remove
crankshaft
crankshaft
crankshaft damper with aa puller (Fig.
19). Remove Woodruff
Woodruff key
key from
crankshaft.
21-24-11
21-24-11
v-a
Loosenby-pass
by-passhose
hoseatatwater
waterpump.
pump.
9.9. Loosen
Disconnect heater
heater return
return tube
tube atat
Disconnect
waterpump.
pump.
water
10.Disconnect
Disconnectand
andplug
plugfuel
fuelinlet
inletline
lineatat
10.
fuel pump.
pump. Disconnect
Disconnect fuel
fuel line
line toto
fuel
carburetoratatfuel
fuelpump.
pump.Remove
Removefuel
fuel
carburetor
pump.
pump.
11.Remove
Removebolts
boltsattaching
attachingcylinder
cylinderfront
front
11.
covertotocylinder
cylinderblock.
block. Using
Usingaathin
thin
cover
bladeknife,
knife,cut
cut the
theoil
oilpan
pan seal
sealflush
flush
blade
with cylinder
cylinder block
block face
face prior
prior toto
with
separatingthe
thecover
coverfrom
fromthe
thecylinder
cylinder
separating
block. Remove
Remove cylinder
cylinder front
front cover
cover
block.
and water
water pump
pump as
as an
an assembly.
assembly.
and
Discard cylinder
cylinder front
front cover
cover gasket
gasket
Discard
and oil
oil pan
pan seal.
seal.
and
12.IfIf new
new cylinder
cylinder front
front cover
cover isis to
to be
be
12.
installed, remove
remove water
water pump
pump and
and
iJistalled,
install itit and
and aanew
new gasket
gasket on
on the
the new
new
install
front cover.
cover.
front
13.Check
Check timing
timing chain
chain deflection
deflection by
by
13.
r o t a t i n g the
the crankshaft
c r a n k s h a f t in
in aa
rotating
counterclockwise direction
direction to
to take
take up
up
counterclockwise
the slack
slack on
on the
the left
left side
side of
of the
the chain.
chain.
the
(All directions
directions are
are as
as viewed
viewed from
from the
the
(All
front of
of the
the engine.)
engine.)
front
Establish aa reference
reference point
point on
on the
the
Establish
block and
and measure
measure from
from this
this point
point to
to
block
the left
left side
side of
of the
the chain
chain as
as shown
shown in
in
the
Fig. 21.
21.
Fig.
REFERENCE
POINT
"i
iil'lllfl"
, ,A2954-A
FIG.
FIG. 21
21 Timing
Timing Chain
Chain Deflection
Deflection
UNIVERSAL
PULLER
A2953A
FIG.
FIG. 22
22 Aligning
Aligning Timing
Timing Marks
Marks
A3248-A
FIG.
FIG. 20
20 Removing
Removing Crankshaft
Crankshaft
Vibration
Vibration Damper
Damper
Rotate the crankshaft in the
Rotate the crankshaft in the
opposite direction to take up the slack
opposite direction to take up the slack
on the right side of the chain. Force
on the right side of the chain. Force
the left side of the chain out with the
the left side of the chain out with the
fingers
and measure the distance
fingers and measure the distance
between
the reference point and the
between the reference point and the
chain.
The
chain. The deflection
deflection isis the
the difference
difference
between
between the
the two
two measurements.
measurements.
IfIf tthe
h e ddeflection
e f l e c t i o n eexceeds
xceeds
specification,
specification,replace
replacethe
thetiming
timingchain
chain
and
and sprockets.
sprockets.
14.
14.IfIfthe
the timing
timing chain
chain and
and sprocket
sprocket are
are
totobe
crankthe
theengine
engineuntil
until
beremoved,
removed,crank
timing
timing marks
marks on
on sprockets
sprockets are
are asas
shown
shown inin Fig.
Fig. 22.
22.
15.
15.Remove
Removecamshaft
camshaftsprocket
sprocketcap
capscrew,
screw,
washer,
washer, and
and two
two piece
piece fuel
fuel pump
pump
BACK TO GROUP INDEX
21-24-11
460
460 CID
CID V-8Engines
Engines
eccentric.
eccentric. Slide
Slide timing
timing chain
chain and
and
sprockets
sprockets forward,
forward, and
and remove
remove as
as an
an
assembly
assembly (Fig.
(Fig. 23).
23).
Refer
Part 21-01
21-01 for
for cleaning
cleaning
Refer to
to Part
and inspection
inspection procedures.
procedures.
and
Installation
Installation
1.1. Assemble
Assemble the
the timing
timing chain
chain and
and
sprockets
sprockets so
so sprocket
sprocket timing
timing marks
marks
point
point directly
directly toward
toward each
each other
other as
as
shownin
inFig.
Fig.22.
22. Install
Install the
thechain
chain and
and
shown
as an
an aassembly
to
ssprockets
p r o c k e t s as
s s e m b l y to
crankshaft and
and camshaft.
camshaft. Verify
Verify
crankshaft
proper alignment
alignment of
of timing
timing marks
marks
proper
after installation.
installation.
after
2.2. Install
Install the
the fuel
fuel pump
pump eccentric,
eccentric,
camshaft
camshaft sprocket
sprocket cap
cap screw
screw and
and
washer.
o r q u e cap
washer. TTorque
cap screw
screw to
to
specifications.
specifications.Lubricate
Lubricatetiming
timingchain
chain
with
withengine
engineoil.
oil.
3.3. Coat
Coatthe
thegasket
gasketsurface
surfaceofofthe
theoil
oilpan
pan
with
with sealer.
sealer. Cut
Cut and
and position
position the
the
FIG.
FIG. 23
23 Removing
Removing or
or Installing
Installing Timing
Timing
Chain
Chain
required
required sections
sections of
of aa new
new seal
seal on
on the
the
oil
oil pan.
pan. Apply
Apply sealer
sealer at
at the
the corners.
corners.
4.
4. Coat
Coat the
the gasket
gasket surfaces
surfaces of
of the
the block
block
and
and cover
cover with
with sealer,
sealer, and
and position
position aa
new
new gasket
gasket on
on the
the block.
block.
5.
5. Position
Position the
the cylinder
cylinder front
front cover
cover on
on
the
the cylinder
cylinder block.
block. Use
Use care
care when
when
installing
installing the
the cover
cover to
to avoid
avoid seal
seal
damage
damage or
or possible
possible mislocation.
mislocation.
6.
the cylinder
front cover
to seal
seal
6. Install
Install the
cylinder front
cover to
alignment
tool into
into proper
proper position.
position. It
It
alignment tool
may be
be necessary
necessary to
to force
force the
the cover
cover
may
downward in
in aa manner
manner to
to slightly
slightly
downward
compress the
the pan
pan seal.
seal. This
This operation
operation
compress
can be
be facilitated
facilitated by
by using
using aa suitable
suitable
can
tool at
at the
the attaching
attaching bolt
bolt hole
hole
tool
locations.
locations.
7. Coat
Coat the
the threads
threads of
of the
the attaching
attaching bolts
bolts
7.
with oil-resistant
sealer and
and install
install the
the
with
screws.
8. While
While pushing
pushing in
in on
on the
the alignment
alignment
8.
24), torque
torque the
the oil
oil pan
pan to
to
tool (Fig.
(Fig. 24),
tool
cover attaching
attaching bolts
bolts to
to specification.
specification.
cover
Torque the
the cover
cover to
to cylinder
cylinder block
block
Torque
attaching screws.
screws. Remove
Remove alignment
alignment
attaching
tool.
tool.
TOOL-TS1 P-6019B
TOOL-T61P-6019-B
or (S059-F)
or(6059-F)
A2956-A
FIG. 24
24Aligning
Aligning Cylinder
CylinderFront
Front
FIG.
Cover
Cover
460
Engines
460 CID
CID V-8
v-a Engines
21-24-12
21-24-12
-T64T-6306-A
A2957-A
FIG. 25
251nstalling
Crankshaft
Installing Crankshaft
Damper
Vibration Damper
9. Apply
Apply white lead and
and oil mixture to
to
front of crankshaft
crankshaft for damper
front
installation.
10. Po sit ion c rran
10.Position
a n kksshhaft
a f t dam
d a m pper
er
Woodruff key and
and install crankshaft
Woodruff
damper (Fig.
(Fig. 25).
25). Install damper
damper
attaching screw and
and washer.
the crankshaft
crankshaft pulley.
11. Install the
12. Coat new
new fuel pump gasket with oiloiland place on
on fuel
resistant sealer and
pump. Install fuel pump. Connect fuel
lines to fuel pump.
13. Install compressor support bracket to
to
and water pump, if so
so
compressor and
equipped.
14. Install water pump pulley and
and all
all
drive belts.
15. Position radiator to
to lower support,
position upper support to
to radiator,
and install attaching bolts. Connect
radiator upper and
and lower hoses at
engine. Connect oil
oil cookr
cooler lines.
16. Place fan
fan assembly inside radiator
shroud and
and set
set in
in position in
in vehicle.
vehicle.
Position the
the fan
fan on
on the
the water pump
and install and
and torque the
the attaching
bolts.
bolts. Install screws attaching shroud
to radiator.
radiator.
17.
17. Adjust belt tensions to
to specification.
specification.
Tighten alternator and
and air
air pump
pump
attaching bolts and
and compressor idler
pulley, if so
so equipped, to specification.
specification.
18.
system. Fill
the crankcase to the correct level with
the recommended oil.
oil.
19.
for
19. Run engine at
at fast idle
idle and
and check for
coolant and
and oil
oil leaks.
leaks. Adjust ignition
ignition
timing.
timing.
FRONT
FRONT OIL
OIL SEAL
SEAL
Removal
Replacement
Replacement of
of the
the front
front oil
oil seal
seal is
is
recommended
recommended whenever
whenever the
the cylinder
cylinder
front
front cover
cover is
is removed.
removed.
1.1. Drive
pin
Drive out
out the
the old
old seal
seal with
with aa pin
punch.
the
punch. Clean
Clean the
the seal
seal recess
recess in
in the
cylinder
cylinder front
front cover.
cover.
Installation
Installation
1.1. Coat
Coat aa new
new seal
seal with
with grease.
grease. Install
Install
the
the seal
seal with
with Tool
Tool T68P-6700-A
T68P-67OO-A (Fig.
(Fig.
26).
26). After
After installation,
installation, be
be sure
sure seal
seal
spring
spring remains
remains in
in proper
proper position.
position.
BACK TO GROUP INDEX
Tool- T68P-6700-A
Too/-T68P-6700-A
A2955-A
A1955-A
26 Installing Front Oil

Oil Seal
FIG. 26
Seal
CAMSHAFT
The camshaft
camshaft and
and related parts are
are
Fig. 27.
shown in Fig.
27.
Removal
Removal
and sprockets,
1. Remove timing chain and
following procedure under Cylinder
Front Cover
Cover and
and Timing
Timing Chain.
Front
deflection before
Check timing chain deflection
removal.
the intake manifold
manifold and
and
2. Remove the
carburetor as
as an
an assembly, following
carburetor
under Intake
the iinstructions
n s t r u c t i o n s under
Intake
Manifold.
arm covers.
3. Remove valve rocker arm
Back off all
all rocker arm
arm bolts, turn
rocker arms sideways, and remove the
17).
push rods in
in sequence (Fig. 17).
4. Remove the
the valve lifters
lifters with aa
magnet and
and place them in
in aa rack in
in
21-24-12
21-24-12
sequence.
sequence. If
If the
the lifters
lifters are
are stuck
stuck in
in
bores,
bores, use
use Tool
Tool (T70P-14151)
(T70P-14151) to
to
remove
remove them.
them. Rotate
Rotate the
the lifter
lifter back
back
and
and forth
forth to
to loosen
loosen it
it from
from gum
gum or
or
varnish
varnish deposits.
deposits.
5.
5. Remove
Remove the
the bolts
bolts attaching
attaching the
the air
air
conditioning
conditioning condenser
condenser to
to the
the chassis,
chassis,
ifif so equipped,
equipped, and
and carefully
carefully move
move the
condenser
condenser to
to rest
rest on
on the
the left
left fender.
Secure
Secure it
it in
in this
this position.
position.
6. Remove the grille.
grille.
7. Remove
Remove the camshaft
camshaft thrust
thrust plate
attaching
attaching bolts, and carefully
carefully remove
the camshaft
camshaft from
from the front
front of
of engine.
Do not
not damage the
the camshaft
bearings.
Refer
Refer to Part
Part 21-01
21-01 for cleaning
and inspection
Refer to Part
Part 21-01
21-01 for repair
Refer
procedure.
Installation
1. Oil
Oil the
the camshaft
camshaft journals and
and apply
Lubriplate or equivalent to the
cam
the cam
lobes. Carefully
Carefully slide camshaft
camshaft into
position.
2. Install camshaft
camshaft thrust plate. Check
camshaft
following
camshaft end play, following
procedure in
in Part 21-01. If end play
is excessive, replace the
camshaft
the camshaft
thrust plate.
3. Install timing chain, sprockets, and
and
cylinder front cover as detailed under
and Timing
Cylinder Front Cover and
Chain.
the radiator in
in the
the vehicle
4. Position the
BEARINGS------6-26-2--6-2-70-~-;;;,
BEARING
~
CAMSHAFT-6250
THRUST PLATE-6269
TIMING CHAIN
CHAIN AND
AND SPROCKET
SPROCKET
.--or..-_--T1MING
6268
6256
6268
6256
TWO
TWOPIECE
PIECE
FUEL PUMP
PUMP ECCENTRIC-6287
ECCENTRIC-6287
FUEL
A2959A2959B
FIG. 27
27 Camshaft
Camshaft and
and Related
Related Parts
Parts
FIG.
21-24-13
and install the radiator upper support
to secure radiator. Connect
Connect the
radiator lower hose and oil cooler
lines.
5. Install the grille center support and
conditioning condenser, if so
air conditioning
equipped.
lifter bores
6. Lubricate the lifters and lifter
with heavy oil SE before installing
them. Lubricate the push rod ends
with Lubriplate or equivalent. Install
the valve lifters and push rods in their
original position.
7. Install
manifold
I n s t a l l intake
intake m
a n i f o l d and
and
carburetor, following the procedure
under Intake Manifold.
Manifold.
crankshaft damper until
No. 1 piston is at TDC at the end of
of
compression
compression stroke. Position the
distributor in the block with the rotor
at No.
firing position and points just
No.11 firing
starting to open. Install the hold
down clamp.
valve stem tips. Position rocker arms
over push rods and tighten bolts
following the procedure under Valve
Rocker Arm Installation. Check
Rocker
valve clearance, as shown in Part
21-01.
10. Clean the valve rocker arm covers
and cylinder head gasket surfaces.
Apply oil-resistant sealer to one side
of the new cover gaskets. Lay the
of
cemented side of gaskets in place in
the
covers.
the covers.
11. Position the covers on the cylinder
heads and make sure that gaskets seat
evenly. Install cover attaching bolts
and torque to specifications. Two
minutes later, torque bolts to same
specifications.
12. Connect the radiator upper hose.
Connect hheater
e a t e r hose at intake
intake
Connect
manifold
manifold and at water pump.
13. Connect the fuel line to carburetor.
14. Install the coil and bracket assembly
to intake manifold.
manifold.
15. Install the accelerator linkage. Install
the speed control
control linkage, if
if so
equipped.
16. Engage engine wiring harness in clips
on left cylinder head and connect all
wire terminals. Connect
Connect engine
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
17. Install
Install the distributor
d i s t r i b u t o r cap and
connect the coil and spark plug wires.
18. Place the water pump pulley and
drive belts in position. Place the fan
assembly in the radiator shroud and
set in position. Position
Position the fan
fan
assembly to water pump hub and
install and torque the attaching
attaching
screws to specification. Install screws
BACK TO GROUP INDEX
460 CtO
CID v-a
V-8 Engines
attaching shroud to the radiator.
19. Adjust
Adjust the tension of drive belts to
specifications and tighten attaching
specifications
screws.
20. Fill and bleed the cooling system and
power steering reservoir. Run engine
at fast idle and check for leaks.
Adjust the ignition
21. Adjust
ignition timing and
connect distributor vacuum line.
22. Check and adjust
adjust the carburetor
carburetor idle
speed and mixture as required after
engine temperature has stabilized.
Adjust transmission
transmission linkage, if
Adjust
if
necessary. Install the air cleaner and
intake duct.
FLYWHEEL
Remoyal
Removal
from
1.
transmission from
vehicle. Remove the mounting
moun ting bolts
and remove flywheel
from the
and
flywheel from
crankshaft.
Refer to Part 21-01, for inspection.
Installation
Installation
1.
1. Install flywheel on crankshaft. Install
the mounting bolts and torque to
specifications.
2. Check flywheel runout (Fig. 28) and
ring gear runout following procedure
in Part 21-01.
TOOL^201-C
A2966A
A2966-A
FIG. 28 Checking Flywheel Runout

3. Install transmission assembly in
vehicle.
C
A M S H A F T REAR BEARING BORE
CAMSHAFT
PLUG
Remoyal
Removal
1.
transmISSion from the
vehicle as detailed in Group 17.
2. Remove flywheel and engine rear
cover plate, following
following procedure
procedure
under Flywheel Removal.
3. Replace the plug as detailed in Part
21-01.
Installation
Installation
1. Install the engine rear cover plate and
1.
flywheel, following procedure under
Flywheel Installation.
21-24-13
2. Install the transmission as detailed in
Group 17.
OIL PAN
Continental
Continental Mark
Mark IV
IV
Remoyal
Removal
1.
the battery
battery ground
ground cable.
1. Disconnect
Disconnect the
cable.
Disconnect the two transmission oil
Disconnect the two transmission oil
cooler lines from the radiator.
cooler lines from the radiator.
2. Remove the radiator shroud
2. R e m o v e t h e r a d i a t o r s h r o u d
attaching bolts and position the
attaching bolts and position the
3. Raise the vehicle on a hoist.
4. Drain the crankcase, then remove the
4.
Drain the crankcase, then remove the
oil filter.
oil
filter.
5. Remove
attachments of
5.
Remove end
end attachments
of front
front
bar
and
rotate
ends
stabilizer
stabilizer bar and rotate ends of
of bar
bar
down
to raise
raise center
down to
center of
of bar.
bar.
6.
the engine
with aa jack,
jack, then
6. Support
Support the
engine with
then
remove the
the bolt
bolt that
that attaches
remove
attaches each
each
engine
to insulator.
engine support
support to
insulator.
7. Remove
the bolt
bolt that
that attaches
7.
Remove the
attaches the
the
transmission
oil
cooler
line
bracket to
transmission oil cooler line bracket
to
the cylinder
cylinder block.
the
block.
8. Remove
the two
two starter
8.
Remove the
s t a r t e r motor
motor
attaching bolts.
boIts.
attaching
9.
the engine
high enough
9. Raise
Raise the
engine high
enough to
to
remove the
the engine
remove
engine support
support insulator
insulator
attaching
bolts, then
then remove
remove the
the right
attaching bolts,
right
insulator
and
heat
shield.
Position
insulator and heat shield. Position aa
wood block
block 33 inches
high between
wood
inches high
between
each
engine
support
bracket and
each engine support bracket
and
exhaust
manifold. Lower
the engine
exhaust manifold.
Lower the
engine
to allow
allow the
the blocks
blocks to
to support
to
support the
the
engine.
engine.
10.
the converter
housing to
10. Remove
Remove the
converter housing
to
cylinder
block support
cylinder block
support attaching
attaching bolts
bolts
and
remove the
the brackets.
and remove
brackets.
11.
the oil
pan attaching
11. Remove
Remove the
oil pan
attaching bolts
bolts
and
lower
the
pan
to the
the No.
No. 22
and lower the pan to
crossmember.
crossmember.
12.
the transmission
transmission oil
12. Move
Move the
oil cooler
cooler lines
lines
upward, then
then remove
remove the
the pan.
upward,
pan.
Refer
to Part
21-01 for
Refer to
Part 21-01
for cleaning
cleaning
and inspection
procedures. Check
and
Check the
the
gasket surface
by
gasket
surface for
for damage
damage caused
caused by
over-torqued
bolts. Straighten
over-torqued bolts.
Straighten the
the
surface
required to
to restore
restore original
surface as
as required
original
flatness.
flatness.
Installation
Installation
1.
Clean the
the gasket
the block
1. Clean
gasket surfaces
surfaces of
of the
block
and
oil
pan.
Coat
the
block
and oil pan. Coat the block gasket
gasket
and oil
oil pan
pan gasket
gasket surface
surface and
surface
surface
with
oil-resistant
sealer.
with oil-resistant sealer. Position
Position the
the
oil
pan gaskets
gaskets on
the cylinder
oil pan
on the
cylinder block.
block.
2. Position
the oil
pan front
2.
Position the
oil pan
front seal
seal on
on the
the
cylinder
that the
cylinder front
front cover.
cover. Be
Be sure
sure that
the
tabs on
the seal
the oil
tabs
on the
seal are
are over
over the
oil pan
pan
gasket.
gasket.
3.
the oil
pan rear
rear seal
3. Position
Position the
oil pan
seal on
on the
the
rear main
bearing cap.
rear
main bearing
cap. Be
Be sure
sure that
that
the tabs
tabs on
the seals
the oil
oil
the
on the
seals are
are over
over the
pan gasket.
pan
gasket.
4. Hold
the oil
oil pan
pan in
place against
against the
4.
Hold the
in place
the
block and
and install
bolt, fingertight,
block
install aa bolt,
fingertight, on
on
each
the pan.
pan. Install
Install the
each side
side of
of the
the
remaining bolts.
bolts. Torque
the bolts
remaining
Torque the
bolts
from
the center
from the
center outward
outward in
in each
each
direction
to specification.
direction to
specification.
21-24-14
5.
5. Install the converter housing to
cylinder block supports and torque
the attaching bolts to specification.
specification.
6.
6. Tighten the starting motor attaching
specification.
7.
7. Raise the engine and remove the two
wood support blocks.
8.
8. Install the engine support insulator
and heat shield on the right side of the
the
engine and torque the attaching bolts
to
to specification.
specification.
9.
9. Lower the engine into place and
install and torque the engine support
specification.
10.
10. Rotate
Rotate front
front stabilizer
stabilizer bar
bar into
into
position and attach ends to lower
control arms.
arms.
11.
11. Clean the oil filter mating surface and
install the filter.
filter.
12.
12. Secure
Securethe
the transmission
transmission oil
oil cooler
cooler line
line
retaining bracket to the cylinder
block with the attaching bolt.
13.
13. Lower
Lower the
the vehicle
vehicle to
to the
the floor.
floor.
14.
14. Position
Position the
the radiator
radiator shroud
shroud and
and
install the attaching bolts.
15.
15. Connect
Connect the
the transmission
transmission oil
oil cooler
cooler
lines to the radiator.
radiator.
lines
16.
16. Fill
Fill the
the crankcase
crankcase to
to the
the proper
proper level
level
with the recommended oil.
17.
17. Fill
Fillthe
thepower
powersteering
steering reservoir
reservoir to
tothe
the
with the specified
specified
correct level with.
lubricant.
18. Connect
Connect the
the battery
battery ground
ground cable.
cable.
18.
Start the engine and check for leaks
as required.
required.
and correct as
Lincoln
Lincoln Continental
Continental
RemoyaJ
Removal
i.1. Disconnect the battery ground cable.
Disconnect the radiator shroud from
the radiator.
radiator.
2.
2. Raise the vehicle on a hoist and drain
the crankcase.
crankcase.
3. Remove the starter attaching bolts.
3.
4. Place aa floor
floor jack under front of oil
4.
pan, with a block of wood between
pan,
pan. Raise the jack just high
jack and pan.
enough to remove weight of engine
supports. Remove the
from the front supports.
support.
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.
bolts.
5. Install aa one inch wood block under
5.
each engine support bracket, then
remove the jack.
6. Remove the end attachments of the
6.
stabilizer bar and rotate ends of
front stabiJjzer
bar down to raise the center of bar.
oil filter.
filter.
Remove the oil
7. Remove the oil pan attaching bolts,
7.
remove the oil pan.
pan.
then remove
Refer to Part 21-01
procedures. Check the gasket
surface for damage caused
caused by
surface
over-torqued bolts.
bolts. Straighten the surface
BACK TO GROUP INDEX
460 (ID
CID v-a
V-8 Engines
as required to restore original flatness.
flatness.
Installstion
Installation
1.
the block
block
1. Clean
Clean the
the gasket
gasket surfaces
surfaces of
of the
and
block gasket
gasket
and oil
oil pan.
pan. Coat
Coat the
the block
surface
pan gasket
surface and
and oil
oil pan
gasket surface
surface
with oil-resistant sealer. Position the
oil pan gaskets on the cylinder block.
2.
cylinder front cover. Be sure that the
tabs on
on the seal are over the oil pan
gasket.
cap. Be sure that
the tabs on
on the seal are over the oil
pan
pan gasket.
4.
4. Hold the oil pan in place against the
block and install a bolt,
bolt, fingertight, on
each side of the pan. Install the
remaining bolts. Torque the bolts
direction to specification.
specification.
5.
5. Clean the oil filter seal surface and
install the oil filter.
filter.
6.
6. Rotate the front stabilizer bar into
position and attach the ends to lower
control arms.
7.
7. Install and tighten the starter
attaching bolts.
8. Raise the engine slightly with a floor
floor
8.
jack and wood block against forward
edge of oil pan. Remove the wood
blocks from under the front support
insulators. Install the two insulator
attaching bolts on the right insulator.
T i g h t e n the
t h e three
t h r e e bbolts
o l t s to
Tighten
specification. Lower the engine as
required to install the through bolts.
Torque the nuts and bolts to
specification.
9.
attach shroud to radiator. Connect
the battery ground cable.
10. Fill
Fill crankcase
crankcase to
to proper
proper level
level with
with the
the
10.
specified oil. Start the engine and
check for leaks.
Ford, Mercury, Torino, Elite,
Ford,
Montego, Cougar and
Thunderbird
Removal
RemoysJ
1. Disconnect the battery ground cable.
1.
Disconnect the radiator shroud from
the radiator, and position it over the
fan.
2. Raise the vehicle on a hoist and drain
2.
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
Move the
the sway
sway bar forward
forward on
arms.
the struts.
struts.
the
4. Remove the through bolt from each
4.
engine support. Placefloor
floor jack under
the front edge of the oil pan, with
block of wood between jack and oil
pan. Raise the engine just enough to
1-1/4 inch blocks of wood
insert 1-1/4
between the insulators and brackets.
Remove the floor
floor jack.
21-24-14
5. Remove the oil filter.
6.
and remove the pan. It may be
necessary to rotate the crankshaft
crankshaft to
provide clearance between the pan
and crankshaft
crankshaft throws or counterweights.
inspection procedures. Check the
by
gasket surface for damage caused by
over-torqued bolts. Straighten the
surface as required to restore original
flatness.
flatness.
Instal/ation
Installation
1.
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.
the
cylinder front cover. Be sure that the
pan
tabs on the seal are over the pan
gasket.
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,
bolt, fingertight, on
each side of the oil pan. Install the
remaining bolts. Torque the bolts
direction to specification.
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
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
torque the nuts to
specification.
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
Remoyll1
1. Remove the oil pan, following the
1.
procedure under Oil Pan Removal.
2. Remove the oil pump mounting bolts,
and remove the pump from the
cylinder block.
Installation
InstslJation
1.
port with engine oil. Rotate the pump
shaft to distribute oil within the pump
body.
21-24-15
21-24-15
2. Install the
the distributor intermediate
intermediate
2.
in the
the oil
oil pump
pump rotor shaft.
shaft.
shaft in
3. Insert the
the intermediate shaft into
into the
3.
distributor shaft hex
hex bore.
bore. Make
the intermediate shaft is
certain that the
properly seated. Do
Do not
not force the
it will
will not
not seat
pump into position if it
readily. The
The intermediate shaft hex
readily.
may be
be misaligned with distributor
may
shaft. To align,
a l i g n , rotate
r o t a t e the
the
shaft.
can be
intermediate shaft until it can
seated. Secure the
the oil
oil pump to
and torque the
the screws
cylinder block and
to specifications.
specifications.
4. Install the
the oil
oil pan
pan and
and related parts,
4.
Oil Pan
following procedure under Oil
Installation.
OIL SEAL
CRANKSHAFT REAR OIL
crankshaft rear oil
Replacement of aa crankshaft
oil leakage requires
seal because of oil
and lower seals as
replacement of upper and
in Part 21-01.
detailed in
MAIN BEARING
and connecting rod
rod bearing
Main and
are selective fits.
fits.
inserts are
are available for
Selective fit
fit bearings are
in standard size,
size, 0.001
0.001 and
and 0.002
service in
inch undersize. Undersize bearings,
and 0.040 inch)
(0.010, 0.020, 0.030 and
are not
not selective fit,
are available
which are
fit, are
on crankshaft
crankshaft journals that have
for use
use on
been refinished.
Removal
Remoyal
1. Drain the
oil
1.
the crankcase. Remove the
the oil
level dipstick. Remove the
oil pan and
theoil
related parts, following the procedure
under Oil
Oil Pan
Pan Removal.
2. Remove the oil pump.
3. Replace one bearing at a time, leaving
other bearings securely fastened.
which new bearings are to be
installed.
4. Insert the upper bearing removal tool
(Tool 6331) in oil hole in crankshaft
(Fig. 29).
29).
v-a
21-24-15
CID V-8 Engines

Engines
460 CID
bearing)
bearing) has
has been
been removed,
removed, install
install as
as
follows:
follows:
Install the
cap with
bolts finger-tight.
finger-tight. Pry
Pry the
the crankshaft
crankshaft
forward against the
the thrust surface of
upper half of bearing (Fig.
(Fig. 31).
31). Hold
the crankshaft forward and pry thrust
bearing cap to
to rear.
rear. This aligns
aligns thrust
surfaces of both halves of bearing.
bearing.
forward pressure on
Retain forward
cap bolts to
crankshaft. Torque cap
specification.
10.
10. Clean
Clean the
theoil
oil pump
pump inlet
inlet tube
tube screen.
screen.
Prime the oil pump by
by filling the inlet
opening with oil
oil and
and rotate the
the pump
pump
opening. Install the
the oil
oil pump
pump
following procedure under Oil
Oil Pump
Installation.
11.
Install the oil pan,
11.Install
pan, following
following
procedure under Oil Pan Installation.
12.
12. Fill
Fill the
thecrankcase
crankcase to
to the
the proper
proper level
level
with the
the recommended oil.
oil. Start the
and check for
for oil
oil pressure.
engine and
the engine at fast idle and
Operate the
for oil
oil leaks.
check for
6.
6. Clean the
the crankshaft
journals.
and thrust faces

faces
Inspect journals and
bearing) for
for nicks,
nicks, burrs or
(thrust bearing)
bearing pickup that would cause
wear.
Installation
Installation
1. To
To install upper main bearing,
bearing, place
1.
plain end
end of bearing over shaft on
locking tang side of block and
so Tool 6331
6331
partially install bearing so
be inserted in oil
oil hole in
can be
(Fig. 29).
29). With Tool 6331
6331
crankshaft (Fig.
in oil hole,
hole, rotate the crankshaft in the
opposite direction of engine rotation
until the
the bearing seats itself.
itself. Remove
tool.
the tool.
2. Fit
Fit the
the main bearings as
as detailed in
2.
21-01 under Fitting Bearings
Part 21-01
with Plastigage.
3. After the
the bearing has
has been fitted,
fitted,
3.
apply light coat of engine oil
oil to
journal and
and bearings. Install the
bearing cap.
cap. Torque the
the cap
cap bolts to
specification.
4. Repeat the
the procedure for
for remaining
4.
bearings that require replacement.
5. If the
is to be
5.
the rear main bearing is
replaced, remove the rear main
cap. Remove and
and discard the
bearing cap.
oil seal.
rear oil
6.
6. Clean rear journal oil seal groove and
mating surfaces of block and
and rear
cap.
main bearing cap.
7.
the new
new seal as
7. Install the
as shown in Fig.
Fig.
30.
8.
21-01 for procedure
the rear main bearing
used in sealing the
cap. After sealing, install the
the rear
main bearing cap and torque cap bolts
to specification.
cap (No.
(No. 3
3 main
9. If thrust bearing cap
CONNECTING ROD
ROD BEARING
Remoyal
Removal
1.
1. Follow steps 11 and
and 22 under Main
Bearing Removal.
2.
2. Turn the
the crankshaft
crankshaft until connecting
new bearings are
rod to which new
are to be
be
fitted
fitted is down. Remove
Remove the
connecting rod cap.
cap. Remove the
rod and
bearing inserts from rod
and cap.
cap.
3. Be
Be sure the bearing inserts and
rod and
and
bearing bore in connecting rod
cap are clean. Foreign material under
and cause
inserts will distort bearing and
a failure.
failure.
INSTALL SEAL WITH LIP
OF ENGINE
TOWARDS FRONT OF
3/8"
I
I
-+-
FRONT OF ENGINE
I
TO PROTRUDE BEYOND PARTING FACES
SEAL HALVES TO
TO ALLOW FOR
FOR CAP
CAP TO
TO BLOCK ALIGNMENT
THIS DISTANCE TO
~_L
Tool-6331-E
I
BEARING INSERT
CRANKSHAFT JOURNAL
A2962-A
FIG. 29 Removing or Installing Upper

Upper
Main Bearing Insert

of
of engine rotation to force bearing out
of
of block.
BACK TO GROUP INDEX
-----r
3/8"
OF REAR MAIN
REAR FACE OF
CAP AND
AND CYLINDER
CYLINDER BLOCK
BLOCK
BEARING CAP
AT PARTING FACE
VIEW LOOKING AT
OF SPLIT,
SPLIT, LIP-TYPE
LIP. TYPE CRANKSHAFT
CRANKSHAFT SEAL
SEAL
OF
A2639-C
A2639-C
FIG. 30 Crankshaft Rear Oil Seal Installation

v-a
21-24-16
21-24-16
CID V-8 Engines

460 CIO
3.TORQUE
TORQUECAP
CAPSOL
BOLTS
3.
T5
WHILE HOLDING
WHILE
CRANKSHAFT FORWARD
1. PRY
PRYCRANKSHAFT
CRANKSHAFT
1.
FORWARD AND
AND HOLD
2. PRY
PRYCAP
CAPREARWARD
REARWARD
2.
I
A2964-A
FIG. 31
31 Aligning Thrust Bearing
FIG.
the crankshaft
crankshaft journal. When
4. Clean the
replacing standard bearings with new
is good practice to fit the
bearings, it is
bearing to minim
minimum
specified
urn specified
clearance.
Installation
Instsllation
1. Fit connecting rod bearings as
1.
detailed in Part 21-01
21-01 under Fitting
Bearings with Plastigage.
2.
connecting rod
rod and
and cap
cap with tangs in
the slots provided.
crankshaft
journal.
oil to the
the
4. Apply a light coat of engine oil
journal and bearings. Install the
connecting rod cap.
cap. Be
Be sure the
connecting rod bolt heads are
connecting
properly seated in the connecting rod.
the nuts to specification.
specification.
Torque the
5. Repeat
5.
procedure for the
remaining connecting rods that
require new
new bearings.
6. To complete installation, follow
6.
instructions under Main Bearing
Installation.
Refer to Part 21-01
21-01 for cleaning
AND CONNECTING
PISTONS AND
RODS
Removal
Removal
1.
crankcase. Remove the intake
manifold, cylinder heads, oil
oil pan and
and
oil pump, following procedures in this
section.
any ridge and/or deposits
2. Remove any
end of cylinder bores as
from upper end
follows:
follows:
Turn the crankshaft
piston to
to be
is at bottom of
be removed is
of
on top
top of the
its travel. Place a cloth on
piston to collect cuttings. Remove any
ridge and/or
and/or deposits
depositsfrom
from the
theupper
upper
ridge
end of the cylinder bore. Remove the
BACK TO GROUP INDEX
cylinder ridge with a ridge cutter.

by tool
Follow instructions furnished by
manufacturer. Never cut
cut into ring
in excess of 1/32 inch
travel area in
when removing ridges. Repeat the
procedure at the
the remaining cylinders.
3. Make sure that all connecting rod
caps are marked so they can be
4.
down.
5.
5. Remove the
the connecting rod
rod nuts and
cap.
6.
6. Push the
the connecting rod
rod and
and piston
assembly out through the
the top
top of the
cylinder with the
the handle end
end of a
hammer. Avoid damage to the
or cylinder wall
crankshaft journal or
the piston and
and rod.
rod.
when removing the
7. Remove the
the bearing inserts from the
7.
rod and
and cap.
cap.
connecting rod
8.
8. Install the
the cap
cap on the
the connecting rod
from which it was
was removed.
Installation
Instsllation
1.
1. If new piston rings are to be installed,
remove the cylinder wall glaze.
Follow instructions as detailed in
in Part
21-01.
the same
Be sure to install pistons in the
cylinders from which they were
rod and
and bearing caps are
Connecting rod
the right
numbered from 1 to 4 in the
bank, and
and 5 to 8 in the left bank,
beginning at the front of engine.
Numbers on
on the
the connecting rod
rod and
and
bearing cap
cap must be on the same side
when installed in the cylinder bore. If
rod is ever transposed
a connecting rod
from one block or cylinder to another,
and the
the
new bearings should be fitted and
connecting rod should be numbered to
new cylinder
correspond with the new
number.
3. Make sure that ring gaps are properly
spaced around circumference

circumference or
piston (Fig.
(Fig. 32).
32).
OIL RING SPACER
OIL RING
SEGMENT
OIL RING
SEGMENT
PIN BORE
PISTON
Cf.
FRONT OF ENGINE
A2811-A
32 Piston Ring
Ring Spacing
FIG. 32
compressor
4. Install piston ring com
pressor on
piston and push in with hammer
handle until it is
is slightly below top
top of
of
(Fig. 33).
33). Be
Be sure to
to guide
cylinder (Fig.
connecting rods while tapping them
into position to avoid damaging
crankshaft
crankshaft journals. Install piston
with indentation notch in piston head
toward front of engine.
A2965-A
33 Installing Piston Assembly

FIG. 33

21-24-17
5.
5. Check clearance of each bearing,
following procedure under Fitting
Connecting Rod Bearings, Part
21-01.
6.
6. After the bearings have been fitted,
7.
bottom of the stroke. Push the piston
rod bearings seat on the crankshaft
crankshaft
journal.
8.
cap. Be
sure connecting rod bolt heads are
properly seated in the connecting rod.
9. After the piston and connecting rod
9.
crankshaft
journal.
10.
10. Disassemble,
Disassemble, clean
clean and
and assemble
assemble the
the
tube screen, and oil pan and the block
gasket surfaces.
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.
12. Install
Install the
the cylinder
cylinder heads,
heads, following
following
instructions under Cylinder Head
Installation.
13. Install
Install the
the intake
intake manifold,
manifold, following
following
instructions under Intake Manifold
Installation.
14.
14. Fill
Fill and
and bleed
bleed the
the cooling
cooling system.
system. Fill
Fill
the
with
the crankcase
crankcase to
to the
the correct
correct level
level with
the
oil.
the specified
specified engine
engine oil.
15.
15. Start
Start the
the engine
engine and
and adjust
adjust the
the
ignition
ignition timing.
timing. Connect
Connect the
the
distributor
line.
distributor vacuum
vacuum line.
16.
16. Operate
Operate the
the engine
engine at
at fast
fast idle
idle and
and
check
With
check for
for oil
oil and
and coolant
coolant leaks.
leaks. With
the
the engine
engine temperatures
temperatures stabilized,
stabilized,
adjust
the engine
idle speed
and
adjust the
engine curb
curb idle
speed and
mixture.
mixture.
17.
17. Install
Install the
the air
air cleaner
cleaner and
and intake
intake duct
duct
assembly.
assembly.
CRANKSHAFT
To perform the following operation,
it is necessary to remove the engine and
install it on a work stand.
Crankshaft
Crankshaft and related parts are
shown in Fig.
Fig. 34.
Remoyll1
Removal
1. Disconnect the wires from the spark

1.
plugs. Remove the spark plugs to
allow easy rotation of crankshaft.
crankshaft.
2. Remove the fuel pump and the oil
filter. Slide water pump by-pass hose
clamp toward the water pump.
the vibration damper.
4. Remove the cap screw and washer
from the end of the crankshaft. Install
BACK TO GROUP INDEX
460 CID v-a

V-8 Engines
a puller on the crankshaft vibration
damper (Fig. 20) and remove damper.
Woodruff key.
Remove Woodruff
5.
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.
6.
Remove the flywheel and the engine
rear cover plate. Remove the oil pan
and gasket. Remove the oil pump.
7. Make sure that all bearing caps (main
7.
and connecting rod) are marked so
locations.
Turn the crankshaft
connecting rod from which cap is
being removed is down, then remove
cap. Push the connecting
the bearing cap.
rod and
and piston
assembly up
up out
out of
of the
the
rod
piston assembly
cylinder. Repeat
Repeat this
this procedure
procedure until
cylinder.
until
all connecting
connecting rod
rod bearing
bearing caps
caps are
all
are
removed.
removed.
8.
9.
9. Carefully
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
inspection procedures. Clean the
crankshaft damper.
crankshaft
To refinish journals, dress minor
imperfections, etc., refer to Part
21-01.
Installation
Instlllllltion
1.
block and rear main bearing cap.
caps.
4. If
If the crankshaft
journals have been refinished to a
undersize bearing. Be sure that
clean. Foreign material under inserts
will distort the bearing and cause
failure.
in the bores with tang in slot.
6.
6. Install lower main bearing inserts in
bearing caps.
7.
and mating surfaces of the block and
8.
8. Install a new rear main bearing oil
seal in the block and cap as detailed
in Part 21-01.
9. Carefully
Carefully lower the crankshaft
crankshaft into
9.
place. Be careful not to damage
bearing surfaces.
10.
10. Check
Check the
the clearance
clearance of
of each
each main
main
bearing as detailed in Part 21-01.
21-24-17
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
cap. Install all bearing
main bearing cap.
(No. 3
caps except thrust bearing cap (No.3
bearing). Be sure that main bearing
caps are installed in original
locations. Torque the bearing cap
12.
12. Install
Install the
the thrust
thrust bearing
bearing cap
cap with
with
bolts fingertight.
fingertight.
13. Pry
Pry the
the crankshaft
crankshaft forward
forward against
against
thrust surface of upper half of bearing
(Fig.
(Fig. 31).
14.
14. Hold
Hold crankshaft
crankshaft forward
forward and
and pry
pry
thrust bearing cap to rear. This aligns
thrust surfaces of both halves of
of
bearing.
Retain forward
forward pressure
pressure on
on the
the
15. Retain
crankshaft. Tighten cap bolts to
crankshaft.
specifications.
16. Force
Force the
the crankshaft
crankshaft toward
toward the
the rear
rear
16.
of engine.
17.
17. Check
Check the
the crankshaft
crankshaft end
end play
play (refer
(refer
to Part 21-01).
18. Install
Install new
new bearing
bearing inserts
inserts in
in the
the
connecting rods and caps. Check
clearance of each bearing, following
procedure detailed in Part 21-01,
Fitting Bearings with Plastigage.
19.
19. After
After the
the connecting
connecting rod
rod bearings
bearings
have been fitted, apply light coat of
of
engine oil to journals and bearings.
20. Turn
Turn the
the crankshaft
crankshaft throw
throw to
to bottom
bottom
of its stroke. Push the piston all the
way down until rod bearing seats on
crankshaft journal.
the crankshaft
cap. Be
sure that connecting rod bolt heads
are properly seated in connecting rod.
Torque nuts to specifications.
22. After
After piston
piston and
and connecting
connecting rod
rod
side clearance between connecting
rods on each connecting
connecting rod
crankshaft journal.
crankshaft
23. Install timing chain and sprockets,
crankshaft
cylinder front cover, and crankshaft
damper as detailed in Cylinder Front
Cover and Timing Chain Installation.
24.
24. Install the engine rear cover plate.
Coat flywheel attaching bolt threads
with oil-resistant sealer. Position
flywheelononcrankshaft
crankshaftflange.
flange.Install
Install
flywheel
and torque the bolts to specifications.
25. Clean the oil pan, oil pump and oil
filling inlet
inlet port
port with
with engine
engine oil
oil and
and
filling
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.
21-24-18
21-24-18
460
460 CIO
CID V~8
V-8 Engines
Engines
21-24-18
21-24-18
MAIN
MAIN BEARING
BEARING INSERTS
INSERTS
t~,
6333
6337
6t:
REAR BEARING
BEARING
REAR
CAP
CAP JOURNAL
JOURNAL
SEAL-6701
FLYWHEEL-6375
(6701
~
6333
.
REAR BEARING
CAP JOURNAL
SEAL-6701
CRANKSHAFT
SPROCKET-6306
PULLEY-6312
PULLEY-6312
OIL SLINGER -6310

MAIN BEARING CAPS
SLEEVE-6359
A29700
A2970-D
FIG. 34 Crankshaft and Related Parts
DETAIL-l,-2or
-3
DETAIL.l,.2 or 3
EXPANDING COLLET
THRUST BEARING
DETAIL-8
PULLING NUT
DETAIL-1,-2 or -3
BACK-UP NUT
EXPANDING MANDREL
2.
3.
DETAIL-5
DETAIL5
PULLER
SCREW
PULLER SCREW
CAMSHAFT BEARING (LOOSE)

DETAIL-4
DETAIL4
PULLING
PULLING PLATE
DETAIL-6or-7
DETAIL6 or 7
PULLER
SCREW EXTENSION
PULLER SCREW
Tool-T65L-625Q.A
1001-165L6250.A
4.
A2813-A
A2813A
FIG. 35
35 Replacing
Replacing Camshaft
Camshaft Bearing
CAMSHAFT
CAMSHAFT BEARINGS
Camshaft
Camshaft bearings
bearings are
are available
prefinished
prefinished to
to size
size for
for standard
standard and
and
undersize journal
journal diameters.
diameters.
undersize
Removal
RemoysJ
1.
1. Remove
Remove the
the camshaft,
camshaft, flywheel,
flywheel, and
and
crankshaft,
following the
the appropriate
procedures
procedures in
in this
this part.
part. Push
Push pistons
pistons
to top
top of
of cylinders.
cylinders.
to
BACK TO GROUP INDEX
2. Remove the
the camshaft
camshaft rear
rear bearing
bore
bore plug
plug as
as detailed
detailed in
in Part
Part 21-01.
21-01.
Remove
Remove camshaft
camshaft bearings
bearings (Fig.
(Fig. 35).
35).
Installation
[nals/Jlllion
Select the
the proper
proper size
size expanding collet
1. Select
and
and back-up
back-up nut
nut and
and assemble
assemble on
on
expanding
expanding mandrel.
mandrel. With
With the
expanding
expanding collet
collet collapsed,
collapsed, install
install the
the
5.
5.
6.
6.
collet in the camshaft

camshaft bearing, and
tighten back-up nut on expanding
mandrel until collet fits camshaft
camshaft
bearing.
Assemble the puller screw arid
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
and pulling plate to remove camshaft
bearing. Hold a wrench on the end of
of
puller
puller screw to prevent
prevent it from
turning.
procedure for
for each
Repeat
puller screw from
from rear of
of
install puller
cylinder block.
Position new bearings at bearing
Position
bores" and
arid press in place with the tool
bores,
shown in Fig. 35. Be sure to center the
puller screw to avoid
pulling plate and puller
bearing damage. Failure
Failure to use
bearing
cause
correct expanding collet can cause
bearing damage. Align
Align oil
severe bearing
holes in bearings
bearings with
with oil holes
holes in
in
holes
cylinder block
block before
before pressing
pressing them
them
cylinder
front bearing
bearing is
is
block. Be sure front
into block.
installed specified
specified distance
distance below
below
installed
front face
face of
of cylinder
cylinder block
block (Fig.
(Fig. 36).
36).
front
Install the
the core
core plug
plug as
as detailed
detailed in
in
Install
Part 21-01.
21-01.
Part
Install the
the camshaft,
Install
crankshaft,
flywheel and
flywheel
and related
related parts,
parts, following
following
appropriate procedures
procedures in
in this
this part,
part,
appropriate
v-a
21-24-19
21-24-19
21-24-19
460 (10
CID V-8 Engines
except do
rod
do not
not check connecting rod
and main bearing clearances.
OIL FILTER
Removsl
Removal
The oil
is shown in
in
oil filter assembly is
Fig.
Fig. 37.
FILTER ELEMENT
6731
6731
ADAPTER FITTING
6890
Insta//ation
Installation
1.
on a new filter with
1. Coat the gasket on
oil. Place a new filter on the adapter
the filter until
fitting. Hand tighten the
the gasket contacts the sealing surface
then tighten 1/2 turn more.
the engine at fast idle and
and
2. Operate the
oil leaks are
are
for oil
oil leaks. If oil
check for
evident, perform the necessary repairs
to correct the leakage. Check the oil
and fill the
the crankcase to
to the
level and
the
correct level.
A3704- B
FIG. 37
37 Oil
Oil Filter
A2972-A
1.
pan under the
the filter.
1. Place aa drip pan
Unscrew the
the adapter
the filter from the
fitting and
the adapter recess.
and clean the
Clean the oil filter gasket surface.
FIG.
of
FIG. 36
36 Measuring Depth of
Camshaft Front Bearing

or bolts that
must be
be torqued, refer to
to Specifications.
Specifications.
Oil the threads with light engine oil.
oil. Do
Do
not oil
oil threads that require oil-resistant
VALVE LIFTER
Each lifter is
If
is aa matched assembly.
assembly. If
parts of one
one are intermixed with those of
another, improper valve operation may
result.
result. Disassemble and
and assemble each
lifter separately. Valve lifters should be
be
tested after assembly as described in Part
the lifter assemblies in
21-01. Keep the
in
proper sequence so they can be installed
bores.
in their original bores.
DisllSsembly
Disassembly
Hydraulic valve lifter assembly is
is
shown in
in Fig.
Fig. 38.
n,L
PUSH ROD
ROD SOCKET
SOCKET
PUSH
~:~~:
METERING VALVE
/METERING
VALVE
CHECK VALVE
CHECK VALVE SPRING
I... C.HECK VALVE SPRING

. . ./ , , _ PLUNGER SPRING
\ ; , ; " ' . .:....I.....,
LOCK
RINGpJGERW~'
BODY
. .
BODY
PLUNGER
VALVE
CHECK VALVE
RETAINER
A2867-B
FIG. 38
38 Hydraulic Valve Lifter
FIG.

1.
it from the groove.
groove. ItIt
pliers to release it
be necessary to
to depress the
may be
the
to fully release lock ring.
plunger to
2. Remove the push rod
rod cup,
cup, metering
2.
valve (disc),
(disc), plunger and spring.
3. Remove the plunger assembly and the
3.
plunger spring.
spring. Carefully remove the
BACK TO GROUP INDEX
plunger spring, check valve retainer

spring, check valve retainer and check
valve disc from the plunger.
Refer to
21-01 for
to Part 21-01
for cleaning
Assembly
Assembly
1.
on aa
1. Place the plunger upside down on
clean work bench.
2.
or ball
2. Place the
the check valve (disc or
check) in position over the oil hole on
the bottom of the plunger. Set
Set the
the
check valve spring on top of the check
valve (disc or
or ball check).
3. Position the check valve retainer over
the check valve and spring then push
the retainer down into place on
the
on the
plunger.
4.
the plunger spring and
and the
4. Place the
the
body.
plunger (open end up) into lifter body.
5.
5. Position the metering valve (disc) in
in
the plunger, and place push rod seat
in the plunger.
6. Depress the plunger and position the
6.
closed end of lock ring in the groove
of the lifter body. With the
the plunger
still depressed, position the open ends
of lock ring in the groove. Release the
plunger, and then depress it again to
to
fully seat the lock ring.
ring.
7. Use a hydraulic valve lifter leak-down
7.
to fill the lifter with test fluid.
tester to
fluid.
and valves.
springs, stem seals, and
Discard stem seals.
Clean and inspect cylinder head(s)
related components, using
and related
in Part 21-01.
pertinent procedures in
to Part
Part 21-01 for
for repair
Refer to
for cylinder heads and
and
procedures for
valves.
Assembly
Lubricate all valves, valve stems and
valve guides with heavy oil SE. The valve
tips are to have Lubriplate or equivalent
applied. The
The lubricant
lubricant isis toto be
beapplied
applied
1. Install each valve in port from which
1.
it was
was
was removed or to
to which it was
fitted. Install new stem seal on
on each
valve.
2. Set
Set valve spring and
and retainer over
valve stem. Compress spring (Fig. 39)
and install retainer locks.
VALVE SPRING
COMPRESSOR
CYLINDER HEAD
Disassembly
DisllSsembly
1. Remove rocker
rocker arm
arm bolts, oil
1.
oil
deflectors, fulcrum seats and
and rocker
arms. Remove exhaust manifolds and
spark plugs.
2. Clean carbon from combustion
2.
chambers before removing valves.
3. Compress valve springs (Fig. 39).
39).
and
Remove spring retainer locks and
release springs. Remove retainers,
A 3145-A
FIG. 39
39 Compressing Valve
SpringOn
Spring-On Bench
21-24-20
21-24-20
With dividers,
dividers, measure
measure assembled
assembled
3.3. With
height of
ofvalve
valvespring
springfrom
from surface
surfaceof
of
height
spring pad
pad on
on cylinder
cylinder head
head to
to
spring
underside of
ofspring
spring retainer
retainer (Fig.
(Fig. 40).
40).
underside
If
Check dividers
dividers with
with accurate
accurate scale.
scale. If
Check
aassembled
s s e m b l e d hheight
e i g h t eexceeds
xceeds
specification, install
install spacer(s)
spacer(s) below
below
specification,
to rreduce
to
sspring
p r i n g to
e d u c e hheight
e i g h t to
recommended dimension.
dimension. Reducing
Reducing
recommended
460
Engines
460 CID
CID V-8
v-a Engines
number
number side
side of
of the
the connecting
connectingrod
rod
and indentation
indentation notch
notch in
in piston
piston
and
positioned
positioned as
as shown
shown in
in Fig.
Fig. 42.
42.
Press Ram
y-p,essRam
assembled height
height below
below specification
specification
assembled
can cause
cause spring
spring breakage
breakage and
and rapid
rapid
can
of cam
cam lobe.
lobe.
wear of
wear
Driver
Detail A-7
INSERT
INSERT
TAPERED
TAPERED PILOT
PILOT
IN
IN PISTON
PISTON PIN
PIN
FOR
FOR PIN
PIN REMOVAL
REMOVAL
INSERT
INSERT THIS
THIS END
END
....."'"...~ _- IN
IN PISTON
PISTCl-l HOLE
HOLE
FOR
FOR INSTALLATION
~
FIG. 40
40 Measuring Valve Spring
Assembled Height
the fulcrum seats and

and sockets
4. Coat the
with Lubriplate. Make certain that
the rocker arm
arm bolts are
are in
in aa
serviceable condition before installing
them. Install rocker arms, fulcrum
fulcrum
seats, oil
as
oil deflectors and
and bolts as
detailed under Valve Rocker Arm
Arm
Installation.
5.
5. Install
Install exhaust
exhaust manifolds
manifolds and
and spark
spark
plugs.
plugs. Refer
Refer to
to Part
Part 21-01
21-01 for
forcleaning
cleaning
and
and inspection
procedures.
PISTON
PISTON AND CONNECTING ROD
ROD
Disassembly
Disassembly
1.1. Remove
Remove the
the bearing
bearing inserts
inserts from
from the
the
connecting
connecting rod
rod and
and cap.
cap.
2.
2. Mark
Mark the
the pistons
pistons to
to assure
assure assembly
assembly
with
with same
same rod
rod and
and installation
installation in
in the
the
same
same cylinders
cylinders from
from which
which they
they were
were
removed.
removed.
3.3. Using
Using an
an arbor
arbor press
press and
and tool
tool shown
shown
in
in Fig.
Fig. 41,
41, press
press the
the piston
piston pin
pin from
from
the
rod.
the piston
piston and
and connecting
connecting rod.
Remove
Remove the
the piston
piston rings.
rings.
Refer
Refer to
to Part
Part 21-01,
21-01, for
for cleaning
cleaning
and
and inspection
procedures.
Refer
Refer to
to Part
Part 21-01,
21-01, for
for repair
repair
procedures.
procedures.
Assembly
Assembly
Check
Check the
thefit
fit of
of aa new
new piston
piston in
inthe
the
cylinder
cylinder bore
bore before
before assembling
assembling piston
piston
and
and piston
piston pin
pin to
toconnecting
connecting rod.
rod. Piston
Piston
pin
pin bore
bore of
ofconnecting
connecting rod
rod and
and diameter
diameter
of
of piston
p i s t o n pin
p i n must
m u s t be
be within
within
specifications.
specifications.
1.1. Apply
Apply aalight
lightcoat
coat of
ofengine
engineoil
oiltotoall
all
parts.
parts. Assemble
Assemble the
thepiston
piston toto the
the
connecting
connecting rod
rod with
with the
the cylinder
cylinder
BACK TO GROUP INDEX
Adaptor
DetailA-2
A-2
Adapto, Detail
Tool-T65L-6135-C
Tool- T65L-6135-C
Cup
Cup Detail
Detai I A-l
A-l
21-24-20
21-24-20
compression
compressionrings
ringswith
withaafeeler
feelergauge
gauge
inserted
the ring
ring and
and the
the
inserted between
between the
lower
lower land.
land. Feeler
Feeler gauge
gauge should
should slide
slide
freely
freely around
around the
the ring
ring circumference
circumference
without
without binding.
binding. Any
Any wear
wear will
will form
form
aa step
ofthe
the lower
lower
step at
at the
the inner
inner portion
portion of
land.
If the
the lower
lower lands
lands have
have high
high
land. If
steps,
steps, replace
replace the
the piston.
5.5. Be
Be sure
sure the
the bearing
bearing inserts
inserts and
and
bearing
bearing bore
bore in
in the
the connecting
connecting rod
rod
and
and cap
cap are
are clean.
clean. Foreign
Foreign material
material
under
under the
the inserts
inserts will
will distort
distort the
the
bearing
bearing and
and cause
cause failure.
failure. Install
Install
bearing
bearing inserts
inserts in
in connecting
connecting rod
rod and
and
cap
cap with
with tangs
tangs fitting
fitting in
in slots
slots
provided.
provided.
OIL
OIL PUMP
PUMP
Disassembly
Disassembly
1. Remove
Remove the
the four
four screws and washers
washers
securing the
the oil pump
pump cover to
to the
the oil
oil
pump.
2. Remove the oil pump outer
outer rotor
rotor and
and
rotor
oil
rotor shaft
shaft assembly from
from the
the oil
pump housing.
3. Remove the
the cotter pin
pin that secures
the relief
relief valve plug in
in the oil
oil pump
housing. To remove the plug, drill aa
small hole and
and insert a self-tapping
screw in
in the
the relief
relief valve plug. Use
Use
pliers to
to remove plug from oil pump
housing (Fig. 43). Use care to prevent
prevent
the loss of the relief valve spring.
A 2967-B
FIG. 41
41 Removing or
or Installing Piston
FIG.
Pin-Typical
PinTypical
LEFT BANK
RIGHT BANK
NOTCH TOWARD
TOWARD
NOTCH
FRONT OF
OF ENGINE
ENGINE
FRONT
A2969-A
AZ969-A
FIG. 43
43 Removing
Removing Oil
Oil Pump
Pump Relief
Relief
FIG.
Valve Plug
Plug
Valve
NUMBERED
NUMBERED SIDE
SIDE OF
OFROD
ROD
A2975-C
A2975-C
FIG.
FIG. 42
42 Correct
Correct Piston
Piston and
and Rod
Rod
Positions
Positions
Start the
the piston
piston pin
pin in
in the
the piston
piston and
and
2.2. Start
the
the connecting
connecting rod.
rod. Using
Using an
an arbor
arbor
press,press
pressthe
thepiston
piston pin
pinthrough
through the
the
press,
piston and
andconnecting
connecting rod
rod until
until the
piston
the
end of
of pin
pin isis 1/16-inch
1/16-inch toto 1/8-inch
1/8-inch
end
below
below chamfer
chamfer of
of the
the pin
pin bore
bore ininthe
the
piston.
piston.
3.3. Check
Check the
theend
end gap
gapof
ofall
allpiston
piston rings.
rings.
End
Endgap
gapmust
mustbe
bewithin
withinspecification.
specification.
Follow
Follow the
the instructions
instructions contained
contained on
on
piston
piston ring
ring package
package and
andinstall
install the
the
piston
piston rings.
rings.
4.4. Check
Check the
the ring
ring side
side clearance
clearance of
of
4. Remove
Remove the
the spring
spring and
and relief
relief valve
valve
4.
from the
the oil
oil pump
pump housing.
housing.
from
Refer to
to Part
Part 21-01
21-01 for
for cleaning
cleaning
Refer
and inspection
procedures.
and
Assembly
Assembly
Install the
the relief
relief valve,
valve, spring
spring and
and the
the
1.1. Install
relief valve
valve plug
plug in
in the
the oil
oil pump
pump
relief
housing. Press
Press the
the plug
plug inward
inward until
until
housing.
seats; then,
then, install
install the
the cotter
cotter pin.
pin.
itit seats;
Install the
theouter
outer rotor
rotor and
and rotor
rotor shaft
shaft
2.2. Install
in the
the housing.
housing. Be
Be sure
sure that
that the
the
in
identification mark
markon
onthe
theouter
outerrotor
rotor
identification
i s on
on the
t h e same
s a m e side
s i d e as
as the
the
is
identification mark
mark on
on the
the inner
inner
identification
rotor. These
These parts
parts are
arematched
matched sets
sets
rotor.
and should
should only
only be
be replaced
replaced as
as an
an
and
assembly.Fill
Fillthe
thehousing
housingwith
withengine
engine
assembly.
oil for
forpriming
priming purposes.
purposes.
oil
21-24-21
21-24-21
CYLINDER ASSEMBLY
Di6llS8embly
Disassembly
1.
and remove all
all the
the parts not furnished
furnished
with the new cylinder assembly,
this Part.
Part.
2.
2. Remove the 4 cylinder head locating
3.
Assembly
Assembly
1.
2.
a work stand and install the cylinder
head locating dowels and block drain
plugs.
plugs.
BACK TO GROUP INDEX
460 CtO
CID v-a
V-8 Engines
from the old cylinder assembly,
of
this Part.
4.
CYLINDER BLOCK
determine if it is repairable. If so, make
Disassembly
DiSllSSembly
1.
and completely disassemble it,
of
this Part.
21-24-21
before removing
removing piston
bores before
assemblies.
3. Remove the cylinder head locating
Assembly
1.
of
2. Position the new cylinder block in a
work stand and install the cylinder
head locating dowels and the block
drain plugs.
3. Transfer
from the old cylinder block, following
the procedures given in the Removal
PaI1.
and Installation Section of this Part.

v-a
21-24-22
21-24-22
CID V-8 Engines

Engines
460 CIO
SPECIFICATIONS1975
SPECIFICATIONS-1975
SPECIFICATIONS
GENERAL
Engine
Engine
Bore and
and Stroke
Stroke
Bore
460
460
4.36x3.850
4.36
x 3.850
Pressure
Compression
PSI
PSI (Sea
(Sea Level)
Level) @Cranking
@ Cranking
Speed
Speed
Oil
Oil Pressure-Hot
Pressure-Hot
@2000
RPM
@2000RPM
Lowest reuding
reading must
must be
Lowest
be
40-6b
40-65
Drive
Drive Belt
Belt Tensions
Tensions (lbs.)
(lbs.)
Newly
Used
Newly Installed
Installed
Used
Size
Size
(1)
Over 10
Up
Up to
to 10
10 Min.
Mm.
10 Min.
Mm
(1)
Firing 0Order
rder
75% of
of the
the highest
highest
within 75%
50-flO
50-80
1-5-4-21-5-4-2-
1/4"
1/4'
6-3-7-13
6-3-7-8
Exc.
Exc. 1/4" 120-160
120-160
4fJ-fjfJ
40-60 (2)
(2)
(4)
75-120 (4)
40-HO
40-90 (2)
(2)
(3)
90-160
90-160 (3)
(1) ReiJrl
Read tension
tension immedidtely
immediately after
after belt
belt isis installed,
installed, before
before itit stretches
stretches or
or seats
seats in
in pulley
pulley grooves.
grooves.
(1)
(2)
(2) IfIf less
less thdn
than 40
40 pounds,
pounds, reddlust
readjust to
to 40-60
40-60 pounds.
pounds.
(3) IfIf less

less than
than 90
90 pounds,
pounds, readjust
readjust to
to 90-120
90-120 pounds.
pounds.
(3)
(4)
(4) IfIf less
less than
than 75
75 pounds,
pounds, readjust
readjust to
to 90-120
90-120 pounds.
pounds.
CYLINOER HEAD
HEAD
CYLINDER
Engine
Engine
Combustion
Chamber
Chamb.r
Volume
Guide
Valve Guid.
Bore
Bor.
Diameter
(Standard
and
Intake and
Exhaust)
Valve
Seat Width
SutWidth
Exhaust
Intake
Intak.
Valve
Arrange(Front
ment (Front
to Rur)
Rear)
Valve
Seat
Runout
(Maximum)
Valve
Seat
Angle
460
460
94.7-97.7
0.3433-0.3443
45
45
0.0600.080
CD
0.003
Right I-E-I-EI-E-I-E
Intake
0.0600.080
Gasket
Surface
Flatn..
Flatness
0.0016
inch
in Any
Left
E-l-E-I-E-I
E-l-E-l-E-l
Exhaust
450
45
6 inches,
inches,
0.006
Overall
E-l
E-'
H e a d Gasket Surface Finish RMS...

RMS .... 60-150
Q)Head
AND LIFTERS
Engine
Valve
Push
Push
Rod
(Maximum
Runout)
Rocker
Arm
Lift
Ratio
0.015
1.731
460
VALVE LIFTER
Standard
Diameter
Clearance
Clearanc.
To BoreCD
BoreQ
0.8740-
0.0007-
0.8745
0.0027
Hydraulic
Lifter
Leakdown Rate
Lukdown
Collapsed
Gap
Tappet Gap
5-50 Seconds
MaximumMeasured
at
Measured at
1116
1/16 Inch
plunger travel
Allowable
Desired
Oesired
0.075-0.175
0.100
0.150
WWear
e a r Limit-0.005
Limit0.005
0)
VALVE SPRINGS
Pres .,e
Lbs
Lbs. Specified Length
L.ngth
Engine
(j)0
Pressure
Preuure
76-84@
76-84
@ 1.81
1.81
460
Valve Spring
Valv. Spring
Valve
Free Length
AlIII1Ibl.d Height
Assembled
Approximate
Pad to Retainer
Out-of-Squar.
Out-of-Square
(Maximum)
1 51/64-1
51/64-1 53/64
2.03
@1.33
240-265 @
1.33
Valve Spring
5/64 (.078)
~'<D
Wear Limit - 10n
specified length
length.
1O~n pressure loss @
@ specified
VALVES
Valve Stem
Clearance
(D
CD Wear Limit
Limit - 0.0055.
Face
Diameter
CD
Exhaust
0.0010-
Intake
0.0010-
460
Valve
Head
Valve Heed
To Valve Guide
Engine
0.0027
0.0027
~ Valve face runout

runout - Maximum 0.0020.
Intake
Exhaust
2.075-2.090
2.075-2.090
1.646- 1.661
1.646-1.661
Angled)
Anll.(%)
and
Intake and
440
Exhaust 44
VALVES (Continued)
Engine
460
BACK TO GROUP INDEX
Standard
Standlrd
Diam.ter
Valve Stem Diameter
0.015 Oversize
0.015
0.003 Oversize
Intake
Exhaust
Intake
0.34160.3416
0.34160.3416-
0.3446
0.3446-
0.3423
0.3423
0.3423
0.3453
0:3453
Intake
Exhaust
0.34460.3446-
0.35660.3566-
0.3453
0.3453
0.3573
0.3573
I
1
00.030
0 3 0 Oversize
Exhaust
Intake
0.35660.3566
037160.3716-
0.3573
0.3573
03723
03723
Exhaust
03716
0.3716-
0.3723
03723
CA1310-C
CA1310C

v-a
21-24-23
460 (10
Engines
CID V-8 Engines
21-24-23
CRANKSHAFT AND
AND FLYWHEEL
FLYWHEEL
CRANKSHAFT
i i i
Main Bearing
Bearing
Main
Main Bearing
Bearing
Main
Journal
Journal
Journal RunoutRunoutJournal
Diameter
DiameterG)
Maximum
Maximum
Engine
Engine
CD1
Surface
Surface Finish
Finish
RMS
RMS Maximum
Maximum
JournalG)
length
Length
(3)
@
Thrust
Thrust Face
Face
Journal
Journal
25
25 Front
12
.12
1.124-1.126
1.124-1.126
Per
Per Inch
Inch
Wear Limit
Limit - 0.005
0.005
22 Wear
Main
Main Bea,.ng
Bearing
Thrust
Thrust
Bearing
Bearing
0.0006
0.0006
0.001
0.001
Main bearing
bearing journal
maximum 0.0006
0.0006 (all
(allengines).
engines).
Main
Main
Main Bearing
Bearing
Journal
Journal
Taper
Taper Max
Thrust Face
Face
Thrust
Runout
Runout
0.002
0.002
2.9994-3.0002
2.9994-3.0002
460
460
Main Bearing
Bearing
Main
Journal
Journal
23
23 Rear
Main
Main Bearing
Bearing Thrust
Thrust Face
Face Runout
Runout....
. . 0.001
0.001 Max.
Max.
CRANKSHAFT AND
AND FLYWHEel
FLYWHEEL (Continued)
(Continued)
CRANKSHAFT
Connecting Rod
Rod
Journal Diameter
Diameter CD0
Journal
Engine
460
460
0
CD
Connecting Rod
Connecting
Rod
Bearing Journal
Journal
Bearing
Maximum Taper
Crankshaft Free
End
End Play~
Play (2>
0.0006 Per
Per Inch
Inch
0.004-0.008
2.4992-2.500
Flywheel Ring
Ring Gear lateral
Lateral Runout
Runout
Transmission
Automatic
Standard
0.060
0.060
0.012
22 Wear
Wear Limit
Limit - 0.012
Connecting rod
rod journal
maximum 0.0006
0.0006
Connecting
BEARINGS
CRANKSHAFT BEARINGS
Rod Bearings
Connecting Rod
Engine
(j)
Desired
Wall
Wall ThicknessStandard (J)0
Allowable
0.0008-0.0028
0.0006-0.0026
0.0008-0.0015
0.0006-0.0015
460
Main Bearings
Desired
NO.1
0.00040.0015
No. 1.0.0004-0.0015
No.2,
No. 2, 3,
3, 44 and
and 55
0.0009-0.0015
0.0756-0.0761
Wall
Wall Thickness
ThicknessStandard
Standard o
CD
Allowable
NO.1
No. 1 0.0004-0.0020
0.0004-0.0020
No.1
No. 1 Only 0.0960-0.0965
0.0960-0.0965
Others
0.0955-0.0961
0.0955-0.0961
No.2,
No. 2, 3, 4 and
and 55
0.0009-0.0026
Add 0.0010 to Standard Thickness

. .. A.dd
Thickness
0.002 Undersize Thickness.
CAMSHAFT CD0
Item
Bearing
(No. 1)
(No.1)
Camshaft Journal
(No. 2)
(No.2)
Diameter
(No. 3)
(No.3)
Standard
Item
Inches
Camshaft Bearings
(No.2)
(No. 2)
2.1238-2.1248
2.1258-2.1268
(No.3)
(No. 3)
Inside Diameter
(No. 4)
(No.4)
Q)
Inches
Bearing
(No.1)
(No. 1)
(No.4)
(No. 4)
(No.5)
(No. 5)
(No.5)
(No. 5)
0(2) Camshaft journal maximum runout

runout....
. . 0.005 T.I.R.
T.I.R.
Camshaft Bearing
Location Q)
(No.1)
(No. 1)
0CD Timing Chain Deflection (Maximum) .
Camshaft journal maximum out-of-round

out-ot-round ...
. . . 0.0005 T.I.R.
0.0400-0.0600
0.0400-0.0600
~ Distance in
at the bearing is
Q)
in inches that the tront
front edge of
is installed below
0.500
. ..0.500
tace of
of the cylinder block (towards the rear).
the front face
Lobe Lift
Engine
460
Intake
Theoretical
Valve Lift
CD0
Exhaust
Intake
0.4370
0.2780
0.253
0.2G3
Camshaft Journal
to Bearing Clearance
Camshaft
Exhaust
End Play
0.4509
0.0010.006
Wear Limit
Clearance
Wear Limit
0.009
0.001
0.003
0.006
0CD Maximum allowable lift loss 0.005

CAMSHAFT
CAMSHAFT VALVE
VALVE TIMING
II
Engine
460 - PI
PI
Intake Valve
I
I
Opens
0.004 @ 18
BTC
180 BTC
Exhaust Valve
Closes
0.006 @ 72
ABC
72 0 ABC
Opens
0 SSC
0.004 @ 86
86
BBC
I
I
Closes
0 ATC
00.006
006 @
@ 26
26
ATC
CYLINDER
CYLINDER BLOCK
Cylinder Bore Diameter 0

3)
CD( Q)
Main Bearing Bore Diameter

Diamete,
4.3600-4.3636
4.3600-43636
0.8752-0.8767
08752 -0.8 76 7
3.1922-3.1930
31922-3.1930
Maximum out-of-round-0.0015
out-of-round - 0.0015
CD Maximum
Wear Limit
Limit -- 0.005
Cylinder
Cylinder bore
bore surface
surface finish
finish RMS
RMS -- 18-38
Cylinder
Cylinder Block Distributor
Head Gasket
Crankshaft To Rear Face Of

Of
Crankshaft
Shaft
Shaft Bearing Bore Diameter
(%))
Surface Flatness &
(Runout TIR
T1R Max)
Max)
Block (Runout
0.5160-0.5175
0.5160-0.5175
0.003 inch in any 6 inches

or 0.006 inch overall
0.005
(2) Head surface finish RMS

RMS -- 60-.150
60-150
(j) Maximum
MaXimum taper
taper - 0.001
0.001
O
Limit - 00.010
Wear Limit
.010
CA1310-Cl1
CA1310-C
BACK TO GROUP INDEX

460 CID v-a

V-8 Engines
21-24-24
21-24-24
CONNECTING ROD
RID
Engine
Enline
460
Piston Pin
Pin
Bore Of
Or
.....ing
Bushing
Crank Bearing
Bore Diameter
ID
10
<D
2.6522-2.6530
1.0386-1.0393
Connecting Rod
Rod
Aaembly
Assembly
(AaembtedTo
(Assembled
To
Crankshaft)
Crankshlft)
Wear
Weir
Side
Limit
Clearance
Clllrince
0.023
0.010-0.020 I
Connecting Rod
Rod
Alignment
Mlximum Totlt
Meximum
Total
Difference
Difference
CV
Connecting
Rod Length
Cent.r
Center
To Center
II
Twist
6.6035-6.6065
0.024
Bend
0.012
(T)Crank bearing
bear ng bore maximum out-of-round and
and taper - 0.0004.
@rank
()Pin bushing and
be parallel and
and in the
the same vertical plane within the
the specified total difference
~in
bar, 4 inches on
on each side of rod.
when measured at ends of 8-inch long bar,
rod.
PISTON
PISTON
Diameter
Diameter
CD
Engine
Engin,i
460
Coded
Red
Red
Coded
Blue
Blu.
Oversize
4.35854.3591
4.3591
4.35974.3603
4.36094.3615
Piston To
Cylinder Bore
Clearance
CI.arance
O.DG3
0.003
0.0014-0.0022
Piston Pin
Pin
Ring Groove Width
Bore
Diameter
Dilmeter
R ng .......... ... ....... .... ........ 0.0805-0.0815

Upper. Compression Ring
Lower Compression Ring ... ...
....... ..... . ..... 0.0805-0.0815
0.188-0.189
Oil Ring .............. " .. ....... ........ ........ .. . .. 0.1880.189
1.04021.0405
Measured at the
the piston pin
pin bore centerline at 90
90 to the
the pin
pin bore.
leD
0
PISTON PIN
Diameter
Engine
Enline
Length
Standerd
Standard
460
3.290-3.320
1.0399-1.0402
0.001 Ov.rsize
Oversize
1.0410-1.0413
0.002 Ov.rsize
Oversize
To Piston
Clearance
Clearlnee
To Connecting
Rod Bushing
Bu"'ing
Clllr.nc.
Clearance
0.0002-0.0004
Interference Fit
PISTON RINGS
Ring Width
Comprlllion
Compression
Ring
Engin.
Engine
TOp
Top
460
Bottom
0.077-0.078
0.077-0.078
0.0770.078
Side CI..r.nc.
Clearance
Sid.
Compression
RingeD
Ring
TOp
Bottom
Top
0.0020.0020.004
0.004
Oil
Ring
Snug
Gap Width
Ring G.p
Compre.ion
Compression
Ring
TOp
Top
Bottom
I
Oil
Ring
0.0150.055
0.015-0.055
0.0100.020
0.010-0.020
~Steel
Steel Rail
2)Wear Limit .......................... 0.006

ICDWear
Q)
0.01D-0.020
0.010-0.020
OIL PUMP
~IL
RotorType
Rotor-Type Oil
Relief VIIw
Verve
Pump "lIitt
Tension
Spring T.nsien
9 Specifitd
Specified
Lbs ..
Length
Ltngtb
20.6-22.6 @ 2.49
2.49
Engine
460
Drive Shift
Shaft
Driv.
To Housing
Bearing
B.ring
Cleerance
CI.rlnee
0.0015-0.0029
APPROXIMATE OIL PAN

CD
PAN CAPACITIES (T)
Engin.
US
r.
Engine
U S
Measure
4 Quarts
460
1'0
(T) Add one
one Quart
quart with filter
f Iter replacement.
Relief Vllv.
Velve
Clllrine.
Clearance
0.0015-0.0029
Rotor Aaembly
Assembly
End CI.arance
Clearance
Out.r
R.c.
Outer Race
To Housing
(Radial
CIranel)
Clearance)
0.001-0.004
0.001-0.013
Imp.iII
Imperial MlllUr.
Measure
4 Quarts
(7) Torino, Elite,
El te, Montego &
(6)
Cougar require 6 quarts, add

add one
one quart for filter replacement.
rORQUE LIMITS
~ORQUE
Cylinder H.d
Head Bolts
Cylind.
Engi",
Engine
460
Step 2
St.p2
St.p1
l
Step
7080
70-80
Step3
Step
3
100110
100-110
130140
130-140
Oil Pin
Pan To
Cylinder Block
Cylind.
9-11
(5/16)
9-11(5/16)
7-9
(1/4)
7-9(1/4)
Manifolds To
Cylindtr
H.d
Cylinder Heed
Intake
25-30
I
I
Exhlust
Exhaust
28-33
Distributor
Vacuum
Control
Valve
V.lv.
1518
15-18
Flywhtel
Flywheel
To
Crank....ft
Crankshaft
7585
75-85
~ORQUE
rORQUE LIMITS (Continultl)
(Continued)
Main
Oil Pin
Pan
Gil
Engine
E..ine
Bearing
Bttrilll
Cap Bolts
ClP
Drain
Plug
Plul
OHPump
OH Pump
To
Cylinder
Cylindtr
Block
Oil
Pump
Cover
Plate
Pllt.
Oil Filter
Insert to
Cylind.r
Cylinder
Block
460
95-105
1525
15-25
2D-25
20-25
6-10
20-30
Oil Filt.r
Filter
Adapter
To Adlpter
Or Cylinder
Block
Cylinder
Cvlinder
Front
Cover
Cov.r
With grease on
on the
the gasket surface,
hand-tighten until gasket contacts adapter
1520
15-20
CA1310B2
CA1310B 2
BACK TO GROUP INDEX

460 (to
CID v-a
V-8 Engines
21-24-25
21-24-25
TORQUE LIMITS (Continued)

(Continutd)
Engin.
Engine
Camshaft
Cam....1t
C1t
Camshaft
Sprocktt
Sprocklt
To
Camshaft
Camshlft
Thrult
Thrust
PI.t.
Plata
In Block
4Q-45
40-45
9-12
912
460
460
D.mper
Damper Or
Pullty To
Pulley
Crankshaft
Crenk....ft
Connecting
Rod
Nuts
Valve
V.Iv.
Rocker
Arm
Covar
Cover
70-90
7090
4045
40-45
5-6
56
TORQUE LIMITS (Continu.d)

(Continued)
Engine
Engin.
Oil Inlet Tub.

Tuba
To Oil Pump
Fu.1
Fuel Pump To
Cylinder Block Or
Cylinder Front Covar
Cov.r
Pull.y To
Pulley
Damper Bolts
D.mptr
Boltl

Altern.tor
Valve Rocker Arm

Valv.
Stud To Cylind.r
Hlld
Cylinder Head
460
460
Press Fit
19-27
1927
35-50
3550
45-57
4557
1825
18-25
MISCELLANEOUS TORQUES - FTLB

FT-LB
Spaik~ Plug
Plug Tll
To Cylinder Head
Spell
10-15
80-115 in-Ib
in-lb
Altelll,ltlH
35-50
Alternator
Allr~rlldllH
24-40
35-50
25-35
25-35
25-35
35-50
12-18
Adjusting Arm to Alternator
Therlllllctur
Thermactor Pump Brocket
Bracket tll
to Cylinder Block
Thermilctor
Thermilctllr
Thermactor Adiusting
Adjusting Arm to Cylinder Block
Therrnactor

Fan

EGR
EG
12-15
max.
15 max.
29-31
29-31
12-18
U.S. Thread Sizes

20 ::= 6-9
1/4 5/165/16 5/165/16 -
18 ::= 12-18
24::
24 = 14-20
3/8 - 16 ::- 22-32
Pipe Thread Sizes

-- 24 ::= 27-38
7/1
57
= 4545-57
7 / 1 6G 14 ::
3/8
1/8 ::= 5-8

1/4 ::= 12-18
3/8 :== 22-33

1/2 :== 25-35
7/1G
7 / 1 6-- 20 ::- 40-60
1/2 -- 13 ::= 55-80

BOLTS-FTLBS
CAUTION: If any of the torque limits listed in this table disagree with any of those listed in the preceding tables,
tables, the limits listed in the preceding tables prevail.
7/16-14
Size (inches)
1/420
5/1618
3/816
7/1614
1/213
3/8-16
1/2-13
5/16-18
1/4-20
22-32
Torque (Ftlbs)
69
1218
2232
4055
5580
(Ft-lbs)
40-55
55-80
12-18
6-9
9/1618
9/16-18
85-120
85120
SEALERS
ILoctite (thread locking compound)
C3AZ-19554-A
C3AZ19554A
3
CA1310C
CA1310C3
BACK TO GROUP INDEX

21-24-26
21-24-26
212426
CID V-8
V-8 Engines
Engines
460 Cto
SPECIFICATIONS1976
SPECIFICATIONS-1976
SPECIFICATIONS
Engine
and Stroke
Stroke
Bore and
460
460
4 . 3 6 xx33.850
.850
4,36
Compression Preaure
Pressure
Compression
PSI
PSI (Sea
(Sea leven
Level) il
@ Cranking
Cranking
Speed
Speed
Firing O,rder
Order
Firing
1/4"
5080
1/4"
50-80
Exc.1/4"
120-160
Exc. 1/4' 120160
1-5-4-215-4-2-
40-65
Lowest reading
reading must
must be
Lowest
be
75% of
of the
the highest
highest
within 75%
Drive
Drive Belt
Belt Tensions
Tensions Ubs.)
(lbs.)
Newly
U.d
Newly Installed
Installed
Used
(1)
Over
10 Min.
Up
Min.
U p to
t o i10
OM
in.
OveHOMin
(1)
Size
Size
Oil PressureHot
Pressure-Hot
Dil
2000RPM
il2000
RPM
6-3-7-8
6378
40-80
(2)
40-80 (2)
90160
(3)
90-160 (3)
(1) Read
Read tension immediately
immediately after belt
belt is
is installed.
installed, before
before itit stretches or
or seats
seats in
in pulley
pulley grooves.
grooves.
(1)
(2)
(2) If
If less
less than
than 40
40 pounds.
pounds, readjust
readjust to
to 4060
40-60 pounds.
pounds.
less than 90
90 pounds.
pounds, readjust
readjust to
to 90-120 pounds.
pounds.
(3) IfIf less
(4)
(4) IIff less
less than 75
75 pounds,
pounds, readjust
readjust to
to 90120
90-120 pounds.
pounds.
4060
(2)
40-60 (2)
75120
(4)
75-120 (4)
CYLINOER HEAD
CYLINDER
Combustion
Chi
Ch.mber
V
Volum.
Enfint
ERline
460
460
94.7-97.7
Valve Guidi
Guide
Vllve
Bora
lor.
Diam.ter
(Standard
Intake and
Intllllind
Exhaust)
ExhMlst)
VIIvt
S t Width
Width
SlIt
Exhaust
Exhlust
Intaka
Intlkl
Valve
Vllve
Saat
SlIt
Runout
(Maximum)
Valve
ArrangeAmn...
ment (Front
(Front
m.nt
to Rear)
toR.r)
0.0016
Right IE
I-E-I-EI-E
IEIE
I-E-I-E
Left
E-l-E-l-E-l
EIEIE1
E-l
E-l
Intake
0
450
45
0.0600.060
0.080
0.0600.060
0.080
0.3433-0.3443
Valve
Vllve
SlIt
Anll'
Exhaust
450
45
G_et
Surface
Surflc.
Flltn_
Flatness
CD
0.003
0.003
inch
inch
in
in Any
Any
6
6 inches,
inches,
0.006
Overall
Overall
H e a d Gasket Surface Finish RMS........

RMS
60-150
!CDHead
60150
LIFTERS
VALVE ROCKER ARMS, PUSH RODS AND LIFTERS
Engine
Engin.
Valve
Vllvt
Rocker
Rocker
Arm
Rod
(Mlximum
Runout)
Lift
Ratio
Rltio
460
460
VALVE
VALVE LIFTER
LIFTER
Push
0.015
1.73:11
1.73:
Hydnulic
Hydraulic
Lifter
Leakdown Rlt.
Rite
L.kdown
Claaranca
CI.rlnel
Standard
Stlndlrd
Diameter
Dilmet.r
To 10r.CD
Bora
To
0.87400.8740'
0.00070.0007
0.8745
0.0027
Colli""
Tippet
Tippet Glp
Gap
5-50 Seco
Seconds
550
nds
MaximumMaximumMeasured
at
Measured at
1/16
1/16 Inch
Inch
plunger travel
Allowlbl.
D.rld
0.075-0.175
0.075-0.175
0.100
0.100
0.150
0.150
( D Wear Limit-0.005
Limit0.005
ICD
VALVE
VALVE SPRINGS
Valve
VI've Spring
Spring Pressure
Pr...r.
Lbs
Specified Length
L.ngth
L
o s(I
e Specified
Engine
Engin.
Valve
VI've Spring
<D0
Fr. Length
Free
Length
Approximlt.
Approximate
Pressure
PrlllUr.
76-84
@ 1.81
76-84@
1.81
460
2.07
2.07
218-240
1.33
218240 @ 1.33
<D
Valve
Spring
VII" Spring
"-"bled H.ight
Pad
Retainer
Pld to
to Retlinl'
Vlive
Vllve Spring
1 51/64153/64
51/64-1
53/64
5/64 (.078)
(.078)
5/64
Out-ofSqulre
OutofSouire
(Maximum)
(T) Wear Limit

specified length.
length.
Limit - 10% pressure loss @ specified
VALVES
VALVES
varve
stem
V.Iv. Stem
Clearance
et.r.nc.
Intake
460
<D
Wear
Wear Limit
Limit -- 0.0055.
0.0055.
Vllv.
F.e.
An".(%)
Vllv. H.d
Dilmltlr
To
To Valve
V.Iv. Guide
Guid.
Engin.
CD
0
Exhlust
0.0010
0.0010
0.0027
0.0027
Q)
~ Valve
Valve face runout
runout -- Maximum
Maximum 0.0020
0.0020.
Intllll
ExhlUlt
2.075-2.090
1.646-1.661
Intake and
Exhaust 440
VALVES
(Continued)
VALVES (Continu.d)
Valve
Diameter
VII" Stem
Stem Dilm.t.r
Engine
Engin.
Standard
Standlrd
Intake
Intllll
460
0.34160.34160.3423
0.3423
BACK TO GROUP INDEX
0.003
0.003 Oversize
Oversiz.
Exhaust
Exhlult
Intake
Intllll
0.34160.3416-
0.3446
0.3446-
0.3423
0.3423
0:3453
0.3453
0.015 Oversize
Ovnz.
0.015
ExhlUlt
Exhaust
Intlke
Intake
0.34460.3446-
0.35660.3566-
0.3453
0.3453
0.3573
0.3573
0.030 Oversize
Ov.rsiz.
0.030
Exhlust
Exhaust
Intlke
Intake
Exhlust
Exhaust
0.35660.3566-
0.37160.37160.3723
0.3723
0.3716
0.3716-
0.3573
0.3573
0.3723
0.3723
CA1310-D
CA1310D

460 CID
CIO V-8
v-a Engines
Engines
21-24-27
21-24-27
21-24-27
CRANKSHAFT AND
AND FLYWHEEL
FLYWHEel
CRANKSHAFT
Main Bearing
Bearing
Main
Engine
Engine
Journal
Journal
Journal
Journal
Thrust Face
Face
Thrust
Maximum
299943.0002
2.9994-3.0002
Main Bearing
Bearing
Main
Journal
Journal
Journal
CD
Diameter
Diameter
460
460
Main Bearing
Bearing
Main
Main Bearing
Bearing
Main
0.0006
0.001
CD Main bearing journal

journal out-of-round
maximum 0.0006 (all engines).
CD
Main
Main Bearing
Bearing
Surface
Surface Finish
Finish
Journal
Journal
Taper
Taper Max
Max
Per Inch
0~ Wear Limit
- 0.005
Q)
(3)
G)fi)
RMS
RMS Maximum
Length
Journal
Journal
1.124-1.126
1.124-1.126
12
Runout
0.002
Thrust
Thrust
Bearing
Bearing
Thrust
Thrust Face
Face
25 Front
Front
23 Rear
Rear
Main Bearing Thrust

Thrust Face Runout
Runout . . . 0.001 Max.
Max.

flYWHEEL (Continued)
CRANKSHAFT
Engine
Rod
Connecting Rod
Journal Diameter CD
0
Rod
Connecting Rod
Bearing Journal
Maximum Taper
Taper
Crankshaft Free
Play(%)
End Play
(2)
460
2.4992-2.5000
2.4992-2.5000
0.0006 Per Inch
0.004-0.008
0004-0.008

Transmission
Standard
Automatic
N.A.
N.A.
0.060
CD Connecting rod journal

journal out-of-round maximum 0.0006.
Q) Wear Limit
- 0.012
0.012
CD
CRANKSHAFT BEARINGS
Rod Bearings
Bearings
Connecting Rod
Main Bearings
Engine
Desired
Wall ThicknessStandard 0
CD
Allowable
_._-
Desired
Wall ThicknessStandard
Allowable
No 1 0.00040.00040.0022
0.0022
00008-0.0015
0.0008-0.0O15
460
0.0756-0.0761
0.0008-0.0026
0.0008-0.0026
0.0008-0.0015
0.0008-0.0015
CDQ
No. 1 Only 0.0960-0.0965
No 2,3,4
2.3.4 and 55
No.
Others 0.0955-0.0961
0.0955-0.0961
0.0008-0.0026
0.0008-0.0026
Add 0
00010
Stand,Hd Thickness
Add
0010 to Standard
0 . 0 0 2 U S. Thickness
CD
CAMSHAFT (D
Item
Bearing
Camshaft
Camshaft Journal
Journal
(No.1)
(No. 1)
(No.2)
(No. 2)
Diameter
(No.3)
(No.
3)
Item
Inches
Inches
(No.1)
(No. 1)
Camshaft Bearings
2.1238-2.1248
(No.2)
(No. 2)
(No.3)
(No.
3)
Inside Diameter
InSide
(No.4)
(No. 4)
Standard Q>
(Z)
Bearing
2.1258-21268
2.1258-2.1268
(No.4)
(No. 4)
(No.5)
(No. 5)
(No.5)
(No. 5)
Camshaft Bearing
(Z)
<2) Camshaft journal
max mum runout.
runout
lournal maximum
Location (3)
(j)
(No.1)
(No. 1)
0Q) Timing Chain

Chain Deflection (Maximum),
(Maximum). . .... ....
. 0.005 T.I.R.
. 0.0005 T.I.R.
T.I.R.
.0.0005
Camshaft |ournal
max mum outofround.
out-of-round
journal maximum
0.0400-0.0600
Q)
is installed below the
CD Distance in
in inches that the
the bearing is
.0.500
0.500
front face of the

the cylinder block (towards the
the rear),
rear).
Theoretic.1
Theoretical
V.lve
Valve lift
Lift
Lobe lift
Lift CD
fl)
CD
0
Engine
Intake
460
0.253
MaXimum
Maximum allowable lilt
lift loss
loss 0.005
0.005
Camshaft Journal
Camshaft
Exhaust
Intake
Exhaust
End PI.y
Play
0.2780
0.4370
0.481
0.481
0.0010.006
Limit
Wear limit
Clearance
Wear Limit
0.009
0.001
0.0010.003
0.006
CAMSHAFT VALVE TIMING

TIMING
Intake Valve
Engine
Opens
0.004 @ 18
18 BTe
BTC
460 - PI
PI
Exhaust Valve
Closes
0.006 @ 72
72 ABC
ABC
Opens
Opens
0
86
BBC
0.004 @ 86
SSC
Closes
0 ATC
26
0.006 @ 26
CYLINDER BLOCK
Cylinder Bore
Bore Diameter CD
0 ( (3)
3)
Tappet Bore
Bore Diameter
Main Bearing
Bearing Bore
Bore Diameter
Main

Shaft Bearing
Bearing Bore
Bora Diameter
Sh.ft
Head Gasket
Head
Flatness (%)
(2)
Surface Flatness
To Rear
Rear Face
Face Of
Crankshaft To
TIR Max)
Block (Runout TIR
Mu)
4.36004.3636
4.3600-4.3636
0.8752-0.8767
3.19223.1930
3.1922-3.1930
0.51600.5175
0.5160-0.5175
in any
any 6
0.003 inch In
inches or
or 0.006 Inch
inch overill!
overall
0005
0005
CD
0 Maximum
0.0015
Wear
Wear limit
Limit - 0.005
0.005
Cylinder bore
bore surface
surface finish
finish RMS
RMS - 18-38
18-38
Q) Head
Head surface
surface finish
finish RMS
RMS - 60150
60-150
~
Q) Maximum
Maximum taper
taper - 0.001
(3)
0.001
Wear Limit
Limit - 0.010
Wear
0.010
CA1310D
CA'3'OO
'
BACK TO GROUP INDEX

460 CID v-a

V-8 Engines
21-24-28
21-24-28
CONNECTING
ROD
CONNECTING ROD
Connecting Rod
Rod
Connecting
Connecting Rod
Rod
CD
Connecting
Rod Length
Length
Rod
Center
To Center
2.6522-2.6530
6.6035-6.6065
Piston
Pin
Piston Pin
Bore Or
Or
Bushing
Engine
Engine
Crank Bearing
Bore Diameter
10
ID
460
460
1.03861.0393
1.0386-1.0393
Alignment
Alignment
Assembly
Assembly
Maximum Total
Maximum
(Assembled To
To
(Assembled
CD
Crankshaft)
Difference
Difference
Twist
Twist
Bend
Bend
Clearance
0.010-0.020
0.010-0.020
0.012
0024
0.024
Side
Side
Wear
Wear
limit
Limit
0.023
G)Crank
CvCrank bearing bore maximum out-of-round and
and taper - 0.0004.
@Pin
(J)Pin bore and
be parallel and
and in
in the
the same vertical plane within the
the specified total difference
when
when measured
measured at
at ends of
of 8-inch long bar, 4 inches on
on each
each side of rod
rod centerline.
>ISTON
'ISTON
DiametereD
Diameter 0
Engine
460
Coded
Red
Red
Coded
Blue
0.003
Oversize
4.35854.3591
4.3591
4.35974.3603
4.36094.3615
Piston To
Cylinder Bore
Clearance
Piston Pin
Pin
Bore
Diameter
0.0014-0.0022
1.04021.0405
Ring Groove Width
. 0lJOFm~j-OQ(J
1:)
0805-0.0815
Upper.
Compression Ring.
Upper.Compression
Ring
Lower Compression Ring ..
Oil Ring .... ..... ....
..
.,
0080:J-OOfJ1Sb
... 0.0805-0.081
0.188-0.189
. .0.188-0.189
"
0 to
ICD
Q j Measured
Measured at
at the
the piston pin
at 90
90
to the
the pin.
pin.
PISTON PIN
PIN
Diameter
Engine
Length
Standard
460
460
3.290-3.320
1.0399-1.0402
0.001 Oversize
To Piston
To Connecting
0.002 Oversize
Clearance
Rod Bushing
0.0002-0.0004
0.0002-0.0004
Interference Fi
Fit
Interference
Clearance
1.0410-1.0413
PISTON RINGS
RINGS
Ring Width
Compression
Ring
TOp
Top
I
Engine
460
0.0770.078
0.077-0.078
Bottom
0.077-0.078
0.0770.078
Side Clearance
Compression
Ring
RingeD
Top
Bottom
0.00250.00250.0045
0.0045
Ring Gap Width

Compression
Ring
Oil
Ring
Snug
(2)
(2)
Top
Top
Bottom
0.0100.020
0.010-0.020
0.010-0.020
0.010-0.020
(2) Steel Rai

Rail
Steel
Wear Limit .......................... 0.006

IQ)Wear
Oil
Ring
0.0150.055
0.015-0.055
OIL PUMP
Rotor-Type Oil
RotorType
Pump Relief Valve
Spring Tension
<s>Specified
Specified
Lbs @
L.ngth
Length
20.6-22.6 @
@ 2.49
2.49
Engine
460
460
Drive Shaft
To Housing
B.lring
Bearing
Clearance
0.0015-0.0030
PAN CAPACITIES CD
(])
APPROXIMATE OIL PAN
U S Melsure
Measure
Engine
US
4 Quarts
Quar
460
CO
Add one
one qUc1fl
quart with fiiter
filter replacement
replacement.
1) .i\dd
Outer Race
Relief Vllve
Valve
Rotor Assembly
Clearance
End Clearance
0.0015-0.0030
Max.
0.004 Max.
To Housing
(Radial
Clearance)
0.001-0.013
Imperial Measure
3Y2
31/2 Quarts
FORQUE LIMITS
LIMITS
TORQUE
Cylinder Head Bolts

Engine
Engin.
460
460
Step 2
Step 1
70-80
100-110
Step 3
130-140
130140
Pan To
To
Oil Pan
Cylinder Block
9-11 (5/16)
9-11
7-9(1/4)
7-9
(1/4)
Manifolds To
Cylinder Head
Intake
22-32
I
I
Exhaust
Distributor
Distributor
Vacuum
Control
Valve (PVS)
(PVS)
28-33
2833
15-18
1518
Flywheel
To
Crankshaft
Crlnkshlft
75-85
7585
rORQUE LIMITS (Continu.d)

(Continued)
trORQUE
Engine
Engine
460
460
Mlin
Be.nng
Buring
Cap Bolts
Oil Pin
Pan
Drain
Drlin
Plug
95-105
95105
15-25
1525
Oil Pump
To
Cylinder
Block
22-32
Oil
Pump
Cover
Cover
Plate
Pllte
Oil Filter
Insert to
Cylinder
Block
Block
6-10
20-30
2030
Oil Filter
To Adapter
Or Cylinder
Block
Cylinder
Cylinder
Front
Front
Cover
With oil on
on the
the gasket surface,
hand-tighten
handtighten until gasket contacts adapter
more *
15-20
1520
CA1310-C
CA1310C 22
BACK TO GROUP INDEX

V-8 Engines
460 CID v-a
21-24-29
21-24-29
TORQUE LIMITS (Continued)

(Continutd)
Engi",
Engina
460
460
Camshaft
Clm....
ft
Sprocket
Sprocklt
To
Camihaft
c........
ft
Camihaft
c.msh.ft
Thrurt
Thrust
Pliti
PI.tl
In Block
Dampar Or
D.mp.r
Pulley
Pullty To
Cr.nk....
ft
Crankshaft
Connwting
Connecting
Rod
4Q.45
40-45
9-12
912
70-90
4045
40-45
Vahra
Yllv.
Rockar
Rocker
Arm
Covtr
Cover
Nuti
NUb
5-6
56
TORQUE LIMITS (Continu.d)

(Continued)
Engin.
Engint
Oil Inlet
Tub.
Intot Tuba
To Oil Pump
460
460
Fu.1
Futl Pump To
Cylindtr Block Or
Cylinder
Cytindar Front Covtr
Cylind.r
Cover
Pullty To
Pulley
Damptr Bolts
Damp.r
Altirnator Pivot Bolt

Altlrnltor
Valva Rocker
Rockar Arm
Vllvt
Cylindar Haad
Stud To Cylinder
H..d
19-27
35-50
3550
45-57
4557
18-25
Press Fit
FT-LB
MISCELLANEOUS TORQUES - FT-L8
Spcllk
Spaik Plug To Cylinder Head
10-15
130-180

Alterl111tor
35-50
35-50
24-40
35-50
35.-50

Fan
12-18
Mounting Nuts
Carburetor Mountirig
12-15

Therrnllctur
35-50
25-35

EG
EGR
max.
15 max.
29-31
29-31
Therm(lctor
to Cylinder Block
Therrnactor Adjusting Arm 10
25-35
25-35
12-18
U.S. Thread Sizes
Pipe Thread Sizes
1/4 - 20 == 6-9
3/8 -- 24 == 27-38
1/8 ==
5/165/16 - 18 == 12-18
5/16 - 24 =- 14-20
7/16
7 / 1 6-- 14 == 45-57
1/4 == 12-18
3/8 - 16 == 22-32
5-8
3/8 == 22-33
1/2 == 25-35
7/1G
7 / 1 6-- 20 == 40-60
1/2 -- 13 == 55-80
SEALERS
I[Loctite
Loctite (thread locking compound)
C3AZ-19554-A
C3AZ19554A
CA1310-0
CA1310-D33
BACK TO GROUP INDEX

21-27-1
21-27-1
21-27-1
21-27-1
460 CID Police Interceptor Engine
PART 21-27 460 CIO

CID Police Interceptor Engine
Applies to Ford,
Ford, Torino, Mercury and
and Montego
COMPONENT INDEX
COMPONENT INDEX
Page
GENERAL INFORMATION ........... .
27-2
Oil Filter
...............................................
27-3
REMOVAL AND INSTALLATION .......
27-3
Filter
Oil Fi
Iter Adapter ...................
27-3
27-3
SPECiFiCATIONS
27-4
Crankcase Oil Cooler
................................
Page
WATER HOSE
18472
WATER OUTLET NIPPLE

180266
18D266
WATER INLET
180265
NOTE: USE TWO WRENCHES

TO TORQUE SWIVEL NUTS.
(BOTH ENDS) TO SPECIFICATION
'",
U , ' \ ___
'~)-_~\-'
~~60LER
I,
OUTLET HOSF
88451
/_---7'~
/'~--~'
T~
TORQUE TO SPECIFICATION
ENO
, TOP
TOP END
WATER HOSE CLIP \

37749 ~ . S100
WATER PUMP
WATER
PUMP
d ::=\\\ \,
f
OIL F I L T E R
INLET
RI B
.//V"- ~~
OIL FILTER
t:,~
""~ 6731
/
~(~
,I
I ./
----.~~~
~ -----///
/
REAR STRAP
6B868
-~
ALIGN
ALIGN BLUE
BLUE
//
,~ !r-c!~~~STRIP~/?f'
PAINT STRIPES^
ALIGN
ALIGN RED
RED PAINT
PAINT STRIPES,
STRIPES
.\-C-L__
~-?~
~. F~.' " , / / / /
,.<.:::-
!d,
I,
~~,
TOOILCOOLER--..(J
TO OIL COOLER
6881
-)
WATER HOSE
HOSE BRACKET ""'-----6B870
NOT USED W
AIR CONDITIONER
W/AIR
~~-
OIL
ER
OIL FIL
F I L TTER
E R ADAPl
ADAPTE
R
FENDER APRON
~--
__
.,
_///
FRONT STRAP
6B868
FRONT SUPPORT
6B74
6B7433
OfL
OIL COOLER INLET HOSE
8N039
A3699-B
FIG. 1 Crankcase Oil Cooler Installation-1975

Installation1975 FordlMercury
Ford/Mercury With AIC
A/C
FIG.
BACK TO GROUP INDEX

21-27-2
21-27-2
21-27-2
CID Police
Police Interceptor
Interceptor Engine
460 CID
NOTE:
information in
in this
this Part
Part applies
applies to
to both 1975
1975 and
and 1976
1976 model year
year vehicles
vehicles unless
unless otherspecified.
wise specified.
CR1966A
CR1966-A
GENERAL INFORMATION
INFORMATION
GENERAL
Interceptor
The 460 CID Police Interceptor
is basically the same as
as 460 CID
CID
Engine is
OUTLET NIPPLE
NIPPLE
WATER OUiLE~
18D266
180266
WATER SUPPLY
HOSE - 381252-S280Y
/ ~
N-
21-24. All service

engine covered in Part 21-24.
procedures are common to both engines
except for the crankcase oil cooler (Figs.
(Figs.
OIL COOLER
OUTLET HOSE
8B451
WATER RETURN
_ 381252-S33O8
H0SE
11 and
and 2)
2) used
used with
with all
all 460
460 CID
CID Police
Police
Interceptor Engine installations.
installations.
33777-S2
TORQUE 55-85 IN-LB
OIL COOLER 6A642

6A642
NOTE: USE TWO WRENCHES

TO TORQUE SWIVEL NUTS \
(BOTH ENDS) TO SPECIFICATION.
r>L TORQUE TO
W
/ 50-85 IN-LB
\ V
SPECIFICATION
WATER HOSE CLIP
- 6B871
WATER PUMP
WATER HOSE BRACKET

6B870
(NOT USED W/AIR CONDITIONER).
CONDITIONER)
FRONT
SUPPORT
6B743
57472-S2
TORQUE
70-105 IN-LB
REAR STRAP
- 68869
ALIGN BLUE
PAINT STRIPES
STRIPES
ALIGN RED PAINT STRIPESL----I---:.~,~t.~~--....._::.,
TO OIL COOLER------4I..
IJ.".H~COOLER
OIL COOLER INLET HOSE

8N039
A3G8IoC
A36M-C
FIG. 2 Crankcase Oil Cooler Installation1976

A/C
Installation-1976 Ford/Mercury
FordlMercury With AIC
BACK TO GROUP INDEX

21-27-3
Interceptor Engine
460 CID Police Interceptor
21-27-3
REMOVAL AND INSlALLAliON

INSTALLATION
CRANKCASE OIL COOLER
Removal
Removal
1.
2. Disconnect the water coolant lines
from the oil cooler (Fig. 1).
3. Disconnect the oil cooler inlet and
outlet hoses.
R e m oa vvet
e the
onee nut
nut and
and one
one
4. Rem
h eon
capscrew
capscrew that attaches the front
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
Installation
1.
1. Install the front support bracket on
the oil cooler with the top end as
shown in Fig. 1 to fit the contour of
of
the fender apron.
fender
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
of the cooler
cooler and
and torque
torque it to
specification. Connect the oil outlet
BACK TO GROUP INDEX
4.
4.
5.
6.
7.
hose to the front of the cooler and

torque it to specifications. Be careful
careful
not
bend the
not to
to bend
the hoses
hoses in
in aa tight
tight radius.
radius.
The
be
The teflon
teflon liner
liner in
in the
the hose
hose could
could be
crimped
crimped causing
causing an
an oil
oil leak
leak or
or
obstruction
bent too
obstruction if
if bent
too sharply.
sharply.
Connect
Connect the
the water
water inlet
inlet hose
hose to
to the
the
upper
upper fitting
fitting on
on the
the oil
oil cooler
cooler and
and the
the
outlet
outlet hose
hose to
to the
the lower
lower fitting.
fitting.
Tighten the hose clamps.
Fill the cooling system with the
specified
specified coolant.
Check the oil level and fill to the
proper level with the specified
specified oil.
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
Removal
1.
1. Remove the oil filter.
filter.
2. Disconnect the oil cooler inlet and
outlet hoses from the oil filter adapter
(Fig. 1).
Remove the oil filter

filter adapter
adapter
3. Remove
attaching bolt and gasket. Remove
adapter and mounting gasket
the adapter
from the cylinder block.
Installation
Installation
1.
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.
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
specified oil.
with the specified
7. Start the engine and check for oil
leaks.
8.
8. Recheck oil level after
after running and
add oil as necessary to obtain correct
level.

21-27-4

460 CIO
21-27-4
SPECIFICATIONS
Bore and Stroke
Engine
4.36x3.850
4.36
x 3.850
460
PSI (Sea Level) @Cranking
@ Cranking
Speed
Oil Pressure-Hot
@2000
RPM
@2000RPM
Lowest reading must be

be
40-65
Firing Order
within 75% of
of the
the highest
1/4"
1/4"
Exc. 1/4" 120-160
(2)
40-60 (2)
(2)
40-80 (2)
(3)
90-160 (3)
50-80
1-5-4-26-3-7-8
(4)
75-120 (4)
(2) If less than 40

to 40-60 pounds.
(1) Read tension immediately after belt isis installed, before itit stretches or
or seats in
in pulley grooves.
(3)
Drive Belt Tensions (Ibs.)

(lbs.)
Newly Installed
Used
Size
10 Min.
Mm.
(1)
Over 10
Up to 10 Min.
Mm.
Up
(1)
(4) If less than 75

to 90-120 pounds.
If less than 90
to 90-120 pounds.
CYLINDER HEAD
Combustion
Chamber
Volume
CC
Engine
Valve Guide
Bore 0Diameter
iameter
(Standard Intake
and Exhaust)
Intake
Exhaust
0.34330.3443
0.0600.080
0.060
0.080
94.7
460
97.7
Valve
Seat Width
Valve
Seat
Angle
Valve Seat
RunoutTIR
Runout
T1R
(Maximum)
45
450
0.0016
Gasket
Surface
Flatness
(t)
0
Valve
Arrangement
(Front to
to Rear)
0.003 m
in
any 6 inches,
0.006
Overall
RI-E-I-E'-E-I-E
R-l-E-l-E-l-E-l-E
lL-E-l-E-l-E-l-E-l
- E-\-E-\-E-\-E-\
CD
.. ...
.60150
urface Finish R.M.S.
R.M S
60-150
0 Head Gasket SSurface
VALVE ROCKER ARMS,
ARMS, ROCKER ARM
ARM SHAFT,
SHAFT, PUSH
PUSH RODS
RODS AND
AND TAPPETS
TAPPETS
.,
,-
Valve Tappet or
or Lifter
Engine
Valve Push Rod

Rod
(Maximum Runout)
Standard
Standard Diameter
Diameter
Clearance
Clearance to
to Bore
Bore <D
0
Hydraulic Lifter
Leakdown Rate
i1.73-1
.731
0.015
0.08740-08745
0.08740-0.8745
0.0007-0.0027
550
Max.
5-50 Seconds Max.
Measured at
at 1/16
1/16
Inch plunger travel
460
CD
0
0.075-0.175
0.100-0.150
Wear
- 0005
Wear Limit
Limit-0.005
VALVE
VALVE SPRINGS
Valve Spring Pressure /CD

T\
Lbs @
<> Specified Length W
Pressure
Engine
Valve Spring
Free Length
Approximate
Valve Spring
Assembled Height
to Retainer
Pad to
Valve Spring
OutofSquare
Outof-Square
(Maximum)
2.03
1-51/64-1-53/64
151/641-53/64
5/64 (0.078)
76-84@
1.81
76-84 @ 1.81
240-265 @ 1.33
1.33
460
460
CD
Collapsed Tappet Gap

Hydraulic Lifters
Desired
Allowed
Rocker Arm
Lift Ratio
@ specified length.
Wear Limit 10% pressure loss @specified
VALVES
D
To Valve Guide Clearance (CD
Intake
Exhaust
I[
Engine
0.0010-0.0027
460
Wear Limit - 0.0055
ICDWear
Valve Head Diameter

Intake
Exhaust
2.075-2.090
1.646-1.661
1.6461.661
(2)
) Valve Face Runout, Maximum - 0.002
Valve Face Angle (2)

44
440
VALVES (Continued)
Engine
Intake
Exhaust
Valve Stem Diameter

0.003 Oversize
0.015 Oversize
Intake
Intake
Exhaust
Exhaust
460
460
0.34160.3423
0.34160.3423
0.34460.3453
Standard
CAMSHAFT CD0
Item
Camshaft Journal
Diameter
Diameter
(No.3)
(No. 3)
0.35660.3573
0.35660.3566
0.3573
IItem
terri
Inches
Bearing
(No.1)
(No. 1)
(No.2)
(No. 2)
0.34460.3453
Camshaft Bearings
2.1238-2.1248
Inches
(No 2)
(No.
(No.3)
(No. 3)
Inside Diameter
InSide
2.1258-2.1268
(No.4)
(No. 4)
(No.5)
(No. 5)
(No.5)
(No. 5)
(No.1)
(No. 1)
0.37160.3723
(No.1)
(No. 1)
Camshaft Bearing
Location ~
0.37160.3723
Bearing
(No.4)
(No. 4)
Standard (2)
~
0.030 Oversize
Exhaust
Intake
(D
Camshaft journal maximum runout .

Camshaft journal
Journal maximum out-of-round .
Q)
(D
Distance in
in inches that the
the front
front edge
edge of
ofthe
thebearing
bearing iss installed below
the front face of
rear).
of the
the cylinder block (towards the
the rear
0.0400-0.0600
(J)
0
Chain Deflection (Maximum)
(Maximum).... .. . . . . . . . . . 0.500
Timing Chain
. . . . 0.005TIR
0.005 TIR
. . . . 0.0005 TIR
TIR
Theoretical
Valve Lift
Lobe Lift (t)0
0
CD
Engine
Intake
460
460
0.253
Camshaft
Exhaust
Intake
Exhaust
Play
End Plav
Wear Limit
0.278
0.4370
0.4809
0.0010.006
0.009
Camshaft Journal
Wear Limit
Wllr
Clearance
0.0010.001
0.003
0.006
Maximum allowable lift loss

loss 0.005
CA1311-B
CA1311B
BACK TO GROUP INDEX

21-27-5
21-27-5
21-27-5

460 CIO
CYLINDER BLOCK
Cylinder Bor.
Bore Diam.t.r
Diameter CD
3 ) (3)
3
Tapp.t
iam.t.r
Tappet Bor.
Bore 0
Diameter
Bearing Bor.
Bore Diam.t.r
Diameter
Main B.aring

Cylind.r
Diameter
Shaft Bearing Bore Diamet.r
Head Gasket
H.ad
Gask.t
Surface Flatn.ss
Flatness (%)
(2)
Crankshaft To
To Rllr
Rear Flee
Face Of
Crlnkshlft
Of
Block (Runout TIR MIX)
Max)
4360043636
43600-4.3636
0.8752-0.8767
0875208767
3 19223.
1930
1922-3.1930
0.51600.5175
0.5160-0.5175
inch In
m any
any 66
0.003 Inch
inches or 0.006 Inch
inch overall
Inches
0.005
Q)
1 Maximum ou:ofround
Wear Limit
Limn - 0005
0 005
Cylinder bore surface finish RMS
RMS - 1838
18-38
i
I
(2)
rleaa surface f,nlsh
Q) rieaa
finish RMS
RMS - 60-150
Q) Maximum taper - 0.001
0.001
0.010 Max.
Max.
Taper Wear Limit - 0.010
PISTON
Diameter (])
(D
Dilmet.r
Coded
Red
4.3585-4.3591
Engine
460
460
Coded
Blue
4.35974.3603
4.3597-4.3603
Piston To
Cvlinder
Bor.
Cylinder Bore
Clearance
CI.arlnce
0.003
Oversize
Ov.rsiz.
Strvic.~
Service (J)
0.0022-0.0030
4.3609 4.3615
4.3609-4.3615
0
CD
at the piston pin
pm above.
pm bore centerline
centerime at
at 90
90
to the pin
CD Measured at
Piston
Piston Pin
Pin
Bor.
Bore
Diamet.r
Diameter
Ring Groove Width

Upper
Compression
Uppe ' CompreSSion
0.0805-0.0815
Ring 0.0805-0.0815
Lowe r CompreSSion
Lower
Compression
Ring..
Ring.
. . 0.0805-0.0815
Oil Ring.
R ng
011
0.1880-0.1890
. 0.1880-0.1890
1.0402-1_0405
1.0402 1.0405
OJ
(2) Selective Fit
PISTON PIN
PIN
L.ngth
Length
Engin.
Engine
460
460
QWear
<D
Wear
Limit-0.0008
Llmlt-0.0008
Standard
Stlndard
1.0399-1.0402
3.2903.290
3.320
(2)
Qj Selective Fit
PISTON RINGS
Ring Width
Compr.ssion
Compression Ring
Top
Top
I Bottom
0.0770.0770.078
0.078
CDWear
Wear Llml!.
Limit .
0.006
Diameter
I
1.
04 1O 1.04 13
1.0410-1.0413
Connecting Rod
To Conn.cting
Rod
Bushing Clearance
Interference
Fit
To Piston
Pilton
Claaranc.
Clearance <D
0.0002-0.0004
0.001 Oversize
OverSIze
Ring Gap Width
Sid.
Side CI.lrlnce
Clearance
Oil
Ring
Compression Ring CD
<D
Top
Bottom
Top
I
0.0020.002
0.0020.004
0.0026
OjSteel
Steel Rail
Top
Top
0.0100.020
Snug
Oil
Ring
~
0.0150055
0.055
Compression Ring
Bottom
0.010
0.0100.020
CRANKSHAFT BEARINGS
Main Bearings (Selective Fit)
Fit)
Rod Bearings
Connecting Rod
To Crankshaft
Crankshlft Clearance
Wall Thickness
Crlnkshaft Clearance
Clearanc.
To Crankshaft
Wail
Will
Wall Thickness
Standard CD
Standard CD
fl)
Stlndard
Desired
Desir.d
Allowable
Allowable
Desired
Engine
D.sired
I
I
0.0756
0.0756No.
NO.11 Upper only
No.
NO.11 --0.0004-0.0015
0.00040.0015
No.11 --0.0004-0.0020
0.0004-0.0020
0.00080.0008
No.
o n l y --0 .0.0960-0.0965
0960-0.0965
0.0008460
460
0.0015
0-0761
All others
- O.OOO~-0_0015 All others --0.0008-0.0026
0-0761
0.0008-0.0026 All others
o t h e r s-- 0.0955-0.0961
0.0955 0.0961
others-0.0008-0.0015
0.0028
mch to standard thickness
.. Add 0.001 Inch
0 0.002
. 0 0 2 Inch
mch uundersize.
CD
nders\ ze
CRANKSHAFT AND
AND FLYWHEEL
Main Bearing
Bllring
Journal
Diameter ( D
Diameter<D
Bearing Surface
Main BeBring
Finish RMS Maximum
Main SlIring
Bearing
Journal
Runout
Maximum (J)
Cl)
Main Bearing
Journal
Thrust Face
Runout
Bearing
Main SlIring
Journal
Maximum
Taper
Thrust Bearing
Journal L.ngth
Length
0.002
0.001
0.00016
Per Inch
1.1241.126
2.99942.9994
3.0002
kD
0 Connecting rod
rod and
and main
mam bearing Journal
journal out-oj-round
out-of-round maximum ~
(2) Wear Llm!t
Limit - 0.005
0.0006
Journal
Thrust Face
Connecting
Rod Journal
Diameter
o
iam.t.r ($)
(J)
12
12
25 FrOil!
Front
23 Rear
2.49922.4992
2.5000
Crankshaft
Free End
End
Play (3)
~
Flywheel Ring
Lateral
Gear Llt.rll
Runout
0.00016
Per Inch
0.0040.008
0.060
CD Wear Llml!
Limit - 0.012
(J)
0.012
(3) Connecting rod
rod Journal
journal outol-round
out-of-round maximum - 0.0006
APPROXIMATE Oil
OIL PAN
PAN CAPACITIES
OIL PUMP
Relief Valve
Spring Tension
Lbs 9 Specified L.ngth
Length
Lbt'
20.6-22.6 @
<> 2.49
2.49
20.622.6
Conn.cting
Connecting
Rod Bearing
Journal
. Maximum
Maximum
Taper
Drive Shaft
To Housing
B
ring
Bearing
Clear.nc.
Clearance
0.001500029
0.0015-0.0029
Engine
Relief Valve
To Bore
Clearance
Rotor Assembly
Assembled
End Clearance
0.00150.0029
0.0015-0.0029
0.001-0.004
Outer Race
Out.r
R.c.
To Housing
(Radial
(Rldial
Clearance)
Cle.rance)
000
10.0 13
0.001-0.013
460-PI
460 PI
U.S. Measure
Imperi.1
Measur.
Imperial Measure
6 Quarts
Quarts Q)0
<D
Includes 1 quart with filter
fiite r
5718 Quarts (7)

5-7/8
CD
replacement
replacement.
CA1311-B1
CA1311B1
BACK TO GROUP INDEX

21-27-6
21-27-6
460 CID
CIO Police Interceptor
Interceptor Engine
460
CONNECTING ROD
ROD
CONNECTING
Crank
Crank
Piston Pin
Pin Bore
Bore
Piston
CD
or Bushing
Bushing ID
10
or
Bearing Bore
Bore Diameter
Diameter ( D
Bearing
10386-1.0393
1.0386-1.0393
CD
Connecting Rod
Rod
Connecting
Connecting
Connecting Rod
Rod Alignment
Alignment
Connecting
Connecting Rod
Rod Assembly
Aspmbly
Maximum
Maximum Total
Total Difference
Difference (2)
(2)
(Assembled
(Assembled To
To Crankshaft)
Crankshlft)
Length To
To Center
Center
Length
Twist
Twist
6.6035-6.6065
6.6035-6.6065
O()24
0.024
2.6522-2.6530
2.6522-2.6530
Crilll~ bearing
lJedrinu bore
bore maximum"out-of-round
nlejximum-out-of-round and
and taper
taper -- 0.0004.
Crank
0.0004.
a;,
Bend
Bend
Side
Side Clearance
Cillranci (3)
U.U 12
0.012
0.010-0.020
0.010-0.020
Pm Bore
Bore and
ilild crankshaft
crankshaft bearing
hearing bore
bore must
must be
be parallel
parallel and
aild in
in the
the same
same vertical
vertical plane
plane wwithin
the specified
specified
~ Pin
i t h i n the
total difference
difference when
when measured
measured ends
ends of
of 8-inch
8-inch long
long rod
rod measured
measured 44 inches
Inches on
on each
each side
side of
of rod
rod.
total
(3) Wear
Wear Limit
Llfnit -- 0.023
0.023
(3)
TORGUE LLIMITS
TORQUE
I M I T S -- F FT.-LBS.
T.-LBS.
Fuel Pump
Pump
Fuel
Valve
Va:ve Rocker
To Cylinder
Cylinder
To
Arm
Arm Bolt
Bolt To
Oil Pan
Pan
Oil
Oil Filter
Filter
Oil
Oil Filter
Filter
Oil
Drain
Drain
Block Or
Or
Block
Pulley
Pulley To
Insert
Insert To
Cylinder
Cylinder
Damper
Damper
Cylinder
Cylinder
Plug
Plug
Adapter Or
Or
To Adapter
To
Engine
Engine
Main
Main
Bearing
Bearing
Cap Bolts
Bolts
Cap
Cylinder Block
Block
Cylinder
Cylinder Block
Block
Cylinder
Front
Front Cover
Cover
Bolts
Bolts
Head
460-PI
460-PI
95-105
95-105
15-25
15-25
20-30
20-30
19-27
19-27
35-50
35-50
With grease
qrease on the gasket
gasket
With
I
18-25
18-25
tighten until
surface, hand tighten
gasket
gasket contacts
contacts adapter
face, then tighten 1/2
1/2
<D
turn more.
Rocker A
Arm
r m Hold-Down Nut 18-25 Ft-Lbs.
TORGUE
LIMITS
FT.-LBS. (Continued)
T
ORQUE L
I M I T S -- FT.-LBS.
(Continued)
Cylinder Head
Head Bolts
Cylinder
Bolts
Manifolds To Cylinder
Cylinder Head
Connecting
Oil Pan
Pan To
Oil
Engine
Engine
46D-PI
460-PI
Step 11
Step
Step 22
Step
70-80
70-80
Step 33
Step
130130140
140
100-110
100-110
Cylinder Block
Cylinder
Intake
Exhaust
9-11 (5/16
9-11
7-9
7
- 9 ((1/4
1/4
22-32
28-33
28-33
Distributor
Distributor
Rod
Rod
Nuts
or Bolts
Flywheel
Vacuum Control
To
Valve (PVS)
Crankshaft
Crankshaft
15-18
75-85
40-45
.
TORGUE
LIMITS -- FT.-LBS.
FT.-LBS. (Continued)
T
O R Q U E LIMITS
(Continued)
Engine
Engine
Rocker Arm
Arm Cover
To Cylinder Head
Camshaft
Camshaft Thrust
Thrust Plate
Plate
To Cylinder Block
Camshaft Sprocket
To Camshaft
Damper To Crankshaft
EGR Valve To
Carburetor Spacer
460-PI
460-PI
5-6
5-6
912
9 12
40-45
70-90
12-18
45-57
C A 11311-B2
311-B2
CA

- FTLBS
LIMITS-FT-LBS
U.S. Thread Sizes
Pipe Thread Sizes
1/4
- 20 =
1/4-20
= 6-9
3/8
= 27-38
3/8-- 24 =
5/16
- 18 = 12-18
5/16-18
7/16
- 45-57
7/16-- 14 =
5/16
- 24 = 14-20
5/16-24
7/16
7/16-- 20 = 40-60
3/8
- 16 = 22-32
3/8-16
1/2
1/2-- 13 = 55-80
1/8 = 5-8
3/8 = 22-33
1/4 = 12-18
1/2 = 25-35
MISCELLANEOUS TORQUES - FT-LBS

Spark Plug
Plug To Cylinder Head
Thermactor Pump
Pump Bracket to Cylinder Block
Thermactor Pump
Pump Pivot Bolt
Thermactor Pump
Pump Adjusting Arm to Pump
Thermactor Adjusting Arm to Cylinder Block
Thermactor Pu
mp Pu
Iley to Shaft
Pump
Pulley
Power Steering
Steering Pump
Pump Pulley to Damper
Fan
Fan to Water Pump
Pump Hub
Carburetor Mounting Stud
Stud to Intake Manifold
Manifold
Fuel
Oil
Oil Cooler/Filter Adapter to Cylinder Block
Oil
Oil Cooler Hose
Hose Assembly to
to Adapter - Swivel
Swivel Nut
Oil
Oil Cooler Hose
Hose Assembly to
to Oil
Oil Cooler - Swivel
Swivel Nut
10-15
35-50
45-57
24-40
35-50
25-35
25-35
25-35
in-lb
80-115 in-Ib
35-50
35-50
12-18
12-15
15 flldX.
max.
15
29-31
29-31
40-50
35-45
35-45
35-45
35-45
CA1448-A
BACK TO GROUP INDEX

23-00-1
23-00-1
23-00-1
23-00-1
Ignition System
System
Ignition
GROUP
GROUP
Ignition System
PART 23-01
23-01
23
PAGE
General Ignition Service.

Service . . . . . . . . . . . . . . .
General
23-01-1
23-01-1
N01'E:
NOTE: The
The infonnation
information in
1976 model
model year
year vehicles
vehicles unless
unless otherotherspecified.
wise specified.
CR1966-A
CR1966A
PART 23-01
23-01 General Ignition Service
COMPONENT INDEX
Page
COMPONENT INDEX
Page
Cylinder Engine......
Engine
INFORMATION
GENERAL INFORMATION
01-8
Distributor . . . . . . . . . . . . . . . . . . . . . . .
Distributor.
01-2
Mag
netic Pic
ku p Assemb
Iy . . . . . . . . . . . .
Magnetic
Pickup
Assembly
01-8
Centrifugal Advance
Advance. . . . . . . . . . . . . . . . .
01-2
Vacuum Advance Unit
01-8
Advance . . . . . . . . . . . . . . . . . .
Vacuum Advance.
01-3
Spark Plug Wires - Secondary
Operation . . . . . . . . . . . . . . . . . .
Circuit Operation.
01-3
01-4
ADJUSTMENTS
'"
(High Tensio
n) Wi
res
Tension)
Wires
01-8
Replacing Spark Plugs
01-9
Connecting To
New Coil Connector
To New
TESTING
Functional Checks . . . . . . . . . . . . . . . . . .
01-4
For Tachometer Test - All

Vehicles
Vehicles......................
Distributor Advance and

Distributor
and
Retard Check
Check............. .....
01-4
Diaphragm Check
Check. . . . . . . . . . . . . . .
01-4
01-4
Ignition Timing
REMOVAL AND
AND INSTALLATION
01-10
Spark Plug Boot Replacement -All Engines

Engines. . . . . . . . . . . . . . . . . . . . ..
Distributor
Distr ibut 0 r Dual
DuaI
01-10
CLEANING AND
AND INSPECTION
Spark Plugs
Plugs. . . . . . . . . . .. . . . . . . . . . . ..
01-11
01-11
Distributor
Distributor . . . . . . . . . . . . . . . . . . . . . . ..
01-11
01-11
Distributor
Distributor - 8 Cylinder
Cylinder Engines
01-6
Distributor
Cap
DistributorCap
01-11
Magnetic
MagnetiG Pickup Assembly
01-6
Secondary Wiring
01-11
01-11
Coil
Ignition Resistor Wire
.
.
01-11
01-11
01-11
01-11
..
01-15
Vacuum Advance Unit -Dual Diaphragm

Fixed Base Plate
Distributor
Distributor - 4 and 66
BACK TO GROUP INDEX
01-6
01-6
SPECIFICATIONS
SPECIFICATIONS
SPECIAL TOOLS
SPECIALTOOLS
01-15
23-01-2
GENERAL INFORMAliON
INFORMATION
The new Solid State Ignition System
is found on all passenger cars. It employs
a unique armature and magnetic pick-up
coil assembly in the distributor and aa
solid-state amplifier
amplifier module (Figs. 1 and
and
2).
It is important to note that the
amplifier module and coil are "on" when
when
the ignition switch is "on". Because of
of
this, the ignition system will generate a
spark when the key is turned "off".
"off'. This
feature may be used as a diagnostic tool,
to verify continuity of circuit, coil and
ignition switch. Certain other service
actions such as removing the distributor
cap with the ignition switch "on" may
also cause the system to fire. For this
reason, the ignition switch should remain
remain
"off" during any underhood operations
"off
unless the intent is to start the vehicle
engine, or to perform a specific test that
"on".
requires the ignition switch to be "on".
This procedure will prevent the
possibility of inadvertent engine rotation
caused by triggering of the ignition
system during servicing.
23-01-2
General Ignition Service
VACUUM
VACUUM ADVANCE
ADVANCE LINK
LINK
MAGNETIC PICKUP
ASSEMBLY
DISTRIBUTOR
HOUSING
.~
VACUUM
VACUUM ADVANCE/
ADVANCE!
RETARD ASSEMBLY
ASSEMBLY
ADVANCE
ADVANCE PLATE
SLEEVE
SLEEVE
ARMATURE
FIXED BASE PLATE
SYSTEM GROUI\lD
GROUND
B3505-B
83505-8
FIG. 1 Solid State Ignition System DistributorV-8

ShownOthers Similar
Distributor-V-8 Shown-Others
DISTRIBUTOR
DISTRIBUTOR
armature turns with the
The armature
distributor shaft, causing fluctuations in
the magnetic field generated by the
pickup coil assembly. These fluctuations
fluctuations
cause the amplifier to turn the ignition
coil current off and on, generating high
tension spark needed to fire the spark
plugs.
plugs. The distributor is equipped with a
standard rotor and cap.
All distributors are equipped with
both vacuum and centrifugal
centrifugal spark
advance control units. The vacuum
advance unit governs ignition timing
according to engine load, while the
centrifugal advance unit governs ignition
timing according to engine speed (rpm).
A dual diaphragm vacuum advance unit
A
is used on some engines to provide
additional ignition timing retard during
engine closed throttle operation. This
occurs both at curb idle and during
throttle.
engine coast-down with closed throttle.
Retarding the timing during these
helps control engine
engine emissions.
emissions.
periods helps
The distributor on
on four or six
six cylinder
engines
engines rotates in
in aa clockwise direction.
direction.
To
To advance timing;
timing; rotate the distributor
counterclockwise.
counterclockwise. The distributor on
on V-8
engines rotates counterclockwise. To
timing, rotate the distributor
distributor
advance timing,
clockwise.
clockwise.
CENTRIFUGAL ADVANCE (FIG.

(FIG. 3)
3)
The
The distributor advance
advance units
units operate
independently, with vacuum advance
advance
operating the
the base
base plate assembly and
centrifugal
centrifugal advance operating the
the
BACK TO GROUP INDEX
I
B3777-A
Module
FIG. 2 Solid State Ignition System Amplifier Module
position of the
the armature in
in relation to
to the
the
distributor shaft. The
The centrifugal advance
assembly,
assembly, located below
below the
the base
base plate,
plate,
has
has centrifugal weights
weights that move
move inward
or outward with
with changes
changes in
in engine
engine speed
(Fig.
3).
(Fig. 3).
As engine
engine speed
speed increases,
increases, the
the weights
weights
As
move the
the sleeve
sleeve and plate assembly ahead
move
the distributor shaft, thus
thus advancing
of the
the position of the
the armature.
armature. The
The rate
rate of
the
is controlled by
by calibrated
calibrated
advance is
springs.
springs.
23-01-3
VACUUM ADVANCE
ADVANCE
VACUUM
The dual
dual diaphragm unit
unit consists
consists of
The
two diaphragms that operate from two
two
two
sources of vacuum (Fig.
(Fig. 4).
4).
independent sources
The outer
outer (primary)
(primary) diaphragm
diaphragm operates
operates
The
from carburetor
carburetor venturi
venturi vacuum
vacuum to
to
from
WEIGHT
~I
~. i
SPRING
SPRING
23-01-3
General Ignition
Ignition Service
Service
i I~
\~':
~
SPRING
SPRING
BUSHING
B3507-A
provide timing
timing advance
advance during
during normal
normal
provide
off-idle driving conditions. This
This
off-idle
is connected to
to the
the distributor
distributor
diaphragm is
coil assembly by
by the
the
magnetic pickup coil
vacuum advance link.
link.
diaphragm
The inner (secondary) diaphragm
operates from intake manifold vacuum
acts to
to retard ignition timing.
timing. This
and acts
is connected to
to the
the
retard diaphragm is
by means
means of aa sliding
outer diaphragm by
linkage. Since
Since intake manifold vacuum is
linkage.
stronger than carburetor venturi vacuum
during closed throttle operation, the
secondary diaphragm will retard the
these periods.
periods. In all
all other
spark during these
phases, the larger primary diaphragm
phases,
operates from venturi vacuum and pulls
distributor
the base plate against distributor
timing.
rotation, advancing the spark timing.
Return springs in both the advance
and retard
retard portions center
center the
the
diaphragms when vacuum drops.
drops.
Vacuum modulators installed in
in the
vacuum supply lines from the carburetor
and intake manifold
manifold will vary the
operation of the advance and retard
diaphragms. These modulators are
covered in Group 29
29 and Group 50.
CIRCUIT OPERATION
The Solid State System consists of a
primary (low voltage) and a secondary
(high voltage) circuit (Fig.
(Fig. 5).
Advance
FIG. 3 Centrifugal Advance
FIG.
MechanismTypical
Mechanism-Typical
The
The primary circuit consists
consists of the:
the:
1.1. Battery.
Battery.
2.
2. Ignition Switch.
Switch.
3.
3. Primary Circuit Resistance Wire.
Wire.
4.
4. Primary Windings of the Ignition
Coil.
Coil.
5.
5. Magnetic pickup assembly.
assembly.
6.
6. Amplifier Module.
Module.
The
The secondary circuit consists
consists of
the:
the:
1.
1. Secondary windings of the ignition
coil.
coil.
2.
2. Distributor rotor.
rotor.
3.
cap.
3. Distributor cap.
4.
wires.
4. High tension (spark plug)
plug) wires.
5.
plugs.
5. Spark plugs.
With the ignition switch "on", the
primary circuit is
is on and the ignition coil
is energized. When the armature
armature
"spokes"
"spokes" approach the magnetic pickup
coil assembly, they induce aa voltage
which tells the amplifier to turn the coil
primary current off. A
A timing circuit in
the amplifier
amplifier module will turn the
current on again after the coil field has
collapsed. When the current is
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.
When the current is
is off, the magnetic
field built up in the ignition coil is
allowed to collapse, inducing a high
AMOUNT OF TRAVEL FOR RETARD DIAPHRAGM00 RETARD

PLATE RESTING 0
FULL RETARDRETARD DIAPHRAGM AT :=ULL

PLATE RESTING ON STOP
RETARD STOP
ADVMJCE DIAPHRAGM IN
ADVANCE
FULL ADVANCE POSITION
MANIFOLD
VACUUM
CONNECTION
RETARD DIAPHRAGM
RETARD
DIAPHRAGM SPRING
VACUUM
ADVANCE STOP
ADVANCE TRAVEL
FULL VACUUM RETARD
FULL VACUUM ADVANCE
CARBURETOR
CARBURETOR VACUUM CONNECTION
VACUUM ADVANCE SPRING
ADVANCE DIAPHRAGM
DISTRI BUTOR BASE
DISTRIBUTOR
VACUUM ADVANCE AND RETARD DIAPHRAGMS

DIAPHRAGMS AT REST
FIG. 4 Dual Diaphragm Vacuum Advance Mechanism
BACK TO GROUP INDEX
B3394-A

23-01-4
23-01-4
TERMINAL CONNECTOR
IGNITION
SWITCH
SPARK PLUG
CONNECTOR
PRIMARY
PRIMARY CIRCUIT
CIRCUIT
SECONDARY CIRCUIT
BREAKERLESS
DISTRIBUTOR
B3741-A
FIG. 5 Typical Ignition System Circuit
voltage into the secondary windings of

of
the coil.
coil. High voltage is produced each
thus
time the field is th
us 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
cap. This process is repeated
distributor cap.
for every power stroke of the engine.
Ignition system troubles are caused
by a failure in the primary and/or the
secondary circuit; incorrect ignition
timing; or incorrect distributor advance.
Circuit failures may be caused by shorts,
corroded or dirty terminals, loose
connections, defective wire insulation,
cracked distributor
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
On engines that will
verify the complaint. Qn
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
t~st,
of the ohmmeter test procedure.
ADJUSTMENTS
No adjustments are to be made
made to
to the
the
ignition system except initial engine
timing and spark plug gap (Part 50-29).
TESTING
For testing and system diagnosis,
refer to Part 29-02.
FUNCTIONAL CHECKS
Distributor Advance and Retard
Check
Check the initial ignition timing,
centrifugal
centrifugal advance, vacuum advance,
and vacuuql
vacuum retard (dual-diaphragm
distributor), following the procedure
under Ignition Timing.
Distributor Dual Diaphragm Test
1. To check
check vacuum
vacuum advance,
advance,
1.
disconnect the vacuum lines from
both the outer and inner diaphragms.
Plug the line removed from the inner
diaphragm.
2.
2. Using a tachometer, increase the idle
speed by setting on the first step of the
fast idle cam.
3. Using a timing light, observe the
ignition timing setting.
4.
4. Connect carburetor vacuum to the
outer diaphragm. Timing should
advance slowly as vacuum equalizes
SDV. Adjust if needed.
through the SOY.
BACK TO GROUP INDEX
5. To check vacuum retard, readjust the

5.
engine idle speed to 550-600 rpm.
6. Using a timing light observe the spark
6.
timing.
timing.
7.
7. Remove the plug from the manifold
vacuum line and connect the line to
the inner diaphragm.
8.
8. The
The tim
t i m iinngg s h o0 uu lIdd ret
r e t aa r d
immediately. Replace the dual
diaphragm unit if either of the
diaphragms are leaking.
IGNITION TIMING
All engines are equipped with both
conventional ignition timing and the new
new
"monolithic"
"monolithic*' timing features. The
conventional system employs degree
numbers on the crankshaft
damper, a timing pointer near the
damper, and an index mark on both the
t}1e
rotor and distributor body.
distributor fotor
The "monolithic" system employs a
timing receptacle designed to accept an
electronic probe (Fig.
(Fig. 6)
6) that
that isis connectep
connected
Thus, the
to digital read out equipment. Tltus,
the
timing is determined electronically. The
receptacle is located at the front of all

engines except the 2300cc
23OOcc four cylinder
which has a boss for monolithic timing
in the left rear of the cylinder block.
To check and adjust timing, follow
50 and
and
the procedures outlined in Groups 50
29.
29.
TIMING POINTER
MONOLITHIC TIMING
PROBE
PROBE RECEPTACLE
(EXCEPT 2300 CC
CC
FOUR CYLINDER)
B3500-A
FIG. 6 Typical Timing Pointer and

Probe Receptacle
CYLINDER NUMBeRING
NUMBERING AND
DISTRIBUTOR
DISTRIBUTOR LOCATION
CYLINDER NUMBERING AND

DISTRIBUTOR


DISTRIBUTOR
...
I
CD
CD
CD
CD
CD
CD
DISTRIBUTOR
CD
CD
DISTRIBUTOR
D
ISTR I BUTOR
CD
G)@/
FRONT
FIRING ORDER
ORDER AND POSITION
FRONT
FRONT
DISTRIBUTOR
CD
CD CD
CD CD
1
FRONT
FIRING ORDER AND ROTATION
FIRING ORDER AND ROTATION

ROTATION
POSITION OF
CAP ATTACHING
SCREWS
POSITION OF
CAP ATTACHING
SCREWS
SCREWS ~---~
tit
DISTRIBUTOR
FIRING
FIRING ORDER
ORDER AND ROTATION
ROTATION
CLOCKWISE
CLOCKWISE
.d\
COUNTERCLOCKWISE
POSITION OF
CAP ATTACHING
SCREWS
FRONT
FRONT
FRONT
FIRING
FIR
ING ORDER - 1-3-4-2
CLOCKWISE
CAP CLIP
POSITION
FRONT
FRONT
FIR
ING ORDER - 1-4-2-5-3-6
FIRING
FIRING ORDER - 1-5-3-6-2-4
FIRINGORDER
FIR
ING ORDER
351,
400 - 1-3-7 -2-6-5-4-8
351,400-1-3-7-2-6-5-4-8
302,460-1-5-4-2-6-3-7-8
302,460
- 1-5-4-2-6-3-7-8
VIEW 351M/400 W/FRIGIDAIRE MC
A/C
ENGINE FROM LEFT SIDE OF ENGINEFRONT
FRONT
FRONT
TIMING
POINTER
ATDC
TDC
TIMING
POINTER
BTDC
TDC
U4
BTDC
;~~~~~f-- j
. +
VIEW ALL OTHERS

FROM RIGHT SIDE.
BTDC
FRONT
TIMING
POINTER
TOC
TDC
r~DC
TDC
TDC
)c;v
"
10
TC
10
20
I
I
I
BTDC
30
TC 3 6 9 12
3 0 3 6 9 12
f
ROTATION
ROTATION-'
CRANKSHAFT TIMING MARKS
ROTATION - - .
~TIMING
^TIMING
MARK
ROTATION ^
~
^ ^ ^
MARK
ROTATION - . .
2.3L
4-CYLINDER
2.3L4-CYLINDER
2.8L V-6
200/250 C.I.D. IN-LINE SIX CYLINDER
...o
I
302/351/400/460 C.I.D. V-8

B3435-F
FIG. 7 Engine Timing and Cylinder Firing Order
BACK TO GROUP INDEX
tit
23-01-6
23-01-6
Ignition Service
Service
General Ignition
INSTALLATION
DISTRIBUTOR8 CYLINDER
DISTRIBUTOR-8
ENGINES
Removal
Remoyal
1. Remove the air cleaner. Disconnect
Disconnect
1.
from
the distributor wiring connector from
harness.
the vehicle wiring harness.
2. Disconnect the vacuum advance lines
2.
the
at the distributor. Remove the
distributor cap and place it and wires
side.
to one side.
3. Scribe a mark on the distributor body
3.
and the cylinder block indicating the
distributor
position of the rotor in the distributor
and the distributor in the block. These
marks will be used as guides when
distributor.
installing the distributor.
4. Remove the distributor hold-down
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
Installation
crankshaft was rotated while
1.
the distributor was removed from the
engine, it will be necessary to time the
R o t a t e the
the
engine as follows: Rotate
crankshaft until No. 1 piston is on
crankshaft
after the compression stroke.
TDC after
Align the correct initial timing mark
on the timing pointer with the timing
pointer on the crankshaft
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 sure
s u r e tthe
h e ooil
i l pump
pump
Make
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
If the crankshaft
crankshaft has not been moved
position the distributor
distributor in the block
with the rotor aligned with the mark
previously scribed on the distributor
body and the marks on the distributor
body and cylinder
cylinder block in alignment.
3. Install the distributor
distributor cap and wires.
4. Connect
Connect the
the distributor
distributor wiring
connector
connector to the vehicle harness.
5. Check
Check the ignition
ignition timing
timing with a
ttiming
i m i n g llight
i g h t aand
n d aadjust
d j u s t to
to
specifications.
specifications. Connect
Connect the vacuum
line(s), and check
check the advance with
the timing light when the engine is
accelerated.
BACK TO GROUP INDEX
MAGNETIC PICKUP ASSEMBLY

Remoyal
Removal
rotor,
1.1. Remove the distributor cap and rotor,
distributor
and disconnect the distributor
(Fig. 9).
9),
harness plug (Fig.
2. Using a small gear puller or two
two
2.
armature
screwdrivers, lift or pry the armature
sleeve.
from the advance plate sleeve.
pin.
Remove the roll pin.
3. Remove the large wire retaining clip
groove.
from the base plate annular groove.
4.
4. Remove the snap ring that secures the
vacuum advance link to the pickup
assembly.
5.
5. Remove
R e m o v e the
t h e magnetic
m a g n e t i c pickup
pickup
assembly ground screw and lift the
assembly from the distributor.
distributor.
6.
6. Lift the vacuum advance arm off
off the
post on the pickup assembly and
move it out against the distributor
distributor
housing.
Installation
Installation
1.
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 pickup assembly
and install the snap ring.
4. Install the grounding screw through
the tab on the wiring harness and into
the fixed base plate.
5. Install the armature on the advance
plate sleeve, making sure the roll pin
is engaged in the matching slots.
6. Install the distributor rotor and cap.
7. Connect the distributor wiring plug to
the vehicle harness.
STATOR
VACUUM ADVANCE UNIT-DUAL

UNITDUAL
DIAPHRAGM
Refer to Fig.
Fig. 9 for proper relationship
relationship
of internal parts.
parts.
Remoyal
Removal
1.
1. Remove the rotor.
rotor.
2.
2. Disconnect the vacuum lines.
lines.
3.
3. Remove the spring clip that secures
the diaphragm link to the movable
advance plate.
plate.
4.
4. Remove the diaphragm unit attaching
attaching
screws and carefully remove the unit
by tilting downward to disengage the
link from the post on the movable
advance plate.
Installation
Installation
1.
1. Position the diaphragm unit on the
distributor and hook the diaphragm
link in position.
2.
2. Install the spring clip that secures the
diaphragm
diaphragm link to the movable
movable
advance plate. Install the diaphragm
diaphragm
unit attaching screws.
3. Connect the vacuum lines.
4. Install the rotor and distributor cap.
FIXED BASE
BASE PLATE
Remoyal
Removal
1.
1. Remove the distributor cap and rotor.
2. Remove
R e m o v e the
t h e vacuum
v a c u u m advance
advance
diaphragm unit.
3. Remove
R e m o v e the magnetic
m a g n e t i c pickup
pickup
assembly.
4. Remove the remaining attaching
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
Installation
1.
1. Position fixed
fixed base plate in distributor
distributor
and install first attaching screw.
TOOTH MUST BE PERFECTLY

ALIGNED WITH STATOR
I
1/2 TOOTH ERROR IS

EACH 1/2
EQUAL TO 7-3/4 ENGINE
DEGREES TIMING ERROR
I~----- ARMATURE
ARMATURE
B3509-A
B3509-A
Position-a-Cylinder Engine Distributor

FIG. 8a Static Timing Position8-Cylinder
23-01-7
23-01-7
ROLLPIN~
ROLL PIN
ARMATURE
ARMATURE
_ _ _-
ARMATURE STOP RING
"~WIRERETAINING CLIP
~

(STATOR ASSEMBLY)
~\~~~~~
SYSTEM GROUND
VACUUM ADVANCE
ADVANCE
LINK
FIXED BASE
PLATE
WIRING HARNESS
CONNECTION
---~
WIRE RETAINER----...
BASE PLATE ASSEMBL Y
SLEEVE AND
PLATE ASSEMBLY
_'.
"
~/BASE
, I
, ~ ..-
\'- ~-U
-. --I -,~ ,I
\~
..
"
-I
A':
~/
.~ ~"
A--77:; . --\
/,' I
>-
~
~"-('
\-.
CASTING
~:
I'I'
l
\ ' -'I
,\~J
-- .'0'
B3508-A
B3508-A
DistributorDisassembled
FIG. 9 Typical Solid State Distributor-Disassembled
BACK TO GROUP INDEX

23-01-8
23-01-8
2. Install pick-up assembly and wiring.

3.
3. Install vacuum advance unit,
4. Install the distributor rotor and cap.
STATOR
ROTOR
TOOTH MUST BE PERFECTLY

ALIGNED
ALIGNED WITH
WITH TIMING
TIMING MARKS
MARKS
I
DISTRIBUTOR-4
DISTRIBUTOR4 AND 6
CYLINDER ENGINE
Removal
Removal
1.
1. Remove the air cleaner assembly on
V-6 engines. On 4-cylinder
4-cylinder and
6-cylinder in-line engines, remove one
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.
filter
2.
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
crankshaft
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.
(Fig. 10),
and the marks on the side of the
distributor body.
4.
4. Disconnect the vacuum hose(s) from
the distributor. Disconnect the
ignition lead from the wiring harness.
5.
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
Installation
1.
1. Make sure the engine is still aligned
with the proper timing marks.
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.
(Fig. 10).
10). If the oil
pump drive shaft was withdrawn with
the distributor, coat one end with
grease, insert that end into the
heavy grease,
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
2.
and bracket.
3. Install the vacuum hose(s) and
connect the ignition wire to
to the
the wiring
wiring
harness.
harness.
5.
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.
BACK TO GROUP INDEX
EACH 1/2 TOOTH ERROR IS

EQUAL TO 7-3/4 ENGINE
DEGREES TIMING ERROR
ARMATURE
TIMING POSITION - 6-CYLINDER

6-CYLINDER SHOWN,
8-CYLINDER SIMILAR
8-CYLINDER
B3739-B
83739-8
FIG. 10 Static Timing Position6-Cylinder

Shown4-Cylinder Similar
Position-6-Cylinder Shown-4-Cylinder
Removal
Removal
1.
1. Remove the distributor cap and rotor
and disconnect
disconnect the distributor
distributor
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
pickup
assembly ground screw and lift the
assembly from the distributor.
Installation
Installation
1.
1. Place the pickup assembly in position
over the fixed
fixed base 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
sleeve, making sure the roll pin
plate sleeve,
is engaged in the matching slots.
4. Install the distributor rotor and cap
and connect the distributor wiring
plug to the vehicle harness.
VACUUM ADVANCE UNIT
Removal
Removal
1.
1. Remove the rotor.
2. Disconnect the vacuum line(s).
3. Remove the diaphragm unit attaching
carefully remove the unit
screws and carefully
by tilting downward to disengage the
link from the advance plate.
Installation
Installation
1. Hook the diaphragm link in position
1.
and position the diaphragm unit on
the distributor.
2. Install the diaphragm unit attaching
2.
screws.
screws.
3. Connect the vacuum line(s).
!ine(s).
4. Install the rotor and distributor cap.
SPARK PLUG WIRES
Secondary (High Tension) Wires
The secondary wires include the 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 resistancetype which filter
filter out the high frequency
frequency
electrical impulses that are the source of
of
ignition noise interference.
Check ignition wire resistance
resistance
through the distributor cap. To check the
secondary wire resistance, turn the
"off" and then remove the
ignition switch "off"
cap. It is important that the
distributor cap.
ignition system be "off'
"off to prevent
inadvertant engine rotation due to firing
of the ignition system.
Do not, under any circumstance,
an ignition
ignition cable
cable when
whenchecking
checking
puncture an
resistance. Do not use aa commercial
probing device, but measure resistance
only from the ends
ends of
of the
thewire
wireororthe
thewire
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 th~
the wire ends.
ends. If the resistance still
exceeds 5,000 ohms per inch, the wire
should be replaced.
23-01-9
23-01-9
When removing wires from spark

plugs, use
use Tool T74P-6666-A
T 7 4 P - 6 6 6 6 - A or
equivalent. (Fig.
(Fig. 11.) Grasp and
and twist the
molded cap
cap back and
and forth on
on the
the plug
insulator to
to free cap. Use
Use the
the special tool
to pull the
the cap
cap from
from the
the plug.
plug. Do
Do not
not pull
pull
on the
the wire directly, or it may
may become
separated from the
the connector inside the
cap.
then pull it off the spark plug. Do not

not
pull on the
the connection
the wire, as
as the
may become damaged.
2. Any wire damaged must be
be replaced.
Each original spark plug wire is
numbered for the
the cylinder to which it
If wires
wires aare
is ddesigned.
e s i g n e d . If
r e not
numbered, each
each wire should
should be
be
numbered,
numbered as to the plug from which
was removed.
it was
around each spark
3. Clean the area around
compressed air.
air.
plug port with compressed
SECONDARY WIRES
TOOL T74P-6666-A
T74P-6666-A
TWIST & PljLL

PULL
83496-A
B3496-A
FIG. 11
11 Removing Wires from Spark
Plugs
Plugs
Installation
Instal/ation
1.
1. Insert each wire in
in the
the proper socket
the distributor cap.
cap. Be
Be sure the
of the
all the way down into
wires are forced all
their sockets. The
The No.
No. 11 socket is
on the
the cap. Install the
the wires
identified on
at the
the No.1
No. 1socket.
socket.Cylinders
Cylinders
starting at
on all
all inline
are numbered 1-2-3-4-5-6 on
and from front to
6-cylinder engines and
rear; right bank 1-2-3-4, left bank
all V-8
V-8 engines. V-6
5-6-7-8 on all
are numbered from front to
engines are
rear; right bank 1-2-3, left bank 4-5-6.
are numbered
Four-cylinder engines are
to rear, 1-2-3-4.
from front to
2. Remove the
the wire retaining brackets
2.
the old
old spark plug wire set
set and
from the
on the
the new
new set
set in
in the
install them on
same relative position. Install the
in the
the brackets on
on the
the valve
wires in
arm covers (V-8
(V-8 and
and V-6).
V-6).
rocket arm
the wires to
to the
the proper spark
3. Connect the
the coil high tension
plugs. Install the
Be sure the
the No.
No. 7 spark plug
lead. Be
is positioned in
in the
the bracket.
wire is
Notice that the wires are positioned
in aa special order from
in this bracket in
to rear (7-5-6-8). This applies to
front to
all V-8 engines except the 351 engine.
for the
the 351
351 V-8
V-8 should be
The wires for
in the
the bracket from front
positioned in
to rear (5-7-8-6). Arranging the wires
in this manner will prevent cylinder
cross-fire.
~~~~~
--~
INSULATORS
INSULATORS
~------
-<.~~
~.~/
r'
83503-8
B3503-B
12 Typical Four Cylinder Engine Secondary Ignition Wiring

FIG. 12
REPLACING SPARK PLUGS
Removal
Removsl
1. Remove the
the wire from each spark
1.
by grasping the
the molded boot
plug by
with Tool T74P-6666-A (Fig.
(Fig. 16).
16).
the boot until it loosens and
Twist the
BACK TO GROUP INDEX
FIG. 13
13 Typical In-line
In-Line Six
Six Cylinder Engine Secondary Ignition Wiring
23-01-10
23-01-10
Using the
the proper
proper size
size spark
spark plug
plug
4.4. Using
socketremove
removethe
thespark
sparkplugs.
plugs.
socket
Installation
Installation
Checkthe
thegap
gapon
oneach
eachnew
newspark
sparkplug
plug
1.1. Check
and set
set totospecification,
specification, ififnecessary
necessary
and
(Fig. 18).
18).
(Fig.
23-01-10
23-01-10
General
GeneralIgnition
IgnitionService
Service
2.2. Install
Installeach
eachspark
sparkplug
plugand
andtorque
torquetoto
specification.
specification.
3.3. Connect
Connecteach
eachspark
sparkplug
plugwire
wiretotothe
the
plug
plugfrom
from which
whichititwas
wasremoved.
removed.Be
Be
sure
sureeach
each wire
wireisisfully
fully depressed
depressed on
on
each
eachplug
plugand
andmolded
moldedboot
bootisisfirmly
firmly
ininplace.
place.
CONNECTING
CONNECTINGTO
TONEW
NEWCOIL
COIL
CONNECTOR
CONNECTORFOR
FORTACHOMETER
TACHOMETER
TEST-ALL
TESTALLVEHICLES
VEHICLES
The
new
solid
The new solid state
state ignition
ignition coil
coil
connector
connectorallows
allowsaatachometer
tachometer test
test lead
lead
with
with an
an alligator-type
a l l i g a t o r - t y p e clip
clip toto be
be
connected
connected toto the
the DEC
DEC (Distributor
(Distributor
Electronic
Electronic Control)
Control) terminal
terminal without
without
removing
removing the
theconnector
connector (Fig.
(Fig. 19).
19).
When
When engine
engine rpm
rpm must
must be
be checked,
checked,
install
install the
the tachometer
tachometer alligator
alligator clip
clip into
into
the
"TACH
TEST"
cavity
as
shown.
the "TACH TEST" cavity as shown. IfIf
the
the coil
coil connector
connector must
must be
be removed,
removed,
grasp
the
wires
and
pull
horizontally
grasp the wires and pull horizontally
until
until itit disconnects
disconnects from
from the
the terminals.
terminals.
SPARK
SPARK PLUG
PLUG BOOT
BOOT
REPLACEMENT-ALL
REPLACEMENTALL ENGINES
ENGINES
When
When itit isis necessary
necessary to
to replace
replace only
only
the
the boot
boot on
on aa particular
particular spark
spark plug
plug wire,
wire,
proceed
proceed as
as follows:
follows:
1.1. Cut
Cut off
off the
the old
old boot.
boot. Apply
Apply silicone
silicone
lubricant
lubricant to
to that
that area
area of
of the
the old
old wire
wire
that
that will
will contact
contact the
the new
new boot.
boot.
2.
2. Position
Position the
the new
new boot
boot onto
onto Tool
Tool
P73-192-1
P73-192-1 as
as shown
shown in
in Fig
Fig 20.
20.
TOOL T74P-6666-A
B3504-A
B3504-A
FIG.
Wiring
FIG. 14
14 Typical
Typical V-6
V-6 Engine
Engine Secondary
Secondary Ignition
Ignition Wiring
TOOL T74P-6666-A
---+
TWIST &
& PULL
PULL
TWIST
83496-A
B3496-A
FIG. 16
16 Removing
Removing Wires
Wires from
from Spark
Spark
FIG.
Plugs
Plugs
B 3106-B
FIG.
FIG. 15
15Typical
TypicalV-8
v-aEngine
EngineSecondary
SecondaryIgnition
IgnitionWiring
Wiring(Except
(Except302
302CID).
CID).
BACK TO GROUP INDEX
B3234A
FIG. 17
17Filing
FilingSpark
SparkPlug
PlugElectrode
Electrode
FIG.
23-01-11
23-01-11
23-01-11
23-01-11
3. Position
Position the tool onto the wire
terminal and slide the boot onto the
wire. Remove the tool from the end
of the wire terminal.
COIL CONNECTOR
TO "DEC" TERMINAL
(DISTRIBUTOR ELECTRONIC CONTROL)
MUELLER 60 SERIES
ALLIGATOR CLIP
TACHOMETER TEST LEAD
B3516-A
B3514 A
B1391-D
FIG. 19 Attaching Tachometer Lead

to Coil Connector
FIG. 20 Installing Spark Plug Wire

Boot on Wire
FIG. 18 Checking and Setting Spark

Plug Gap
CLEANING AND INSPECTION

SPARK PLUGS
Examine the firing ends of the spark
plugs, noting the type of deposits and the
degree of electrode erosion. Refer to Fig.
21 for the various types of spark plug
21
fouling and their causes.
Clean the plugs on a sand blast
manufacturer's
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
carefully for
cracked or broken insulators, badly
pitted electrodes, and other signs of
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
compressed air.
assembly clean with compressed
Make sure no filings or metal chips
face.
adhere to pickup magnet face.
Distributor Cap
Distributor
Clean the distributor cap with a soft
bristle brush and mild cleaning solvent or
mineral spirits. Dry
Dry the cap with
mineral
compressed air. Inspect the cap for
compressed
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
BACK TO GROUP INDEX
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
from
torn boots. Do not remove wires from
distributor cap. Replace wires that are
If spark plug boot is damaged,
damaged. If
replace it (refer
(refer to Spark Plug Boot
ReplacementAll Engines, in this Part).
Replacement-All
Coil
Wipe the coil with a damp cloth and
check for any cracks or other defects.
IGNITION RESISTOR WIRE

The special ignition resistance WIre
wire
must be of
of a specified
specified length
length and
must
diameter to reduce the operating voltage
of the ignition system. Due to its special
under no circumstances
circumstances
resistance, under
should it be replaced by any other wire
other than the correct service resistor
When a new resistor
resistor wire is
wire. W"hen
installed, the old one should be isolated
from the system.
All Except Ford,

Ford, Mercury and
Meteor
Meteor
Replacement
Replacement
1.
1. Disconnect the battery cable from the
battery negative post.
2. Examine both sides of the dash panel
and drill
d r i l l a 5/8
5 / 8 inch
i n c h hole
hole to
and
354972-S grommet
accommodate a 354972-5
for the replacement resistance wire.
The hole should be located as close as
possible, approximately 1 to 1-1/2
1-1/2
inches from the 14401 and 14290

fuse
wiring harness connectors or fuse
panel. Before drilling, make sure that
the drill will not contact any wiring,
v a c u u m hose
h o s e or any
a n y other
other
vacuum
Drill a 5/8
5 / 8 inch
components. Drill
diameter hole through the dash panel.
3. On all cars except Mustang and
Cougar with a tachometer, cut the
wire shown in Fig. 24, approximately
14401 wiring
2 inches below the No. 14401
harness connector.
Installation
1.
1. Install a bullet connector on each end
of the wire that was just cut. Plug
these two wires into the fixed
fixed
connector
connector on the C9AB-12250-A
C9AB-12250-A
resistor wire.
2. On a Mustang or Cougar equipped
with a tachometer, reach up under the
instrument panel and unplug the
instrument
tachometer wires from the connector
24). Cut and tape both ends of
(Fig. 24).
of
the old resistor wire as shown.
If working on a Mustang or Cougar,
3. If
pplug
l u g one
o n e end
e n d of
of the
t h e new
new
COLF-12250-A resistor wire into the
tachometer connector. Connect the
No. 14401 wiring harness to the
tachometer connector.
4. Thread the new resistor wire through
the 5/8 inch hole that was drilled in
354972-S
the dash panel. Install the 354972-5
5/8 inch diameter
grommet in the 518
hole.
5. Cut the No. 16 red-light blue stripe
14401 or 14398 (Fig.
wire of the No. 14401
23) harness and install a bullet
connector on each end of the wires
23-01-12
23-01-12
GAP BRIDGED
BRIDGED
GAP
IDENTIFIED BY
BY DEPOSIT
DEPOSIT
IDENTIFIED
BUILD-UP CLOSING
CLOSING GAP
GAP
BUILD-UP
BETWEEN
ELECTRODES.
BETWEEN ELECTRODES.
CAUSED
BY
01
LOR
CAUSED BY OIL OR
CARBON FOULING.
FOULING. REPLACE
REPLACE
CARBON
PLUG, OR,
OR, IF
I F DEPOSITS
DEPOSITS ARE
ARE
PLUG,
NOT
EXCESSIVE,
THE
PLUG
NOT EXCESSIVE, THE PLUG
CAN BE
BE CLEANED.
CLEANED.
CAN
23-01-12
23-01-12
General Ignition
Ignition Service
Service
General
OIL FOULED
FOULED
OIL
IDENTIFIED BY
BY WET
WET BLACK
BLACK DEPDEPIDENTIFIED
THE INSULATOR
INSULATOR SHELL
SHELL
OSITS ON
ON THE
OSITS
BORE ELECTRODES
ELECTRODES CAUSED
CAUSEDBY
BY
BORE
EXCESSIVE OIL
OIL ENTERING
ENTERING COMBUSCOMBUSEXCESSIVE
TION CHAMBER
CHAMBER THROUGH
THROUGH WORN
WORN
TION
RINGS AND
AND PISTONS,
PISTONS, EXCESSIVE
EXCESSIVE
RINGS
CLEARANCE BETWEEN
BETWEEN VALVE
VALVE
CLEARANCE
GUIDES AND
AND STEMS,
STEMS, OR
OR WORN
WORN OR
OR
GUIDES
LOOSE
LOOSE BEARINGS.
BEARINGS. REPLACE
REPLACE THE
THE
PLUG.
PLUG. IF
IF ENGINE
ENGINE IS
IS NOT
NOT REPAIRED,
REPAIRED,
USE
USE A
A HOTTER
HOTTER PLUG.
PLUG.
WORN
WORN
NORMAL
NORMAL
IDENTIFIED
IDENTIFIED BY
BY SEVERELY
SEVERELY
ERODED
ERODED OR
OR WORN
WORN ELECTRODES.
ELECTRODES.
CAUSED
CAUSED BY
BY NORMAL
NORMAL WEAR.
WEAR.
SHOULD
BE
REPLACED
SHOULD BE REPLACED
IDENTIFIED
IDENTIFIED BY
BY LIGHT TAN OR
OR
GRAY
GRAY DEPOSITS
DEPOSITS ON
ON THE
THE
FIRING
FIRING TIP.
TIP.
CARBON FOULED
FOU LED
CARBON
IDENTIFIED BY
I3Y BLACK,
BLACK,
IDENTIFIED
DRY FLUFFY
FLUFFY CARBON
CARBON
DRY
DEPOSITS
DEPOSITS ON
ON INSULATOR
INSULATOR
TIPS,
TIPS, EXPOSED
EXPOSED SHELL
SHE LL
SURFACES
SURFACES AND
AND ELECTRODES.
ELECTRODES.
CAUSED BY
BY TOO
TOO COLD
COLD AA
CAUSED
PLUG,
PLUG, WEAK
WEAK IGNITION,
IGNITION, DIRTY
DIRTY
AIR
AIR CLEANER,
CLEANER, DEFECTIVE
DEFECTIVE FUEL
FUEL
PUMP,
PUMP, TOO
TOO RICH
RICH A
A FUEL
FUEL
MIXTURE,
MIXTURE, IMPROPERLY
IMPROPERLY
OPERATING
OPERATING HEAT
HEAT RISER
RISER
OR
OR EXCESSIVE
EXCESSIVE IDLING.
IDLING.
CAN
BE
CLEANED.
CAN BE CLEANED.
LEAD FOULED
BY DARK
DARK
IDENTIFIED BY
GRAY, BLACK, YELLOW
GRAY,BLACK,YELLOW
OR TAN DEPOSITS OR
OR A
OR
A
FUSED GLAZED
GLAZED COATING
COATING
FUSED
ON THE
THE INSULATOR
INSULATOR TIP.
ON
TIP.
CAUSED BY
BY HIGHLY
HIGHLY
CAUSED
LEADED GASOLINE.
GASOLINE.
LEADED
REPLACE THE
THE PLUG.
PLUG.
REPLACE
PRE-IGNITION
PRE-IGNITION
OVERHEATING
OVERHEATING
FUSED SPOT
SPOT DEPOSIT
DEPOSIT
FUSED
IDENTIFIED
IDENTIFIED BY
BYMELTED
MELTED
ELECTRODES
ELECTRODESAND
ANDPOSSIBLY
POSSIBLY
BLISTERED
BLISTERED INSULATOR.
INSULATOR.
METALLIC
METALLIC DEPOSITS
DEPOSITSON
ON
INSULATOR
INSULATOR INDICATE
INDICATE ENGINE
ENGINE
DAMAGE.
DAMAGE.
CAUSED
CAUSEDBY
BYWRONG
WRONGTYPE
TYPE
OF
OFFUEL,
FUEL,INCORRECT
INCORRECT IGNITION
IGNITION
TIMING
TIMING OR
ORADVANCE,
ADVANCE,TOO
TOOHOT
HOT
AAPLUG,
PLUG,BURNT
BURNTVALVES
VALVESOR
OR
ENGINE
ENGINEOVERHEATING.
OVERHEATING.
REPLACE
REPLACETHE
THEPLUG.
PLUG.
IDENTIFIED
IDENTIFIED BY
BYAAWHITE
WHITE OR
OR LIGHT
LIGHT
GRAY
GRAY INSULATOR
INSULATOR WITH
WITHSMALL
SMALL
BLACK
BLACK OR
ORGRAY
GRAY BROWN
BROWNSPOTS
SPOTS
AND
ANDWITH
WITHBLUISH-BURNT
BLUISH-BURNT APPEARAPPEARANCE
ANCEOF
OFELECTRODES,
ELECTRODES,CAUSED
CAUSED
BY
BYENGINE
ENGINEOVERHEATING.
OVERHEATING.WRONG
WRONG
TYPE
L, LOOSE
TYPEOF
OFFUE
FUEL,
LOOSESPARK
SPARK
PLUGS,
PLUGS,TOO
TOOHOT
HOTAAPLUG,
PLUG,LOW
LOW
FUEL
FUELPUMP
PUMPPRESSURE
PRESSUREOR
ORINCORINCORRECTIGNITION
IGNITIONTIMING.
TIMING.REPLACE
REPLACE
RECT
THE
THEPLUG.
PLUG.
IDENTIFIED BY
BYMELTED
MELTED
IDENTIFIED
OR SPOTTY
SPOTTY DEPOSITS
DEPOSITS
OR
RESEMBLING BUBBLES
BUBBLES
RESEMBLING
OR BLISTERS.
BLISTERS.
OR
CAUSED BY
BYSUDDEN
SUDDEN
CAUSED
ACCELERATION.CAN
CAN BE
BE
ACCELERATION.
CLEANED IFIFNOT
NOT EXCESSIVE.
EXCESSIVE.
CLEANED
OTHERWISE REPLACE
REPLACE PLUG.
PLUG.
OTHERWISE
that
thatwere
werejust
justcut.
cut. Plug
Plugeach
each wire
wireinto
into
the
the new
new resistance
resistance wire.
wire.
6.6. Connect
Connect the
the battery
battery cable
cable to
to the
the
negative
negative post.
post.
Ford,
Ford, Mercury
Mercury and
and Meteor
Meteor
1.1. Disconnect
Disconnect the
the battery
battery ground
ground cable.
cable.
2.2. Working
Working from
from under
under the
the hood,
hood, cut
cut
the
the old
old resistance
resistance wire
wire and
and the
the
number
number 16
16 red-light
red-light green
green wire
wire
approximately
approximately 22 inches
inches from
from the
the
number
number 14401
14401 to
to 14289
14289 harness
harness
connector
connector (Fig.
(Fig. 22).
22).
3.3. Tape
Tape each
each end
end of
ofthe
the old
old resistor
resistor wire
wire
that
that was
was just
justcut.
cut.
4.
4. Strip
Strip each
each end
end of
of the
the number
number 16
16 redredlight
light green
green stripe
stripe wire
wire and
and install
install aa
bullet-type
bullet-type connector
connector on
on each
each wire.
wire.
5.
double
5. Join
Join the
the number
number 16
16 wire with a double
connector.
connector.
6.
6. Drill
Drill aa hole
hole in
in the
the number
number 14401
14401
harness
harness dash
dash panel
panel grommet
grommet just
just
large
new
large enough
enough to
to install
install the
the new
resistor
resistor wire.
wire.
7. Connect
new resistor
resistor wire
wire to
to the
the
Connect the
the new
double connector.
8. Slip the other
other end of
of the resistor
resistor wire
wire
through the
the number 14401 harness
grommet
grommet and
and into the passenger
passenger
compartment. Seal as
as required.
9.
9. Route
Route the
the new
new resistor
resistor wire
wire along
along the
the
number
in
number 14401
14401 harness
harness and
and tape
tape it
it in
place.
place.
10. Disconnect
Disconnect the
the fuse
fuse panel
panel from
from its
10.
its
base.
11. Cut
11.
Cut the
the old
old resistor
resistor wire
wire and
and the
the
number 16
16 red-light
wire
number
red-light green
green wire
approximately 2
approximately
2 inches
inches from
from the
the
panel.
panel.
83235-B
FIG.
FIG. 21
21 Spark
Spark Plug
Plug Inspection
Inspection
BACK TO GROUP INDEX

23-01-13
23-01-13
RESISTOR WIRE
C0LF-12250-A
AND PINK STRIPE
T A P E AND ISOLATE
BOTH ENDS OF OLD
RESISTOR WIRE NO. 16A
D R I L L H O L E THROUGH 14401
WIRING HARNESS GROMMET
3477-A
B 3477-A
FIG. 22 Typical Resistance Wire Installation-Ford,

InstallationFord, Mercury and Meteor
Color Cad.
Cod.
Calor
C.,
Car Lint
Lint
Pinto-Bobcat
Maverick-Comet-G ranada-Monarch
Mustang-Cougar
Mustang-(,;ougar
Torino-Montego-Elite
Ford, Meteor, Mercury
Thunderbird
Continental Mark IV
Lincoln Continental
No. 18
No.1'
R/LG
R/LG
R/LG
R/LG
R/LG
R/LG
R/LG
R/LG
No. 32
32
R/LS
R/LB
R/LS
R/LB
R/LS
R/LB
R/LS
R/LB
R/LS
R/LB
R/LB
R/LS
R/LB
A/LS
R/LB
262
No. 282
-_
-BR/PK
SR/PK
BR/PK
BR/PK
BA/PK
BR/PK
CB1058B
CB1058B
FIG. 23 No. 14401 Wire Harness Color Codes
BACK TO GROUP INDEX

......
I
BATTERY
BATTERY
14300
14300 ASSY
ASSY
IGNITION
SWITCH
14431 ASSY
14431 ASSY
yD----...., TO
TO STARTER
STARTER MOTOR
MOTOR
WIRING
WIRING COLOR
COLOR CODE
CODE
--~---~--------,
16A,
16A, 16
16 RED-LT.
RED-LT. GREEN
GREEN STRIP
STRIP
32A,
32 RED-LT.
32A.32
RED-LT. BLUE
BLUE STRIP
STRIP
STARTER
MOTOR
RELAY
IGNITION
TERMINAL
STARTER
TERMINAL
32A
32A
14301 CABLE
CABLE ASSY
ASSY
""""-------- 14301
16A
ALL CAR
CAR LINES
LINES EXCEPT
EXCEPT
COUGAR-MUSTANG
COUGAR-MUSTANG
WITH
WITH TACHOMETER
TACHOMETER
16
TO
TO NO.
NO. 14289
14289 HARNESS
HARNESS COUGAR
COUGAR
1 TO
TO TACHOMETER
TACHOMETER ON
ON
MUSTAN
G-COUGAR
MUSTANG-COUGAR
WIRING
14290 WIRING
HARNESS
CONNECTOR
CD
:J
CD
"""l
TACHOMETER
TACHOMETER
MUSTANG
MUSTANG COUGAR
COUGAR
16A~32,A' ~2
co
m~LY
ONLY
32'
~.
:!'.
DISTRIBUTOR
DISTRIBUTOR
1--_-------IGNITION
16
:J
(Jl
16 - - - - - - - -
CD
IGNITION
"""l
COIL
COIL
~.
14401
14401 WIRING
HARNESS
CONNECTOR
DASH
PANEL
PANEL
CD
14401 CONNECTOR
WRAP WITH TAPE
AFTER
AFTER CONNECTIONS
ARE MADE
NEW RESISTANCE
RESISTANCE
NEW
WIRE COLF-1225
COLF-1225A
WIRE
A
\...)
-1J
t-..)
NEW RESISTANCE
RESISTANCE WIRE
WIRE
NEW
C9AZ-12250A
C9AZ-12250
A
MUSTANG-COUGAR
MUSTANG
-COUGAR W/TACH
ACCESSIBLE
ACCESSI BLE FROM
FROM
UNDER
UNDER INSTRUMENT
INSTRUMENT PANEL
PANEL
FIG. 24 Typical Resistance Wire InstallationExcept

Installation-Except Ford, Mercury
Mercury and Meteor
Meteor
BACK TO GROUP INDEX
......
I
o
I
B3402A
B3402-A

'
23-01-15
23-01-15
SPECIFICATIONS
Distriltutor
Distributor Identification
Identification
DISTRIBUTOR GENERAL INFORMATION
Engine
2.3L
2.8L
200
200
250
250
302
302
351
351
400
460
460
460 PI
(T)
CD
(2)
0
0(3)
identification number
The distributor identification
is stamped on the distributor housing.
The basic part number for distributors is
12127. To procure replacement parts,
suffix
refer to the part number prefix and suffix
stamped on the distributor
stamped
distributor housing,
identifying the particular distributor. If
If
identifying
the Master Parts Catalog lists a change
date relating to the part needed, it may
also be necessary to refer to the date code
stamped on the distributor body.
CD0
Rotor Air
Gap Voltage
Drop (Max.)
Distributor
Shaft End
Play ~)
(2)
Gear
Location
7.5KV
7.5KV
0.022-0.033
0.022-0.033
0.022-0.033
0.022-0.033
0.024-0.035
0.024-0.035
0.024-0.035
0.024-0.035
0.024-0.035
2.220-2.230
2.210-2.230
2.655-2.660
2.510-2.515
2.510-2.515
4.031-4.038
4.031-4.038
4.031-4.038
4.031-4.038
4.031-4.038
(])
(D
PART NUMBER PREFIX

PART NUMBER SUFFIX
SUF FIX
Refer to specification booklet fur

for performance specifications.
distributor removed.
Measured with distributor
removed
Distance from bottom of mounting flange to bottom of gear.
geol
Primary Resistance
(Ohms)
DATE CODE
Primary
Circuit
Resistor
Coil
MANUFACTURER
B3401A
B3401-A
Resistance
1.0-2.0
(Ohms)
7,000-13,000
1.30-1.40
0 F)
(75
(75F)
Identification
FIG. 25 Distributor Identification
Secondary Resistance
(Ohms)
CB3742B
CB3742-B
SPECIAL TOOLS
Tool Description
Spark Plug
Plug Boot Replacing Tool
Ignition Oscilloscopes
Tool No.
P73-192-1
P73-192-1
ARE-27-55or
ARE-881
ARE-27-55
or ARE-881
Tool Description
Spark Plug Wire Removing Tool
Timing Light
Tool No.
T74P-6666-A
13-07
CB1098-D
CB1098D
BACK TO GROUP INDEX

24-01-1
24-01-1
24-01-1
24-01-1
Fuel System
GROUP
Fuel System
PART 24-01
24-01
General Fuel System Service
PART 24-06
YFA 1-V
1-V Carburetor
Carter Model YFA
PART 24-10
Motoreraft
Motorcraft Model 5200 2-V Carburetor
PART 24-25
Motoreraft
PART 24-26
Motoreraft
PART 24-30
Fuel Pump-Mechanical
PAGE
24-01-1
24-06-1
..
..
24-10-1
..
..
24-25-1
..
..
24-26-1
24-30-1
24
PART 24-41
2441
Air Cleaner-Dry Type
PART 24-42
Air Cleaner Duct System
PART 24-50
Fuel Tank, Fuel Lines and
Evaporative Emission System
PART 24-51
24-51
Fuel Filters
PART 24-60
Throttle Linkage
PAGE
24-41-1
24-41-1
24-42-1
24-42-1
24-50-1
24-50-1
24-51-1
24-51-1
24-60-1
24-60-1
PART 24-01 General Fuel System Service

Page
COMPONENT INDEX
Page
COMPONENT INDEX
INSPECTION
DESCRIPTION
Fuel System .......................
01-1
01-1
Air Cleaner ........................
01-2
.......................
01-2
Carburetor . .......................
01-2
TESTING AND ADJUSTMENT ..........
01-2
Fuel Pump ........................
01-2
Decel Valve
Deeel

information in this Part applies to both 1975 and 1976 ITIodel
model year vehic.les
vehicles unless otherwise specified.
CR1966-A
DESCRIPTION
FUEL SYSTEM
Ford Motor Company vehicles
manufactured for domestic sale are
manufactured
equipped with a variety of emission
Modification or
control systems. Modification
adjustment of these systems so as to
adjustment
render them inoperative constitutes a
violation of
of federal
federal law.
violation
This Part of the shop Imanual
'manual will
cover those test and adjustment
adjustment
BACK TO GROUP INDEX
p r o c e d u r e s related
related directly
directly to
procedures
carburetors. Other emission systems
related to the fuel system, but not directly
to the carburetor, will be covered in
29 or in Volume 5,
5, Part 50-29.
Group 29
Carburetor
Identification
Ca
rbu retor Identification
A carburetor identification
identification tag is
attached to each carburetor, usually
under one of the fuel bowl cover

screws. The basic part number
attaching screws.
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)
1) must
must also
also be
be supplied.
supplied. Always
(Fig.
refer to
to the
the Master
Master Parts
Parts List
for parts
parts
refer
List for
interchangeability before
usage and interchangeability
24-01-2
replacing a carburetor or any of its
component parts.
parts.
DECEL
DECEL VALVE
VALVE
A
decel
(deceleration) valve is
A
installed on some vehicles.
vehicles. The valve
provides fuel system enrichment during
closed throttle engine deceleration for
purposes of emission reduction. A typical
valve isis shown in Figure 2.
decel valve
Testing, problem
problem diagnosis,
diagnosis,
maintenance and replacement of decel
valves
valves isis covered in Part 50-29 and in
Group 29.
29.
24-01-2
General Fuel System Service
PART NO.
NO. PREFIX
INDICATES NEW
DESIGN
PART NO. SUFFIX
Motorcraft~
Motorcraft
"DD5AZ
5AZ
RA
Â
/A
DESIGN
CHANGE
CHANGE
4C6
ASSEMBLY CODE-YEAR,
MONTH AND DAY
V1290-F
FIG. 1 Typical Carburetor

Identification Tag
A4082-A
FIG. 2 Typical Decel Valve
TESTING AND ADJUSTMENT

All adjustments
adjustments affect
affect engine
engine
emissions and should be performed by
competent personnel using specified
specified
equipment. Refer to Part 50-29 of
Volume 5 before performing critical fuel

system adjustments.
Refer to each carburetor section for
specific adjustment
adjustment points for individual
carburetors. Refer to Groups 29 and 50

for test and adjustment
adjustment procedures for
decel valves, EGR valves, PVS switches
and all other emission control systems
equipment.

AIR CLEANER
Refer
Refer to Volume
V o l u m e 5 for the
the
recommended air cleaner assembly
interval. Cleaning
maintenance mileage interval.
the air cleaner or crankcase ventilation
filter elements is not recommended. They
specified
should be replaced at the specified
mileage intervals.
intervals. Clean the air cleaner
body and the cover with a solvent or
air. Wipe the air cleaner
compressed air.
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
filter in
in front
front of
of aa light
light and
and carefully
carefully
the
inspect itit for
for any
any splits
splits or
or cracks.
cracks. If
If the
the
inspect
filter is
is split
split or
or cracked,
cracked, replace
replace it.
it.
filter
CARBURETOR
D i r t , gum, water
water or carbon
carbon
Dirt,
contamination in the carburetor or the
exterior moving parts of the carburetor
unsatisfactory
are often responsible for unsatisfactory
Efficient carburetion
carburetion
performance. Efficient
careful cleaning and
depends upon careful
inspection.
The cleaning and inspection of those
parts not included in the carburetor
here. All
overhaul repair kit are covered here.
gaskets and parts included in the repair
kit should be installed when the
carburetor is assembled and the old
gaskets and
and parts
parts should
should be
be discarded.
discarded.
gaskets
BACK TO GROUP INDEX
Wash all the carburetor parts (except

the accelerating pump diaphragm, the
valve,
power val
ve, the choke pulldown
diaphragm, and the anti-stall dashpot
clean commercial
commercial
assembly) in clean
carburetor cleaning solvent. If
carburetor
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
clean, soft, dry cloth.
cloth. Be
Be sure all dirt,
a clean,
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
calibration of
of the
changing
carburetor.
Check the choke shaft for grooves,
wear and excessive looseness or binding.
Inspect the choke plate for nicked edges
if
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
it has
has free
free movement.
movement.
certain
Check the throttle shafts in the bores

for excessive looseness or binding and
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,
power valve cover and accelerating pump
cover for cracks.
Check metallic float(s) for leaks by
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
of
fuel or water. If
If a float leaks, replace it.
Replace the float if
if the arm needle
contact surface is grooved. If
If the floats
floats
are serviceable, polish the needle contact
surface of the arm with crocus cloth or
steel wool. Replace thefloat
float shafts if they
are worn. Replace all screws and nuts
that
that have
have stripped
stripped threads.
threads. Replace
Replace all
all
distorted
distorted or
or broken
broken springs.
springs.
Inspect all gasket mating surfaces for
nicks and burrs. Repair or replace any
parts that have a damaged gasket surface.
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.
distortion. Inspect
Inspect the
the rocker
rocker
flange for
arm and pin for wear, cracks or damage.
Replace the pump if
if any of
of these
conditions are noted.
24-06-1
24-06-1
24-06-1
24-06-1
YFA 1-V Carburetor

Model YFA
PART 24-06
YFA 1-V
24-06 Model YFA
1-V Carburetor
Applies To Allin-line
All In-Line Six-Cylinder Engines
COMPONENT INDEX
COMPONENT INDEX
Page
DESCRIPTION
Page
Fuel Bowl Vent Clearance.

Clearance . . . . . . . . . . .
06-1
06-1
Carburetor Assembly
Carburetor
ADJUSTMENTS
ADJUSTMENTS
06-5
REMOVAL
INSTALLATION
Air Horn to
to Main
Fast Idle Adjustment
06-3
Anti-Stall Dashpot
06-4
Automatic
Automatic Thermostat Spring Housing ..
Dechoke
Decho
ke Adjustment
Choke Plate Pulldown
06-6
Float or
or Needle Valve
06-6
064
06-4
Carburetor Assembly
06-6
06-4
Main Metering Jet, Low

Low
064
06-4
Speed Jet, Metering
Fast Idle Cam Adjustment ...........
06-5
Rod and Accelerator
Adjustment
Metering Rod Adjustment
06-5
Pump
06-7
Float Level Adjustment
06-5
Float Drop Adjustment .............
06-5
06-7
Body Gasket

ASSEMBLY
DISASSEMBLY
Carburetor
Assembly
Ca
rbu reto r Assemb
Iy
NOTE: The
The information in
1976 model
model year
year vehicles
vehicles unless
CR1966-A
CR1966-A
DESCRIPTION
CARBURETOR
CARBURETOR ASSEMBLY
ASSEMBLY
Carter Model YFA

YFA 1-V
The Carter
1- V
is made up
up of three main
carburetor is
assemblies: the
the air
air horn, the
the main body
assemblies:
and throttle body (Figs.
1, 22 and
3).
(Figs. 1,
and 3).
The air
the
air horn, which serves as
as the
main body cover, contains the
the choke
plate, an
an internal'
internal" vent for
for the
the fuel bowl,
automatic choke thermostatic control
and electric assist choke (if equipped),
fuel inlet fitting, inlet needle and seat and
and lever assembly. The
The antithe float and
dashpot
throttle
stall dash
pot or solenoid throttle
positioner is
is attached to
to the
the air
air horn by
by
The Model YFA
means of aa bracket. The
YFA
carburetor has
has a choke hot
hot air inlet
and some models are
are equipped
adapter and
with aa mechanical external bowl vent for
improved control of evaporative
evaporative
improved
emissions.
BACK TO GROUP INDEX
The Model YFA Carburetors used on

some in-line six-cylinder engines are
equipped
equipped with solenoid
solenoid throttle
throttle
positioners (Fig.
(Fig. 1). The solenoid reduces
after-running by
by allowing
"dieseling" or after-running
the
the throttle plate to close further than the
normal curb idle position when the
is turned off.
ignition is
The main body contains
contains the
accelerator pump assembly, metering
rod, main metering jet,
jet, low-speed jet,
jet,
and weight,
accelerator pump check ball and
the main discharge nozzle.
and the
The throttle body con
tains the
contains
throttle plate, throttle shaft and lever and
idle mixture adjusting
adjusting screw with a
cap.
plastic limiter cap.
The engine speed is
and
is regulated and
by the
the proportion of fuel and
controlled by
and
air delivered to
to the
the cylinders for all
engine operating conditions. Operation is
based on
on the
the principle of pressure
differences.
is drawn into the
the carburetor air
Air is
air
by manifold vacuum. As
As the
the air
horn by
way
passes through the carburetor on the way
the cylinders, low
low pressure is
to enter the
created at the fuel discharge outlets of the
the
carburetor. The fuel bowl is vented to the
carburetor air horn. The
The higher air
carburetor
pressure exerted on
on the
the fuel in
in the
the bowl
the fuel to
to travel up
up through the
forces the
the
and out
out into the
fuel discharge channels and
the
air stream
stream passing through
through the
The fuel and
and air
air is
is mixed at
carburetor. The
this point and distributed into the engine
for combustion.
cylinders for

24-06-2
24-06-2
24-06-2
24-06-2
Model
Model YFA
YFA l-V
1-V Carburetor
Carburetor
INTERNAL FUEL
BOWL VENT
CHOKE COLD AIR

PICK-UP CONNECTION
CONNECTION
AUTOMATIC
CHOKE
THROTTLE LEVER
THROTTLE
SOLENOID POSITIONER
(TSP)
(TSP) SOME
SOME MODELS
MODELS
V2136-A
FIG. 11 Model
Model YFA
YFA l-V
1-V Carburetor-Rear
CarburetorRear View
FIG.
CHOKE PLATE
FUEL INLET
:-~~~~;:~~~~~~~,-~~
MECHANICAL
MECHANICAL
FUEL BOWL VENT
CHOKE HOT AIR

AIR
INLET
INLET ADAPTER
VENTURI VACUUM
CONNECTION
FUEL BOWL
ANTI-STALL
ANTI-STALL
DASHPOT (SOME MODELS)
V2137-A
V2137A
FIG. 2 Model YFA

YFA 1-V
l-V CarburetorLeft
Carburetor-Left Front View
BACK TO GROUP INDEX

24-06-3
24-06-3
24-06-3
24-06-3
Model YFA
YFA 1-V
l-V Carburetor
Carburetor
Model
V2050-A
FIG. 3 YFA l-V

1-V Carburetor Equipped with Solenoid-Rear
SolenoidRear View
ADJUSTMENTS
Most carburetor adjustments are
factory
factory set,
set, and
and based on
on guidelines
guidelines
determined
determined for
for reduced engine
engine emission.
emission.
In
In order
order to
to adjust:
adjust:
Automatic
Automatic Choke
Choke and
and Electric
Electric Assist
Idle
Idle Speeds
Speeds
Fuel
Fuel Mixture
Mixture
Idle
Idle CO
CO
you
you must
must refer
refer to
to Engine
Engine Emission
Emission
Control
Control System
System Part
Part 29-01
29-01 of
of this
this
Volume
Volume or
or Part
Part 50-29
50-29 of
of Volume
Volume 5.
5.
Adjustment
Adjustment points
points for
for the
the YFA
YFA I-V
1-V
Carburetor
Carburetor are
are shown
shown in
in Figs.
Figs. 1,1, 2,2, 33and
and
AUTOMATIC
CHOKE
CHOKE
THROTTLE SOLENOID
POSITIONER
(TSP) ADJ.
4.4.
FAST
FAST IDLE
IDLE ADJUSTMENT
ADJUSTMENT
Make
Make certain
certain the
the curb
curb idle
idle speed
speed and
and
mixture
mixture are
are adjusted
adjusted to
to specification
specification
before
before attempting
attempting to
to set
set the
the fast
fast idle
idle
speed.
speed.
1.1. With
W i t h the
t h e engine
e n g i n e operating
operating
temperature
temperature normalized
normalized (hot),
(hot), EGR
EGR
vacuum
vacuum disconnected
disconnected and
and aa jumper
jumper
line
line(if
(ifrequired)
required)to
tothe
thedistributor,
distributor, air
air
cleaner
cleaner removed
removed and
and the
the tachometer
tachometer
attached,
attached,manually
manually rotate
rotatethe
thefast
fast idle
idle
camuntil
untilthe
thefast
fast idle
idleadjusting
adjusting screw
screw
cam
rests
restson
onthe
thestep
stepof
of the
the cam
cam as
asshown
shown
in
in Fig.
Fig. 5.5.
BACK TO GROUP INDEX
TSP OFF
IDLE SPEED
ADJUSTMENT
ADJUSTMENT
IDLE FUEL MIXTURE

POSITIONER
.FAST
IDLE
ADJUSTMENT
SCREW
V2039-A
V2039A
FIG. 44 Carburetor
Carburetor Adjustments-Model
AdjustmentsModel YFA
YFA l-V
1-V
FIG.
24-06-4
24-06-4
Model YFA 1-V Carburetor
ANTI-STALL DASHPOT
1.
1. With the engine idle speed and
mixture properly adjusted, and the
engine at normal
operating
engine
temperature, loosen the anti-stall
dashpot lock nut.
2.
2. Hold the throttle in the curb idle
dashpot
position and depress the dash
pot
plunger with a screwdriver blade.
Measure the clearance between the
throttle lever and the plunger tip.
dashpot
Turn the anti-stall dash
pot in a
specified
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
automatic choke has an
The automatic
adjustment to control its reaction to
adjustment
engine temperature. By loosening the
c l a m p screws
screws that
t h a t attach
a t t a c h the
the
clamp
thermostatic spring housing to the choke
housing, the spring housing can be turned
to alter the adjustment. Refer to the
specifications for the proper setting.
1.
1. Remove the air cleaner assembly from
the carburetor.
2.
2. Loosen the thermostatic spring
housing retaining screws. Set the
spring housing to the specified index
mark and tighten the attaching
screws.
screws.
3. If other carburetor adjustments are
not required, install the air cleaner
assembly on the carburetor.
FAST IDLE CAM
FAST IDLE SPEED

ADJUSTING SCREW
V2138 A
V2138-A
FIG. 5 Fast Idle Adjusting Screw
DRILL
GAUGE
DECHOKE ADJUSTMENT
1.
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
proper diameter
diameter to check the
clearance between the choke plate
and air horn (Fig. 6).
3. If
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
decrease the
downward
clearance, and bending it upward will
increase the clearance. Always
recheck the clearance after making
adjustment.
any adjustment.
CHOKE PLATE PULLDOWN

1. Remove the air cleaner assembly,
1.
then remove the choke thermostatic
spring housing 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
l/8-inch
bent end of the gauge between the
BACK TO GROUP INDEX
THROTTLELEVER~~----~~
THROTTLE
LEVER
(OPEN POSITION)
MAKE
DECHOKE
MAKEDECHOKE
ADJUSTMENT HERE
V2139-A
V2139A
FIG. 6 Choke Plate Clearance Adjustment

24-06-5
24-06-5
choke piston
piston slot
slot and
and the
the right
right hand
hand
choke
slot in
in the
the choke
choke housing.
housing. Rotate
Rotate the
the
slot
choke piston
piston lever
lever counterclockwise
counterclockwise
choke
until the
the gauge
gauge isis snug
snug in
in the
the piston
piston
until
slot (Fig.
(Fig. 7).
7).
slot
3. Exert
Exert aa light
light pressure
pressure on
on the
the choke
choke
3.
piston lever
lever to
to hold
hold the
the gauge
gaugeininplace,
place,
piston
then use
use aa drill
drill with
with aa diameter
diameter equal
equal
then
to the
the specified
specified pulldown
pulldown clearance
clearance
to
between the
the lower
lower edge
edge of
of the
the choke
choke
between
plate and
and the
the carburetor
carburetor bore
bore to
to check
check
plate
clearance (Fig.
(Fig. 7).
7).
clearance
4. To
To adjust
adjust the
the choke
choke plate
plate pulldown
4.
clearance, bend
bend the
the choke
choke piston lever
clearance,
as required to
to obtain the
the specified
specified
as
setting. When
When bending
bending the
the lever,
lever, be
setting.
not to
to distort
distort the
the piston
piston link.
link.
careful not
5. Install the
the choke
choke thermostatic spring
5.
gasket. Set
Set the
the housing
housing and gasket.
to specifications.
specifications.
to
IDLE CAM SETTING
FAST IDLE
1. Position the fast idle screw on the
1.
kickdown step of the fast idle cam
against the shoulder of the high step
(Fig. 5).
(Fig.
2. Adjust by bending the choke plate
2.
connecting rod to obtain the specified
clearance between lower edge of the
choke plate and the carburetor bore.
METERING ROD ADJUSTMENT

1. Remove the carburetor air horn and
1.
gasket from the carburetor.
2. Back out the idle speed adjusting
adjusting
screw until the throttle plate is closed
tight in the throttle bore.
3. Press down on the end of the pump
diaphragm shaft
shaft until the assembly
bottoms.
4. To adjust the metering rod, hold the
diaphragm assembly as in Step 3,
then, turn the rod adjustment
adjustment screw
(Fig. 8) until the metering rod just
bottoms in the body casting.
5. Turn the metering rod adjustment
screw in (clockwise) one additional
turn for the final adjustment.
carburetor air horn with a
new gasket on the carburetor.
FLOAT LEVEL ADJUSTMENT

The dry float fuel level adjustment is
a final float or fuel level adjustment.
1. Remove the carburetor
carburetor air horn and
gasket from the carburetor. Refer
Refer to
Air
Air Horn
Horn to
to Main
Main Body
Body Gasket
Gasket
Replacement
proper
Replacement for
for the
the proper
procedure.
procedure.
2. Fabricate
Fabricate a float
float level gauge (Fig. 9)
9)
to
to the
the specified
specified float
float level
level dimension.
dimension.
3.
3. Invert
Invert the
the air
air horn
horn assembly,
assembly, and
and
check
check the
the clearance
clearance from
from the
the float
float
indentation
indentation on
on the
the top
top of
of the
the float
float to
to
the
of the
the air
air horn
horn with
with the
the
the bottom
bottom of
float
level gauge
gauge (Fig.
(Fig. 9).
9). Hold
Hold the
the air
air
float level
BACK TO GROUP INDEX
24-06-5
24-06-5
Model YFA
YFA 1-V
1-V Carburetor
Carburetor
Model
horn
horn at
at eye
eye level
level when
when gauging
gauging the
the
float
float level.
level. The
The float
float arm
arm (lever)
(lever)
should be
be resting
resting on
on the
the needle
needle pin.
pin.
should
Do not
not load
load the
the needle
needle when
when
Do
adjusting the
the float.
float. Bend
Bend the
the float
float
adjusting
arm as
as necessary
necessary to
to adjust
adjust the
the float
arm
float
level (clearance).
(clearance). Do
Do not
not bend
bend the
the tab
tab
level
at the
the end
endof
ofthe
thefloat
floatarm.
arm.ItItprevents
prevents
at
the float
float from
from striking
striking the
the bottom
bottom of
the
the fuel
fuel bowl
bowl when
when empty.
empty.
the
4. Install
Install the
the carburetor
carburetor air
air horn
horn and
and aa
4.
new gasket
gasket on
on the
the carburetor.
carburetor. Refer
Refer
new
to Carburetor
Carburetor Air
Air Horn
Horn to
to Main
Main
to
Body Gasket
Gasket Replacement
Replacement for
for the
the
Body
procedure.
proper procedure.
FLOAT DROP ADJUSTMENT

ADJUSTMENT
1.
1. Remove
Remove the
the carburetor air horn and
gasket from the
the carburetor. Refer to
to
Air Horn to Main Body Gasket
Gasket
Replacement for the proper
proper
Replacement
procedure.
procedure.
2. Fabricate aa float
float drop gauge to
to the
2.
dimension.
specified dimension.
3.
3. Hold the airhorn upright and let the
float hang free. Measure the
the
maximum clearance from the top of
the float
float to the bottom of the air horn
gauge. Hold the
with the float
float drop gauge.
air horn at eye level when gauging the
dimension.
4. To adjust, bend the tab at the end of
the float
float arm to obtain the specified
setting.
5. Install the carburetor air horn and a
5.
new gasket on the carburetor
carburetor as
described in this Part.
FUEL
FUEL BOWL
BOWL VENT
VENT CLEARANCE
CLEARANCE
(1975
(1975 ONLY)
ONLY)
1.1. Check
Check curb
curb idle
idle rpm
rpm with
with solenoid
solenoid
activated
activated adjust
adjust as
as required.
required.
2.
2. Stop
Stop engine
engine and
and turn
turn ignition
ignition key
key to
to
"on"
"on" position
position so
so that
that the
the solenoid
solenoid isis
activated
activated but
but the
the engine
engine isis not
not
running.
running.
3.
3. Open
Open throttle
throttle so
so that
that the
the throttle
throttle vent
vent
lever
lever does
does not
not touch
touch the
the fuel
fuel bowl
bowl
vent
vent rod
rod (Fig.
(Fig. 10).
10).
4.
4. Close
Close throttle
throttle and
and measure
measure the
the travel
travel
of
of the
the fuel
fuel bowl
bowl vent
vent rod
rod at
at point
point "A"
"A"
from
from open
open throttle
throttle position
position (Step
(Step 3)
3)
to
to idle
idle position (Step
(Step 2).
2). Travel
Travel of the
the
fuel bowl vent rod at point "A"
"A"
should be
.010.
be .020
.020.010.
5.
5. If vent rod
rod travel
travel isis not correct, bend
throttle vent lever at indentation to
to
obtain required travel.
travel.
ROD
ROD ACTION
ACTION CAUSED
CAUSED
BY SCR
EW ACT
ING AS
SCREW
ACTING
PIVOT POINT FOR
FOR LEVER
SCREW
SCREW RETAINING
RETAINING
SPRING
SPRING
METER ING
ROD
PUMP
DIAPHRAGM
SHAFT
DRILL GAUGE
CHOKE PISTON
LEVER
FIG. 8 Metering Rod Adjustment
FUEL LEVEL)
TAB (LOW FUEL
FLOAT ARM
FLOAT
FLOAT
.026"
.026"
WIRE
WIRE
GAUGE
GAUGE
V1452-A
FIG.7
Pulldown Clearance
Clearance
FIG.
7 Pulldown
AdjustmentModel
Adjustment-Model
YFA
YFA 1-V
1-V
V2079-A
V2079-A
FIG. 99 Fuel
Fuel Level
Level Float
Float Adjustment
Adjustment
FIG.
24-06-6
1-V Carburetor
Model YFA l-V
24-06-6
V1976-A
FIG. 10 Fuel
Fuel Bowl Vent Valve
AdjustmentYFA 1-V (1975
Adjustment-YFA
Only)

M A I N BODY
AIR HORN TO MAIN
GASKET
Remoyal
Removal
1.
2. Disconnect the choke heat tube at the
carburetor air horn. Disconnect the
carburetor.
fuel inlet line at the carburetor.
Disconnect the choke clean air 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. Remove the clip retaining the link
joining the choke shaft lever to the
fast idle cam and remove the link.
5.
5. Remove the air horn assembly
attaching screws, dash
pot and
dashpot
bracket assembly or solenoid throttle
positioner and air horn gasket.
positioner
Discard the gasket.
Installation
Installation
1.
1. Install a new air horn to main body
all holes
holes in
in the
thenew
new
gasket. Make sure all
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
screws.
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 tube to the
carburetor air hom.
horn.
3. Connect the solenoid wire and electric
choke wire (if equipped).
4. Install the air cleaner. Start the engine
and run it until normal operating
BACK TO GROUP INDEX
temperature is reached. Adjust the

idle fuel mixture and idle speed.
FLOAT OR NEEDLE VALVE
Remoyal
Removal
I.
gasket. Follow instructions under Air
Horn to Main
Main Body Gasket
Gasket
Horn
Replacement.
2.
2. Hold the air horn assembly bottom
up, and remove the float pin and
side up,
float and lever assembly. Turn the air
horn assembly over and catch the
needle pin, spring and needle.
3. Remove the needle seat and gasket.
Installation
Installation
1.
1. Replace the float if the needle pin
contact surface is grooved. If the float
float
is serviceable, polish the needle pin
contact surface with crocus cloth or
steel wool.
float pin if it
wool. Replace the float
is worn.
2.
2. Install the needle seat and gasket in
the air horn. With the air horn
inverted, install the needle, pin
pin spring,
spring,
pin,float
needle pin,
float and lever assembly
and float
float pin (Fig. 14).
3. Adjust
A d j u s t the
t h e float
f l o a t level
l e v e l to
to
specifications.
4. Install the carburetor air hom
horn and
gasket.
CARBURETOR ASSEMBLY
Remoyal
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
carefully removed from the engine
without removing the fuel from the bowl.
bowl.
The contents of the bowl may then be
examined for contamination
contamination as the
carburetor is disassembled.
1.
2. Remove the throttle cable or rod from
2.
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 line
from the air horn.
5.
carburetor retaining
nuts; then remove the carburetor.
Remove the carburetor mounting
gasket, spacer (if equipped) and lower
gasket, from the intake manifold.
Installation
IRstallation
1.
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.
manifold. Position
Position the
carburetor on the spacer and gasket
and secure it with the attaching nuts.
To prevent leakage, distortion or
flange,
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.
24-06-7
3. Connect the choke clean air line to
to the
horn. Connect the solenoid wire
air hom.
and electric choke wire (if equipped).
5.
5. Adjust the engine idle speed, the idle
fuel mixture and anti-stall dashpot (if
(if
so equipped).
MAIN
M A I N METERING JET,
LOW-SPEED JET, METERING ROD
AND ACCELERATOR PUMP
Removal
Removal
1.
carburetor from the
engine as described in this Part.
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
accelerator pump
5.
screws. Remove
diaphragm housing screws.
the accelerator pump discharge tube.
Lift out the pump diaphragm
diaphragm
Lift
assembly, the pump lifter link, the
anti-rock plate, the metering rod as a
(Figs. 11
11 and 12).
unit (Figs.
6.
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 upper spring, the
metering rod arm assembly and the
lifter link from the pump
pump lifter
diaphragm shaft. Compress the pump
diaphragm spring. Remove the pump
diaphragm spring retainer, spring and
pump diaphragm assembly from the
pump diaphragm housing assembly.
24-06-7
1-V Carburetor
Model YFA l-V
7.
7. With the proper size jet tool or
screwdriver, remove the low speed jet
(Fig. 14).
and the main metering jet (Fig.
Installation
Instsllstion
1.
1. With the proper size jet tool (or
screwdriver) install the low speed jet
and the main metering jet (Fig. 14).
2. Install the pump diaphragm in the
pump diaphragm housing. Position
the pump diaphragm spring on the
diaphragm
diaphragm shaft
shaft and housing
housing
assembly. Install the spring shim
washers in the proper locations.
Install the spring retainer. Install the
pump lifter link, the anti-rock plate,
metering rod arm and spring
spring
metering
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. 11. Align the pump diaphragm
with the diaphragm housing; make
4.
4.
5.
6.
6.
7.
7.
sure holes are aligned. Install the

housing attaching screws to keep the
diaphragm and housing aligned.
Install the accelerator
accelerator pump
Install
discharge tube.
Install the throttle shaft arm and link
to the end of the throttle shaft.
Adjust metering rod as described in
Section 3 of this Part.
Install the carburetor air horn and
gasket as described under Air Horn
to Main Body Gasket Replacement.
Install the carburetor on the engine as
described in this Part.
ACCELERATOR
PUMP NOZZLE
PUMP CHECK
BALL AND WEIGHT
DIAPHRAGM
HOUSING SCREW
METERING
ROD ARM
SPRING
PUMP
DIAPHRAGM
AND HOUSING
ASSEMBLY
PUMP DIAPHRAGM
METERING ROD
V1448-C
FIG. 11
11 Accelerating Pump and Lifter
Link Assembly
METERING
ROD
V2051-A
FIG. 12 Pump Diaphragm and

Housing Installation

DISASSEMBLY
24-01 for Cleaning and
Refer to Part 24-01
Inspection procedures.
CARBURETOR
CARBURETOR ASSEMBLY
ASSEMBLY
Disassembly
Disassembly
Use a separate container for the
component parts of
of the various
various
component
assemblies to facilitate
facilitate cleaning,
inspection and assembly.
The following is a step-by-step
step-by-step
sequence of operations for completely
overhauling the carburetor; however,
certain components of the carburetor
may be serviced without a disassembly of
of
the entire unit.
BACK TO GROUP INDEX
1.
1. Remove the attaching screws and
retainers, 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. 14).
3. Hold the air horn assembly bottom
side up and remove the float
float pin and
float and
andlever
leverassembly.
assembly.Turn
Turn the
theair
air
float
horn assembly over and catch the
needle pin, spring and needle.
4.
4. Remove the needle seat and gasket.
5. Remove the air cleaner bracket.

5.
Remove the choke plate attaching
screws. File the staked ends, if
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. 13).
Remove the assembly from the air
horn. Remove the piston pin and
piston from the choke piston lever
and link assembly.
24-06-8
CHOKE PISTON
CYLINDER
Model YFA l-V

1-V Carburetor
Carburetor
CHOKE PISTON LEVER

A N D LINK
LINK ASSEMBLY
ASSEMBLY
AND
PISTON
CHOKE PISTON
PIN
PIN
FIG. 13 Automatic Choke Piston

Installation
Removal or Installation
6. Turn main body casting upside down

6.
and catch the accelerating pump
check ball and weight.
7. Loosen the throttle shaft arm screw,
7.
and remove the arm and pump
connector link.
8. Remove the fast idle cam and
8.
shoulder screw.
9. Remove the accelerating pump
9.
screws. Lift out
diaphragm housing screws.
the pump diaphragm assembly, the
pump lifter link, the metering rod as
unit.
a unit.
Disengage the
the metering
metering rod
rod arm
arm
10. Disengage
spring from the metering rod, and
remove the metering rod from the
metering rod arm assembly. Note the
location of
of any washers shimming
either spring for proper reassembly.
Compress the upper pump spring,
and remove the spring retainer.
Remove the upper
upper spring, the
metering rod arm assembly and the
pump lifter
lifter link from the pump
diaphragm shaft. Compress the pump
diaphragm spring, and remove the
pump diaphragm spring retainer,
spring, and pump diaphragm
diaphragm
assembly from the pump diaphragm
housing assembly.
11. With the proper size jet tool or
screwdriver,
screwdri ver, remove the main
metering rod jet and the low speed jet
(Figs. 12 and 14).
12. Remove the retaining screws
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
if
necessary, and use new screws upon
assembly. Slide the throttle shaft
shaft and
BACK TO GROUP INDEX
throttle
lever assembly out of the throttle
the
body flange assembly. Note the
torsion
location of the ends of the torsion
on the throttle shaft for proper
spring on
reassembly. When removing the idle
mixture limiter cap be sure to note the
tab. After removing
position of the tab.
cap count the number of
the limiter cap
turns to lightly seat the needle. This
i n f o r m a t i o n will
w i l l be used in
in
information
reassembly.
Assembly
Assembly
1. Install the throttle shaft and lever
1.
assembly with torsion throttle return
(Figs. 14
14 and 15)
spring and bushing (Figs.
in the throttle body flange.
flange. Position
shaft
the throttle plate on the throttle shaft
with the notch in the plate aligned
(Fig. 15)
15) in
with the slotted idle port (Fig.
the throttle body flange.
flange. Install the
throttle plate attaching screws snug,
tight. Move the shaft back and
but not tight.
forth and rotate it to be sure the
throttle plate does not bind in the
flange bore.
bore. It is necessary that the
flange
throttle plate should close tight in the
bore therefore the idle speed screw
sufficiently to
should be backed out sufficiently
insure it does not contact the throttle
Reposition the plate, if
if
stop. Reposition
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
seatea.
same position as removed.
2. Place a new body flange
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.
12 and 14)
4. Install the pump diaphragm in the
pump diaphragm housing (Fig. 12).
Position the pump diaphragm spring
on the diaphragm shaft
shaft and housing
assembly. Install the spring shim
washers in the proper locations.
Install the spring retainer. Install the
pump lifter
lifter link, metering rod arm
and spring assembly, and upper pump
spring on the diaphragm
shaft.
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. 11. 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.
24-06-8
6.
6. Align the
the pump
pump housing,
housing, pump
pump lifter
lifter
link,
link, metering rod and baffle plate
with
with the
the main body casting.
casting. Be
Be sure
the vacuum passage in the diaphragm
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,
body, and to
insert the metering rod in
in the main
metering rod jet. Install the pump
snug, but
housing attaching screws snug,
tight.
the
not tigh
1. Push down on the
diaphragm shaft to compress the
diaphragm, and tighten the attaching
screws. Adjust the metering
meterin'g rod,
rod,
screws.
under
Adjustment.
Metering Rod Adjustment.
7.
7. Install the fast idle cam and shoulder
screw.
screw. Install the throttle shaft arm
and pump connector link on the
throttle shaft and pump lifter link
(Fig.
(Fig. 15).
15). Tighten the lock screw.
8.
8. Assemble the choke piston and pin to
the choke piston lever and link
assembly. Install the choke shaft
shaft
assembly in the air horn and position
the piston as shown in Fig.
Fig. 13.
9.
9. Align the piston with the cylinder and
rotate the shaft assembly clockwise
until the piston pin is inside the piston
cylinder.
10.
10. Position
Position the
the choke
choke plate
plate on
on the
the choke
choke
shaft
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 leveleveY 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,
float and lever assembly,
needle pin, float
Adjust the float
float level to
and float pin. Adjust
specifications.
12. Place
Place the
the pump
pump check
check ball
ball and
and weight
in the main body casting (Fig. 12).
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
the thermostatic coil
coil housing,
housing,
baffie plate, identification
gasket and baffle
mark facing outward, with the gasket
baffie and coil housing.
between the baffle
thermostatic spring
Be sure the thermostatic
engages the choke lever tang and is
not stopped by a retaining tab on the
baffle
baffie plate (if
(if equipped). Install the
retainers and housing screws. Set the
coil housing index to specifications
and tighten the screws.
14. Install the
the air cleaner bracket.
bracket. Install
the fast idle link.
24-06-9
24-06-9
Model
Model YFA
YFA l-V
1-V Carburetor
Carburetor
SCREWS
AIR CLEANER BRACKET
BRACKET
SCREW
SCREW
ANTI-STALL DASHPOT
ANTI-STALL
/'
CHOKE PLATE
PLATE
AIR HORN
HORN ASSEMBLY
ASSEMBLY
FAST IDLE CHOKE LEVER
9*/
COIL HOUSING BAFFLE PLATE

COIL HOUSING GASKET
ELECTRIC ASSIST
CHOKE CAP
AIR HORN
HORN GASKET
GASKET
NEEDLE PIN
PIN
SPRING,
SPRING, SEAT AND
AND . .------1~
GASKET ASSEMBLY
ASSEMBLY
COIL HOUSING RETAINER

UPPER PUMP SPRING 9D598
FLOAT PIN
A"tj'. . . . .-ANTIROCK
PLATE
PUMP LIFTER LINK

LINK
FLOAT
FLOAT AND LEVER
ASSEMBLY
CCL3"l-011----
PUMP DIAPHRAGM SPRING RETAINER

PUMP DIAPHRAGM SPRING
METERING ROD JET
DIAPHRAGM HOUSING ATTACHING SCREW
C W - - PUMP CHECK WEIGHT
........a...~:y:j ....t----PUMP
PUMP DIAPHRAGM HOUSING ASSEMBLY
MAIN
MAIN BODY CASTING
CASTING
BODY FLANGE
ATTACH ING SCREW
THROTTLE SHAFT ARM
THROTTLE
S~_
SCREW
SCREW
BODY FLANGE
GASKET
~.
BODY
BODY FLANGE
FLANGE
-L
WI
I
)---
PUMP CONNECTOR
CONNECTOR LINK
LINK
PUMP
::STIDLE CAM
. ,(IJ((J;
*-{|
SCRE~
Q
ATTACHING
ATTACHING SCREW
ID
~-
THROTT~P~\
-,-.~
.......-
.~""'-::~W-~',~, ~~
FASTIDLE
CAM LINK
SOLENOID "OFF"
"OFF"
OR CURB
IDLE SPEED SCREW
BUSHING
i'i~8
~
SPRING
SPRING
LIMITER CAP
IDLE FUE L
IDLE FUEL
....^MIXTURE
MIXTURE ADJUSTING
SCREW
SCREW AND
AND SPRING
SPRING
THROTTLE SHAFT AND

LEVER ASSEMBLY
ALUMINUM THROTTLE
THROTTLE
BODY FLANGE ASSEMBLY
V1129-M
14 Model YFA
YFA 1-V
1-V Carburetor Assembly
FIG. 14
BACK TO GROUP INDEX

24-06-10
24-06-10
Model
ModelYFA
YFAl-V
1-VCarburetor
Carburetor
24-06-10
24-06-10
THROTTLE SHAFT
AND LEVER ASSEMBLY
SLOTTED
IDLE PORT
NOTCH
\
THROTTLE PLATE
V1453-A
FIG. 15
15 Throttle
Throttle Plate
Plate and
and Shaft
Shaft Arm
Arm
FIG.
Installation
Installation
BACK TO GROUP INDEX

24-10-1
24-10-1
24-10-1
24-10-1
Model 5200 2-V Carburetor
PART 24-10
24-10 Model 5200 2-V Carburetor
Applies to Pinto, Bobcat and Mustang Engines Only
COMPONENT INDEX
Page
COMPONENT INDEX
Page
10-6
CAM CLEARANCE .........

FAST IDLE CAM
FAST IDLE SPEED ADJUSTMENT
ADJUSTMENT ......
. .
DRY FLOAT SETTING ................
IDLESPEED
FUELM
I X T U R E .....
IDLE
SPEED AND
AND FUEL
MIXTURE
10-3
10-3
10-4
10-3

Disassembly and
CHOKEPLATEPULLDOWN
CHOKE PLATE PULLDOWN .................
CHOKE THERMOSTATIC
THERMOSTATIC SPRING
10-6
10-3
MAIN BODY
o
isassemb Iy and
Assemb Iy ............
Disassembly
and Assembly
SECONDARY
SECONDARY THROTTLE STOP ........
10-8
10-4
HOUSING ........................
HOUSiNG
DESCRIPTION
DES
CRIPT ION .............................
10-3
10-1
10-1
TESTING
Using
Choke
Usi
ng Cho
ke Tester
10-2
ACCELERATOR PUMP
ACCELERATOR
Disassembly and
10-6
AUTOMATIC
AUTOMATIC CHOKE
Disassembly
and Assembly
o
isassemb Iy and
Assemb Iy ............
BOWL COVER
..
................................
NOTE: The
The infonnation
information in
1976 Inodel
model year
year vehicles
vehicles unless
CR1966-A
CR1966A
DESCRIPTION
The Motorcraft
2- V
Motorcraft Model 5200 2-V
carburetor is
is a two
two stage, two
two venturi
carburetor
carburetor. The primary
primary venturi is
the secondary venturi. The
smaller than the
s e c o n d a r y system
system is operated
o p e r a t e d by
secondary
mechanical linkage.
The primary stage includes a curb idle
system, accelerator pump system, idle
transfer
transfer system, main metering system
and power enrichment system.
The secondary side includes a transfer
transfer
system, main metering system and
and power
the primary and
and secondary
system. Both the
systems draw fuel from a common fuel
bowl.
The Model 5200 2-V isis equipped
equipped with
with
an automatic choke featuring a housing
for coolant flow and an electric heater
assist. This provides for choke pull-off
pull-off in
a short time after engine start. Testing
information for
for the
and adjustment information
in Part 29-01 of this
choke is contained in
volume.
The Motorcraft
2-V
carburetor is provided with four new
carburetor
new
Cam Latch (Fig.
(Fig. I)
1) isis
features. Fast Idle Cam
provided to hold the
the fast idle cam
cam in the
the
the choke
high position (fast idle) until the
and the
the bimetal latch "B" backs
heats up and
off and allows the
the latch pin and
and fast idle
off
cam to rotate to the
the normal run position.
An overcenter spring is also provided to
assist in closing the
the choke plate for initial
BACK TO GROUP INDEX
V1912-A
V1912 A
FIG. 11 Fast Idle Cam

Cam Latch
latch
24-10-2
24-10-2
5200 2-V
2-V Carburetor
Model 5200
(TSP)
(TSP)
so LE NOI D "OF
F" ----=---~::. Hili'2..A
SOLENOID
"OFF"
IDLE SPEED
ADJUSTING SCREW
(TSP)
SOLENOID ""ON"
ON"
(CURB) IDLE SPEED
ADJUSTING SCREW
V1911-A
V1911A
2-V Carburetor
Carburetor With Solenoid Throttle Positioner
FIG. 2 Model 5200 2-V
starting of a cold engine in high ambient
temperatures. After
After initial choke
pull-down occurs, the overcenter spring
has little or no effect
effect on choke operation.
A new solenoid throttle positioner
1975 carburetor
(TSP) is used on the 1975
(Fig. 2).
2). The TSP operates the same as
on other models (energized when ignition
is on).
on). An adjustment
adjustment screw is
switch is
provided in
in the
the throttle
throttle lever.
lever.
provided
A
A primary velocity pull-over
pull-over
enrichment system is used (on 1975
carburetors only) to supply an additional
amount of fuel to the system after 80
CFM of air is
is reached
reached in
in the
the main
main system.
system.
80 CFM,
CFM, fuel is
is pulled from
from
Starting at 80
the bowl through the fuel enrichment
mainwell. It is
is then mixed
valve into the mainwell.
with the normal fuel supply and
discharged out through the discharge
nozzle.
nozzle.
Dual activated diaphragm-the
diaphragmthe
carburetor is
is provided with aa drilled
passage to connect the transmission dual

area diaphragm (DAD) to the carburetor
automatic-transmission
on some automatic-transmission
equipped vehicles for 1975 (Fig. 3).
3). For
1976, this
this connection
connection is used
used for the
the EGR
EGR
1976,
valve.
valve.
TRANSMISSION VACUUM
CONNECTION 1975
(D.A.D.) (EGR VALVE 1976)
V1969-B
FIG. 3 Dual Activated Diaphragm

Diaphragm
Connection
TESTING
USING CHOKE TESTER
TESTER LRE
LRE 34618
34618
WITH MODEL 5200 2-V
2-V
CARBURETOR
Several automatic choke
choke tests
tests call
call for
use
use of the
the Choke
Choke Tester LRE 34618
34618 to
to
provide artificial cooling of the
the choke
bimetal spring.
spring. Observe this
this procedure
BACK TO GROUP INDEX
when
when using
using the
the Tester with Model
Model 5200
5200
2-V
2-V carburetor:
carburetor:
1.
1. Remove
Remove clamp
clamp and fitting from extra
hose and attach hose
hose to
to Choke
Choke Tester
hose
34618 output connection.
connection.
LRE 34618
2. Chamber end of hose

hose approximately
2.
1/4 inch back from end (Fig.
(Fig. 4).
4).
1/4
3.
3. Insert chamfered end of hose
hose into
into
Model 5200
5200 2-V carburetor choke
housing and perform test.
test.
24-10-3
24-10-3
CHAMFER HOSE
MODEL
5200 2-V
CHOKE
HOUSING
INSERT HOSE
INTO WATER
PASSAGE
V1913-A
FIG.
FIG. 4. Making Choke Housing Test
Adapter
ADJUSTMENTS
Most carburetor
carburetor adjustments
adjustments are
factory
factory set, and based on guidelines
determined for reduced engine emission.
In order to adjust:
adjust:
Automatic Choke and Electric Assist
Idle Speeds
Fuel Mixture
Idle CO
refer to Engine Emission
you must refer
Part 29-02 of
of this
Control Systems Part
Volume or Part 50-29 of Volume 5.
Adjustment
Adjustment points for the Motorcraft
Motorcraft
2-VV carburetor are shown in Figs.
5200 22, 5 and 6.
3. Set the fast idle cam on the top step.

4. Using a screwdriver,
push the
screwdriver, push
the
diaphragm stem back against its stop

(Fig. 9). Place a specified
specified gage rod or
drill between the lower edge of the
choke plate and the air horn wall.
5. Remove the slack from the choke

linkage by attaching a rubber band to
the choke operating lever as shown in
Fig. 9.
adjust the choke plate-to-air horn
6. To adjust
c l e a r a n c e , turn
t u r n the
t h e vacuum
vacuum
clearance,
FAST IDLE CAM CLEARANCE

specified inch drill between
1. Insert a specified
the lower edge of the choke plate and
the air horn wall.
2. With the fast idle screw held on the
bottom step of
of the fast idle cam,
against the top step, measure the
of the
clearance between the tang of
choke lever and the arm on the fast
idle cam (Fig. 7).
7). The tang and arm
should be in light contact. Bend choke
lever tang up or down as required.
CHOKE PLATE VACUUM
VACUUM
PULLDOWN
1. Remove the
the three hex
hex head
head screws
screws
and the ring retaining the choke
thermostatic spring cover. Do not
remove the water cover screw.
2. Pull the water cover and thermostatic
spring cover assembly out of the way
8). Remove choke electric assist
(Fig. 8).
assembly. CAUTION: Choke plate
must be closed in air horn when reinstalling the electric assist with
latch.
BACK TO GROUP INDEX
IDLE MIXTURE
MIXTURE
ADJUSTMENT
CURB IDLE (TSP

OFF)
OFF) ADJUSTMENT
ADJUSTMENT
---I
VZ134A
V2134-A
FIG. 55 Curb Idle Speed and Mixture Adjustments

FIG.
24-10-4
24-10-4
24-10-4
adjusting screw in or out
diaphragm adjusting
as required (Fig. 10).
FAST IDLE SPEED

ADJUSTING SCREW
DRY
FLOAT SETTING
DRY FLOAT
With the bowl cover held in an
inverted position and the float tang
resting lightly on the spring loaded fuel
inlet needle, measure the clearance
float and the bowl
between the edge of thefloat
adjust the clearance,
cover (Fig. 11).
11). To adjust
bend the float tang up or down as
required (Fig. 12). Do not scratch or
damage the tang.
Adjust both floats equally.

Adjust
V2135-A
FIG. 6 Fast Idle Speed Adjustment
DRILL OR
GAUGE ROD
CHOKE TANG
FAST IDLE CAM
V1705-A
Clearance
FIG. 7 Fast Idle Cam Clearance
FIG. 9 Measuring Choke Plate Pulldown

SECONDARY
SECONDARY THROTTLE
THROTTLE STOP
SCREW
SCREW
CHOKE HOUSING
1. Back off
1.
off the secondary throttle stop
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 2000 or 2300 cc 4-cylinder
engine. For a 2800 cc V-6,
V6, turn the
screw an additional 3/4
3/4 turn (Fig. 13).
V1414-C
FIG. 8 Removing Choke Water Cover
BACK TO GROUP INDEX

24-10-5
24-10-5
24-10-5
24-10-5
Model
Model 5200
5200 2-V
2-V Carburetor
Carburetor
VACUUM
VACUUM DIAPHRAGM
DIAPHRAGM
V1712A
V1712-A
FIG. 10 Adjusting Choke Plate Pulldown
FLOAT
FLOAT
DRILL OR
OR
DRILL
GAUGE ROD
ROD
GAUGE
V14188
V1418-B
FIG.
FIG. 11
11 Dry
Dry Float
Float Setting
Setting
BACK TO GROUP INDEX

24-10-6
24-10-6
FLOAT LEVEL
ADJUSTING
TANG
t-LUA
I-LUA II Utwt-'
UK UK
ADJUSTINC
ADJUSTINC
TANG
TANG
420-A
FIG. 12 Float Adjustment
SECONDARY
THROTTLE
STOP
STOP
ADJUSTING
SCREW
SECONDARY
THROTTLE
LEVER
V1708-B
FIG. 13 Secondary Throttle Stop Adjustment

DISASSEMBLY
DISASSEMBLY
Refer to Fig. 14 for the disassembled
view of the carburetor.
Bowl Cover
Bowl
1. Remove the fuel inlet filter plug and
1.
filter screen assembly.
assembly.
filter
2. Remove the bowl cover screws and
2.
lockwashers.
lockwashers.
3. Remove the retainer clips from the
3.
choke rod and carefully remove the
bowl cover (Fig.
(Fig. 15).
15). Remove the
seal.
choke rod seal.
4. Remove the float hinge pin,
pin, float and
4.
needle.
inlet needle.
5. Remove the inlet needle seat and
5.
gasket.
gasket.
6. Remove the three power valve
6.
screws, washers
vacuum diaphragm screws,
diaphragm.
and diaphragm.
BACK TO GROUP INDEX
Automatic Choke
1. Remove the choke water housing

1.
attaching screw and washer. Note
position of water hose connections for
reassembly in correct relationship to
hoses on vehicle. Remove the water
cover and gasket.
2. Remove the choke thermostatic
2.
spring housing retaining
retaining ring
screws. Remove the ring,
attaching screws.
housing and electric heater assembly.
3. Remove the choke housing assembly
screws. Note that the long screw goes
screws.
in the long leg of the assembly. Slip
the housing
housing away
away from
from the
the main body
the
and disengage
disengage the
the fast
fast idle
idle rod.
rod.
and
Remove the
the O-ring
O-ring from
from the
Remove
the vacuum
vacuum
passage (Fig.
(Fig. 16).
passage
16).
4. Remove the choke shaft

shaft nut and
lockwasher, choke lever and fast idle
cam.
5. Remove the fast idle lever attaching
screw, fast idle lever and spacer.
Remove the screw and spring from
the lever.
6. Remove the choke diaphragm cover
screws and cover, return spring,
diaphragm and rod assembly.
Accelerator Pump
1. Remove the four pump cover screws
1.
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. 14).
14).
24-10-7
TYPICAL DECEL
PORT
24-10-7
AIR HORN
CHOKE PLATES
AIR CLEANER
STUD
CHOKE SHAFT
AND LEVER
SOLENOID
THROTTLE
POSITIONER
ASSEMBLY
CHOKE
ROD
THROTTLE
PLATE
SECONDARY
OPERATING
RETURN SPRING
COVER
FAST IDLE
ADJUSTING
SCREW
THROTTLE
RETURN
SPRING
ELECTRIC
CHOKE
HEATER
THERMOSTATIC
HOUSING
IDLE
/'tf
ADJUSTING
SCREW
RETAINER
THROTTLE
LEVER
ASSEMBLY
THROTTLE SOLENOID
POSITIONER "OFF"
"OFF"
ADJUSTING SCREW
OVERCENTER
SPRING
DIAPHRAGM
AND SHAFT
COVER
DIAPHRAGM
ADJUSTING
SCREW
V1422-H
V1422H
FIG. 14 Model 5200 Carburetor Disassembled
BACK TO GROUP INDEX

24-10-8
24-10-8
24-10-8
Model
Model 5200 2-V
2-V Carburetor
Main
Main Body
1. Remove the
the primary high speed bleed
1.
well tube (Fig.
(Fig. 18).
and main well
18).
2. Remove the
the secondary high speed
speed
2.
and main wt'll
well tube.
tube. Note the
bleed and
size of the
the air
air bleed plugs and
and main
so they may be
be installed in
well tubes so
position.
the correct position.
3. Remove the
the primary and
and secondary
secondary
3.
the different
different
main metering jets. Note the
so they may
may be
be installed in
size jets so
(Fig 18).
the correct position. (Fig
18).
4. Remove the
the power valve and
and gasket.
gasket.
4.
the primary and
and secondary
secondary
Remove the
and idle jets located
idle jet retainers and
the sides of the
the carburetor body
on the
(Fig. 18).
(Fig.
18).
5. Turn the
the idle limiter cap
cap in
in to
to the
5.
the idle limiter cap.
cap.
stop. Remove the
the turns required to
to lightly
Count the
the idle adjustment
adjustment needle.
needle.
seat the
the nearest 1/16 turn.
turn.
Count to the
the idle needle and
and spring.
Remove the
6. Remove the
the secondary operating
operating
6.
lever return spring.
OWL COVER
V1711-A
17 Removing Main Well Tubes

FIG. 17
BODY
SECONDARY VENTURI
PRIMARY VENTURI
M A I N BODY
V1709-A
15 Removing Bowl Cover

FIG. 15
FUEL BOWL
VACUUM
DIAPHRAGM
FAST IDLE
CAM
^mmrnm
IDLE JET
JET RETAINER
IDLE JET
JET
HOKE LEVER
FASTIDL
ADJUSTING SCREW
V1710-A
V1710-A
iJ ~
., (\<~"""'-ft
.~ ~
.~-
FIG. 16 Removing Automatic

Automatic Choke
BACK TO GROUP INDEX
MAl N JET
JET
MAIN
IDLE JET
JET RETAINER
IDLE
RETAINER
JET
IDLE JET
A I N WELL TUBE
~ ............ MMAINWELL
TUBE
I N WELL TUBE PLUG
" ' - - M AMIAN
V1427.C
V1427-C
FIG. 18 Main Metering Jets and

and Idle Jets
24-10-9
7. Remove the primary throttle lever
7.
nut and lock tab. Remove the primary
lever and flat washer. Remove the
secondary operating lever assembly
and lever bushing.
8.
8. Remove the idle adjusting
adjusting lever
spring and shaft washer. Note how
the primary throttle return spring is
hooked over the idle adjusting lever
and the carburetor body.
and
9.
an,p
9. Remove the idle speed screw an*l
spring from the idle adjusting lever.
10.
10. Remove
Remove the
the secondary
secondary throttle
throttle lever
lever
nut, lockwasher, flat washer and
secondary throttle lever. Remove the
secondary idle adjusting screw.
ASSEMBLY
Main Body
1. Install the secondary idle adjusting

adjusting
1.
screw, secondary throttle lever, flat
flat
washer, lockwasher and nut.
2. Install the idle speed screw and spring
2.
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. 14).
4. Install the flat
4.
flat washer and primary
throttle lever. Install the lockwasher
secondary
and nut. Attach the secondary
operating lever return spring.
5. Install the idle mixture adjusting
adjusting
5.
needle and spring. Turn it in until it
bottoms. Back out the screw
lightly bottoms.
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
6.
assemblies on each side of the
carefully for
carburetor body. Check carefully
BACK TO GROUP INDEX

the correct primary and secondary
sizes (Fig.
(Fig. 18).
7. Install the power valve gasket and
7.
power valve.
8.
8. Install the primary and secondary
main jets. Be
Be sure
sure the
the correct
correct sizes
sizes are
are
installed.
9.
9. Install the primary and secondary
main well tubes and high speed
bleeds. Be
Be sure the correct sizes are
bleeds.
installed.
Accelerator
Accelerator Pump Assembly
1. Install the pump discharge check
1.
balls (2) screw. Install the pump
discharge nozzle with a gasket on top
and bottom. Install the pump
discharge screw.
2.
2. Install the pump return spring and
pump diaphragm assembly. Start the
four pump cover screws.
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
adjusting
1.
screw. Initially adjust the screw so
that the threads are flush
flush with the
inside of the cover.
2. Install the choke diaphragm and rod
2.
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
shaft into the
housing and position the fast idle cam
on the housing post.
5.
5. Install the choke lever, lockwasher
and nut.
6.
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.
24-10-9
7. Position the choke housing against
7.
the main carburetor body and install
the long attaching screw in the long
leg of the housing. Install the other
screws.
screws.
8. Adjust
Adjust choke plate pulldown,
pulldown,
8.
referring to ADJUSTMENT Section.
9.
9. Install the electric choke heater,
thermostatic housing, retaining ring
screws. Be sure choke
and attaching screws.
plate is in full closed position before
installing the choke electric assist
heater element. Index the housing
and tighten the screws.
10.
10. Install
Install the
the choke
choke water
water housing
housing
gasket, water housing lock washer
and attaching bolt. Position housing
as it will be when installed on vehicle
and tighten the attaching bolt.
Bowl Cover
1.
1. Install the inlet needle seat and
gasket.
2.
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
float needle clip on the
float
float and
float tab and position the float
needle.
float shaft.
needle. Install the float
4. Hold the bowl cover in an inverted
4.
adjust the dry float
position and adjust
setting (Fig. 11).
5.
5. Hold the cover in its normal position
adjust the float
(Fig. 12).
float drop (Fig.
and ~djust
6. Install the choke rod seal and seal
6.
plug. Install the choke rod through
plug.
the seal and hook it into the choke
lever. Install the retaining clip.
7. Install the bowl cover gasket.
7.
8.
8. Install the choke link into the choke
lever. Install the retaining clip.
9.
9. Install the five bowl screws and
torque them evenly.
10.
10. Install
Install the
the fuel
fuel filter
filter screen,
screen, open
open end
end
in.
in. Install the filter screen plug.
11. Install the throttle solenoid positioner
(TSP).
(TSP).

24-25-1
24-25-1
24-25-1
24-25-1
Model 2150
2150 2-V Carburetor
PART 24-25 Model 2150

2150 2-V Carburetor
COMPONENT INDEX
DESCRIPTION .,. ......
Page
Page
Page
COMPONENT
COMPONENT INDEX
.................
25-1
25-1
REMOVAL AND
AND INSTALLATION .......
25-6
DIAGNOSIS AND
AND TESTING ............
25-4
Carburetor Assembly ................
25-6
25-4
Air Horn to Main Body Gasket .........
25-6
ADJUSTMENTS
,.
,..,.
............
".,.,.,.,.,.
Accelerating Pump Stroke

Adjustment
Float, Needle Valve and Seat,
. .... ... .....

,.
,.
,.
,..,.
..
25-4
Choke Plate Pulldown and

and
25-4
Fuel Level (Float)

,.
,..,.
.. ,.
..........
25-6
Accelerator Pump Diaphragm
Cam Clearance ............

Fast Idle Cam
Adjustment - Dry
Inlet Screen or Main Jets
.........................
,.
..
25-5
Fuel Level (Float)

Adjustment - Wet ............... ,. .......
25-5
,.
25-6
...
Choke Pulldown Diaphragm Assembly ...
25-7
MAJOR REPAIR OPERATIONS .........
25-7
Disassembly .......................
25-7
Assembly .........................
25-8
and/or Elastomer Valve
..
......
,.
............
NOTE: The
The infonnation
information in
in this Part applies to both 1975 and 1976 model year vehicles unless otherwise specified.
CR1966-A
CR1966-A
DESCRIPTION
The Motorcraft
2150 2-V
Motorcraft Model 2150
2-V
carburetor (Figs. 1,2
1, 2and
and3)3)has
hastwo
twomain
main
and the
assemblies; the
the air horn and
the main
body.
air horn assembly, which serves

The air
the main body cover, contains the
as the
the
choke plate and the fuel bowl vent valve.
contains the pullover
pullover
It also contains
enrichment system, which provides
additional fuel flow at high air flow
flow
through the
air horn (Fig.
1). Fuel is
the air
(Fig. 1).
drawn through metering orifices from the
fuel bowl and
and into the
the air flow
flow through
bleeds in
in the
the upper body air
air horn.
The air
air horn assembly also contains
a fuel deceleration metering system
consisting of a metered pickup orifice in
in
the fuel bowl and fuel/air
fuel/air mixing orifices
and bleeds. This system is
is only used on
on
those carburetors used with the 2.8L V-6
(Fig 1).
1).
engine (Fig
BACK TO GROUP INDEX
The throttle plate, the

the accelerating
the enrichment valve
pump assembly, the
assembly, the fuel bowl and the
mechanical high speed bleed system are
are
in the
The automatic choke
the main body. The
housing and
and choke pulldown diaphragm
are attached to
to the
the main body.
Each bore contains a main and
and
booster venturi, main fuel discharge,
accelerating pump discharge, idle fuel
and throttle plate.
discharge and
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
rod that actuates reversethe
tapered "ballbat" metering rods in
in the
high speed bleed orifices. This allows
control of fuel/air mixture to
to the booster
Venturis
for more precise high speed
venturis for
operation and improved low-speed
response.
The Model 2150

the
2150 2V
2-V also uses the
electric assist automatic choke system.
This system consists of a choke cap,
cap,
thermostatic spring, bimetallic
bimetallic
thermostatic
temperature sensing disc (switch), and
and aa
ceramic heater powered from the
the stator
tap of the alternator (Fig. 4).
4).
Voltage is
the
is constantly supplied to the
temperature sensing switch as long as the
engine is running. The
The system is
grounded through a strip connected to
the carburetor body. At temperatures
o
80-110F.,
above approximately 80
110F., the
temperature sensing switch closes, and
and
is supplied to
the
current is
to the
the heater. As
As the
heater warms, it causes the
the thermostatic
spring to
to pull the
the choke plate open.
Testing and
and adjustment
adjustment of electric
assist choke is
is covered in
in Part 29-02 of
of
this Volume.

24-25-2
24-25-2
24-25-2
24-25-2
Model
Model2150
21502-V
2-VCarburetor
Carburetor
MECHANICALFUEL
FUELBOWL
BOWL "
MECHANICAL
VENTVALVE
VALVE
VENT
SOLENOID OFF (TSPOFF)

. I D L E SPEED ADJUSTING
ACCELERATOR PUMP
PUMP
ACCELERATOR
LEVER
LEVER
'SCREW
SOLENOID THROTTLE
POSITIONER
V1885-B
V1885B
FIG. 1 Model
Model 2150 2-V CarburetorLeft
Carburetor-Left Front 3/4
3/4 View
View
FAST IDLE CAM

ADJUSTING SCREW
CHOKE
CHOKEDIAPHRAGM
DIAPHRAGM
ASSEMBLY
ASSEMBLY
CHOKETHERMOSTATIC
THERMOSTATIC
CHOKE
SPRINGHOUSING
HOUSING
SPRING
FASTIDLE
IDLESPEED
SPEED
FAST
ADJUSTINGSCREW
SCREW
ADJUSTING
V1884-B
V1884-B
FIG.
FIG.2 2Model
Model2150
2150Carburetor-Right
CarburetorRightRear
Rear3/4
3/4View
View
BACK TO GROUP INDEX

24-25-3
24-25-3
24-25-3
Model
Model2150
21502-V
2-VCarburetor
Carburetor
CHOKE
CLEAN
CHOKE
CLEAN(COLD)
(COLD)
AIR TUBE
AIR TUBE
MECHANICAL
MECHANICALHIGH
HIGHSPEED
SPEED
BLEED
BLEEDCAM
CAM
THROTTLE LEVER
CHOKE HEAT
TUBE CONNECTION
SOLENOID -DASHPOT
THROTTLE POSITIONER
ENRICHMENT
ENRICHMENT
VALVE COVER
COVER
VALVE
THROTTLE
THROTTLE
PLATES
PLATES
IDLE MIXTURE
ADJUSTMENT
LIMITERCAP
AUTOMATIC CHOKE
AUTOMATIC
HOUSINGCHOKE
HOUSING
V1886B
V1886-B
2150 2-V
2-V Carburetor-Bottom
CarburetorBottom View
FIG. 3 Model 2150
POSITIVE TEMPERATURE
COEFFICIENT (PTC) CERAMIC
HEATER
TEMPERATURE
TEMPERATURE
SENSITIVE
SENSITIVE
BIMETALLICDISC
DISC
BIMETALLIC
SILVER
CONTACTS
QUICK-DISCONNECT
QUICK-DISCONNECT
TERMINAL
TERMINAL
GROUN D
STRAP
GROUND
STRAP
V1595-B
V1595-B
FIG.
FIG.4 4Electric
ElectricAssist
AssistChokeTypical
Choke-Typical
BACK TO GROUP INDEX

24-25-4
Model 2150
2150 2-V
2-V Carburetor
24-25-4

Refer to the Engine Diagnosis in Part
29-02 of this
this Volume
Volume for all
all diagnosis
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.
ADJUST SOLENOID
V1888A
A PJi
2150
IDLE MIXTURE ADJUSTING

SCREW LIMITER CAPS
FIG. 7
7 Idle Speed
Adiustments-Vehicles
AdjustmentsVehicles
Equipped With Solenoid
Dashpot Throttle Positioner
(TSP)
(TSP)
FAST IDLE CAM

CAM
FAST IDLE SPEED

ADJUSTING SCREW
LI MITER STOPS
V1887-B
FIG. 55 Idle Fuel

Fuel Mixture Adiusting
Adjusting
Screw Limiters and
and Stops
V1889B
V1889-B
Adjustment
FIG. 88 Fast Idle Speed Adiustment
SOLENOID "OFF" IDLE.

SPEED ADJUSTING SCREW
V1679-B
FIG. 66 Idle Speed

AdjustmentsVehicles
Adjustments-Vehicles
Equipped With Throttle
(TSP)
Solenoid Positioner (TSP)
ACCELERATING PUMP STROKE

ADJUSTMENT
The accelerating pump stroke has
has
set for
for aa particular engine
been factory set
readjusted.
application and should not be readjusted.
If the stroke has
has been changed from
the specified hole, reset to
to specification
by following these procedures (Fig.
(Fig. 9):
9):
1. To
To release the
the rod
rod from the
the retaining
1.
clip, lift upward on the portion of the
clip that snaps over the shaft and then
disengage the
rod.
the rod.
BACK TO GROUP INDEX
2. Position the
2.
the clip over the
the specified
overtravellever
hole in the overtravel
lever and insert
the operating rod through the clip and
overtravel lever. Snap the
the end
end of
of
the overtravellever.
the rod
rod to
to secure.
secure.
the clip over the
CHOKE PLATE PULLDOWN AND
AND
C A M CLEARANCE
FAST IDLE CAM
The Model 2150
2150 2-V
2-V carburetor is
is
equipped with aa remotely-mounted
remotely-mounted
pulldqwn diaphragm assembly.
choke pulldown
is metered to
to the
the diaphragm
Vacuum is
through
the
through internal passages in
in the
connecting
carburetor, through aa connecting
external tube. As
As the
the vacuum bleeds
through the orifices in the carburetor, the
the
choke diaphragm pulls the choke plate to
to
the pulldown position (Fig.
(Fig. 10).
10).
To check choke pulldown, proceed as
follows:
1.
1. Set throttle on
on fast idle cam top step.
2. Note index position

position of choke
bimetallic cap.
cap. Loosen retaining
screws and
and rotate
rotate cap
cap90
90degrees
degrees in
in
the rich (closing) direction (Fig.
(Fig. 11).
11).
3. Activate choke plate pulldown motor
by manually forcing pulldown control
diaphragm link in
the direction of
of
in the
applied vacuum or
or by
by applying
vacuum to external vacuum tube (Fig.
(Fig.
10).
4. Measure vertical hard gage clearance
between bottom edge of
of choke plate
and center of carburetor air horn wall
nearest fuel bowl (Fig. 10).
10).
be within
Pulldown setting should be
specification
specification for
for minimum choke
plate
Car
plate opening. Refer
Refer to
to Car
Specifications book for
for specified
specified
Specifications
opening.
If choke plate pulldown is found to
be out
out of specification,
specification, reset by
by
of
adjusting diaphragm stop on
on end
end of
choke pulldown diaphragm.
Loctite 290
290 was
was applied to
to the
the
threads of
of the
the pulldown adjusting
screw during manufacturing to
to
prevent the
the screw from backing due
due
to vibration. DO
DO NOT
NOT attempt to
to
the screw without first heating
turn the
to loosen
the immediate area enough to
the area with an
an
the Loctite. Heat the
electric soldering gun
gun while applying
to the
the screw until the
the Loctite
torque to
and the
the screw can
can be
softens and
be easily
turned.
turned.
completed,
After pulldown check is completed,
reset choke bimetallic
bimetallic cap
cap to
recommended index position as
as
in Car
Car Specifications Book
specified in
on Engine Tune-up decal.
decal. Check
or on
reset fast
fast idle speed to
and reset
specification if necessary.
V1890-B
FIG. 99 Accelerating Pump Stroke

Adjustment
Adiustment
24-25-5
24-25-5
Carburetor
MEASURE CLEARANCE
BOTTEM EDGE OF CHOKE
VALVE TO WALL OF AIR HORN
B2590-A
FIG. 12 Fuel Level (Float)

Adjustment-Dry
AdjustmentDry
CHOKE PULLDOWN DIAPHRAGM

DIAPHRAGM
ADJUSTMENT SCREW
V1891C
V1891-C
FIG. 10 Adjusting Choke Plate Pulldown
NOTE:
NOTE: To adjust fast idle cam
clearance or other choke functions,
refer to Part
Part 29-02
this
2902 of
of this
Supplement.
CHOKE INDEX MARKS
FUEL LEVEL (FLOAT)

ADJUSTMENTDRY
ADJUSTMENT-DRY
The dry float
float adjustment
adjustment is a
preliminary fuel level adjustment
adjustment only.
The final adjustment
adjustment (Fuel Level Float
AdjustmentWet)
Adjustment-Wet) must be made after
the carburetor is mounted on the engine.
With the air horn removed, the float

float
raised and the fuel inlet needle seated,
check the distance between the top
surface
surface of
of the main body (gasket
removed) and the top surface of the float
float
for conformance to specification. Depress
the float tab to seat the fuel inlet needle.
Take the measurement near the center of
of
the float at a point 1/8
1/8 inch from the free
end of the float.
float.
If the cardboard float gauge is used,
used,
place the gauge in the corner of the
enlarged end
end section
section of
of the
thefuel
fuelbowl
bowl(Fig.
(Fig.
12). The gauge should touch the float
near the end, but not on the end radius.
radius.
If
float
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.
BACK TO GROUP INDEX
FIG. 13 Fuel Level (Float)

Adjustment-Wet
AdjustmentWet
V1681A
V1681-A
FIG. 11 Automatic Choke

Thermostatic Spring Housing
Adjustment
FUEL LEVEL (FLOAT)

ADJUSTMENTWET
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.
carburetor air cleaner
assembly if not previously removed.
3. Remove the air horn attaching screws
and the carburetor
carburetor identification
identification tag.
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
from the top
vertical distance from
machined surface of the carburetor
main body to the level of the fuel in
the fuel bowl (Fig. 13).
The measurement must be made at
1/4 inch away from any vertical
least 1/4
surface to assure an accurate reading,
because the surface
of the fuel is
surface of
concave (higher at the edges than in
the center). Care must be exercised to
measure the fuel level at the point of
of
contact with the gauge. Refer to the
specifications
level
specifications for the correct fuel level
(wet) setting.
If any adjustment
adjustment is required, stop the
5. If
the
engine to minimize the hazard of fire
due to fuel spray when the float
setting is disturbed. To adjust the fuel
24-25-6
level, bend the float
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
adjustment is made
to the float
float tab to alter the fuel level,
the air horn must be re-installed, and
the engine started and permitted to
idle for a few minutes to stabilize the
level. Remove the air horn and
fuel level.

gasket and check the fuel level after
each adjustment
adjustment until the specified
level is obtained.
6. Install a new air horn gasket, the air
6.
horn
h o r n assembly,
a s s e m b l y , carburetor
carburetor
identification
identification tag and the attaching
screws.
screws. Be sure the plastic dust seal
on the choke operating rod is
positioned correctly and does not
cause the rod to bind. Tighten the
24-25-6
screws.
screws. Install the air cleaner anchor
stud and tighten to the specified
specified
torque.
torque.
7. Check the idle fuel mixture,
7.
mixture, idle
idle speed
speed
adjustments
adjustments and the carburetor
carburetor
throttle positioner adjustment
adjustment (if so
equipped).
equipped). Adjust the carburetor as
required.
8.

CARBURETOR ASSEMBLY
Removlll
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
carefully removed from the engine
bowl.
without removing the fuel from the bowl.
The contents of the bowl may then be
examined for contamination as the
carburetor is disassembled.
1.
2.
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.
carburetor retaining
nuts; then remove the carburetor.
Remove the carburetor mounting
gasket, spacer (if equipped) and lower
gasket from the intake manifold.
Installation
InstBllstion
1. Clean the gasket mounting surfaces of
1.
of
the spacer and carburetor. Place the
manifold. Position
Position the
intake manifold.
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
2.
lines before bolting carburetor in
place. Secure the carburetor with the
nuts. To prevent leakage,
attaching nuts.
distortion or damage to the
distortion
flange, snug the nuts;
carburetor bodyflange,
nuts;
then, alternately tighten each nut in
a criss-cross pattern to the specified
specified
torque.
3. Connect the fuel line, throttle cable,
and all emission lines and vacuum
lines removed. Observe color coded
vacuum line connections
connections on
vacuum
carburetor.
4. Adjust the engine idle speeds, fuel
mixture, and check and adjust the
accelerator stroke if necessary. (Make
sure the rod is set in the specified
hole.)
BACK TO GROUP INDEX
AIR HORN TO MAIN

M A I N BODY
GASKET
Removal
Removal
1. Remove the air cleaner. Remove the
1.
air cleaner anchor screw.
2.
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
identification
horn gasket.
Instllllstion
Installation
1.
1. Install a new air horn to main body
gasket. Make sure all holes in
in the
thenew
new
gasket have been properly punched
and that no foreign material has
adhered to the gasket.
2.
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
a n d lock
l o c k washers
w a s h e r s and
a n d the
the
and
identification tag. Install the air
identification
cleaner anchor screw, and tighten to
the specified torque.
4. Connect the automatic choke clean
4.
air tube to the carburetor.
5.
5. Adjust the idle fuel mixture and idle
speed as outlined in Part 29-02.
6. Install the carburetor air cleaner
6.
assembly.
FLOAT, NEEDLE VALVE AND
SEAT,
SEATf INLET SCREEN OR MAIN
MAIN
JETS
Removal
Removal
1.
1. Remove the carburetor air horn to
main body gasket by following the
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
float
seat. Remove the float,

float, float
float shaft
shaft
retainer
retainer and fuel inlet needle
assembly.
3. If required, remove the fuel inlet
needle seat, filter screen, baffie
baffle and
main jets with a jet wrench. Be sure
the correct (specified)
(specified) jets are
installed.
Instllllation
Installation
1.
1. If required, install the fuel inlet filter
bore. Install the
in the inlet valve seat bore.
baffle and gasket. Install
valve seat, baffie
the fuel inlet needle valve.
2.
2. Slide the float shaft into the float
lever. Position the float
float shaft retainer
on the float
float shaft.
3. Insert the float
float assembly into the fuel
bowl and hook the float lever tab
clip. Insert
under the fuel inlet needle clip.
the float
float shaft into the guides at the
sides of the fuel bowl.
4. With the use of the screwdriver,
position the float
float shaft retainer on the
groove of the fuel inlet needle seat.
5. Refer to Float Adjustment-Dry,
AdjustmentDry,
5.
and perform a dry float fuel level
adjustment on the float.
adjustment
float.
6. Install the carburetor air horn and
6.
gasket and related parts. Refer to Air
Horn to Main
Main Body
Body Gasket
Gasket
Horn
Replacement.
7.
Fuel L
e v e l Float
Float
7. Refer
Refer to Fuel
Level
AdjustmentWet, and perform the
Adjustment-Wet,
adjustment procedures.
wet fuel level adjustment
8. Adjust
Adjust the idle fuel mixture and
8.
engine idle speed.
ACCELERATOR PUMP
AND/OR
DIAPHRAGM AND/OR
ELASTOMER VALVE
RemovaJ
Removal
1. Remove the carburetor air horn to
1.
main body gasket following the
procedure under Air Horn to Main
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
shaft and then
disengage the rod. Remove the rod.
24-25-7
24-25-7
2-V Carburetor
Model 2150 2-V
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
If the
firmly
Elastomer valve tip broke off
off during
(luring
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.
bod)'. See Fig.
19 and 22.
Installation
Instsllation
1. If the Elastomer valve w^
1.
w~ 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.
tip. Pull the valve in
until it seats, and cut off
off the tip
forward of the retainer shoulder.
Remove the tip from the bowl.
2. Position the new accelerator pump
2.
diaphragm assembly to the cover and
place the cover and diaphragm
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
accelerator pump
operating rod in the hole in the pump
operating arm.
4. Adjust the accelerator pump stroke to
specification by installing the
specification
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.
LINK
FIG. 14 Choke Pulldown Diaphragm Assembly
5. Install the carburetor air horn and

gasket. Refer to the Air Horn to Main
DIAPHRAGM
CHOKE PULLDOWN DIAPHRAGM
ASSEMBLY
Removal
Removal
1.
2. Disconnect the choke pulldown link

2.
by removing the rod retainer and
pulling the rod out of the diaphragm
(Fig. 14)
link slot (Fig.
3. Remove the two (2) attaching screws
from the bracket, disconnect the
vacuum supply tube and remove the
pulldown diaphragm.
Installation
Installation
1.
1. Position
Position the choke pulldown
pulldown
diaphragm mounting bracket against
the main body casting and install the
two (2) attaching screws.
2. Connect the vacuum supply tube to

2.
the correct
correct vacuum base tube
connection.
3. Insert the choke pulldown control rod
through the slot in the diaphragm link
and install the retainer clip over the
end of the rod, in the slot.
4. Perform
Perform the automatic
automatic choke
pulldown and fast
pulldown
fast idle cam
adjustments as described in Part
adjustments
29-02 of this manual.
5. Install the air cleaner assembly.
MAJOR REPAIR OPERATIONS

DISASSEMBLY
DISASSEMBLY
To facilitate
facilitate working on the
carburetor, and to prevent damage to the
throttle plates, install carburetor legs on
the base.
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.
component
component parts of
of the various
various
facilitate cleaning,
assemblies to facilitate
inspection and assembly.
step-by-step
overhauling the carburetor. However
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.
BACK TO GROUP INDEX
Air Horn
1. Remove the air cleaner anchor screw.
2. Remove the automatic choke control
rod retainer.
3. Remove the air horn attaching
attaching
screws, lock washers and the
identification tag.
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.
screws. Remove the choke
plate by sliding it out of the
the shaft from
from
the top of the air horn. Remove any
burrs around screw holes prior to

removing chokeshaft. Slide the choke
shaft out of the air horn.
Idle Decel Metering
Assembly2800cc
Assembly-2800cc V-6
Installations Only
Removal
Removal
1.
1. Invert the air horn assembly and
remove the three (3) attaching screws
from the decel metering assembly
(Fig.
(Fig. 15).
2. Remove the metering assembly and
gasket from the air horn.
Installation
Installation
1. Using a new gasket, position the decel
1.
assembly to the bottom of the air
horn.
2. Install and torque the attaching
screws evenly. After assembly, use
shop air to make sure all passages in
the decel metering assembly are open.
24-25-8
24-25-8
24-25-8
24-25-8
Model
Model 2150
2150 2-V
2-V Carburetor
Carburetor
DECEL
VALVE
CONNECTION
ATTACHINGSCREWS
SCREWS(3)
(3)
ATTACHING
FUEL INLET NEEDLE CHIP

AND ANTI-SPLASH WASHER
GUIDE
PUMP COVER AND LEVER

RETURN
RETURN SPRING
SPR ING
t1
FUEL
ORIFICE
'::':~<;:::ELASTOMER
VALVE
ELASTOMER VALVE
V1898-A
DIAPHRAGM
DIAPHRAGM
FIG. 15
15 Idle
Idle Decel
Decel Metering
Metering
FIG.
Assembly
Assembly
Choke Pulldown
Pulldown Diaphragm
Choke
Assembly
Assembly
Follow procedures
procedures given
given under
under
Follow
Removal and
and Installation.
Removal
Automatic Choke
Choke
Automatic
1. Remove
Remove the fast
fast idle cam retainer
retainer
16).
(Fig. 16).
(Fig.
x/1296-D
\/12960
FIG.
FIG. 19
19 Accelerating
Accelerating Pump
Pump Assembly
Assembly
7.
Invert
the
main
body
and
remove
7. Invert the main body and remove the
the
enrichment
enrichment valve
valve cover
cover and
and the
the
gasket.
gasket. Remove
Remove the
the enrichment
enrichment valve
valve
with
with aa box
box wrench
wrench or
or socket
socket wrench
wrench
(Fig.
(Fig. 20).
20). Remove
Remove the
the enrichment
enrichment
valve
valve gasket.
gasket. Discard
Discard the
the gasket.
gasket.
FIG. 17 Float
Float Assembly
Assembly
FIG.
8-Point
8Point
Socket
Socket Wrench
Wrench
RETAINER
FAST IDLE
SCREW
V1685-A
FIG. 18 Removing or Installing Float

Shaft Retainer
FAST IDLE CAM
(){\
I/
c:
FAST IDLE \AM
Vl683-A
V1683-A
FIG.
FIG. 16
16 Fast
Fast Idle
Idle Cam
Cam and
and Fast
Fast Idle
Idle
Lever
Lever
2.
2. Remove
Remove the
the thermostatic
thermostatic choke
choke
spring
spring housing
housing retaining
retaining screws
screws and
and
remove
remove the
the clamp,
clamp, housing
housing and
and
gasket.
gasket.
3.
3. Remove
Remove the
the choke
choke housing
housing assembly
assembly
retaining
retaining screws.
screws. If
If the
the air
air horn
horn was
was
not
not previously
previously removed,
removed, remove
remove the
the
choke
choke control
control rod
rod retainer.
retainer. Remove
Remove
the
the choke
choke housing
housing assembly,
assembly, gasket
gasket
and
and the
thefast
fast idle
idlecam
cam and
and rod
rod from
from the
the
fast
fast idle
idle cam
cam lever.
lever.
4.4. Remove
Remove the
the choke
choke lever
lever retaining
retaining
screw
screw and
and washer.
washer. Disconnect
Disconnect the
the
choke
choke control
control rod
rod from
from the
the choke
choke
lever.
lever. Remove
Remove the
the choke
choke lever
lever and
and
fast
fast idle
idle cam
cam lever
lever from
from the
the choke
choke
housing.
housing.
Main
Main Body
Body
1.1. With
With the
theuse
useof
ofaascrewdriver,
screwdriver, pry
prythe
the
float
float shaft
shaft retainer
retainer from
from the
thefuel
fuel inlet
inlet
seat
seat (Figs.
(Figs. 17
17 and
and 18).
18). Remove
Remove the
the
float,
float,float
floatshaft
shaft retainer
retainer and
and fuel
fuel inlet
needle
needleassembly.
assembly.Remove
Removethe
theretainer
retainer
and
and float
floatshaft
shaft from
from the
the float
floatlever.
lever.
BACK TO GROUP INDEX
2. Remove the fuel inlet needle,

needle, seat,
2.
filter screen,
screen, and the main jets with
aa jet wrench.
wrench.
3.
3. Remove the booster venturi screw
(accelerator pump
discharge),
discharge),
booster venturi and metering rod
assembly and
and gasket.
gasket. Invert
Invert the
the
assembly
main body and
and let
let the
the accelerating
accelerating
main
pump
pump discharge
discharge weight
weight and
and ball
ball fall
fall
into
into the
the hand.
hand.
4. Remove
Remove the
the accelerator
accelerator pump
pump
4.
operating rod
rod from
from the
the overtravel
overtravel
operating
lever and
and the
the retainer.
retainer. To
To release
release the
the
lever
operating rod
rod from
from the
the overtravel
overtravel
operating
lever retainer,
retainer,press
press upward
upward on
on that
that
lever
part of
ofthe
the retainer
retainer that
that snaps
snapsover
over the
the
part
rod. Disengage
Disengage the
the rod
rod from
from the
the
rod.
retainer and
andfrom
from the
theovertravel
overtravel lever.
lever.
retainer
Remove the
the rod
rod and
and retainer.
retainer.
Remove
Remove the
the accelerator
accelerator pump
pump cover
cover
5.5. Remove
attaching screws.
screws. Remove
Remove the
the
attaching
accelerator pump
pump cover,
cover, diaphragm
diaphragm
accelerator
assembly and
and spring
spring (Fig.
(Fig. 19).
19).
assembly
If itit isis necessary
necessary to
to remove
remove the
the
6.6. If
Elastomer valve,
valve, grasp
grasp itit firmly
firmly and
and
Elastomer
pull itit out.
out. IfIf the
the Elastomer
Elastomer valve
valvetip
tip
pull
broke off
off during
during removal,
removal, be
be sure
sure toto
broke
removethe
thetip
tipfrom
from the
thefuel
fuelbowl.
bowl.An
An
remove
Elastomer valve
valve must
must be
be replaced
replaced
Elastomer
whenever itit has
has been
been removed
removed from
from
whenever
the carubretor.
carubretor.
the
FIG. 20
20 Removing
Removing or
or Installing
Installing
FIG.
Enrichment Valve
Valve
Enrichment
8. Remove
Remove the
the idle
idle fuel
fuel mixture
mixture
8.
adjusting screws
screws (needles)
(needles) and
and the
the
adjusting
springs. Remove
Remove the
the limiters
limiters from
from the
the
springs.
adjusting screws.
screws.
adjusting
9. If
If necessary,
necessary, remove
remove the
the nut
nut and
and
9.
washer securing
securing the
the fast
fast idle
idle adjusting
adjusting
washer
lever assembly
assembly to
to the
the throttle
throttle shaft,
shaft,
lever
and remove
remove the
the lever
lever assembly.
assembly. If
If
and
necessary, remove
remove the
the idle
idle screw
screw and
and
necessary,
the spring
spring from
from the
the fast
fast idle
idle adjusting
adjusting
the
lever.
lever.
10.Remove
Remove the
the anti-stall
anti-stall dashpot
dashpot or
or
10.
solenoid (if
(if so
so equipped).
equipped).
solenoid
11. If
necessary to
to remove
remove the
the
11.
throttle plates,
plates, lightly
lightly scribe
scribe the
the
throttle
throttle plates
plates along
along the
the throttle
throttle shaft,
shaft,
throttle
and mark
mark each
each plate
plate and
and its
its
and
corresponding bore
bore with
with aa number
number or
or
corresponding
letter for
for proper
proper installation
installation (Fig.
(Fig. 21).
21).
letter
12.Slide
Slidethe
thethrottle
throttleshaft
shaftout
outofofthe
themain
main
12.
body, making
making sure
sure you
you catch
catch the
the
body,
mechanical high
high speed
speed bleed
bleed actuator
actuator
mechanical
located on
on the
the throttle
throttle shaft
shaft between
between
located
the throttle
throttle plates.
plates.
the
Clean and
and inspect
inspect the
the carburetor
carburetor
Clean
component parts
parts according
according to
to
component
proceduresoutlined
outlinedininPart
Part29-02
29-02and
and
procedures
24-01 of
of this
this Manual.
Manual.
24-01
ASSEMBLY
ASSEMBLY
Make sure
sure all
all holes
holes inin new
new gaskets
gaskets
Make
havebeen
beenproperly
properlypunched,
punched,and
andthat
thatno
no
have
24-25-9
foreign material has adhered to the

gaskets. Make sure the accelerator pump
diaphragm is not torn or cut. The Model
2- V carburetor
2150 2-V
c a r b u r e t o r is shown
shown
disassembled in Fig.
Fig. 22
Main Body
1.
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.
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
"Off' idle speed screw.
for the TSP "Off"
Continue inserting
inserting the
the shaft
shaft into
into
Continue
proper position,
position, rotating
rotating as
as necessary
proper
necessary
to
position cam.
to properly
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.
HIGH SPEED BLEED CAM
SCRIBE LINES AND

IDENTIFICATION MARKS
.\%$f' V1896-A
FIG. 21
21 Scribing Throttle Plates
fiG.
4. Close the throttle plates.

plates. Invert the
main body, and hold it up to the light.
Little or no light should show
between the throttle plates and the
bores. Tap the plates lightly
throttle bores.
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
5.
spring and the screw on the fast idle
adjusting lever.
6. Install the an
anti-stall
dashpot,
6.
ti-s tall dash
pot,
solenoid-dashpot if
solenoid, or solenoid-dashpot
equipped.
7. Place the fast idle adjusting lever
7.
assembly on the throttle shaft and
install the retaining washer and nut
(Fig. 22).
(Fig.
8. If the Elastomer valve was removed,
8.
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.
tip. Pull the valve in until it
BACK TO GROUP INDEX
seats in the pump cavity wall and cut

off
off the tip forward of the retaining
shoulder. Remove the tip from the
bowl.
bowl.
9.
9. Install the accelerating
accelerating pump
diaphragm return spring on the boss
in the chamber (Fig.
(Fig. 19).
19). Insert the
diaphragm assembly in the cover and
place the cover and diaphragm
assembly into position on the main
body. Install the cover screws.
10.
Insert the accelerating
lO.Insert
accelerating pump
operating rod into the hole in the
accelerator pump actuating lever.
accelerator pump
Position the accelerator
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.
11. Invert the main body. Install the
enrichment valve and new
new gasket with
a wrench (Fig.
(Fig. 20).
20). Tighten the valve
securely.
12.
12. Install
Install the
the idle
idle mixture
mixture adjusting
adjusting
screws (needles) and springs (Fig.
(Fig. 22).
22).
Turn the needles in gently with the
fingers until they just touch the seat,
off 1-1/2
1-1/2 turns for a
then back them off
preliminary idle fuel mixture
mixture
preliminary
adjustment. Do not install the idle
time. Install
mixture limiters at this time.
and new
the enrichment valve cover and
gasket. The cover must be installed
with the limiter stops on the cover in
position to provide aa positive stop for
on the
the idle
idle mixture
mixture adjusting
adjusting
the tabs on
screws limiters.
13. Install
Install the
the main
main jets
jets and
and the
the fuel
fuel inlet
inlet
seat, filter screen, baffle and new
gasket. Be sure the correct jets are
installed.
14.
14. Install
Install the
the fuel
fuel inlet
inlet needle
needle assembly
assembly
in the fuel inlet seat.
15. Slide
Slide the
thefloat
float shaft
shaft into
intothe
thefloat
float lever
lever
(Fig. 17).
17). Position the float shaft
shaft
retainer on the float
float shaft.
16.
16. Insert
Insert the
the float
float assembly
assembly into
into the
the fuel
fuel
bowl and hook the float lever tab
under the fuel inlet needle assembly.
Insert the float
float shaft into its guides at
the sides of the fuel bowl.
17.
17. With
With aa screwdriver,
screwdriver, position
position the
the float
float
shaft retainer in the groove on the fuel
(Fig. 18).
18). Check the
inlet needle seat (Fig.
float setting.
float
18.
Drop the accelerating
accelerating pump
18.Drop
pump
discharge ball and weight into the
passage in the main body.
19. Position
Position the
the new
new booster
booster assembly
assembly
19.
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
1.
thermostatic choke shaft and lever
24-25-9
assembly. The bottom of the fast idle
cam lever adjusting screw must rest
against the tang on the choke lever.
of
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.
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
flange.
gasket on the choke housing flange.
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.
screws. Install the fast idle
cam retainer. Install the thermostatic
spring housing.
Choke Pulldown Diaphragm
Assembly
Refer to procedure under Removal
and Installation.
Air Horn
Refer to Fig. 22 for the correct
location of the parts.
1.
1. If the choke plate shaft was removed,
position the shaft in the air horn, then
install the choke plate rod on the end
of the choke shaft.
2. 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
If necessary,
the open position. If
remove the choke plate and grind or
file the plate edge where it is binding
or scraping on the air horn wall.
wall. If the
choke plate and shaft moves freely,
tighten the choke plate screws while
holding the choke in the fully closed
position.
3. 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.
4. Insert the end of the choke plate rod
into the automatic choke lever.
lever. Install
the air horn attaching screws and the
identification tag.
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
Perform all automatic choke
adjustments
adjustments and other carburetor
functions as required
required to meet
functions
specifications. See Group 29 for
adjustments not covered in this Part.
24-25-10
24-25-10
Carburetor
HIGH-SPEED BLEED
BLEED
HIGH-SPEED
METERING ROD
ROD YOKE
YOKE
METERING
AND LIFT
LIFT ROD
AND
ROD
NOZZLE BAR, HIGH-SPEED

BLEED AND BOOSTER
VENTURI ASSEMBLY
BOOSTER
--~/'f'
VENTURI
ELASTOMER
ELASTOMER
IDLE
MIXTURE
NEEDLE
VALVE
LI~I~~R~~I~~~~REE
VAL~VE
c.-:SPRING
IDLE
LIMITER
CAP
CAP
RETAINER~
PUMP DIAPHRAGM
PUMP COVER
~(
~~~~~~I~VGE--:}i~~
LEVER
~\
\
RETURN
~~:tll''''''
~-
I ""'"
SP~NG
SPRING
~~
V"
UPPER BODY
THROTTLE
PLATES
~ ~
ACCELERATING
PUMP ROD
RETAINING
CLIP
ACCELERATING PUMP
OVERTRAVEL
OVER-TRAVEL SPRING
FUEL BOWL
VENT VALVE
DECEL VALVE
CONNECTION
(SOME MODELS)
KICKDOWN
KICKDOWN
ADJUSTMENT
ADJUSTMENT
SCREW
SCREW
ACCELERATING
ACCELERATING
THROTTLE SHAFT
LEVER ASSEMBLY
CHOKE PLATE
SHAFT
THROTTLE SOLENOID
SOLENOID
POSITIONER
(SO
LENOI D-DASHPOT)
(SOLENOID-DASHPOT)
CHOKE PLATE LEVER

CHOKE PLATE
ROD
CURB IDLE RPM

RPM
ADJUSTING NUT
NUT
CHOKE CLEAN
AIR TUBE
SOLENOID OFF
OFF
IDLE (HOT
(HOT ENGINE)
SPEED ADJUSTING
SCREW
SHAFT RETAINER
FUEL INLET NEEDLE

FUEL INLET NEEDLE SEAT
SHIELD
FILTER SCREEN
DIAPHRAGM
LINK
^, FAST IDLE CAM

RETAINER
HOT IDLE
COMPENSATOR
SHIELD
CHOKE PULLDOWN
DIAPHRAGM
ASSEMBLY
GASKET
PULLDOWN
VACUUM
SUPPLY
TUBE
THERMOSTATIC
SPRING HOUSING
~~INER
V
FASTlDLE
ADJUSTING
SCREW
RETAINER
SCREW
SCREW
~
SPRING
V1897-e
V1897-C
FIG. 22 Model 2150

2150 2-V CarburetorDisassembled
Carburetor-Disassembled View
BACK TO GROUP INDEX

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

Page
Page
COMPONENT INDEX
Page
Page
COMPONENT INDEX
.................... .
26-1
26-1
Automatic Choke Functions
General ..........................
26-1
26-1
Fuel Inlet System Adj,ustment

Adjustment .........
26-7
and Fast
Delayed Choke Pulldown and
Idle
Idle Top
Top Step
Step Pulloff
Pulloff .............
26-2
and Metering
Vacuum Piston and
Rods Adjustment .................
26-8
High Altitude Compensation ..........
26-3
INSTALLATION .......
26-8
.....................
26-4
MAJOR REPAIR OPERATIONS .........
26-9
Accelerator Pump Adjustment ........
26-4
Disassembly .....................
26-9
.....
26-5
Assembly .......................
26-11
26-11
DESC
RIPT ION
DESCRIPTION
ADJUSTMENT
Mechanical Fuel Bowl Vent Valve
.........
26-6
NOTE: The information in this Part applies to both 1975 and 1976 Illodel
NOTE:
CR1966-A
CR1966-A
DESCRIPTION
GENERAL
The Motorcraft
4- V
carburetor (Figs.
(Figs. 1,
1, 22 and
and 3)
3) has
has three
main assemblies; the
the
the upper body, the
main body and
and the
the throttle body.
The upper body, which serves as
as the
the
the choke
main body cover, contains the
plate, booster venturi assembly, the
air valve,
valve, accelerating pump
secondary air
plunger, mechanical fuel bowl vent valve
and fuel inlet and
and float
float system.
The main body contains the fuel bowl
and primary fuel metering system
vacuum piston and
and rods.
"INTERNAL" FUEL BOWL VENTS
DELAYED CHOKE
PULLDOWN DIAPHRAGM
DIAPHRAGM
CHOKE PLATE
MECHANICAL FUEL
BOWL VENT VALVE
SOLENOID THROTTLE
POSITIONER
"I
:: ...-,..:P.t::.,.:::::.,
UPPER
BODY
EGR CONNECTION
f ^THROTTLE
X ^ BODY
IDLE MIXTURE
ADJUSTMENT SCREWS
SPARK
PORT
V1914-A

4-V
Carburetor-Main Assemblies
CarburetorMain
BACK TO GROUP INDEX
V1915B
V1915-B

4-V CarburetorFront
Carburetor-Front View
24-26-2
24-26-2
Model
Model 4350
4350 4-V
4-V Carburetor
Carburetor
The throttle
throttle body
body contains
contains both
both
The
primary and
and secondary
secondary throttle
throttle plates.
plates.
primary
Primary throttle
throttle operation
operation isis from
from the
the
Primary
accelerator linkage.
linkage. Secondary
Secondary throttle
throttle
accelerator
operation isisaccomplished
accomplished by
bymechanical
mechanical
operation
linkage from
from the
the primary
primary throttle
throttle lever.
lever.
linkage
lockout tang
tang coupled
coupled to
to the
theautomatic
automatic
AA lockout
choke linkage
linkage prevents
prevents operation
operation until
until
choke
the choke
choke isis fully
fully off.
off. The
The secondary
secondary
the
throttle shaft
shaft isissplit
split and
and loosely
loosely coupled
coupled
throttle
in the
the center
center to
to allow
allow tighter
tighter secondary
secondary
in
throttle plate
plateseating
seating inin the
thebores
bores(Pig.
(Fig.4).
4).
throttle
Primary
P r i m a r y fuel
fuel metering
m e t e r i n g isis
accomplished
accomplished by
by tapered
tapered metering
metering rods
rods
that are
are raised
raised or
or lowered
lowered according
according toto
that
engine vacuum,
vacuum, limited
limited by
by mechanical
mechanical
engine
system that
that isis positioned
positioned according
according to
to
system
throttle plate
plateopening
opening(Pigs.
(Figs.55and
and30).
30).AA
throttle
leveron
on the
theacceleration
acceleration pump
pumpoperating
operating
lever
shaft moves
moves upward
upward as
as the
the throttle
throttle isis
shaft
opened.
opened.
Under
U n d e r high
high engine
engine vacuum
vacuum
conditions,
conditions, the
the vacuum
vacuum piston
piston pulls
pulls the
the
metering
metering rods
rods down
down into
into the
the main
main jets,
jets,
PCV CONNECTION
SECONDARY
SECONDARY
AIR
AIR VALVE
VALVE
CHOKE
CHOKE PLATE
PLATE
V1916B
V1916-B

4-V CarburetorTop
Carburetor-Top View
View
FIG.
FIG. 44 Split
Split Secondary
Secondary Throttle
Throttle Shaft
Shaft
BACK TO GROUP INDEX
24-26-2
24-26-2
causing
causing aa lean
lean mixture
mixture toto be
be delivered.
delivered.
Under
Underacceleration,
acceleration,when
whenengine
enginevacuum
vacuum
isis lowered,
lowered, an
an internal
internal spring
spring causes
causes the
the
piston
pistontotorise.
rise.This
Thisputs
putsthe
thenarrower
narrowerpart
part
of
of the
the metering
metering rod
rod inin the
the jet,
jet, causing
causing aa
larger
largerfuel
fuel opening
openingand
andenriching
enrichingthe
thefuel
fuel
mixture.
mixture.
Puel
Fuel inlet
inlet to
to the
the fuel
fuel bowl
bowl isis
controlled
controlled by
by aa twin
twin pontoon
pontoon type
type float
float
hinged
hinged to
to the
the upper
upper body
body of
of the
the
carburetor.
carburetor. The
The acceleration
acceleration pump
pump isis
piston
piston type.
type. The
The linkage
linkage and
and operating
operating
rod
rod are
are part
part of
of the
the upper
upper body,
body, and
and the
the
piston
piston isis suspended
suspended into
into the
the pump
pump well
well
in
in the
the fuel
fuel bowl.
bowl.
The
The automatic
automatic choke
choke system
system consists
consists
of
of aa standard
standard bimetallic
bimetallic thermostatic
thermostatic
choke
choke system
system which
which operates
operates when
when
underhood
underhood temperatures
temperatures are
are below
below 60F.
60F.
Also,
Also, an
an electric
electric assist
assist isis used
used when
when
o
underhood
P.
underhood temperatures
temperatures are
are above
above 6O
60F.
This
This system
system operates
operates to
to assure
assure full
full choke
choke
opening
opening within
within 70
70seconds
secondsof
ofengine
enginestart.
start.
The electric
electric assist
assist choke system
system
consists
consists of aa choke
choke cap,
cap, thermostatic
thermostatic
spring,
spring, bimetallic temperature sensing
disc (switch), and ceramic Positive
Positive
Temperature
Temperature Coefficient
Coefficient (PTC)
(PTC) heater
heater
(Pig.
(Fig. 6).
The choke is
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
grounded through
through
a ground strap connected to the
the
carburetor body.
At temperatures below approximately
60 oP., the switch is open and no current
60F.,
is supplied to the ceramic heater located
within the thermostatic spring. Normal
thermostatic choking action then occurs.
At temperatures
temperatures above
above approximately
approximately
At
60o P., the temperature sensing switch
60F.,
.closes
PTe
closes and current is supplied to the PTC
heater warms, itit
ceramic heater. As the neater
causes the thermostatic spring to pull the
seconds.
choke plate open within 70 seconds.
For test
test and adjustment
adjustment information,
Part and
and to
to Part
Part 50-29.
50-29.
refer to
to this
this Part
refer
DELAYED CHOKE
CHOKE PULLDOWN
DELAYED
AND FAST
FAST IDLE
IDLE TOP
TOP STEP
STEP
AND
PULLOFF
PULLOFF
The Motorcraft
Motorcraft 4350
4350 4-V
4-V carburetor
carburetor
The
is eequipped
with
is
quipped w
i t h aa uunique,
nique,
vacuum-operated delayed
delayed choke
choke
vacuum-operated
pulldown diaphragm.
diaphragm. This
This system
system
pulldown
operates in
in addition
addition to
to the
the usual
usual
operates
pulldown system
system found
found in
in the
the Model
Model
pulldown
4300 carburetor.
carburetor.
4300
Theremotely-mounted
remotely-mounted delayed
delayed choke
choke
The
pulldown diaphragm
diaphragm assembly
assembly isis
pulldown
connectedto
to the
theautomatic
automaticchoke
chokelinkage
linkage
connected
by an
an override
override linkage
linkage (Fig.
(Pig. 7).
7).
by
When the
the engine
engine isis first
first started,
started, the
the
When
piston inside
inside the
the choke
choke housing
housing pulls
pulls the
the
piston
choke plate
plate slightly
slightly open
open (initial
(initial choke
choke
choke
pulldown). This
This isis accomplished
accomplished with
with
pulldown).
24-26-3
24-26-3
Model
.Model 4350 4-V Carburetor
24-26-3
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
after engine start) it
(about 6-18 seconds after
opens the choke to the delayed pulldown
setting. At the same time, linkage pulls
the fast idle screw from the top step of
of
the fast idle cam to the kickdown step.
ALTITUDE COMPENSATION
HIGH ALTITUDE
1976 Carburetors Built for
Some 1976
High Altitude Operation
Some Motorcraft
equippep with altitude
carburetors are equipped
compensation, designed to provide
improved high-altitude emission 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 isiscontrolled
flow
controlledby
byaavalve
valveactivated
activatedby
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.
HEATER
TEMPERATURE
TEMPERATURE
SENSITIVE
SENSITIVE
BIMETALLIC
BIMETALLIC DISC
SILVER
CONTACTS
QUICK-DISCONNECT
QUICK-DISCONNECT
TERMINAL
TERMINAL
GROUND STRAP
V1595-B
FIG. 6 Electric Assist ChokeModel

Choke-Model 4350 4-V
4-V Carburetor
k MA!N
JETS
V1918-A
FIG. 5 Metering Rod Primary

Metering System
FAST IDLE SPEED
ADJUSTMENT SCREW
DIAPHRAGM
LINK
DIAPHRAGM
PURGE HOLE
CHOKE
CHOKE DELAYED
DELAYED
PULLDOWN
PULLDOWN
DIAPHRAGM
DIAPHRAGM
DIAPHRAGM
STOP SCREW
:.-_---FILT
E R CAP
FILTER
CAP
V1919B
V1919-B
Diaphragm
FIG. 7 Delayed Choke Pulldown and Fast Idle Top Step Pulloff Diaphragm
BACK TO GROUP INDEX

24-26-4
24-26-4
24-26-4
24-26-4
Model
Model 4350
4350 4-V
4-V Carburetor
Carburetor
BYPASS (COMPENSATION)
(COMPENSATION)
BYPASS
CHOKE PLATE
PLATE LINK,
CHOKE
BYPASS
BYPASS (COMPENSATION)
(COMPENSATION)
CHOKE
CHOKE PLATE
PLATE
BYPASS INTAKE
^r'tJ:.;
POPPET
POPPET METERING
METERING
VALVE
VALVE
ANEROID
(BELLOWS)
ANEROID
HOUSING
POPPET METERING
VALVE HOUSING
V2049-A
FIG. 8 Motorcraft Model 4350 4-V Carburetor With Altitude Compensation

(Cutaway View)
ADJUSTMENT
Most carburetor adjustments
adjustments are set
at assembly, based on guidelines
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.
50-29.
Adjustment
Adjustment points for all carburetor
carburetor
adjustments are shown in Figs.
Figs. 8 thru 22.
which is set at the factory to deliver the

proper amount of fuel for the engine on
which it is installed. This setting should
specified
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).
ACCELERATOR PUMP
PUMP
ADJUSTMENT
The accelerator pump has only one
adjustment, a piston-to-shaft pin position
position
TSP "OFF"
"OFF"
TSP
IDLE SPEED
SPEED
IDLE
ADJ. SCREW
SCREW
ADJ.
4350
IDLE FUEL MIXTURE
ADJUSTMENT SCREWS
3ANDLIMITERCAPS
...... ~
THROTTLE
THROTTLE
LEVER
LEVER
SOLENOID
SOLENOID
V1920-B
FIG.
FIG. 99 Idle
Idle Fuel
Fuel Mixture
Mixture Adiusting
Adjusting
Screws,
Screws, Limiters
Limiters and
and Stops
Stops
BACK TO GROUP INDEX
THROTTLE
THROTTLE POSITIONER
POSITIONER
ADJUSTMENT
ADJUSTMENT (EITHER
(EITHER END)
END)
(TSP
(TSP "ON"
" O N " CURB
CURB IDLE)
IDLE)
V1921-A
V1921-A
FIG. 10
10 Idle
Idle Speed
Speed Adjustment
Adjustment Points-Vehicles
PointsVehicles With
With Solenoid
Solenoid Throttle
Throttle
FIG.
Positioner
Positioner
24-26-5
24-26-5
MECHANICAL FUEL BOWL VENT

VALVE
FAST IDLE CAM ADJ.

SCREW
CHOKE CAP
INDEX MARK
The vent valve is designed to be open

to the carbon canister when the engine is
off
off and closed
closed when the engine is
operating. Adjust
Adjust the valve with the
carburetor installed on the vehicle.
1. With the engine at CURB IDLE
1.
solenoid throttle
throttle
speed, and the solenoid
positioner (if
equipped) in the
positioner
(if equipped)
extended (energized) position, adjust
adjust
the vent valve so that the adjustment
adjustment
screw just touches the drive tab on the
accelerator pump lever (Fig. 14). (If
(If
vehicle is not equipped with a TSP, set
fast idle screw on high step of cam
and adjust
adjust the vent valve so that the
adjusting
adjusting screw just touches the drive
tab on the accelerator pump lever.)
ADJUST
DELAYEDPULLDOWN
DELAYED PULLDOWN
DIAPHRAGM LINK ROD
V1923-B
FIG. 11
11 Automatic Choke Adjustments
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.
Remove the upper body assembly and
invert it (see Removal and Installation).
Disconnect
Disconnect the accelerator
accelerator pump
from the operating
operating arm by holding
from
downward on the spring and sliding the
shaft slot.
arm out of the pump shaft
1. Disassemble the spring and nylon
keeper that retains the adjustment
adjustment pin
(Fig. 12). If
If the pin is not in the
PUMP SHAFT
SHAFT
PUMP
n~
FIG. 14 Adjusting Mechanical Fuel

Bowl Vent Valve
2. Turn the engine off

off and observe that
the vent operating linkage pushes
down on the vent valve stem.
\\ ACCELERATOR
PUMP OPERATING
LEVER
ACCELERATING PUMP
J] J
I
specified
specified hole, remove it, reposItion
reposition
shaft to the correct hole in the
the shaft
piston assembly and reinstall the pin.
2. Slide the nylon retainer over the pin
shaft.
and position the spring on the shaft.
shaft and
Compress the spring on the shaft
install the pump on the pump arm.
~::~~I~ER
RETAINER
SPRING
PIN
~__
NO'l~'
~~
NO. 2
PUMP
THROTTLE
LEVER
ACCELERATOR
PUMP
SPRING
PIN
WRETAINER
NO.3
PUMP
PUMP PISTON
PISTON
V1925-A
FIG. 12 Setting Accelerator Pump

Stroke
BACK TO GROUP INDEX
VACUUM PISTON LIMITER

LEVER ADJUSTMENT
PUMP LINK
V1924B
FIG. 13 Throttle-To-Accelerator Pump linkage

Linkage
24-26-6
24-26-6
Model 4350
4350 4-V
4-V Carburetor
Carburetor
Model
DRILL GAUGE
GAUGEOF
OF SPECIFIED
SPECIFIED
DRILL
CLEARANCE SIZE
SIZE
CLEARANCE
TAPER-LOCKCHOKE
CHOKE SHAFT
SHAFT
TAPER-LOCK
SCREW (LEFT
(LEFTHAND
HANDTHREAD)
THREAD)
SCREW
CHOKE PLATE
PLATE
CHOKE
FAST IDLE CAM

ADJUSTING SCREW
0.036 INCH
WIRE GAUGE
APPLY LIGHT PRESSURE

TO CHOKE LEVER
FAST IDLE ADJUSTMENT SCREW
V1967-A
V1967
A
FIG.
FIG. 15
15 Checking and
and Adjusting Initial Choke Plate Pulldown
AUTOMATIC CHOKE
CHOKE FUNCTIONS
Initial
Initial Choke
Choke Pulldown
Pulldown
When the
the engine is
is first started, the
choke
choke plate is
is pulled to
to an
an initial
initial
pulldown position by
by aa small piston in
in the
the
choke
choke housing,
housing, operated
operated by
by engine
engine
vacuum.
vacuum. To
To adjust
adjust initial
initial choke
choke plate
plate
pulldown,
pulldown, follow
follow this
this procedure:
procedure:
1.1. Remove
Remove the
the choke
choke thermostatic
thermostatic
spring
spring housing
housing assembly.
assembly.
2.2. Open
Open throttle
throttle about
about half-throttle
half-throttle and
and
position
position the
the fast
fast idle
idle adjusting
adjusting screw
screw
on
cam.
on the
the high
high step
step of
of the
the fast
fast idle
idle cam.
3.3. Bend
Bend aa 0.036
0.036 inch
inch diameter
diameter wire
wire
gauge
g a u g e at
at aa 90
90 degree
d e g r e e angle
angle
approximately
approximately 1/8
1/8 inch
inch from
from its
its end.
end.
Insert
Insert the
the bent
bent end
end of
of the
the gauge
gauge
between
between the
thechoke
choke piston
piston slot
slot and
and the
the
upper
upper edge
edge of
of the
the right-hand
right-hand slot
slot in
in
the
the choke
choke housing
housing (Fig.
(Fig. 15).
15).
4.4. Rotate
Rotate the
the choke
choke thermostat
thermostat lever
lever
counterclockwise
counterclockwise until
until the
the gauge
gauge isis
snug
snugininthe
thepiston
piston slot.
slot. Hold
Hold the
thegauge
gauge
inin position
position with
with light
light force
force on
on the
the
lever
lever and
and move
move the
the top
topof
of the
the choke
choke
rod
rod away
away from
from the
the carburetor
carburetor while
while
moving
moving the
thebottom
bottom of
ofthe
the rod
rodtoward
toward
carburetor
carburetor toto remove
remove end
end play
play from
from
linkage.
linkage.
5.5. Using
Using aa drill
drill gauge
gauge or
or equivalent,
equivalent,
check
check initial
i n i t i a l choke
c h o k e pulldown
pulldown
clearance
clearanceby
byplacing
placingthe
thegauge
gaugeagainst
against
the
the inner
inner wall
wall of
ofthe
thechoke
choke air
air horn
horn
on
on the
t h e downstream
d o w n s t r e a m side
s i d e at
at
BACK TO GROUP INDEX
6.
6.
7.7.
8.8.
9.9.
approximately the longitudinal

longitudinal
approximately
carburetor and check
centerline of the carburetor
to edge of choke
clearance from wall to
plate.
plate.
the measured clearance is
is not
If the
within specification, adjust clearance
by turning the hex head lock screw on
the choke plate shaft in
in aa clockwise
clockwise
(3) full turns.
turns. (Note:
(Note:
direction three (3)
Lock
Lock screw
screw is
is left-hand
left-hand threaded).
threaded).
Pry choke
choke lever
lever from
from shaft
shaft to
to loosen
loosen
Pry
taper lock.
lock. Choke
Choke lever
lever should
should rotate
rotate
taper
freely on
on choke
choke shaft.
shaft.
freely
Hold the
the drill
drill gauge
gauge with
with diameter
diameter
Hold
equal to
to specified
specified pulldown
pulldown clearance
clearance
equal
between the
the lower
lower edge
edge of
of the
the choke
choke
between
plate and
and air
air horn
horn wall,
wall, maintaining
maintaining
plate
light closing
closing force
force on
on choke
choke plate.
plate.
light
With choke
choke piston
piston snug
snug against
against the
the
With
0.036 inch
inch wire
wire gauge,
gauge, the
the top
top of
of the
the
0.036
choke rod
rod held
held away
away from
from the
the
choke
carburetor while
while moving
moving the
the bottom
bottom
carburetor
of the
the rod
rod toward
toward the
the carburetor
carburetor to
to
of
remove end
end play
play from
from linkage,
linkage, and
and
remove
the choke
choke plate
plate held
held against
against the
the drill
drill
the
gauge, tighten
tighten the
the hex
hexhead
head screw
screw on
on
gauge,
the choke
choke shaft.
shaft.
the
Reinstall the
the choke
choke thermostatic
thermostatic
Reinstall
spring housing
housing assembly.
assembly.
spring
Delayed Choke
Choke Pulldown
Pulldown
Delayed
The Model
Model 4350
4350 4-V
4-V carburetor
carburetor isis
The
equipped with
with aa vacuum-diaphragm
vacuum-diaphragm
equipped
operated delayed
delayed choke
choke pulldown
pulldown that
that
operated
opens the
the choke
choke to
to aa wider
wider setting
setting
opens
24-26-6
24-26-6
approximately
approximately 6-18
6-18 seconds
seconds after
after engine
engine
startup.
startup. To
To check
check and
and adjust,
adjust, follow
follow this
this
procedure:
procedure:
1.1. With
With throttle
throttle set
set on
on fast
fast idle
idle cam,
cam,
note
note position
position of
of index
index marks
marks on
on cap
cap
of
of choke
choke bimetallic
bimetallic cap.
cap. Loosen
Loosen
retaining
retaining screws
screws and
and rotate
rotate cap
cap 90
90
degrees
degrees in
in the
the closing
closing (rich)
(rich) direction.
2.2. Disconnect
Disconnect the
the vacuum
vacuum supply
supply hose
hose
from
from the
the port
port on
on the
the delayed
delayed choke
choke
pulldown
pulldown diaphragm
diaphragm assembly.
assembly. Place
Place
aa piece
of tape
tape over
over the
the purge
purge hole
hole
piece of
after
after removing
removing the
the filter
filter cap
cap and
and
connect
connect aa vacuum
vacuum source
source of
of at
at least
least
14-18
16).
14-18 in.
in. Hg
Hg to
to the
the port
port (Fig.
(Fig. 16).
3.3. M
e a s u r e hhard
a r d gage
ulldown
Measure
gage ppulldown
dimension
dimension at
at lower
lower edge
edge of
of choke
choke
plate,
plate, in
in center
center of
of air
air horn,
horn, using
using
gage
gage of
of specified
specified diameter
diameter (see
(see
Group
Group 29).
29). Adjust
Adjust by
by turning
turning stop
stop
screw
choke pulldown
pulldown
screw on
on delayed
delayed choke
diaphragm.
diaphragm.
4.
4. After
After pulldown
pulldown is
is properly
properly set,
set,
remove
remove external
external vacuum
vacuum source,
source,
reconnect
reconnect tube
tube to
to carburetor
carburetor port
port and
and
reset
reset choke
choke thermostatic
thermostatic cap
cap to
to
specified
specified index
index setting. When
When using
using aa
hand
hand vacuum
vacuum pump, cover
cover purge
purge hole
(Fig. 7).
7).
Fast Idle Top Step Pulloff

Pulloff
As the delayed
delayed choke
choke pulldown
diaphragm
diaphragm operates, additional
additional linkage
pulls the fast idle lever and screw from
the top
top step of the fast idle cam
cam to the
the
second step, reducing cold engine idle
(Fig 17).
speed (Fig
17).
To check
check the operation of the fast idle
To
top step pulloff
pulloff linkage, operate the
delayed pulldown diaphragm manually
or by
by connecting an
an external vacuum
14-18 in.
in. Hg
Hg to
to the
the vacuum
source of 14-18
port. Place hand over holes in
in filter cap.
cap.
the fast idle speed screw on
on the
Position the
the fast idle cam
cam with the
top step of the
choke
choke plate closed. (Rotate choke
cap if necessary to
to close
thermostatic cap
choke plate.) Observe
Observe the
the fast idle speed
choke
a d j u s t i n g screw
screw drops
d r o p s to
to second
second
adjusting
(kickdown) step
step of
of cam
cam as
as delayed
delayed choke
choke
(kickdown)
pulldown diaphragm
diaphragm is
is operated.
operated.
pulldown
Fast Idle
Idle Cam
Cam Clearance
Clearance
Fast
Loosen the
the attaching
attaching screws
screws and
and
1.1. Loosen
rotate the
the spring
spring housing
housing to
to align
align the
the
rotate
center index
index mark
mark on
on the
the choke
choke
center
housing with
with the
the index
index mark
mark on
on the
the
housing
spring housing.
housing. Rotate
Rotate the
the spring
spring
spring
housing an
an additional
additional 90
90 degrees
degrees
housing
counterclockwise
and
tighten
the
counterclockwise and tighten the
attaching screws.
screws.
attaching
Position the
thefast
fast idle
idle speed,
speed, adjusting
adjusting
2.2. Position
screw end
end on
on the
the kickdown
kickdown (center)
(center)
screw
step of
of the
the fast
fast idle
idle cam.
cam. Close
Close the
the
step
choke plate
plate as
asfar
far as
asitit will
will go.
go. Check
Check
choke
the clearance
clearance between
between the
the lower
lower edge
edge
the
of the
the choke
choke plate
plate and
and the
the air
air horn
horn
of
wall. Turn
Turn the
thefast
fast idle
idle cam
cam adjusting
adjusting
wall.
screw inward
i n w a r d to
to increase
i n c r e a s e the
the
screw
24-26-7
24-26-7
24-26-7
24-26-7
Model
Model 4350
4350 4-V
4-V Carburetor
Carburetor
clearance
clearance or
or outward
outward toto decrease
decrease the
the
clearance.
clearance. Make
Make sure
sure the
the fast
fast idle
idle
speed
speed adjusting
adjusting screw
screw stays
stays atat the
the
kickdown
kickdown step
step of
of the
the fast
fast idle
idle cam
cam
during
during the
the adjustment.
adjustment.
3.3. Loosen
Loosen the
the attaching
attaching screws,
screws, set
set the
the
thermostatic
thermostatic choke
choke housing
housing to
to the
the
specified
specified index
index mark
mark and
and tighten
tighten the
the
attaching
attaching screws.
screws.
4.4. If
If the
the choke
choke plate
plate clearance
clearance and
and fast
fast
idle
idle cam
cam linkage
linkage adjustment
adjustment was
was
performed
performed with
with the
the carburetor
carburetor on
on the
the
engine,
engine, adjust
adjust the
the engine
engine idle
idle speed
speed
and
and fuel
fuel mixture.
mixture.
Dechoke
Clearance
Dechoke Clearance
1. Open
Open the
the throttle
t h r o t t l e plate
plate to
to the
the
wide
wide open
open position
position and
and hold.
hold.
2. Rotate
Rotate the
the choke
choke plate
plate toward
toward the
the
closed
closed position
position until
until the
the pawl
pawl on
on the
the
fast
fast idle
idle speed
speed lever
lever contacts
contacts the
the fast
fast
idle
idle cam.
cam.
3. Check
Check the
the clearance
clearance between
between the
the
lower
lower edge
edge of
of the
the choke
choke plate
plate and
and the
the
air
air horn
horn wall
wall (Fig.
(Fig. 18).
18).
4.
specification
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.
clearance.
ATTACH VACUUM
VACUUM
ATTACH
PUMP
PUMP
V1927A
V1927-A
FUEL
FUEL INLET SYSTEM
ADJUSTMENTS
Float Setting (With Fabricated
Fabricated
Gauge and Bending Tools)
To simplify
simplify parallel setting of the dual
pontoons, refer
refer to Fig. 19 for the
of an adjustable
adjustable float gauge
construction of
and a float tab bending tool.
FIG. 16 Choke Plate Delayed Pulldown Adjustment
1/8"
DRILL TWO 3/16" HOLES
6" BETWEEN CENTERS
TOP STEP PULLOFF LINKAGE
Ufa*
**
m+
V1928-A
FIG.
FIG. 17
17 Fast
Fast Idle
Idle Top
Top Step
Step Pulloff
Pulloff
Linkage
Linkage
NO. 12
12 32
32 xx 22 SCREWS
SCREWS (2
(2 REQ'D.)
REO'DJ
NO.
NO. 12
12 NUTS
NUTS (6
(6 REQ'D.)
REO'D.)
NO.
DRILL OR GAUGE OF
SPECIFIED SIZE
1/2
1/2 "
ADJUST BOTH
BOTH NUTS
NUTSTO
TO FLOAT
FLOAT
ADJUST
HEIGHT SPECIFICATIONS
SPECIFICATIONS
HEIGHT
1/8"
BENDINGTOOL
TOOL-- 1/16"
1/16" DIAMETER
DIAMETER
BENDING
SPRINGSTEEL
STEELWIRE
WIRE OR
OR WELDING
WELDING
SPRING
RODS"
LONG
ROD
8" LONG
B2859-<:
FIG.
FIG. 18
18 Checking
Checking Dechoke
Dechoke Clearance
Clearance
BACK TO GROUP INDEX
FIG.
FIG. 19
19 Float
Float Gauge
Gauge and
and Bending
Bending Tool
Tool Details
Details
24-26-8
24-26-8
adjust the alignment

alignment and
and
2. If necessary, adjust
outlined under
height of the floats as outlined
adjustments for fabricated
fabricated gage and
and
adjustments
tool.
Auxiliary (Supplemental) Fuel
Inlet Valve Setting
Check the auxiliary valve clearance
adjust the
the
22). If it is necessary to adjust
(Fig. 22).
auxiliary valve and float
float tab to the
the
auxiliary
specified clearance, use
use the bending tool
specified
19.
Fig. 19.
shown in Fig.
BEND TAB
TAB TO
TO RAISE OR
OR LOWER FLOAT
FLOATS
FLOATS SHOULD JUST CONTACT GAGE
SET GAGE TO
SPECIFICATIONS
(BOTH SIDES)
FLOAT
INSTALL FLOAT PIN

PIN
FROM THIS
SIDE
THISSIDE
V1151-D
V1151D
FIG.
FIG. 20
20 Float Setting-Fabricated
SettingFabricated Gage
Carburetor Similar)
(4300 Carburetor Shown-4350

Shown4350
1. Adjust gauge to
to the
the specified height.
1.
2. Insert gage into the
the air horn
horn
2.
outboard holes (Fig.
(Fig. 20).
20).
3.
3. Check the
the clearance and
and alignment of
the gage. Both
Both
the pontoons to the
the gauge
pontoons should just touch the
the proper setting. Align the
for the
by slightly
slightly
pontoons if necessary by
the pontoons.
twisting the
is necessary to
to adjust the
the float
float
If it is
the primary needle
clearance, bend the
to raise the
the float and
tab downward to
to lower the
the float.
float.
upward to
the tabs with the
the float
float
To bend the
the procedure is
is as
bending tool, the
follows:
follows:
the Float, insert the
the open
To Raise the
to the RIGHT
RIGHT
end of the bending tool to
and between
side of the float lever tab and
and float hinge. Raise the
the needle and
and bend the
float lever off the needle "and
To lower the
the Float,
tab downward. To
insert the open end of the bending tool
to the LEFT side of the float lever tab,
between the
the needle and
and float
float hinge.
Support the
the float
the
float lever and
and bend the
tab upward.
Float Setting (With Gage
Gagel
Supplied in
Kit)
in Rebuilding Kit)
1.
the
1. With the
the air horn removed from the
and inverted, check the
carburetor and
the
the
clearance of the pontoon floats to the
gage (Fig. 21).
21).
FL0
UPPER BODY
V1930-A
21 Float Setting-Rebuilding
SettingRebuilding Kit
Kit
FIG. 21
Gauge
AUXILIARY
VALVE
CLEARANCE
V1152-C
22 Auxiliary (Supplemental)
FIG. 22
Valve Setting
AND
VACUUM PISTON AND
METERING RODS ADJUSTMENT
There
"driveability"
There are no "driveability"
the main fuel
adjustments to be made to the
The metering
metering rod
rod
metering system. The
and
setting is unique to each carburetor and
manufacture with "flow
is set during manufacture
box" test equipment to a critical air/fuel
ratio at a given part throttle opening.
This setting cannot be determined in
in
service
HIGH ALTITUDE COMPENSATION
SYSTEM
No adjustment of the
the high altitude
system is permitted. To clean the poppettype metering valve (See
(See Maintenance
Schedule for interval) remove the three
screws that attach the aneroid bellows
housing to the valve and remove the
the
housing. Spray Ford Carburetor
Carburetor Choke
Cleaner C9AZ-19A501-B or equivalent
directly on the poppet valve and stem/
guide area. Check to see that valve moves
freely
freely by depressing
depressing and releasing.
Repeat
Repeat if valve is sticking. Reinstall
housing and tighten screws.
AND INSTALLATION
REMOVAL AND
Removal
Removsl
on acceleration
acceleration
Flooding, stumble on
are in
in
and other performance complaints are
by foreign matter
many instances caused by
the carburetor. To
To aid
aid in
in diagnosing
in the
the cause of complaint, the
the carburetor
carburetor
be carefully
carefully removed from the
should be
engine without removing the
the fuel from
from
BACK TO GROUP INDEX
the bowl can

can
the bowl. The
The contents of the
be examined for contamination
contamination as
then be
the carburetor is
is disassembled.
1. Remove the
the air cleaner assembly.
1.
2. Disconnect the throttle cable from the
throttle lever. Disconnect and remove
transmission kickdown
kickdown linkage.
transmission
Disconnect all fuel, vacuum and heat

lines from the carburetor.
3. Disconnect
Disconnect the choke clean (cold) air
air
pick-up connecting
connecting tube from
from the
the
carburetor
carburetor air horn.
carburetor attaching nuts
and the carburetor.
24-26-9
5.
5. Remove the carburetor spacer, if
equipped, the carburetor and spacer
gasket from the intake manifold.
Installation
Installation
1.
1. Clean the gasket surfaces of the
spacer and carburetor. Place the

intake manifold.
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
attaching nuts and washers.
24-26-9
Alternately torque the carburetor
specification,
attaching nuts to specification,
working in a criss-cross pattern.
3. Connect the throttle cable and all
lines.
lines.
4. Adjust
Adjust engine idle speeds, fuel
fuel
mixture and throttle positioner, if
if
equipped. Refer to Part 29-02 or 50-2
for procedures.

DISASSEMBLY
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
established during
during
manufacturing
manufacturing and should not be
changed.
To maintain the relationship during
carburetor disassembly and assembly,
follow this procedure:
1.
1. Before disassembly, scribe a line on
both the pump operating lever and
the carburetor air horn casting, with
the throttle set at TSP OFF idle
position (with the throttle lever
against the stop screw).
screw). See Fig.
Fig. 23.
DO NOT USE THE LINES
LINES
ALREADY SCRIBED ON THE
LEVER AND HOUSING. THEY
ARE FOR MANUFACTURING
MANUFACTURING
REFERENCE ONLY.
/ \
J ^V1960-A
FIG. 23 Scribing New Index Line

Before Removal of Air Horn
Assembly
2.
2. Now the throttle link to the vacuum
piston limiter lever can be removed by
unscrewing the nylon adjusting nut.
To facilitate
facilitate working on the
carburetor, and to prevent damage to
the throttle plates, install carburetor
If legs are
are
legs on the base. If
unavailable, install four 5/16 x 2-1/2
inch bolts and 8 nuts;
nuts; install nuts on
BACK TO GROUP INDEX
the bolts, above and below the

carburetor base.
component parts of the various
assemblies to facilitate cleaning,
inspection, and assembly. Refer to
Part
Part 24-01 for cleaning
cleaning and
inspection.
overhauling the carburetor. However,
may be serviced without aa complete
may
disassembly of the entire unit.
Air Horn
Horn
Air
1.
1. Remove the fuel inlet line from the
fuel filter.
filter.
2.
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.
4.
4. Remove the air cleaner assembly
anchor screw and remove the air horn
to fuel bowl attaching screws.
5.
5. Remove accelerator pump drive rod
at the throttle lever.
6.
6. Lift the air horn off
off the main body.
7.
7. Invert the air horn, pull the float pivot
pin and remove the float assembly.
8. Using the proper tool, remove the
8.
main and auxiliary (supplemental)
fuel inlet valve seats and gaskets.
9.
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.
10. If
necessary to
to remove
remove the
the
secondary air valve plates or shaft
follows: Do not perform
proceed as follows:
this operation with carburetor on
may fall through to
engine, as parts may
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
Slide the
the shaft
shaft out
out of
of the
the body.
body.
screws.
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. 24).
11. If necessary to remove choke plate,

first
first remove the staking marks on the
choke plate attaching screws and
remove the screws.
screws. If the tips of the
screws are flared excessively, file
file the
flared portion to prevent damage to
the threads in the shaft. If equipped
with altitude
altitude compensation,
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.
12. Disconnect
Disconnect the
the operating
operating arm
arm from
from
the accelerator pump piston. Remove
the clip from accelerator
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.
13. Remove
Remove the
the hex-head
hex-head screw
screw that
that
attaches the mechanical fuel bowl
vent valve operating rod retainer.
Remove the retainer and operating
Fig. 25).
rod (see Fig.
14.
14. Renlove
Remove the
the C-clip
C-clip that
that retains
retains the
the
spring on the shaft. Remove the
spring and plunger assembly.
Main Body
1. Turn the main body upside down and
1.
catch the accelerator pump discharge
needle and ball, (Fig.
(Fig. 25).
2. Turn
Turn the body
body right
right side
side up
up again
againand
and
depress the metering rod
rod hanger and
check the gap
gap between the bottom
edge of the metering rod
rod hanger and
the top
top of the vacuum cylinder (Fig.
27). Record the dimension for
reference during assembly. With a
pair of needle-nosed pliers, remove
from
the vacuum piston stop (nylon) frOln
the channel in the main body casting.
3. Remove the main metering vacuum
piston and fuel metering rods as an
assembly DO NOT DISTURB
assembly.
S E T T I N G OF
OF PISTON
PISTON
SETTING
ADJUSTMENT SCREW OR
ADJUSTMENT
ROD ADJUSTMENT
METERING ROD
SCREWS.
4.
4. With the appropriate screwdriver,
unscrew the vacuum piston cylinder
24-26-10
24-26-10
24-26-10
CD
HOLD HANGER
HANGER
(T) HOLD
DOWN
DOWN
AIR VALVE
VALVE PLATE
AIR
VACUUM
VACUUM PISTON
PISTON
ADJUSTING
ADJUSTING SCREW,
SCREW\
\\
MEASURE
[CLEARANCE
SET AT
FACTORY
V2047-A
V2047-A
METERING RODS
FIG. 27 Measuring Vacuum Piston

Disassembly
Setting Before Disassembly
THROTTLE BODY
BODY TO
TO
THROTTLE
BODY ATTACHING
ATTACHING
MAIN BODY
SCREWS (6 REQUIRED)
CHOKE HOUSING
V1931-A
FIG.
FIG. 24 Removing Air Valve Plate
ACCELERATOR PUMP
DISCHARGE BALL & WEIGHT
VACUUM PISTON'
W %
VACUUM
CYLINDER
VENT VALVE
SECONDARY THROTTLE
SHAFT & LEVERS
PRIMARY
PRIMARY THROTTLE
& LEVERS
SHAFT &
V1934
A
V1934-A
V1932-A
V1932-A
FIG.
FIG. 25
25 Mechanical
Mechanical Fuel
Fuel Bowl
Bowl Vent
ValveRemoval and
and
Valve-Removal
Installation
Installation
FIG. 28 Throttle Body Bottom View

ACCELERATOR PUMP
BALL CHECK
& RETAINER
MAIN JETS
and remove
remove the
the cylinder,
cylinder, the return
return
and
spring and
and guide
guide pin (Fig.
(Fig. 27).
27).
spring
5. Remove
Remove the
the main
main metering jets from
from
5.
the fuel
fuel bowl with aa jet tool.
tool.
the
6. Using
Using long
long nose
nose pliers,
pliers, remove the
the
6.
accelerator pump inlet check ball
ball
accelerator
retainer, then
then turn
turn the main body over
over
retainer,
and catch
catch the
the ball
ball from
from the
the pump
pump
and
well.
well.
7. Remove
R e m o v e the
t h e four
four (4)
(4) altitude
altitude
7.
compensation aneroid
aneroid assembly
assembly
compensation
attaching screws
screws and
and remove
remove the
the
attaching
assembly from
from the
the carburetor
carburetor body
body
assembly
(1976 models
models so
so equipped).
equipped).
(1976
BACK TO GROUP INDEX
V-1933-A
FIG. 26 Main Body Components-Air

Component; -Air
FIG.
Horn Removed
Removed
Horn
Throttle Body
mixture
Do not remove the idle mixture
or the
the mixture screws from
from
limiter caps or
the
the throttle body.
body.
1. Remove the throttle body to main

1.
body screws from the bottom of the
(Fig. 28) and separate
separate
throttle body (Fig.
castings.
the two castings.
2. Remove the choke housing cover

s c r e w s , ccover,
o v e r , ggasket
a s k e t and
and
screws,
thermostatic spring.
choke piston
3. Remove the choke
piston lever
retaining screw, then remove the
piston assembly.
retainers from
4. Remove the retainers
from the
secondary throttle
throttle lever
lever to
to primary
primary
secondary
throttle connecting
connecting link,
link, then
then remove
remove
throttle
the link.
link.
the
5. If
If it is necessary to remove the
5.
throttle plates or shafts from the
staking
throttle body, remove the staking
marks on the throttle plate attaching
screws. Remove the screws and the
screws.
plates.
6. The secondary throttle shaft is of two6.
piece design, and is removed in
24-26-11
24-26-11
7.
8.
9.
each half
half out
out of
of the
halves. Pull each
shaft bores after
after the plates are
throttle shaft
removed.
from the primary
Remove the screw from
shaft, remove
renHwe the fast idle
throttle shaft,
adjusting screw. Slide the
lever and adjusting
shaft assembly out of
of the primary
shaft
shaft bore.
throttle shaft
off the
Slide the primary return spring off
shaft assembly.
throttle shaft
If it is necessary to remove the fast
If
carefully press
idle cam or bushing, carefully
of the choke housing
the bushing out. of
and bushing column. The column may
of alignment or break
bend out of
without proper support to the column
during
bushing
d
uring b
u s h i n g rremoval
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. 29.
ASSEMBLY
Throttle Body
1.
1. If
If the throttle plates and shafts have
beem removed, slide the primary
throttle return spring on the primary
shaft (one-piece shaft) and
throttle shaft
shaft into the primary shaft
slide the 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.
4. Install the secondary throttle lock out
lever.
5.
5. Install the fast idle speed lever and
adjusting screw.
6.
6. Engage the throttle plate return
return
spring tang in the recess provided in
the throttle body casting.
casting. Make sure
spring operates in a closing direction.
direction.
7.
7. Install return springs on each half of
the secondary throttle plate shaft,
shaft,
with the hook positioned over the
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.
boss. Rotate the halves of
the shaft in
in opposite directions until
the center key
key indexes.
indexes.
8.
8. Position the secondary throttle plates
in
in the bores with the ground flat edge
BACK TO GROUP INDEX

of the plates
plates facing
facing upward
upward and
of
toward
toward the rear
rear of
of the carburetor.
Install the attaching
attaching screws snugly
but not tight. Position and check as
with the primary
primary throttle
throttle plates.
Make sure return springs operate in
a closed direction.
If the fast idle cam and bushing were
9. If
removed, insert the automatic choke
shaft bushing
bushing through
through the choke
shaft
housing. Position the fast idle cam
between the choke housing
housing and
between
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.
shaft and
10. Insert the automatic choke shaft
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. Insert
Insert the secondary
secondary throttle to
primary throttle connecting rod into
and install
the tthrottle
h r o t t l e levers and
retainers.
Main Body To Throttle Body

1.
1. Position the main body on a working
If
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.
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.
5. With the appropriate jet wrench or
screwdriver, install main jets in the
fuel bowl.
6.
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.
7. Carefully position the metering piston
and metering rods into the cylinder
and main metering jets. Push the
full
piston and metering rods to the full
downward position and install the
nylon piston stop in the channel in the
casting.
main body casting.
8.
8. If the metering rod adjustment has
been disturbed, manually depress the
metering rod hanger. Using a small
screwdri
ver, carefully
screwdriver,
carefully turn the
the
vacuum piston adjusting screw (Fig.
(Fig.
31) and the metering rod adjusting
adjusting
31)
screws counterclockwise until the
metering rod hanger is
is fully seated
against the vacuum cylinder top face.
face.
24-26-11
24-26-11
9. Holding
Holding tbe metering
metering rod
rod hanger
lightly in the full downward
downward position,
turn
turn each
each metering
metering rod adjusting
screw clockwise until the metering
rod hanger just
just starts to rise. (The
metering rods are now set in the
proper relationship with the vacuum
piston.)
lO.Now
10. Now turn
turn the
the vacuum
vacuum piston
adjusting screw
screw. clockwise until the
adjusting
clearance between the bottom of
of the
metering rod hanger and the top edge
of
of the vacuum
vacuum piston
piston cylinder
(recorded
(recorded during disassembly) is
achieved (Fig. 31).
11. Drop the accelerator
accelerator pump inlet
check ball into the bottom of
of the
pump well and install the retainer.
12. Install the choke-to-throttle lockout
lever.
13. Place the accelerator pump discharge
check ball and weight in position in
the body.
Air Horn
1. IInstall
n s t a l l the aaccelerator
c c e l e r a t o r pump
operating shaft
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
shaft and secure with
a clip (Fig.
(Fig. 32).
2. Install the accelerator pump on the
arm. Install the vent valve plunger,
spring and clip.
shaft were
3. If the choke plate and shaft
shaft
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.
and shaft are
are tapered and
The lever and
has aa left hand
the attaching screw has
the choke plate into the
the
thread. Insert the
in the
the choke shaft and
and install the
slot in
but not
plate attaching screws snug but
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.
horn.
plate
Tighten and stake the plate
attaching screws.
screws.
5. If the air valve plate and shaft were
5.
removed, slide the shaft through the
holes on the secondary side of the air
horn and with the slotted end of the
chamber.
shaft in the air valve spring chamber.
6. Install the secondary metering rods in
6.
plate.
the keyed slots on the air valve plate.
Do not
not attempt to
to remove
remove or
or install
the secondary air valve plate and
metering rods
rods with the
the carburetor
on the
the engine,
engine, as
as the
the shaft
shaft
installed on
and
spacer(s), metering rods and
can fall into the
attaching screws can
24-26-12
24-26-12
24-26-12
24-26-12
Model
Model 4350
4350 4-V
4-V Carburetor
Carburetor
SCREW
SCREW
C-CLIP
VENT VALVE
VALVE
VENT
C-CLIP
RETAINER
URETAINER
ADJUSTING
ADJUSTING
ALTITUDE
ALTITUDE COMP
COMP
ICHOKE
'CHOKE PLATE
PLATE LINK
LINK
SCREW
SCREW
~~LKv~D~~ SC~
SCREW
~ ~
ALTITUDE COMP
ALTITUOECOMP
CHOKEPLATE~
CHOKE PLATE*"
AIR VALVE
PLATE
CHOKE PLATE
/ ; ; ; k C H O K E PLATE
I~
SCREW
SCREW
~<:
--!.~~
_-----Gi
.....-SHAFT
a.....---- SCR
EW
SCREW
.........-:::
Gi.....---
~
SHAFT~. ~
AIR VALVE
SPACER
METERING----[
ROD
ACCELERATORPUMP~~
GASKET~
ACCELERATOR PUMP
}-
LEVER AND
AND ROD
ROD
LEVER
ACCELERATOR
ACCELERATOR
~ r~'
~.~i
PUMP
SPRING
AIR VALVE
VALVE DAMPER
DAMPER
AIR
PISTON AND
AND ROD
ROD
PISTON
CHOKE
CHOKE PLATE
PLATE
SHAFT
SHAFT
/i
VACUUM
VACUUM PISTON
PISTON
LIMITER
LI MITER LEVER
LEVER
~ACCELERATORPUMPARM
ACCELERATOR PUMP ARM
~SHAFT
LEVER
UPPER
UPPER BODY
BODY
PUMP L I N K : ; ;
_""""""'~~~~~;;;:;;.--
,(}
(SU
~I ~
FUEL B O W L
VENT VALVE
FUEL BOWL
VENT VALVE
ACCELERATOR
ACCELERATOR PUMP
PUMP
SPRING RETAINER
SPRING RETAINER
PUMP
PUMP SPHING
SPRING
~
PUMP
PUMP SHAFT
SHAFT
~
P I NRETAINER
RETAINER
_
PIN
/^ ' "
LJ
~~
- PUMP PISTON
~ RETAINER
10m.'
PIN
PIN
FUELINLETVALVE
FUEL INLET VALVE
,~
FLOATAND
AND SEAT
SEAT
AND
METERING RODS
,"""--
LEVER)
ASSEMBlY
GASKET -----~
ALTITUDE
COMPENSATION
ASSEMBLY
&YOKE
MAIN JETS
VACUUM PISTON
i...-
SPRING
~VALVE
VACUUM PISTON
CYLINDER
GASKET
H ^ * _ _
THROTTLE
'~THROTTLE
,
.c.,UXI LIARY
PRIMARY THROTTLE SHAFT

ASSEMBL Y
AND LEVER ASSEMBLY
/ P ^ ^ " ~
JJI
AUXILIARY
^m
LINK
/
SCREW
LEVER
LEVER
CHOKE
AUTOMATIC CHOKE
SHAFT AND
AND LEVER
LEVER
SHAFT
CAM ADJUSTING SCREW

FAST IDLE CAM
SECONDARY THROTTLE
THROTTLE
SECONDARY
SHAFT AND
AND LEVER
LEVER (L
IL H
H I
SHAFT
SECONDARY
THROTTLE
PLATES
__
2o:y7
RETURN SPR I NG
CHOKE CONTROL ROD

SCREW
IDLE
PISTON AND LEVER ASSEMBLY
SPEED
SCREW
THROTTLE BODY
BODY
THROTTLE
AND CHOKE
CHOKE
AND
HOUSING
HOUSING
CHOKE
THERMOSTATIC
CAP
CHOKE HEAT
CONNECTION
THROTTLE
THROTTLE
STOPLEVER
STOP
LEVER
Bl
CHOKE DELAYED
DELAYED PULLDOWN
PULLDOWN
CHOKE
AND
AND FAST
FAST IDLE
IDLE TOP
TOP STEP
STEP
PULLOFF
PULLOFF DIAPHRAGM
DIAIJHRAGM
ASSEMBLY
ASSEMBLY
()3))
FILTER
CAP
LINK
PULLOFF
L1NKA::
TURN
SPRING
FAST IDLE
LEVER
FAST IDLE
IDLE SPEED
SPEED
FAST
ADJUSTING SCREW
SCREW
ADJUSTING
::,ECONDARY THROTTLE
THROTTLE
SECONDARY
SHAFT AND
AND LEVER
LEVER (R
IR H
H )I
SHAFT
V2048A
V2048-A
FIG.
FIG. 29
29 Model
Model 4350
4350 4-V
4-V Carburetor
Carburetor With
With Altitude
Altitude Compensation
Compensation (1976)Disassembled
(1976)-Disassembled View
View
BACK TO GROUP INDEX

24-26-13
Model 4350 4-V

4-V Carburetor
24-26-13
/
v
C-cuP
C-CLH3
O~~::R
AIR
VALVE
VALVE
LINK
AIR VALVE
PLATE
RETAINER
/RETAINER
OP~~~~ ~:HOKE
SCREW
SCR
""
L1NK~
SCREW
VENT VALVE
V:~JU~;,~"c,E
CHOKE PLATE
PLATE
SCREW
~
~~~udD
c::::~
_----
Q-o......- - -
..........-:::
VALVE
AIR VALVE
SHAFT
SHAFT
SflACER
~-
~~ ~ 6)---
-~
---nr
METERING _
ACCELERATOR PUMP ' "

LEV-ER AND ROB
~
ACCEL~RATOR
~MP
LINK : ; ;
AIR VALVE
7/
~}-
1J1
OA"PER~
Gl
PIN
FUftL INLET VALVE

AND SEAT
WEIGHT
~ oc:;
~~T~.:__
.,
C)~
PRIMARY THROTTLE SHAFT

AND LEVER ASSEMBLY
---n
-u f'.....
! ~. . .
~
C>
....
ACCELERATOR PUMP
SPRING RETAINER
~PUMPSPRING
/j
0_
,'-
MAIN BODY
ACCELERATOR PUMP ARM
~~~~EV/~PUMPSHAFT
PIN RETAINER/""
PISTON AND ROD
PRIMARY
THROTTLE PLATE
SHAFT
rl
GASKET - - - - -...
CHOKE PLATE
SHAFT
VACUUM PISTON
LIMITER LEVER
()
GASKET
~RING
o'
SCREW
LEVER
LEVER
UPPER BODY
ROO
-""
>
FLOAT AND
PUMP PISTON
rr=:-m
0
AS~~~~RLY
B~~~A~~~~K
-..---
INLET BALL
~.
~;R~~~M
VACUUM PISTON
PISTON
SPRING
VALVE
VACUUM PISTON
CYLINDER
CYLINDER
.....
GASKET
~.-,
METERING RODS
YOKE
& YOKE
~ MAIN JETS
~HECK
RETAINER
~THROTTLE
AUXILIARY
....
GASKET
LEVER
LINK
SCREW
AUTOMATIC CHOKE
SHAFT AND LEVER
SECONDARY THROTTLE
SHAFT
AND LEVER
SHAFT AND
LEVER (L.H.\
(L.H.) _-_~._<:'51011!.
SECONDARY
SECONOARY
THROTTLE
PLATES
~~~
U
RETURN SPRING
IDLE
SPEED
SCREW
CHOKE
THERMOSTATIC
CAP
THROTTLE BODY
AND CHOKE
HOUSING
<!HOKE HEAT
CONNECTION
THROTTLE
STOPLEVER
Jl
~
~
LINK
AND FAST
FAST IDLE
IDLE TOP
TOP STEP
AND
stEP
PULLOFF DIAPHRAGM
DIAPHRAGM
PULLOFF
ASSEMBLY
SCREW
G "
CHOKE
CHOKE DELAYED
DELAYED PULLDOWN
PULLDOWN
RETAINER
".:
FILTER
CAP
PULLOFF
LINKAGE
RETURN
SPRING
FAST IDLE SPEED

ADJUSTING SCREW
SECONDARY
SECONDARY THROTTLE
THROTTLE
SHAFT
(R.H.\
SHAFT AND
AND LEVER
LEVER (R.H.
V1935C
V1935-C
FK3. 30
30 Model 4350 4-V
4-V Carburetor--Disassembled
Carburetors-Disassembled View
HG.
BACK TO GROUP INDEX

24-26-14
24-26-14
Model
SCREW DRIVER
/ V1959 A
FIG. 31
31 Preliminary
Preliminary Vacuum
Vacuum Piston
Piston
FIG.
Adjustment
VACUUM PISTON
PISTON LIMITER
LIMITER
VACUUM
SHAFT
A
"E"-CLIP
ACCELERATOR
PUMP OPERATING ARM
V1936-A
FIG. 32 Assembling Components to

FIG.
Vacuum Piston
Piston limiter
Limiter Lever
Vacuum
lever
Shaft
BACK TO GROUP INDEX
intake
intake manifold. Lower the air valve
plate into
into position while guiding the
the
metering rods into the air valve wells.
wells.
Then slide the air valve shaft and
spacer(s) into position and install the
air valve plate to the shaft.
shaft.
7.
7. Close the air valve plate and lightly
tap the plate with end of a screwdriver
screwdriver
or similar tool to properly position it
in the air horn.
horn.
Tighten
T i g h t e n and stake the plate
plate
attaching screws.
screws. Be sure the plate
and shaft turns freely after assembly.
8.
8. Install fuel inlet needle seat and
and
gasket, using proper tool.
tool. Insert fuel
fuel
inlet needle into the fuel inlet needle
seat.
9.
9. Install the supplementary fuel inlet
valve and gasket.
10.
10. Position float and lever assembly
between hinge post and over fuel inlet
valves.
valves.
11. Insert the float hinge pin through the
post and float lever. The pin must be
inserted from the accelerator pump
self-retention.
plunger side for self-retention.
12. Position return spring over air valve
damper rod. Insert assembly through
upper body and insert cranked end of
of
damper rod into inner arm hole in
damper link.
13. Position damper link (bell crank) over
post on upper body and install split
shaft.
pin shaft.
14. Insert cranked end of air valve link
through tang on air valve plate and
position other end throughout board
through remaining
remaining hole in
end through
damper link (bell crank). Install Cclip over end of air valve link.
15. Insert the accelerating pump bleed
disc into the pump bleed cavity.
16. Set the float level.
24-26-14
17.
17. Position the mechanical vent valve
operating lever in the cast slots and
install the retainer and screw.
Upper Body To Main Body
1.
1. Position the main body to upper body
gasket on the main body.
2.
2. Carefully
Carefully position the upper body
assembly over the main body. Guide
the accelerator pump plunger and the
secondary throttle dashpot piston
into their chambers as the upper body
is gently lowered into position.
3. Install the other upper body attaching
screws.
4. Position the throttle levers so that the
tang rests against the "TSP OFF" idle
speed adjusting
adjusting screw. Insert the key
end of the accelerator pump link into
the keyed hole in the primary throttle
lever.
5. Insert the end of the accelerator pump
link
link through
t h r o u g h tthe
h e hhole
o l e in the
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
nose pliers, install the retaining clip.
7. Check
choke gasket
gasket cover
Check the choke
clearance.
8. Install the choke gasket cover and
retainer. Set the cap to the 90 degree
rich position.
9. Check the fast idle cam clearance.
110.
o. Reset the choke cap to specifications.
carburetor legs or bolts
from the throttle body.
Note: Adjust mechanical fuel bowl

vent valve after carburetor is reinstalled
on vehicle. (See ADJUSTMENT.)

24-30-1
24-30-1
24-30-1
24-30-1
PumpMechanical
2 4 - 3 0 Fuel Pump - Mechanical

PART 24-30
Applies To All Models
COMPONENT INDEX
DESCRIPTION
Page
......................
30-1
30-1
TESTING
Pressu
re Test
Pressure
......................
30-1
30-1
COMPONENT INDEX
Page
Capacity (Volume) Test ..............
30-1
30-1
30-3
SPECiFiCATIONS
30-3
NOTE: The information in this Part applies to both 1975

NOTE:
1975 and 1976
1976 Illodel
CR1966-A
CR1966-A
DESCRIPTION
A
A single
s i n g l e action
a c t i o n fuel
fuel pump
pump
(mechanically operated) is standard
equipment for all vehicle models.
The fuel pump on the 6-cylinder
6-cylinder
engine is mounted on the lower left center
of the engine cylinder block.
On all V-8 engines, the fuel pump is
TESTING
Incorrect fuel pump pressure and low
volume (capacity of flow rate) are the two
most likely fuel pump troubles that will
affect engine performance. Low pressure
affect
fuel
will cause a lean mixture and fuel
starvation at high speeds. Excessive
p r e s s u r e will
w i l l cause
c a u s e high
h i g h fuel
fuel
pressure
flooding.
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
safisfactory
both fuel pump pressure and fuel pump
capacity (volume) should be performed.
performed with the fuel

The tests are performed
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.
filter.
PRESSURE TEST
Refer to Fuel System Specifications at
BACK TO GROUP INDEX
mounted on the left-side of the cylinder

front cover. On the Pinto, Bobcat and
Mustang engines the fuel pump is
left-front of the engine.
mounted on the left-front
The pump is actuated by an eccentric on
shaft on the 2300 cc
the auxiliary shaft
camshaft
4-cylinder engines, and on the camshaft
on 2800 cc V-6 engines.
A separate fuel filter is used on all
engines. The filter

filter is of
of one piece
construction and does not contain a
cleanable filter element.
All passenger
passenger car engines are
equipped with a disposable-type fuel
fuel
pump (Fig. 1).
I).
These pumps have no serviceable
parts, and must be replaced if out of
of
specification.
the end of this Part and note the fuel

pump pressure and capacity (volume)
specifications.
satisfactory condition, the

filter are in satisfactory
pump is defective and should be
replaced.
If the pump pressure is within
If
specifications, perform the test for
fuel capacity (volume).

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
flexible hose (Fig. 2) between
the fuel filter and the carburetor.
3. Position the flexible hose and the
r e s t r i c t o r so the fuel
fuel can be
restrictor
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
con
tainer 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
CAPACITY (VOLUME) TEST

With the fuel pump pressure within
specifications, test the capacity (volume)
as follows:
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
been
discharged within the specified time
pump volume is below
limit. If the pump
an
specifications, repeat the test using an
auxiliary fuel supply and a new fuel
filter. If the pump volume meets
specifications while using the
specifications
auxiliary fuel supply, check for a
restriction in the fuel supply from the
improper tank
tank and for improper
ventilation.
24-30-2
24-30-2
24-30-2
24-30-2
Fuel PumpMechanical
Pump-Mechanical
Fuel
,^>%teM0z^
302,
302, 351-WCID
351-W CID V-8
V-8
460
460 CID V-8
1976
ONLY
\
2.3L FOUR
351-MMOO CID
351-M/400
V-8
1975
ONLY
2.8L V-6
V1937-C
V1937-C
FIG.
FIG. 1
1 Typical
Typical Mechanical
Mechanical Fuel
Fuel Pumps
Pumps
BACK TO GROUP INDEX

24-30-3
24-30-3
Fuel
PumpMechanical
Fuel Outlet
Fuel
Outlet Hose
Ho se Restr;
ctor
Hose
Restricto
Pressure
Pressure Gauge
Gauge
CARBURETOR FUEL INLET PORT
r
1
Fuel
Containe
B2630B
B2630-B
and Capacity Test Equipment

FIG. 2 Typical Fuel Pump Pressure and
REMOVAL
INSTALLATION
Removal
Removal
1.
the inlet line and the
1 Disconnect the
outlet line at the
the fuel pump.
2. Remove the fuel pump attaching bolts
2.
and remove the
the pump and
and the
the gasket.
gasket.
Discard the
the gasket.
Installation
Installation
1.
the gasket
1. Remove
Remove all
all the
gasket material
material from
from
the
the mounting
mounting pad and
and pump. Apply
oil-resistant
both sides
sealer to
to both
sides of
of aa
the new
new gasket
new gasket. Position the
on the
the pump flange and hold the
pump in position
position against the
pad. Make sure the
the rocker
mounting pad.
rod is riding on
on the
the camshaft
arm or rod
or intermediate shaft eccentric.
2. Press the
the pump tight against the
the pad,
pad,
install the attaching bolts and
alternately
a l t e r n a t e l y torque
t o r q u e them
t h e m to
to
specifications.
3. Connect the fuel inlet line or hose (use
new clamp on the
the hose) and the
a new
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.
SPECIFICATIONS
PUMPMECHANICAL (1975)
FUEL PUMP-MECHANICAL
CD
]J
STATIC PRESPRES
SURE (PSI)
(PSI) ( T )
SURE
2.3L
2.3l
3.5-5.5 (J)
Pt.inin25
25Sec.
Sec.
1 Pt.
.304 - .324
2.8L
200/250
3.5 - 5.5
4.0 - 6.0
Pt.inin25
25Sec.
Sec.
1 Pt.
302
302
351W
5.0 - 7.0
5.0 - 7.0
.193
. 1 9 3-- . 2.213
13
.290
. 2 9 0-- . 3.310
10
.690
. 6 9 0-- . 7.710
10
.690
. 6 9 0-- . 7.710
10
351M
400
5.0 - 7.0
5.0
5 . 0-7.0
-7.0
1 Pt.
in 20
Sec.
Pt.tn
20Sec.
.602 - .622
1 Pt.
Pt.inin20
20Sec.
Sec.
.602 - .622
460
5.7 - 7.7
Pt.inin20
20Sec.
Sec.
1 Pt.
.890
. 8 9 0-- . 9.910
10
CD
CD
MIN. VOLUME FLOW
ECCENTRIC TOTAL
LIFT (Inches)
ENGINE
C.I.D.
CD0
1 Pt.
Pt.inin20
20Sec.
Sec.
Pt.inin20
20Sec.
Sec.
1 Pt.
Pt.inin20
20Sec.
Sec.
1 Pt.
On
On engine, with temperatures normalized and
and at normal curb idle speed,
speed, transmission in
neutral.
CD
7)
off, and a new

new fuel
fuel filter
filter installed
installed in
in fuel
fuel line.
line.
With the
the pump-to-tank fuel return line pinched ott,
3j
be smaller than 0.220".

Inside diameter of smallest passage in test flow circuit must not be
BACK TO GROUP INDEX
CV1274-B
CV1274-B
24-30-4
PumpMechanical
24-30-4
PUMPMECHANICAL
FUEL PUMP-MECHANICAL
(1976)
ENGINE
C.1.0.
C.I.D.
2.3L
2.Sl
2.8L
250
250
302
302
351W
351M
400
460
CD
1)
CD
2)
3J
STATIC PRES-
CD
5
.
0
7
.
0
@
5.0-7.0 CD
SURE (PSI) ( T )
MIN. VOLUME FLOW
CD0
1 Pt.
Pt.inin25
25Sec.
Sec.
ECCENTRIC TOTAL
LIFT (Inches)
.304 - .324
3.5
- 5.8
3.5-5.8
Pt.inin25
25Sec.
Sec.
1 Pt.
. 1 9 3- . 2.213
13
.193
5.0-7.0
1 Pt.
Pt.inin2020Sec.
Sec.
.290
. 2 9 0-- . 3.310
10
6.0
- 8.0
6.0-8.0
6.0
6.0 -- 8.0
8.0
I1 Pt.
Pt.inin20
20Sec.
Sec.
1 Pt. in
in 20
20 Sec.
Sec.
1 Pt.
Pt.inin20
20Sec.
Sec.
.690-.710
.690-.710
.690
. 6 9 0- . 7.710
10
.602 - .622
6.0
- 8.0
6.0-8.0
1! Pt.
Pt. in
in 20
20 Sec.
Sec.
.602 - .622
6.7-8.7
1 Pt.
Pt.inin20
20Sec.
Sec.
. 8 9 0- . 9.910
10
.890
6.0
- 8.0
6.0-8.0
On engine, with temperatures normalized and at normal curb idle speed,

speed, transmission in
neutral.
With the pump-to-tank fuel return line pinched off, and a new fuel filter installed in fuel line.
passage in test flow circuit must not be
be smaller than 0.220".
Inside diameter of smallest passage
CV1274-C
BACK TO GROUP INDEX

24-41-1
24-41-1
Air Cleaner
PART 24-41 Air Cleaner - Dry Type

Page
Page
COMPONENT
COMPONENT INDEX
INDEX
AIR FILTER ELEMENT
Removal and Installation ...........
CLEANING AND INSPECTION ........
COMPONENT
COMPONENT INDEX
INDEX
Page
Page
41-1
41-1
(Refer to
FILTER
CRANKCASE VENTILATION FIL
TER
Removal and Installation ...........
OESCR
IPTION .....................
DESCRIPTION
Part 24-01)
SPECIFICATIONS ...................
41-2
41-1
41-1
41-2
NOTE: The inforlllation

information in this Part applies to both 1975 and 1976 Illodel
model year vehicles unless otherwise specified
specified..
CR1966-A
CR1966-A
TEMPERATURE
SENSOR
DESCRIPTION
All car engines are equipped with dry
type air cleaners with replaceable filter
elements and replaceable crankcase
ventilation system filter element. The air
cleaner
cleaner body is mounted
mounted on the
carburetor body and secured with a wing
nut (or nuts) or bolts. To prevent
inadvertantly dropping dirt into the
carburetor, always remove the air filter
filter
body before removing the filter element
(Fig. 1).
(Fig.
COVER
FILTER ELEMENT
TVS VALVE (SOME MODELS)
COLD WEATHER MODULATOR
FRONT OF VEHICLE
DUCT AND VALVE ASSEMBLY

VACUUM MOTOR
AMBIENT
TEMPERATURE
SENSOR
(CATALYST
VEHICLES)
FROM CANNISTER
PURGE SOURCE
FROM CRANKCASE
CLOSURE HOLE
HEAT SHROUD
AND RISER TUBE
(HOT
(HOT AIR
AIR PICKUP)
PICKUP)
FRESH AIR
PICKUP
V1899-B
V1899B
CleanerV-8 Engine
FIG. 1 Typical Air Cleaner-V-8

REPLACING AIR FILTER ELEMENT
Removsl
Removal
Refer
Refer to Part 50-29, Emissions
Systems Maintenance Schedule for
frequency of filter inspection and/or
replacement.
1.
1. Remove the wing nut(s) attaching the
air cleaner body to the carburetor air
Disconnect the
horn stud(s). Disconnect
crankcase ventilation system hose at
the air cleaner body. Disconnect the
evaporative emission control system
cleaner body.
hose at the air cleaner
Disconnect the zip tube clip.
Disconnect
Disconnect the catalyst switch by
removing the retaining clip on
vehicles so equipped. Disconnect the
TVS valve,
valve, if
vacuum lines from the TVS
equipped.
BACK TO GROUP INDEX
NOTE: Where the <;atalyst

NOTE:
catalyst switch
is pop-riveted to the air cleaner tray,
disconnect the switch by separating
the connectors. Disconnect
Disconnect the
vacuum supply
supply hose
hose for
for the
the air
air
vacuum
cleaner
cleaner valve.
valve.
NOTE: When removing the 2.3L
NOTE:
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.
fittings.
2. Remove the air cleaner cover and
filter element. To prevent dirt 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
t1}e element for dust
on the clean air side, the slightest hole,
or damaged end seals.
seals. Place a light on
on the
the
inside and look through the filter at the
light. Any hole in the element, even the
smallest, is cause to 'replace
replace the filter.
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.
hole. Discoloration only, caused
by backfire,
backfire, is not a cause for
for
replacement.
Installation
Installation
1. Install a new air cleaner mounting
1.
gasket on the carburetor, if necessary.
2.
2. Wipe all inside surfaces of the air
cleaner body before installing filter
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.
4. Connect the catalyst switch or
connect the vacuum lines to the TVS
switch (if equipped).
5.
5. Place the air cleaner filter element in
the cleaner body. Make sure the
element is properly seated.
6.
Install the
cover and
wing
6. Install
the cover
and tighten
tighten the
the wing
nut(s)
nut(s) or
or bo1t(s)
bolt(s) to
to the
the specified
specified
torque.
torque.
NOTE: On those air cleaners
having two attaching wing nuts, it is
necessary to recheck the torque on
Air Cleaner
24-41-2
the first wing nut after tightening the

second.
7.
7. Connect the crankcase ventilation
system hose to the air cleaner body.
Connect the evaporative emission
control system hose.
Replacing Crankcase Ventilation
Filter in Air Cleaner
The crankcase ventilation system air
filter
filter is shown in Fig.
Fig. 2.
Removal
Removal
1.
filter cap to air
1. Disconnect the oil filter
cleaner closure hose at the air cleaner
by unsnapping the elbow from the
retainer clip.
2.
2. Remove the air cleaner body cover.
3. Remove the crankcase ventilation
filter retainer clip and remove the
filter retainer from the air cleaner
filter
body.
4.
4. Remove the filter pack from the
retainer, clean out the retainer and
install a new filter pack.
Installation
Insta//ation
1.
1. Position crankcase ventilation filter
assembly in air cleaner body and
install retainer clip.
2.
filler cap to air cleaner
2. Connect oil filler
closure hose at filter
filter retainer clip.
3. Install air cleaner cover and secure
with wing nut(s) or bolt(s), and
torque air cleaner nut to specification.
NOTE: On air cleaners having two

attaching wing nuts, it is necessary to
recheck the torque on the first wing
nut tightened after tightening the
second.
FILTERPACK~
FILTER PACK
RETAINER
FILTER RETAINER
......
_~
AIR CLEANER
(R~F')'
SHELL (REF.)
SHELL
CUP
^ S "
ClI
P
I
I
~l'
C~~~~E ~ ~-J
ELBOW
Vl.0B.S
V1408-B
FIG. 2 Crankcase Ventilation System

Filter
SPECIFICAliONS
SPECIFICATIONS
SPECIFICATIONS-AIR CLEANER WING NUTS OR BOLTS
TORQUE SPECIFICATIONS-AIR
TORQUE (IN-LB)
FASTENER COMPOSITION
STEEL ...
PLASTIC ...
15-25
.
20-30
CV2046A
CV2046-A
BACK TO GROUP INDEX

24-42-1
24-42-1
24-42-1
24-42-1
Air Cleaner Duct Systems
PART 24-42 Air Cleaner Duct Systems

COMPONENT INDEX
DESCRIPTION
TESTING
Duct and
and Valve Assembly -Thermostat 0
perated
Operated
Duct and
and Valve Assembly -Vacuum 0
perated
Operated
Air Inlet Valve .. ,
Auxiliary Air
COMPONENT INDEX
Page
Page
.
.
42-1
42-1
42-1
42-1
42-1
42-1
.
.
42-2
42-3
A""
Appendix " A
Vacuum Motor Test
REMOVAL AND
AND INSTALLATION
INSTALLATION
Duct and Valve Assembly
Assembly-perat ure Operated
0 perated
Tem
Temperature
Duct and Valve
Va Ive Assembly
Assemb Iy -Vacuum Operated
1/
Page
.
.
42-3
42-3
42-3
42-3
NOTE:
NOTE: The
The infonnation
information in
1976 ITIodel
model year
year vehicles
vehicles unless
specified.
CR1966A
CR1966-A
AIR CLEANER
ASSEMBLY
DESCRIPTION
DUCT AND
AND VALVE ASSEMBLY
All
All vehicles except 2.8L
2.8L V-6
V-6 engine
applications have
have aa fresh air
air inlet tube
leading to
to the
the air
air cleaner to
to allow
air to
to enter the
the system (Fig.
(Fig. 1).
ambient air
1).
To
To determine whether the
the system is
functioning properly, perform the
the tests
in this Part.
Part.
detailed in
HEAT SHROUD
AND RISER TUBE
(HOT AIR PICKUP)
V1938-A
FIG. 11 Fresh
Fresh Air
Air Inlet-Typical
InletTypical
FIG.
TESTING
AND VALVE
DUCT AND
ASSEMBLYTHERMOSTAT
ASSEMBLYTHERMOSTAT
OPERATED
Air Temperature Method
Method
A. Air
1. Remove necessary items to
to visually
1.
see the
the duct door.
door. Remove the
the air
see
cover.
cleaner cover.
2. With aa cold engine and
and ambient air
2.
or less,
less, the
the duct
temperature of aa 95F or
valve shoulq.
should be
be in
in the
the FULL HEAT
valve
(closed). If the duct valve is
position (closed).
open, cool
cool the thermostat by
by spraying
open,
liquid from
from aa small
small can
can of
of R-12
liquid
R-12
refrigerant and
and ZRE-6271
ZRE-6271 can
refrigerant
can
adapter or
or equivalent.
equivalent. If
If the
the duct
duct
adapter
valve remains
remains open,
open, replace
replace it.
valve
it.
CAUTION: DO
DO NOT
NOT SPRAY
CAUTION:
THERMOSTAT WITH LIQUID
R-12 REFRIGERANT WHILE
IS RUNNING. IF
IF R-12
ENGINE IS
R-12
IS DRAWN
DRAWN
REFRIGERANT IS
THE CARBURETOR
CARBURETOR
INTO THE
W H I L E THE
THE ENGINE
E N G I N E IS
WHILE
R U N N I N G , POISONOUS
POISONOUS
:RUNNING,
PHOSGENE GAS
GAS WILL
WILL BE
PHOSGENE
BACK TO GROUP INDEX
THE TEST
EXHAUSTED INTO THE
AREA. CONDUCT THIS TEST
ONLY IN A WELL VENTILATED
AREA.
3. Place aa magnetic base temperature
3.
as near
indicator Tool T75L-9601-A as
as possible to
to the
the thermostat.
4. Reinstall the
the air cleaner cover
4.
the wing nut(s).
without installing the
the engine and
and allow to
Start the
to run
run at
rpm.
idle rpm.
5. As
As the
the engine warms up, observe the
the
S.
duct valve door. When the duct valve
to open (Heat OFF
door begins to
OFF
the air cleaner
position), remove the
and note the
the temperature
cover and
reading on
on the
the temperature
temperature indicator
indicator
reading
at the
the thermostat. It should be
be
13O-15OF. Replace ifif
approximately 130-1S0F.
not to
to this
this specification.
specification.
not
6. Remove instruments and
and reinstall
6.
related system components. Torque
nut to
to specification
specification (See
(See Part
wing nut
24-41).
24-41
).
B. Water Immersion Test

(Alternate Method)
1. Disconnect duct and valve assembly
from air cleaner and heat tube and
and
remove.
2. Insert unit in water so that bulb end

end
of
of wax pellet is submerged, and check
for operation of valve.
3. With water temperature at 95F or
less, duct and valve should be closed
(allow 5 minutes for temperature
stabilization).
4. W
ith w
a t e r ttemperature
e m p e r a t u r e at
With
water
13O-15OF., duct and valve should
130-150F.,
start to open (allow 5 minutes for
temperature stabilization).
5.
S. Replace unit if defective.
6. R
e i n s t a l l unit
e h i c l e and
Reinstall
unit in vvehicle
reconnect to heat tube and air cleaner.
NOTE: Open means that the duct
and valve door is open to fresh air
air
(Fig. 2).
2).
24-42-2
24-42-2
24-42-2
24-42-2
Air
Air Cleaner
Cleaner Duct
Duct Systems
Systems
AIR CLEANER
AIR CLEANER
THERMOSTAT
THERMOSTAT
COLD
AIR
B3191-A
83191-A
FIG. 22 Temperature
Temperature Operated
Operated Duct
Duct and
and Valve
Valve Assembly
Assembly in
in Heat
Heat ON
ON and
and Heat
Heat OFF
OFF Positions
Positions
FIG.
DUCT AND
AND VALVE
VALVE ASSEMBLYASSEMBLYDUCT
VACUUM
OPERATED
VACUUM
NOTE: For
For air cleaner
cleaner systems with
with
NOTE:
aa vacuum system delay valve, see Part
weather
29-01. On vehicles with a cold weather
modulator or
or vacuum
vacuum delay
delay valve,
valve,
modulator
by-pass these valves by connecting the
3/16 inch (ID) vacuum line from
from the
3/16
114 inch (ID)
sensor directly to the 1/4
vacuum motor line with a reducer.
CAUTION: DO NOT IMMERSE
ANY PART OF THE VACUUM
OPERATED DUCT AND VALVE
If the sensor
ASSEMBLY IN WATER. If
switch vacuum bleed opens, water will be
be
introducted into the vacuum system. This
can
can ppermanently
e r m a n e n t l y damage
d a m a g e the
the
temperature sensor switch.
1.
1. Remove necessary items to see duct
door.
door. Remove the air cleaner cover.
2.
2. Check to see
see that the duct valve door
is in the open (Heat OFF-no
OFFno
vacuum) position when the engine is
not running (Fig.
(Fig. 3).
3). If the
the duct valve
door is
is closed,
closed, check for binding and
sticking.
sticking. Repair and/or replace as
as
necessary.
necessary.
3.
3. Place
Place aa magnetic
magnetic base
base temperature
temperature
indicator
indicator Tool
Tool T75L-9601-A
T75L-9601-A as
as near
as
as possible
possible to
to the
the temperature
temperature sensor
on
on the
the air
air inlet
inlet side.
side.
4.
4. Start
Start the
the engine.
engine. With
With aa cold
cold engine
engine
and
and an
an ambient
ambient temperature
temperature below
below
75F,
75F, the
the duct
duct and
and valve
valve door
door should
should
be
be in
in the
the closed
closed or
or FULL
FULL HEAT
HEAT
position.
position. If
If the
the door
door isisclosed,
closed, proceed
proceed
to
to Step
Step 5.5. IfIf the
the duct
duct valve
valve door
door isis not
not
closed,
closed, turn
turn off
off the
the engine.
engine. Cool
Cool the
the
temperature
temperature sensor
sensor to
to aa temperature
temperature
below
below 75F
75F by
by spraying
spraying with
with liquid
liquid
from
from aa small
small can
can of
of R-12
R-12 refrigerant
refrigerant
and aa ZRE-6271
ZRE-6271 can
can adapter
adapter or
or
and
equivalent.
equivalent.
CAUTION:
CAUTION: DO
DO NOT
NOT COOL
COOL
THE
THE TEMPERATURE
TEMPERATURE SENSOR
SENSOR
WHILE
WHILE THE
THE ENGINE
E N G I N E IS
IS
RUNNING.
R U N N I N G . IF
I F R-12
R-12
REFRIGERANT
WN
REFRIGERANT IS
IS DRA
DRAWN
INTO
INTO THE
THE CARBURETOR
CARBURETOR
WHILE
WHILE THE
THE ENGINE
E N G I N E IS
IS
RUNNING,
R U N N I N G , POISONOUS
POISONOUS
PHOSGENE
PHOSGENE GAS
GAS WILL
WILL BE
BE
BACK TO GROUP INDEX
BI-METAL
BIMETAL SWITCH
SWITCH
FULL
FULL FRESH
FRESH AIR
AIR
FULL HEAT
\
TO
TO VACUUM
VACUUM SOURCE
<;QURCE
TO
DUCT VALVE
VALVE
TO DUCT
MOTOR
MOTOR
V1231-C
V1231C
Duct and VQ~ve

Vaive Assembly
FIG. 3 Vacuum-Operated Duet
EXHAUSTED INTO THE TEST
A R E A . CONDUCT
C O N D U C T THIS
THIS
AREA.
A WELL
WELL
PROCEDURE ONLY IN A
VENTILATED AREA.
the engine.
engine. If
If the
the duct valve
Restart the
is closed,
closed, proceed to
to Step
Step 5.
5. If
If
door is
is open
open during
during idle,
idle,check
check related
related
door is
vacuum system per Appendix "A'"
"A"
(24-42). Repair or
or replace as
as
(24-42).
necessary.
necessary.
5. Reinstall
Reinstall the
the air
air cleaner
cleaner cover
cover
5.
without installing
installing the
the wing
wing nut(s).
nut(s).
without
6. Start
Start engine
engine (if
(if necessary).
necessary). As
As the
the
6.
sensor warms
warms up,
up, observe
observe the
the duct
duct
sensor
valve door.
door. When
When itit starts
starts to
to open
open to
to
valve
the FULL
FULL FRESH
FRESH AIR
AIR position,
position,
the
remove the
the air
air cleaner
cleaner cover
cover and
and note
note
remove
the temperature
temperature reading
reading of
of the
the
the
t e m p e r a t u r e indicator.
i n d i c a t o r . The
The
temperature
temperature should
should not
not exceed
exceed 120F.
120F.
temperature
If the
the duct
duct valve
valve door
door does
does not
not
If
open, replace
replace the
the temperature
temperature sensor.
sensor.
open,
After completion
completion of
of this
this test,
test, turn
turn off
off
After
the engine.
engine. Reinstall
Reinstall air
air cleaner
cleaner cover
cover
the
and cold
cold weather
weather modulator.
modulator.
and
Cold Weather
Weather Modulator
Modulator (Only
(Only on
on
7.7. Cold
Applicable Models).
Models).
Applicable
Coolthe
thecold
coldweather
weathermodulator
modulator toto
a.a. Cool
40For
orless.
less.The
Themodulator
modulator can
canbe
be
40F
cooledby
byspraying
sprayingwith
withliquid
liquidR-12
R-12
cooled
refrigerant and
and aa ZRE-6271
ZRE-6271 can
can
refrigerant
adapter or
or equivalent.
equivalent. Allow
Allow
adapter
sufficient
sufficient time
time for
for the
the modulator
modulator
temperature to
to stabilize
stabilize and
and the
the
temperature
modulator valve
valve to
to close.
modulator
close.
CAUTION: DO
DO NOT
NOT COOL
COOL
CAUTION:
THE COLD
C O L D WEATHER
WEATHER
THE
MODULATOR WHILE
WHILE THE
THE
MODULATOR
ENGINE IS
IS RUNNING.
RUNNING. IF
IF R-12
R-12
ENGINE
REFRIGERANT IS
IS DRAWN
DRAWN
REFRIGERANT
INTO THE
THE CARBURETOR
CARBURETOR
INTO
WHILE THE ENGINE IS
IS
POISONOUS
RUNNING, POISONOUS
PHOSGENE GAS
GAS WILL
WILL BE
BE
EXHAUSTED INTO
INTO THE
THE TEST
TEST
EXHAUSTED
AREA. CONDUCT
CONDUCT THIS
THIS
AREA.
PROCEDURE ONLY
ONLY IN
IN A
PROCEDURE
A
WELL VENTILATED
VENTILATED AREA.
AREA.
WELL
b. AA 24-inch
24-inch length
length of
of 1/4-inch
1/4-inch ID
ID
b.
vacuum hose
hose should
should be
be used
used
vacuum
between the
the cold
cold weather
weather
between
modulator and
and the
the vacuum
vacuum gauge.
gauge.
modulator
Using an
an external
external vacuum
vacuum source,
source,
Using
apply aa minimum
minimum of
of 16
16inches
inches Hg.
Hg.
apply
to the
the va~uum
vacuum motor
motor side
side of
of the
the
to
m o d u l a t o r and
and trap.
t r a p . The
The
modulator
modulator must
must hold
hold atat least
least 55
modulator
inches Hg
Hg vacuum
vacuum for
for 30
30 seconds,
seconds,
inches
otherwise, replace
replace the
the modulator.
modulator.
otherwise,
Warm the
the modulator
modulator toto 70F
70F or
or
c.c. Warm
above. The
The modulator
modulator should
should oot
not
above.
hold vacuum
vacuum atat or
or above
above this
this
hold
temperature.IfIfthe
themodulator
modulator does
does
temperature.
notfunction
function asasindicated,
indicated,ititmust
mustbe
be
not
replaced.
replaced.

24-42-3
AUXILIARY AIR INLET VALVE
In addition to checking the duct and
valve assembly, the vacuum motor that
is attached to the air cleaner should be
checked for functional operation.
1.
1. Start the engine, observe the vacuum
motor plate. It should be fully closed
(Fig. 4).
24-42-3
Air Cleaner Duct Systems

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.
2. Disconnect the vacuum hose at the

vacuum motor. The plate should be
in the full-open position.
3. If
If the positions as described, are not
obtained, check for interference and
alignment of plate and motor rod and
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.
If the vacuum motor plate still
4. If
remains in one position, remove the
vacuum motor from the air cleaner,
connect it to another vacuum source
connect
to confirm that vacuum motor is not
If the motor rod does not
operating. If
move when vacuum is applied, the
motor should be replaced.
5.
5. Reassemble the motor to the air
cleaner and repeat Steps 1 and 2.
AUXILIARY AIR INLET VALVE AND

VACUUM MOTOR ASSEMBLY
APPENDIX "A"
Vacuum Motor Test

Vacuum
1.
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.
If duct valve door remains open,
replace vacuum motor. If
If door closes,
proceed to Step 4.
B31698
B3169-B
and Vacuum
Vacuum Motor
FIG. 4 Air Cleaner With Auxiliary Air Inlet Valve and
AND INSTALLATION
REMOVAL AND
DUCT AND VALVE ASSEMBLYTEMPERATURE OPERATED
Removal
Removal
1. Remove the hex-head cap screws that
1.
secure the air intake duct and valve
assembly to the air cleaner.
2. Remove the air intake duct and valve
assembly from the engine.
3. If the duct and valve assembly was
removed because of a suspected
temperature malfunction, check the
operation of the thermostat and valve
plate assembly. Refer to the DUCT
A N D VALVE
VALVE ASSEMBLYASSEMBLYAND
VACUUM OPERATED for the
proper procedure.
4. If inspection reveals that the valve
plate is sticking, correct any sticking
or binding
binding conditions.
c o n d i t i o n s . If
If the
the
BACK TO GROUP INDEX
thermostat is malfunctioning,
thermostat
malfunctioning,
unscrew it from
from the mounting
mounting
bracket.
Installation
1.
1. Install new thermostat to mounting
bracket in duct, if removed. Check the
operation of the new thermostat.
Refer to DUCT AND VALVE
Refer
ASSEMBLY-THERMOSTAT OPASSEMBLYTHERMOSTAT
ERATED for proper test procedure.
2. Install the air intake duct and valve
assembly on the shroud tube.
3. Connect the air intake duct and valve
assembly to the air cleaner and
tighten the 2 hex-head retaining cap
screws.
4. Install the vacuum override motor (if
(if
applicable) and check for proper
operation.
DUCT AND VALVE ASSEMBLYVACUUM OPERATED
Removal
Removal
1.
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.
3. Remove the duct and valve assembly
from the engine.
Installation
1.
1. Position the duct and valve assembly
to the air cleaner and heat stove tube.

Install the attaching cap screws.
2.
2. Connect the vacuum line at the
vacuum motor.
24-50-1
24-50-1
24-50-1
Fuel Tanks and Lines

lines
PART 24-50 Fuel Tanks and Lines

Applies To All Models
COMPONENT INDEX
DESCRIPTION AND OPERATION
OPERATION
Fuel
Fuel Tanks and
and Fillers
Double Locking Fuel Cap
Cap
Fuel
Fuel Vapor Emission
Control System
Auxiliary Fuel
Fuel Tanks
Page
.
.
50-1
50-1
.
.
50-1
50-3
COMPONENT INDEX
Page

INSTALLATION
Fuel Cap
Auxiliary
Auxil iary Fuel Tanks
Fuel Tanks
Auxiliary
Au xii ia ry Fuel Tanks
Tan ks
Fuel Lines
SPECIFICATIONS
SPECIFiCATIONS
.
.
50-8
50-8
.
.
.
.
50-9
50-9
50-9
50-38
NOTE:
Inodel year vehicles unless otherNOTE: The information in this Part applies to both 1975 and 1976 model
wise specified.
specified.
CR1966A
CR1966-A

FUEL
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. I).
1).
The restrictor consists of a narrow
opening in the filler covered by a trap
door held in position by a helical spring.
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
and
closed causes a fuel back-up, and
shutoff.
automatic nozzle shutoff.
The restricted fuel filler is serviced as
an assembly, and cannot be repaired.
filler
Tank capacity is limited by the filler
control tube or the position at which the
filler tube enters the tank, depending on
model. During filling, fuel vapors and air
are vented through the filler neck or
tube. When the fuel covers the
control tube.
filler control tube or filler neck, a dead
air space is created in the top of the tank.
This will cause a backup in the filler neck
shutoff.
and cause automatic shutoff.
FUEL CAP
DOUBLE LOCKING FUEL
A double set of locking tangs or tabs
fuel
are used on the pressure/vacuum fuel
cap. These tangs require a two stage
removal/installation procedure and
removal/installation
residual
provide for escape of any residual
pressure in
in the
the system
system during
during cap
cap
pressure
removal. This
This system
system is
is also
also used
used with
with the
the
removal.
optional locking-type fuel cap. Whenever
BACK TO GROUP INDEX
a fuel cap is replaced, it should be

replaced with the proper pressure relief
relief
double locking cap to prevent possible
malfunction (Fig. 1).
system malfunction
I).
FUEL VAPOR EMISSION
CONTROL SYSTEM
of the fuel system, all
As a part of
passenger cars are equipped with fuel
evaporative emission control systems to
effect at the
meet federal requirements in effect
time of production.
operation are
System control and operation
accomplished through four separate basic
functions in the system which are:
a. Fill Control Vent System
b. Tank Vapor Vent and Storage
System
Pressure and Vacuum
Relief
c. Pressure
Vacuum Relief
System (fuel cap)
d. Fuel Vapor Return System
Fill Control Vent System
Fill
Fill limiting is accomplished through
configuration and/or
and/or internal
fill neck configuration
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
Venting
In-Tank Venting
This system provides a vapor space
above the gasoline surface in the fuel
sufficient to permit
tank. This area is sufficient
adequate breathing space for the tank
vapor separator
separator assembly under all static
most
aand
nd m
o s t ddynamic
y n a m i c conditions.
conditions.
Horizontally mounted
mounted tanks accomplish
Horizontally
this by a raised mounting section for the
separator assembly that is centrally
vapor separator
of the tank.
surface of
located on the upper surface
Vertically mounted tanks use a centrally
mounted vapor separator
separator assembly on
mounted
surface of
of the fuel tank.
the uppermost surface
Tank Vapor Separator
(Orifice)
Separator (Orifice)
Assembly
Assembly
All fuel tank vapor separators make
use of
of a small orifice
orifice that tends to allow
only vapor and not fuel to pass into the
forward to the vapor storage
line running forward
canister. For 1975 this assembly mounts
directly to the fuel tank using the same
type cam lock ring as the fuel sending
unit.
A second
second type
type separator
separator used
used in
in 1975
1975
A
and
1976
consists
of
a
plastic
90
degree
and 1976 consists of a plastic 90 degree
elbow, in
in some
some cases
cases containing
containing aa float
float
elbow,
mounts
in aa
(Fig.
10).
This
assembly
(Fig. 10). This assembly mounts in
of the
the fuel
fuel tank.
tank. The
The
rubber flange
flange on
on top
top of
rubber
is
removed
or
installed
in
the
assembly
assembly is removed or installed in the
same manner
manner that
that aa PCV
PCV valve
valve is
is
same
removed
or
installed,
with
certain
removed or installed, with certain
precautions.
precautions.
Carbon
Carbon Canister
Canister
vapor separated
separated by the
Fuel tank vapor
orificed vapor
vapor separator
separator is
is stored
stored in
in aa
orificed
carbon-filled
canister
located
in
carbon-filled canister located in the
the
engine compartment
compartment (Fig.
(Fig. 2).
2).
engine
Pressure and Vacuum Relief
Relief
System
Sealed
Sealed Fill Cap
The fill cap is a sealed cap with a built
in pressure-vacuum
pressure-vacuum relief
relief valve. Fuel
24-50-2
24-50-2
FUEL CAP
CAP ASSEMBLY (9030)
TWO
TWO STAGE REMOVAL
REMOVAL
FUEL
FUEL FILLER
FILLER PIPE
PIPE (9034)
(9034)
WITH
WITH RESTRICTED
RESTRICTED OPENING
OPENING
PIN-RIVETED IN POSITION
AFTER ASSEMBLY OF
DOOR AND SPR
ING
SPRING
SPRING
. --J
fJ
SPECIAL UNLEADED FUEL NOZZLE

FITS THROUGH RESTRICTED
FILL PIPE AS SHOWN
ELLIPTICAL SHAPED
OPENING
DOOR
VIEW
A
V2115-A
FIG. 11 Restricted Fuel

Fuel Tank Filler Opening and Double locking
Locking Fuel Cap
FIG.
system vacuum relief is provided after

after
negative 00 to 1/4 PSI and pressure
1.8
relief from 3/4 to 1-1/4 PSI (over 1.8
systems). NOTE:
NOTE: 1976
PSI on 1976 systems).
are identified with aa number
number
fuel caps are
"50" stamped inside and
and aa silver"50"
and camcup.
camcup. They are
colored valve and
not interchangeable with 1976 fuel
caps. Under
Under normal
normal operating
operating condicondicaps.
tions, the
the fill
fill cap
cap operates
operates as
as aa check
check
tions,
valve, allowing
allowing air
air to
to enter
enter the
the tank
tank as
valve,
as
gasoline is
is used,
used, while
while preventing
preventing
gasoline
vapors from
from escaping
escaping the
the tank
tank through
through
vapors
the cap.
cap.
the
System
Fuel Vapor Return System
A fuel vapor return system has
has been
A
to certain engines to reduce the
added to
amount of fuel vapor entering the
carburetor.
FROM TANK
FROM
The system consists of a fuel vapor

separator installed in the fuel supply tube
between the pump and carburetor and a
one-piece vapor return line from the
(Figs. 3 and
and 4).
4).
separator to the fuel tank (Figs.
Fuel vapors are collected in the separator
and routed to the fuel tank where they
recondense or are contained by the
evaporative emission control system.
OPERATION
Fuel vapors trapped in the sealed fuel
tank are vented through the orificed
vapor separator assembly in the top of the
The vapors leave the separator
tank. The.
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
to the engine
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.
RETURN LINE'
TO
CARBURETOR
VAPOR SEPARATOR
GA UGESE N0 IN GUN I T
CANISTER
V1619-A
FIG. 22 Typical Canister

FIG.
BACK TO GROUP INDEX
V1617-B
Line Vapor Separator

FIG. 3 Supply line
V
1618-A
V1618-A
FIG. 4 Fuel Return Line

line Connections
At Sender Unit
24-50-3
24-50-3
Fuel Tanks
Tanks and
and Lines
lines
Fuel
24-50-3
24-50-3
DIAGNOSIS
DIAGNOSIS
Physical damage,
damage, leaks,
leaks, and
and missing
missing
Physical
items are
are the
the major
major answers
answers to
to diagdiagitems
problem for
for emission
emission system
system
nosis problem
nosis
malfunctions. Fill cap damage or conmalfunctions.
tamination that
that renders
renders the
the pressurepressuretamination
vacuum valve
valve inoperative
inoperative may
may result
result in
in
vacuum
deformation of
of the
the tank.
tank. Care
Care should
should
deformation
always be
be exercised
exercised to be
be sure that
that aa
proper
proper fill
fill cap
cap (in
(in working
working order)
order) is
is
used.
used.
separator, fill
fill vent tube connector
connector and aa
restraining strap and hose clamps to
complete the system between the fill
opening
opening and
and the
the main
main tank. The
fuel/vapor
fuel/vapor separator
separator is connected to the
carbon cannister. The fill vent tube
connector
connector is attached
attached to another
connector in the main tank. A unique
retaining strap is also used on Mustang
auxiliary tanks. When the bolt is tight,
the strap is properly positioned.
positioned.
Single
fuel/vapor
Single orifice
orifice push
push in fuel/vapor
separators are located on top of
of auxiliary
tank with a line leading to the carbon
canister. Fill limit vent tubes from the
main tank
tank to the upper
upper filler
filler pipe
complete the interconnecting parts of the
system. Two exceptions to the above are:
(1) on station wagons, an additional hose
is required between thefill
fill limit vent tube
and the auxiliary tank and; (2) on sedans,
a fuel tank drain line connects from the
bottom of the auxiliary tank to the lower
portion of the main tank. Both the sedan
and station
station wagon models use a
restraining
restraining strap
strap similar
similar to
to those
those used
used on
on
main fuel tanks. This strap, which goes
directly over the fuel tank, attaches the
tank to the tray assembly. The strap is
tightened
tigh tened by
by use
use of
of aa nut
nut and
and bolt
bolt
assembly
specific
assembly that
that requires
requires aa specific
dimension between
between the
the strap
strap and
and bolt
dimension
bolt end
end
to assure
assure proper
tension. The
The protective
protective
to
proper tension.
cover is
is screwed
screwed to
to the
the tray
tray assembly
assembly and
cover
and
the tray
tray assembly,
assembly, in
in turn,
turn, is
is bolted
bolted to
to the
the
the
vehicle.
vehicle.
AUXILIARY FUEL TANKS

AUXILIARY
the
On all Mustang II equipped with the
V~8 engine, a separate auxiliary
302 CID V-8
fuel tank is required (see Fig. 5). Ford,
Mercury and Lincoln Continental sedans
wagons
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
ofTer auxiliary fuel tanks as an option.
offer
Auxiliary fuel tank locations are
dependent on car line or body type. Ford,
Mercury and Lincoln Continental sedans
have auxiliary fuel tanks located in the
compartment to the left of the
luggage compartment
spare tire well (Fig. 6), whereas station
wagon auxiliary tanks located behind
the left rear trim panel in the cargo area
(Fig. 7). Mustang vehicles have the
auxiliary tank located in the left rear
wheelhouse behind the tire and metal
splash shield.
Component parts required with
Mustang auxiliary fuel tanks include an
upper filler pipe with rubber seal,
seal, lower
filler
filler pipe
pipe with
with hose
hose connection
connection between
between
the auxiliary tank and pipe, a vapor
BACK TO GROUP INDEX
Ford,
Ford, Mercury
Mercury and
and Lincoln
Continental
Continental auxiliary
auxiliary fuel
fuel tank
assemblies require a somewhat more
complicated list of components due to
their location in the vehicle. These
vehicles have the tank completely
enclosed in a cover and tray assembly
in addition to a three piece filler pipe
assembly that utilizes two rubber hose
sections and an intermediate "Y" pipe.
Rubber seals are used between the
protective cover and wheelhouse openA drain in the tray allows for
ing. A
possible gas leakage to drain directly to
to
the ground.

24-50-4
24-50-4
LINE TO MAIN
TANK VAPOR
SEPARATOR
FUEL
FILLER
TUBE
LINE TO EVAPORATIVE
EVAPORATIVE
EMISSION SYSTEM
CANISTER
VAPOR SEPARATOR -----_~~~~~~
FUEL
CAP
MAIN TANK
INLET NECK
AUXILIARY FUEL TANK

(4 GALLONS)
RUBBER
HOSE
TANK
RETAINING
STRAP
STRAP
RETAINING
SCREW
AUXILIARY TANK
TANK
MAIN TANK
V1939-A
V1939-A
FIG. 55 Fuel
Fuel and
and Vapor Emission
Emission Control System-Mustang
SystemMustang W
W/302
FIG.
1302 CID V-8
V-B or Optional Installation of Auxiliary Fuel
Tank(1975)
Tonk
(1975)
BACK TO GROUP INDEX

24-50-5
24-50-5
Fuel Tanks and lines

Lines
LINE TO EVAPORATIVE,
EMISSION SYSTEM
CANISTER
VAPOR SEPARATOR
- 9B593
LINE TO MAIN
TANK VAPOR
SEPARATOR
FUEL
FILLER
TUBE-9B138
FUEL
CAP9030
------I
----RUBBER
HOSE
STRAP
RETAINING
SCREW
AUXILIARY TANK
MAIN TANK
V1939-C
v-a
Fuel and Vapor Emission Control System-Mustang

SystemMustang with 302 CIO
CID V-8 or Optional Installation of Auxiliary Fuel
FIG. 6 Fuel
Tank (1976)
BACK TO GROUP INDEX

24-50-6
24-50-6
24-50-6
Tanks and Lines

Fuel TQnks
381136-S080A
STRAP - 95873-S
FUEL VAPOR LINE

-9B228REF.
VIEWZ
MAIN VIEW
BRACKET-9A108
BRACKET
- 9A108
(LINCOLN)
(L1!'JCOLN)
SLEEVE -- 99A151
A151
AUXILIARY
AUXILIARY TANK
ASSY. - 9B160
ASSY.-9B160
~~_/~
55908-S36M
4REQ'D.
TORQUE 25-30 IN-LBS
9B593
VAPOR SEPARATOR - 98593
9B175
98175
AUXILIARY
AUXILIARY FUEL TANK
1.83
COVER REINFORCEMENT
-9B187
STRAP - 9092
2
R EQ'D.
2REQ'D.
CLAMP CLAMP 9002

386539-S320
386911-S
386844-S101
4 REQ'D.
TORQUE NIPPLE 15-22 FT-LBS
HOSE-381123-S035A
MUST NOT LEAK.
DRAIN HOSE FROM
AUX. TANK - 9B172 REF.
55914
4 REQ'D.
FILLER P I P E 9034
386196-S100
4 REQ'D.
TORQUE
12-18 FT-LBS
FILLER PIPE - 9 0 3 4
WITH (9B176) DECAL
FOR ALL CANADIAN USAGE.
VIEWZ
V2116B
V2116-B
W/Auxiliary
FIG. 7 Fuel and Vapor Emission Control SystemFord,
System-Ford, Mercury and Lincoln Continental Sedan W
/ Auxiliary Fuel Tank
BACK TO GROUP INDEX

24-50-7
24-50-7
24-50-7
lines
381136-S080-A
381136-S080-A
STRAP
STR AP - 95873-S
9A228
AUXILIARY
FUELTANK
AUXILIARY FUEL
TANK
ASSEMBLY-9B160
ASSEMBLY - 9B160
VIEWZ
FUEL C A P - 9 0 3 0
FILLER PIPE
P I P E-- 9034 WITH k
(9B176) DECAL
FOR ALL
ALL
DECALFOR
CANADIAN USAGE.
FILL VENT TUBE

N276
- 99N276
FILLER PIPE
-9034
AUXILIARY FUEL
FUELTANK
AUXILIARY
TANK
ASSEMBLY
- 9B160
ASSEMBLY-9B160
VAPOR SEPARATOR
B593
--(REF.)
(REF.) -- 99B593
1.831.50 AFTER
TIGHTENING
CLAMP - 386911-S
TOROUE SCREW
15-20 IN-LBS
~~/'
~ ~ 386196-S100
'lllt:~=::::;~~
2 REO'D.
TOROUE
12-18 FT-LB
353538-S
4 REO'D.
1--
386910-S
2 REQ'D.
TORQUE SCREW
15-20IN-LBS
STRAP - 9092
9092
22 REO'D.
REQ'D.
MAIN FUEL
FUEL TANK
T A N K-- 99062
062
MAIN
55908-S36M
55908-S36M
REQ'D.
44 REO'D.
25-30
25-30 FT-LB
FT-LB
DRAIN
- 9B172
DRAIN HOSE
HOSE-9B172
386196-S100
2 REQ'D.
TORQUE
12-18 FT-LBS
RETAINER
RETAINER -- 99109
109
VIEW
VIEWZ
V2117B
V2117-B
FIG.
/ Auxiliary Fuel
FIG. 88 Fuel
Fuel and
and Vapor Emission
Emission Control
Control System-Ford
SystemFord and
and Mercury Station
Station Wagon W
W/Auxiliary
Fuel Tank
BACK TO GROUP INDEX

24-50-8
lines
24-50-8

All component parts of the standard
fuel system are serviced by a simple nut,
bolt, or screw part removal and
installation.
installation. Refer
Refer to
to individual
individual systems
systems
drawings
drawings for
for specific
specific part
part references.
references.
FUEL CAP
REMOVAL/INSTALLATION
To remove the fuel cap:
1.
1. Rotate the cap approximately
approximately
one-third turn counterclockwise to
allow the first
first set of tabs to clear the
slots inside the filler
filler pipe.
2.
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.
filler pipe and
1. Place the cap on the filler
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.
Caution must be used during removal
of auxiliary fuel tanks on Ford/Mercury
and Lincoln Continental vehicles to
prevent fuel spillage inside the vehicle
as a certain amount of fuel is apt to
remain in the auxiliary tank after
after the
bulk of
of the fuel in the system has been
removed. Mustang vehicles will require
care during au
xiliary tank removal to
auxiliary
ensure 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 (Ford/Mercury
sedans and Lincoln Continental below
the drain pipe) by disconnecting the
fuel sending unit hose at the point
where it connects to the fuel line
leading to the fuel pump.
pump..
Mustang (See
(See Figs.
Figs. 55 and
and 6)
6)
Mustang
Removal
RemoyaJ
1. Siphon or pump out the auxiliary fuel
1.
tank.
2.
2. Remove the four screws holding the
filler
filler tube
tube toto the
the body
body sheet
sheet metal
metal atat
the fill
fill opening. Remove the filler
filler
tube.
tube.
3. Inside the left rear wheelhousing,
remove the four bolts holding the
inner splash panel that covers the
auxiliary fuel tank. Remove the panel.
4.
4. Disconnect the hose between the
main tank fuel sending unit and the
fuel line at the fuel line.
line. Drain a
sufficient
sufficient quantity of fuel to drop the
BACK TO GROUP INDEX
main tank level below the auxiliary

tank fill
fill pipe connection.
5. Loosen the two clamps that hold the
5.
rubber hose located on the filler
filler tube
between the auxiliary and main tank.
6.
6. Carefully
Carefully slide the rubber hose ofT
off the
auxiliary tank and downward on the
metal pipe attached to the main fuel
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
7.
auxiliary fuel tank retaining strap and
remove the strap.
8.
8. Lower the tank until the clamp
holding the boot to the fill
fill tube neck
of the auxiliary tank can be loosened
and the rubber boot removed.
9.
9. Continue to lower the tank until the
vapor separator (and fill
fill vent tube
connector-1976)
connector1976) can be disengaged from the top of the tank..
tank.
10. Remove
Remove the
the auxiliary
auxiliary tank
tank from
from the
the
10.
vehicle.
vehicle.
Installation
Installation
1.
fill
1. Install
Install the
the vapor
vapor separator
separator (and
(and fill
vent
the
vent tube
tube connector-1976)
connector1976) then
then the
fill
fill tube
tubeneck
neckrubber
rubberboot
bootusing
usingclamp
clamp
380153-S8.
38O153-S8. Be sure to correctly align
the locating notch in the boot with the
locating rib on the tank filler
filler neck.
Tighten the boot clamp and position
the tank in the fender well.
2.
2. Raise the tank sufficiently
sufficiently to install
the rubber boot to the lip of the filler
filler
tube opening in the quarter panel.
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
new
hose clamp.
5.
filler tube into the
5. Install the fuel filler
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
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.
Ford/Mercury and Lincoln
Ford/Mercury
Continental (See Figs. 7 and 8)
RemoyaJ
Removal
1.
1. Siphon or pump out the main and
auxiliary fuel tanks.
filler neck attaching
2. Remove the four filler
screws at the fill
fill pipe opening in the
left quarter panel.
3. Inside the left rear wheel opening,

locate the upper rubber hose in the
filler pipe assembly. Loosen the
retaining clamp that holds this hose
to the uppermost filler
filler pipe (9034) in
the assembly.
4. Loosen the nut holding the fill
fill limit
vent tube (9N276) to the filler
filler pipe
(9034). Separate the tube from the
(9034).
pipe. Station
Station Wagons Onlyfrom
Disconnect the hose leading from
the auxiliary fuel tank to the fill
limit tube (9N276) at the tube
connection.
5.
5. Pull the filler pipe (9034) upward
through the quarter panel opening
until the pipe and rubber connecting
hose are separated.
6. Locate the retaining clamp holding
6.
the lower (closest to main tank)
rubber hose to the "Y" filler
filler pipe
(9B 168) of the filler pipe assembly.
(9B168)
Loosen this clamp and separate the
hose from the "Y" pipe.
7.
filler pipe (9B168),
(9B 168),
7. Remove the "Y" filler
with the upper rubber hose attached,
from the auxiliary fuel tankfiller
filler pipe
opening and the vehicle.
vehicle. Special care
during "Y" pipe removal is necessary
on station wagons since the fuel
cannot be completely removed from
this auxiliary tank and spillage inside
the car is likely unless the pipe is
carefully.
removed carefully.
8.
8. Separate the auxiliary tank fuel
fuel
emission vapor line hose to tube
(9BI75)
(9B175) connection located on the
main f\,lel
fuel tank.
9.
9. Sedans Only-Disconnect
Only Disconnect the
the
auxiliary tank to main tank drain hose
at the main tank. Care should be
taken to prevent gas spillage should
the tanks not be completely drained.
10. Station
Station Wagons
Wagons Only-Disconnect
OnlyDisconnect
10.
the grommets holding the fill
fill limit
and fuel
fuel vapor
vapor hose to the
wheelhousing and push the drain hose
grommet (located in the body floor
floor
panel behind the left rear fender
panel) up into the vehicle.
11. Remove the four attaching nuts
holding the auxiliary tank assembly to
the body floor pan sheet metal
(sedans) or two floor
floor pan and two
inner sheet metal
wheelhouse inner
attaching nuts on station wagons.
12. Inside
Inside the
the luggage
luggage compartment
compartment
12.
(sedans) or the left rear trim panel in
the cargo area (station wagons),
remove the clamp attaching the
(9A159)
rubber sleeve (9A
159) to the auxiliary
fuel tank protective cover. Separate
the sleeve from the cover.
Carefully remove
remove the
the auxiliary
auxiliary fuel
fuel
13. Carefully
tank as a complete assembly. This
assembly will consist of the protective
24-50-9
cover, auxiliary fuel tank, tray
assembly, and connecting hoses.
NOTE: DURING THIS FINAL
NOTE:
THE FORWARD
FORWARDEND
END
REMOVAL THE
OF THE ASSEMBLY SHOULD
BE LIFTED
LIFTEDFIRST
FIRSTAND
AND
ALWAYS BE
H E L D IN
IN AN UPWARD
UPWARD
HELD
POSITION TO PREVENT ANY
POSSIBLE GASOLINE RESIDUE
IN THE TANK FROM BEING
S P I L L E D INSIDE
I N S I D E THE
THE
SPILLED
VEHICLE. ANY SPILLS MUST
BE THOROUGHLY CLEANED
PREVENT GASOLINE
GASOLINE
TO PREVENT
ODORS IN THE CAR.
14.
14. On
On the
the bench,
bench, remove
remove the
the screws
screws
holding the protective cover to the
tray assembly and remove the cover.
On station wagons a grommet
holding the vapor line and vent tube
hoses to the cover must be removed
prior to removing the protective
cover.
15.
15. With
With the
the protective
protective cover
cover removed,
removed,
the auxiliary fuel tank retaining strap
holding the tank to the tray assembly
must be removed to complete the tank
removal procedure.
Instal/ation
Installation
1.
1. Install the fuel tank to the tray
assembly using the retainer strap.
This strap must be tightened to
specification.
2. Install the fuel/vapor
fuel/vapor separator and
2.
be sure the hoses attached to the tank

are securely attached and correctly
routed. Install the protective cover
over the fuel tank and attach to the
tray making sure the gasket is
properly positioned and the attaching
wagons, the
screws seated. On station wagons,
grommet holding the vapor hose and
fuel fill limit hose must be installed to
the protective cover after the cover
installation.
3. Position the complete tank assembly
in position in the vehicle and tighten
the four
four attaching
a t t a c h i n g nuts
n u t s to
specification. On sedans, the drain
hose to the main tank must be routed
through the floor pan and over the
frame inboard to the main tank. Be
sure the hose also routes behind the
body mount. On station wagons,
wagons, the
tray drain tube must be pulled
through the floor pan and the
grommet properly attached. A string
or wire should be attached to the
lower end of the drain hose and fed
through the hole in the bodyfloor
floor pan
before the tank assembly is installed.
After the tank assembly is installed,
the string (or wire) can be used to pull
the hose through the hole in the floor
floor
pan from under the vehicle.
4.
159) to
4. Attach the rubber sleeve (9A
(9A159)
the protective cover with the hose
clamp. The vapor vent hose and the
clamp.
station wagon fill vent hose must be
properly
routed through
through the
properly routed
24-50-9
wheelhouse openings either through
the grommet and seat grommet in
wheel house opening (station wagons)
or rubber sleeve and retainer 9B174
9B 174
(sedans).
(sedans).
5.
168) to the
5. Assemble the "Y" pipe (9B
(9B168)
auxiliary tank and then install the
lower rubber hose (leading to the
main tank) to the "Y" pipe.
pipe. Install,
but do not tighten the hose clamp.
6.
6. Push the upper fill pipe (9034)
downward until it can be installed on
the upper rubber hose attached to the
(9B168).
"Y" pipe (9B
168). Install the four
attaching screws to the fill pipe at the
fill opening in the quarter panel.
7.
7. Position the hose clamp and tighten
to specification along with the hose
clamp on the lower hose.
8.
fill limit
8. On Station Wagons, start fill
vent pipe (9N276) nut in upper fill
pipe (9034) fitting. Do not tighten
nut. Attach auxiliary fuel tank limit
hose to nipple on vent pipe (9N276).
fill
Tighten nut on vent pipe in upper fill
pipe (9034) fitting.
fitting.
9.
fill limit vent pipe
9. Attach the fill
pipe (9N276)
to the upper fill
fill pipe (9034) fitting.
10. Attach
Attach the
the fuel
fuel emission
emission vapor
vapor hose
hose
10.
(9B175)
to the vapor tube (9B
175) above the
main tank.
11. On
On sedans,
sedans, connect
connect the
the drain
drain hose
hose
from the auxiliary tank to the nipple
on the main tank using a new clamp.

TANKS
FUEL TANKS
Fuel emission type fuel tanks do not
require special repair procedures and
may be steam-cleaned and/or repaired
standard procedures. After
After
using standard
steaming, allow to thoroughly air dry.
separator assembly
The orificed vapor s.eparator
should be replaced, if found to be
damaged or inoperative.
AUXILIARY FUEL TANKS

Maintenance and repair consists of
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
using aa detergent
detergent solusoluaccomplished
tion to
to thoroughly
thoroughly flush
flush the
the tank
tank and
and
tion
clean water
water rinsing
rinsing until
until all
all detergent
detergent is
clean
is
removed. The
The tank
tank must
must be
completely
removed.
be completely
dry prior
to re-installing
re-installing in
in the
the system.
system.
dry
prior to
BACK TO GROUP INDEX
AUXILIARY FUEL TANKS MUST

NOT BE STEAM CLEANED OR
TO EXTREME HEAT OF
EXPOSED TO
ANY KIND.
FUEL LINES
Repair
Repair
With the exception of the pump-tocarburetor fuel supply tubes used in fuel/
vapor return systems (Fig.
(Fig. 9) the various
fuel lines are not serviced as assemblies.
They must be cut, squared and formed
VAPOR RETURN LINE
out of rolls of fuel system service tubing

material available
available at
and hose material
dealerships.
A damaged section of tubing longer
than 12
12 inches can be cut out of the
existing
existing line and replaced
replaced by a
comparable service tubing section,
spliced into the line by means of
of
clamps. A
A
connecting hoses and retaining clamps.
damaged section of tubing shorter than
12 inches can be cut out of the line and
12
replaced by a length of service hose and
two retaining clamps.
TO CARBURETOR
~TOFUELPUMP
TO FUEL PUMP
V1621-B
Fuel Supply Tube Assembly

FIG. 9 Fuel
24-50-10
All replacement hoses must be cut to
a length that will assure proper clamp
retention beyond the flared ends of the
connecting tubing.
Removal
Removal
1. Drain the fuel from the tank.
1.
2. Disconnect the line at the fuel gauge
sender
sender unit and the fuel pump.
Remove the lines from the holding
clips along the underbody. Remove
all damaged hose sections and tube
sections.
BACK TO GROUP INDEX
Fuel
lines
Installation
1. Cut a new section
section of
of tubing to
1.
approximately the same length as the
section to be replaced. Allow extra
length for flaring the ends of the
tubing. Square the ends of the cut
tubing with a file.
2. Ream the inside edges of the cut
tubing with the reamer blade on the
tube cutter. Be sure metal chips are
removed from inside the tube(s).
of the cut
Double flare the ends of
tubing, as required.
24-50-10
3. Bend the tube section to conform
conform to
the contour of the original tube. Cut
an ample length of hose to form a
coupling between the flared ends of
of
Connect the hose
the fuel lines. Connect
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
and the fuel pump. Fill the tank and
check for leaks.

24-50-11
24-50-11
24-50-11
24-50-11
Fuel Tanks and

and Lines
THESE VALVES PUSH

PUSH INTO POSITION IN A GROMMET-TYPE SEAL, LIKE A pcv
PCV VALVE.
SHARP OBJECTS MUST NOT BE USED BETWEEN THE TANK SEAL AND PUSH-IN SEPARATOR DURING REMOVAL OR INSTALLATION.
,......----- 1976---------,
1976-
----------------1975---------------1975
ORIFICE
ORIFICE
~~~~~
TO VAPOR
STORAGE
FLOAT
FLOAT
O~
,,,.,.,,.
SPRING
TYPICAL SECTION
VAPOR SEPARATOR VALVE WITHOUT
FLOAT VALVE
(FORD, MERCURY, MUSTANG, PINTO)
TYPICAL SECTION
VAPOR SEPARATOR VALVE WITH
MECHANICAL FLOAT VALVE
(TORINO, MONTEGO, COUGAR, RANCHERO,
THUNDERBIRD, MARK IV, LINCOLN)
TYPICAL SECTION
VAPOR SEPARATOR VALVE WITH
FLOAT VALVE AND INTERNAL SPRING
(ALL 1976 MODELS)
1976
-------------------1975--------------------1975'
IS LOCKED INTO THE TANK WITH A CAM-TYPE SEAL

THIS VALVE IS
TABS MUST BE
BE AGAINST
STOP AFTER ASSEMBLY
VAPOR SEPARATOR
ASSEMBLY
VAPOR SEPARATOR
POLICE VEHICLES
WITH ELECTRIC FUEL PUMP
FUEL TANK
TYPICAL SECTION
THROUGH VAPOR SEPARATOR
(SOME MAVERICK AND COMET ONLY)
V1780-C
FIG. 10
10 Vapor Separators
BACK TO GROUP INDEX

9002 ASSY. REF.

/2.8 L. FUEL PUMP REF.
98337
9B337 REF.
REF
VIEW IN CIRCLE N
L.H. SIDE ONLY SEDAN
L.H. &R.H.SIDE STATION WAGON
VlEWZ
VIEWZ
9B337
9B337 REF.
REF
INSTALLATION FOR
FOR 2.8
2.8 LITER
LITER ENG.
ENG.
A
INSTALLATION
9291 REF
9A228 REF.
REF.
.,~
9034 ASSY.
ASSY.
9034
9030 ASSY.
'~~
19-.
9076
FUEL
~_9291
VIEWU
SENDE~029'S32
ASSY. REF.
TYPICAL INSTALLA~TIO.N
/
.
MARKED*
.:~
REF.
~%:
1 ~383~2
VIEWX
_. 98337 REF.
9A228 REF.
HOSE MUST BE WITHIN

FUEL TANK DEPRESSION
~91REF
~~
VIEWY
VIEWY
1.87 AFTER
2.12 TIGHTENING
VIEW
VIEW SHOWING
SHOWING INSTALLATION
INSTALLATION
OF
OF FUEL
FUEL TANK INSULATOR
INSULATOR STATION
STATION WAGON
WAGON
TYPICAL
TYPICAL INSTALLATION
INSTALLATION MARKED
MARKED * *
>#
~l
.--::
9A228
--.
C
Q
INSTALLATION MARKED.
3 PLACES
1/
~,
.J
..
!
\)
:::J
VIEWR
Q.
Q_
383369-52
VIEWX
9C29~1
~.
384029-S2
383369-52
383369-S2
SAME AS
AS 2.3
2.3 LITER
LITER EXCEPT
EXCEPT AS
AS SHOWN.
SHOWN.
SAME
'"...I
oI
II
385766-S32 22 REQD.
REQD.
385766-532
~
~
9B328 REF
9A228 REF.
~384029'S2
)~:~
J
VIEWR
9B337 REF.
VIEWY
TYPICAL INSTALLATION MARKED.

381136-5080A
9B337 REF.
NOTE:
NOTE:
FUEL RETURN
RETURN LINE (98337)
(9B337)
FUEL
NOT USED
USED ON
ON 2.8
2.8 LITER ENGINE
NOT
ESE-M2C96-B. SAE-10W-30
SAE-10W-30 ENGINE
ENGINE OIL
OIL
eESE,M2C96-B,
MAY 8E
BE USED
USED AS
AS AN
AN ASSEMBLY
ASSEMBLY AID
AID
MAY
FOR ASSEMBLY
ASSEMBLY OF
OF FUEL
FUEL HOSE
HOSE ON
FOR
ON
TUBES NO
NO OTHER
OTHER MATERIAL
MATERIAL MAY
MAY BE
TUBES
BE
USED.
USED.
* INSTALL
INSTALL HOSE
HOSE ON
ON TO
TO TU8E
TUBE .62
.62 MIN.
MIN.
CLAMP MUST
MUST BE
BE ON
ON HOSE
HOSE AND
AND FLUSH
FLUSH
CLAMP
TO 1/8"
1/8" FROM
FROM END
END OF
OF HOSE.
HOSE.
TO
HOSE TO
TO SECOND
SECOND BEAD OF
OF TUBE
INSTALL HOSE
CLAMP MUST
MUST BE
BE ON
ON HOSE
HOSE AND
AND FLUSH
FLUSH TO
TO
CLAMP
1/8"
FROM
END
OF
HOSE.
118" FROM END OF HOSE.
\ ...J I
9B058 ASSY. REF.
~;
---
4'B~AFTER
/~~.2.'2
TIGHTENING
9092 ASSY.
~
to
I
VIEWB
STATION WAGON ONLY
VIEWT
VIEW
V
VIEWV
11 Fuel and
and Vapor Emission Control SystemsPinto/Bobcat
FIG. 11
Systems-Pinto/Bobcat Sedan and
and Station Wagon
Wagon (1975)
BACK TO GROUP INDEX
t'"
~
VIEW IN
IN CIRCLE
CIRCLE P
P
VIEW
R.H. SIDE ONLY SEDAN
V2118-A
V2118-A
...ioo
I

~:;~R)tLlNEiii~~';;'-s2
~~6~~~100
VAPOR L I N E 9A228
"'~
Q
SCREW55914-S36M
WITHOUT
~I~~URN
;_._',
_.
FUEL L1NE-
~:::R
SUPPORT STRAPSTRAPSUPPORT
9092
9092
:-::..~
9C29~1,~~)
S/!~
... J
----::::
~SCREW-
s"
~f~~;~3;~E_~291
J
(3
SCREW55914-S36M
.J-----~8~~~:~S100~"
CLAMP380882-S100
2REQ/D.
~\
TUBINGTU8ING-
~",~"",
'k
~;V~
o(7{J
\.~~
WITHOUT
WITHOUT VAPOR
VAPOR
RETURN LINE
VIEW
VIEW Z
Z
FUEL RETURN
LINE-9B337
VIEW SHOWING INSTALLATION

OF FUEL TANK INSULATOR
VAPOR L I N E 9A228
CLAMP 385766-S2
(2 REQ'D )
CLIP384029-S2
SCREW55914-S36M
CLAMP 380882-S100 * ^
o
~
a.
|g
TUBINGTUBING381136-S120A
381136-S120A
FUEL RETURN
LINE-9G291
TYPICAL
TYPICAL OF
OF ALL
ALL
INSTALLATIONS
INSTALLATIONS
OIL
COOLER
LINES
VIEW
W
VIEW W
ESE-M2C96B.
ESE-M2C96-B, SAE10W30
SAE-10W30 ENGINE
ENGINE OIL
OIL
MAY
MAY BE
BE USED
USED ON
ON 9034
9034 AND/OR
AND/OR 9072
9072
AS
AS AN
AN ASSEMBLY
ASSEMBLY AID.
AID. NO
NO OTHER
OTHER
MATERIAL
MATERIAL MAY
MAY BE
BE USED.
USED.
FILLER
FILLER TUBE
TUBE
-9034
9 034
MAIN VIEW
FUE
L CAP
FUEL
C A P_.9030
55882-S2
2.3 LITER 4-CYL ENGINE
TUBING381138-S080A
FUELLINE9A084
VAPOR LINE 9A228
TUBING381136-S080A
CLlP384029
3 REO'O
GASKET~
FUEL LINE9291
VAPOR
VAPOR LINE
LINE - 9A228
9A228
SCREW55914-S36M
2.8 LITER
LITER V-6
V-6 ENGINE
ENGINE
2.8
SCREW 55914-S36M
~
~
I
VIEW
VIEW Y
Y
-9002
VIEW
VIEW VV
FIG.
FIG. 12
12 Fuel
Fuel and
and Vapor
Vapor Emission
Emission Control
Control Systems-Pinto/Bobcat
SystemsPinto/Bobcat Sedan
Sedan and
and Station
Station Wagon
Wagon (1976)
(1976)
BACK TO GROUP INDEX
CLAMP380882-S100
2 REQ'D.
9076
----~~
~~FUELTANK
VIEW X
TUBING381136-S080A
TUBE
TUBE TO
TO
CARBURETOR
~ /\:~}
'~\
'_
----~/
(2.3 LITER WAGON

WAGON SHOWN
SHOWN OTHERS SIMILAR)
SIMILAR)
0I
\~~~SCREW
G,
~.
~'
-- \ - ; / \
...
~~,"
'\.)
\,
VAPOR
VAPOR L1NELINE9A228
9A228~
U'I
oI
VC~.
WITH VAPOR
RETURN LINE
VIEW U
j9291
CLAMP-
~
~
~,
VAPO~~~~;~::;~~CES
97
FUEL
FUEL LINE
LINE
9291
8&O~
"
VIEW
VIEW T
T
FUEL
FUEL LINEL1NE9A0844
381138-S080A
~ \./'
~~381138-S080A
TUBING
TUBING -- ~;j
381136-S080A
381136-S080A
f/~l)
~~,-j[j( AI.
SEDAN -_ ONE
ONE PLACE
PLACE
SEDAN
WAGON _ TWO PLACES
WAGON
- TWO PLACES
VIEW IN
IN CIRCLE
CIRCLE N
N TAPE
VIEW
^.nnr. _
TAPEINSULATOR-9A068
ESB-M2G55-A
INSULATOR-9A068
ESB-M2G55-A
,
,', ,
',ESB-M2G149-A
ESB-M2G149-A
_
/- ~
2 REO'D.
~~
2 REQ'D.
SCREWFUEL L I N E 55914-S36M
FUEL L1NE55914-S36M
9A084
9A084
TYPICAL
MARKED*2PLACES
VAPOR SEPARATOR9B593
98593 \
~--r---
1.87 AFTER
AFTER
1.87
212TIGHTENING
1
~
2.12
TIGHTENING
NUT382802-S100
SHIELD-
/'
~c_~......---
--
---li
FUEL RETURN
RETURN
FUEL
L1NE-9G291
LINE-9G291
WITH
-, /
RETURN;JY!
LINE
...~
II . . . . . ~
Y
lih~-'
"-'"
CLlP-CLIP
383369-S2 CLIP
CLIP -383369-S2
384029-S2
/
384O29-S2
VAPOR
LINE
LINE
9A228
-- 9A228
FUEL
FUEL RETURN
RETURN
LIN E-9G291
U'I
V2118-B
V2118-B
oI
...
W

384672_S1001~
+.. . J
9291 REF.
9C327
9C327
384672-S100
9N04
9N04 ASSY.
ASSY. REF
REF.
~
~
383369-S2 2 REQD.
REaD.
9B337
383369-S
1.87 AFTER
1.87
UI
9B328
9291
9B337 REF.
...
oI
9A228 REF.
2.12 TIGHTENING
,;,..."'12.12
REaD.
383369-52 2 REQD.
383369-S2
VIEW IN CIRCLE C
C
VIEW
VIEWT
VIEWT
9291 REF
9B337 REF.
VIEWU
1.87 AFTER
2.12 TIGHTENING
VIEWY
382802-S100
384029-52
384029-S2
0
VIEW IN CIRCLE
CIRCLED
383369-52
98337 REF
9291 REF.
9A228 REF.
REaD.
384029-S2 2 REQD.
9291
9291
VIEWX
~'o(
9B337
9A228
~
J
o
~
Q..
9A228
REF.
9A228 REF.
385916-S2
385916-52
SECTION A-A
VIEWV
VIEWV
VIEWX
NOTE: FUEL RETURN LINE (9B337)

NOT USED ON
ON 2.8 LITER ENGINE
ESE/M2C9&B,
SAE 10W30
ESE/M2C96-B.SAE
10W3O ENGINE OIL
OIL
MAY BE
BE USED AS
AS AN ASSEMBLY AID FOR
ASSEMBLY OF
OF HOSES
HOSES ON
ON TUBES.
TUBES. NO
OTHER MATERIAL MAY BE
BE USED.
USED.
VIEWT
INSTALL
INSTALL HOSE
HOSE ONTO TUBE .62
.62 MIN.
MIN.
CLAMP MUST BE
BE ON HOSE AND FLUSH
TO 1/8" FROM END OF HOSE.
INSTALL
INSTALL HOSE
HOSE TO
TO SECOND
SECOND BEAD
BEAD OF
OF
TUBE CLAMP MUST BE
BE ON
ON HOSE AND
AND
FLUSH TO 1/8" FROM
FROM END OF HOSE.
HOSE.
9030
ESE-M2C96-B, SAE1OW30
SAE-10W30 ENGINE OIL
ESE-M2C96-B,
BE USED ON
ON 9034 ANDIOR
AND/OR 9072
MAY BE
AS AN A5SEMBL
ASSEMBLY
AS
Y AID. NO OTHER
BE USED.
MATERIAL MAY BE
9A228 REF.
9B337REF.~
9034 ASSY.
9291 REF
9291 REF.
9291REF'~
9B337 REF.
9N041 ASSY. REF
385916-52
385916-S2
383369-52
383369-S2
VIEWW
VIEW Z
9A228 REF.
*
**
V2119A
FIG.
/2.3 L Engine
FIG. 13
13 Fuel
Fuel and
and Vapor Emission
Emission Control Systems-Mustang
SystemsMustang W
W/2.3
Engine (1975)
BACK TO GROUP INDEX

SCREW-~
~.~
384672-S 100
(2 REO'D.)
Bf'1
1.87
12 AFTER
2
.
TIGHTENING
~
I
SCREW384672-S100
384672-S100
9092
APSUPPORT STR
STRAPSUPPORT
9092
382802~S100
NUT-
~
-r::I':.
~
*[t---1 ~~;~rGT:;
TUBING -
~i~~29S2
FUEL RETURN
LINE - 9 B 3 3 7
CLAMP 380882-S100
2 REO'D.
SCREW 55914-S36M
FUEL RETURN
LINE - 9B337
381138S\015A
NUT__
382802-S100VIEW IN CIRCLE 0
'"
~LJ
~ #
~
[J
//)~~~~.~
FUELPUMP
...j
9291
FUEL RETURN
VAPOR SEPARATORLINE-9B337
CLIP96593
I
383369-S2
FUEL L I N E 9291 REF.
u-\~~;;;
VIEW IN CIRCLE C
SCREW-
VAPOR L I N E 9A228
CLIP 383369-S2
FUEL LINE
~G--~
.....('fL J
382802-S100
CLAMP-
36-S080A
SUPPORT STR
STRAP- ............... 6
SUPPORT
9N041
AP'AI.
9N041
NUTNUT382802-S100
385766~S32
TUBING _
3811
ENING
~~ ~
~ ~
380882~';100~
CLAMP
2 REO'D
..
383369-S2
*- .
@z-
TUBING
"\!J
FUEL RETURN
VIEWY
(2 REQ'D )
TUBING
381136-S040A
~':
~~~;;~~6~040A
CLIP _
VIEWT
CLAMP 385766-S2
385766-S2
CLAMP
(2 REQ'D.)
~~NEEL~~~T)r-~3~N9
FUEL RETURN
3337
LINE-9B337
FUEL TANK
9002
-
FUE
L LIN
FUEL
LINE 9291
.291
Nfr-
VIEWS
EVAPOR
VAPOR
LINE
LINE
-- 9A228
9A228
Q
7T
VAPOR LlNEVAPOR
LINE9A228
FUEL L1NELINE9A228
9291
9291
(I
CLlPCLIP385916-S2
385916-S2
SECTION A-A
A-A
SECTION
I
)
VIEW X
VIEW
X
VIEWX
I ESE-M2C96-B,
ESE-M2C96-B,
SA E -10W30 ENGINE
MAY
BE USEDSAE-10W30
ENGINE OIL
I. MAY
USED ON 9034 AND/OR
AS ANBE
ASSEM
ANDIOR 9072
01 L
.,MATERIAL
AS AN ASSEMBLY
AID. NO OTHER
8LYAID.NOOT
9072
MAY BE USED.
HER
I MATERIAL MAY BE USED.
VAPOR
VAPOR LINELINE
* INSTALL
HOSE
TUBE .62 MIN.
INSTALL
HOSE ONTO
CLAMP
MU
ONTOHOSE
TUBE
CLAMP
FLUSH
BE ON
ON HOSE AND MIN.
TO 1/8"MUST
FRST BE
OM END
TO 1 / 8 " FROM
END OF
OF HOSE
HOSE. D FLUSH
A~2
.INSTALL
INSTALL HOSE
TO SECOND BEAD
OF
H
.
TUBE CLAMP MUST BE ON HOSE AND
FLUSH TO 1/8" FROM
END
OF
HOSE.
OM END OF
D
;~~;HCi~~~:~~~TS~~~%[)H~ES~DA~F
ESE/M2C96-B SAE
SA 10W30 ENGINE
HOSE.
ESE/M2C96-B,
OIL
MAY BE
BE USED
uSED ASEAN
10W30
ENG IN AID FOR
MAY
ASSEMBLY
ASSEMBLY
ASANASSEM
EOIL
ASSEMBLY
OF
HOSES
ON
TUBES.
NO
NO
O
OTHER MAT : HOSES ON
AID FOR
OTHER MATERIAL
RIAL MAY
MAY BE
BE USED.
USED.
TU~~~
FIG. 14 Fuel and
9A228
9A228
~
.~
:J~~
/
FUEL LlNE-
FUEL LINE9291 REF

9291 REF.
:6
FUEL RETUR
FUEL RETURN
LINE-9B337
LlNE-9B337 N
~\
CLlP385916-S2
CLIP /384029-S2
l ' '!ffIl
~br::>
~
8"
'
'"
VAPOR LINE
LIN - , .
VAPOR
9A228
E9A228
FUEL FILLER
TUBE-9034
FUEL LINE9291
FUEL RETURN
LINE-9B337
STRAP -9N041
VIEWV
VIEWV
CLIP - 384029-S2
CLIP
CLIP _ 383369
-S2
CLIP-383369-S2
VIEWZ
VIEWZ
VAP
OR LINE
U N E
^9A228
- 384029-S2
"-
V2119-B
V2119-B
VIEWW
FIG. 14 Fuel and Vapor

(1976)
Engine (1976)
Vapor Emissions
Emissions Control
Cantral SystemsMustang
Systems-M ustang W/2.3L
W/2 .3l Engine
BACK TO GROUP INDEX

384672-S100~
REF'j~
384029-52
2 REO'D.
UtI
384672-S100.
REO'D.
22REQ'D.
1.87 AFTER
9N04ASSY.
9N04
ASSY. REF
.,.
o
...
~
384029-S2
384029-52
..............11'S7 AFTER
TIGHTENING
f~
2.12 TIGHTENING
0-
Y
382S02-5
100
382802-S100.
VIEWV
9 A 228
9A228
384672-S100
383369-S2
9A228 REF.
REF.
9~lREF~
VIEW IN
IN CIRCLE C
1.87
1.87 AFTER
AFTER
2.12 TIGHTENING
TIGHTENING
9092 ASSY.
9291
9291
VIEWU
VIEWU
382802-S100
VIEW IN CIRCLE
D
CIRCLED
A-A
SECTION AA
9B328
384029-S2
383369-S2
VIEWW
331136-S080A* *
9N041 ASSY.
**
381138-S070A**
381138-S070A
'~)k-'. 9291 REF

383369^2
VIEWY
VIEWY
383369-52
9291 REF.
':
oo~
9A228 REF.
9A228
REF
VIEWX
VIEwT
9291 REF.
ESE-M2C96-B, SAE-10W30
SAE-1OW30 ENGINE OIL
MAY BE USED AS AN ASSEMBLY AID
FOR ASSEMBLY OF FUEL HOSE ON
TUBES. NO OTHER MATERIAL
MAY
MATERIAL MAY
BE
BE USED.
USED.
INSTALL HOSE
HOSE ONTO
ONTO TUBE
TUBE .62
.62 MIN.
MIN.
INSTALL
CLAMP MUST BE ON HOSE AND
FLUSH TO 1/8"
lIS" FROM END OF HOSE.
INSTALL HOSE TO SECOND BEAD OF

TUBE CLAMP MUST BE ON HOSE AND
FLUSH TO 1/8"
1/S" FROM END OF HOSE.
ESE-M2C96-B, SAE-10W30 ENGINE OIL

MAY BE USED ON 9034 AND/OR 9072
AS AN ASSEMBLY AID. NO OTHER
MATERIAL MAY BE USED
USED.
MATERIAL
381136-S120A
, , - - . , . UO'.... , . 1 " \
55882-52
4REO'D.
"'-I
9034
9291 REF.--....
**
* 381136-S090A
381136-5090A.--""
2REOD./
2REQ'D.
9N041--~\1~~~
ASSY. REF.
384029-52
VIEWT
VIEwT
384029-52
384029-S2
.c.
I
9A228 REF
UI
VIEWZ
FIG. 15 Fuel and Vapor Emission Control SystemsMustang

Systems-Mustang W/2.8
W /2.8 L
l Engine (1975)
BACK TO GROUP INDEX
...o
I
V2120-A
V2120
A
0-.

VAPOR L1NELINEVAPOR
9A228
CLIP-384029-S2
CL
IP-384029-S2
(2REO'D)
(2REQ'D)
SCREWSCREW55914-S36M
'
55914-S36M
~ " "~,~
j~X=
/
~~~
::::'~jJ7
'd
VAPOR L1NELINEVAPOR
9A228
9A228
55914-S36M
(2REO'D)
(2REQ'D)
VIEW U
VIEWU
~
~1't
01
~--
~I
S~::6:~-S100 ~1J
VIEWV
NUT-382802-S1
00 "A'
NUT-382802-S100-"
,---
,"""'"@
...o
I
11.87
.87 AFTER
AFTER
2.12
2.12 TIGHTENING
TIGHTENING
'-I
VIEW
C
VIEW IN
IN CIRCLE
CIRCLE C
1.87 AFTER
AFTER
1.87
2.12
2.12 TIGHTENING
TIGHTENING
VIEW
0
VIEW IN
IN CIRCLE
CIRCLE D
VAPOR
SEPARATOR-
SCREW55914-S36M
-M.
NUT382802-S100
-:--
384672-S100
STRAP9092
-----..~~
9092
CLlP383369-S2
VAPOR L1NELINE
9A228
9A228
FUEL L1NELINEFUEL
9291
9291
STRAP_j~Y
SCREWSCREW-
FUEL L1NEL I N E - ---....:c

FUEL
9291
9291
UI
384672-S100~
9N041
VAPOR
VAPOR L1NELINE9A228
9A228
.a:.
I
~~
SCREW-
h)
SECTION AA
"'>-::~
CLlP363369-S2
.-
VIEWW
VAPOR LINE
- 9A228
CLIP384029-S2
FUEL
L1NEFUELL
INE9291
9291
TUBING381136-S080A
9B328
FUEL TANK9002
c;:,
Q
c..
Q_
~~
~-fj//~~~~
~/
~~/ I /"''\
r{
~
VIEW X
VIEWW
v~:U (L)
\G
INSTALL
INSTALL HOSE
HOSE ONTO
ONTO TUBE
TUBE .62
.62 MIN.
MIN.
CLAMP
CLAMP MUST
MUST BE
BE ON
ON HOSE
HOSE AND
AND
FLUSH
TO
1/8"
FROM
END
OF
HOSE.
FLUSH TO 1/8" FROM END OF HOSE.
_ INSTALL
INSTALL HOSE TO
TO SECOND BEAD
BEAD OF
OF
TUBE
TUBE CLAMP
CLAMP MUST
MUST BE
BE ON
ON HOSE
HOSE AND
AND
FLUSH
F LUSH TO
TO 1/8"
1/8" FROM
FROM END
EN D OF
OF HOSE.
HOSE.
.-
TUBING9324
CLAMP-
""o~9291
9291
CLlP-
eN
380882-S100
2REO'D.
FUEL
INEFUEL L
L1NE9291
9291
STRAP-9N041
STRAP-9N041
\\.-
~ ./
~
~~>..:~-~\
' J/
\'
~
~I/
\~ v~1
'/
SCREW-55914-S36M
SCREW-55914-S36M
(2REO'D)
(2REQ'D)
VIEWT
VIEWT
~~1~~~~S~20A
~\1."~
CLlPCLIP384029-S2
384029-S2
FIG.
FIG. 16 Fuel
Fuel and
and Vapor
Vapor Emission
Emission Control
Control SystemsMustang
Systems-Mustang W/2.8L
W /2.8L Engine
Engine (1976)
BACK TO GROUP INDEX
.-
..
/ ' (-\II~;)
,./ / ' IIV~I
~.
55914-S36M
ESE-M2C96-B,
ESE-M2C96-B. SAE-10W30
SAE-l0W30 ENGINE OIL
OIL
MAY
MAY BE
BE USED
USED ON
ON 9034
9034 AND/OR
AND/OR 9072
9072
ASSEMBLY AID. NO
NO OTHER
AS AN ASSEMBLY
MATERIAL
MATERIAL MAY
MAY BE
BE USED.
FUEL CAP-
~~9030~
9A228
Q",
TUBING381138-S070A
VIEWY
(\~I!~VAPOR
VAPOR L1NELINEVIEWX
~rj)N' ~384029-S2
~7
J
--
\:;~
FUEL L
L1NEFUEL
INE9291
ESE-M2C96-B.SAE-10W30
ESE-M2C96-B, SAE-l0W30 ENGINE
ENGINE OIL
OIL
MAY
MAY BE
BE USED
USED AS
AS AN
AN ASSEMBLY
ASSEMBLY AID
AID
FOR
ASSEMBLY
OF
FUEL
HOSE
ON
FOR ASSEMBLY OF FUEL HOSE ON
TUBES.
TUBES. NO
NO OTHER
OTHER MATERIAL
MATERIALMAY
MAY
BE
BE USED.
USED.
~I/
... "
CLlPCLIP383369-S2
383369-S2
FUEL L1NELINE-
SCREWSCREW5582-52 (4REQ'D)
(4REO'O)
5582-S2
FUEL FILLER
FILLER
FUEL
TUBE- 9034
TUBE-9034
CLlP' CLIP384029-S2
384029-S2
h)
.a:.
I
VAPOR L
L1NEVAPOR
INE9A228
9A228
VIEWZ
VIEW Z
V2120-B
V2120-B
UI
in
oI
...
?
'-I

**
384029-52
~-,
1
383369-S2
CO
382802-5100
VIEW IN CIRCLE 0
9291 REF.
384029-$2
2 REO'D.
9N04 ASSY. REF.
...
1.87 AFTER
9C327
9N04A55Y'RE~~~
oI
1 2.12 TIGHTENING
VIEWT
384672-S100384672-5100-
UI
9F321
380682-S100
380682-5100
22REQ'D.
REO'D.
**
~
~
381142-S220A
381142-S220A
9291 REF
REF
9291
9104 ASSY.
VIEWU
OPTIONAL FOR 2.3 &

2.8 LITER ENGINES
1.87 AFTER
2.12 TIGHTENING
**
382802-5100-........
381138-S070A
VIEWY
9A228 REF.
9291 REF.
VIEW IN CIRCLE C
VIEWV
9A228
**
331136-S080A
383369-52
VIEWW
VIEWX
9146
.9041
VIEWT
* INSTALL
INSTALL HOSE
HOSE ONTO
ONTO TUBE.62
TUBE.62 MIN.
MIN.
CLAMP
CLAMP MUST
MUST BE ON HOSE AND FLUSH
TO 1/8
1/8 FROM END OF HOSE.
HOSE.
383369-S2
~::'REF.
9291 REF.
4c
INSTALL HOSE
HOSE TO
TO SECOND
SECOND BEAD
BEAD OF
OF
INSTALL
TUBE
TUBE CLAMP
CLAMP MUST
MUST BE
BE ON
ON HOSE
HOSE AND
AND
FLUSH
FLUSH TO
TO 1/8
1/8 FROM
FROM END
END OF
OF HOSE.
HOSE.
ESE-M2C69-B,
ESE~2C69-B, SAE-10W30
SAE-1OW30 ENGINE
ENGINE OIL
OIL
MAY
MAY BE
BE USED
USED OM
OM 9041
9041 AND
AND /OR
lOR 9072
9072
AS
AS AN
AN ASSEMBLY
ASSEMBLY AID.
AID. NO
NO OTHER
OTHER
MATERIAL
MATERIAL MAY
MAY BE
BE USED.
USED.
9291 REF.
380153-S8
~3~
9N041 ASSY. REF
9104 ASSY. REF.

REF .
9104
384029-52
9A228
9A228 REF.
REF.
~
~
9092 ASSY.
ASSY.
9092
9A228REF.
VIEWX
VIEWX
380153-S8
2REQ'D.
386157-S100
VIEWZ
VIEW
2
UI
...
oI
V2121A
CO

Vapor Emission Control SystemsMustang
Systems-Mustang W/302
W 1302 Engine (1975)
BACK TO GROUP INDEX

FUEL L1NE9291
TUBINGTUBING381138S140A
381138-S140A
..
~
CLlP384029S2
(2REO'O)
C LI P-384029-S2
(2REQ'OI
/.~
STRAPSTRAP382931$
382931
~TS3.M
SCREW55914-536M
(2REO'O)
FUEL L
L1NEFUEL
INE9291
9291
ClIPCLIP383369-S2
383369S2
SCREW-
?' /
INSTALL
INSTALL HOSE
HOSE ONTO
ONTO TUBE.62
TUBE.62 MIN.
MIN.
CLAMP
CLAMP MUST
MUST BE
BE ON
ON HOSE
HOSE AND
AND FLUSH
FLUSH
TO
1/8 FROM
FROM END
END OF
OF HOSE.
HOSE.
TO 1/8
\~~
f^l
^ ^
VAPOR L I N E ~
9A228
FUEL
FUEL LINEL1NE-
2 9 1
^ - ^ " * 9 9291
^~\"lIl
U ^ ^
9A22.
\
VAPOR LINEL1NEVAPOR
9A228
9A228
*/IEW V
VIEW
V
VAPOR L1NE9A228
VIEW P
VIEWT
'"...
-0
VAPOR L1NE-
~"~
VIEW S
- INSTALL
INSTALL HOSE
HOSE TO
TO SECOND
SECOND BEAD
BEAD OF
OF
TUBE
TUBE CLAMP
CLAMP MUST
MUST BE
BE ON
ON HOSE
HOSE AND
AND
FLUSH
FLUSH TO
TO 1/8
1/8 FROM
FROM END
END OF
OF HOSE.
HOSE.
oI
CLIPClIP363369-S2
363369-52
ESE-M2C88-6.
ESE~2C88-B, SAE-10W30
SAE-1OW30 ENGINE
ENGINE OIL
OIL
MAY
MAY BE
BE USED
USED OM
OM 9041
9041 AND
AND /OR
lOR 9072
9072
AS
AN
ASSEMBLY
AID.
NO
AS AN ASSEMBL Y AID. NO OTHER
OTHER
MATERIAL
MATERIAL MAY
MAY BE
BE USED.
USED.
VIEW
VIEW U
U
VAPOR
SEPARATOR-
9F321
CLAMP380882-S100
CUP-
384029S2
y /
V"5""^
> ^
TUBING381138-S080A
FUEL LINE\
9291 \
^ C i k S ^ ^"
SCREW55914-S36M
km
VAPOR L I N E 9101
/
W
CLIP384029-S2
<d
*
TUBING381138-S062A
VAPOR SEPARATORSEPARATORVAPOR
9F321
NUT
-376656-5100 9]F321
NUT-376656-S100
FUEL FILLERFILLER96138
961/38
(2 REO'O)
REQ'D)
(2
CLAMPCLAMP-
FUEL
FUEL FILLER
FILLER
VAPORLlNE~
9~228
FUEL L1NE9291
CLlPCLIP383369-52
383369-S2
TUBINGTUBING-
SECTION
SECTION 0D D
D
SECTION C C
- --
SCREWSCREW55914S36M
55914-S36M
SECTION
SECTION AA
AA
TUBINGTUBING381138-5200A
381138-S200A
331136-SO8OA
331136'5~
;~~L
,i1a
FUELLINE9291 L l N E j 7 \
VAPOR
VAPOR L1NELINE-
9A228
CLlPCLIP372223-S2
372223-S2
SECTION
SECTION BBBB
9A228
TAPE-
I~"
~
'~
;'
TAPE\
ESB-M3G56-A
1OOW
ESB-M3G56-A100W
VIEWY
TRANSFER
TRANSFER TUBETUBE
9041
9041
CLlPCLIP384029-S2
384029-S2
FUEL
FUEL L1NEL I N E - -_
9291
9291
(2REO D)
1
,1.'.
J ~_------\
~~_
C)
_.
380882S100
(2REQ'D)
'
FUEL CAPFUEL CAP9030

9030
.-r-"'\
-.::,.-
\.1
CLlP384029-S2
/"
(;
*-
(('\
-::1- hl~'/
"\\
. C:'--
':xPl.
*.
\ \'
CLAMPCLAMP3869115
15-20 IN.
IN. LB.
LB
15-20
VIEW X
./
SCREW-
5582-S2 (4REQ'DI
5582-S214REO'O)
---.
j-
FUEL FILLER
FILLER
FUEL
TUBE-9A104
TUBE-9A104
CLAMPCLAMP1-S
386911 S
15-20 IN. LB.
15-20 IN LB
AUXILIARY FUEL
AUXILIARY FUEL
TANK-9104
TANK-9104
.'"
~""'~
~~~
1.."
/VAPOR LINE
TUBESCREW-55914-S36M 9A228
SCREW-55914-S36M
TUBE(2REQ'D)
381123-S043A
(2REQ'O)
TUBING381123-S043A
TUBING381136-5260A
381136S260A
f}....:I',
~.,.,
n"
TUBINGTUBING381136S200A
381136
S200A
:"\0
_ -'~""Y~Ii"~--r--::::::-"'----' . . ~\.'
.,.,{": i'/:- ~ ~
"" ~
\
l .~/.~ ~ '17l~I/'T /"\ \ ,
,/I.~
;~
("j.';!'
t\ \ \
~~
~",> ~
. W"--..--l;l ,- '/.' !\', ~\ \
1i~
____
STRAP-9N041
STRAP-9N04
~
~[j
~O:\(~(:?;..
'\r-<~~~
~ 9~,
~\-~
38088~-S100 ~"
~:, ~r,~n~j~~g/ ~,"",--5CREW~'a~~.'~!
5SCREW-56720-S2
CREW_56720.52
25 3
VAPOR L1NELINE- 25-35
- 5 FT
FT. LB
LB
9101
(2REQ-D'
9101
(2REO'O)
"MOUNTING STRAP.
STRAPMOUNTING
9092
9092
SCREW-386157-S1OO
SCREW-386157-5100
TORQUE TO
TO25-35
25-35 FT.
FT. LB.
LB.
TOROUE
...
oI
V2121-B
V2121-8
-0
FIG.18
FIG. 18Fuel
Fuel and
and Vapor
Vapor Emission
Emission Control
Control Systems-Mustang
Systems-Mustang W/302
W/302 CID
CID V-8
V-8 Engine
Engine (1976)
(1976)
BACK TO GROUP INDEX

9A037
TABS MUST BE
AGAINST STOP
AFTER ASSY.
381138-S200A
9A228 REF.
98828 REF.
MEMBER-SHOCK
ABSORBER MOUNTING
385265-S2
383368-S2
.,
3771 06-S - _.....".~,\
377106-S
381140 REF
38114O-SoaOA
381140-S080A
;~~~~EPR~~~,~::~~"oFUEL
HOSE MUST
382119-S1oo
382119-S100
2
2 REQ'D
REQ'D.
9064 REF
HOSE MUST LIE WITHIN FUEL

TANK DEPRFSSION
AND NOTCH
NOTCH IN
IN
ANK SUPPORT
FUEL
TANK
VIEW
W SUPPORT AFTER ASSY.
9002
ASSY. REF.
9002 ASSY.
REF.
VIEWY
VIEVWW
385777
9092 ASSY
ASSY.
2 REQ'D
REQ'D .
9002 ASSY.
9002
ASS~
VIEWX
9A228REF/*"
384243-S2
1 PLACE MARKED
CROSSMEM
CROSSMEMBER
- FRONT
FLOOR REF~ER - FRONT
FLOOR REF.
VIEW R
VIEWU
1.87
2.12
AFTER
TIGHTENING
3811~S080A
CARBON CANISTER
884O29-S2
55981-S86M
45341-S36
SECOND NUT
o
INSTALL HOSE TO SECOND
BEAD OF TUBE.
SECOND
BEAD OF TUBE.
~((;,
-
$ INSTALL HOSE ONTO

TUBE
.62 MIN. ONTO
TUBE.62MIN.
* CLAMP
HOSE
TO SECOND BEAD OF TUBE
INSTALL
HOS
MUST
E TO SECOND BEA
CLAMP
TO
1/8 ..MUST
FRO BE ON HOSE AND
ANO FLUSH
0 OF TUBE.
M
END
HOSE FLUSH
TO 1/8 " FROM END OF
OF HOSE.
. MIN.
INSTALL
INSTALL HOSE
HOSE ONTO TUBE .62
CLAMP MUST B~NTO TUBE .62 MIN
CLAMP MUST BE ON HOSE AND FLUSH
TO 118" FROM
AND FLUSH
TO 1/8" FROM END OF
F HOSE.
EN~NOHOSE
BACK PANEL REF .--",---:I ,--::--
:\
9AM4
9034 ASSY.
~
~
9291 REF.
9291
REF.
Emission
V'EWV
VIEWV
C
ontrol Syst
BRAKE TUBE REF
9AmREFY~r3~
~_ t
,.
,/,..
9030
COMET ONLY
C
--_~
903a
ASSY.
~JO.ASSY.
?/
1
D.MAVERIC
STD.
MAVERICK
ONLY
K
ONLY
TYPICAL
TYPICAL INST
INSTALLATION
...
PLACES MAALLATION
MARKEDVV
88 PLACES
RKEO*
9076 REF
VIEWZ
VIEW S
/.
~'I
.' ;
9030 ASSY.
9030 ASSY.
DELUXE
MAVERICK
MAVERICK ONLY
V2122-A
V2122
A
ems-Ma venck/Comet
.
FIG. 19 Fuel
Fuel and Vapor Emission Control SystemsMaverick/Comet
(1975)
BACK TO GROUP INDEX

9A228REF.
381136-S200A
9B593REF
MEMBER-SHOCK
ABSORBER MOUNTING
383368-S2
WIRE
HARNESS
377106-S
9A068 2 REQ'D.
CENTER ON TANK TOP
AND TAPE IN
POSITION
SHOWN
384672-S100
2 REQ'D.
VIEWR
381140-S15M
384839-S32
6 CYLINDER SHOWN
TANK DEPRFSSION AND NOTCH IN
FUEL TANK SUPPORT AFTER ASSY.
VIEWW
VIEW Y
BRAKE TUBE REF.

9A228REF
CROSSMEMBER - FRONT
FLOOR REF.
2.12
AFTER
TIGHTENING
CARBON CANISTER
884O29-S2
I !55981-S86M
45341-S36
SECOND NUT
8CYL.REF
BACK PANEL REF.

VIEWV
D INSTALL HOSE TO SECOND

BEAD OF TUBE.
9G291
9030
COMET ONLY /?
9A084
% INSTALL HOSE ONTO

TUBE .62MIN.
DECAL FOR
CANDIAN
-oi
USE ONLY
* INSTALL HOSE TO SECOND BEAD OF TUBE.

TO 1/8 " FROM END OF HOSE.
INSTALL HOSE ONTO TUBE .62 MIN.
VIEWS
903a ASSY.
STD. MAVERICK
ONLY
9291 REF.
VIEWV
8 PLACES M A R K E D ^
1
9030 ASSY.
DELUXE
MAVERICK ONLY
VIEWZ
V2123-A
FIG. 2 0 Fuel and Vapor Emission Control SystemsMaverick, Comet (1975 /2)
BACK TO GROUP INDEX

DEFORMATION OF CLIP
PERMISSIBLE WHEN NUT
IS FULLY TORQUED.
BRAKE TUBE
VAPOR LINE 9A228 REF.
1.87 AFTER
2.12 TIGHTENING
CROSSMEMBER - FRONT
FLOOR REF.
NUT45341-S36
(SECOND NUT)
CLIP-383369-S2
SCREW-55981-S36M
7 PLACES MARKED
VAPOR LINE
-9A228REF.
9 PLACES MARKED
BRAKE RELEASE
TUBING VAPOR SEPARATOR

381136-SX01A - 9 B 5 9 3
SHOCK ABSORBER
MOUNTING MEMBER
CLIP - 385427-S2
VAPOR L I N E 9A228

TANK DEPRESSION AND NOTCH IN
FUEL TANK SUPPORT AFTER ASSY
Q_
SCREW55989-S36M
VAPOR
SEPARATOR
-9B593
ESE-M2C96. SAE-10W30 ENGINE OIL

FOR ASSEMBLY OF HOSES ON TUBES.
NO OTHER MATERIAL MAY BE USED.
VIEWX
O INSTALL HOSE TO SECOND BEAD OF TUBE

TO 1/8 " FROM END OF HOSE.
INSTALL HOSE ONTO TUBE .62 MIN.

FUEL TANK 9002
ESE-M2C96-B. SAE-10W-30
ENG. OIL MAY BE USED ON
9034 AND/OR 9072 AS AN
ASSEMBLY AID. NO OTHER
MATERIAL MAY BE USED.
VIEWZ
FUEL T A N K CLIP9002
384420-S32
VIEWY
FIG. 21 Fuel and Vapor Emission Control SystemsMaverick and Comet (1976)
BACK TO GROUP INDEX
V2123-B

MEMBER - SHOCK ABSORBER MOUNTING
386176-S2 REF.
381136-S200A
381676-S2REF
9B593REF.
9B593 ASSY.
9A068 2 REQ'D.
CENTER ON TANK TOP
AND TAPE IN
381136-S080A
9A228REF
HOSE MUST LIE WITHIN FUEL TANK
DEPRESSION AND NOTCH IN FUEL
TANK SUPPORT AFTER ASSY.
CARBON
CANISTER REF
386175-S2 REF
9288 REF.
11 PLACES M A R K E D *
is
.__
9A228REF
386176-S2REF.

9G321
NOT USED WITH 6 CYLINDER
ENGINES.
* INSTALL HOSE TO SECOND BEAD OF TUBE.

CLAMP MUST BE ON HOSE AND FLUSH TO
1/8" FROM END OF HOSE WHERE REQUIRED.
9030 ASSY
LOCKING
# INSTALL HOSE ONTO TUBE .62 MIN.

384839-S32
ESE-M2C96, SAE-10W3O ENGINE OIL
13 PLACES MARKED*
8 CYLINDER SHOWN
6 CYLINDER SIMILAR EXCEPT
FOR RETURN LINE (9B337)
ESE-M2C96-B.SAE 10W30
ENGINE OIL MAY BE USED
ON 9034 AND/OR 9072 AS
AN ASSEMBLY AID. NO
OTHER MATERIAL MAY
BE USED
9030 ASSY.
LOW SERIES
9002 ASSY. REF.
FIG. 22 Fuel and Vapor Emission Control SystemsGranada/Monarch (1975)
BACK TO GROUP INDEX

SHOCK ABSORBER
MOUNTING MEMBER
TUBING381136-S080A
\
INSULATOR-9A068 (2 REQ'D)
CENTER ON TANK TOP AND
TAPE IN POSITION SHOWN
BOLT-384672-S100
TUBING381136-SX01A
VAPOR L I N E 9A228
^ L
TANK DEPRESSION AND NOTCH
IN FUEL TANK SUPPORT AFTER
ASSEMBLY
CLAMP382119-S100
NUT-382802-S100
CROSSMEMBER9064
CLAMP380882-S100
VIEW R
TAPEESB-M3G56-A
(4 REQ'D)
SUPPORT STRAP9092 (2 REQ'D)
FUEL LINE-9A084 OR
VAPOR LINE-9A228
FUEL L I N E 9A084
0.25 MAX. GAP

VIEW S
2 PLACES
21 PLACES MARKED *
VAPOR LINETUBING-
9 A 2 2 8
381140-S150A
1.63 AFTER
1.87 TIGHTENING
FUEL L I N E 9A084
SCREW55981-S36M
(5 REQ'D)
TUBING381138-S045A
NOT USED WITH 6 CYLINDER
ENGINES.
FUEL FILLER
TUBE-9034
VAPOR LINE9A228
INSTALL HOSE TO SECOND BEAD OF TUBE.

FUEL FILLER9076
IN6TALL HOSE ONTO TUBE .62 MIN.

382119-S100
ESE-M2C96. SAE-KJW30 ENGINE OIL
FUELCAP-9030
(HIGH SERIES)
FUEL CAP-9030
(LOCKING)
FUEL CAP-9030
FUEL T A N K -
TUBING381140-S150A
C L I P
~
384420-S32
VIEW Y
ESE-M2C96-B,SAE-10W30 ENGINE OIL

AS AN ASSEMBLY AID NO OTHER
MAY BE USED
(LOW SERIES)
9002
VIEW Z
V2124B
FIG. 23 Fuel and Vapor Emission Control SystemsMonarch and Granada 6-Cylinder (8-Cylinder Similar) (1976)
BACK TO GROUP INDEX

9076 REF.
~~
FUEL TANK
SUPPORT REF
9002 ASSY. REF.
2.25 AFTER
2.00TIGHTENIN
9030 ASSY.
381136
VIEWY
9002 ASSY. REF.
9092 ASSY.
2 REOD.
ESE-M2C96-B, SAE-10W-30
SAE-1OW-30 ENG. OIL MAY
BE USED ON 9034 AND/OR
AND/OR 9072 AS AN
ASSEMBLY AID. NO OTHER MATERIAL
MATERIAL MAY
BE USED.
FRAM\-BRAKE LINE REF.
384243
~-
9291 REF.
FUEL LINE
VIEWZ
VIEWW
9B337 REF.
FUEL RETURN
TYPICAL
INSTALLATION MARKED_
MARKED*
CANNISTER ASSY. REF.
C
:::J
Q.
~\
384790 --
\.':_.-
BRAKE LINE REF.
---.~
"
i'
9291
9291 REF.
FUEL LINE
FUELLI~
"""
NOTE:
--~
FUEL RETURN LINE (9B337)

& 460 PI
USED ON 460 &
ENGINES ONLY
9B337
FUEL RETURN LINE
9B337 REF.
FUEL RETURN LINE
LINE
MARKED
ASSY. REF.
REF.
9034 ASSY.
UNDERBODY REF.
r~HOSE
[J HOSE MUST BE
BE INSTALLED WITH
WITH
SMOOTH BENDS AND NO KINKS

ESE-M2C96-8,
ESE-M2C96-B, SAE
SAE lOW-30
10W-30 ENGINE OIL
MAY BE
BE USED AS
AS AN
AN ASSEMBLY AID
AID
FOR ASSEMBLY OF
OF HOSES ON
ON TUBES.
TUBES.
NO OTHER MATERIALM.A.Y
MATERIAL MAY BE
BE USED.
OINSTALL
QlNSTALL HOSE
HOSE TO SECOND BEAD
OF TUBE,
TUBE, CLAMP MUST BE
BE ON
ON HOSE
31
& FLUSH
FLUSH TO
TO 1/8"
1/8" FROM
FROM END
END OF
OF HOSE
HOSE
INSTALL
INSTALL HOSE
HOSE ON
ON TO
TO TUBE
TUBE .62
.62 MIN.
MIN.
CLAMP MUST BE
BE ON
ON HOSE &
& FLUSH
FLUSH
TO 118"
1/8" FROM
FROM END
END OF HOSE
HOSE
FUEL TANK REF."\
~,L ~j;7REF.
_ _._
9072
385265-52
SECT. A
98337
9291 REF.
~-9291
REF.
228 REF.
VIEWT
VIEWT
INSTALLATION MARKEDO
MARKED O
INSTALLATION MARKED*
MARKED*
V2125*
V2125-t
FIG.
FIG. 24 Fuel
Fuel and
and Vapor Emission
Emission Control Systems-Torino/Elite/Montego/Cougar
SystemsTorino/Elite/Montego/Cougar
BACK TO GROUP INDEX

......~9030ASSY.
9030 ASSY.
381136
381136
FRAME REF.
381136-S
9002
9002 ASSY.
ASSY. REF.
REF.
VAPOR SEPARATOR MUST BOTTOM OUT

ON GROMMET AFTER ASSY.
--a~
_. - -T ---
385467-832B
385467-S32B
45265-S2
UJ~~!l------ ESP-M3G56-A
ESP-M3G56-A
22 REaD.
REQO.
2~30
LB. FT.
9291 REF.
VIEWT
CANNISTER
ASSY. REF.
386532-5100
~-~9A228 REF.
9B337 REF.
~~~
9061
~385733-82
385733-S2
9092 ASSY. REF.
MARKED
384790
BRAKE TUBE REF.
REF.
9B337 REF.
9291 REF.
9291 REF.
9B337 REF.
TYPICAL INSTALLATION MARKED Q
9092 ASSY.
VIEWZ
9002 ASSY.
2.25 AFTER
2.00 TIGHTENING /
~A22BREF.
384265-S2
MARKED
VIEWW
,.~~
9A228 REF.
..
C
MARKEDO
TYPICAL INSTALLATION MARKEDO
::::J
384243
Q..
9B337 RETURN LINE
VIEWY
VAPOR LINE 9A228

9291 REF
~~~:~REF.
FUEL LINE 9291
9291 REF.
384029-S2
384029-52
TYPICAL
INSTALLATION MARKED
MARKED ft
BHOSE
rlHOSE MUST
MUST BE
BE INSTALLED
INSTALLED WITH
WITH
SMOOTH
SMOOTH BENDS
BENDS AND
AND NO
NO KINKS.
KINKS.
ESE-M2C96. SAE-10W-30 ENGINE

OIL MAY BE USED AS AN ASSEMBLY
AID FOR ASSEMBLY OF FUEL HOSE
ON TUBES. NO OTHER MATERIAL
MAY BE USED.
INSTALL HOSE TO SECOND BEAD
OF TUBE CLAMP MUST BE ON HOSE
& FLUSH TO 1/8" FROM END OF HOSE.
INSTALL
62 MIN.
INSTALL HOSE ONTO TUBE
TUB .62
CLAMP
CLAMP MUST
MUST BE
BE ON
ON HOSE
HOSE &
& FLUSH
TO
TO 1/8"
1/S" FROM
FROM END
END OF
OF HOSE.
HOSE.
l}
331140-S120A Q
f
~'
~
VIEWV
385265-S2
385265-52
INSTALLATION MARKED*
TYPICAL
MARKED*
./
384265..g2
384265-S2
9291 REF.
REF.
9B337 RETURN
RETURN LINE
LINE
9B337
INSTALLATION MARKED
MARKED #
TYPICAL
#
9A228 REF
384029-82
384029-S2
9B337 REF.
VIEWV
NOTE: FUEL
FUEL RETURN LINE
(9B337) USED
USED ON
ON 460
460
(9B337)
ENGINES
ENGINES ONLY.
9291 REF.
TYPICAL INSTALLATION M A R K E D ^

Vapor Emission Control SystemsTorino/Montego
Systems-Torino/Montego Wagons (1975)
BACK TO GROUP INDEX
~9A228REF.
9A228 REF
INSTALLATION MARKED
MARKED *
TYPICAL
9291 REF
9291
REF..
INSTALLATION MARKED
MARKED %
TYPICAL
%
V2126-A
V2126A

VAPOR LINE9A228
FRAME
VAPOR SEPARATOR MUST BOTTOM OUT

ON GROMMET AFTER ASSY.
CLIP385467-S32B
-_D'~L1P-
----I
45265-S2
ESP-M3G56-A
2 REQD.
CARBON
CANISTER
ASSEMBLY
FUEL RETURN
LINE-9B337
CLIP-
384190
9092 ASSY. REF.
..",/
TYPICAL
MARKED
CLlPCLIP385468-S2
385468-S2
~...-....I
~SIDE RAIL
VAPOR L1NE9A228
REF.
FUEL RETURN
L1NE-9B337
0.~
~
/
CLlP...-....-
38536482
-'I
9291 REF
~CLlP-
/'
,~,
FUEL
FUEL RETURN
RETURN
L1NE-9B337
LINE-9B337
TYPICAL
INSTALLATION
TYPICAL INSTALLATION MARKED
MARKED
FUEL L1NE-
~~~/
~
~
~APORLlNE
2.25 AFTER
2.00 TIGHTENING
9A228
385265-S2
TYPICAL
INSTALLATION
..... ~
MARKED~
MARKED
TYPICAL INSTALLATION MARKEDO

MARKEDO
CLlP-
::J
384243
a..
9B337 RETURN LINE
VIEWY
VAPOR LINE 9A228
{/;
CLlP384029-S2
INSTALLATION MARKED
MARKED
TYPICAL
ft
CHOSE MUST
MUST BE
BE INSTALLED
INSTALLED WITH
WITH
~HOSE
SMOOTH BENDS
BENDS AND
AND NO
NO KINKS.
KINKS.
SMOOTH
VIEW X
ESE-M2C96.
ESE-M2C96. SAE1OW30
SAE-10W-30 ENGINE
ENGINE

OILMAYBEUSEDASANASSEMBLY
AID FOR
FOR ASSEMBL.Y
ASSEMBLY OF
OF FUEL
FUEL HOSE
HOSE | ~I.~
AID
s
ONTUBES
"-...::
ON TUBES. NO
NO OTHER MATERIAL
MAY
MAY BE
BE USED
USED.
.
QlNSTALL HOSE TO SECOND BEAD

OINSTALLHOSETOSECONDBEAD
OF TUBE
TUBE CLAMP
CLAMP MUST
MUST BE
BE ON
ON HOSE
HOSE
OF
& FLUSH
FLUSH TO
TO 1/8"
1/8" FROM
FROM END
END OF
OF HOSE.
HOSE.
381136
"'"'"'---_._
VIEWV
VIEWV
l!!f!I!!
I~*
I
VIEW V
,
TUBINGTUBING-
INSTALL HOSE
HOSE ONTO
ONTO TUBE
TUBE .62
.62 MIN.
MIN.
INSTALL
CLAMP MUST
MUST BE
BE ON
ON HOSE
HOSE a
& FLUSH
FLUSH
CLAMP
TO
1/8"
FROM
END
OF
HOSE.
.........
'0
-~al' .
NOTE:
NOTE: FUEL RETURN LINE
LINE
(9B337)
(9B337) USED
USED ON
ON 460
ENGINES ONL
y~
ONLY.
--j'
/)'
~. ./
~P
CLI-
Y
.
385265-52
FUEL
RETUR~'
~\~
L1NE-9B337'~
FUEL L1NELINE-.
9291
9291
/"
'.
E RETURN
E
RN
FUEL
FU
LR TU
LINE-9B337
L1NE-9B337
~
\ ..f;-.
~
\,
FUEL RETURN
L1NE-9B337
FUEL LINE
FUEL
LINE 9291
9291
/--~~~
.~ ~M~ ~
/ IX
I.'\
~..
.-
FUEL L1NE-
~~
./ ,
.
~
CLlPFUEL
RETURN
FUEL RETURN
385265-S2
LINE-9B337
L1NE-9B337
..
TYPICAL
A P 0 R L1NEUNE_
INSTALLATION MARKED
MARKED # VVAPOR
CLIP9A228
CLlP9A228
~'/b
384029-S2
384029-52
~
..
'~VAPORLlNE~
9A228
FUEL RETURN
L1NE-9B337
~~
CLlP385265-52
INSTALLATION MARKEO*
MARKED*
~ 9291~.
t
~~~4
MARKED^
FUEL LINEL1NEFUEL
REF .
9291 REF.
'"
9291 REF
REF..
TYPICAL
INSTALLATION MARKED
MARKED *
INSTALLATION MARKED
MARKED ~
TYPICAL
%
V2126B
V2126-B
FIG. 26 Fuel
Fuel and
and Vapor Emission
Emission Control Systems-Torino/Montego
SystemsTorino/Montego Wagons (1976)
FIG.
BACK TO GROUP INDEX

UNDERBODY REF.
UNDERBODY REF
ESE-M2C96B,
ESE-M2C96B,SAE-10W30
SAE-10W30 ENGINE
ENGINEOIL
OIL MAY
MAY
BE
BEUSED
USEDON
ON9034
9034AND/OR
AND/OR 9072
9072AS
ASAN
AN
ASSEMBLY
ASSEMBLY AID.
AID.NO
NOOTHER
OTHER MATERIAL
MATERIAL
MAY
BE U~ED.
MAYBE
USED.
381136 13
381136~
FRAME REF
381142S
9034 ASSY.
VIEWX
9092 ASSY. REF.
fI!{!
\\ I
9291 REF.
FUEL LINE
385265-S2
384790
CANISTER ASSY.
ASSY. REF.
REF.
CANISTER
9B337
VIEVWW
VIEWW
3842\
384243
9B337 REF.
FUEL RETURN LINE
,~
9~1~
\~\
REF.~ 9291 REF

11
TYPICAL
INSTALLATION
FUEL SYSTEM
SYSTEM RELEASE
RELEASE -- 55 PLACES
PLACES MARKED
MARKED *
FUEL
460 ENGINE ONLY - 3 PLACES MARKED.
INSTALLATION -- 1
1 PLACE
PLACE MARKED.J;l
MARKED^
TYPICAL
:l
384029-S2
Q.
9A228REF.
~614~S2T~
~9A228REF.
TYPICAL 4 PLACES MARKED *

TYPICAL 4 PLACES MARKED
VIEWW
384243
BRAKE LINE REF
.*
NOTE.
NOTE: FUEL
FUEL RETURN
RETURN LINE
LINE (9B337)
(9B337)
USED
USED ON
ON 460
460 ENGINES
ENGINES ONLY
ONL Y
3~ HOSE
HOSE MUST
MUST BE
BE INSTALLED
INSTALLED WITH
WITH
SMOOTH
KINKS
SMOOTH BENDS
BENDS AND
AND NO
NO KINKS.
KINKS.
ESE-M2C96-B.
ESE-M2C96B, SAE-10W-30
SAE-1OW-JO ENGINE
ENGINE
OIL
OIL MAY
MAY BE
BE USED
USED AS
AS AN
AN ASSEMBLY
ASSEMBLY
AID
AID FOR
FOR ASSEMBLY
ASSEMBLY OF
OF FUEL
FUEL HOSE
HOSE
ON
ON TUBES.
TUBES, NO
NO OTHER
OTHER MATERIAL
MATERIAL
MAYBE
MAY BE USED.
USED.
INSTALL
o OF
INSTALL HOSE
HOSE TO
TO SECOND
SECOND BEAD
BEAD
TUBE. CLAMP MUST BE ON HOSE
0291 RE
_
FUEL LINE
*
RETURN LINE
9B337 FUEL RETURN LINE
,
ABn
U 1 U C
460 ENGINE
ENGINE ONLY
ONLY46O
2 PLACES MARKE~
~~
OF TUBE. CLAMP MUST BE ON HOSE

&& FLUSH
FLUSH TO
TO 1/8"
118" FROM
FROM END
END OF
OF HOSE.
HOSE.
B INSTALL
INSTALL HOSE
HOSE ON
ON TO
TO TUBE
TUBE .62
.62 MIN.
MIN.
CLAMP
CLAMP MUST
MUST BE
BE ON
ON HOSE
HOSE && FLUSH
FLUSH
TO
1/8"
FROM
END
OF
HOSE.
2RE1.D.
FUEL TANK
SUPPORT REF .......
6 PLACES MARKED
-----...
~NDERB\~
'FU'EL TANK
381136
VIEWT
,~
~93ASSY
SUPPOR~
"/
~:~::
'"
_/
.-------
/'
9~228
REF.
A~:E;7T1G~
r~~
386148-52
386148
S2
0
VIEWY
PLACE MARKEOO
11 PLACE
MARKED
VIEWR
V2127-A
V2127
A
FIG.
FiG. 27
27 Fuel
Fuel and
and Vapor
Vapor Emission
Emission Control
Control SystemsRanchero
Systems-Ranchero (1975)
(1975)
BACK TO GROUP INDEX

IO
r":'::'
FRAME
FUEL LINE9291 REF.
UNDERBODY REF.
ESE-M2C96B. SAE-10W30 ENGINE OIL MAY

BE USED ON 9034 AND/OR 9072 AS AN
ASSEMBLY AID. NO OTHER MATERIAL
MAY BE USED.
"
~I
VIEWW
BRAKE LINE REF.
CLlP-
.~
'..u
FUEL RETURN
L1NE-9B337
TUBING381136
FUEL L1NE-
FUEL LINE9291 REF

9291
REF.
5
PLACES MARKED
MARKED*
5 PLACES
t~
ii~
\~
384790
FUEL LINE\..
FUEL FILLER9034
VIEWX
~:;~:t L1NE~_,
)jl;f~_-_IJ-_-/~~~~:E
I
CLlP384243
9109
CARBON
CANISTER
ASSEMBLY
TUBING381136-S0BOA
UNDERBODY REF.
460 ENGINE ONLY - 3 PLACES MARKED

4c
929'~
Q
7T
/>
TYPICAL
TYPICAL INSTALLATIONINSTALLATION - 11 PLACE MARKEDJyl
MARKED-
CLlP-
oQ
VAPOR
VAPOR L1NELINE-
3~
Q..
Q_
9A228
TYPICAL
TYPICAL 44 PLACES
PLACES MARKED.
MARKED *
NOTE: FUEL RETURN

RETURN LINE (9B337)
NOTE: FUEL
ENGINES ONLY
USED
USED ON
ON 460 ENGINES ONLY
WI ~~~~~~~~~~6'~~E~I~~~~
SMOOTH BENDS AND NO KINKS.
~,~
a HOSE MUST BE INSTALLED WITH

OW-30 ENGINE
ESE-M2C96-8. SAE-10W-30
ENGINE
ESE-M2C96-8. ~~~~S AN ASSEMBLY
OIL
MAY BE USED AS AN ASSEMBLY
OIL MAY BES~MBLY OF FUEL HOSE
AIDTUBES.
FOR ASN 0 OTHER MATERIAL
ON
ON
TUBES,
NO OTHER MATERIAL
MAY BE
USED.
BE USED.
SECOND
BEAD
INSTALL
INSTALL HOSE
HOSEJ~
TOMUST
SECOND
BEAD
o
BE ON HOSE
OF TUBE. CLAMP MUST BE ON HOSE
TUBE.TO
CLA
aOF
1/8
ft FLUSH
FLUSH
TO
1/8""FROM
FROM END
END OF
OF HOSE.
HOSE.
~ta
480
460 ENGINE
ENGINE ONLY
ONLY - 22 PLACES
PLACES MARKE~
MARKED^
L~
,
2REtt-- ----..;~~
TUBINGTUBING381136
381136
VIEWT
BACK TO GROUP INDEX
~/'"
./'"
VAPOR L1NE-
~
I
CLlP-B148-$2
VIEWR
0r j
76
apor Emission
FIG.
d V
FIG. 28 Fuel
Fuel an
and
Vapor
Emission Control
Control Systems-Ranchero
SystemsRanchero (19
(1976))
VIEWT
,/
FUEL TANK9002
FUEL RETURN
L1NE-9B337
,/ ~""-.
~.----
,....
FUEL RETURN L1NE-9B337
2 REQ'D.
TUBE
62 MIN.
INSTALL HOSE
HOSEEOONN
ON TO
TO
TUBE
.62
MIN.
INSTALL
HOSE
a FLUSH
CLAMP
CLAMP MUST
MUST BBE ON HOSE ft FLUSH
TO
TO 1/8"
1/8" FROM
FROM END
END OF
OF HOSE.
HOSE.
-......./-~9B&83ASSY.
<e>","
k ~-=-./ .
\
CLlP. . - - - 384029-52
"
VAPOR LINE9A228
6 PLACES MARKEOO
1 PLACE MARKED
VIEWY
K)
in
V2127-8

9002 ASSY.
ASSY. REF.
REF.
9002
385467 REF.
h)
~
I
CII
384029-S2
384029-S2
385265 REF.
385265 REF.
386021 REF.
386021 REF.
MERC. ONLY
MERC.ONLY
(WITH REAR
REAR
(WITH
DISC BRAKES)
BRAKES) 1
DISC
oI
W
o
385467-S32B
385467-S32B 22 REO'D.
REQ'D
VIEWW
381877-52
9B337 REF.
\-'::lj~~"'---
VIEWZ
384766
384766 REF.
REF.
55 PLACES
PLACES MARKED.
MARKED A
384790
384790 REF.
REF.
USED
USED WITH
WITH (9B337)
(9B337)
55 PLACES
PLACES
VIEWW
VIEWV
381877-52
381877-52
381877-S2
385265-52
385265-S2 USED
USED WITH
WITH (9B337)
(9B337)
22REQD.
REOD.
9B337
::s
Q..
384265 REF.
386021 REF. MERC. ONLY
386021
VIEWT
9291 REF
REF.
9291
(,!
'--'~J"'---~'~
-
NOTE:

USED WITH 460 & 460 PI
ENGINES ONLY.
9291 REF.
(WITH
REAR
DISCS
BRAKES)
385265-S2
~A
K
E
I 385265-52
2REQD.
/
2 REOD.
R E F . - - -........-__-9B337 REF.
gr
*INSTALL
INSTALL HOSE
HOSE TO
TO SECOND
SECOND BEAD
BEAD
OF TUBE.
-OF
TUBE. CLAMP
CLAMP MUST
MUST BE
BE ON
ON
HOSE
& FLUSH
FLUSH TO
TO 1/8"
1/8" FROM
FROM END
END OF
OF HOSE
HOSE.
HOSE &
VIEWX
r->~ ~98328ASSY.
9030 ASSY.
9076 REF.
~ ~
VIEWU
.381136 REF.---.:7---..L..fIr
ESE-M2C96-B.
SAEl0W30 ENGINE
ENGINE
OIL
OIL MAY
MAY BE
BE USED
USED AS
AS AN
AN ASSEMBLY
ASSEMBLY
AID
AID FOR
FOR ASSEMBLY
ASSEMBLY OF
OF HOSES
HOSES
ON
MATERIAL
ON TUBES.
TUBES. NO
NO OTHER
OTHER MATERIAL
MAY
MAY BE
BE USED.
USED.
9B337 REF.
9B176 DECAL FOR ALL
ALL
9B176DECALFOR
CANADA USAGE EXCEPT
EXCEPT 460
CANADA
929\ REF.
9291
1.50-1.83
1.50-1.83
AFTER TIGHTENING
AFTER
AINSTALL
.INSTALL HOSE
HOSE ON
ON TO
TO TUBE
TUBE .62
.62 MIN.
MIN.
CLAMP
CLAMP MUST
MUST BE
BE ON
ON HOSE
HOSE &
& FLUSH
FLUSH TO
TO
1/8"
1/8" FROM
FROM END
END OF
OF HOSE.
HOSE.
95873-S
95873-S STRAP
STRAP
9324 MOLDED HOSE

VIEWT
FOR 460 POLICE INTERCEPTER ONLY
SAME AS MAIN VIEW EXCEPT AS SHOWN
FIG.
FIG. 29
29 Fuel
Fuel and
and Vapor
Vapor Emission Control
Control SystemsFord/Mercury
Systems-Ford/Mercury Sedans
Sedans (1975)
BACK TO GROUP INDEX
9B337 REF.
SAE-1OW-30 ENG. OIL

OIL MAY
MAY BE
BE
ESE -- M2C96-B, SAE-10W-30
9034 AND/OR
AND/OR 9072
9072 AS
AS AN
AN ASSEMBLY
ASSEMBLY
USED ON
ON 9034
USED
AID. NO OTHER
OTHER MATERIAL
MATERIAL MAY
MAY BE USED.
USED.
AID.
9092 ASSY.
2 REOD.
VIEWY
VIEWY
V2128-A
V2128
A
h)
~
I
CII
oI

FUEL TANKTANKFUEL
9002
9002
CLIP385467
VAPOR LINE-
CLIPClIP384029-S2
384029-52
CLIPCLIP385265 REF.
REF.
385265
386021 REf.
REF.
386021
MERC. ONLY
MERC.ONLY
ClIP385467-532B
(WITH REAR
DISC BRAKES)
384766
~~~~- 384766
VIEWZ
REF.
REF.
PLACES MARKED
MARKED A
55 PLACES
REF.
384790 REF.
USED WITH
WITH (9B337)
(9B337)
USED
PLACES
55 PLACES
VIEWV
ClIPCLIP381817-52
381877-S2
385265-52
385265-S2 USED
USED WITH
WITH (9B337)
(9B337)
2
2 REQD.
REQD.
TUBING381136-S080A
Q
Q
j
Q..
Q_
CLAMP385766-S32
2 REO'D.
384265 REF.
386021 REF. MERC. ONLY
(WITH REAR DISC BRAKES)
TUBING 381140-S135A
FUEL lINE9291 REF.
VIEWT
NOTE:
FUEL RETURN
L1NE-9B337

USED
USED WITH
WITH 460 &
& 460 PI
PI
ENGINES
ENGINES ONLY.
ONLY.
INSTALL
INSTALL HOSE
HOSE TO
TO SECOND
SECOND BEAD
BEAD
OF TUBE.
CLAMP MUST
MUST BE
BE ON
ON
UBE CLAMP
OF
T
.
1/S"
HOSE.
HOSE
&
FLUSH
TO
1/8"
FROM
END OF HOSE
HOSE & FLUSH
ESE-M2C96-B,
~2C96-8 SAE-10W-30
SAE1OW30 ENGINE
ENGINE
OIL MAY
MAY BE
BE USED
USED AS
AS AN
AN ASSEMBLY
ASSEMBLY
AID
AID FOR
FOR ASSEMBLY
ASSEMBLY OF
OF HOSES
HOSES
ON
MATERIAL
ON TUBES.
TUBES. NO
NO OTHER
OTHER MATERIAL
MAY
MAY BE
BE USED.
USED.
~~~
98176 DECAL FOR ALL

CANADA USAGE EXCEPT 460
AlNSTALL HOSE ON TO TUBE .62 MIN.

CLAMP MUST BE ON HOSE & FLUSH TO
1/8"
1/S" FROM
FROM END
END OF
OF HOSE.
HOSE.
~~~~;~~~:;~~~~~~:;'~~SI~TO
VIEWT
FOR 460 POLICE INTERCEPTER ONLY
FIG.
0 Fuel and Vapor Emission Control SystemsFord/Mercury Sedans (1976)
FIG. 330
BACK TO GROUP INDEX
.
h)
TUBING381136-S160A
OIL MAY
MAY BE
BE
M2C96-8 SAE-10W-30
SAE1OW-30 ENG.
ENG. OIL
ESE - M2C96-B,
ON 9034 AND/OR
AND/OR 9072
9072 AS
AS AN
AN ASSEMBLY
ASSEMBLY
USED ON
AID. NO
NO OTHER
OTHER MATERIAL
MATERIAL MAY
MAY BE
BE USED.
USED.
AID.
~:~~
9092 ASSY.
2 REQD.
VIEWY
VIEWY
V2128-B
V2128-B
...'"
oI

385467
385467 REF.
REF.
385265 REF.
REF.
385265
386021
386021 REF.
REF. MERC.
MERC. ONLY
ONLY
(WITH REAR
REAR DISC
DISC BRAKES)
BRAKES)
(WITH
.,.
h)
384029-S2
CIt
oI
9A228 REF.
h)
9291 REF.
REF.
9291
386148-S2
10 REO'D. MARKED*
9B337 REF.
REF.
9B337
385233-52
385467-S32B
2 REaD.
9002 ASSY.
9291 REF.
C
Q
:::J
a.
9N276 ASSY.
22-35 FT. LBS.
o
*
NOTE:
FUEL RETURN LINE

USED WITH 460 AND
ENGINES ONLY.
(9B337)
460 PI
384029-S2
USED WITH 9B337
9A125
385265 REF.
INSTALL HOSE TO SECOND BEAD

*,NSTALL
OF TUBE. CLAMP MUST BE
BE ON
ON HOSE &
FLUSH TO 1/8"
1/8" FROM END OF HOSE.
ESE-M2C96B, SAE-10W-30
SAE-1OW-30 ENGINE
OIL
OIL MAY BE
BE USED AS AN ASSEMBLY
AID FOR
FOR ASSEMBLY
ASSEMBLY OF FUEL HOSE
ON TUBES NO
MATERIAL
NO OTHER
OTHER MATERIAL
MAY
MAY BE USED.
INSTALL
MIN.
INSTALL HOSE TO TUBE .62 MIN.
CLAMP MUST BE ON HOSE & FLUSH
TO 1/8" FROM END
END OF HOSE.
.381136 REF.
9034 ASSY.
386021 REF.
386021
MERC. ONLY
(WITH REAR
DISC BRAKES)
9B176 DECAL
FOR ALL
ALL CANADA
CANADA USAGE
USAGE EXCEPT
EXCEPT 460
4bO
FOR
9291 REF.
REF
9B337 REF.
384766 REF.
5 PLACES MARKEDO
MARKED
384790 REF.
USED WITH (98337)
5 PLACES
E~G. OIL MAY

MAY BE
ESE -M2C96-B, SAE --1OW-30
10W-30 ENG.
AND/OR 9072 AS AN ASSEMBLY
USED ON 9034 AND/OR
AID, NO OTHER MATERIAL
MATERIAL MAY
MAY BE USED
AID,
9092 ASSY.
2REQD.
VIEWZ
VIEWZ
FIG. 31
31 Fuel
Fuel and Vapor Emission
Emission Control SystemsFord/Mercury
Systems-Ford/Mercury Wagons (1975)
(1975)
BACK TO GROUP INDEX
.,.
h)
I
UNDERBODY REF.
UNDERBODY
CIt
9002 ASSY. REF.

V2129-A
V2129
A
h)

385265 REF. BRAKE RELEASE

386021 REF. MERC. ONLY WITH
386021
REAR DISC
DISC BRAKES-BRAKE
BRAKES-BRAKE
REAR
RELEASE
RELEASE
^
,~,..==~~~~~~~~
~,
CLlP385461 REF.
CLlP384029-S2
VAPOR lINE9A228
FUEL L1NELINE9291
9291 REF.
RETURN L1NELINE9B337 REF.
CLIP385467-S32B
2REQD
385233-52
CLJp-385265-S2
CLIP-385265-S2 WITH
WITH
RETURN
RETURN lINE-9B337
LINE-9B337 ONLY
ONLY
TUBING381136-S140A
FUEL TANK
9002
FUEL lINE9291
1L
VIEWZ
NOTE:
INSTALL HOSE TO seCOND

SECOND BEAD
OF TUBE. CLAMP MUST BE ON HOSE &
1/8" FROM ENOOF
END OF HOSE.
FLUSH TO lIS"
ESE-M2C96B. SAEl(M130
SAE-10W-30 ENGINE
ESE-M2C96B,
MATERIAL
ON TUBES NO OTHER MATERIAL
MAY BE USED.
p-a@

USED WITH 460 AND 460 PI
ENGINES ONLY.
62 MIN.
INSTALL HOSE TO TUBE .62
& FLUSH
CLAMP MUST BE ON HOSE &
/
TUBING-
FUELCAP9030
~~~
,-
FUELFILLER9076
381136
386021 REF.
MERC. ONLY
(WITH REAR
DISC BRAKES)
FUEL LINE9291 REF.

FUEL RETURN
384766 REF. LINE-9B337
5 PLACES M A R K E D O
384790 REF.
USED WITH (98337)
5 PLACES
98116
DECAL
9B176DECAL
FOR ALL CANADA USAGE EXCEPT 4bO
460
ESE -M2C96-B,
-M2C96-B. SAE
SAE -- lOWJO
10W-30 ENG.
ENG. OIL
OIL MAY
MAY BE
BE
ESE
USED ON 9034 AND/OR
ANDIOR 9072 AS AN ASSEMBLY
AID, NO OTHER MATERIAL MAY BE
AID.
BE USED
9092 ASSY.
2REQD.
2 REQD.
VIEW 2
VIEWZ
FIG. 32 Fuel
Fuel and Vapor Emission Control Systems-Ford/Mercury
SystemsFord/Mercury Wagons (1976)
BACK TO GROUP INDEX
9N216 ASSY.
22-35 FT. LBS.
CLAMP385766-S32
(2REO/D)
TUBING-"
381136-S140A
UNDERBODY REF.
FUEL
TANKFUELTANK9002
V2129-B
V2129B
CO
CO

FRAME REF
~,
9A228 REF.
FUELTANK
SUPPORT REF.
UI
..
oI
9B593
384790-S2
384790-52
9291 REF.
ESB-M3G56-A
4REQ'D.
9B337 REF.
REF
9B337
CANISTER
ASSY. REF.
INSTALLATION
TYPICAL
PLACESMARKED
MARKED Q
Q.
44 PLACES
VIEWW
9B337
REF.~.
9291
9002 REF.
386148-S32
9002 ASSY.
...
VIEWZ
VIEWZ
9A221 REF.
3840 29-S2
5 PLACES MARKED*
1_
i~1
f.
VIEWY
Q
:::J
Q.
9A22S
.~
9291
9291 REF
REF.
TYPICAL
INSTALLATION
7 PLACES M A R K E D *
7 PLACES MARKED
FUEL TANKSUPPORT REF.
ESE-M2C96-B.
SAE-1OW-30 ENGINE
ENGINE OIL
OIL MAY
MAY
BE
BE USED
USED AS
AS AN
AN ASSEMBLY
ASSEMBLY ON
ON TUBES.
TUBES, NO
NO
OTHER
MATERIAL
MAY
BE
USED.
OTHER MATERIAL MAY BE USED.
INSTALL
INSTALL HOSE
HOSE TO
TO SECOND
SECOND BEAD
BEAD OF
OF TUBE.
TUBE.
CLAMP
CLAMP MUST
MUST BE
BE ON
ON HOSE
HOSE &
& FLUSH
FLUSH TO
TO 1/8"
l/S"
FROM
END
OF
HOSE.
FROM END OF HOSE.
INSTALL
D MUST
INSTALL HOSE
HOSE ON
ON TO
TO TUBE
TUBE .62
.62 MIN.
MIN. CLAMP
CLAMP
BE ON HOSE & FLUSH TO 1/8" FROM
MUST BE ON HOSE & FLUSH TO l/S" FROM
END
END OF
OF HOSE.
HOSE.
INSTALL
INSTALL HOSE
HOSE TO
TO SECOND
SECOND BEAD
BEAD OF
OF TUBE.
TUBE.
+ INSTALL
INSTALL HOSE
HOSE ON
ON TO
TO TUBE
TUBE .62
.62 MIN.
MIN.
VIEWV
I~
9291
REF.
9291AEF.
96337 REF
9B337 REF. SAME
SAMEAS
ASINSTALLATION
INSTALLATION MARKED
MARKED~
EXCEPT
AS
SHOWN
EXCEPT AS SHOWN
VIEWV
VIEWV
385265-52 -
98337
P
RJ
AE~"-..9291
AEF.
INSTALLATION
TYPICAL
PLACES MARKED
MARKED *
77 PLACES
FIG.
FIG. 33
33 Fuel
Fuel and
and Vapor
Vapor Emission
Emission Control
Control SystemsThunderbird/Continental
Systems-Thunderbird/Continental Mark
Mark IV
IV (1975)
(1975)
BACK TO GROUP INDEX
382S02S1oo
2 REO'D.
~
I
9002 ASSY
ASSY REF.
REF.
9002
UI
VIEWX
VIEWX
V2130A
V2130
A
..
oI

.
....,
VAPOR L.'NE9A228
CLlP384790-82
~---FUEL
TUBINGTUSING-
L1NE9291 REF.
381136-S100A
381136-S100A
L~'NE-
~URNlINE
RETURN LINE98337
9B337
INSTALLATION
4 PLACES MARKED (Ii)
VAPOR
VAPOR L I N E 9A228
UI
,
CLIP-
~~AJ"
.__ 384029-S2
~~__
I'~
FRAME REF.
CLlP-
'V' ..-. . . .
FUELTANK9002
FUEL FILLER-
~~61~
9076
VIEW W
FUEL TANK-
..v_~~~:_~-_:_90~~J.
~_
r;J-! -_-_...~
UNDERBODY
UNDERBODY REF.
REF
9049
~~
!0~POR
VAPOR L I N E ~:228
FUEL FILLER
J/ - G~~~lS17S2
SUPPORT STRAP9092
9092 REF.
REF.
~"':::.:-',~
c~
-9031
FUEL CAP9000
L1NE-
9A228
INSTALLATION
TYPICAL INSTALLAT~N
4 PLACES MARKED
MARKED ).{
9B593
'
~.~
CLlP3840 29-S2
oI
ASSY.REF.
"'I~
381877-S2
UI
VAPOR SEPARTORSEPARTOR-
.~CANISTER
.: ~
-~
__)1
;~-:f
I'(ID~,,;
e-ff'
FUEL TANK
VIEWZ
I.
~'~}'
_
VIEWY'
Q
:::::J
a.
9A228
FUEL
F U E L LL1NEINE9291REF.
INSTALLATION
M A RKED
KED*
5 PLACES MAR
FUEL TANK
SUPPORT
ESE-M2C96-B,
ESE-M2C96-B. SAE-1OW-30
SAE-10W-30 ENGINE OIL MAY
TUBES, NO
BE USED AS AN ASSEMBLY ON TUBES,
OTHER MATERIAL
381877-82
VIEWV
HOSE TO SECOND BEAD OF TUBE,:

TUBE.
INSTALL HOSE
1/8"
CLAMP MUST BE ON HOSE & FLUSH TO 1/8
FROM END OF HOSE.
fj
D
INSTALL HOSE ON TO TUBE .62 MIN. CLAMP

1/8" FROM
MUST BE ON HOSE & FLUSH TO 1/8"
END OF HOSE.
ENDOF
INSTALL HOSE
HOSE TO SECOND BEAD OF
OF TUBE.
TUBE.
tJ" INSTALL HOSE ON TO TUBE .62 MIN.
RETURN
RETURN LINE
LINE
9B377
-- 9B377
SAME
S
AME
FUEL LINE
_- 99291
291
ÂS IINSTALLATION
W
MARKED'ii)
N S T A L L A T | O N MARKED
EXCEPT
VIEWAS
V SHOWN
VIEW V
CLlP385265-S2
~
\
9B337
REF.
9B337REF.
....,
~9291REF.
INSTALLATION
7 PLACES MARKED *
FIG. 34 Fuel and Vapor Emission C

on t ro I Systems-Thunderbird/Continental
Control
SystemsThunderbird/Continental Mark IV (1976)
BACK TO GROUP INDEX
t..
STRAP9092 (2 REO'D)
VIEWX
UI
FUEL TANKTANK9002
oI
V2130-B
UI

b'
9B337REF.
385265-S2
9B331 REF.
55914
9030 ASSY. LOCKING
55914
9030 ASSY. LOCKING
(4 REQ'D.)
C4~Ea'D.I~
CII
oI
~. ;.(; < .-'

384029
384029
BRAKE REL.
REL.
BRAKE
9291 REF.
W
0-
9030 ASSY.
9A 125 R E F . ' VIEWZ
9291 REF.
381877-S2
381871-S2
h)
~
9034
9034 ASSY.
ASSY. REF.
REF.
381871-S2
BRAKE TUBEREF
1 PLACE MARKED
9B593_~
TYPICAL
INSTALLATION
22 PLACES
PLACES MARKED.
MARKED
INSTALLATION
TYPICAL
FUEL
TANK
FUEL TANK
SUPPORT
SUPPORT REF
REF
PLACES MARKED
MARKED ~3
66 Pl.ACES
9002 ASSY.
VIEWU.
9A228 REF
385265-S2
385265S2
----....."""
r-
(^98337
REF
9A228 REF.
REF.
11 PLACES MARKED *
9B331 REF.
9291 REF.
"'-9291
REF.
VIEWU
VIEWW
381136-529Q-A
ESE-M2C96-B. SAE-10W30 ENGINE OIL

AS AN ASSEMBLY AID. NO OTHER
381136-S080A
Q
~
Q.
AFTER TIGHTENING
AFTER
TIGHTENING
9291 REF.
CARBON
CANISTER REF
9B337 REF.
FUEL PUMPREF
382119-S100
UNDERBODY REF.
REF.
UNDERBODY
381140-S135A
9092 ASSY
381136-5080A
(2 REQ'D.)
VIEW Y
2 REO'D.
NO.
4CROSSMEMBER
NO.4
CROSSMEMBER
ESE
M2096-B. SAE-10W-30
ESEM2096-B,
SAE-1OW-30 ENGINE
ENGINE
OIL
OIL MAY
MAY BE
BE USED
USED AS
AS AN
AN ASSEMBLY
ASSEMBLY
AID
FOR
ASSEMBLY
OF
FUEL
HOSE
ON TUBES. NO OTHER MATERIAL
ON TUBES, NO OTHER MATERIAL
MAY BE USED
MAY BE USED.
.INSTALL
INSTALL HOSE
62M
IN.
HOSE ON
ON TO
TO TUBE
TUBE .62
MIN
CLAMP
CLAMP MUST
MUST BE
BE ON
ON HOSE
HOSE AND
AND FLUSH
FLUSH
TO
1/8"
FROM
END
OF
HOSE.
* INSTALL
INSTALL HOSE
HOSE TO
TO SECOND
SECOND BEAD
BEAD ON
ON TUBE
TUBE
CLAMP
CLAMP MUST
MUST BE
BE ON
ON HOSE
HOSE AND
AND FLUSH
FLUSH
TO 1/8 " FROM END OF HOSE
TO 118" FROM END OF HOSE.
VIEW
X
VIEWX
384029-S2
384029S2
385766~S32
385766-532
(2
(2 REQ'D.
REO'DJ
---
9A22BREF~~~
~
381877-S2
381871-S2~~
9B337 REF.
381140-5070A
NO
4CROSSMEMBER
NO.4CROSSMEMBER
VIEWT
VIEWT
TYPICAL
INSTALLATION
33 PLACES
ARKEDQ
PLACES M
MARKEDO
382119-S1OO
(2 REO'DJ
9275
VIEWV
'/
FUEL PUMP REF

.
~'-._~
*
VIEWR
VIEVWR
h)
~
I
CII
V2131-8
V2131-B
oI
W
0-
FIG.
Continental (1975)
(1975)
FIG" 35
35 Fuel
Fuel and
and Vapor
Vapor Emission
Emission Control
Control Systems-Lincoln
Systems-l"lncoln Continental
BACK TO GROUP INDEX

RETURN LINE9B337 REF.
CLlP385265-S2
CLlP385265-S2
. ;.
RETURN
RETURN L1NELINE9B337
9B337 REF.
REF.
~~
<~~~ ~(:R::'~~jO
JJ"
BRAKE LINE
CLlP384029
'l
1 PLACE AS MARKED Q
RETURN LINE
-9B337
TYPICAL
INSTALLATION
66 PLACES
PLACES MARKED
MARKED ~3
f~PRING
SPRING POCKET
~
sz=^
\
FUEL
CAPFUELCAP,,903
0
9030
'-
FILLERFUEL FILLER9034
TYPICAL
INSTALLATION
4
4 PLACES
PLACES AS
AS MARKED.
MARKED
FUEL TANK
SUPPORT REF
FUEL TANK9002
VIEWU.
VAPOR LINE9A228 REF.
--- "
"""
"
,I Co
9A125 R E F . VIEW Z
FUEL L I N E 9291 REF.
381877-S2
381877-S2
CLlP385265-S2
(4 REQ'D.
FUEL LINE
-9291
LOCKING FUEL
FUEL
LOCKING
CAP-9030
55914
55914
RETURN LINE
LINE9B337
9 PLACES AS MARKED *
" ' " FUEL L1NE9291
VAPOR L1NELINE9A228
TUBING
TUBING - 381136-S290A
381136-S290A
VIEW U
VIEWW
ESE-M2C96-B,
ESE-M2C96-B, SAE-l0W30
SAE-10W30 ENGINE OIL
MAY
AND/OR 9072
MAY BE
BE USED
USED ON
ON 9034
9034 AND/OR
9072
AS
AN
ASSEMBL
Y AID.
AID. NO
AS AN ASSEMBLY
NO OTHER
OTHER
TUBING381136-S080A

FUEL TANK
-9002
CLAMPS382119-S100
(2 REQ'D
RETURN LINE
-9B337
38177
CARBON
CANISTE
FUEL PUMP
ESE-M2096-B. SAE-1OW-30
SAE-10W-30 ENGINE
ESE-M2096-B,
BE USED AS
OIL MAY BE
AS AN ASSEMBLY
AID FOR ASSEMBLY
ASSEMBL Y OF FUEL HOSE
TUBES. NO OTHER MATERIAL
MATERIAL
ON TUBES,
MAY BE USED.
INSTALL HOSE
HOSE ON
ON TO
TO TUBE .62
.62MIN.
.INSTALL
MIN.
CLAMP MUST BE
TO 1/8"
4c INSTALL HOSE TO SECOND BEAD ON TUBE
CLAMP MUST BE
TO 1/8"
AFTER TIGHTENING
AFTER
TIGHTENING
~~9~LRLEI~.E
FUEL FILLER9034
9291 REF.
RETURN L1NE~
LINE9B337
REF
9B337REF
UNDERBODY
TUBING - 381136-S080A
TUBING381140-S120A
NO.4
CROSSMEMBER
NO. 4CROSSMEMBER
CLlPCLIP-
VAPOR
VAPOR L1NELINE-
..,.':l
9092
ASSY
9092 ASSY
-----2
2 REO'D.
REQ'D.
VIEWY
TUBING - 381140-S070A
381140-S070A
CLAMPS - -
385766-S32
7~~7:~~~~~
384029-S2
384029-S2
CLAMPS385766-S32
(2RE0/D)
(2 REQ'D.)
~~f----- CLAMPS
CLAMPS - 382119-S100
382119-S100
(2
(2 REO'DJ
REQ'D.)
0 ----------
/'_______.t
9A228
,"
9A228
_
. ~/
381172-S72 ~
NO
CROSSMEMBER
NO. 44CROSSMEMBER
VIEWT
INSTALLATION
3 PLACES MARKEDO
MARKED^
-,,,,----
VIEWV
FIG. 36 Fuel
Fuel and Vapor Emission Control Systems-Lincoln
SystemsLincoln Continental (1976)
9B337 REF.
TUBING381 136-S104A
VIEWR
BACK TO GROUP INDEX
C
::J
c...
".
I
UI
oI
V2131-C
V2131 C
W
'I

24-50-38
24-50-38
SPECIFICATIONS
GALLONS
IMP.
CAR MODEL
u.S.
U.S.
Comet, Maverick
Cougar
Ford, Mercury Cars*
Ford, Mercury Wagons*
Lincoln Continental*
Mark IV
Pinto and Bobcat Sedan
Pinto and Bobcat Wagon
26.5
24.2
21
21
24.2
26.5
13
14.0
*Add approximately 8 gallons for auxiliary tank.
BACK TO GROUP INDEX
19.2
16.5
21.3
20.1
20.1
17.5
20.1
20.1
22
10.7
11.7
GALLONS
IMP.
CAR MODEL
u.S.
U.S.
Montego Cars
Montego Wagon
Mustang**
Ranchero
Thunderbird
Torino Cars
Torino Wagon
Granada,
Granada, Monarch
26.5
21.2
13
26.5
26.5
26.5
21.3
'Add approximately 3.5 gallons for auxiliary tank.

**Add
19.2
22
17.6
10.7
22
22
22
17.5
16.5
CV1114-G

24-51-1
24-51-1
Fuel Filter
24-51-1
24-51-1
PART 24-51
24-51 Fuel Filter
NOTE: The
The infonnation
information in
to both 1975 and 1976 model year vehicles unless otherwise specified.
CR1966,.A
CR1966A
DESCRIPTION
The in-line fuel filters used on
on all
all
engines are of one-piece construction and
cannot be
be cleaned. Inside the
the filter
filter is
is aa
magnetic washer to
to trap metallic
particles which might be
be present in
in the
the
fuel. Replace the
the filter at
at the
the specified
senice
service interval or
or if it
it becomes clogged
or restricted.

FUEL FILTER
All Models, All
All Engines
Removll1
Removal
1.
1. Remove the
the air
air cleaner.
2.
the
2. Loosen or
or remove (crimp type) the
the inlet hose to
to the
the
clamp securing the
fuel filter line.
BACK TO GROUP INDEX
3. Unscrew the
the
the fuel filter from the
the fuel filter
carburetor. Disconnect the
filter
the metal line and
hose from the
and discard
and hose.
the clamp, filter
filter and
Installstion
Installation
1.
1. Install new clamps on a new inlet hose
and connect the hose to
filter and
to the filter
and
line. Thread the

the
the filter
filter into the
carburetor inlet port. Tighten the
the
filter.
filter.
2.
2. Position the fuel line hose clamps and
tighten the
the clamps securely.
3. Start the
the engine and
and check for
for fuel
leaks.

24-60-1
Throttle Linkage
24-60-1
PART 24-60 Throttle Linkage

COMPONENT INDEX
Page
Page
COMPONENT INDEX
ILLUSTRATIONS - Cont'd.
ADJUSTMENTS
Downshift Linkage ..................
60-1
60-1
Granada and Monarch . ..............
60-4
Accelerator Cable ...................
60-1
60-1
Maverick and Comet .................
60-5
60-11
60-11
60-11
60-11
Torino, Elite, Montego

and Cougar .......................
60-6
........... .
60-1
60-1
Mercury ............
Ford, Meteor and Mercurv
60-7
Pinto and Bobcat ...................
60-2
Thunderb
ird and Continental
Thunderbird
Mark IV .........................
60-8
Mustang ..........................
60-3
Lincoln Continental .................
60-10
Accelerator Cable Mounting Bracket
....
Accelerator Pedal Assembly ...........
GENERAL INFORMATION
ILLUSTRATIONS
NOTE: The information in this Part applies to both 1975 and 1976 model year vehicles unless otherCR1966-A
wise specified.
CR1966-A
GENERAL INFORMATION
New linkage systems have been added
Monarch and
for 1975 Granada, Monarch
Mustang with 302 CID V-8,
V-8, and Pinto
Engine. In
and Bobcat with 2.8L V-6 Engine.
addition, there is a new accelerator plate
assembly and a retainer for sound
absorption. The retainer attaches to the
accelerator cable as it passes through the
accelerator plate
dash panel. The accelerator
of the
the sound-deadening
sound-deadening
assembly is aa part of
that is located between the accelerator
pedal and the dash panel attachment.

No special procedures are required
for the accelerator plate assembly, but the
retainer on the accelerator cable must be
removed prior to cable removal and
installed prior to final hook-up of a cable
to the pedal assembly. The retainer is
similar to a Tinnerman nut and can be
off the cable body in the same
pryed off
manner. Install the retainer to the cable
before attaching the cable to the pedal
assembly and press securely against the

sound absorber material.
An insulator has been added between
the accelerator cable and engine bracket
T h u n d e r b i r d and
and
on the 1976 Thunderbird
IV. The insulator is
Continental Mark IV.
integral with the cable flange and the
engine bracket has a large slot to accept
it. The removal and installation remains
the same for the cable and bracket.
ADJUSTMENTS
2. Using a suitable tool, push the
6.
6. Remove the cable from the dash
panel.
Instsllstion
Installation
1.
1. Position the cable end through the
dash panel and install the attaching
screws.
screws.
2.
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.
4. Press the snap-in nylon bushing on
accelerator cable into the
the accelerator
accelerator pedal arm.
DOWNSHIFT
LINKAGEAUTOMATIC
LINKAGE-AUTOMATIC
TRANSMISSION
All Models
Adjustment
Adjustment instructions are given on
the illustrations, Figs.
Figs. 1 through 9.
ACCELERATOR CABLE
All Models
Remoysl
Removal
1.
1. Refer to the applicable illustration.
BACK TO GROUP INDEX
accelerator cable nylon bushing out of

the accelerator pedal arm. Remove
to the
the cable
cable
the retaining clip attached to
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.
cable.
4. Disconnect the cable-attaching screw
from the engine bracket.
5. Remove the screws attaching the

5.
cable to the dash panel.

N-800001-S51M
N-800001-S51 M
22REQ'D.
REO'D.
10-15
FT-LB
10-15FT-LB
CARBREF.
REF.
CARB
55981-S36M 2 REQ'D.
./'"
FHONT OF ENGINE
KICKDOWN
KICKDOWNADJ.
ADJ.
SCREW
SCREWREF.
REF.
SLIDINGINNER
INNERMEMBER
MEMBER
SLIDING
9K713
9K713ASSY.
ASSY.
FRONT OF ENGINE
9728
7B146
7B146
AUTO. TRANS.
AUTO. TRANS
ONLY
ONLY
PEDESTAL & STUD
2.3 LITER AUTO. TRANS.

OTHERWISE SAME AS MAIN VIEW
98767 REF.
PART OF
(6501670)
ASSY.
9A758
9A758 ASSY.
ASSY.
.........
" ' " 55981-S36M
7A186ASSY.
7A186 ASSY.
......
VIEWZ
MAIN VIEW
MAIN VIEW
VIEWy
97409-S2
97409-S2
2
2 REQ'D.
REO'D.
ADJUSTMENT OF
OF THE
THE TRANS.
TRANS. K.D.
K.D. CONTROL
ADJUSTMENT
CONTROL
9A758 ASSY.
1.
WITH CARBURETORHELD
AT W.O.T.
W.O.T. POSITION
AND THE
1. WITH
CARBURETOR HELD AT
POSITION AND
THE
KICKDOWN
KICKDOWN ROD
ROD 7A186
7A186 HELD
HELD DOWNWARD
DOWNWARD AGAINST
AGAINST THE
THE
"THROUGH
DETENT"
STOP,
ADJUST
THE
KICKDOWN
"THROUGH DETENT" STOP, ADJUST THE KICKDOWN
ADJUSTING
ADJUSTING SCREW
SCREW TO
TO OBTAIN
OBTAIN .01
.01 TO
TO .08
.08 CLEARANCE
CLEARANCE
BETWEEN
BETWEEN SCREW
SCREW AND
AND THROTTLE
THROTTLE ARM.
ARM.
9728
.
2.
2. RETURN
RETURN SYSTEM
SYSTEM TO
TO IDLE.
IDLE.
N602548-S51M
. /N602548-S51
M
(2 REQ'D.)
(2REQ'D.)
10-15 FT-LB
FT-LB
10-15
Q
<Q
N-800001-S51M
N-800001-S51
M
REQ'D.
22 REO'D.
10-15 FT-LB
FT-LB
10-15
55981.S36M
55981-S36M
2.8 LITER
LITER
2.8
OTHERWISE SAME AS MAW VIEW,
VIEW
OTHRWISESAMEASMAJN
9A758 ASSY.
REF.
.25
MIN.
.25MIN.
383212-52
383212-S2
......./
REF.
VIEWy
VIEW
9A758 ASSY. REF.
lA186 ASSY. REF.
7B146
7B146REF.
REF.
VIEW
VIEWIN
INCIRCLE
CIRCLEYY
AUTO.
AUTO.TRANS.
TRANS.ONLY
ONLY
FIG.
FIG. 11 Throttle
Throttle and
and Downshift
Downshift Linkage-Pinto
LinkagePinto and
and Bobcat
Bobcatwith
with 2.3L
2.3L and
and 2.8L
2.8L Engines'
Engines
BACK TO GROUP INDEX
L.
9E728REF.
ABSORBER ASSY. REF.
DASH PANEL
DASH PANEL
REF.
9728 ASSY.
9728 ASSY.
2.3 LITER STD. TRANS.

OTHERWISE SAME AS MAIN VIEW
55981-S36M
VIEWZ
V1Q64-C

N602548-S51M
(2 REQ'D.)
10-15 FT-LB
9A758 ASSY. REF.
h)
N-800001-S51
M
N-800001-S51M
2 REQ'D.
2REO'D.
10-15 FT-LS
FT-LB
10-15
~....
KICKDOWN ADJ.
SCREW REF.
55981-S36M
ADJ.
KICKDOWN ADJ.
SCREW REF.
9728 ASSY.
9A758 ASSY. REF.
L.
N-800001-S51M
2 REQ'D.
10-15 FT-LB
oI
9A758 ASSY.
/'
FRONT
FRONT OF
OF VEHICLE
VEHICLE
97409-S2 REF.
9728
9728 ASSY.
ASSY. REF.
REF.
.......1--_ _
7A186 ASSY.
ASSY. REF.
REF.
AUTO.
AUTO. TRANS.
TRANS. ONLY
ONLY
INTAKE
MANIFOLD REF
55981-S35M
ARD TRANS.
2.3 LITER STANDARD
2.3 LITER STAND EXCEPT AS SHOWN
SAME AS
AS MAIN VIEW EXCEPT AS SHOWN
VIEW
VIEW JTJ 2.3
2.3 &
& 2.8
2.8 LITER
LITER ENGINE
ENGINE
9A758
ASSY. REF.
9A758ASSY.
REF.
55981-S36M
78146
57632-S2
57632-S2 22 REO'D.
REQ'D.
10-15
10-15 FT-L8
FT-LB
...---
7A186 ASSY.
97409-S2~. _/'
2REO'D.
SLIDING INNER
MEMBER
CARBREF.
o TRANS.
2.3 LITRE AUTO.
LITRE AU~XCEPT AS SHOWN
VIEW EXCEPT AS SHOWN
SAME AS2.3
MAIN
VIEW
9728
9728 REF.
REF.
VIEW
VIEW 2
302
302 CID
CID ENGINE
ENGINE
Q
(Q
a>
78146
7B146
9728
/
FRONT OF VEHICLE
/
9728
FRONT OF VEHICLE
302 2V2V - A
AUTOMATIC
TRANSMISSION
UTOMATIC TRANSMISSION
302
SOUND ABSORBER
-J--q.382212-S2
382212-S2
~ 7A186
7A186 ASSY.
ASSY. REF.
REF.
DASH PANEL REF.
-Aitff'D
KICKDOWN ROD
ROD
7A186 ASSY.
7A186
ASSY,
ONLY
AUTO. TRANS. ONLY
ASSY. REF.
REF.
9A758 ASSY.
7B146REF.78146
REF,
VIEW IN
IN CIRCLE
CIRCLE V
VIEW
V
MAIN VIEW
2.8 LITER STANDARD AUTO. TRANS.
~:~~~~;~
ADJUSTMENT OF THE TRANS.

K.D. CONTROL
CONTROL
S K.D.
T~~:::~D
POS~T~~""~NNS~~~~
ADJUSTM
ENT OF
T W.O.T.
1. WITH CARBURETOR
HELD A
AT
W.O.T. POSITION AND THE
1. WITH
CARBURE
KICKDOWN
ROD 7A186
7A186 HELD
HELD DOWNWAR
DOWNWARDKICKDOWN
AGAINST THE
~~~ENT"
9E728 REF.
~HO~
"THROUGH DETENT" STOP.

STOP. ADJUST
ADJUST THE KICKDOWN
KICKDOWN
CLEARANCE
"THROUGH
ADJUSTING SCREW TO
TO OBTAIN
OBTAIN .01
.01 TTO ..08 CLEARANCE
ADJUSTING SCREW ND THROTTLE ARM.
BETWEEN SCREW
SCREW A
AND THROTTLE ARM.
BETWEEN
2. RETURN SYSTEM TO IDLE.
BACK TO GROUP INDEX
h)
~
ABSORBER ASSY. REF.

VIEW
hOft linkage-Mustang
FIG. 22 Throttle and
and Downs
Downshift
LinkageMustang
FIG.
I
2. RETURN SYSTEM TO 'OLE.
97409-S2
~2REO'D.
V1955-C
V1955-e
oI

~
~
~~~
VIEWB
,'I
9A758
9A758
..
DASH
DASH PANEL
PANEL REF.
REF.
9A758
9A758 ASSY.
ASSY. REF.
REF.
55981-S36M
55981-S36M
~~l
~
ABSORBER
ASSY. REF.
9728
9728
VIEW
VIEwB
VIEW 3
INSTALLATION FOR
FOR 351W
351W
INSTALLATION
CYLINDER AUTO.
AUTO. TRANS.
TRANS.
88 CYLINDER
TYPICAL
TYPICAL -- ALL
ALL ENGINES
ENGINES
KICKDOWN
KICKDOWN ADJ.
ADJ.
SCREW
SCREW REF.
REF.
33921-S2
33921-S2
FT-LB MIN.
66FT-LB
MIN.
VIEWZ
~7E310
9A758
9A758
7B182~\\ - .~
7A186 (REF.)
~(REFJ
57632-S2
/2REQ'D.
10-15 FT-LB
VIEWW
352358-S2
356297-S2
7A186
~-
383212-S2
7B 146 / " "
--I
:r
..,
/"'!)
....o
....(b
9728
VIEWA
VIEW
IN CIRCLE
CIRCLE V
V
VIEW IN
302-351 88 CYLINDER
CYLINDER
302-351
250 CID 6 CYLINDER

INSTALLATION FOR
AUTO. TRANS. SAME
AS STD. TRANS. EXCEPT
AS SHOWN
SPRING
7B146
SPRING 7B146
VIEW
250 C I D - 6 CYLINDER
~383212-S2
9A758
B O L T - 302217-S2
WASHER - 34792-S2
(2REQ'D.)
15-25 FT-LB
SOUND ABSORBER
RETAINER 9E728
SLIDING INNER
SLIDING
INNER
MEMBER
MEMBER
CABLE 9A758
SLIDING INNER
MEMBER
9728
9728
9728 REF.
REF.
9728
ADJUSTMENT
ADJUSTMENT OF
OF THE
THE TRANS.
TRANS. K.D.
K.D. CONTROL
CONTROL
1.
1. WITH
WITH CARBURETOR
CARBURETOR HELD
HELD AT
AT W.O.T.
W.O.T. POSITION
POSITION AND
AND THE
THE
KICKDOWN
KICKDOWN ROD
ROD 7A186
7A186 HELD
HELD DOWNWARD
DOWNWARD AGAINST
AGAINST THE
THE
"THROUGH
"THROUGH DETENT"
DETENT" STOP,
STOP, ADJUST
ADJUST THE
THE KICKDOWN
KICKDOWN
ADJUSTING
SCREW
TO
OBTAIN
.01
TO
.08
CLEARANCE
ADJUSTING SCREW TO OB,AIN .01 TO .08 CLEARANCE
BETWEEN
BETWEEN SCREW
SCREW AND
AND THROTTLE
THROTTLE ARM.
ARM.
INSTALLATION
INSTALLATION FOR
FOR
302-2V
302-2V 88 CYLINDER
CYLINDER AUTO.
AUTO.
TRANS.
TRANS. SAME
SAME AS
AS MAIN
MAIN
VIEW
EXCEPT
AS
SHOWN
VIEW EXCEPT AS SHOWN
2.
2. RETURN
RETURN SYSTEM
SYSTEM TO
TO IDLE.
IDLE.
SOUND ABSORBER
MAIN VIEW
VIEW
MAIN
INSTALLATION FOR
FOR STANDARD
STANDARD
INSTALLATION
TRANSMISSION 6-CYLINDER
6-CYLINDER 250
250 CID
CID
TRANSMISSION
PLATE 98767
98767
PLATE
VIEWy
VIEW
TYPICAL ALL
ALL ENGINES
ENGINES
TYPICAL
V1956~
FIG.
FIG. 33 Throttle
Throttle and
and Downshift
Downshift LinkageMonarch
linkage-Monarch and
and Granada
Granada
BACK TO GROUP INDEX

'SOUND
ABSORBER
SOUND ABSORBER
VIEWZ
9A758 ASSEMBLY
57632-S2
2 REQUIRED
57632-522
REQUIRED
10-15
10-15 FT-LB
FT-LB
VtEWZ
.-VIfEWZ
KICKDOWN
ADJUSTMENT
SCREW
9E728
9E728
9A758 ASSEMBLY
SLIDING INNER
MEMBER
55981-S36M
9728
7B182 ASSEMBLY
9726 ASSEMBLY
3O2
2V 8 CYLINDER
ENGINE
3I)2-2V
CYLINDER ,ENGINE
CARBURETOR
ADJUSTING SCREW
VIEW
Z
VIEWZ
7A186
1A186 ASSEMBLY
7A186 ASSEMBLY
KICKDOWN CONTROL ADJUSTMENT

1. WITH CARBURETOR
CARBURETOR HELD AT W.O.T.
W~O.T. POSITION AND THE
1.
DOWNWARD-AGAINST
KICKDOWN ROD 7A186 HELD DOWNWARD
AGAINST THE
"THROUGH DETENT" STOP,
STOP. ADJUST THE KICKDOWN
'THROUGH
OBTAtN .01
ADJUSTING SCREW TO OBTAIN
.01 TO .08 CLEARANCE
THROlTLEARM.
BETWEEN SCREW HEAD AND THROTTLE
ARM. LOCK IN
POSITION WITH LOCK NUT 33921.
f"
97409-52
97409-S2
7A394
7A394 ASSEMBLY
VIEWY
VIEWY
902-2V
CYLINDER ENGINE
302 2V 8 CYLINDER
AUTOMATIC TRANSMISSION
383212-S2
----4
::r
.,
6 CYLINDER ENGINE AUTOMATIC

AUTOMATIC
TRANSMISSION SAME AS STANDARD
TRANSMISSION EXCEPT AS SHOWN.
...
en
78146
7B146

RETAINER 9E728
EXISTING NUT
9A758 ASSEMBLY
SLIDING INNER MEMBER
7T
Q
CO
ABSORBER ASSEMBLY
(6501670)
7A186 ASSEMBLY
ASSEMBLY
7A186
9A758 ASSEMBLY
352358-S2
33921 REF.
REF. NUT-JAM
NUT-JAM
33921
55981-S36M 2 REQUIRED
~
~
_ _-
9726 ASSEMBLY
ASSEMBLY
356297-52
9728
5573-S36 2 REQUIRED
10-15 FT-LB
NOTE:
NOTE:
ABSORBER
VIEWY
VIEWY
PLATE
PLATE
COIL
COIL TO
TO BE
BE
MOUNTED
MOUNTED OVER
OVER
CABLE
CABLE BRACKET
BRACKET (9728
(9728 REF.)
REF.)
INSTALLATION
INSTALLATION FOR
FOR STANDARD
STANDARD TRANSMISSION
TRANSMISSION
66 CYLINDER
CYLINDER ENGINE
ENGINE
PEDESTAL & STUD
9A788 REF.
PART OF (6501670) ASSY.
DASH PANEL
PANEL REF.
REF.
DASH
AND 88 CYLINDER
CYLINDER ENGINES
ENGINES
66 AND
VIEWY
VIEWY
WASHER - 39792-S2
2 REQ'D.
302217-S2
2 REQUIRED
15-25 FT-LB
7E310 RER
7E310
REF.
KICKDOWN ADJ.
ADJ.
B 0 L T KICKDOWN
BOLT
CYLINDER ENGINE
ENGINE
66 CYLINDER
VIEWZ
VIEWZ
V1605-D
V1605-D
FIG.
FIG. 4 Throttle
Throttle and
and Downshift
Downshift linkageLinkage Maverick and
and Comet
Comet 6 Cylinder
Cylinder and
and 8 Cylinder
Cylinder Engines
Engines
BACK TO GROUP INDEX

9A758 ASSY.
9A758 ASSY.
9A758ASSY.
ASSY.
9A758
9B870
55981-S36M
55981-S36M
~.
_ - - _ 57632-S2
2 REO'D.
10-15 FT-LB
9728
9728
460-4V ENG.
ENG. INSTALLATION
INSTALLATION
460-4V
55981-S36M
VIEWZ
VIEWZ
351 "W"
"W" ENG.
ENG. INSTALLATION
INSTALLATION
351
VIEWZ
VIEWZ
VIEWZ
VIEW
Z 55981-S36M
55981-S36M
/2REO'D.
2 REQ'D.
~
)
9E728
9726
9726 ASSY.
ASSY. REF.
REF.
SLIDING
SLIDING INNER
INNER MEMBER
MEMBER
VIEWY
VIEWY
l~
97409-S2
9A758 ASSY.
REF.
7A186
7Al86 ASSY.
ASSY. REF.
REF.
DASH PANEL
DASH
PANEL
REF.
REF.
9E728REF.
9E728 REF.
VIEW
VIEW IN
IN CIRCLE
CIRCLE X
X
9E728 REF.
7A186 ASSY.
ASSY.
7A186
AUTOMATIC
AUTOMATIC
TRANS. ONLY
ONLY
TRANS.
DASH PANEL REF.
VIEWW
VIEWW
7A186 ASSY. REF.

/.~SSY.REF.
9A758
9A758 ASSY.
ASSY. REF.
REF.
9726 ASSY.
~9726ASSY.
55981-S36M
3~212~2
383212-S2
.-.r1~---55736-S36
10-15 FT-LB
PEDESTAL
PEDESTAL AND
AND STUD
STUD
'.25 MIN.
9728
KICKDOWN
KICKDOWN CONTROL
CONTROL ADJUSTMENT
ADJUSTMENT
SOUND
SOUND ABSORBER
ABSORBER 6501670
6501670
VIEWV
VIEW
V
1.1. WITH
WITH CARBURETOR
CARBURETOR HELD
HELD AT
AT W.O.T.
W.O.T. POSITION
POSITION
AND
ANDTHE
THE KICKDOWN
KICKDOWN ROD
ROD7A186
7A186 HELD
HELD DOWNWARD
DOWNWARD
AGAINST
AGAINSTTHE
THE "THROUGH
"THROUGH DETENT"
DETENT"STOP.
STOP,
ADJUST
E KICKD0WN
ADJUST
THE KICKDOWNADJUSTING
ADJUSTINGSCREW
SCREW
OBTAIN.01
.01 TO
TO.08
.08CLEARANCE
CLEARANCEBETWEEN
BETWEEN
T TO
0 OBTAIN
SCREW
SCREWAND
ANDTHROTTLE
THROTTLEARM.
ARM.
2.2. RETURN
RETURN SYSTEM
SYSTEMTO
TO IDLE.
IDLE.
~KICKDOWN
KICKDOWN
, NINSTALLATION
3 351M
5 1 M & &4 0400
0 E NENG.
G
S T ALLATION
VIEWZ
VIEW Z
VIEW IN
INCIRCLE
CIRCLEW
W
VIEW
ADJUSTMENT
ADJUSTMENT
SCREW
SCREW
V1609-E
V1609-E
FIG.
FIG. 55 Throttle
Throttle and
and Downshift
Downshift LinkageTorino,
Linkage-Torino, Elite,
Elite, Montego
Montego and
and Cougar
Cougar
BACK TO GROUP INDEX

9A758 ASSY.
.25 MIN.
MIN.
57632-S2
2 REO'D.
10-15 FT-LB
9A758 ASSY.
9A758 ASSY. - - _......
55981-S36M
~...--9E728
9E728
57632-S2 2REO/D.
10-15 FT-LB
9728
ABSORBER ASSY.
351M & 400 ENG.

ENG. INSTALLATION
INSTALLATION
FOR 351M&
~--- ......--
55981-S36M
VIEWS
VIEWW
VIEWT
9728 REF.
DASH PANEL REF.
VIEWS
RETAINER 9E728
VIEWS
INSTALLATION
FOR 460 ENG. INSTALLATION
ADJUSTMENT OF THE TRANS. K.D. CONTROL

1. WITH CARBURETOR HELD AT W.O.T. POSITION AND
THE KICKDOWN ROD 7A186 HELD DOWNWARD
'THROUGH DETENT" STOP ADJUST
AGAINST THE "THROUGH
THE KICKDOWN ADJUSTING SCREW TO OBTAIN
.01 TO .08 CLEARANCE BETWEEN SCREW AND
.01
THROTTLE ARM.
LARGE HOOK
9A758 ASSY. REF.

RETAINER 9E728
VIEWU
7B146
KICKDOWN ADJUSTING
SCREW REF.
9726 ASSY. REF.
. 7A186
AUTO. ONLY
VIEWV
7A186REF'
(9B7671 PART OF (65016701 ASSY.
_~97409-S2
~-~
/
7A186 REF.
VIEWT
VIEWV
VIEWV
DASH PANEL REF.

PEDESTAL &
& STUD
VIEW Z
V1610-E
V1610E
LinkageFord, Mercury and Meteor

FIG. 6 Throttle and Downshift Linkage-Ford,
BACK TO GROUP INDEX

..$
w
9A758 ASSEMBLY
ASSEMBLY
9A758
TYPICAL CABLE
CABLE INSTALLATION
INSTALLATION
TYPICAL
ALL ENGINES
ENGINES
ALL
7Al86
7A186 ASSEMBLY
ASSEMBLY
383212S2
383212-S2
'.
7Al86
7A186 ASSEMBLY
ASSEMBLY
55914-S36M
9140952
97409-S2
VIEWW
VIEWW
VIEW
VIEW IN
IN CIRCLE
CIRCLE V
V
57632-S2 22 REQUIRED
REQUIRED
51632-S2
FT-LB
10-15 FT-lB
9728
9728
.25 MIN.
9A758 ASSEMBLY
ASSEMBLY
VIEW X
ASSY. REF.
REF.
9A758 ASSY.
7A186 ASSEMBLY
ASSEMBLY
1A186
COLOR CODE
CODE THIS
THIS
COLOR
AREA
AREA
DASH
DASH PANEL REF.
REF.
9E728REF.
REQUIRED
VIEWX
VIEWW
Qb~
L.
RETAINER 9E728
ABSORBER ASSY. REF.
7B146
7B146
9A758 ASSEMBLY
VIEWW
9726 ASSEMBLY
LARGE
lARGE HOOK
DASH PANEL
9726
ASSEMBLY
ABSORBER ASSY. (6501670)
SH 1FT CABLE REF.
55736S2
55736-S2
REQUIRED
22 REQUIRED
8-14
FT-LB
8-14 FT-LB
KICKDOWN
KICKDOWN CONTROL
CONTROL ADJUSTMENT
ADJUSTMENT
1.
1. WITH
WITH CARBURETOR
CARBURETOR HELD
HELD AT
AT W.O.T.
W.O.T. POSITION
POSITION AND
AND THE
THE
KICKDOWN
KICKDOWN ROD
ROD 7A186
7A186 HELD
HELD DOWNWARD
DOWNWARD AGAINST
AGAINST THE
THE
'THROUGH
"THROUGH DETENT"
DETENT" STOP,
STOP, ADJUST
ADJUST THE
THE KICKDOWN
KICKDOWN ADJUSTING
ADJUSTING
SCREW
TO
OBTAIN
.01
TO
.08
CLEARANCE
BETWEEN
SCREW TO OBTAIN .01 TO .08 CLEARANCE BETWEEN SCREW
SCREW
AND
AND THROTTLE
THROTTLE ARM.
ARM.
2.
2. RETURN
RETURN SYSTEM
SYSTEM TO
TO IDLE.
IDLE.
sour~D ABSORBER
ABSORBER
SOUND
~
~
I
VIEW ZZ
VIEW
V1611-D
V1611-D
0-
oI
CD
FIG. 7 Throttle
Throttle and
and Downshift
Downshift LinkageThunderbird
Linkage-Thunderbird and
and Continental Mark
Mark IV (1975)
BACK TO GROUP INDEX

9A758 ASSEMBLY
TYPICAL CABLE INSTALLATION
ALL ENGINES
7A186 ASSEMBLY
383212-S2
7A186 ASSEMBLY
55914-S36M
97409-S2
97409-S2
VIEWW
VIEW IN CIRCLE V
57632-S22
57632-S2 2 REQUIRED
10-15 FT-LB
9728
9A758 ASSEMBLY
VIEWX
9A758 ASSY. REF. -
7A186 ASSEMBLY
COLOR CODE THIS
AREA
AREA.
VIEWX
DASH PANEL REF.
~
L_
VIEWW
9E728
REF.
9E728REF.
55981-S36M
REQUIRED
RETAINER 9E728
ABSORBER ASSY. REF.
7B146
9A758 ASSEMBLY
VIEWW
VIEWZ
LARGE HOOK
DASH PANEL
9726
ASSEMBLY
SHIFT CABLE REF.
ABSORBER ASSY. (6501670)

55736-S2
2 REQUIRED
REQUIRED
8-14 FT-LB

1. WITH CARBURETOR HELD AT W.O.T. POSITION AND THE
KICKDOWN ROD 7A186 HELD DOWNWARD AGAINST THE
STOP, ADJUST THE KICKDOWN ADJUSTING
"THROUGH DETENT" STOP.
SCREW TO OBTAIN .01
.01 TO .08 CLEARANCE BETWEEN SCREW
AND THROTTLE ARM.
SOUND ABSORBER
VIEWZ
VIEW Z
V1611-E
FIG. 8
V (1976)
8 Throttle and
and Downshift Linkage-Thunderbird and
and Continental Mark IIV
BACK TO GROUP INDEX

..
~
I
0-
...
oI
o
9A758 ASSY.
9E728
9726 ASSY.
.-
KICKDOWN ROD
CABLE
ACCELERATOR CABLE
j'
_~I \
--
55914-S36M
55914-536M~~I'~/T.
a; .
-~
,-3,
....-
57632-52
(2 REO'DJ
10-15 FT-LB
BRACKET 9728
BRACKET9728~_.~"'I"--
VIEWX
--..::---
~~
DASH PANEL
)-
VIEWy
VIEWV
r-
~
+
:r
ACCELERATOR CABLE 9A758
"
CO
KICKDOWN ROD
CD
VIEWZ
LARGE HOOK - - - . -... "'.-
KICKDOWN ADJUSTMENT
SCRE~
COLOR CODE FOR ACCELERATOR CABLE ASSEMBLY

ENGINE 460 4V
COLOR CODE
BLACK
BLACK
---
VIEWV
;;[./
I-~'
~--

A. WITH CARBURETOR
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 0.010 - 0.080 INCH
CLEARANCE BETWEEN SCREW AND THROTTLE ARM.
B. RETURN SYSTEM TO IDLE
IDLE-NEUTRAL.
- NEUTRAL.
.
~
VIEWX
0-
...o
oI
V1723 D
0
V1723
FIG. 9 Throttle and Downshift LinkageLincoln

Linkage-Lincoln Continental
BACK TO GROUP INDEX

24-60-11
24-60-11
ACCELERATOR CABLE
MOUNTING BRACKET
All Models
Removal
Removal
accelerator cable
1.
mounting screw. Remove the cable
from the bracket.
2.
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).
Ins/aHa/ion
Installation
1. Install the acceleraror
accelerator cable mounting
1.
bracket on the engine and torque the
specification.
attaching bolts to specification.
BACK TO GROUP INDEX
24-60-11
24-60-11
Throttle Linkage
Reinstall the cable and attaching
Pinto/Bobcat and
screw. On Pinto/Bobcat
Mustang 2.3L engines, reconnect
automatic transmission kickdown rod
(if equipped).
ACCELERATOR PEDAL ASSEMBLY
All Models
Removal
Removal
1.
1. Using a suitable tool, push the
accelerator cable nylon bushing out of
the accelerator pedal arm.
2.
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.
Ins/aHa/ion
Installation
1.
1. Install the pedal pad cover, if so
carefully crimp the
equipped, and carefully
retaining tabs.
2. Position the pedal assembly on the

2.
two mounting studs and install the
nuts. Check to be sure
two attaching nuts.
that carpeting and/or sound deadener
is properly assembled. Torque to
specifications.
3. Install the snap-in nylon bushing of
of
accelerator cable into the
the accelerator
accelerator pedal arm.

26-01-1
26-01-1
26-01-1
26-01-1
Exhaust System
System
Exhaust
GROUP
GROUP
Exhaust System
PART 26-01
26-01
PART
General Exhaust
Exhaust System
System" """. "." ". ". """
General
PART
26-02
PART 26-02
Four Cylinder
Cylinder Engine
Engine Single
Single
Four
Exhaust System
"
"
"..
PAGE
PAGE
26-01-1
26-01-1
26-02-1
26-02-1
PART 26-03
26-03
PART
V-6 Exhaust
Exhaust Systems
Systems
V-6
26-03-1
26-03-1
26
PART 26-10
26-10
PART
PAGE
PAGE
Six Cylinder
Cylinder Single
Single
Six
Exhaust
Exhaust System
System
PART 26-20
26-20
PART
V-8 Single
Single Exhaust
Exhaust System
System
V-8
PART 26-22
PART
V-8
V-8 Dual
Dual Exhaust
Exhaust System
System
"
26-10-1
26-10-1
26-20-1
26-20-1
"..
26-22-1
26-22-1
PART 26-01 General Exhaust System Service

infonnation in this Part applies to both 1975 and 1976 model
ITIodel year vehicles unless otherotherNOTE: The information
wise specified.
CR1966A
CR1966A
GENERAL INFORMATION
INFORMATION
This Part covers the general exhaust
system, adjustments
adjustments and repair
repair
procedures.
procedures.
Always refer to the Master Parts
Catalog
C a t a l o g for parts
p a r t s usage
u s a g e and
and
interchageability before replacing a
component part of the
the exhaust system.
system.
The
The exhaust system must be
be free of
leaks,
leaks, binding,
binding, grounding
grounding and excessive
vibrations.
vibrations.
These
These conditions
conditions are
are usually
usually caused
by
by loose,
loose, broken
broken or
or misaligned
misaligned clamps,
clamps,
shields, brackets or pipes.

pipes. If any of these
conditions exist, check the exl)aust
exhaust
system components and alignment.
Adjust or replace as necessary to
maintain the specified clearances (refer
to the illustrations in each part).
insulators
Brackets, clamps and insulators
should be replaced if they are damaged
or badly corroded. Do not attempt to
these parts.
parts.
repair these
outlet
Inspect the inlet pipe(s), outlet
pipe(s), catalytic converters,
converters, resonator(s)
pipe(s),
and muffler(s)
muffier(s) for cracked joints, broken
welds and corrosion damage that would
result in a leaking exhaust system.
Inspect the clamps, brackets and
Inspect
insulators for cracks and stripped or
badly corroded
corroded bolt threads. When pipe
badly
clamp(s) are loosened and/or removed to
replace aa pipe,
pipe, muffler
muffler 'or
or resonator,
resonator,
replace
replace the
the clamp(s)
clamp(s) if
if there
there is
is reasonable
reasonable
replace
doubt that
that its
its service
service life
life is
limited.
is limited.
doubt
DESCRIPTION
DESCRIPTION AND APPLICATION
APPLICATION
Fig.
Fig. 11lists
liststhe
thevarious
variousexhaust
exhaustsystem
system
applications.
applications.
SINGLE
SINGLE EXHAUST
EXHAUST SYSTEMS
SYSTEMS
The
The factory-installed
factory-installed single
single exhaust
exhaust
system
system in
in aa veliicle
vehicle with
with aa 4-cylinder
4-cylinder
engine
engine consists
consists of
of aa muffier
muffler inlet
inlet pipe,
pipe,
connected
connected to
tothe
theexhaust
exhaustmanifold,
manifold, which
which
is,
is, in
in turn,
turn, connected
connected to
to aa muffier.
muffler.
The
Thesingle
singleexhaust
exhaust system
system in
in aavehicle
vehicle
with
with an
an in-line
in-line 6-cylinder
6-cylinder engine
engine isis the
the
same
same basic
basic design
design as
as that
that for
for the
the
4-cylinder
4-cylinder engine.
engine.
The
The single
single exhaust
exhaust system
system on
on some
some
vehicles
vehicles equipped
equipped with
with aa V-6
V-6 engine
engine isis
new
new for
for 1976.
1976. The
The new
new exhaust
exhaust system
system
consists of
of aa one-piece
one-piece catalytic
catalytic conconconsists
verter and
and inlet
inlet pipe
pipe assembly,
assembly, conconverter
nected to
to the
the exhaust
exhaust manifold,
manifold, and
and
nected
alsoconnected
connected to
toaamuffler.
muffler.
also
BACK TO GROUP INDEX
INLET PIPE
PIPE EXTENSION
EXTENSION AND
AND
INLET
MUFFLER ASSEMBLY
ASSEMBLY
MUFFLER
Some 4-cylinder
4-cylinder and
and 6-cylinder
6-cylinder
Some
exhaust systems
systems may
may also
also include
include a
exhaust
converter. Refer
Refer to
to Parts
Parts 26-02,
26-02,
catalytic
26-03 or
or 26-10
26-10 for
for appropriate
appropriate
26-03
procedures.
replacement
DUAL EXHAUST
EXHAUST SYSTEMS
SYSTEMS
DUAL
Dual exhaust
exhaust systems
systems used
used with
with the
the
Dual
V-6 engine
engine consist
consist of:
of: A
A muffier
muffler inlet
inlet
V-6
"H" pipe,
pipe, leading
leading from
from the
the engine
engine into
into
"H"
two resonators
resonators and
and in
in turn
turn into
into one
one
two
muffler.
muffier.
Dualexhaust
exhaust systems
systemsfor
for use
usewith
with the
the
Dual
V-8 engines
engines are
are similar
similar but
but mayor
may or may
may
V-8
notuse
useaaresonator.
resonator. Both
Both66and
and88cylinder
cylinder
not
exhaust systems
systems can
can also
also include
include one
one or
or
exhaust
two catalytic converters.
converters. Refer to
to Part
two
26-22 for
for replacement
procedures.
26-22
EXHAUST SHIELD
SHIELD REPAIR
EXHAUST
AND/OR REPLACEMENT-ALL
REPLACEMENTALL
ANDIOR
VEHICLES SO
SO EQUIPPED
EQUIPPED
VEHICLES
Exhaust shields,
shields, consisting
consisting of
of formed
formed
Exhaust
and perforated
perforated metal
metal sheets
sheets (Fig.
(Fig. 2),
2),
and
attach to
to the
the exhaust
exhaust system
system or
or the
the
attach
catalytic converter
converter connections
connections using
using
catalytic
various methods.
methods.
various
Exhaust shields
shields are
are not
not subject
subject to
to
Exhaust
r e p a i r other
o t h e r than
t h a n replacing
replacing
repair
missing/damaged attaching
attaching parts
parts such
such as
as
missing/damaged
clamps or
or screws
screws and
and removing
removing debris
debris
clamps
that may
may collect
collect in
in the
the shield
shield area.
area. If
If an
an
that
26-01-2
General Exhaust System
exhaust shield is damaged or shows

evidence of deterioration it should be
replaced rather than repaired.
are,
Removal/Installation procedures are,
in most cases, a matter of removing the
shield attachments
attachments and shield;
shield;
shield
installation is the
the reverse process using
new parts. However, some exhaust
shields are
are welded
welded to
to the
the exhaust
exhaust system
system
and require additional instructions.
Car Line
Engine
Pinto/
Bobcat
Mustang
(A)
(A)
Maverick!
(A)
Maverick/ (A)
Comet
(A)
Granada!
(A)
Granada/ (A)
Monarch
(A)
Torlno/
Torino/
Elite
Montego
Cougar
Ford/
Mercury
Thunderbird
Mark IV
IV
Lincoln
2.3L4
2.3l4
2.8 V6
2.a
2.3l4
2.3L4
2.3L4
2.3l4
2.al
2.8L V6
V8
302 va
V8
302 va
200-6
250-6
250-6
V8
302 va
200-6
250-6
250-6
302 V8
va
351-W
351-W
351 -W
351M-400
460-4V
460-P.I.
351-M
351
-M
400
400
460-4V
460..P.I.
460-P.I.
460 (E)
460 (F)
400
400
Single
Exhaust
26-01-2
be removed using a
Welded shields must be
the weld joints being
chisel to separate the
careful not to damage the pipe.
careful
Installation of the new shield is
the new
accomplished by positioning the
new
shield to the pipe in the previously
and attaching it
removed shield position and
with proper size Prestole type clamps.
The car line exhaust illustrations
indicate the types and proper positioning
Dual
Exhaust
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
(A) Released for

for 1975Vz.
(B) Automatic transmission uses one converter.
(C) Diffuser not required on Sedan.
CONVERTER USAGE
49
Canada
Calif.
States
0
1
0
2
0
2
1
0
0
1
1
0
2
0
2
N/A
0
0
N/A
N/A
1
N/A
2
1
0
N/A
N/A
0
0
1
1
1
0
(B)
1
(B)00
0
1
N/A
0
N/A
1
0
0
1
0
1
1
1
0
1
0
0
1
N/A
N/A
NlA
N/A
1
2
0
1
0
2
1
0
2
1
2
0
1
0
2
1
2
0
1
0
2
N/A
1
N/A
2
N/A
1
0
N/A
1
2
0
and clamps. In
of exhaust shields and
addition, the illustrations list the Prestole
clamp sizes necessary for shield
applications.
car line exhaust illustrations
The car
indicate the types and proper positioning
and clamps. In
of exhaust shields and
addition, the illustrations list the Prestole
clamp sizes necessary for shield
applications.
fflQQoiS
Models
Resonator
Diffuser
Sedan &
&
Station Wagon
Yes
Yes
Yes
Yes
No
No
No
No
Sedan
Yes
Yes
No
No
Sedan
Yes
Yes
No
No
Yes
Yes
Yes
Yes
Sedan
Yes
Yes
No
No
Sedan & Ranchero

Sedan - Station Wagon - Ranchero
Sedan
sedan
Sedan
Sedan & Station Wagon
Sedan
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
Yes
Yes
Yes
Yes
(C) Yes
No
No
Yes
Yes
Yes
Yes
(D)
No
(D)No
No
No
Sedan
Yes
Yes
No
No
Sedan
Yes
Yes
Yes
Yes
(D)
(D) Station Wagon requires a diffuser.
(E)
(E) With 3.00 axle.
(F)
(F) With 2.75 axle.
CU1497-C
FIG. 1 Exhaust System Applications-1975

Applications1975
BACK TO GROUP INDEX

26-01-3
Line
Car line
Pinto/
Pintol
Bobcat
Mustang
Maverick!
Maverick/
Comet
Granada/
Granada!
Monarch
Torino/
Torinol
Elite
Montego
Cougar
Ford/
Fordl
Mercury
Thunderbirdl
Thunderbird/
Mark IV
Lincoln
General Exhaust System
Engine
2.3L4
2.3L 4
2.8 V6
2.3L44
2.3L
2.8 V6
302 V8
200-6
250-6
302-V8
300-6
250-6
302-V8
351-W
351-W
351M-400
All 460-4V &
&
Cal. P.1.
P.I.
49S 460-P.I.
351-M
400
All 460-4V &
&
Cal. P.1.
P.I.
49S 460-P.I.
460-P.1.
460 (E)
460 (F)
460
Single
Exhaust
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Dual
Exhaust
CONVERTER USAGE
49
Canada
Calif.
0
0
0
0
0
(B)
(B)00
(B)
(B)00
(B)
(B)00
(B) 0
(B)0
(B)
(B)00
(B)
(B)00
(B)
(B)00
N/A
0
1
2
1
2
2
N/A
1
1
N/A
1
1
1
N/A
2
X
X
2
1
2
2
0
N/A
0
0
2
N/A
2
2
X
X
1
2
2
2
N/A
N/A
0
0
N/A
2
2
2
(A)
(A)XX
(A)
(A)XX
(A)
(A)XX
States
1
2
1
2
2
1
1
1
1
1
#
* 11
1
1
X
X
X
X
For Canadian only.

(A) For
(B) Manual transmission requires one converter.
not required on
on Sedan.
(C) Diffuser not
26-01-3
Models
Resonator
Diffuser
Sedan &
&
Station Wagon
Yes
Yes
No
No
Sedan
Yes
Yes
No
No
Sedan
Yes
Yes
Yes
Yes
Yes
Yes
No
No
No
No
Yes
Yes
Sedan
Yes
Yes
No
No
Sedan & Ranchero

Sedan - Station Wagon -
Ranchero
Sedan
Sedan
Sedan &
&
Station Wagon
Sedan
No
No
No
No
Yes
Yes
Yes
Yes
No
No
No
No
No
No
No
No
(C) Yes
No
No
Yes
Yes
Yes
Yes
No
No
(D)
No
(D)No
No
No
No
No
Sedan
Yes
Yes
No
No
Sedan
Yes
Yes
Yes
Yes
(D)
(D) Station Wagon requires a diffuser.
(E) With 3.00
(E)
3.00 axle.
axle.
(F)
(F) With 2.75
2.75 axle.
CU1497-D
FIG.
FIG. 2 Exhaust System Applications-1976
Applications1976
BACK TO GROUP INDEX

MAVERICK/COMET
TYPE I - MAVERICK/COMET
GRANADA/MONARCH
FORD/MERCURY
TYPE V - FORD/MERCURY
EXHAUST SHIELD CLAMP USAGE - 1975 APPLICATION
1A
TYPE lA
EXHAUST SHIELD
VEHICLE
VEHICLE
TYPE V B
TYPE SHIELD
SHIELD
GRANADA/MONARCH J
GRANADA/MONARCH
2'
'1
TYPE IC
"TYPE
EXHAUST SHIELD
't--""""iJ~======~~ TYPE II B
6.J
(TOP VIEW)
TYPE VIA
VI A
TYPE II - MUSTANG
2"
2"
2-1/4"
MUSTANG
IIA
II
A
II B
liB
2
2
FORD/MERCURY
FORD/MERCURY
III
A
iliA
HI B
IIIB
III C
C
IV A
A
IV B
B
IV C
C
IV D
VA
V A
VB
B
FORD/MERCURY
FORD/MERCURY
RESONATOR
TYPE IlA
II A
MAVERICK/COMET
MAVERICK/COMET
TORINO/MONTEGO )
TORINO/MONTEGO
COUGAR/ELITE
COUGAR/ELITE
VI A
VIA
VI B
VIB
VII A
A
VII B
B
LOCATION
LOCATION
2-1/2"
INLET
INLET
PIPES
2
2
2
}
'
EXHAUST SHIELD
MAVERICK/COMET
TYPE VI - MAVERICK/COMET
SIZE/QUANTITY
SIZE/QUANTITY
IA
1 A
IB
B
IC
IC
MAVERICK/COMET
MAVERICK/COMET
~~
CLAMP
1-3/4"
1 *
1*
h\r.
1#
INLET
PIPES
INLET
PIPES
INLET
PIPES
11
2
2
11
11
2
2
11
INLET
PIPES
EXHAUST SHIELDS
*GRANADA/MONARCH*iIIIAVERICK/COMET
*GRANADA/MONARCH
WlAVERICK/COMET
TYPE II B
SCREW
PRESTOLE CLAMP ORIENTATION
PRESTOLE CLAMP
FORD/MERCURY
TYPE III - FORO/MERCURY
PRE:;TOLE
PRE.STOLE CLAMP
TYPE 1MB
TYPE III A
EXHAUST SHIELD
TYPE IIIC
EXHAUST SHIELD
EXHAUST SHIELD
SEE
SEE VIEW 11 - 1
EXHAUST SHIELD
SEE VIEW
V I E W3 3- - 3
SEE VIEW4
V I E W 4-- 4
SEE VIEW 2 - 2
SEE
TYPE IV - FORD/MERCURY
TYPE IVA
IV A
TORINO/MONTEGO/COUGAR/ELITE
TYPE VII - TORINO/MONTEGO/COUGAR/ElITE
TYPE IVB
-TYPE VII B
h)
TYPE IVC
....
0I
TYPE VII A
D
TYPE IV
IVO
U1557B
U1557-B
Installation1975
FIG. 3 Exhaust Shield Installation-1975
BACK TO GROUP INDEX

TYPE I -- MAVERICK/COMET
MAVERICK/COMET
TYPE'
h
0-.
...o
EXHAUST SHIELD CLAMP USAGE -- 1976 APPLICATION
TYPE 1A
IA
EXHAUST SHIELD
TYPE SHIELD
VEHICLE
CLAMP
2"
2"
1-3/4"
MUSTANG
MUSTANG
IIA
II A
II B
liB
CM CM
2'
'+----1j~======~~ TYPE'
B
TYPE IB
6
..J
EXHAUST SHIELD
MAVERICK/COMET
TYPE V
V -- MAVERICK/COMET
TOR
INO/MONTEGO/
TORINO/MONTEGO/
COUGAR/ELITE
lilA
III A
III B
IllB
(TOP VIEW)
TYPE II -- MUSTANG
RESONATOR
TYPE V A
FORD/MERCURY
IV A
IVA
IV B
IV C
D
IV 0
TYPE HA
IIA
MAVERICK/COMET
MAVERICK/COMET
11
LOCATION
(II
2-1/2"
2 1/2"
INLET
PIPES
2
2
'(..,.J
IC
' \ TYPE IC
EXHAUST SHIELD
2-1/4"
IA
I A
IIB
B
IC
MAVERICK/COMET
MAVERICK/COMET
")
SIZE/QUANTITY
SIZE/QUANTITY
2
2
INLET
PIPES
INLET
PIPES
11
INLET
PIPES
11
2
V
A
VA
1
1
VB
VB
5'
TYPE VB
EXHAUST SHIELDS
SHI ELDS
TYPE II B
SCREW
PRESTOLE CLAMP ORIENTATION
PRESTOLE CLAMP
III -- TORINO/MONTEGO/COUGAR/ELITE
TORINO/MONTEGO/COUGAR/ELITE
TYPE III
PRE~iTOLE CLAMP
PRESTOLE
TYPE III B
CJ)
"<
CIt
3
EXHAUST SHIELD
TYPE III A
EXHAUST SHIELD
EXHAUST SHIELD
EXHAUST SHIELD
SEE VIEW 1 -- 1
SEE
1
SEE
3- 3
SEE VIEW
VIEW3-3
SEE VIEW
VIEW4-4
SEE
4- 4
SEE VIEW 2
2 -- 2
SEE
2
VEHICLE MEMBER
PRESTOLE CLAMP
IV -- FORD/MERCURY
TYPE IV
PRESTOLE CLAMP
A
TYPE IV A
TYPE IVB
TYPE IVC
EXHAUST SHIELD
h
0-.
TYPE IV O
TYPE'VD
SEE VIEW
V I E W6 6- - 6
SEE
...o
I
EXHAUST SHIELD
SEE VIEW5
VIEW5-5
SEE
- 5
U1557-C
(II
FIG. 44 Exhaust Shield Installation-1976

Installation1976
BACK TO GROUP INDEX

26-02-1
26-02-1
26-02-1
26-02-1
Four Cylinder Engine Single Exhaust System
PART 26-02 Four - Cylinder Engine

Single Exhaust System
COMPONENT INDEX
DESCRIPTION ......................
REMOVAL AND
Resonator Inlet Pipe -Pinto/Bobcat/
Pi
nto/Bobcat/
Mustang (Front)
Without Catalytic
Converter .................
Page
02-1
02-1
02-1
02-1
!
02-1
02-1
Page
COMPONENT INDEX
Resonator Inlet Pipe -Pinto/Bobcat/
Pinto/Bobcat/
Mustang (Front) With
Catalytic Converter .............
Muffler and ResonatoJ
Resonator Assembly -Pinto/Bobcat/Musiang .............
Pinto/Bobcat/Mustang
Catalytic Converter - Pinto ...........
Catalytic Converter - Mustang .........
02-1
02-1
02-2
02-2
02-2

information in
to both 1975 and
and 1976 anodel
CR1966-A
CR1966A
DESCRIPTION
The 4-cylinder Pinto, Bobcat and
and
use a single-pipe type exhaust
Mustang use
system. The
The production exhaust system
differs from the
the service replacement
differs
in the
the number of basic pieces
system in
used.
For instance, the
the factory-installed
factory-installed
Pinto/Bobcat system consists of two
two
pieces for non-catalytic converter
for converter
systems, and
and three pieces for
systems. The
The first piece is
is the
the mumer
muffler
to the
the engine
inlet pipe which connects to
exhaust manifold. The

The second piece
the
consists of a section of inlet pipe, the
to muffler
muffler pipe,
resonator, resonator to
muffler and tailpipe, all
all welded together.
mumer
On catalytic converter systems, the
is a bolt-on unit
converter assembly is
the inlet pipe to
to the
connected between the
the
manifold and
the inlet pipe to the
manifold
and the
The connections used are
are a
reasonator. The
flat flange
new cone flange
flat
flange and new
flange or ball
flange atat the
the rear
rear of
of the
theconverter.
converter. For
For
flange
service replacement, this Pinto/Bobcat
system is usually furnished

furnished in four
separate pieces and
and is
is assembled with
clamps. The
The rear section of the
the mumer
muffler
clamps.
is furnished separate from the
the
inlet pipe is
muffler and
and is usually called the
muffler
muffler inlet pipe.
intermediate mumer
and
All models of the Pinto, Bobcat and
Mustang are
are equipped with exhaust
system resonators.
For exact service replacement parts
information, refer to
to the
the Motorcraft
Motorcraft
Master Parts Catalog.
REMOVAL AND
AND INSTALLATION
Typical factory installed exhaust
for the 2300cc
23OOcc engines
engines are
are shown
shown
systems for
Figs. 1 through 4.
in Figs.
4.
RESONATOR INLET
PIPEPINTO/BOBCAT/MUSTANG
PIPE-PINTO/BOBCAT/MUSTANG
(FRONT) WITHOUT CATALYTIC
CONVERTER
RemoYal
Removal
1.
1. Raise the
the vehicle.
2.
the
2. Remove the
the screws that attach the
front hanger insulator to the inlet pipe
bracket.
3. Support
Support the
the resonator/muffler
resonator/muffler
assembly with a soft wire and remove
to resonator slip joint
the inlet pipe to
clamp.
clamp.
the attaching nuts securing
4. Remove the
the inlet pipe to
to the exhaust manifold
and remove the
the inlet pipe.
5.
parts.
5. Replace
Replace any
any damaged
damaged parts.
Installstion
Installation
1.
1. Clean
Clean the
the exhaust
exhaust manifold
manifold outlet
outlet
seat.
seat.
BACK TO GROUP INDEX
2.
2. Insert the
the inlet pipe in
in the
the resonator
pipe and install but do not tighten the
the
clamp.
clamp.
3. Position the inlet pipe to the manifold
flange and loosely install the
attaching nuts.
4. Loosely attach the
the front hanger
insulator to
to the
the inlet pipe bracket.
5. Align the
the exhaust
exhaust system
system to
to conform
conform
to clearance specifications (Figs.
(Figs. 11
3). Starting at the rear of the
through 3).
system, torque all
all nuts, screws or
bolts.
6.
6. Check the system for
for leaks and lower
the vehicle.
RESONATOR INLET
PIPE-PINTO/BOBCAT/
MUSTANG
PIPEPINTO/BOBCAT/MUSTANG
(FRONT) WITH CATALYTIC
CONVERTER
Removal
RemoYal
1.
1. Raise the
the vehicle.
2.
the
2. Remove the
the screws that attach the
front hanger insulator to the inlet pipe
bracket.
Support the
resonator/muffler
3. Support
assembly with a soft wire.
4.
4. Pinto and
and Bobcat Vehicles-Remove
VehiclesRemove
the nuts that attach the
the conVerter
converter
outlet to
flange
to the
the resonator pipe flange
connection and
and remove the
the nuts that
flange to the
attach the converter inletflange
inlet pipe.
5. Mustang Vehicles-Remove
VehiclesRemove the
attaching nuts at the cone type flange
flange
connection located at the
the rear of the
6. Remove the
the nuts attaching the
the inlet
pipe flange
flange to
to the
the exhaust manifold,
and remove the
On
the inlet pipe. On
Mustang, the inlet pipe and converter
are one
one assembly and
and must be
as a unit.
removed as
7.
7. Replace any
any damaged parts.
Installation
Instsllstion
1. Clean the
the exhaust manifold
manifold and
1.
and
catalytic converter flange

flange seats.
2.
2. Pinto and
and Bobcat Vehicles-Using
VehiclesUsing a
new gasket, position the
the inlet pipe to
26-02-2
3.
4.
5.
5.
6.
6.
7.
7.
8.
8.
Four Cylinder Engine Single Exhaust System
the catalytic converter and loosely

start the attaching nuts.
Mustang Vehicles-Position
VehiclesPosition the inlet
pipe/catalytic converter assembly to
the resonator pipe flange and loosely
Position the inlet pipe to the manifold
and install but do not tighten the
attaching nuts.
Install the front hanger bracket
insulator to inlet pipe bracket. Do not
tighten the attaching screws.
Remove the wire support for the
resonator muffler
muffler assembly.
Align the exhaust system to proper
clearance specifications and starting
at the front, tighten all nuts, screws,
and bolts to specification.
Check the exhaust system for leaks
and lower the vehicle.
MUFFLER AND RESONATOR

ASSEMBLY-PINTO/BOBCAT/
ASSEMBLYPINTO/BOBCAT/
MUSTANG
Removlll
Removal
1.
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
and
replace the muffier,
muffler, resonator and
pipe.
2.
Non
2. N
o n cat
c a t a lI yy ttic
i c con
c o n vvee rr t e r
vehiclesloosen and remove the inlet
vehicles-loosen
pipe to resonator pipe clamp.
3. Catalytic
Catalytic converter
converter equipped
equipped
vehicles-remove the rear converter
vehiclesremove
BACK TO GROUP INDEX
to resonator pipe flange connection

attaching nuts (Figs.
(Figs. 1 through 3).
4. Remove the attaching screws from
the rear hanger assembly to muffier
muffler
support.
5.
5. Slide the muffler
muffler and resonator
assembly rearward to disconnect it
from the resonator inlet pipe.
6.
the intermediate support on the
muffler inlet pipe and remove the
muffler
resonator/muffler assembly.
resonator/muffier
7.
7. Replace any damaged parts.
Instlll/stion
Installation
1.
1. Position the resonator and muffler
muffler
assembly over the rear axle and
loosely attach the intermediate
intermediate
support bracket (Figs.
2. N
Non
o n cat
c a t aa lI yy ttic
i c con
c o n vvee rr tt e r
vehicles-assemble
vehiclesassemble the resonator pipe
to the inlet pipe from the manifold
and loosely attach the retaining
clamp.
3. Catalytic converter vehicles(Figs.
vehicles-(Figs. 11
position the
the resonator
resonator pipe
pipe
through 3) position
flange.
and flange to the converter flange.
Install but do not tighten the
attaching nuts.
muffler rear support
bracket and loosely install the
attaching screws.
5.
5. Align the exhaust system to conform
specifications
to the proper clearance specifications
and, starting from the resonator pipe
connection, torque all nuts and
26-02-2
6.
6. Check the system for leaks and lower
the vehicle.
CATALYTIC CONVERTER-PINTO
CONVERTERPINTO
AND BOBCAT
Removal
Removlll
1.
2.
2. Loosen the intermediate and rear
exhaust system hanger bracket
attaching bolts.
3. Remove the front and rear catalytic
converter flange attaching nuts.
convenor inlet
4. Separate the catalytic convertor
outlet flange connection
connection
and outlet
attaching nuts.
5.
5. Remove the converter.
Installation
InstBlJstion
1. Position the catalytic converter to the
1.
inlet pipe using a new gasket between
the flanges. Loosely install the
attaching nuts.
2.
2. Install the resonator inlet flange to the
converter outlet flange. Loosely
install the attaching nuts.
3. Align the exhaust
exhaust system to
specification and starting at the front
of the system, tighten all nuts and
specification.
the vehicle.
MUSTANG
See Resonator Inlet Pipe-Pinto,
PipePinto,
Bobcat, Mustang (front) with catalytic
converter Removal Procedure.

CLAMP-5A231
CLAMP
- 5A231
25-35 FT-LB
FT-LB
25-35
FLOOR PAN
VERTICAL
5246 ASSY.
ASSY
5246
~/)J
N-800064-S2" /
25_35:
/T.LB
5280
.78
{~
N-800064-S2
375636-S7 #
375636-57"
25-35 FT-LB
Ci
BRACKET
BRACKET AND
AND
INSULATOR
INSULATOR - 5260
5260
_,
'"TIGHTEN NUTS
TIGHTEN NUTS
ALTERNATELY
ALTERNATELY
TO MAINTAIN
MAINTAIN
TO
TORQUE AND
AND
TORQUE
DRAW FLANGE
FLANGE
DRAW
EVENLY.
EVENLY
5246
....... ~
FFERENTIAL
Ol
DIFFERENTIAL
.50
.75
VIEWS
WITHOUT CONVERTER
V
IEWX& W
VIEWX&
W
MUFFLER
VIEWZ
FLOOR PAN
VIEWZ
WITH CONVERTER
M:II~HVIEW
CONVERTER
SAME AS MAIN VIEW
EXCEPT AS
AS SHOWN
SHOWN
EXCEPT
VIEWR
SAME AS
.'
({ ~~~
"
MAINVIE~
WIO ( ... "ER~ER ~-
m
::s
BRACKET AND
INSULATOR 5260
VIEW R
VIEWR
CQ
:i"
CD
(J')
:i"
<D
CQ
5280
VIEWY
"
382400-S2
FOR MANUAL
TRANS. ONLY
SECTION A
CONVERTER
CONVERTER
VIEWU
VIEWU
;r
Q
....
BRACKET AND
INSULATOR
INSULATOR -5A246
382400-S2
FOR MANUAL
TRANS. ONLY
NO. 3CROSSMEMBER REF.
CROSSMEMBER
CROSSMEMBER REF.
REF
)(
108 IN-LB MAX.
CI'
5246
409*0 -S2
108 IN. LB. MAX.
40962-S2
FRONT FLOOR PAN

iFRONT
5A246 - ASSY.
CONVERTER
ASSY. I
5E276 REF.
386165-S2
386165-S2
FT.LB
15-25 FT.LB.
15-25
VIEWS
.
VIEWS
WITH CONVERTER
CONVERTER
WITH
33799-S2
20-30 FT. LB.
CROSSMEMBER REF
REF.
CROSSMEMBER
System-POInto and
FIG.
4-Cylinder
Without
Sedan-1975/76-With
. and
andW'
and Bobcat
Bo bcat Sedan-1975/76-With
y I'mder Single
Single Exhaust
Ex haust System-Pinto
FIG. 114-C
Ithout Converter
Converter
BACK TO GROUP INDEX
"
381877-52
381877-S2
108
108 IN-LB
IN-LB MAX
MAX.
VIEWU
VIEW
U
WITH CONVERTER
CONVERTER
WITH
U1558-B
U1558-B

CONVERTER
5E212
CROSSMEMBER
CROSSMEMBER
BRACKET
BRACKET
5E212~\/
CONVERTER -
FRT. FLOOR PAN
5 230
MAN UA L TRANS.
TRANS.
1.00 MANUAL
1.00
0 TRANS.
.86 AUTO. TRANS.

.a6AUT . \
-~lSl"-
ffiIlli
CRO~MEMBER
\..\~CONVERTOR-
VIBRATION
VIBRATION
,I
DAMPER
DAMPER SECTION A
STUD
386757-S2
2
REO'D. TO
SHOULDER
INSTALL
45358-S7
(2 REO'OJ
20-30 FT-LB
~'%,
/
/'
,
t}
~ .~
..!-('I)
//'
52801
"f ...,.
WITH CONVERTER
BRACKET AND5260
INSULATOR -
'~-"+
I'
VIEW 0Q NVERTER
VIEW
WITH CONVERTER
R E S O N A T O R AND
RES
5250
MUFFLER
MUFFLER -5250
\ .\
VIEW R
""
VIEW R
4.12
3.88
RWITHCO~ATORANO ~~I,f~~VIEWW
B
CONVERTER
CONVERTE
Q_ OF CRANK
tl'LOFCRANK
,~~
~
'"
RESONATOR
(PART OF 5280)
.74
4--.
99
;,W V
_-..=
~~.
VIEWZ
REAR FACE/
OF BLOCK /
:::J
<g.
9.
:::J
5*
CD
~
:::J
T CONVERTER
WITHOU
'~
Q_
4.46
4.22
TRANS. E.XT.
CC
5.03
(i'"
4 . 79
><
=r
Q
~~~~
SCREW- /
40962-S2
40962-S2
INLET PIPE
~~~~~~~JSECURELY
~I
WITHOUT CONVERTER
VIEWS
VIEWZ
MUFFLER
~
!
:JL
Oo _ _
VIEWR
.. \
108 IN-LB MAX.
THIS LINE MUST

BE HORIZONTAL
--~
INLET PIPE _
5246
VIEW U
"
orrbrI=:J -
\p J~~~~L~~
~ ~\---.J.-.",-::..
~
40962-~2 ~~~A
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A-
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~-
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RESONATOR ~~g
MUFFLER -
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VERTICAL'L
-KITf"r1-IIT-/l\-
:06
- - 12 REO D.I
FT~_LB
tr
'7/
(2 REO'OJ
25-35
SECTION B
UNDERBODY
CROS~
MEMBER
I~
25_35FT_LB\
"NUT-
"C'l:"
CLAMP - 5A231
25-35 FT-LB
5E212
BRACKET AND INSULATOR

- 5260
TAPPINGP~
~O
NUT-3a6575-S7
~ --~~
NO 3
STUD - N-900064-S2
N-900064-52
(2 REQ'D.)
(2 REO'OJ
L Y INSTALLED
MUST
BE
INSTALLED
UST
BE FULLY
FUL OF\STU
0
SHOULDER
\
TO SHOULDER OF STUD
MUFFLER MUFFLER 5230
::j
MUFFLER
1.03
'
-J
REAR
1.05
cCIt
FA::'94~t;1ill-l
~:~ _
_~~_ t
....
CO
OF BLOCK
FLOOR PAN
(4 REQ'D.)
TIGHTEN SECURELY
108
MAX.
108 IN.
IN. LB.
LB.MAX.
J
.82
VIEWY
--+C:~
~~~~H~CK
~
ST~~O
TRANS. EXT.
GASKET - 5B266
52aO
VIEWT
__
N~~----
II {:~~'v
BRKT/
~I~
"
AND
INSULA TOR 5A246
BRACKET -
INLET PIPE
PIPE - 5246
CROSSMEMBER'
WITHOUT
CONVERTER
OUT CONVERTER
END OF STUD WITH SHORTEST THREAD LENGTH TO BE

SCREWED INTO
MANIFOLD.
WITH
SHORTEST TH READ LENGTH TO BE
END OF
MANIFOLD.
WITH CONVERTER
INLET PIPE GAGING
DIFFERENTIAL
DIFFERENTIAL
SCREWED I
VIEW V
BRACKET AND
INSULATOR
_ 5A246
WITH
SCREW
40962-S2
(2
(2 REO'O.)
REQ'D.)
108 IN-LB MAX.
108 IN-LB MAX.
REAR ENG.
ENG.
RFACE OF
SCREW- 1.34
1.34 FROMESRUTER
FROM SURFACE
OF MOUNT
MOUNT
FLANGE
386547-S2 1.26
1.26 CONY
CONVERTER FLANGE
(2
(2 REO'OJ
REQ'D.)
0 MAINTAIN TOROUE
VIEWU
UTS ALTERNATELY T
TIGHTEN NUTS
TO MAINTAIN TORQUE
AND DRAW FLANGE
EVENLY.
1975/76-I
ANDSystemsDRA FLANGE EVENLY.

TIGHTEN
Wagon Ex haust
/
CROSSMEMBER
THESE DIMENSIONS MUST

W"th and Wit
"h OU t Converter
SCREW40962-S2
(2 REQ'D.)
108 IN-LB MAX.
BE HELD AND CONTROLLED
U1574-A
bca t Station
FIG.
FIG. 22 Pinto
Pinto and
and 80
Bobcat
Station Wagon Exhaust Systems1975/76With and Without Converter
BACK TO GROUP INDEX

1.00
5230
5246
MUFFLER INLET PIPE

SUPPORT BRACKET
VERTIC;i1~.. ~
-\2T~'
SHOCK BRACKET
HORIZONTAL TO
TO GROUND
GROUND
HORIZONTAL
5230
BRACKET AND
INSULATOR 5260
II
_-"
VIEWU
5230
5230
VIEWV
CLAMP - 5A231
5A231
36-48
36^*8 FT-LB STATIC
--~
381877-S2 4REQ'D.
108 IN-LB MAX.
WITHOUT CONVERTER
VIEWW
~---~.-
EXHAUST HANGER
BRACKET
VIEWV
~.~
CONVERTER - 5E212
386763-52
386763-S2
15-25 FT-LB
45358-S7G
20-30 FT-LB
VIEW
X
VIEWX
WITH CONVERTER
RESONATOR AND
MUFFLER
MUFFLER ASSY.
ASSY.
INLET
INLET PIPE
PIPE -- 5246
5246
VIEW Y
BRACKET AND
INSULATOR ~,""><~INSULATOR
5260
:. ~ ~
~. 5260
~)~:. ~
."
c:
381877-S2 4 REO'D.
REQ'D.
lOB
108 IN. LB. MAX.
MAX.
-5230
- 5230
5A246
CRO~SSMEMBER.96
~."
4O962-S2 2 REQ'D
108 IN. LB. MAX
""~.
~~'~~lJ
~ltI
5E212ASSY. REF.
385637-522
385637-S2
2 REO'O.
REQ'D
WITH CONVERTER
VIEWY
VIEWY
5246 OR 5230
MAIN
MAIN VIEW
VIEW
WITHOUT
WITHOUT CONVERTER
CONVERTER
SECTION A
~..
N-800064-S2
N-8O0064-S2
5A246
2 REQ'D.
2REO'D.
~
MUST BE
BE INSTAL~LD
INSTALLED TO
TO
MUST
SHOULDER OF STUD
\\;-
. ~IV'
(_~ '-~/~
\" -
382802-52
382802-S2
REQ'D. 17-28 FT-LB
2 REO'O.17-28
REAR
REAR ENGINE
ENGINE
MOUNT
'\
.. .-./1
/~
/~57A6
OR 5E212
WITH CONVERTER
SAME AS MAIN VIEW
EXCEPT
EXCEPT AS
AS SHOWN
SHOWN
375636-57
2REO'D.
25-35 FT-LB
VIEWZ
385637-52
2REOO.
WITHOUT CONVERTER
VIEWY
VIEWY
U1559-B
U1559-8
SystemMustang 1975/76
1975/76
FIG. 3 4-Cylinder Single Exhaust System-Mustang
BACK TO GROUP INDEX

26-03-1
26-03-1
26-03-1
V-6 Exhaust Systems
V - 6 Exhaust Systems
PART 26-03 V-6
COMPONENT INDEX
Page
COMPONENT INDEX
Page
DES
CRIPT ION ......................
DESCRIPTION
03-1
03-1
03-1
03-1
03-1
03-1
03-2
Resonato
utlet Pipe - . (.(LL.. HH.. Side) . ....
Resonatorrand
and 0
Outlet
03-1
03-1
Muffler Assembly .........

Resonator and Muffler
03-2
Converter
Catalytic Co
nverter ...................
03-2

REMOVAL AND
Resonator Inlet (H-pipe) .............
Resonator Inlet (Single Exhaust) ..... .
NOTE: The
The information in
to both 1975 and 1976 model
nlodel year vehicles unless otherNOTE:
wise specified.
CR1966-A
CR1966-A
DESCRIPTION
The 1975
1975 V-6
V-6 dual exhaust system
on Pinto, Bobcat and
and Mustang is
is aa
used on
an H-pipe
unique design consisting of an
the two
two engine exhaust
connecting the
manifolds to
one or
or two
catalytic
to one
two catalytic
in tum
turn connect to
to dual
dual
converters which in
assemblies. The outlet pipes on
resonator assemblies.
muffler and
the resonators lead to a single muffier
muffler outlet pipe.
muffier
The factory-installed system consists
of the
the welded H-pipe (resonator inlet
pipe), one
one or
or two
two bolt-on catalytic
converters, aa welded resonator and
and
muffler assembly R.H.
R.H. side and
and aa
muffler
L.H. side.
side.
resonator assembly L.H.
Refer to
to the Motorcraft
Motorcraft Master Parts
Catalog for
for the
the service-replacement
service-replacement
assemblies.
assemblies.
1976 V-6
V-6 Pinto, Bobcat and
The 1976
and
Mustang may use either a dual or ~a single
exhaust system. The dual exhaust 'system
system
on Canadian vehicles and

and isis
is used only on
as aa non-converter equipped
the same as
1975 system. The
The single exhaust system
1975
consists of two one-piece welded inlet
pipe and
and converter assemblies which
connect to the exhaust manifolds and the
resonator and
and muffler
muffler assembly. For
For
information,
service replacement parts information,
refer to
to the
the Motorcraft
Catalog.

RESONATOR INLET (H-PIPE) -DUAL EXHAUST
Removal
Removal
1. Raise the
the vehicle.
2. Support the resonators with soft wire.
3. Remove the
the screws holding the
the "H"
"H"
to the
the front hanger bracket.
pipe to
4. Remove the
the inlet "H"
" H " pipe to
converter flange connection nuts,
both sides.
the nuts
nuts attaching
attaching the
theinlet
inlet
5. Remove the
"H" pipe to
to the
"H"
Lower the inlet "H" pipe and remove
the pipe.
6.
6. Clean the
the gasket surfaces of the
the
and converter flange(s).
manifolds and
flange(s).
7. Discard the converter flange gasket(s)
any damaged parts.
and replace any
Installation
Installation
1. Position the
flanges to
the "H"
"H" pipe flanges
to the
the
converter flanges
flanges using new
new gaskets.
Install but
the
but do
do not
not tighten the
attaching nuts.
2. Install the
the inlet pipe (H-pipe) on
on the
the
exhaust manifolds. Loosely install the
flange attaching nuts. On
On Mustang
BACK TO GROUP INDEX
units be
be sure the
the heat valve on
on the
the
is properly positioned.
L.H. manifold is
3. Loosely install the
the front "H"
"H" pipe
hanger bracket screws.
4. Align the
the exhaust system to
to conform
to the
the clearance specifications (Figs.
through 4).
4). Starting
Starting at
at the
the front
front
1 through
the system, torque all
all nuts and
of the
and
to specifications
specifications given in
bolts to
in
Section 9, Part 26-01.
the soft wire support, check
5. Remove the
the exhaust system for
for leaks.
leaks.
RESONATOR AND
PIPEAND OUTLET PIPE
L.H.
LH. SIDE
RemovaJ
Removal
1. Raise the
the vehicle by
by means of the
the
to allow the axle full
frame lift points to
to replace the
clearance necessary to
the
resonator and
and outlet pipe.
the clamp at
at the
the connection
2. Loosen the
between the
the resonator inlet pipe (H(Hpipe) and
and the
the resonator or
or the
the nuts
3.
4.
5.
the flange connection

connection
holding the
the catalytic converter and
between the
and
resonator pipe (Figs.
4).
Remove the
the
the screws attaching the
resonator outlet
outlet pipe to
to the
resonator
the
intermediate support bracket.
the clamps securing the
the
Loosen the
to the
the muffier.
muffler.
resonator outlet pipe to
Remove the
the resonator and
and outlet
pipe.
pipe.
any damaged parts.
Replace any
6.
6.
InstaJlation
Installation
1. Position the
the resonator assembly and
and
to the
the intermediate
the outlet pipe to
support bracket and loosely install the
attaching screws.
2. Install the resonator outlet pipe to the
muffler and
and properly position the
muffler
the
clamp. Do not tighten the clamp nuts.
nuts.
clamp.
to maintain the
the specified
specified
Be sure to
for the clamps and be sure
clearances for
the locating tab
tab is
is fully inserted
that the
into the locating slot (Figs.
(Figs. 1 through
4).
26-03-2
3.
3. Install the resonator inlet to the Hpipe or to the rear flange of the
catalytic converter. Properly position
the pipe clamp
clamp or install
install the
the converter
to
to pipe flange nuts.
nuts. Do not tighten the
clamp or attaching nuts.
nuts.
4.
4. Align the exhaust system to comply
with clearance specifications and,
starting from the front of the car,
torque all nuts and screws to
specifications.
5.
5. Check system for leaks and lower the
vehicle.
vehicle.
RESONATOR AND MUFFLER
ASSEMBLY
Removal
Removal
1.
1. Raise
Raise the vehicle on aa hoist by means
of the
the frame lift points to allow the
axle full downward travel.
travel.
axle
2.
2. Remove the converter to resonator
connection flange attaching nuts.
3.
muffler to
to the rear support bracket.
mumer
4.
resonator
resonator outlet
outlet pipe to the
the
5.
5. Loosen the left hand resonator
resonator
assembly clamp and remove
remove
muffler.
resonator pipe from mumer.
6.
6. Remove the resonator and muffler
muffler
assembly.
assembly.
Installation
Installation
1.
muffler
assembly to the intermediate support
bracket at the resonator outlet pipe.
Loosely install the attaching screws.
2. Insert the left hand resonator
resonator
2.
muffler and loosely
assembly into the mumer
attach the clamp.
clamp.
3.
3. Install the
the resonator to the catalytic
converter. Install,
Install, but do not tighten,
the flange
flange attaching nuts.
nuts.
4.
4. Position and loosely install the rear
muffler.
support bracket screws at the mumer.
5.
5. Align the resonator and muffler
muffler
assembly to obtain proper clearance
specifications.
6. Starting from the front, tighten all
6.
n u t s , bolts
b o l t s and screws
s c r e w s to
to
nuts,
specification.
7. Check system for leaks
leaks and lower the
7.
vehicle.
vehicle.
CATALYTIC CONVERTER
Removal
Removal
1. Raise
Raise the vehicle on a hoist.
hoist.
1.
2. Loosen the left and right hand
2.
intermediate support
support hanger
hanger
intermediate
screws.
attaching screws.
3. Loosen the muffler support hanger
3.
screws.
attaching screws.
BACK TO GROUP INDEX
V-6 Exhaust Systems

4.
4. Remove the catalytic converter inlet
and outlet flange attaching nuts on
both converters.
5.
5. Separate the converters from the inlet
and resonator inlet pipes and remove
the converters.
Instmlation
Installation
1.
1. Position the catalytic converters to
the inlet "H" pipe and resonator pipe
flanges. Install a new gasket or
gaskets between the flat flange
flange
connection (front
(front of converter) and
loosely install all attaching nuts.
2.
2. Align the exhaust system to proper
clearance specification
specification and starting at
the front of system, tighten all
aU nuts,
bolts
b o l t s or screws
s c r e w s to proper
proper
specifications. Replace the exhaust
shields and secure the attaching
specification.
3. Check the exhaust system for leaks
RESONATOR INLET PIPE-SINGLE
PIPESINGLE
EXHAUST
Removlll
Removal
1.
2.
2. Support
Support the resonator/muffler
resonator/muffler
3. Remove the screws that attach the
3.
front hanger support bracket to the
inlet pipe brackets.
4.
4. Remove the attaching nuts at the
cone type flange
flange connection located at
catalytic
the rear of the L.H. catalytic
Remove the U-bolt
converter. :Remove
assembly at the R.H. rear of the
converter.
catalytic
5. Remove the nuts attaching the inlet
5.
pipe flange
flange to the exhaust manifold,
and remove the inlet pipe. NOTE:
Apply heat to the catalytic converter
slip joint connection as required to
disassemble. The inlet pipe and
converter are one assembly and must
be removed
removed as
as aa unit.
unit.
be
6.
Installation
Installation
1.
1. Clean the exhaust manifold, slip joint
connection and catalytic converter
flange
flange seat.
seat.
2.
2. Position the inlet pipe/catalytic
pipe/catalytic
converter ass'embly
assembly to the resonator
pipe flange
flange and slip joint and loosely
attaching nuts.
4.
4. Install the front
front hanger support
bracket to inlet pipe bracket. Do not
tighten the attaching screws.
5.
5. Remove the wire support for the
resonator mumer
muffler assembly.
26-03-2
specifications and starting
clearance specifications
at the front, tighten all nuts, screws,
and bolts to specification.
ASSEMBLY-PINTO/BOBCAT/
ASSEMBLYPINTO/BOBCAT/
MUSTANG
Removal
Removal
1.
of the
1. Raise the vehicle by means of
allQw the axle full
frame lift points to allqw
replace the muffler,
pipe.
2. Remove the rear
rear converter
converter to
U -bolt
resonator pipe flange and U-bolt
connection attaching nuts (Figs. 11
and 2).
the rear hanger assembly to mumer
muffler
support.
from the resonator inlet pipe. NOTE:
slip joint connection as required to
disassemble.
support on the
the intermediate
muffler
resonator/mumer assembly.
resonator/muffler
Installation
Instlll/ation
1. Clean the slip joint connection and
1.
flange seat.
loosely attach
attach the intermediate
support bracket (Figs. 1 and 2).
2).
3. Position the resonator pipe and flange
flange
to the converter flange
flange and slip joint.
Install
Install but do not tighten
tighten the
attaching nuts.
bracket
bracket and loosely install
install the
attaching screws.
the vehicle.
CATALYTIC CONVERTER
See Resonator inlet pipe removal
procedure for single exhaust.

5A242
5A242
REAR ENG.
MOUNT
CROSSMEMBER
CROSSMEMBER
or
~
~/~~
~n---7......HG--~-"
f--
5246
\....1 --
~,.......
~'y{J?i:.
--~(
CLAMP
CLAMP -- 5252
5252
25-35
25-35 FT-LB
FT-LB
TIGHTEN
NUTS
TIGHTEN NUTS ALTERNATELY
ALTERNATELY
40062-S2
2 REO'D.
108 IN-LB MAX.
5246
,~3!,
AND EVENLY TO MAINTAIN TORQUE
:-,~
~.~.-~';'~'~CO.~529~~oRi~~';
0.84
~~
~I
........
" .
L )(
365271-S2
52?~&[JmV?OJ1G~~~~5E212
~)t:(
~'"~~ /
45356-S7
8 REO'D,
20-30 FT-LB
58266
58266,
REQ'D.
22 REO
D.
1 34
r
/
.
SECTION BB ,
'i: fP
~~0.
,,~//;
386757-S2
386757-S2
REQ'D.
44 REO'D.
INSTALL TO
INSTALL TO
SHOULDER
I)~
L.H.
~W
~~
. WITH CATALYTIC
CONVERTERS
SHOULDER
~
~
MAN\.:d]r
D~_. ~~~ ~ A:::::~W ((~
~(:~~230
R.H. EXHAUST
RESONATOR ASSY.
- 5230
VIEWU
PART
PART OF
OF
5E276
0.94
,.,
VIEWZ
<
DIFFERENTIAL
AUXILIARY VIEW
WITHOUT CATALYTIC
CATALYTIC
CONVERTERS
CONVERTERS
i VIEW T
VIEWV
~
WITHOUT CATALYTIC
CATALYTIC
CONVERTERS
MUFFLER
MUFFLER AND
AND
RESONATOR
ASSY.
VIEWW
"VIEWT
NUT -- 387039-S7
387039-S7
NUT
2 REO'D.
REQ'D.
2
25-35 FT-LB
5E276
RH.
5A289
L.H.
VIEW V
_
5A289
RH.
~~(~
~,V~
1.26
FROM SURFACE1.26
OF
FROM SURFACE OF
CONVERTER FLANGE
FLANGE
CONVERTER
STUD -- N800064-S2
N800064-S2
STUD
REQ'D. MUST BE
2 REO'D.
INSTALLED TO
5E276
5 E276
INLET PIPE
_ 5246
40962-S2
6 REO'D.
108 IN-LB MAX.
SHOULDER OF STUD
SHOULO'~~q
><
:r
C
cCI'
..
CO
<
L.H.
EXHAUST
L.H. EXHAUST
MANIFOLD
MANIFOLD
VIEWT
CLEARANCE R.H.
RH.
0.78 CLEARANCE
CLEARANCE L.H.
0.75 CLEARANCE
R.H. 4.93
4.69
8.89
-
FLOOR
PAN,
8 65
~_
~.
'--..
~ ~~RANS.EXT.
~ Ii
~VIEWR
1.80 R
BLO~CK
__ ~
0.75
5.65/5.41 R.H.
R.H.
5.65/5.41
4.63/4.39
4.63/4.39 L.H.
L.H.
:t--Tf
VIEWW
VIEW W
L.H.
INLET
L.H.INLET
PIPE
PIPE GAGING
GAGING
FLOOR
FLOOR
PAN
,---/~5
5A289
TRANS. EXT.
'- OF
OF CRANK
REAR FACE
OF
REAR
AXLE
FUEL
DIFFERENTIAL
~
FIG. 11 Dual
--FIG.
Dual Exhaust
Exhaust SystemPinto/Bobcat
System-Pinto/Bobcat Sedan
TANK
L.H. SHOCK
BRACKET
~ 5A289
50204
381877-S2
4 REQ'D.
108 IN-LB MAX.
THIS LINE MUST BE

BE
VERTICAL
VERTICAL HORIZONTAL
HORIZONTAL <
<i
2 PLACES
2PLACES
CLAMP -- 386503-S
CLAMP
FT-LB STATIC
STATIC
25-35 FT-LB
25-35
TIGHTEN NUTS
NUTS
TIGHTEN
ALTERNATELY AND
ALTERNATELY
EVENLY TO
TO MAINTAIN
EVENLY
TOROUE.
TORQUE.
--- I
-:\~
~~
-
34877-52
34877-S2
REO'D.
22 REQ'D.
108 IN-LB
IN-LB MAX.
108
MAX.
5A289
5A289
0.74
0.99
SECTION AA
AA'
SECTION
0.06
0.00
~
~
I
U1515-A
U1575-A
W
I
W

BRACKET AND
AND
BRACKET
INSULATOR ASSY.
ASSY
INSULATOR
\.
_- 5A246
5A246
CROSSMEMBER
CROSSMEMBER
\
~ __ ~..
-#~~
~~~%~NG
5246
TYPICAL
8 REQ'D.
20-30 FT-LB
~'].
""
.__')
"7
EXHAUST
EXHAUST
MANIFOLD R.H.
R.H.
MANIFOLD
~~~~6Q'DI
.......
fO
'. /
~~~Q.g86575-S7 '~-/0~
-W/L~~(I~
STUD
STUD _- N800064-S2
N800064-S2
22 REO'D.
REQ'D.
INSTALL
INSTALL TO
TO SHOULDER
SHOULDER
r---s~ f2L;~~,;.)5A231
30 FT-LB MAX.
"
~
J?-~!;;
STUD-N800116-S2
'\
2 REQ'D.
NUT - 386575-S7
2REO'D.
NUT-386575-S7
INSTALL TO
TO SHOULDER
SHOULDER 22 REO'D.
REQ'D.
INSTALL
25-35 FT-LB
FT-LB
25-35
~~
B
IVIEWTI
INLET PIPE
ASSY. - 5246
ASSY.
I ~_l
~I';~~:~~
~ L::.::l)IlJ
~Cflln_
MUFFLER AND
VIEWY
VIEWY
,
"
AUXILIARY VIEW
WITHOUT CATALYTIC
CATALYTIC
CONVERTERS
C'
'~I
(J
-ttCO
VIEWZ
"75
~:"
'"~
~~
--.-
SHOCK BRACKET
C=:J_~:'~~K
BRACKET
(R.H.)
<
DIFFERENTIAL
DIFFERENTIAL
><
=r
C
CI'
EBrr- --l
----cl- -
~---1
VIEWU
5230 ASSY.
CATALYTIC
CONVERTERS - 5E212
8.89
8.65
OUARTER
QUARTER PANEL
PANEL
VIEWW'
--1
~ VIEWU
RESONATOR
ASSY. - 5A289
. .~
SPRING
DAMPER
WITHOUT
WITHOUT CATALYTIC
CATALYTIC CONVERTERS
CONVERTERS
VIEWW
ASSY. - 5230
ASSY.-~
59
MUFFLER
MUFFLER
I. VIEW
V
VIEWV
MUFFLERAND
RESONATOR
t
V
~~~~ ,~ ~~i
WITH
WITH CATALYTIC CONVERTERS
CONVERTERS
5A289
5A289
TIGHTEN
~,V'A
~~
TIGHTEN
ALTERNATELY
5E2'12
~G~//'.
~~
ALTERNATELY
TO MAINTAIN
MAINTAIN
~ . ~ ' ~ ~ TO
386757-S2
tJ _
TOROUE
386757S2
TORQUE AND
AND DRAW
DRAW
(4 REQ'D.)
(4REO'D.)
~
FLANGE
FLANGE EVENLY.
EVENLY.
INSTALL TO
TO SHOULDER
SHOULDER
INSTALL
VIEW
V
VIEWV |
~.
02
~l ~7'05
(K5230
~~(~
WHEEL
~~-
~~~
_/fj?f)
1.26,
1.261.34 FROM
FROM SURFACE
SURFACE OF
OF
1.34
CONVERTER FLANGE
FLANGE
CONVERTER
5E212
5230
/\"L~~5230
EXHAUST
EXHAUST
MANIFOLD L.H.
L.H.
MANIFOLD
.J:i(''.
~6l
NUT-386575-S7
2 REQ'D.
25-35
FT-LB
25-35 FT-LB
~-r-
-~
5246 ASSY.
ASSY.
5246
GASKET-
~,~/. ~---"Q'~'
6.~
'-..e';"
GASKET5B266
(2 REQ'D.)
365271-S2
(4 REQ'D.)
30 FT-LB MAX.
,,'--'"
~oRioQ~~:LB ~~'C/~-~".~r/,~YE212
'",---SEC_TI
ON_BB,
);
]
~.
;-1_ '
/ ~~---\
NUT -- 4p358-S7
45358-S7
NUT
40962-S2
40962-S2
22REQ'D.
REO'D.
1 5 ,47
5.23
L.H.
15 .65
R.H.
BRACKET AND
INSULATOR - 5260
BRACKET AND
INSULATOR - 5230
MAIN VIEW
WITH CATAL YTIC
CONVERTERS
BRACKET AND
INSULATOR - 5 2 6 0
5A289 ASSY.
5.41
"-.
WITH
CONVERTERS
WITH CATALYTIC
CATAL YTIC CONVERTERS
TYPICAL
TYPICAL EXCEPT
EXCEPT AS
AS SHOWN
SHOWN
8.24
381877-S2
(2 REO'DJ
108 IN-LB MAX.
8!OO
-J
I
\
UNDERBODY
UNDERBODY
CLAMP_~VERT~~AL<i ~'
5A231
TRANS. EXT.
L.H.
25-35FT-LB
<i CRANK
REAR FACE
REAR FACE
L..llJUTfl4'63
OF
OF BLOCK
BLOCK
4.39 L.H.
INLET
INLET PIPE
PI~_~
5.65
GAGING~-..J
5.41 R.H.
GAGING
WITHOUT
WITHOUT CATALYTIC
CATALYTIC CONVERTERS
CONVERTERS
.74-.99~il
-..~.OO
5A289 ASSY.
I VIEWU
VIEWU I
FIG.
FIG. 22 Dual
Dual Exhaust
Exhaust SystemPinto/Bobcat
System-Pinto/Bobcat Station
Station Wagon
BACK TO GROUP INDEX
~~-~ I '
SECTION A
OF (VIEWX)
(VIEW Xl
OF
0-
.06
.
I
U1576-A
U1576A
W
I

CROSSMEMBER
CROSSMEMBER
BRACKET AND
INSULATOR 5A246
REF.
REF.
~~
~
.
FUEL~1J~~
J
5E212 ASSY. REF:

5-E214 ASSY.
TANK
SECTION B
'VIEW X
5E276
ASSY
CONVERTER ASSY.
-5E212
EXHAUST
MANIFOLD
EXHA
U
R/H
R/H REF.
REF.
STMANIF~O
~
Jr ~{4REQ'OJ
"
,. ..."
~7~~7
5E276S:
25-35 FTLB
VIEWZ
.00
-rrD .
N
~~
N-800064-S2
(4 REQ'D.)
.. ~
(4 REO'DJ STALLED TO
MUST BE INSTALLED TO
MUST BE IN F STUD.
SHOULDER 0OF STUD.
SHOULDER
SHOCK BRKT.
R.H. REF.
DIFFERENTIAL
IVIEWTI
BOTH SIDES
,VIEwyl
REAR FLOOR
CROSSMEMBER
i ~.~.~
_~
T
Jur~;t:
5C263 ASSY.
5E276
ASSY.
I~39_--..28~_
39.52
1"'26~.
27_13
I
:
/R.H.
--_..
T
14.93-1
4.93t8.89
rTfc-i f 4.69 T 8.89
8.65
at~8.65
r::-nr..
L..1JT
REAR FACE
OF
-.
INLET PIPE GAGING

GAGING
VIEW U I
INLETI PIPE
VIEW U
5.23
TRANS. EXT. REF.

F CRANK
(L OF
" 'LO 5.65
5.41 R.H.
5.65
5.41
5.47 R.H.
L.H.
5.47
5.23 LH.
t
8L~-"....._
~--~
REAR FACE
OF BLOCK
2.
3.81 R.H.
3.75
5E212 ASSV.
~~./TRANSC::KREF.
~
,+ 28.60
'
28.36
REAR FACE
OF BLQCK""'l
7.66
7.54
~ J
37.98
LH.
-37.74
.
TRANS.~
I VIEW U I
}.
W/CONVERTERS
W/CONVERTERSX
4.91 R . H.
4.85
4.73 LH.
4.67
'
.74
5E276 A,SS"Y '"R, E

VERTICAL'L
&\;;:-,.
f?~
5E212 ASSY.
\ ;
5A246 ASSV.
RE
F.~"
.:~kif
~, ~7
',,-,
."..
AR AXLE REF.
....-
/'-
\
: \
-~1((~_ J }Jv~/~
.-
r. OF CRANK
........
(4 REO'O.I
40962-S2
(4
108REQ'D.)
IN-LB MAX.
108 IN LB MAX.
4096252
40962-S2
12 REO'OJ
(2 REQ'D.)
100 IN LB
MAX.
108
B MAX.
381877-52
I VIEW Z I
381877
S2
(2 REO'D.)
<2 REQ'D.)
108 IN-LB MAX.
_-_I: (
~~\!~
CLAMP-5A231
4
..JL
MP - 5A231
THIS LINE MUST
THIS
LINE MUST
BE HORIZONTAL
HORIZONTAL
BE
, VIEwwl
(~VIEWW|
R_H.
R.H. SIDE ONLY
CLA
LV
25-35
FT-LB
2535 FTLB
TIGHTEN
MAINTAIN TO ROUE.
NUTS ALTERNATE
ALTERNATELY
AND EVENLY
NUT~O
AND EVENLY TO MAINTAIN TORQUE.

U1577-A
FIG. 3
3 Smge
Single
Sedan
. I Exhaust 5SystemPinto/Bobcat
ys tem- Pmto/Bobcat Sedan
FIG.
BACK TO GROUP INDEX

CROSSMEMBER
BRACKET AND
INSULATOR - 5A242 ASSY.
40962-S2
(6 REQ'D.)
108 IN-LB MAX.
REAR ENGINE
MOUNT
5E212ASSY.
| SECTION B~|
EXHAUST MANIFOLD
SPRING
DAMPER
CONVERTER 5E212 ASSY.
5E212ASSY
CONVERTER
- 5E212 ASSY. REF.
1.05
387039-S7
(4 REQ'D.)
25 35 F T L B
N-800064-S2
'
(4 REQ'D.)
SHOULDER OF STUD.
386757-S2
(2 REQ'D.)
INSTALL TO
SHOULDER
5E276
ASSY.
5E276 ASSY.
45358-S7,
(2 REQ'D.)
20-30 FT-LBS
5E276
[ VIEW T I
SAME BOTH SIDES
SHOCK BRKT. R.H.
MUFFLER AND
RESONATOR - 5E276
VIEWS .
5E212 ASSY. R.H.
-^
&"]
40962-S2
(2 REQ'D.)
108 IN-LB MAX
UNDERBODY
381877-S2
(2 REQ'D.)
108 IN-LB MAX.
THIS LINE MUST

BE HORIZONTAL
' \
5E276 ASSY. REF.
VIEWX
R.H. SIDE ONLY
CLAMP - 5A231
25-35 FTLB STATIC
AND EVENLY TO MAINTAIN TORQUE.
U1578 A
FIG. 4 Single Exhaust SystemPinto/Bobcat Station Wagon
BACK TO GROUP INDEX

NO'4CROSSMEM~~B~ER~~~_FL_00~N
NO.4CROSSMEMBER
CONVERTER ASSY.
CONVERTER
- 5 5E212
E212
EXHAUST MANIFOLD
FLOOR PAN
FLOOR PAN
NO 4CROSSMEMBER
0I
FLOOR PAN
W
I
'"
N-800064-52
(2 REO'DJ
(2 REO'DJ
25-35 FT-L8
37563657
'~~~235FT:L8
r'
HEAT VALVE AEF

HEAT VALVE REF
L.H. SIDE ONLY
VIEWY
5246 ASSY. REF.
SECTION A
45358-S7G
20-30 FT-LB
FT-LB
20-30
:~:::SSV
5C247 ASSY
"?~j~:~
f.' '-- -- - ~
<
VIEWS
~
m
MUFFLERV~
5A242 ASSY.
tf--
\~g
5246 REF
-~
VIEW l
TYPICAL
382802-52
2 REo'D. 17-28 FT-LB
~~REARENG
-.
\~
/'
. J\\'
AUTO. TRANS.
CONVERTER BOSS
SHOCK8AKT.~'
CLAMP - 5A272
,
MAIN VIEW
.f1?\
'V
.63-1
EIj5246AEF
'
B-B
SECTION B-B
CLUTCH HOUSING BOSS
)(
::s-
CIt
~I~
CLUTCH CABLE
C-C
SECTION C-C
VIEWT
BRACKET EXHAUST
HANGER REF.
AEF
5A289 ASSY. REF.
~ NUT AND
ANO HOUSING
L~..
W
5C257
VIEWU
5E212
OA 5E214
5E212OR
5E214
CONVERTER ASSY
ASSY. REF.
\
386763-S2
45358-S7G
386763-S2
15-25
LB.
FT.
20-30LB.FT
15-25 LB. FT
L.H. SHOWN,
SHOWN, R.H. SYMMETRICALLY
SYMMETRICALLY OPPOSITE
VIEW V
VIEWV
'\/~7~\
~~
~~U
5246 ASSY.
ASSY. REF.
REF
~'-.
2 REo'D
381877-524
REo'D.
381877-S2 4REQD.
108 IN. LB. MAX.
108
SEAT BELT ANCHOR

REINFORCEMENT
VIEWJ
SHOWN - R.H. SYMMETRICALLY

L.H. SHOWN
VIEWX
MAi~~d.~&S2
)
381877S2
108 IN LB MAX.
J-~453~S7G
,tJI.-
R.H.
R.H. SIDE
SIDE ONLY
ONLY
VIEW
Z
VIEWZ
EXHAUST MANIFOLD REF.
N-800116-S2
EXHAUST
2REQ'D.
'I~
5C263
52~,#~
387039-57
\j (
~~
""-1::',0
2 REo'O
"
MOUNT REF
__ 385637-S2
2REo'O
5~
300
5A289 ASSY.REF.
~
~-
3()0
,VIEW K
REF.
VIEW N
SECTION 0-0
D-D
5299
REF.
5C257 ASSY. REF.

5A272 2 REo'D
5252 ASSY.
U A - _ - - ; - - 24-35 FT-LB
0-
84
VIEWG
VIEWS
FOR
FOR RALLY
RALLY OPTION
OPTION ONLY
ONLY
378836-S2 2 REQ'D.
12 FT-LB
FT-LB MAX.
MAX.
12
DIFFERENTIAL REF.
REF
VIEWR
VIEW P
P
VIEW P
P
0I
5C257
5C257 ASSY.REF.
ASSY.REF.
FUEL TANK REF.
U1561-8
U15614
FIG. 5 Dual Exhaust System-Mustang

SystemMustang
BACK TO GROUP INDEX
W
I
'"
EXHAUST MANIFOLD
N-800064-S2
(2 REQ'D.)
SHOULDER OF STUD.
SHOULDER OF STUD.........
387039^7
387~-57
(4REO'Oj',...
REQ'D.)
(4
25-35 FT-LB
25-35 FT-LB """"

.
S T U D- 5246
STUD
N800116-S2
OR 5E212 N800116-52
(2 REO'O.)
REQ'D.)
(2
MUST
BE INSTALLED
INSTALLED
/MUST BE
TO
SHOULDER OF
OFSTUD
STUD
TO SHOULDER
WITHOUT
WITHOUT
CONVERTER
CONVERTER
~~~E212 1i~~.~.~.I-.~
--s:. (b. -i'lf-\ .
~J:4..
MANIFOLD
MANIFOLD
~~
WITHOUT CONVERTER
CONVERTER
/ CABLE
- L .70
WITHOUT
CLUTCH CABLE
CLUTCH
VIEWO
~
VIEWY
CLUTCH
AUTO. TRANS.
TRANS.
CLUTCH
AUTO.
CABLE
CLUTCH HOUSING BOSS
CONVERTER BOSS
BOSS
CABLE
CLUTCH HOUSING BOSS
CONVERTER
HOUSING
NUT V
HOUSING
"
5E212
NUT \
5E212
J.45
.50
JA
INLET PIPE AND

CONVERTER
ASSY.-5E212
H-HI
SECTION C
C -- C,
C
'SECTION
.84
CROSSMEMBER
JCROSSME~~2ER
1.12
SECTION B -1
f/'~-.
SECTION 0D - D
D,
SECTION
5E212
5E212
5230
5230
~~J~.~~\.I'.:~
.~
y-2J
.\..( ~t:.
~
~t-==-:-=-_~~ ~1~'i5230
5D217
50217
5246
5246
VERTICAL Q.
VERTICAL
ct.
THIS
THIS LINE
LINE MUST
MUSTBE
BE
HHORIZONTAL!:.
O R I Z O N T A L ! 20
200
CLAMP - 5A231
CLAMP
- 5A231
25-35
FT-LB
25-35 FT-LB
AND EVENLY TO MAINTAIN
AND EVENLY TO MAINTAIN
TORQUE
TOROUE
WITH
WITH
CONVERTER
CONVERTER
O"//p)//-Y'
'.
t~
~
.50
.50
.75
5230
u.
RESONATOR - 5230
FIG.
FIG. 66 Single
Single Exhaust
Exhaust SystemMustang
System-Mustang
5.73
5.73
ct. OF CRANK
L----nn -, t
-~~ 4.76 L.H.

4.82 R.H.
INLET
INLET PIPE
PIPE GAGING
GAGING
WITHOUT
WITHOUT CONVERTER
CONVERTER
VIEWW
ALLOWABLE VARIATION
VARIATION
ALLOWABLE
IN CLAMP
CLAMP INSTALLATION
INSTALLATION
IN
VIEWP
VIEW P
<
I
_~/}?'-1.00
SHOCK
BRKT.
'.,
0-
1.00
m
)(
:r
Q
cCIt
~5230
..
5230
TWO CONVERTERS
VIEWS
VIEWS
BRACKET AND
AND INSULATOR
BRACKET
INSULATOR
5260
~.('
.~~~c
~
...~
_. .
MUFFleR
MUFFLER
VIEW U
VIEWU
5230
5230
~
.... -.
4--
~ .. _~J ~~.
_.
~~~~l
381877-S2
(4 REQ'D.)
TIGHTEN SECURELY
SECURELY
TIGHTEN
108 IN-LB
IN-LB MAX.
MAX.
108
r:;i
FLOOR SIDE
SIDE MEMBER
MEMBER
FLOOR
-~",.'
~~~~ci:l
~.
CLAMP _ 5C267
381877-S2
(4 REQ'D.)
TIGHTEN SECURELY
TIGHTEN SECURELY
. 108 IN-LB MAX.
108 IN-LB MAX.
L A M P - 5C267
5263
BRACKET AND
AND
5263
BRACKET
INSULATOR _ 5260
INSULATOR - 5260
VIEW RR
VIEW
'500~
~\
MAIN VIEW \
CLAMP
CLAMP CLAMP
5A23~
-_ 5A231
25-35 FT-LB
FT-LB
25-35
TIGHTEN NUTS
NUTS ALTERNATELY
ALTERNATELY
TIGHTEN
R.H.
SIDE
ONLY
R.H.SIOE ONLY AND
AND EVENLY
EVENLYTO
MAINTAIN
TO MAINTAIN
VIEWX
VIEW X
TOROUE
TORQUE
WITHOUT
WITHOUT
CONVERTER
CONVERTER
38.78 R.H.
CLAMP
386504-S REF.
386504SREF.
.30 0
l
f
35.97
35.97 L.H.
L.H.
38.78 R.H. -
~/"
::
5E212 ASSY.
4.76 L.H.
(.l
-.....,
V
. )~
5246 OR
5246 OR
5E212ASSY.
-L ct.
( t OF
OF CRANK
CRANK
..., 4.82 R.H.
4,82 R.H.
4.76 L.H.
1.88
--
WITH
WITH CONVERTER
CONVERTER
\.~..
:~l~
~~~~1.tB
\~--'---:/'~-......,.
1.88
I
INSULATOR - 5
5260 2 6 0 )
382802-S2
(2 REQ'D.)
17-28 FT-LB
REAR ENGINE
./REAR
ENGINE SUPPORT
SUPPORT
.'
385637-S2
.00
--"" <e.>f . 385637-S2.oo
(2
REQ'D.)
.06
\-:=~ REO'DJ
~"-~-~-.
TRANS. EXT..
TRANS. EXT..
REF.
REF.
..,~
\~.
..~,
Y
S-<~
1=t1ft1
.
_
5.73
TRANS. EXT.
~~'-)-;~
(t~ ~~ Uf)'
~~~'-='- \ aV
<f!J!I ~..
.~
.'
.,
, SECTION
CD
INLET
INLET PIPE
PIPE GAGING
GAGING
~~
_!l~ >A ~V.W
Y
~~OCK
VIEWV
5246ASS~Y'
({r5246REF'fff
.63
"---:-r--__
38.86 R.H.~.....
36.06 L.H.
WITH
CONVERTER
AUXILIARY VIEW
VIEW
AUXILIARY
WITHOUT CONVERTER
CONVERTER
WITHOUT
HEAT VALVE
VALVE
HEAT
~.
5246
5246
VIEWV
.70
~-Jf
45358-S7G
2 REQ'D.
20-30* FT-LB
1>-
-~
~-.'
TOSHOUL~DE\OP.,J~ ~~~~ -~J8-~~73
~~!~t~
TO SHOULDER STOP
.;r
STUD- - 38657-52
38657-S2
STUD
REQ'D.
22REO'D.
MUSTBE
BEINSTALLED
INSTALLED
MUST
5E212
.\.
~
h)
~
MUFFLER
VIEWT
VIEWT
~\
378836-S2
VIEW P
378836-S2
VIEWP
TIGHTEN SECURELY
SECURELY
TIGHTEN
12 FT-LB
FT-LB MAX.
MAX.
12
SAME AS
ASVIEW
VIEW U
U
SAME
EXCEPTAS
ASSHOWN
SHOWN
EXCEPT
FOR
RAllY
FOR RALLY
OPTION ONLY
ONLY
OPTION
h)
~
I
U1579-A
U1579-A
W
I
CD

26-10-1
26-10-1
26-10-1
6-Cylinder Engine Single Exhaust System
6-Cylinder Engine
PART 26-10
26-10 6-Cylinder
Single Exhaust System
Page
COMPONENT INDEX
Page
COMPONENT INDEX
......................
10-1
10-1
10-1
Assembly ........................
10-1
Resonator Inlet Pipes ................
10-1
10-1
Catalytic Converter . ................
10-2
DESCRIPTION
DESCRIPT
ION
Muffler
Muffler and Resonator
NOTE: The
The infonnation
information in
to both 1975 and 1976 .nodel
CR1966.A
CR1966-A
DESCRIPTION
The Maverick, Comet, Granada and
and
Monarch with 6-cylinder engines have
basically the
the same
same type
type single
single muffler
muffler
exhaust system. These systems have aa
resonator inlet pipe, resonator, resonator
outlet pipe and

and aa muffler.
muffler. On
On some
is used
systems, aa catalytic converter is
the resonator inlet pipe and
and the
the
between the
resonator.
Service replacement parts for
for these
exhaust systems usually consist of

of more
pieces than do
do the
the factory-installed
factory-installed
systems. Refer to
to the
the Motorcraft
Motorcraft Master
systems.
for information
information on
on the
the
Parts Catalog for
available service assemblies.

The replacement procedures given
all vehicle models unless
apply to
to all
otherwise noted.
RESONATOR INLET PIPES

Removal
Removal
1. Raise the
the vehicle.
2. Without catalytic converter-remove
converterremove
the "U" bolt clamp between the
the inlet
inlet
pipe and
and resonator pipe slip joint
connection.
3. With catalytic converter-remove
converterremove the
front
front flange (converter
(converter inlet)
inlet)
attaching nuts at
at the
the converter.
4. Loosen the
the attaching screws at
at the
the
muffler
muffler rear hanger support.
S.
5. Remove the attaching screws holding
to the
the
the inlet pipe support hanger to
inlet pipe (catalytic converter units
only).
6.
6. Slide the
resonator/muffler assembly
rearward to
to disengage the
the inlet pipe
or the
the front
front
slip joint connection or
flange connection
connection atatthe
theconverter.
converter.
flange
7. Remove the
the inlet pipe to
to exhaust
manifold attaching nuts and
and remove
the vehicle.
the inlet pipe from the
Installation
Installation
1. Clean the
the exhaust manifold
manifold flange
seats and
flange seats, if so
and converter flange
so
equipped. Install aa new gasket on
on the
the
inlet pipe flange.
flange.
2. Without catalytic converter-insert
converterinsert
the inlet pipe into the
the resonator pipe.
Loosely install
install aa new
new "U"
"U" bolt
bolt
Loosely
clamp.
BACK TO GROUP INDEX
converterposition
3. With catalytic converter-position
the studs of
of
the inlet pipeflange
flange onto the
new
the converter flange, using aa new
do not
not tighten,
tighten, the
the
gasket. Install, but
but do
the rear
attaching nuts. Loosen the
converter flange
and loosely install the attaching nuts.
Be sure the
the gasket is
is properly seated
in the
the exhaust manifold.
5. Loosely install the attaching screws to
to
the rear support hanger and
and muffler.
muffler.
6.
6. Loosely install the
the front inlet pipe
hanger attaching screws (catalytic
converter units only).
7. Align the exhaust system to clearance
specifications shown.
8.
8. Starting from the exhaust manifold to
inlet pipe nuts, tighten all
all attaching
nuts or
or screws to
to specification.
specification.
9.
9. Check the
for leaks
and lower the
the vehicle.
ASSEMBLY
Removal
Removal
1. Raise the
the vehicle on
on aa hoist that
permits the
the axle to
to lower to
to the
the full
extent of its travel. This will provide
to replace the
the
the clearance necessary to
and muffler
muffler assembly.
resonator and
2. Support the
the inlet pipe with soft wire.
converterremove
the inlet
the"U" bolt clamp holding the
pipe to
to the
the resonator pipe.

converterremove the
at the
attaching nuts at
the rear flange
of the converter.
connection of
the attaching
attaching screws
screws from
from
5. Remove the
support hanger to
to the
the rear support
the
muffler.
6. Slide the
the resonator and
and muffler
muffler
6.
assembly rearward until the resonator
pipe is
is separated from the
the inlet pipe
or catalytic converter.
7. Remove the
the attaching screws from
the intermediate support bracket to
to
resonator and
the resonator
and remove the
and muffler
muffler assembly.
Installation
Installation
1. Install the
the resonator and
and muffler
muffler
to the
the vehicle and
and position
assembly to
to
the intermediate support bracket to
the resonator. Loosely install the
the
attaching screws.
the resonator pipe into the
2. Install the
the
to the
the
inlet pipe from the manifold or to
rear flange of the catalytic converter.
The converter ball
ball. seat must be
be
to attaching the
cleaned prior to
the
resonator pipe. Install the pipe clamp
do not
not
or flange
flange attaching nuts but
but do
tighten.
tighten.
the muffler
muffler rear hanger
3. Position the
bracket to
to the
the muffler
muffler and
and loosely
the attaching screws.
install the
the exhaust system to
to conform
4. Align the
to clearance specifications. Starting
the inlet pipe to
to resonator pipe
from the
all clamps, nuts
connection, tighten all
or screws to
to specification.
specification.

26-10-2
26-10-2
6-Cylinder
6-Cylinder Engine
Engine Single
Single Exhaust
Exhaust System
System
Remove the
the temporary
temporary support
support wire,
wire,
5.5. Remove
check the
the exhaust
exhaust system
system for
for leaks
leaks
check
and lower
lower the
the vehicle.
vehicle.
and
CATALYTIC CONVERTER
CONVERTER
CATALYTIC
Removal
Remoylll
Raise the
the vehicle
vehicle on
on aa hoist.
hoist.
1.1. Raise
2. Remove
Remove the
the converter
converter inlet
inlet and
and outlet
outlet
2.
flange attaching
attaching nuts.
nuts.
flange
3. Slide
Slide the
the resonator/muffier
assembly
3.
BACK TO GROUP INDEX
rearward until
until the
the converter
converter can
can be
be
rearward
removed. Loosen
Loosen the
the intermediate
intermediate
removed.
and rear
rear hanger
hanger support
support brackets
brackets as
as
and
necessary.
necessary.
4. Replace
Replace any
any damaged
damaged parts.
parts.
4.
Installation
Instlll/stion
Position the
the catalytic
catalytic converter
converter to
to the
the
1.1. Position
inlet pipe
pipe and
and resonator
resonator pipe
pipe flanges.
flanges.
inlet
A
A new
new gasket
gasket must
must be
be used
used on
on the
the
26-10-2
26-10-2
front
front or
or inlet
inlet pipe
pipe flange
flange connection.
connection.
Loosely
Loosely install
install the
the attaching
attaching nuts.
nuts.
2.
2. Align
Align the
the exhaust
exhaust system
system to
to clearance
clearance
specifications,
specifications, and
and starting
starting from
from the
the
front
front of
of the
the converter,
converter, tighten
tighten all
all nuts
nuts
and
and bolts
bolts to
to specification.
specification.
3.
3. Check
Check the
the system
system for
for leaks
leaks and
and lower
lower
the
the vehicle.
vehicle.

381877-S2
381871-52
REQD.
44 REaD.
8-14 FT.
FT. LB.
LB.
8-14
EXHAUST
MANIFOLD REF.
5E212
5E212 CONVERTER
CONVERTER ASSY.
ASSY. REF.
REF.
5E212CONVERTER
CONVERTER ASSY'RE~F'
ASSY.REF
5E212
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376699-S2
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t...,
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I
5246
5246 ASSY.
ASSY. REF.
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ct.
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5246 ASSY.REF.
VIEW X
45358-S7G
20-30 FT-LB
5A242
5A242 ASSY.
ASSY.
WITH
WITH CONVERTER
CONVERTER ONLY
ONLY
VIEW Z
"'III:Z.I~~~'fIL.
-..;::: ,
-' SAME
SAME AS
AS VIEW
VIEW W
WEXCEPT
EXCEPT AS
AS SHOWN
SHOWN
386303S2
VIEW
386303-S2
VIEW X
X
.50--J
.75
VIEW W
5C257 ASSY. REF.
386762-S2
15-25 FT-LB
VIEWU
5252 ASSY.
25-35 FT-LB
~d
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/
/ ~~
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/.
5C257
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..--.
m
:J
ceo
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20-30 FT-LB
..-
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~l:
'-1-'
-J.
45358-S7G
381871-S2
381877-S2.
8-14 FT. LB.
8-14
FT. LB.
WITH CATALYTIC
CATALYTIC CONVERTER
CONVERTER
WITH
'I
V
I E V V TT
VIEW
, 1\
\ 1\.
:J
<C
CD
m
)(
40967 S2
10-20 FT.LB.
""r-
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....
CIl
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381877-S2
8-14 FT. LB.
(1)
5D203 ASSY
VIEW T
T
VIEW
WITliOUTCATALYTIC CONVERTER
CONVERTER
WITHOUTCATALYTIC
'#
# 11 BODY
BODY CROSSMEMBER
CROSSMEMBER REF
REF.
62 +
.62
.25
.25 " ;
.
.62
AND CANADA
CANADA
49 STATES
STATES AND
49
SAME AS
AS MAIN
MAIN VIEW
VIEW EXCEPT
EXCEPT AS
AS SHOWN
SHOWN
SAME
SIDE MEMBER REF.
.25
...--'
FUEL
FUEL TANK
TANK REF.
REF.
h)
VIEWR
VIEWR
SECTION
SECTION C
C
0-
VIEW SS
VIEW
.....
I
REAR
REAR ENGINE
ENGINE
MOUNT
MOUNT REF.
REF.
U1562-B
oI
FIG. 1 Exhaust SystemMaverick/Comet,

System-Maverick/Comet, Granada/Maverick
Granada/Maverick Similar
Similar
BACK TO GROUP INDEX

26-20-1
26-20-1
26-20-1
26-20-1
V-8 Single Exhaust System
PART 26-20 V-8

COMPONENT
COMPONENT INDEX
INDEX
Page
Page
COMPONENT
COMPONENT INDEX
INDEX
DESCRIPTION
20-1
20-1
Muffler
Muffler and Diffuser
REMOVAL AND
AND INSTALLATION
20-1
20-1
Muffler
Muffler and Resonator Assembly
Resonator Inlet Pipe.

Pipe . . . . . . . .. . . . . . . .
20-1
20-1
Muffler Inlet "Y"

" Y " Pipe
20-2
Inlet "Y"
" Y " Pipe
20-2
Muffler and Resonator
20-3
Page
20-3
20-4
Muffler, Resonator and Outlet

Pipe Assembly
20-4
Converter
Catalytic Co
nverter
20-4
NOTE:
NOTE: The
The information
information in
in this
this Part
Part applies
applies to
toboth
both 1975
1975 and
and 1976
1976model
model year
year vehicles
vehicles unless
unless otherotherspecified.
CR1966-A
wise specified.
CR1966-A
DESCRIPTION
The basic single exhaust system used
V-8 engines
enginesconsists
consistsof
ofaamuffler
muffler and
and
with V-8
aa resonator and/or diffuser. This basic
is subject to
to the
the addition of
of one
one
system is
two catalytic converters as
as indicated
or two
in the exhaust systems application chart,
26-01.
Section 26-01.
Mustang has
has aa unique one-piece
welded converter and inlet pipe assembly.

assembly.
The converter inlet pipe is
is connected to
to
muffler and
and resonator assembly by
the muffler
by aa
and U-bolt assembly.
cone-type flange
flange and
The factory-installed exhaust systems
differ
differ from the
the service replacement
in the
the number of pieces used.
systems in
When making aa service replacement,
the Motorcraft
to the
refer to
for the
the current assemblies.
Catalog for
are used with
Single exhaust systems are
IV and
and Lincoln
Thunderbird, Mark IV
vehicles. Thunderbird and Continental
IV require a dual exhaust system
Mark IV
with the
the R.P.D.3.0 rear axle assembly.
INSTALLATION
and installation
installation
The removal and
procedures given apply to
to all
all vehicle
models unless otherwise noted.
to
noted. Refer to
the
when
the appropriate
appropriate system
system illustration
illustration when
servicing
servicing exhaust
exhaust system.
system.
RESONATOR INLET
INLET PIPEPIPEMAVERICK, COMET, GRANADA,
GRANADA,
MONARCH
Removal
Removal
1. Raise the
the vehicle.
vehicle.
1.
the nuts which hold the
2. Remove the
the
(if so
clamped-on exhaust shield (if
so
equipped) to the catalytic converter
"Y" pipe.
pipe. Remove the
and/or "Y"
the
and remove the
attaching clamp and
the
shield.
exhaust shield.
3. Remove the
the attaching nuts securing
3.
"Y" pipe to
to the
the
the resonator inlet "Y"
exhaust manifolds and
and separate the
the
the manifolds. On
On some
Y-pipe from the
vehicles itit may be necessary to
to loosen
loosen
the entire exhaust system supports in
order to
to separate the
the "Y"
"Y" pipe from
manifolds.
4. Remove the
the attaching bolts securing
4.
"Y" pipe to
to the
the front hanger
the "Y"
BACK TO GROUP INDEX
support bracket (used with catalytic

converter system only).
converterremove
5.
"U" bolt
bolt clamp
clamp at
at
the inlet "Y" pipe "U"
the resonator
the connection with the
inlet extension.
6. With catalytic converter-loosen
converterloosen the
6.
the
at the
the rear converter
attaching nuts at
the front converter
flange. Remove the
flangeattaching
attachingnuts
nutsand
andseparate
separatethe
the
flange
the inlet "Y"
"Y" pipe.
pipe.
converter from the
7. Remove the inlet "Y"
*'Y" pipe and clean
7.
the manifold
the gasket surfaces of the
and converter.
8. Discard the
the gaskets, where used, and
and
8.
any damaged parts.
replace any
Installation
Instsllation
1. Place new gasket(s) on the "Y" pipe
flanges where required.
2. Without catalytic converter posithe inlet pipe to the resonator
tion the
and loosely install a new "U"
inlet and
bolt clamp. Be sure to maintain the
specified clearances for
for the
the clamp
and locating tab and be sure that the
tab is fully inserted into the locating
slot.
3. With Catalytic converter-position

converterposition
the inlet "Y"
"Y" pipe to
to the
the catalytic
converter flange,
flange
flange, using a new
new flange
gasket. Loosely install the
the attaching
nuts.
4. Position the
the "Y" pipe on the
the exhaust
manifolds
manifolds and
and loosely install the
the
flange
attaching nuts.
nuts.
flange attaching
5. Install any
any other supports that may
may
have been removed.
removed. Align the exhaust
system to
to conform
conform to
to clearance
specifications. Starting from the front
of the system, torque all
all nuts and
and
bolts to
to specification.
6. Check the exhaust system for leaks.
Install the
the exhaust cover shield,
using the
the clamps and
and attaching
screws. Tighten the screws and nuts
to specification.
specification.
7. Lower the
the vehicle.
RESONATOR INLET PIPEPIPEMUSTANG
Removal
Removal
1. Raise the
1.
the vehicle.
2. Support
Support the
resonator/muffler
26-20-2
3. Remove the screws that attach the
the
3.
the
front hanger support bracket to the
bracket.
inlet pipe bracket.
4. Remove the attaching nuts at the
the
cone type flange connection loL.H.
cated at the rear of the L.H.
the
catalytic converter. Remove the
U-bolt assembly at the R.H.
R.H. fleaf
rear of
V-bolt
converter.
the catalytic converter.
5. Remove
Remove the nuts attaching th.e
the inlet
5.
manifold
pipe flange to the exhaust manifold
pipe. 1'rOTE:
NOTE:
and remove the inlet pipe.
as required to
slip joint connection as
disassemble. The inlet pipe and
converter are one assembly and must
as a unit.
unit.
be removed as
6.
Instllllstion
Installation
1.
1. Clean the exhaust manifold, sHp-joint
slip-joint
connection and catalytic converter
flange seat.
2. Position the inlet pipe/catalytic
pipe/catalytic
resonator
converter assembly to the rt$onator
pipe flange and slip joint and loosely
manifold
3. Position the inlet pipe to the 'manifold
attaching nuts.
support
4. Install the front hanger support
bracket insulator to inlet pipe bracket.
Do not tighten the attaching screws.
5. Remove the wire support for the
muffler assembly.
resonator muffler
6. Align the exhaust the system to
6.
proper clearance specifications and
starting at the front, tighten all nuts,
screws, and bolts to specification.
MUFFLER INLET "Y" PIPE (FORD,
MERCURY, TORINO, ELITE,
MONTEGO, COUGAR)
Removal
RemovsJ
2. Units Equipped
Exhaust
Equipped with Exhaust
Shield(s)
Remove the screws and clamps
damps that
hold the exhaust shield(s) to the
catalytic converter
converter inlet pipe and
exhaust "Y" pipe and remove the
shield(s).
3. Remove the "U" bolt clamps at the
muffler
muffler inlet connections.
4. Support the mufflers
mufflers in their proper
position using soft
soft wire.
5.
S. Units Without Catalytic
Catalytic; Converter(s)
Remove the nuts attaching the inlet
pipe to the right hand
hand. or left
left hand
manifold
manifold connection.
Units With One Catalytic
Catal~'tic Converter
Remove the nuts attaching the left
hand inlet pipe to the converter flat
flange connection and the right hand
inlet pipe to the right hand manifold.
Units With Two Catalytic
Catalytic Converters
Remove the nuts attaching the inlet
pipe
flange
pipe to converter
converter flat
flat flange
BACK TO GROUP INDEX

System
connections. Do
e inlet
Do not
not remove th
the
pipe to right hand or left hand
hand
nuts.
manifold connection nuts.
6.
6. Disconnect the inlet pipe froln
from the
manifold
catalytic converter and/or manifold
connection(s). It may be
be necess,ary
necessary to
connection(s).
disconnect the rear hanger to outlet
pipe attachment in order to obtain
sufficient clearance to sepanlte
separate the
sufficient
converter or manifold connection(s}.
connection(s).
7.
7. Separate the inlet pipe to muffler slip
joint connection(s).
connection(s).
8. Clean the gasket surfaces of the
the
8.
converter(s).
9.
9. Discard all old gaskets and HU"
"U" bolt
clamps.
clamps.
Installation
Instsllstion
1. Slide the "U" bolt clamp(s) over the
1.
muffler end(s) of the "Y" inlet pipe.
muffler
2. Position the inlet pipe to the muffler
slip joint connection(s) and loosely
clamp(s). Be
Be sure
install the "U" bolt clamp(s).
the tab(s) on the inlet pipe is properly
muffler slot(s).
located in the muffler
3. Units Without Catalytic Converter(s)
a. Position the inlet pipe to the right
manifolds.
hand and left hand manifolds.
Loosely install the attaching nuts.
b. Align the inlet pipe and mufflers to
proper clearances and location.
Tighten the left hand manifold
manifold
attaching nuts to specification fLDd
and
then tighten
tighten the right hand
manifold attaching
n u t s to
manifold
specification.
Units With One Catalytic Converter
a. Install a new gasket to the flange
studs on the converter.
b. Position the inlet pipe to the
manifold and converter flat flange
connections. Loosely install the
attaching nuts.
c. Tighten the converter flat flange
specificat ion at
attaching nuts to specification
the inlet pipe.
d. Tighten the right hand manifold to
inlet pipe aattaching
inlet
t t a c h i n g nuts to
specification.
Units With Two Catalytic Con'verters
Converters
the: right
a. Install a new gasket to the
hand and left hand converter studs.
Position the inlet
inlet pipe to the
b. Position
converter flat flange connections
and loosely install the attaching
nuts.
left hand and then the
c. Tighten the left
right hand flat flange connection
attaching nuts to SPecification.
specification.
NOTE: If
If a catalytic converter^)
converter(s)
is being replaced along with the
inlet pipe, the converter(s) should
be installed to the manifold(s)
thf! inlet pipe to
loosely, then the
converters)
converter(s) flat
flat flange
flange connection
attaching nuts must be installed
and tightened to specification
B
E F O R E the
BEFORE
the manifold
manifold to
converter attaching nuts to insure
insure
proper alignment.
26-20-2
4.
4. Tighten the
the "U"
"U" bolt clamp(s)
clamp(s) at the
the
muffler slip
slip joint(s) to
to specification.
specification.
Be
Be sure the tab and slot are properly
engaged.
engaged.
S.
5. Tighten the rear hanger to muffler
muffler
outlet
o u t l e t pipe
p i p e attachment
a t t a c h m e n t to
to
specification, if required.
required.
6.
and alignment and install the exhaust
shields to
to inlet pipe(s)
pipe(s) as
as required.
required.
7.
vehicle.
INLET "Y"
"Y" PIPE-THUNDERBIRD,
PIPETHUNDERBIRD,
MARK IV AND
AND LINCOLN
LINCOLN
RemoYllI
Removal (Includes Service System
Replscements)
Replacements)
1.
vehicle.
2. Remove the screws and clamps that
hold the exhaust shield(s) to the
catalytic converter inlet pipe and
exhaust "Y" pipe and remove the
shield(s).
shield(s).
3. Remove the "U" bolt clamp(s) at the
muffler inlet(s).
4. Support the muffler(s) in car position
only.
5. Units Without Catalytic Converters
Remove the inlet pipe to right hand
and left hand manifold connection
attaching nuts.
a. Remove the nuts attaching the inlet
pipe to the converter flat flange
connection.
b. Remove the nuts attaching the inlet
pipe to the right hand manifold.
Units With Two Catalytic Converters
pipe to the converter flat flange
connections on right hand and left
hand side of vehicle.
b. Do not loosen the converter to
right hand or left hand manifold
connections.
6. Separate the inlet pipe from the
catalytic converter(s) or manifold
connections. (It may be necessary to
disconnect the rear hanger to muffler
o
u t l e t aattachments
t t a c h m e n t s to allow
outlet
movement
movemen t for inlet to converter
separation.)
7. Separate the inlet pipe(s) to muffler
slip joint connection(s).
surfaces of
of the
8. Clean the gasket surfaces
converter flange(s)
flange(s) and discard
converter
gaskets and "U" bolt clamps.
IDstllllstion
Installation
1. Install new "U" bolt clamp(s) over
of the inlet pipe.
the outlet end(s) of
muffler slip
2. Position the inlet pipe to muffler
joint connection(s) making sure the
joint
inlet pipe is properly
tab on the inlet
muffler slot(s). Loosely
located in the muffler
position the "U" bolt clamp(s).
a. Install the inlet pipe loosely to the
left hand and right hand manifolds
left
with the mufflers
mufflers supported
supported in
position and clearances checked.

26-20-3
b. With clearances maintained,
maintained,
tighten the left
left hand manifold
manifold
attaching nuts and then the right
hand to specification.
specification.

a. Install
Install a new gasket
gasket to the
converter flange
flange studs.
converterflange
flange and the right hand
manifold. Loosely install the
attaching nuts.
c.
c. Tighten the converter
converter flange
flange
attachment nuts and then the right
hand manifold attaching nuts to
specification.
Units With Two

TwoCatalytic
CatalyticConverters
Converters
a. Install a new gasket to each
converter flange.
flange.
converters and loosely install the
attaching nuts.
c. Tighten the left hand and then the
right hand inlet pipe to converter
fl
a n g eat
flange
a t t aa cchi
h i nnggnu
n u t ss to
specification.
NOTE: If catalytic converter is

NOTE:
being replaced along with the inlet
pipe, the converter(s) should be
installed to the manifold(s) loosely.
Then the inlet pipe to converter(s)
flat flange connection attaching
nuts must be installed
installed and
specification
tightened to specification
BEFORE the manifold
manifold to
converter attaching nuts to insure
proper alignment.
4. Tighten the "U" bolt clamps at the
mumer
muffler slip joint to specification. Be
sure the tab and slot are properly
engaged.
5.
5. Tighten the rear hanger to muffler
muffler
o u t l e t pipe
pipe attachment
outlet
6.
shield(s) to inlet pipe(s) as required.
RESONATORMUFFLER AND RESONATORMAVERICK, COMET, GRANADA,

GRANADA,
MONARCH
Remoysl
Removal
1.
1. Raise the vehicle on a hoist that
permits the axle to lower to the full
the clearance necessary to replace the
muffler and resonator.
mumer
2. Remove the attaching nuts and
clamp securing the exhaust shield
(if so equipped).
equipped).
converterloosen
4. Without catalytic converter-loosen
the "Y" pipe "U" bolt clamp at the
connection with resonator pipe.
5.
converterremove the
rear converter flange
6.
the rear hanger assembly to mumer
muffler
support.
BACK TO GROUP INDEX

7.
de the resonator and muffler
7. Sli
Slide
muffler
as~,embly
from the inlet pipe or the catalytic
flange.
converter flange.
8.
the intermediate support to resonator
assembly and remove resonator,
connecting pipe and mumer.
muffler.
Installation
Installstion
1.
muffler
assembly to the inlet "Y" pipe or
converter flange connection. The
converter ball seat must be cleaned
prior to attaching the resonator pipe.
Loosely install a new "u"
"U" bolt
clamp or
or flange
flange attaching
attaching nuts.
nuts.
clamp
2.
2. Position
Position the resonator
resonator in the
intermediate hanger bracket and
loosely install the attaching screws.
muffler to the rear
hanger bracket and loosely install the
screws.
screws.
4.
to the clearance specifications (Fig.
1).
1).
5.
5. Starting
Starting from
from the
the inlet
inlet "Y"
"Y" pipe
pipe
outlet
outlet end,
end, torque
torque all
all nuts
nuts and
and bolts
to specifications.
6.
6. Remove the temporary support wire,
check the system for leaks and install
the exhaust shield.
7.
ASSEMBLY-MUSTANG
ASSEMBLYMUSTANG
Remoyal
Removal
1.
replace the muffler,
pipe.
2.
2. Remove the rear converter
converter to
re~;onator
-bolt
resonator pipe flange and U
U-bolt
connection attaching nuts (Figs. 11
and 2).
the rear hanger assembly to mufller
muffler
support.
from the resonator inlet pipe.
pipe. NOTE:
slip joint conn(~ction
connection as required to
disassemble.
5.
intermediate
the in
termediate support on the
muffler
resonator/muffler assembly.
resonator/mumer
6.
Installstion
Installation
1.
1. Clean the slip joint connection and
flange seat.
muffler
attach the intermediate
intermediate
loosely attalch
support bracket.
26-20-3
flange
3. Position the resonator pipe and flange
to the converter flange
flange and slip joint.
Install but do not tighten the
Install
attaching nuts.
4.
bracket and loosely install the
bracket
attaching screws.
5.
5. Al\ign
AMgn the exhaust system to conform
specifications
6.
the vehicle.
MUFFLER AND DIFFUSER TORINO,
ELITE, MONTEGO, COUGAR,
FORD, AND MERCURY
Remoy81
Removal
1.
1. Rai~,e
Raise the vehicle on a hoist that
perrrlits
permits the rear axle to lower to the
full extent of its travel. This will
provide the clearance necessary to
remove the muffler
muffler and diffuser
diffuser
asselnbly(s).
assembly (s).
2.
2. Support the mumer
muffler inlet pipe with a
soft wire and remove the "U" bolt
muffler inlet
clamp at the inlet pipe to mumer
connection(s).
3. Remove the rear support bracket
screw. For Torino, Elite, Montego
and Cougar sedans, remove the rear
prestole attaching clamp screw.
4. Remove the screws securing the
intennediate
intermediate support bracket to the
mutller(s).
mufKler(s).
5. Separate the muffler
muffler to inlet pipe
connection(s) and remove the mumer
muffler
and diffuser
diffuser assembly(s).
6.
6. Replace "U"
**U" bolt clamps and any
other worn or damaged parts.
Instsllstion
Installation
1.
outlet end(s) of the inlet pipe.
2.
diffuser
assembly(s) on the inlet pipe and
loosely install the clamp(s). Be sure
that the tab is fully inserted into the
locating slot.
3. Position
Position the muffler
muffler to the
the
intermediate
support bracket.
bracket.
Loosely install the attaching screws to
specification.
4. Attach the screws holding the rear
support bracket and tighten to
support
specification. For Torino, Montego,
Elite and Cougar sedans, loosely
install the prestole clamp.
5.
to the clearance specifications.
NOTE: If specified alignment
the
specifications cannot be obtained, the
right hand and left hand manifold
attachments should be loosened.
After specifications are obtained,
manifold attaching nuts to
to
tighten the n;\anifold
specification
specification while holding
holding
clearances.
26-20-4
6. Tighten intermediate support bracket
6.
specification.
7.
7. Position and secure the "U" bolt(s) at
the inlet pipe to muffier
muffler connection(s)
to specification. Be sure the tab and
ana
slot are properly engaged.
8. Remove the temporary wire support,
8.
check the system for leaks, and lower
the vehicle.
ASSEMBLY-THUNDERBIRD AND
ASSEMBLYTHUNDERBIRD
MARK IV
CONTINENTAL MARK
Removal (For
Removal
(ForService
ServiceSystem
System
Replacement)
Replacement)
1.
the clearance necessary to remove the
muffier
muffler and outlet pipe.
2.
2. Support the inlet pipe with a soft wire.
wire.
3. Cut the muffier
muffler outlet pipe(s) at the
kick-up area just above the muffier(s).
muffler(s).
4. Remove the screws which attach the
resonator(s) to the rear hanger(s).
Remove the resonator(s) and pipe(s).
5.
muffier(s)
muffler(s) to the intermediate support
bracket(s).
6. Remove the cIamp(s)
clamp(s) securing the
6.
inlet pipe(s) to the muffier(s).
muffler(s).
7. Separate the muffier(s)
muffler(s) from the inlet
7.
pipe(s) and remove the muffier(s).
muffler(s).
8.
8. Replace any damaged or badly rusted
parts and the "U" bolt clamps.
Installation
Instal/ation
1.
1. Position the muffler(s)
muffler(s) and outlet
pipe(s) to the intermediate support
bracket(s) and loosely install the
attaching screws.
2.
2. Slide the muffler(s)
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 the tab
is fully inserted into the locating slot.
3. Install a clamp
clamp on
on each resonator inlet
and slide each resonator onto the
muffler
muffler outlet. Loosely install the
"U" bolt clamp(s) snug, but not tight.
4.
4. Attach the resonator(s) to the rear
hanger bracket(s) and tighten the
attaching screws to specifications.
NOTE: If the
the alignment clearances
clearances
cannot be obtained, loosen the right
hand and left
left hand manifold
manifold
attachments until the necessary
clearance can be obtained. Tighten
specification.
the manifold bolts to specification.
6.
7. Tighten the "u"
"U" bolt clamps at the
7.
inlet pipe(s) to muffier
muffler outlet(s) to
and at the muffler
resonator inlet connection(s) to
specification.
BACK TO GROUP INDEX
26-20-4

8.
check the exhaust system for leaks
and
vehicle.
and lower
lower the
the vehicle.
MUFFLER, RESONATOR AND
OUTLET PIPE ASSEMBLYASSEMBLYLINCOLN
Removal (For
Removal
(ForService
ServiceSystem
System
Replacement)
Replacement)
1.
full limit of its travel. This will
provide
provide clearance
clearance necessary
necessary to
to
remove the muffier
muffler and outlet pipes.
2. Support the "Y" pipe with a soft wire.
3. Cut the muffler
muffler outlet pipe at the
kick-up
kick-up area, just above the
the muffier.
muffler.
4.
screws which attac,h
attach the resonator
tailpipe to the rear hanger and remove
the resonator and pipe.
5.
muffler
muffler to the intermediate support
bracket.
6.
6. Remove the "U" bolt clamp securing
the inlet "Y" pipe to the muffier.
muffler.
7.
7. Separate the muffler
muffler from the inlet
pipe and remove the muffier.
muffler.
8.
clamps.
8. Replace
Replace both
both clamps.
InstsJ/ation
Installation
1.
and
1. Position
Position the
the replacenlent
replacement muffier
muffler and
outlet
outlet pipe
pipe to
to the
the intermediate
intermediate
support
the
support bracket
bracket and
and loosely
loosely install
install the
attaching
screws.
attaching screws.
2.
pipe
2. Install
Install the
the muffler
muffler to
to the
the inlet
inlet pipe
and
the "U"
and properly
properly position
position the
"U" bolt
bolt
clamp.
clamp. Be
Be sure
sure to
to maintain
maintain the
the
specifil~d
clearances for
clamp and
specified clearances
for the
the clamp
and
locating
tab
locating tab
tab and
and be
be sure
sure that
that the
the tab
is
locating slot.
is fully
fully inserted
inserted into
into the
the locating
slot.
3.
3. Install
Install studs
studs into
into muffier
muffler outlet
outlet flange
flange
and
gasket over
and position
position gasket
over ~ituds.
studs. Install
Install
the
the
the new
new resonator
resonator inlet
inlet nange
ilange to
to the
muffier
flange studs.
the
muffler outlet
outletflange
studs. Install
Install the
flange
to
flange attaching
attaching nuts
nuts ani
and tighten
tighten to
specification.
specification.
4.
4. Attach
Attach the
the resonator
resonator to
to the
the rear
rear
hanger
hanger bracket
bracket and
and 100se.'J
loose.';/ install
install the
the
screws
screws aatt the
the hanger
hanger bracket
bracket to
to
tailpipe
tailpipe cnnnection,
connection, and
and tighten
tighten to
to
specification.
specification.
5.
5. Align
Align the
the exhaust
exhaust system
system to
to conform
conform
to the
the clearance
clear.ance specificati,ons.
to
specificati>ons.
6.
6. Tighten
Tighten inteJrmediate
support bracket
bracket
screws
screws to
to spedfication.
specification.
NOTE: If
NOTE:
If BJignment
alignment cl.~arances
clearances
cannot
right
cannot be
be obtained,
obtained, loosen
loosen the
the right
hand
hand and
and left
left hand
hand manifold
manifold
attachments
attachments until
until the
the ne!cessary
necessary
clearance
clearance can
can be
be obtained.
obtained. Tighten
Tighten
the
the manifold
manifold bolts
bolts to
to specifitcation.
specification.
7.
7. Tighten
Tighten the
the "U'~'
"IT bolt
bolt clam}~
clamp at
at the
the
inlet
and
inlet pipe
pipe to
to muftler
muffler connection
connection and
the
to
the Prestole
Prestole clamp
clamp at
at the
the tailpipe
tailpipe to
rear
r e a r hanger
h a n g e r connection
c o n n e c t i o n to
to
specification.
specification.
8.
wire,
8. Remove
Remove the
the temporary
temporary support
support wire,
check
the exhaust
for leaks
check the
exhaust system
system for
leaks
and
vehide.
and lower
lower the
the vehicle.
CATALYTIC CONVERTER
MAVERICK, COMET, GRANADA,
GRANADA,
AND MONARCH
MONARCH
Removal
Removal
1.
,2.
2. Remove the exhaust shield(s) at the
3. Remove the converter inlet and outlet
flange attaching
attaching nuts.
nuts.
flange
4. Slide the resonator/muffier
rearward until the converter can be
removed. Loosen the intermediate
and rear hanger support brackets as
necessary.
5.
5. Replace
Replace any
any damaged
damaged parts.
Instal/ation
Installation
1.
the
1. Position
Position the
the catalytic
catalytic converter
converter to
to the
"Y"
flange and
pipe
"Y" pipe
pipe flange
and resonator
resonator pipe
flange,
flange, using
usingaanew
newgasket
gasketatatthe
the"Y"
"Y"
pipe flange.
flange. Loosely
install the
pipe
Loosely install
the
attaching
flange nuts.
nuts.
attaching flange
2. Align
Align the
exhaust system
2.
the exhaust
system to
to clearance
clearance
specification,
specification, and
and starting
starting from
from the
the
front
the converter,
converter, tighten
tighten all
all nuts,
front of
of the
nuts,
bolts
bolts or
or screws
screws to
to specification.
specification.
3. Check
the
3.
Check the
the system
system for
for leaks,
leaks, install
install the
exhaust
exhaust shield
shield and
and lower
lower the
the car.
car.
CATALYTIC CONVERTER TORINO,
ELITE, MONTEGO, COUGAR,
ELITE,
FORD, AND MERCURY
Removal
Removal
1.
1. Raise the car on a hoist.
2.
2. Remove the exhaust shield(s) from
the catalytic converter(s).
3. Support the exhaust inlet pipe in its
relative position by securing the pipe
to the # 33 frame crossmember with
soft wire.
4.
4. Units With One Catalytic Converter
Remove the attaching nuts that hold
the converter flange to the exhaust
manifold and the inlet pipe (left hand
side). Remove the attaching nuts
holding the inlet pipe to the exhaust
manifold (right hand side).
Units With Two
Two Catalytic
Converters
Remove the con
verter flange
converter
flange
attaching nuts holding the converters
to the exhaust manifold and inlet pipe
(both sides).
5.
5. Slide the inlet pipe rearward until the
catalytic converter(s) can be removed.
removed.
It may be necessary to disconnect the
rear hanger-to-outlet pipe attachment
to obtain sufficient
sufficient clearance to
separate the converter at manifold
connection(s).
6. Clean the manifold
manifold and converter
6.
flange seats, discard gasket(s) and
damaged parts.
Installation
Instsllation
1. Position the catalytic converter(s) to
1.
the exhaust manifold. Loosely install
the attaching nuts.
Install
gasket over the
26-20-5
26-20-5
converter flange
flange studs.
studs. Position
Position the
the
converter
inlet pipe
pipe to
to the
the exhaust
exhaust manifold
manifold
inlet
(right hand
hand side)
side) and
and the
the converter
converter
(right
outlet flange
flange connection
connection (left
(left hand
hand
outlet
side). Loosely
Loosely install
install the
the attaching
attaching
side).
nuts.
nuts.
Units With
With Two
Two Catalytic
Converters
Units
Install new
new gaskets
gaskets over
over the
the converter
converter
Install
flange studs.
studs. Position
Position the
the inlet
inlet pipe
pipe
flange
flange to
flange
flange
to the
the converter
converter outlet
outlet flange
connections. Loosely
Loosely install
install the
the
connections.
attaching nuts.
nuts.
attaching
3. Tighten
Tighten the
the converter
converter to
to inlet
inlet pipe
pipe
3.
flange connection(s)
connection(s) to
to specification
specification
flange
and align
align the
the system
system to
to proper
proper
and
clearance specifications.
specifications. Tighten
Tighten the
the
clearance
manifold nuts to specification.
manifold
4. Check
Check the
the system for
for leaks
leaks and install
install
4.
exhaust shield(s) to the catalytic
the exhaust
converter(s).
converter(s).
5. Lower
Lower the
the vehicle.
vehicle.
5.
CATALYTIC CONVERTER
CONVERTER
CATALYTIC
THUNDERBIRD, CONTINENTAL
THUNDERBIRD,
CONTINENTAL
MARK IV
IV AND
AND LINCOLN
LINCOLN
MARK
CONTINENTAL
CONTINENTAL
RemoYIl/
Removal
1. Raise
Raise the
the car
car on
on aa hoist.
hoist.
1.
2. Remove
Remove the
the exhaust
exhaust shields
shields from
from the
the
2.
converter(s).
catalytic
BACK TO GROUP INDEX
v-a
Single Exhaust
Exhaust System
System
V-8 Single
Support the
the exhaust
exhaust inlet
inlet pipe
pipe in
in its
its
3.3. Support
relative position
position by
by securing
securing the
the pipe
pipe
relative
to the
the ##33 frame
frame crossmember
crossmember with
with
to
soft wire.
wire.
soft
4. Units
Units With
With One
One Catalytic
Catalytic Converter
Converter
4.
Remove
Remove the
the attaching
attaching nuts
nuts that
that hold
hold
the
the converter
converter inlet
inlet and
and outlet
outlet flanges
flanges
to
to the
the exhaust
exhaust manifold
manifold and
and the
the inlet
inlet
pipe
hand side).
side). Remove
Remove the
the
pipe (left
(left hand
attaching
attaching nuts
nuts holding
holding the
the inlet
inlet pipe
pipe
to the
the exhaust
exhaust manifold
manifold (right
(right hand
hand
to
side).
side).
Units With Two
Units
Two Catalytic
Converters
(California Only)
Only)
(California
Remove the
the converter
con verter flange
Remove
attaching nuts
nuts holding
holding the
the converters
attaching
to the
the exhaust
exhaust manifold
manifold and
and inlet
inlet "H"
to
pipe (left
(left and right
right hand
hand sides).
sides).
pipe
inlet pipe rearward
rearward until
until the
5. Slide the inlet
catalytic converters can be removed.
It may be
be necesary to disconnect the
It
hanger-to-outlet pipe attachment
attachmen1;
rear hanger-to-outlet
obtain sufficient
sufficient clearance
clearance to
to obtain
converter at manifold
separate the converter
connection(s).
catalytic converters.
6. Remove the catalytic
con verter flange seats,
Clean the converter
gf,sket and replace any
discard the gasket
damaged parts.
26-20-5
26-20-5
Installation
.lnstsl/Iltion
1.
1. Position
Position the
the catalytic
catalytic converter(s)
converter(s) to
to
the
the exhaust
exhaust manifold(s).
manifold(s). Loosely
Loosely
install
install the
the attaching
attaching nuts.
nuts.
2.
2. Units
Units With
With One
One Catalytic
Catalytic Converter
Converter
Install
Install aa new
new gasket
gasket over
over the
the
converter
converter flange
flange studs.
studs. Position
Position the
the
inlet
inlet pipe
pipe to
to the
the exhaust
exhaust manifold
manifold
(right
(right hand
hand side)
side) and
and the
the converter
converter
outlet
outlet flange
flange connection
connection (left
(left hand
hand
side).
side). Loosely
Loosely install
install the
the attaching
attaching
nuts.
nuts.
Units
Units With
With Two
Two Catalytic
Converters
Install
new gaskets
gaskets over
over the
the converter
converter
Install new
flange
flange studs.
studs. Position
Position the
the inlet
inlet pipe
pipe
flanges
to the
the converter
converter outlet
outlet flange
flange
flanges to
connections. Loosely
Loosely install
install the
attaching
attaching nuts.
nuts.
3. Tighten
Tighten the converter
converter to inlet
inlet pipe
flange
connections to
to specifications.
specifications.
flange connections
4. Align
Align the
the system
system to clearance
specifications
specific-ations and
and tighten
tighten the
manifold
manifold to converter
converter connections to
specifications.
5. Check the system for leaks and install
the exhaust shields to the catalytic
converter(s).

EXHAUST
INLET EXTENSION
EXTENSION
INLET
EXHAUST
FROM SURFACE
SURFACE OF
OF
EXHAUST MANIFOLD
MANIFOLD
FROM
EXHAUST
_ 50294
_
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386757-S2
(2
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MUFFLER
MUFF
LER AND
AND
RESONATOR
RESONATOR
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TRANS. EXT. REF.

TRANs.EXT'REF.~
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^ 4.94 L.H.
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37.70 R.H.
37.70
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~
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L.H. SIDE ONL
ONLY
INSTALLATION FOR
FOR L.H.
L.H. SIDE
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ONLY
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L.H.
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(2 REO'D.)
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CLAMP-5A231
- 5A231
25-35 FT-LB
ALTERNATELY AND
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RALLY OPTION ONLY
FOR RALLY
U1580-A
U1580A
FIG. 1 Exhaust SystemMustang

Converter)1976
System-Mustang With 302
302 V-8
v-a (No
(No Catalytic Converter)-1976
BACK TO GROUP INDEX

REAR ENG. MOUNT

INLET EXTENSION
EXTENSION
INLET
- 5D294
-50294
EXHAUST
EXHAUST MANIFOLD
MANIFOLD
i
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5E281
HEAT VALVE
VALVE
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INSTALLATION FOR
FOR L.H.
L.H. SIDE
SIDE ONLY
ONLY
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SAME AS
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EXCEPT AS
AS SHOWN.
SHOWN.
SAME
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.25
.25
11^
386499-S A S S Y . '
THIS LINE MUST BE
25-35 FT-LB
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TIGHTEN NUTS ALTERNATELY AND
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VIEWU
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TRANS.
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S
TUDSTUD386757-S2
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REO'D.)
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SHOULDER
45358-S7G
SHOULDER
(2 REQ'D.)
REO'DJ
20-30 FT-LB
20-30
SIDE ONLY
ONLY
L.H. SIDE
I VIEW
T |
VIEWT
..
~.\
.~
~
:::J
CO
e;m
><
':T"
Q-
CIt
..~.
CJ)
...
"'<
CIt
BRACKET AND
INSU LATOR - 5260
.OO"'~,06
~~~~~Slo:J~I=![~}-+-t
Q)
VIEWNI
INLET EXTENSION - 50294
381877-S2
381877-S2
(2 REO'DJ
REQ'D.)
(2
SECURELY
TIGHTEN SECURELY
108 IN-LB MAX.
MAX.
1081N-LB
<
5230
~~
BRACKET AND
AND INSULATOR
INSULATOR -- 5A246
5A246
BRACKET
382802-S2
(2 REQ'D.)
17-28 FT-LB
CD
I VIEW p)
~~~ ~
MUFFLER~t>
MUFFLER
CLAMP - 5A272 MUFFLER

\
MUFFLER
pVIEW
L|
VIEWL
ASSY. REF.
REF.
5C257 ASSY.
CLAMP - SA272
---=--=-L
4~~
ALLOWABLE
ALLOWABLE VARIATION
IN
IN CLAMP
CLAMP INSTALLATION.
INSTALLATION.
I VIEWM I
BRACKET
BRACKET AND
INSULATOR
INSULATOR -5260
5260
./
MUFFLER
MUFFLER---.r
381877-S2'~
381877-S2
.
(4 REO'DJ--"
(4
REQ'D.)
TIGHTEN
SECURELY
TIGHTEN SECURELY
â&
VIEWRRll08IN-LB
| 108 IN-LB MAX.
MAX.
VIEWL
VIEWL
V I E W
It'
CLAMP -CLAMP
5A272
5A272
378836-S2
378836-S2
TIGHTEN SECURELY
SECURELY~
TIGHTEN
12
12 FT-LB
FT-LB MAX.
MAX.
~
SAME AS VIEW R EXCEPT AS SHOWN

FOR RALLY OPTION ONLY
'--
..IU1581-A
U1581A
v-a
FIG. 2 Exhaust SystemMustang

Converters)1976
System-Mustang With
With 302
302 V-8 (Two Catalytic
Catalytic Converters)-1976
BACK TO GROUP INDEX

BODY PINION BUMPER BRACKET

284
2.84 FROM SURFACE OF
2:76
2.76 CONVERTER FLANGE
5E212
5E\2
~
f~~I~
~~-~~~~~B
~4, _ I
'"
-'
45358-S7G
!45358-S7G
,,/fi~
SAME AS VIEW W EXCEPT AS SHOWN
(4 REQ'D.)
20-30 FT-LB
386762-S2
(2 REO'O.)
15-25 FT-LB
~iY~~~B
BODY P I N I O \ : K E T
5230
5230 ASSEMBLY
ASSEMBLY
40967-S2
(2 REQ'D.)
10-20 FT-LB
''''-..
~
VIEW U
~-.: ~
.,~............-
381877-S2
(2 REQ'D.)
TIGHTEN SECURELY
8-14 FT-LB
RESONATOR
THIS LINE MUST

BE HORIZONTAL
RESONATOR
BRACKETANDINSULATOR
ASSEMBLYASSEMBLY
- 5260
VIEWT

AND EVENLY TO MAINTAIN TORQUE
5E212
5299
.~~\s ~;Y~!)SECURElY
5230
~,
WITH CATALYTIC CONVERTER
BODY PINION BUMPER BRACKET
RESONATOR
WITH CATAL
YTiCCONVERTER
CATALYTIC
CONVERTER
MUFFLER(PART OF 5230
ASSEMBLY)
381877-S2
(2 REO'D.)
REQ'D.)
TIGHTEN SECURELY
8-14 FT-LB

ASSEMBLY
- 5260
ASSEMBLYVIEWT
5E258
~CKET
ASSEMBLY - 5260
A~SSEMBlY_5260.
,-
386303-S2
(2 REQ'D.)
30 FT-LB MAX.
AUXILIARY VIEW
WITHOUT CONVERTER
------------........--"
VIEW U
VIEW V
VIEWW
INLET EXTENSION
-5A212
FROM SURFACE
OF FLANGE
3.03
2.95
~ ,e?-
"""''''&<. <t~-~-
CATALYTIC
CONVERTER
- 5E212

VIEWW
MUFFLER AND
RESONATOR
ASSEMBLY
-5230
RESONATOR (PART OF 5230

ASSEMBLY)
HEAT VALVE
OR SPACER
5246
387039-S7
(4 REQ'D.)
25035 FT-LB
EXHAUST
MANIFOLD
MAIN VIEW
SHOWN WITH CONVERTER
SECTION 0
SIDE MEMBER
381877-52
381877-S2
(4
(4 REO'D.l
REQ'D.)
TIGHTEN SECURELY
8-14 FT-LB
ft
rn
x
Q~
-14 FT-LB
MUFFLER
r I r4~\
110-+-1
.88
-(
REAR SPRINGS
FUEL TANK
MUFFLER
REAR FACE
OF BLOCK
TRANS. EXT. REF
({.OF CRANK
-5260
VIEWX
VIEW Y
MUFFLER
CLAMP 5C264
SHIELD
- 5E258
381877-S2
(2 REQ'D.)
TIGHTEN SECURELY
8-14 FT-LB
376699-S2
(4 REQ'D.)

1.56 MANIFOLD FLANGE
;$i6302~2
INLET EXTENSION
-5A212
EXHAUST
MANIFOLD
00
"30.10
H
29.86 INLET PIPE GAGING
VIEWV
SECTION E
I?
~
~
U1582-A
oI
CD
FIG. 3 Exhaust System-Maverick/Comet

SystemMaverick/Comet With 302 v-a
V-8
BACK TO GROUP INDEX
00
40967-52
EXHAUST MANIFOLD
NIFOLD REF.
REF.
EXHAUST MA
376699-52
2 REO'D.
5A242 ASSY.
381877-52
2 REaD.
<.,
, ' G - 2 0 FT, LB,
TER ASSY. REF.---.- _......
CONVERTER ASSY. REF..
CONVER
1.34
8-14 FT. LB.
381877~2
1.2~
8-14 FT. LB
5D203ASSY.50203 ASSY.
TIC CONVERTER
WITH CATALY
CATALYTIC CONVERTER
58266
VIEW T
386575-57
25-35 FT-LB
5246 REF.
VIEW X
5246 ASSY. REF .
5C247 ASSY.
. . - - 5E258 REF.
REF.
45358-S7G
45358-S7G
H HEAT SHIELD
REQ'D. WITH
4 REO'D.
WIT HEAT SHIELD
CATALYTIC
20-30
RTER VEHICLES
CONVERTER
20-30 FT-LB
FT-LB
CONVE
VIEW W
VIEW W
5C264
SIDE MEMBER REF.

38187I7-S2
8-14 FT. LB.
5E276 ASSY
HEAT VALVE REF.

L.H.ONLY
SAME AS VIEW Z EXCEPT AS SHOWN
L.H.ONLY
SSHOWN
VIEW Y
SAMEASV~,~;~XCEPTA,
5E258
SECTION E
SECTION
E
NO 302-49
E (CALIF) AND
A
3512V ENGINE
302 49
3512V ENGIN TRANS ONLY)
STATE (AU
TO TRANS ONLY)
(AUTO
5E258
82+.25R.H.
64.25L.H.
~
6~/~O
t'<!'~
~I.JI' \:::==----../ "I~
--"~~-
70.~\
.60
"--
./
11
1 BODY
.
BODY CROSSMEMBER
CROSSMEMBER REF.
REF
f-
.66
5tl276 ASSY.REF
VERTICLECt
4fl~
7";;.i~
~~..
,^*
__
1-50_ '--
,0_J
VIEW W
VIEW
REAR ENGINE
MOUNT
REF
MOUNT REF
CONVERTER ASSY. REF
REF.
5E257 REF.
.==is!
)~
~I [ L~:~~GREF'
1.25
~_"~ ~r- " "'J'5E2~fL~2'~RANSONLY

351 C:~ ~;E~I~ITH
VIEW
VIEW
__
VIEW X
b
SECTION
A
SECTION A
FUEL TANK REF.
VIEW S
~;I
5252 ASSY.
25-35 FT-LB
WITHOUT CONVERTER
REAR ENGINE
VIEW S
- \ "
5252 ASSY.
25-35 FT-LB
.75
:75
WITHOUT CONVERTER
THIS LINE MUST

TH
LINE MUST
BE
HOR'ZONTA
BE IS
HORIZONTAL
L
Jj _'.
"I~
5246 AtOO.ssy
ASSY REi
S246
REF..
5E216 AS5Y.REF.
.
"EHTlCLE'i.",
82.25R.H.
.64:: .25 L.H.
AUTO
5E2581 351 CALIFORNIA

302 49 STATES WITH AUTO
'
TRANS ONLY
351-2V -CALIFORNIA
302-2V - 49 STATES AND
CALIFORNIA
5E276ASSY.
5E276
ASSY.
MAIN VIEW
5246 ASSY.
J8B~
.88-^
VIEWR
386762-S2
381877-S2
.381877-S2
8-14 FT. LB.
LB.
5E276 FIEF.
15-25 LB. FT.
CONVERTER
CATALYTIC CON
V ERTER VEHICLES
5D203 ASSY.
ASSY. --""
5E276 REF. 5D203
VIEW U
TIC CONVERTER
NON~ATALY
NON-CATALYTIC
VIEW T
3512V 49 STATES AND CANADA

302-2V CANADA (LESS HEAT SHIELDS)
CONVERTER
U1563-8
U1563-B
FIG. 44 Exhaust System

SystemGranada/Monarch
-Grana do/Monarch
BACK TO GROUP INDEX

crw
,386302-S2
9 FT-LB MAX.
/~::'AX'
FRAME
B8
FRONT
.88
FLANGE
FRONT
...oo
I
FRAME
)f~o;-~ ~
.66
~I
( I"::"~~
f.21'20
.t--
386271-S2
(4 REQ'D.)
30 FT LB MAX
-~.'
:;~SURFA~EOF ~..
~ CONVERTER FLANGE '\ ldl:\
~
TYPICAL BOTH
BOTH SIDES
SIDES
4~~2~
CLAMP - 5C264
(2 REO'OJ
REQ'D.)
(2
__~t;7.
18.00
LESS SHIELD
. SECTION o.
.
NO. 3 BODY MOUNT HOLE
CLAMP - 5C264
~CLAMP-5C264
AT REAR FLANGE OF
NO. 3 CROSSMEMBER
CROSSMEMBER
NO.3
-86-.94
FROM SURFACE OF
CONVERTER FLANGE
~~~~ ~5426
{-
20-30 FT-LB
3.12
5B266 -
386302-S2
(2 REO'DJ
REQ'D.)
(2
FT-LB MAX.
MAX.
99 FT-LB
SHIELD
VIEWV
SECTION E
~ 386302-S2
CONVERTER
CONVERTER
SHIELD
TYPICAL BOTH SIDES
<
I
(X)
(J)
:r
co
CD
---~
_ ~S~
I\ / ~~~S
'.
m
)(
::r
CIt
AUXILIARY VIEW
ONE CONVERTER
AUXILIARY VIEW
WITHOUT CONVERTERS
EXHAUST MANIFOLD
EXISTING
EXISTING
BUMPER
T AS
SHOWN
SAME AS
MAIN
VIEW
SEAXMCEEp'AS
MAIN
VIEW
EXCEPT AS
SHOWN
EXCEPTASSHOWN
~t},'
JYHM~:'::~::LANGEC3~:SLOCK r::::(~::AN VE~TI~AL<i..~~~~;;BA231
2.96-3.03 (R.H.)
1.56-1.64 (L
H )
(L.H.)
FROM SURFACE OF
FROM SURFACE OF
MANIFOLD FLANGE
g~::;:;IIL.HJ
.\ IR,H.SIOE ONLY)
HEAT VALVE
(R.H. SIDE ONLY)
MAX. STRG. GEAR TRAVEL

MAX
ST
TRANS.
-76
TRANS.
OIL PAN
12 REO'OJ
25-35 -LB
ISECTIONAl
- -
G AVEL
j~~
;'AN: .GEAR.!.IJ:
(!)"~ij
.J~.
376699-S2 (L.H.)
(2 REQ'D.) (RH.)
385382-52
385382-S2 (R.H.)
(2 REQ'D.
387040-S7
(4 REO'DJ
387040-S7
(4 REQ'D.)
25-35 FT
FT-LB
ISECTION~.53- - - -- . I
\..Y
0 lJ
SHIELo~\
-~
OIL PAN
~
VIEWW
WITHOUT CONVERTER
WITHOUT CONVERTER
TRANS.
OIL PAN
'
WITH CONVERTER
.SECTION A.
."
rc
/'
VIEW Z TAB MUST BE '^STALLED

INSTALLED
- - INSIDE OF FRAME
. 1r'
VERTICAL'"
VERTICAL <{_
FUEL
--FUELTANK
5E209 Assy./QttC2.00 R ,,{
7~~
T A B M U S T BE
VIEW X
OO-.ll6~f
.74-.99~I t.+
~
..
CLAM.P.- 5A231-e
~... _~;~
~.~-
CLAMP - 5A231
25-35 FT LB
REAR FACE OF
REAR
BLOCKFACE OF
BRACKET
BRACKET AND
AND
INSULATOR
INSULATOR -- 5260
5260
3:::~2~~;;~
BUMPER
BOLT
SAME AS MAIN VIEW

SAME AS MAIN VIEW
EXCEPT AS SHOWN
/ 2.96-3.03 IR.H.I
EXHAUST MANIFOLD
..
Q
c:
SECTION F
TANK
BRACKET AND
BRACKET AND
INSULATOR - 5 2 6 0
tt~,.~J'~S:;::::260
,J{I
~
I . .-: ~I
1.46
. SECTION G
Ul583-A
U1583A
FIG. 5 Exhaust System-Torino/Montego/Cougar/Elite

Sedan
System - T onno/Montego/Cougar/Elite
.
BACK TO GROUP INDEX

.66 TO
FRONT
FLANGE
.84 TO
.80 TO
REAR
REAR
FLANGE
.88 F LANGE ~88
01
SECTION
F~rE
~-/;~
386302-S
2
(1 REO'DJ
9 FT-LB MA
(i~"0
~i\
/'.~<
18.0 TO PIPE
(LESS SHIELD
IF EOUIPPED)
EQUIPPED)
))
tf
BRACKET AND
BRACKET AND
ÎNSULATOR
dlNSULATOR
5260
5260
:O,4~ bt':c'~
'
CROSSMEMBER
40980-S2
12 REO'O,)
_.~
,~r<
AT REAR
OF
AT
REAR FLANGE
FLANGE OF
NO.3
NO. 3 CROSSMEMBER
CROSSMEMBER
\NTHOLE
6,84
15-25 FT-LB
CONVERTER SHIELD
IEWP
ct.
'
CLAMP - 5A231
...
CLAM.P_5A231
25-35
FT-LB
25-35
FT-LB
t~---
381877-S2
(2 REQ'D.)
8-14 FT-LB
~__ ~
_ _ __
VIEW X
,74-.99~ r- I
~ -:"~
\.
r :..
'"
',.
~VI::S
3.10
.00-.0~6""1~1.
C
/LAMP 45
, f" - . .5230~,
,SECTION E
CLAMP~~00-07
40975-S2
4097 5-S2
(2 REO'DJ
REQ'D.)
8-14 FT-LB
BRACKET AND INSULATOR - (RANCHERO) - 5260
~'
!.~
VIEW Z
--------~~
-~~
c~~
~t\~~
~
~,-~><-.'<7'
_-< "'>~'
~\ \
---
~~~:f~~~Y
,~-,>--<C"-{'>-~--..c:
">.?)c1)
(.'"
Ii
EXHAUST
MANIFOLD
EXHAUST
y/
>
~\~
385383-S2(R.H.)~\g.
. \
"
376699-S2 (L.H.)
(2 REO'DJ
387040-52
-\!(
(R,H, SlOE)
14 R E O ' O , ) '
25-35 FT-LB
-5E2'1'l
HEAT VALVE
,~~
~~
'-(l\'
C
~v=
rl\
WITH CONVERTER
SECTIONCI
A
\~_J,,,,~::=_----",,,(7\
~L,
I,
WITHOUT CONVERTER
5E212
'''.-,
SH IE LO
WITH CONVERTER
I,SECTION
SECTION FF |
L...---.:::::.-:::5\~".
~--...F
1
it
~
"\
r~.~i'>.~.1~ ~
FRAME OUTER
MEMBER
.RAMEOUTER
VIEW V /
MEMBER
(VIEWU
~302-52
'
~?
9 FT-LB MAX
5E212
~
S H5E212
IELD
U*-
.'
REAR FACE
PITMAN
ARM
{
~f\
~ "~)(
.55
5E212
SECTION B
Jf
,53
I
'
STUD -
STUD -
386271-S2
386271-S2
(4
EO'D.)
(4 R
REQ'D.)
A,
PIPE
SHIELD _
PIPE
5K~00
I
SHIELD5K200
l_
r:~ECTION A I
~
V'j::~
,
OF
BLOCK
OF
BLOCK
REAR
FACE
.86-.94 FROM
CONVERTER
CONVERTER
SHIELD
S H I E L D-5F202
5F202
m
x
=r
c:
Q)
-<
CD
~-t~-i
5E262
1.57 AT
. 8 5 ' " 1.57

AT
EXHAUST
EXHAUST FLAT
FLAT
Jt.~~--
MAX.
30 FT-LB MAX
.86-.94 FROM .
SURFACE OF
CONVERTER
FLANGE
FLANGE
Ci)
4,60 AT EXHAUST FLAT
VIEW.P
5'
to
en
4.60 AT EXHAUST FLAT
..
38302-S2
9
FT-LB MAX
rSHIELD
WITHOUT CONVERTER
C6TRANSMISSION
OIL PAN
;.
~\C
~
"'r
=l
.76
'"
t;:
/"
AUXILIARY VIEW
ONE CONVERTER
C6 TRANSMISSION
OIL PAN
\" c;,L.T::NNSMISSION
, 'V' /
""""" 2.95-3.03
2.95-3.03 (R.H.)
(R.H.)
'-56-1,64
1.56-1.64 (LH,)
(L.H.)
"'.
AUXILIARY VIEW
AUXILIARY
VIEW
WITHOUT
WITHOUT CONVERTERS
CONVERTERS
FROM SURFACE
SURFACE OF
-y/->>
"~.. , MANIFOLD
FROM
OF 1=J
j'-YO'
~~ ...8282
~~...
FLANGE
MANIFOLD FLANGE
MANIFOLD "
~~:,~w
_
A
Ji)
~, VIE~ if-d~~"_~
1\
\\\
>
TW:t~~~~~~--=~~~
MAIN VIEW
TWO CONVERTERS
~
/~~,/
<
00
en
VIEW Z
~';Y ~VIEWU
.74-.99
VIEWS
_\\
BRACKET AND INSULATOR (STATION WAGON) - 5260 -
"-
CLAMP
ASSY. _CLAMP ASSY.
5E214
5E214
CONVERTER SHIELD
VERTICAL
NO 3
MOU BODY
WAGON
VIEWU
,;/ .
RANCHERO
CONVERTER CONVERTER 5E212
5E212
~
0!)~"" GASKET -
~ Y~/)'f''''''
" L:!!~
5B266
~(""lklk~~'"'5246
5246
c,,,",,
NUT - 45358-S7G
20-30 FT-LB
..........,* ^
VIEWV
U1587-A
en
N
o
I
FIG.6
.
- T onno/Montego
(Station Wagon) and Ranchero
FIG. 6 Exhaust System
SystemTorino/Montego
BACK TO GROUP INDEX
-'
-'

N>
N)
DIMS. AT TOP OF PIPE

FRAME
.f_~ .75 ~ ./FRAME
75
tD
ffi11
~
~
,
5E258
I SECTION A
A I
I VIEW R
NO.3
NO.
3 CROSSMEMBER REAR FLANGE
11\
\t.J
t SECTIONC
L.H.
5E258
3.30
R.H.
386302-S2
WITH CONVERTERS
(2 REQ'D.)
9 FT-LB MAX.
(400-2VONLY)
SECTION A
VIEWY
I
II VIEW
Y I
NO. 3 CROSSMEMBER
REAR FLANGE
STUD _
385382-S2
(2 REO'OJ
y~
-
.48
/~
~-
---:
\'
_
.-
1.18
~ (2 REO'OJ
REQ'D.)
SECTION 0
~"i'
STUD376699-S2
(2 REO'O.)
:J'/ \.
~(".-t,
e;;~),
,.75 TO PITMAN ARM
::A-- TRANS. CONVERTER
i-I
\-,!d(l/r>c-.
y/c",
HSG. C-{)
(4 REO'O.)
25-35 FT-LB
MANIFOLD CONNECTION R.H.

VI EW Z ]
[ SECTION C j
SHIELD - 5E258
i, 1:--
~
~ -~::-~r'
-.
I U_V/..
-,-
""
I.
~,,~
-~
II- ~
.....-;~ "'---/~1IJ::/~-;
V/ I
~\:~ r-
~
----(,
'\
~
ce-
C~.
~S
rf-)'
~~':"..
~l~t~
~
~
I VIEWS I
"SHIELD5E258
,.e:Y7, /
CONVERTER - 5E212
\ \
\ - - - -.....,
. SECTION C .
'_' ;:;1~-~~-2:-~-~:-.-------::;~'
l!jJ;t:~~~
S T U D-STUD
386271-S2
(4
EO'D.)
(4 R
REQ'D.)
30
30 FT-LB
FT-LB MAX.
MAX.
~"..
.94
_/
IVIEWK
1 00]
.
.90j
~(~
f I
~./
m
rn
><
x
;r
Q
(II
-+
CO
"'-
MUFFLER AND DIFFUSER

_ -:c--------/MUFFLER<ND
/
ASSY.
5230
ASSY. -- 5230
TWO CONVERTERS
SHIELD
- 5E258
SHIELD-5E258
INSULATOR - 5260
~:S~~~~~~ND5260
,SPRING POCKET
DIFFERE~~,~
t1
lu
I VIEW U
7)~--1
'--
BRAKE T U B ; / O T LET PIPE

45358-S7G
4 R EO'D.
20-30 FT-LB
,-\,,--_/
.86
FROM SURFACE OF
CONVERTER ASSY.
FLANGE.
FLANGE.
y/':,
BRACKET AND
MUFFLER
~-r~'
ce
e;CD
5A231
5A231
25-35 FT-LB
25-35FT-LB
MAIN VIEW
~Jr----~HZ('/
\./--:C
--~ \'~~ =:-;// _~-r-I

~.-/':"_j" /'- P ; ;
7~
---:::::~/
R- ~
... ~ ,
./
~
//~WJ
( , - '"
O~FRONTFLODR;~":
AUXILIARY VIEW
AUXILIARY
NO
NO CONVERTERS
CONVERTERS
:i-
!/~~~C"
~~
III JY
~X
~J
! 'II -~ .JJ~ 1, ~;:-:
CLAMP -_~?\/'-"", S~'./}~i5:,'C~>-;:::-/CLAMP
e/_~I\:,~
<
(X)
00
CJ)
~ 387040-S7

/ .
"
5E212
\~
k ~(
SHIELD-5246
<\ ~
U
~
. . 4,00-2VO. NLY
5E212
5E212
'.
~_~/HEATVALVE
WITH CONVERTERS
386302-S2
(2 REO'D.)
REQ'D.)
MAX.
9 FT-LB MAX.
ONLY)
(400-2V ON
LVI
5E212
MANIFOLD . '
-.
--'"iL
{{1
MANIFOLD
.56
FLANGE
~
TIGHTEN SECURELY
~:JI)
I~
VIEWW|
15-25 FT-LB
FT-LB
15-25
387040-S7
TIGHTEN MANIFOLD
MANIFOLD NUTS
NUTS ALTERNATELY
WITH LOWER
LOWER
TIGHTEN
ALTERNATELY WITH
(4 REO'OJ
MANIFOLD NUTS
NUTS TIGHTENED
TIGHTENED TO
TO TOROUE
SPECIFICATIONS
MANIFOLD
25-35 FT-LB
TORQUE
PRIOR TO TIGHTENING THE UPPER NUTS TO TOROUE
SPECIFICATIONS
SPECIFICATIONS
TORQUE TO SPECIFICATION WHILE HOLDING THE
TOROUE
HEAT VALVE
NO. 3 CROSSMEMBER.
SPECIFIED CLEARANCE TO NO.3
TIGHTEN MANIFOLD FLANGE PRIOR TO TIGHTEN/ /i'\
"
U
"
ING
"U"
BOLT.
~ ~l:V) A ~
ARM
ARM
WITHOUT CONVERTER
80
~HUB OF PITMAN
.
\. 1 lL'. ARM
CONVERTER .......
I-.-.
f '~r
.74
.!)~
I > - HHUB
U B OF
OF PITMAN
PITMAN
TRANS.
TRANS. CONVERTER
CONVERTER
HSG.
"HSG. C-{)
C-6
;-.58
-"
.99
NOTE: LOCATE CLAIVIP FROM
END OF PIPE AS SHOWN
EXHAUST
BRACKET AND
INSULATOR -- 5260
5260
INSULATOR
il ~.74
~~~
~\ ~
INOTE: LOCATE CLAMP FROM
.80
DIMS. AT TOP OF PIPE
OUTLET PIPE
(2 REO'OJ
9 FT-LB MAX.
MAX.
(400-2V ONLY)
(40D-2V
BRACKET AND
TIGHTEN SECURELY
SECURELY
TIGHTEN
1220
LB
12-20 FT
FT-LB
.06
&...... 386302-S2
WIO
W/O CONVERTERS
CONVERTERS
~:~8~6;~~J
381877-S2
(2 REQ'D.)
-JJ1~ .00
'
1.2.44
2.44
R.H.
L.H.
~~:':J
~
I ~.-
FRAME ASSY.
d!;~
40980
_ 40980
-.- - ----- ~;~~~~.lSECURELV
(2 REQ'D.)
TIGHTEN SECURELY
15-25 FT-LS
FT-LB
15-25
~~ r~~'
~.-.]
T~~8:~,O
-:?Jl' ! --."
)
;fJ"
TIGHTENSECURELY
";:-....,.
OUTLET PIPE
12-20 FT-LB
WHEN ASSEMBLED.
ASSEMBLED, .96 CLEARANCE BETWEEN
MUFFLER REAR SUPPORT AND REAR SUSPENSION
UPPER ARM MOUNTING BRACKET.
IVIEwxl
I VIEW X I
U1584-A
9
9
System-Ford/Mercury Sedan
FIG. 7 Exhaust System-Ford/Mercury
BACK TO GROUP INDEX

DIMS. AT
AT TOP
TOP OF
OF PIPE
PIPE
DIMS.
.75
FRAME
CLAMP
- 5C264
CLAMP-5C264
FRAME
L~~FRAME
~~
01, l2.44
r*-2.44
L.H.
L.H.
R.H.
R.H.
W/O CONVERTERS
CONVERTERS
WIO
> ^ (2
(2 REO'D.I
REQ'D.)
~/'
,
~~~~
IVIEwsl
5~58'
5E258
NO. 3CROSSMEMBER
NO.3
CROSSMEMBER
REAR FLANGE
FLANGE
REAR
1\
"~4..~ ~
~ <'~~~
_~;(~~,~
,~
1.00-
V^
& \\*
[--,,\-~~e,
~3
I
--:==------' _.--
rs==~!
7(M-~"\----,:--..", ---.\ ,
BRAC~
}I;h
OUTLET
OUTLET PIPE
PIPE
1---Ii
'
\::tK.: ....1
k---
~~?TVALVE
?-
1-P /
\~
CONVERTER ..."
\ / CONVERTER
WIO CONVERTERS
386302-S2
(4 REQ'D.)
9 FT-LB MAX.
~~~

3.03FROM~FACEOF
80
^
.80"Y
/'
387040-S7
SECTION C
C
SECTION
WITH CONVERTERS
CONVERTERS
WITH
I VIEW U I

(J)
VIEW N
:;-
" , VIEWW
.~
MUFFLER
AND
MUFFLER AND
J~
V"//I'
. /-~(! .....,t-
~~
<C
VIEWT
CD
I/; r<--"~) ~~
(;;j
.'
X-r/ 7;
.~~
SHIELD-5246
SHIELD-5246~~
~;..r-
~~
fi
-1,\,
'\
'
~
,.
I-"'/~
/,,~_I~,,'/;
1-1
V
', ,/
':T
..
I;
',://,---1-:
~
~ ~~v~w~
/7<! \~~.
VIEWS
(!It~~~; ~r~~.
\ > J x ^ VIEWV/
-^
~ y ~,~I~W
~:;~1S~.~:'sC'~ ' /
en
....
"
VIEWY
" ~~
\\~~e~tf2~
~-lQ!II~\_
___ U
~...-'
OUTLET
OUTLET PIPE
PIPE
DIFFUSER --5230"
DIFFUSER
5230
/\~~
[~
:.-~
ASSY.
386502-S ASSY.
25-35 FT-LB
387040-S7
(2 REO'D.)
25-35 FT-LB
2
2 REO'D.
REQ'D.
25-35 FT-LB
________
.~.
T'GHTENSECURELY
TIGHTEN SECURELY
12-20
12-20 FT-LB
FT-LB
~J!
V
2.95 MANIFOLD
FLANGE
2.95
MANIFOLD
FLANGE 38}040-S7
AUXILIARY VIEW
AUXILIARY
ONE CONVERTER
AUXI L1ARY VI EW
~~.r.
\::;
~~
-~ ---
4097
40975-S2
(2
(2 REO'D.)
REQ'DJ
, ~l~/
HUB OF
PITMAN ARM
.~d .I
AND
BRACKET AND
INSULATOR
INSULATOR - 5260
5260
/
~g~~~ARM ~~.
~IT-
2 REO'DJ
WITH
CONVERTERS
WITH CONVERTERS
J FT-LB MAX.
,
I SECTION
SECTION AA I
,\,
v-\r
'9~'00~~
HEAT VALVE
l~~i
Til
5E259
5E259
~ l-:~
.75
-#
DIFFERENTIAL
NOTE: LOCATE CLAMP FROM ~

NOTE:LOCATECLAMPFROM
END OF
OF PIPE
PIPE AS
AS SHOWN
SHOWN
END
Y |
BRAKE
| ViEW
VIEWY
BRAKE TUBE
TUBE
STUD385382-S2
(2 REO'D.l
CLAMP 5C264
186302
l86302
ft:
DIFFERENTIAL
-ill-
386302-S2
~V386302-S2
I SECTION
SECTION AA ,I
'ID:-::
~'j-~--
40954-S2
40954-S2
(2
(2 REo'D.)
REQ'D.)
---::,- - TIGHTEN
TIGHTEN SECURELY
SECURELY
I 15-25
15-25 FT-LB
FT-LB
_____ --
SHIELD -5E258
SHIELD - 5E258
~3'~ ~!~\-~' \~~~-- -" '~~/-'
SHIELD
SHIELD-5E258
-'
~~~
~/: j I @/~5B266
5246
\~J ~I~
~~
/ '~tl~/----Q
~_/
MAIN VIEW
TWO CONVERTERS
V I EW
E WV
V
VI
'j
"----~~ y/ /
q}
1.00
GASKET-
,'r / .../
/""_-!. ,-'~r
-::/ ./' /' VIEWU

VI EW U;
~/
II~ __f
5E212
....
CD
'> ~ _oJ' :
(,--)
(J)
"<
en
/
NO.4
CROSSMEMBER
NO.
4 CROSSMEMBER
BRACKET AND
AND
\.~, ,"'"
BRACKET
INSULATOR - 55260
~
_40980-S2
40980-S2
INSULATOR
260, ~
--~
- (2
(2 REQ'D.)
REO'DJ
FRAME
TIGHTEN SECURELY
15-25 FT-LB
~~E
()S<:?;~--~~~G2~TF~~LSBECURELY
~-j'-ID- f:~8~~~2) ~'~ ._~:.'-'-j

-~t
_
1.22-^1
iO
1~8.54 ~~~2~TF~~L~ECURELr~~"
o
|-*-8.54
TIGHTEN SECURELY
12-20 FT-LB
/ ^ ^
/
--.
.94
5E258
~~OM SURFACE
SURFACE OF
OF
FROM
CONVERTER FLANGE
CONVERTER
IVIEWP)
I VIEW N I
/
OUTLET PIPE
WHEN ASSEMBLED
ASSEMBLED .96
.96 CLEARANCE
CLEARANCE BETWEEN
BETWEEN
WHEN
MUFFLER REAR
REAR SUPPORT
SUPPORT AND
AND REAR
REAR SUSPENSION
MUFFLER
UPPER
I WVIEW
ARM MOUNTING
MOUNTING BRACKET.
BRACKET.
UPPER ARM
I F ^ . wXI
cp
U1585-A
U1585-A
o
.I
FIG.
8 Exhaust
FIG.8
Exhaust SystemFord/Mercury
System-Ford/Mercury Station Wagon
Wagon
BACK TO GROUP INDEX

5299
RF.
J~ .
NO.4
CROSSMEM&ER -.........
NO.
4 CROSSMEMBER
5C264
- I I ...._ _.. &-._
-&
40980-52
2 REo'D.
15-25 FT-LB
50255 ASSY.
EXHAUST
EXHAUST
MANIFOLD REF.
MANIFOLD
3761l!J9..S2
5246 REF.
./
5E259 REF.
5E259REF.
4REo'D. / '
15-25 FT-LB
~386302-S2
^ ^
REF
386302-S2
MAX.
108 IN. LB. MAX
VIEWS
FOR CONVERTER
CONVERTER SYSTEMS ONLY
381877-S2
2 REo'D.
8-14 FT-LB
381877-S2
381877-S2
REo'D.
2 REQ'D.
2
108 IN-LB
IN-LB MAX.
MAX.
VIEWT
VIEWZ
SCREWS MUST
MUST BE
BE HORIZONTAL
SCREWS
HORIZONTAL
WITH GROUND
WITH
GROUND
VIEWX
VIEWX
VIEWZ
<
I
())
386271-S2
30FT.LB.MAX
AVAILABLE
IN CANADA WITHOUT
CONVERTER
~~~16~~~i~~~fl~~~A
WITHOUT THE
THE CATALYTIC
CATALYTIC CONVERTER
AS A DELETE OPTION.
en
5
cc
5B266
<i"
m
)(
;r
c
386302-S2
108 IN. LB. MAX
45358-S7G
45358-S7G
20-30
20-30 FT-LB
FT-LB
....
CIt
VIEWV
VIEWV
PART OF
5E214
CONVERTER
ASSY.
CONVERTER
CONVERTER ONLY
ONLY
*3CROSSMEMBER
VIEWR
FOR CONVERTER SYSTEMS ONLY
386502-5
25-35 FT-LB
SECTION D
AT REAR FLANGE
DIMS. TAKEN AT TOP OF PIPE.
:-/,.46 _
G'" PIT~ 0~
REAR FACE
OFBLOCK~
SECTION
SECTION A
A
.50
MAX. STEERING GEAR
GEAR
MAX.
TRAVEL
SECTION
SECTION B
SECTION C
SECTION C
TRANS. OIL
PAN
PAN REF.
REF
/1J
SPRING POCKET
SPRING POCKET
REF.
REF.
H~
~258
ASSY REF
l
~----
--..
VIEWV
VIEWY
SECTION
SECTION F
F
--~
-- - --- I
LCLAMP MUST BE PARALLE L

TO GROUND LINE WITHIN 100
MUFFLER ASSY_
ASSY.
REF.
REF.
LOCATE CLAMP FROM
FROM END
END
OF PIPE
PIPE AS
AS SHOWN
SHOWN
OF
. - .74
.99
U1566-B
FIG. 99 Exhaust System-Thunderbird/Continental

SystemThunderbird/Continental Mark IV
IV
BACK TO GROUP INDEX

5346 ASSY. REF.
.00
.06
EXHAUST
EXHAUST
MANIFOLD REF.
REF
MANIFOLD
40980-S2
40980-S2 22 REO'D.
REQ'D.
15-25
15-25 FT-LB
FT-LB
5252 ASSY.
ASSY.
5252
TOROUE
TORQUE 25-35
25-35 FT-LB
FT-LB
SE276 ASSY.
ASSY. REF.
REF.
IiE276
5246 ASSY.
ASSY. REF.
REF.
5246
5E214 ASSY.
ASSY. L.H.
L.H. ONLY
ONLY
5E214
.)
NO. 4CROSSMEMBERREF.
4 CROSSMEMBER REF.
NO.
;~
100
10
li\'I'
.
e--
L.H. SHOWN
SHOWN -- R.H.
R.H. SYMMETRICALLY
OPPOSITE
L.H.
VIEWZ
VtEWZ
y~'EW
-rMr~
5299
5A246 ASSY.
8.'4FT.~~~
381877-S2
1ao
UPPER
UPPER SUsPENSION
SUSPENSION
ARM
ARM BRACKET
BRACKET REF.
REF.
LOCATE
LOCATE CLAMP
CLAMP FROM
FROM END
END OF
OF PIPE
PIPE AS
AS SHOWN
SHOWN
375636-S7
25-35 FT-LB
~ ....
.()~
~
j: .
- &V~
}\?J
376699-52
4 REO'D.
50Y
~
VIEWV
VIEWV
VIEWW
VIEWW
5E276
5E276 ASSY.
ASSY. REF.
REF.
VIEWU
<
5E276 ASSV.
SPRING POCKET
POCKET REF
REF ..
SPRING
OJ
~
::s
(C
<i'"
m
><
::s-
5246 ASSY.
5246 ASSY. REF.
45358-S7G
20-30 FT-LB
5B266
CI'
-+
386271-S2
30 FT.LB. MAX.
1.28---.......
'5E214
ONLY
5E214 ASSY.
ASSY. L.H.
L.H. ONLY
FOR
FOR CONVERTER
CONVERTER SYSTEMS
SYSTEMS ONLY
ONLY
VIEWY
VIEWY
FLOOR PAN REF.
NO. 3 CROSSMEMBER
/NO.3CROSSMEMBER
.75>;'I~'
--
5E259REF.
5E259 REF.
/"
~iX-
Il.~.
rl;;<75
~~
Q
DRIVE SHAFT
SHAFT REF.
REF.
DRIVE
5246 ASSY.
EF/
R.H
'5246
ASSV. R
REF./
R.H.
SECTION B
B
SECTION
SECTION C
C
SECTION
5E276 ASSY.
REF.
SIDE RAIL REF.

VIEWU
U1567-8
U1567-B
FIG. 10 Exhaust
Exhaust SystemLincoln
System-Lincoln Continental
BACK TO GROUP INDEX

26-22-1
26-22-1
26-22-1
26-22-1
V-8 Dual Exhaust Systems
PART 26-22 V-8

COMPONENT INDEX
Page
DESCRIPTION
.
Dual Exhaust System Without Resonator.
Dual Exhaust System With Resonator . . .
REMOVAL AND
.
AND INSTALLATION
Inlet H-Pipe-Torino/Elite/
H-PipeTorino/Elite/
Montego/Cougar/Ford/Mercury
Montego/Cougar/Ford/Mercury
.
H-PtpeThunderbird/
Inlet H-Pipe-Thunderbird/
IV/Lincoln
Mark lV/Lincoln
,.
H-Pipe-Mustang
Inlet H-Pi
pe-Mustang
.
22-1
22-1
22-1
22-1
22-1
22-1
22-1
22-1
22-1
22-1
22-2
22-2
COMPONENT INDEX
Page
Muffler and Diffuser

.
Resonator Assembly
Muffler and R'esonator
.
Muffler, Resonator and Outlet
Pipe Assemb
Iy
.
Assembly
Muffler and Resonato
Iy Resonatorr Assemb
AssemblyMustang
.
(L.H. Side) . . .
Resonator and Outlet Pipe (L.H.
.
22-3
22-3
22-3
22-4
22-4
22-4
NOTE: The
The information in
CR1966A
CR1966A
DESCRIPTION
DUAL EXHAUST SYSTEM
WITHOUT RESONATOR
The dual-pipe exhaust systems
without resonators are
are of all
all the
the same
same
basic design. The
The H-shaped inlet pipe
assembly is
is of
of one-piece construction.
Muffler
Muffler and
and outlet pipe on
on the
the factory
installation is
All
is aa welded assembly. All
systems without a resonator are equipped
with aa diffuser
diffuser or alternator in
in the outlet
pipe system.
Normal service parts procedure is
is toto
furnish the
the H-pipe
H-pipe asasaasingle,
single, welded
welded
assembly, while the
the muffler
muffler and
andoutlet
outlet
pipe are
and
are serviced
serviced separately
separately and
to the
the
assembled with clamps. Refer to
Motorcraft Master Parts Catalog for
Motorcraft
for
current service parts systems.
DUAL EXHAUST SYSTEM WITH

RESONATOR
As factory-installed,
factory-installed, this system
consists of aa welded H-pipe assembly
connected
connected to
to two
two welded mufflermufflerresonator assemblies (Figs. 2-6).
2-6). The
The
exception to
to this is
is the
the 8-cylinder
8-cylinder
Mustang which uses aa welded H-pipe
assembly connected to
to two
two welded pipe
and resonator assemblies and

and aa single
muffier
muffler (Fig.
(Fig. 1).
1).
For service replacement, the
the H-pipe
is furnished as
as aa single welded assembly,
but the
the muffler/resonator,
muffler/resonator, and
and outlet
pipe are available separately. Refer to the
Motorcraft
for
Motorcraft Master Parts Catalog for
current service parts.
One or
or two
two catalytic converters are
are
connected to
to most dual exhaust systems.
These converters (not
(not required for
for most
are located between
Canadian vehicles) are
the exhaust manifold and
and the
the inlet "H"
"H"
pipe.
pipe.

The replacement procedures given
apply to
to all
all vehicle models and
and to
to right
and left assemblies of dual exhaust
systems unless otherwise noted. Typical
exhaust systems for
for the
the various vehicle
8.
models are
are shown in
in Figs.
Figs. 1 through 8.
3.
4.
4.
INLET uH"
" H " PIPE-TORINO,
PIPE-TORINO,
MONTEGO, ELITE, COUGAR,
AND MERCURY
FORD AND
Removal
Removal
1.
1. Raise the
the vehicle.
2.
2. Units Equipped with Exhaust
Shield(s)
BACK TO GROUP INDEX
5.
5.
Remove the
the screws and
and clamps that
hold the
the exhaust shield(s) to
to the
the
catalytic converter inlet and
and "H"
"H"
pipe. Remove the
the shield(s).
pipe.
shie1d(s).
Remove the
at the
the "U"
"U" bolt clamps at
the
muffler inlet connections.
muffier
the muffiers
mufflers in
in their proper
Support the
position using soft wire.
Units Without Catalytic Converter(s)
Remove the
the inlet
inlet
pipe to
to the
the right hand or
or left hand
manifold connection.
Remove the
the left
hand inlet pipe to
to the
the converter flat
flange connection and

and the
the right hand
to the
the right hand manifold.
inlet pipe to
Two Catalytic
CatalyticConverters
Converters
Units With Two
Remove the
the nuts
nuts attaching
attaching the
theinlet
inlet
pipe to
to converter
flange
converter flat flange
not remove the
the inlet
inlet
connections. Do not
pipe to
to right hand or
or left hand
manifold connection nuts.
the
can be
be removed.
catalytic converter can
7. Disconnect the
the
catalytic converter and/or manifold
It may be
be necessary
necessary to
to
connection(s). It
the rear hanger to
to outlet
disconnect the
pipe attachment in
in order to
to obtain
26-22-2
sufficient
the
to separate the
converter or
or manifold connection(s).
8.
8. Separate the inlet pipe to
to muffier
muffler slip
joint connection(s).
9. Clean the
the
the gasket surfaces
surfaces of the
10. Discard all
all old gaskets and "U" bolt
clamps.
Installation
Installation
1.
the
1. Slide the
the "U" bolt clamp(s) over the
muffler
muffler end(s) of the "H" inlet pipe.
2. Position the
the inlet
inlet pipe
pipe to
tothe
themuffler
muffler
slip joint connection(s) and
and loosely
install the "U" bolt clamp(s). Be sure
the tab(s) on the inlet pipe is properly
located in
in the
the muffler
muffler slot(s).
3. Units Without Catalytic Converter(s)
a. Position the
the inlet pipe to
to the
the right
hand and
and left
left hand manifolds.
manifolds.
Loosely install the
the attaching nuts.
to
b. Align the inlet pipe and muffiers
mufflers to
proper clearances and
and location.
the left
left hand manifold
manifold
Tighten the
to specification
specification and
attaching nuts to
then tighten
tighten the
the right
right band
hand
manifold
manifold attaching
specification.
Units With One Catalytic CORverter
Converter
a. Install aa new
new gasket to
to the
the flange
studs on
on the
the converter.
the
b. Position
Position the
the inlet pipe to
to the
and converter flat flange
manifold and
flange
the
attaching nuts.
c. Tighten the
the converter flat flange
to specification
specification at
attaching nuts to
at
the inlet pipe.
d. Tighten the right hand manifold to
to
inlet
inlet pipe attaching
specification.
a. Install aa new
new gasket to
to the
the right
right
hand and left hand converter studs.
the
b. Position
Position the
the inlet pipe to
to the
converter flat flange connections
the attaching
nuts.
the
right hand flat flange connection
to specification.
specification.
attaching nuts to
NOTE:
NOTE: If aa catalytic converter(s)
is being replaced along with the inlet
be
pipe, the
the converter(s) should be
installed to
to the
the manifold(s) loosely,
then the inlet pipe to CORverter(s)
converter(s) flat
flange connection attaching nuts must
must
be installed
installed and
and tightened
tightened to
specification BEFORE the manifold
to converter attaching nuts to ensure
proper alignment.
4. Tighten the "U" bolt clamp(s) at
at the
the
muffler slip joint(s) to
to specification.
specification.
mumer
Be sure the tab and slot are properly
engaged.
the rear hanger to
to muffler
5. Tighten the
outlet p
i p e attachment
outlet
pipe
BACK TO GROUP INDEX

6. Check the
for leaks
to inlet pipe(s) as
as required.
shields to
7.
7. Lower the
the vehicle.
INLET "H"
" H " PIPE-THUNDERBIRD,
AND
CONTINENTAL MARK IV AND
LINCOLN CONTINENTAL
LINCOLN
RemoJ'al (Includes
Removal
(Includes SerJ'ice
Service Syst-em
System
Replacements)
Replacements)
1.
1. Raise the
the vehicle.
vehicle.
2. Remove the
the screws and
and clamps that
hold the
the
the exhaust shield(s) to
to the
catalytic converter, inlet pipe and
and
exhaust
the
exhaust "H"
" H " pipe. Remove the
shield(s).
3. Remove the "U" bolt clamp(s) at
at the
the
muffler
muffler inlet(s).
4. Support the muffler(s)
muffler(s) in
in car position
only.
Remove the
the inlet pipe to
to right hand
and left hand manifold
manifold connection
attaching nuts.
pipe to
to the
connection.
b. Remove the nuts attaching the inlet
pipe to
to the
the right hand manifold.
Units With Two Catalytic Coftverters
Converters
pipe to
to the
on right hand and left
connections on
hand side of vehicle.
not loosen the
the converter
converter to
b. Do not
to
right hand or
or left hand manifold
manifold
connections.
6. Separate the
the
catalytic converter(s) or
or manifold
manifold
connections. (It
to
(It may be
be necessary to
disconnect the rear hanger to
to muffler
muffler
outlet
o u t l e t attachments
a t t a c h m e n t s to
to allow
allow
movement
movement for
for inlet to
to converter
converter
separation.)
7.
7. Separate the
the inlet pipe(s) to
to mumer
muffler
slip joint connection(s).
8.
the
8. Clean the
the gasket surfaces
surfaces of the
converter flange(s) and
and discard
discard
converter
and "U" bolt clamps.
gaskets and
clam{js.
IRstal/stion
Installation
1.
1. Install new "U"
"U" bolt clamp(s) over
the outlet end(s) of the inlet pipe.
2. Position the inlet pipe to
to muffler
muffler slip
joint connection(s) making sure the
the
on the
the inlet pipe is
is properly
tab on
muffler slot(8).
slot(s). Loosely
located in the mumer
position the
the "U" bolt clamp(s).
a. Install the inlet pipe loosely to
to the
the
left hand and right hand manifolds
the mufflers
mufflers supported
supported in
with the
in
position and
and clearances checked.
b. With clearances maintained,

tighten the
the left hand manifold
the right
right
attaching nuts and then the
to specification.
hand to
26-22-2
a. Ins
tall aa new
k e t tot
he
Install
new gas
gasket
to the
converter flange studs.
the
b. Position
Position the
the inlet pipe to
to the
converter flange and the right hand
manifold. Loosely install the
manifold.
the
attaching nuts.
c. Tigh
ten the
verter flange
Tighten
the con
converter
flange
attachment nuts and then the right
manifold attaching nuts to
hand manifold
to
specification.
a. Install
Install aa new
new gasket
gasket to
to each
converter flange.
flange.
the
b. Position
Position the
the inlet pipe to
to the
converters and
the
attaching nuts.
the
right hand inlet pipe to
to converter
flange
f l a n g e attaching
n u t s tto
o
specification.
NOTE: If catalytic converter is
being replaced along with the
the inlet
be
pipe, the
the converter(s) should be
installed to
to the
the manifold(s) loosely.
Then the inlet pipe to converter(s) flat
flange connection attaching nuts must
must
be installed
installed and
and tightened
tightened to
specification BEFORE the manifold
to converter attaching nuts to ensure
proper alignment.
4. Tighten the
the "u"
"U" bolt clamps at
at the
the
muffler
Be
muffler slip joint to
to specification. Be
the tab
tab and
and slot are
are properly
sure the
engaged.
5. Tighten the
the rear hanger to
to muffler
muffler
outlet p
i p e attachment
a t t a c h m e n t tto
o
outlet
pipe
6. Check the
for leaks
shield(s) to
to inlet pipe(s) as
as required.
7.
7. Lower the
the vehicle.
vehicle.
INLET "H"
" H " PIPt-MUSTANG
PIPEMUSTANG
RemoJ'al (Refer to
Fig. 1)
Removal
to Fig.
1)
1.
1. Raise the
the vehicle.
vehicle.
2. Support the
the resonators with aa soft
wire.
Remove the clamps securing the "H"
{jipe
pipe to
to the
the resonator pipes. Separate
the slip joint connections.
Units With Catalytic Converters
a. Remove the
the
the screws securing the
exhaust shields to
to the
the inlet pipes
and remove the
the shields.
shields.
the
b. Remove the
the screws securing the
inlet "H" pipe to
to the front support
bracket.
c. Loosen the
the rear converter flange
attaching nuts and
the
and remove the
front converter flange attaching
nuts at
at the inlet "R"
"H" pipes.
4. Remove the "H" pipe attaching nuts
the right
right hand exhaust manifold
manifold
at the
and the left hand manifold extension
pipe to
to inlet "H"
"H" pipe. Remove the
the
26-22-3
inlet ""H"
and left
left hand
hand heat
inlet
H " pipe and
valve.
5. Remove the attaching nuts at the left
hand manifold
manifold extension
extension pipe to
hand
exhaust manifold.
manifold. Remove
Remove the
exhaust
pipe.
extension pipe.
Clean the gasket
gasket surfaces
surfaces of
of the
6. Clean
exhaust manifold
manifold seats
seats and
and the
exhaust
front flange gasket
catalytic converter front
seats. Discard the old gaskets.
Instal/ation
Installation
manifold gaskets
1. Place new exhaust manifold
on the inlet pipe flanges. Install the
left hand
hand extension
extension pipe to the
left
manifold and loosely install
exhaust manifold
the attaching nuts.
Slide the inlet ""H"
H " pipe into the
resonator pipes. Loosely install the
"U" bolt clamp.
"U"
Install the inlet "H" pipe to the front
of the catalytic converters
flanges of
using new flange gaskets. Loosely
3. Install the inlet "H"
" H " pipe to the
exhaust manifold (right hand) and the
extension pipe (left hand) with heat
riser properly installed. Loosely
4. Install the attaching screws holding
the inlet "H" pipe support bracket to
the inlet "H" pipe. Do not tighten the
screws.
5. Align the exhaust system to the
clearance specifications. Starting
from the front of the system, tighten
all nuts, bolts, and clamps to
specification.
6.
6. Units With Catalytic Converters
Install the exhaust shields and
specification.
Separate the muffler

muffler to inlet
inlet pipe
5. Separate
connection(s) and remove the muffier
muffler
and diffuser
diffuser assembly(s).
6. Replace "U" bolt clamps and any
other worn or damaged parts.
Instlllistion
Installation
of the inlet pipe.
pipe.
outlet end(s) of
2. Position
Position the muffler
diffuser
assembly(s) on the inlet pipe and
loosely install the clamp(s). Be sure
that the tab is fully inserted into the
locating slot.
Position
muffler to the
3. P
o s i t i o n tthe
h e muffler
the
intermediate
support bracket.
Loosely install the attaching screws.
4. Attach the screws holding the rear
support bracket
bracket and tighten
tighten to
support
specification. For Torino, Montego,
Elite
Eli te and Cougar
Cougar sedans loosely
install the prestole clamp.
to the clearance
specifications.
clearance specifications.
NOTE: If
If specified
specified alignment
specifications cannot be obtained, the
right hand and left hand manifold
attachments should be loosened.
specifications are obtained,
After specifications
tighten the manifold attaching nuts to
s p e c i f i c a t i o n while
holding
specification
while holding
clearances.
7. Position and secure the "U" bolt(s) at
the inlet pipe to muffier
to specification. Be sure the tab and
slot are properly engaged.
8.
8. Remove the temporary wire support,
check the system for leaks, and lower
the vehicle.
MUFFLER AND
AND DIFFUSERDIFFUSER
TORINO, ELITE,
ELITE, MONTEGO,
MONTEGO,
COUGAR, FORD AND
AND MERCURY
Removal
1.
diffuser
remove the muffler
assembly(s). Diffusers on Torino and
assembly(s).
only.
Montego station wagons only.
2.
2. Support the muffier
muffler inlet pipe with a
soft wire and remove the "u"
"U" bolt
clamp at the inlet pipe to muffier
muffler inlet
connection(s).
connection(s).
3.
bracket
screws.
screws. For Torino,
Torino, Montego,
Montego, Elite
and Cougar sedans,
sedans, remove
remove the rear
prestole attaching clamp screw.
screw.
4.
4. Remove the screw securing the
the
intermediate support bracket to the
muffier(s).
mufYler(s).
Removsl
Removal (Refer
(Refer to Fig.
Fig. 5) For
For Service
Service
System Replscement
Replacement
BACK TO GROUP INDEX
MUFFLER AND
AND RESONATOR
ASSEMBLY-THUNDERBIRD
ASSEMBLYTHUNDERBIRD AND
CONTINENTAL MARK IV
1.
full
extent of its travel.
travel. This will provide
the clearance necessary to remove the
muffler and outlet pipe.
muffier
2.
wire.
2. Support the inlet pipe with a soft wire.
3.
3. Cut the muffier
muffler outlet pipe(s) at the
muffler(s).
kick-up area just above the muffier(s).
4.
4. Remove the screws which attach the
hanger(s).
resonator(s) to the rear hanger(s).
pipe(s).
Remove the resonator(s) and pipe(s).
5.
muffler(s) to the intermediate support
muffier(s)
bracket(s).
bracket(s).
6.
6. Remove the clamp(s) securing the
pipe(s) to
to the muffier(s).
muffler(s).
inlet pipe(s)
7.
7. Separate the muffier(s)
muffler(s) from the inlet
pipe(s) and remove the muffier(s).
muffler(s).
pipe(s)
8.
8. Replace any damaged or badly rusted
parts and the "U,.
"U" bolt clamps.
clamps.
26-22-3
Installation
Instal/stion
1. Position
Position the muffler(s)
muffler(s) and outlet
pipe(s) to the intermediate
bracket(s)
bracket(s) and loosely install
install the
attaching screws.
2. Slide the muffler(s)
muffler(s) onto the inlet
properly position
position the
pipe(s) and properly
maintain the
clamp(s). Be sure to maintain
specified
specified clearances for the clamp and
locating tab and be sure that the tab
is fully inserted into the locating slot.
3. Install a clamp on each resonator inlet
and slide each resonator
resonator onto the
muffler
muffler outlet. Loosely install the
"U"
"U" bolt clamp(s) snug, but not tight.
4. Attach the resonator(s) to the rear
hanger bracket(s), install and tighten
the attaching screws to specification.
NOTE: If the alignment clearances
cannot be obtained, loosen the right
hand and left
manifold
left hand manifold
the manifold bolts to specification.
inlet pipe(s) to muffler
muffier connection(s)
and at the muffler
muffler outlet(s) to
resonator
resonator inlet connection(s) to
specification.
8.
check the exhaust system for leaks
MUFFLER, RESONATOR AND

ASSEMBLYOUTLET PIPE ASSEMBLYLINCOLN CONTINENTAL ONLY
Removal (For Service System
Removsl
Replacement)
Replacement)
1.
muffler and outlet pipe
remove the muffler
assemblies.
assemblies.
2. Support the inlet "H" pipe and the
2.
resonator inlet pipes with soft wire.
wire.
3. Cut the right hand muffier
muffler outlet pipe
3.
at the kick-up area, just above the
muffler.
muffier.
4. Remove the Prestole clamp that
that
4.
attaches the right hand resonator to
the
the rear hanger. Remove the
pipe.
resonator and pipe.
5. Remove the nuts that attach the left
5.
hand resonator inlet flange to the
muffler outlet flange. Remove the
muffler
left
Prestole clamp that attaches the left
hanger.
hand resonator to the rear hanger.
Remove the resonator and discard the
Remove
gasket.
gasket.
the
6.
hanger
right and left intermediate hanger
bracket to
to the muffier
muffler outlet pipes.
pipes.
26-22-4
7.
7. Remove the "U" bolt clamps securing
the inlet "H" pipe to the mumers.
mufflers.
8.
8. Separate the mumers
mufflers from the inlet
pipe and remove the mumers.
mufflers.
9.
9. Replace tbe "u"
"U" bolt and Prestole
clamp.
clamp.
Installation
Installation
1.
1. Position the right and left hand
mumers
mufflers to the intermediate support
brackets and install the attaching
attaching
specification.
2.
2. Install the mumers
mufflers to the inlet pipe
and properly position the clamps.
clamps. Be
sure to maintain
maintain the specified
specified
clearances for the clamps and locating
tabs and be sure that the tabs are fully
fully
inserted into the locating slots.
slots.
3.
3. Install studs into the muffler
muffler outlet
flange and install gasket over the
studs. Install the resonator inlet
flange to the muffler
muffler outlet flange
flange
studs on the left hand and right hand
resonators.
resonators. Loosely install the flange
flange
attaching nuts.
nuts.
4.
4. Attach the left hand and right hand
resonators to the rear hanger bracket
at the hanger to tailpipe connections,
and loosely install the clamps and
screws.
screws.
S.
conform
specifications.
to clearance specifications.
NOTE:
NOTE: If the alignment clearances
be obtained, loosen the right
cannot be
manifold
hand and left hand manifold
necessary
the manifold bolts to
to specification.
specification.
the
6.
muffler connections and
inlet pipe to mumer
the Prestole clamps at the tailpipe to
r e a r hanger
h a n g e r connections
c o n n e c t i o n s to
to
rear
specification.
7.
vehicle.
the vehicle.
AND RESONATOR
RESONATOR
MUFFLER AND
ASSEMBLYMUSTANG ONLY
ASSEMBLY-MUSTANG
Removal (Fig.
(Fig,1)1)
Removal
1. Raise the vehicle on a hoist by means
1.
of the frame lift points to allow the
full downward travel.
travel.
axle fun
2.
Loosen and remove the inlet pipe to
resonator pipe clamp.
With Catalytic Converters
Units With
a. Remove screws attaching the
a.
exhaust shields to inlet pipes and
shields.
remove the shields.
b. Remove the converter to resonator
b.
connection flange attaching nuts.
3.
muffler to the rear support bracket.
mumer
4. Loosen the left hand resonator
resonator
4.
assembly clamp and remove the
muffler.
resonator pipe from mumer.
S.
r e s o n a t o r outlet
o u t l e t pipe to the
the
resonator
BACK TO GROUP INDEX
v-a
V-8
Dua1
Dual Exhaust Systems
6.
6. Remove the resonator and muffler
muffler
assembly.
7.
parts.
7. Replace
Replace any
any damaged
damaged parts.
Insta//ation
Installation
1.
1. Position
Position the
the resonator
resonator and
and muffler
muffler
assembly
assembly to
to the
the intermediate
support
bracket
pipe.
bracket at
at the
the resonator
resonator outlet
outlet pipe.
Loosely
screws.
Loosely install
install the
the attaching
attaching screws.
Insert
Insert the
the left
left hand
hand resonator
resonator
assembly
assembly into
into the
the mumer
muffler and
and loosely
loosely
attach
the clamp.
clamp.
attach the
2.
2. Units
Units Without
Without Catalytic
Converters
Assemble
pipe to
to the
Assemble the
the resonator
resonator pipe
the
inlet
attach the
inlet pipe
pipe and
and loosely
loosely attach
the
retaining
retaining clamp.
clamp.
Units
Units With
With Catalytic
Converters
Install
Install the
the resonator
resonator to
to the
the catalytic
catalytic
converter.
not tighten
converter. Install
Install but
but do
do not
tighten
the
nuts.
the flange
flange attaching
attaching nuts.
3.
the rear
3. Position
Position and
and loosely
loosely install
install the
rear
support bracket screws at the mumer.
muffler.
4. Align the resonator
resonator and muffler
muffler
assembly to obtain proper clearance
specifications.
5. Starting from the front, tighten all
nuts,
n u t s , bolts,
b o l t s , and
a n d screws
s c r e w s to
specifications.
6.
Replace the exhaust
exhaust shields and
secure the attaching screws.
7.
AND OUTLET PIPEPIPERESONATOR AND
LEFT SIDE-MUSTANG
SIDEMUSTANG
LEFT
Removal (Fig.
(Fig. 1)1)
1.
clearance necessary to replace the
resonator and outlet pipe.
Remove the screws attaching the
exhaust shields to inlet pipes. Remove
the shields.
3. Loosen the clamp at the connection
("H"
between the resonator inlet pipe ("H"
pipe) and the resonator or the nuts
connection
holding the flange connection
between the catalytic converter and
resonator pipe.
r e s o n a t o r outlet
o u t l e t pipe
the
resonator
pipe to the
5. Loosen the clamps securing the
muffler.
resonator outlet pipe to the mumer.
6. Remove the resonator and outlet
6.
pipe.
pipe.
7.
Instlll/ation
Installation
1.
and
1. Position
Position the
the resonator
resonator assembly
assembly and
the
pipe to
to the
the intermediate
the outlet
outlet pipe
intermediate
support
support bracket
bracket and
and loosely
loosely install
install the
the
attaching
attaching screws.
screws.
2.
pipe to
to the
2. Install
Install the
the resonator
resonator outlet
outlet pipe
the
muffler
position the
muffler and
and properly
properly position
the
clamp. Do not tighten the clamp nuts.
Be sure to maintain the specified
specified
26-22-4
3.
4.
S.
5.
6.
clearances for the clamps and be sure

that the locating tab is fully inserted
into the locating slot.
Install the resonator inlet to the "H"
rear flange
flange of
of the
pipe or to the rear
catalytic converter. Properly position
the pipe clamp or install the converter
to pipe flange nuts. Do not tighten the
clamp or attaching nuts.
Align the exhaust system to comply
specifications and,
with clearance specifications
front of
of the car,
starting from the front
torque all nuts
nuts and
and screws
screws to
torque
specifications.
Replace exhaust shields and secure
Check the exhaust system for leaks
CATALYTIC CONVERTERMUSTANG
Removal (Refer to Fig. 1)
1.
attaching the
2. Remove the screws attaching
exhaust shields to the inlet pipes and
remove the shields.
Loosen the left
left and
and right
righ t hand
3. Loosen
iintermediate
n t e r m e d i a t e ssupport
u p p o r t hanger
hanger
attaching screws.
4. Loosen the muffler
muffler support
support hanger
attaching screws.
S. Remove the catalytic converter inlet
5.
and outlet flange attaching nuts on
both converters.
6. Separate the converters from the inlet
and resonator inlet pipes and remove
the converters.
Installation
Insta//ation
1. Position the catalytic converters to
1.
the inlet "H" pipe and resonator pipe
flanges. Install
gasket or
gaskets between
between the flat
flat flange
connection (front
(front of
of converter) and
loosely install all attaching nuts.
clearance specification
specification and starting at
the front of system, tighten all nuts,
b
o l t s or
c r e w s tto
o proper
proper
bolts
or sscrews
specifications. Replace the exhaust
shields and secure the attaching
screws to specification
specification on 302
Mustang.
CATALYTIC CONVERTER(S)CONVERTERSTORINO, ELITE, MONTEGO,
COUGAR, FORD AND MERCURY
Removal
1.
2. Remove the exhaust shield(s) from
the catalytic converter(s).
to the ## 33 frame crossmember
crossmember with
soft wire.
26-22-5
4. Units With One
One Catalytic Converter
the converter flange to the exhaust
manifold and the inlet pipe (left hand
side). Remove the attaching nuts
holding the inlet pipe to the exhaust
manifold (right hand side).
c o n v e r t e r flange
flange
Remove the converter
to the exhaust manifold and inlet pipe
(both sides).
catalytic converter(s) can be removed.
connection(s).
6.
6. Clean the manifold
manifold and converter
flange seats, discard gasket(s) and
damaged parts.
Installation
Instal/stion
the exhaust manifold. Loosely install
the attaching nuts.
2. Units With One
Install
gasket over the
converter flange studs. Position the
inlet pipe to the exhaust manifold
(right hand side) and the converter
outlet flange connection (left hand
side). Loosely install the attaching
nuts.
Install new gaskets over the converter
flange
flange studs. Position the inlet pipe
flanges
flange
flanges to the converter outlet flange
BACK TO GROUP INDEX

attaching nuts.
3. Tighten the converter to inlet pipe
flange connection(s) to specification
specification
flange
and align the system to proper
clearance specifications. Tighten the
manifold nuts to specification.
the exhaust shield(s) to the catalytic
converter(s).
CATALYTte CONVERTER(S)CATALYTIC
CONVERTER(S)
THUNDERBIRD, CONTINENTAL
MARK
AND LINCOLN
MARK IV AND
CONTINENTAL
Figs. 5 and 6)
Removal (Refer
(Refer to Figs.
2. Remove the exhaust shields from the
# 3 frame crossmember with
to the #3
soft wire.
the converter inlet and outlet flanges
flanges
to the exhaust manifold and the inlet
pipe (left
(left hand side). Remove the
attaching nuts holding the inlet pipe
to the exhaust manifold (right hand
side).
(California Only)
Remove the con
c o n vverter
e r t e r flange
flange
to the exhaust manifold and inlet "H"
pipe (left and right hand sides).
26-22-5
catalytic converters can be removed.
connection(s).
6.
6. Remove the catalytic converters.
Clean the converter flange seats,
discard the gaskets and replace any
damaged parts.
Installation
Instll//stion
1.
the exhaust manifold(s). Loosely
2. Units With One
Install
gasket over the
converter flange studs. Position the
inlet pipe to the exhaust manifold
(right hand side) and the converter
outlet flange connection (left hand
side). Loosely install the attaching
nuts.
Install new gaskets over the converter
flange studs. Position the inlet pipe
flange
flanges to
to the
the converter
converter outlet
outlet flange
flange
flanges
attaching nuts.
3. Tighten the converter to inlet pipe
flange connections to specifications.
flange
4. Align the system to clearance
clearance
specifications
specifications and tighten
tighten the
manifold to converter connections to
specifications.
the exhaust shields to the catalytic
converter(s).
6.

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RH
<-~p
\'=i'S,
VIEWS
~,
V~~:~!~!J'~
I /J
J@I(C
, ' \ . ". -
5C257. ASSy.RH"s.r
VIEWY
VIEW~
..
VIE
\. \
! ~r~502~ASSY
l/ $(/
. /4JI
~ ....
5D294ASSY.
~~
5246A5SY.
SHOCK BRKT. REF.

5D294 ASSY. REF.
^7
/=\^5C257ASSY.REF. 3.03
VIEWG ( L ^ J
VERTICAL^
VERTICAL ~~
MUST
THIS LINE MUTS:
BE
JE HORIZON
HORIZONTAL
L
tt11~\~1
~i~l-
5252
~
25-35 FT-LB
SECTION D
5A289 ASSY
,50204 ASSY.
- 385382-S2
FLOOR PAN
-HEAT VALVE REF
VIEWZ
VIEWZ
Y
LY SAME AS VIEW Y
L.H. SIDE ONLY
L.H. SI~~~PT
AS
SHOWN
EXCEPT AS SHOWN
5252 ASSY.
ASSY. REF.
NO. 4 CROSSMEMBER
DIFFERENTIAL REF
257 ASSY.
ASSY. REF.
VIEWT
U1568-A
FIG. 11 Exhaust System-Mustang

SystemMustang With 302
302 v-a
V-8 (1975)
BACK TO GROUP INDEX

EXHAUST MANIFOLD
MANIFOLD
EXHAUST
INLET EXTEf)jSION
EXTENSION
INLET
5D29~4~,_,l\~)\\
. L', \L} J
- 5D294
-
FROM SURFACE
FROMSURFACE
OF
OF FLANGE
FLANGE
if
3.03
3.03
295
2.95
A\\.
~,
1
/' <:2 /
STUD-
~
.~
SEAT BELT A N C H 0 j l
REINFORCEMENT
==
/;
\..~<1(~~'EO'D.J
1.64
~:~
1.56 ~'\~'=-~STUD-
FROM SURFACE
SURFACE OF
OF ~
FROM
MANIFDLD
MANIFOLD FLANGE
FLANGE
~~'"
376699-S2
5246
jVIEW
vi
(4
///~
(:I "$)
REO'D.)
387039-S7
(6 REO'DJ
25-35 FT-LB
1.18 R.H.
U~
.83 L.H.
ASSY.
'/"0
(rIV
386503-S ASSY. REF.

3B6503S
CROSSMEMBER
TIGHTEN NUTS ALTERNATELY AND

~~GE~TL~NT~U~~~~TA~~~~TRE~~E~ND
EVENLY TO MAINTAIN TORQUE.
S-eCTKlN B
~/
:~ (:~it~~-6:;~ ~-T \
~~>--:---tt
.25
-""'\ \ : .25
~CL5246
5246
REAR FACE
FACE
REAR
OF BLOCK
BLOCK
OF
- \.]B
J!
^
----~
+8.01
f _r=-~-=-rr1tl'l
^C
\J~-Jl~V
REAR FACE
FACE
REAR
OFBLOCKv
OF
BLOCK \
5A289
5A289
I .
(LOF
CRANK
OF CRANK
4.86 L.H.
4.86
L.H.
R.H.
29.77 L.H. ~-=.:.-t-f- 4.62 R.H.
30.24 R.H. -U===----ll{j.1
SECTION
SECTION A
A
INLET PIPE
PIPE GAGING
GAGING
I VIEWW I
IVIEWW/
o
c:
//
~~~
ff ~
I
~~I~
1.~0 R
-\6
",:1 VIEW G
, '.
- f~ / ~~~~~~~.ISECUREL
~" ~
..
~ ~
-)
I VIEW T I
3(2788RE306:5D2.1
VIEWS
(2 REQ'D.)
FOR RALLY OPTION ONLY TIGHTEN
SECURELY
TIGHTEN SECURELY
.00
12 FT-LB MAX.
12 FT-LB MAX.
r .00
06-*-*-* .00
MUFFLER
~MUFFLER
.06---,r.~H-:O":II:~..
"yr,
BRACKET
BRACKET AND
AND
INSULATOR
INSULATOR - 5260
~n--TY~
500~~L500
30
FLOOR
F LOOR SIDE
~{)E MEMBR
MEMB'ER
r
381877-52
381877-S2
(4 REQ'D.)
TIGHTEN SECURELYY
108 IN-LB MAX.
lOBINLB MAX.
FOR RALLY 0.PTlON.O.NL Y
/"
_
'FUEL
* FUEL TANK
DIFFERENTIAL/"
VIEW R
DIFFERENTIAL
VIEW U
....
CIt
I VIEWHI
CLAMP386504-S
(2 REQ'D.)
c:
5230
EXTENSIOW ~~~~~P] ~ I~;6~EN5ION

5263
,1Q'3",/7'
(2REO'D.l
(2
REQ'D.)
~
~ A...'-: :
5230
41--~"
378836-S2
VIEW S
/(ll ~
'T:
~- VIEW~S i~t~:-;
~/~~::-o-.~)
~
m
><
:r
)#~'92
'----,-/
381877-S2
381877-S2
(4 REO'D.1
REQ'D.)
TIGHTEN
SECURELY
TIGHTEN SECURELY
108
IN-LB MAX.
MAX.
lOBINLB
MUFFLER'~
(//
------------
9-
1""-
SHOCK BRKT.
(2 REO'D.)
MUFFLER
VIEW R
TRANS. EXTENSION
EXTENSION
TRANS.
B-lB---- <i.
^ L
i
,....
<
'
VIEWS
~:~8~~~~1
381877-S2
(4 REQ'D.)
TIGHTEN
SECURELY
TtGHTENSECURELY
IN-LB MAX.
MAX .
108 IN-LB
en
MUFFLER
BRACKET AND
INSULATOR -- 5260
INSULATOR
5260
J'
3.66
3.66
.1----____
';,-
~~J
MA,NVIEW
FLOOR PAN
PAN
FLOOR
I VIEWG I
INLET
5246
I N L E T- - 5
2 4 6/;
/ /.
^ .
VIEWZ
\.
~~
( ~
VIEWS
ASSEMB~~~F5~~~ ~~t!~~=~~e.V~;
VIEWYV':X~ ~/t3:~~' L~~~VIE7/(~~/:l
.'~2~T~;/~~
1~1
A~'
_::::::;;-~~~g""---~'RESONATOR
~\~---
84~
-- 5A289
INLET v
't~
/'i'....,,-"- / j j EXT_EN5SD'20gN4r
~/ ...."B\ VIEW W
E X T E N S I O N ^ A ^y~~./
M ~;.~
/
-5D294
4f>
./
d~''=-~7f:S)
'+~ 5246 ..........'[/
------) }
\/-,.....,./
VIEWM
-Y~5230
...-::--~~
~'-'/ VIEW T
~
I /~r:-,----~.~.-----"")
RESONATOR AND
5A289
-r=~~;;:~ ~~
VIEWH
GASKET-
."- .
t? .,
46
SHOCK BRACKET REF.
IVIEwzl
BRACKET AND
INSULATOR - 5260
IV~WMI
-
EXHAUST
EXHAUST MANIFOLD
MANIFOLD
NO.4
CROSSMEMBER
NO.
4 CROSSMEMBER
,~~ ~-~. y~
IVIEW X I
INSTALLATION FOR L.H. Sloe

SIOE ONLY
SAMe
SAME AS
AS VtEW
VIEW Y
Y EXCEPT AS
AS SHOWN
BRACKET AND
INSULATOR _ 5260
FLOOR PAN
REQ'D.)
(2 REO'DJ
.,-~
25-35FT-LB
~': I .50
25-35 FT-LB
~:"',75
ALTERNATELY AND
EVENLY TO MAINTAIN TOROUE.
...
.00
TORQUE.
06
(2REO'D.1
. " GASKET 5E281
.~~
5230 OR
5A289
((}I~ i Jl![T
I ''---:t-("\\-'J!O I
-HORIZONTAL~-~I~_
5246
.~
CLAMP - 5A231
CLAMP-5A231
I
"'it:f.L--...>;f?~ 385382-S2
Q'rr~
THIS LINE MUST

BE
'~:0j
HEAT
HEAT VALVE
VALVE
FLOOR
FLOOR
PAN
PAN
VERTICAL
"---
VIEW L
TYPICAL 2 PLACES
(30
ALLOWABLE VARIATION
IN
INSTALLATION
IN CLAMP
CLAMP INSTALLATION
I VIEW
VIEW K
KI
U1568B
U1568-B
FIG. 22 Exhaust System-Mustang

SystemMustang With 302 v-a
V-8 (1976)
FIG.
BACK TO GROUP INDEX

,)'
5E258 ASSY.
ASSY
5E258
1.64
1.64 RH&LH
RH&LH
.k\
56
NO.4
NO. 4 CROSSMEMBEH
CROSSMEM6ER
CALIFORNIA VEHICLES SAME AS

MAIN VIEW EXCEPT AS SHOWN
5E212R.H.REF
5E212
R.H. REF.
5E214L.H.REF
5E214l.H.
REF.
4O954-S2
15-25 FT-LB
386271-S2
30 FT.LB.MAX
5D255 ASSY2REQ'D
EXHAUST
EXHAUST
REF.
MANIFOLD REF.
5A246 ASSY. REF RH

5256 ASSY REF. LH
45358-S7G
20-30 FT-LB
1.62
49
49 STATES L.H. CALIFORNIA L.H. AND R.H.
VIEWV
VIEW V
381877-S2
MUST BE PARALLEL TO GROUND
TYPICAL BOTH SIDES

VIEWX
49 STATES AND CANADA

CANADA
VIEWT
386302-S2
9 FT-LB MAX.
8-14 FT-LB
TYPICAL BOTH SIDES

SECTION G
5C264
<
::r
386302-S2
9 FT-LB MAX.
c:
CIt
5E259 ASSY. REF.

VIEWH
VIEW
H
NO. 3 BODY
BODY MOUNT
MOUNT HOl.;E
HOLE
NO.3
C J)
"'<
CIt
FRAME REF.
5A246
ASSY
t~
I
I
EXISTING REAR
BUMPER NUT
AND RETAINER
MAIN VIEW
NOTE: DELETE OPTION
AVAILABLE IN CANADA
TO REMOVE CATALYTIC
CATALYTIC
CONVERTER
CONVERTER ASSY.
5230-2 A5SY. REF ................

MUFFLER ASSY. REF.
Q)3
EXISTING BUMPER
BUMPER BOLT
EXISTING
BOLT
TYPICAL BOTH
80TH SIDES
SI DES
TYPICAL
VIEWZ
VIEWZ
PITMAN ARM
SECTION E
312G::::::
:::TIONE
5E259 ASSY.
ssv REF.
CIt
~~--I
2.75
3.12 GAGE DIM.
CD
381877-52
381877-S2
8-14
8-14 FT-LB
FT-LB
~ REARFA~~
? 6
~/
TRANSMISSION
TRANSMISSION OIL
OIL PAN REF
C
SECTION C
REAR FACE OF BLOCK
0
SECTION A
A
5 3
MAX STEERING GEAR
5252 ASSY.
25-35 FT-LB
TO FRONT FLANGE
.66
r 88
TO REAR FLANGE
TO REAR FLANGE
. - .88
gg
CLAMP MUST BE PARALLEL

TO GROUND
MAX. STEERING GEAR
TRAVEL
SECTION 8
TYPICAL BOTH
80TH SIDES
TYPICAL
VIEWY
VIEWY
SECTION D
D
U1569-A
U1569-A
FIG. 3
3 Exhaust SystemTorino/Elite/Montego/Cougar
System-Torino/Elite/Montego/Cougar Sedan and Hardtop With 460 and 460 PI
PI Engines (1975)
BACK TO GROUP INDEX

386302-S2
(2REQ'D.) ~
(2REO'O)
MAX. ~
9 FT-LB MAX.
FRONT
FLANGE
.66
.88
80
(~
;(~7f
--~)!
. .88
.84
~~.
( VIEWS
'~l1
/
18.00
LESS
18.00 LESS
SHIELD
SHIELD (IF
(IF
EOUIPPED)
EQUIPPED)
SECTION 0
-.j
RESTRICTOR AND
GASKET - 5F208
40980-52
40980-S2
(4
TVPICAL
TYPICAL BOTH
BOTH SIDES
SIDES
0.4 CROS5MEMBER
NO. 4 CROSSMEMBER
BRACKET AND
INSULATOR
-BRACKET
AND
INSULATOR
5260
5260
(AT
(AT REAR
REAR FLANGE
FLANGE OF
NO.3
NO. 3 CROSSMEMBER)
CROSSMEMBER)
5E212
NO. 3 BODY MOUNT HOLE
REQ'D.)
14
REO'O.l
15-25
FT-LB
II ...'....----',
15.-2.5 FT-LB
--"l/l:l(
~~di~. ~
~".'.,.~,!
;'
.. , ."
VIEWV
,.',' . .
\Ji~()'Y
]
/ -~5(\)~-)}
/
EXCEPT POLICE INTERCEPTOR
ij...fI5',..~~. '(.-/-/
~~.-._~
~'1'.,cI vl~w-;j
381877-S2
VIEW X | (4 REO'D.)
REQ'D.)
SECTION E
8-14 FT-LB
S~~l:SFT-LB
TYPICAL
TYPICAL BOTH
BOTH SIDES
~~~-~
/(wi :;~-<~/
- \ ,,\... r
~?::--/,z~)?;S~~~~>~
/~~&B
/ i - I_/~
,I
'~
1.56 _ 1
AUXILIARY
AUXILIARY VIEW
WITHOUT CONVERTERS
-----
WITHOUT CONVERTERS
CLAMP5C264
.64 FROM
1.56- 1.64
FROM
SURFACE
SURFACE OF
OF
MANIFOLD
FLANGE
MANFFLANGE
~LOCK
OF BLOCK " \
OF
PITMA~'53
8'(55
386302-S2
(2 REO'D )
386302-S2
3766~g'~
STUD
STUD -- 376699-S2
(4
(4 REO'D.)
REQ'D.)
..-:-?~
(4REO'D.l~~
''l.'\.'
^ ^ ^ T >
387040-57
387040-S7
^-^^Ô
.
II VI-EW T I
V'-WT
SECTION A
SECTION B
e5- t
WITHOUT
.,.76
SHIELOfl):~tt
U
J76
SHIELD
WITHOUT CONVERTER
CONVERTER
W
|TH
WIT.H
SECTION C
- 5E258
I -
CONVERTER
CONVERTER
fJ[
~VERTICAL
5E258
CLAMP VERTICAL
5A231
ES I (
TYPICAL BOTH SIDES
-~ r,.-~.~ v V <t2 REO'D.)
<i.
TYPICA. L BOTH SIO
n'
~FUEL
FUEL
OJ{
TRANSMISSION OIL PAN

-Jt~;RANSMISSION
.60 /
378836-S2
SHIELD
.l--.-.~ CCONVERTER
ONVERTER SHIELD
tft
(2 REQ'D.)
VIEW H
9 FT-LB MAX. I VIEW H
9 FT-LB MAX.
INSULATOR AND BRACKET - 5260
(2 REO'DJ
~--
2
C;=~f;---t1\
!.J'0~~ _- .. 0
PITMAN ARM
REAR FACE
(4 REQ'D.)
25-35 FT-LB
Q--:-/
MAX.
MAX. STEERING
STEERING GEAR
GEAR TRAVEL
TRAVEL
II
2.0 RADIUS
',
...... j
TANK
:r_ TANK
~
'\
"
SECTION F
TYPICAL BOTH
~~'.. '
25-35 FT-LB
25-35 FT-LB
-
-,
VERTICAL
. .00-.06.
,
J r:... .7~.
--.
T~~
CLAMP MUST BE
PARALLEL TO GROUND
PARALLEL
LINE WITHIN
WITHIN lOoROUND
10
LINE
TYPICAL BOTH SIDES

StOES
99
.
<i.
~~
FRAME
SECTION G
TYPICAL
TYPICAL 90TH
BOTH SlOES
SIDES
Ul569-8
ontego/Cougar Sedan
Seckin and Hardtop With 460 and 460 PI
PI Engines (1976)
FIG. 4 Exhaust SystemTorino/Elite/Montego/Cougar
S ysem-Torino/Elite/M
t
BACK TO GROUP INDEX

5E212 R.H. REF

5E214 L H REF.
'.64
RH && LH
LH
1.56 RH
.K
/~~
NO. 4 CROSSMEMBER
CROSSMEMBER REF.
REF.
NO.4
'"
5299
~~"II~
386271-52
502552 R EQ'D.
n\~~-
5C264
5C264
1..
5E214L.H. REF.
5E214 L.H R EF.
~~
VIEW T
381877-S2
8-14 FT-LB
RANCHERO FRAME
381877-S2
8-14 FT-LB
STATION WAGON
FRAME REF.
~OUTLET
TYPICAL
TYPICAL BOTH
BOTH SIDES
SIDES
PIPE REF.
VIEWZ
VIEWZ
MUST BE PARALLEL TO GROUND
P,TMANARM
~-
TYPICAL
TYPICAL BOTH
BOTH SIDES
SIDES
VIEWY
VIEWY
9....-. 386302-S2
386302-S2
'I
~J;=3
5E259L.H. ASSY. REF.

5E258R.H. ASSY. REF
r- 'vn
5E212 R.H.
R H . REF.
REF.
5E212
~~~~~':i.~~SS~':.':F
~~~=*
VIEWW
VIEWW
EXCEPT CANADA
CANADA
EXCEPT
VIEWU
VIEWU
INSIDE OF FRAME
5A246 ASSY
5256 ASSY
2REQD
STATION WAGON
3.50
5E2O9 ASSY. REF
5E224 ASSY. REF
45358-S7G
20-30 FT-LB
376699-S2
TAB
TAB MUST
MUST BE
BE INSTALLED
INSTALLED
40954-S2 4REQ'D.
15-25 FT-LB
40954-S2 15-25 FT-LB
5246 REF
REF
5246
EXHAUST
EXHAUST
MANIFOLD REF.
REF
MANIFOLD
5A246 ASSY. RH
5256 ASSY LH
RANCHERO
5299
FT-LB MAX.
MAX.
99 FT-L8

o
c
o
5246 ASSY. REF.
~5E259L.H.A5SY_REF
5E259 L.H. ASSY. REF.
VIEWS -
5E258 R.H. ASSY. REF.

5E258 R_H.ASSY. REF.
)(
::so
c
....
386302-S2
9 FT-LB MAX.
MAX
CIl
.53
NO.
3 BODY MOUNT HOLE
NO.3
MAX. STEERING GEAR

TRAVEL
SECTION B
B
CALIFORNIA VEHICLES SAME AS

MAIN VIEW EXCEPT AS SHOWN
MAIN VIEW
CA~ADA.
49 STATES AND CANADA.
AVAILABLE IN CANADA
CANADA TO
TO
NOTE: DELETE OPTION AVAILABLE
CATAL YTIC CONVERTER
CONVERTER
REMOVE CATALYTIC
5E259 LH
LH ASSY
ASS\' .
5E259
5E258RH ASSY
ASS\'
5E258RH
VERTICAL <{.
-..
.88
.76
3.12
3.12
GAGE
GAGE DIM
DIM.
SECTION
SECTION EE
REAR FACE
FACE OF
OF BLOCK
BLOCK
REAR
o~
5E259~/
TRANSMISSION
TRANSMt6SION OIL
OIL PAN
PAN REF
REF.
SECTION
Si-CT'ON CC
~55
SECTION
SECTION AA
.55
TO FRONT
FLANGE
66
TO REAR
FLANGE
TO REAR TO REAFl 1_.88
FLANGE FLANGE
.80
84
NO. 3
CROSSMEMBER
SECTION D
0
SECTION
RG.
5 ExhcKist
00.5.
Exhaust SystemTorino/Montego
Sstem-Torino/Mentego Station
StGticm Woôn
W~ and
ana RancherWitfi
ROACherG-Wifh 460
4l>O V-8
V-8 (1975)
{1'975)
BACK TO GROUP INDEX
00
CLAMP MUST BE
PARALLEL TO
GROUND LINE
WITHIN 10
VIWX
VIWX
MUFFLER ASSY. REF.

:50
.75
.75
LOCATE CLAMP
CLAMP FROM
FROM
LOCATE
END OF
OF PIPE
PIPE AS
AS SHOWN
SHOWN
END
U1570-A
U1570A
...,
0-
tJ
....

.84 TO
.66 TO
FRONT
FLANGE
.66 TO
REAR
.84 TO
REAR
FLANGE
CLAMP 5C264
~
~
.88
FLANGE
"
.:88
<J) ,--------,,'
SECTION D
(1 REO'OJ
9 FT-LB MAX
\'c
('~~'/">-)~ -CONVERTER
CONVERTER SHIELD
. >.-,<,1
5E258
SHIELD
18.0 TO PIPE -*A
~.~.
'.
- 5E258
GASKET 5B266
(POLICE ONLY)
.86-.94
FROM SURFACE
OF CONVERTER
FLANGE SURFACE
BRACKET AND
A
INSULATOR
NO INSULATOR
,I -BRACKET
5260
-5260
AT REAR FLA
FLANGE OF NO. 3
CROSSMEMBE~GE
OF NO.3
CROSSMEMBER
-::' ~_j-i
V
i
381877-52
40980-S2
I( ':0 '~~.-.~40980
I.
--W -S2
/__
REQ'D.)
(4 REO'O)
Lr
15-25 FT-LB
15-25 FT-!.B
MUFFLER INLET PIPE - 5246

CONVERTERS- 5E212
VIEWY
fij>,---=--~
~ --><~--~
~~~</
Q~~
IC'~/
~'~
:
I
~*~iA\
\ \
~ n~~
--~",,-;>
5246 REF
45358-S7G
(4 REQ'D.)
25-35 FT-LB
3.10
~.l(
.r('!-!-;i:.'. _____
~~J--'t11:f~ :-.w.:)
(4 REO'O )
8-14 FT-LB
REMOVE ADHESIVE
BACKING AND INSTALL
WITH ADHESIVE SIDE
TOWARD CONVERTER
FLANGE
RESTRICTOR - 5F208
NO.3
OUNT HOLE
NO. 3 BOOY
BODY M
MOUNT
~ 386302S2
TYPICAL BOTH SIDES
BOTH SIDES
-\
~ I,
~~ \: 0~(.J
fi;!j'~
40954-S2
(2 REQ'D.)
15-25 FT-LB
MAIN VIEW
TWO CONVERTERS
AUXILIARY
VIEW
~UXILIARY VIEW
NE CONVERTER
ONE
. \
AUXILIARY VIEW
NO CONVERTERS
MANIFo\j7-~~~~ig~M C6TRA~SSI~~yOl/~vAN
EXHAUST
C6 TRANSMISSION OIL PAN
~.;
.82
5 246
1.56-1.64 FROM
SURFACE OF
MANIFOLD
FLANGE
Y'G
f:~~~g.~6699_S2~)"
STUD - 376699-S2
(4 REQ'D.)
387040-S7
(4REO'OJ~
387040-S7
(4 REQ'D.)
25-35
25-35 FT-LB
FT-LB
~76
(!)
,;-
'
VIEW
U
~
SECTION G
REAR FACE
/ O F BLOCK
VIEWZ
TAB MUST BE
INSTALLED
INSIDE FRAME
TYPICAL BOTH SIDES
L.
SECTION C
CONVERTER
PITMAN
^'V
ARM
^53
CLAMP MUST BE
PARALLEL TO
SECTION B I
GROUND
WITHIN 10
MAX. STEERING
GEAR TRAVEL
TYPICAL BOTH SIDES
U1570-B
ystem-T onno/Montego
.
Station Wagon and Ranchero-With
RancheroWith 460 v-a
V-8 (1976)
FIG. 6 Exhaust 5SystemTorino/Montego
BACK TO GROUP INDEX

1.64
1.64
.56
1.56
.J/
FRONT FLOOR
FLOOR PAN
PAN
FRONT
c=rt:.
i
CENTER FLOOR
FLOOR
CENTER
PAN
PAN REINFORCEMENT
REINFORCEMENT
06
NO.4 CROSSMEMBER
4001
4001 ASSY.
ASSY. REF.
REF.
5230 ASSY.
ASSY. REF.
REF.
5230
PIPE REF.
~"-GS2
~---
L.H. SHOWN
SHOWN R.H.
R.H. OPPOSITE
OPPOSITE
L.H.
SECTION B
B
SECTION
EXHAUST
EXHAUST
MANIFOLD REF.
REF
MANIFOLD
5299
5299
1.36
2267 ASSY.
ASSY. REF.
REF.
2267
BRAKE
BRAKE TUBE
TUBE
.:::;;;;;;iiiiiii::;;iiiiie:::::::::;-
5E212 ASSY. R.H. REF.

5E214 ASSY. L.H. REF.
HUB
HUB PITMAN
PITMAN ARM
ARM
~.05CLEARANCE
375636-S7
4 REo'D.
25-35 FT-LB
L.H. SHOWN.
SHOWN, R.H.
R.H. SYMMETRICALLY
OPPOSITE
L.H.
VIEWU
VIEWU
CATALYTIC
CONVERTER
INSTALLATION
CATALYTIC CONVERTER INSTALLATION
OUTLET PIPE
(~5E214
.30:1
""
~L
TRANS.
TRANS. CONVERTER
CONVERTER
HSG.H. C~
r:=
5256 ASSY. L.H
"rf
VIEW N
AloO ~I
381877-S2
12-20 FT-LB
~~5A246ASSY. R.H.
ASSY.REF.
58CLEARANCE
376699-S2
VIEWS
<
I
en
o
c
o
40980-S2
15-25 FT-LB
STARTER
VIEWW
SOLENOID
5230
375636-S7
25-35 FT-LB
' 5 2 4 6 ASSY. REF.
m
)(
:r
o
c
CI'
5246 ASSY.
SECTION C
OF MANIFOLD CONNECTION
CONNECTION
TYPICAL VIEW OF
WITHOUT CATALYTIC CONVERTER
5C264
t'
ta
.75
386302-S2
....
~~
O~~~
5232 ASSY .
5246 ASSY. REF.
5E259 ASSY.REF.
9 FT.LB. MAX.
SECTION A
DIMENSION
DIMENSION CONSTANT
CONSTANT WITH
WITH
OR
OR WITHOUT
WITHOUT CATALYTIC
CATALYTIC CONVERTER
CONVERTER
E212 ASSY. R.H. REF

E214 ASSY. L.H. REF.
EARLY PRODUCTION
PRODUCTION VEHICLES
NOTE: EARLY
MAY BE
BE EQUIPPED
EQUIPPED WITH
WITH HEAT
HEAT SHIELDS
MAY
386271-S2
30 FT.LB. MAX.
oo~
.
.06
V
.50~1
.75
VIEWP
VIEWP
TYPICAL
TYPICAL EXCEPT
EXCEPT CANADA
CANADA
-lftL
SCCTION
SECTION D
D
C-
VIEWY
VIEWY
\.
CANADA VEHICLES
VEHICLES
CANADA
(DELETE OPTION)
OPTION)
(DELETE
SAME AS
AS MAIN
MAIN VIEW
VIEW EXCEPT
EXCEPT AS
AS SHOWN
SHOWN
SAME
CALIFORNIA VEHICLES
VEHfCLES
CALIFORNIA
SAME AS
AS MAIN
MAIN VIEW
VIEW EXCEPT
EXCEPT AS
AS SHOWN
SHOWN
SAME
U1571-A
U1S71-A
FIG.
FIG. 77 Exhaust
System-Ford/Mercury Station
Station Wagon
Wagon With
With 460
460 V-8
v-a (1975)
(1975)
BACK TO GROUP INDEX

AT TOP
TOP OF
OF PIPE
PIPE
AT
L~
~~
.75
75
2.44
L.H.
CLAMP - -
FRAME
'~FRAME
~l::
5C264
~5C264
2 REQ'D.
~3~02.S2
2~:r
-ill, L
-J~
-T3
\
R.H.
SECTION A
A
SECTION
NO. 3 CROSSMEMBER
CROSSMEMBER REAR
REAR FLANGE
FLANGE
NO.3
5E258
5E25B
02-S2
~""'1.12
I Ir~-
.00-.06 'DIFFERENTIAL
DIFFERENTIAL
~k-
P'~,)J
- ~Ll=
\ ~
[~Y-7/_~1
NOTE'
NOTE: LOCATE
LOCATE CLAMP
CLAMP FROM
FROM
END OF
OF PIPE
PIPE AS
AS SHOWN
SHOWN
END
BRAKE TUBE - 2267
~/
[VIEWS]
!VIEWS!
fVlEWYl
.3
l~
fl~l-=1=
ft.-.
~lrl
SECTION A
.83
BO
'.
R.H.
L.H.
l--C
OF
HUB OF
PITMAN ARM
ARM
. / PITMAN
P:TMAN ARM
;FRAME
5~fTRANS.CONVERTER
J-/.75
\ \1
~-OJ
'.
BRACKET
BRACKET AND INSULATOR _- ...............\, I
5299
~;"---1
5299
REQ'D.
22 R
EQ'D.
40975-S2~........
.
40975-S2
.48
______
'I
~.
".f).'3
/'i
Y~5E214
_W TRANS. CONVERTER v~
~~
40954-S2
(4 REO'DJ
REQ'D.)
TIGHTEN SECURELY
SECURELY
TIGHTEN
15-25 FT-LB
FT-LB
15-25
l~~
(4 REO'D.)SECURELY
TIGHTEN
SECURELY
12-20 FT-LB
FT-LB
HUB
HUB OF
OF
PITMAN ARM
ARM
~ PITMAN
40954-S2
'J'In-
(4 REQ'D.)
.80
----
f(;\~\
~~
1.-------
IVIEWTI
HUB OF
.75
~ ~ -..
OUTLET PIPE
PIPE
OUTLET
TOP OF
OF PIPE
AT TOP
.75
_____
1.0":]
1.0
OUTLET
OUTLET PIPE
PIPE
<
[VIEWW|
00
HSG. C-6
HSG. C6 TRANS.
NO CONVERTERS
ONE CONVERTER
SECTION C
e.-
TWO CONVERTERS
m
)(
':T
Q
MUFFLER
~'/
~~/~~~
cCI'
~\X~
f'~~~
~~~{QJn:~
u ~~
//(.- --1-L
| A-U-X-I-L-IA-R-Y-V-IE-W-I
AUXILIARY VIEW|
[ AUXILIARY
AUXILIARY VIEW
VIEW
NO CONVERTER
NO
CONVERTER
'""I
W/CONVERTER
W/CONVERTER
5E212
1
~
{
386302-S2
386302-S2
(4 REQ'D.)
9 FT-LB MAX.
~\ ~
.
5E
EXHAUST
MANIFOLD
~ ~ ~4F~E~~DJAX.
~
I
258
);:
j' /."
~~\-~
0~J
STUDS
TUD376699-S2
376699-S2
(4 REQ'D.)
,,\.
387040-S7
387040-S7
~"
(4 REO'DJ
(4
REQ'D.)
25-35 FT-LB
25-35
FT-LB
TWO CONVERTERS
~
TWO CONVERTERS
I~
VIEW U I
~.
.~
I-------~
.
MAIN
VIEW
TWO
CONVERTERS
NO. 4 CROSSMEMBER
1.64
1.56
MANIFOLD FLANGE
1.56 MANIFOLD
FLANGE
~~ ~
~/ /
CLAMP - 5A231
(2 REQ'D.)
25-35 FT-LB
SHIELD - 5E258
CONVERTER _ 5E212
CONVERTER - 5E2,2
/\
-5F208
/~
,
W~l
RESTRICTOR (EXCEPT POLICE)
~./)!..
(4REO'D.)AJSTUD-~
f?il~<J0'
STUD-
I
~
~
-
8.54
IVIEW
Z!
.,,..-r.;--O'
" _ r{j
.-....
OUTLET PIPE
~ I/. . . ~~. ~
~~~~~~~.lSECURELY ~-fC (d'" .--."
..
- .---- ~
~ /./t;~:'----;
-~ -t-~--_':'
45358-~7G ~
II~i~ ~ 20-30 FT-LB

386271-S2
(4
(4 REQ'D.)
REO'DJ
.94
--y 30
FT-LB
MAX.
30 FT-LB MAX.
.86
FROM
FROM SURFACE
SURFACE OF
OF
CONVERTER FLANGE.
FLANGE
CONVERTER
.
IIVIEWpl
VIEWPl
.-----------
:rl~'Pf2-'
~~" ~,~
1.00
~C=J
FRAME
FRAME
(-5B266
(-5B266
P.I.)
45358-S7G
P.L) (4 REQ'D.)
i(4REOD.l
20-30 FT-LB
(2 R/EO'D.)
BRACKET AND
BRACKET
AND
INSULATOR
INSULATOR -5260
5260
40980-S2
(4 REQ'D.)
TIGHTEN SECURELY
15-25 FT-LB
1.00
381877-S2 /
~'.
381877-S2
(4 REQ'D.)
TIGHTEN SECURELY
12-20FT-LB
12-20
FT-LB
~ ...
CLEARANC~ BETWEEN
WHEN ASSEMBLED .96 CLEARANCE
MUFFLER REAR SUPPORT AND REAR SUSPENSION
MUFFLER
UPPER ARM MOUNTING BRACKET.
IVIEWXI
~
U1571-B
FIG. 8
a Exhaust
System-Ford/Mercury Station
Station Wagon
Wagon With 460 V-8
v-a (1976)
BACK TO GROUP INDEX

::-tt--_n---J.!
~(
.74.75
R92
JI
2 PLACES
2 PLACES
~;;;~
BRAKETUBE
BRAKE TUBE
DIFFERENTlAL\
DIFFERENTIAL
.99 NJTE:
NOTE: LOCATE
LOCATE CLAMP
CLAMP FROM
FROM
END
END OF
OF PIPE
PIPE AS
AS SHOWN
SHOWN
l.H.
CLAMP 5A231
I
,
~ ~1.12
1.02~
11 r-
FRAME
RJ~~~t~~LET
L-\/~ ~}_,~
~ ~~--211 -
VIEWY
VIEWS
.46
OUTLET PIPE
~ .....--------,
40980-S2
(4 REO'D.)
15-25 FT-LB
L3'30
BRACKET
BRACKET AND
AND
INSULATOR
INSULATOR
-- 55260
260
VIEWW
\ SECTION 0
L.H.
L.H. SHOWN,
SHOWN. R.H.
R.H. SYM.
SYM. OPPOSITE
OPPOSITE
NO CONVERTERS
CONVERTERS
NO
1.06
NO.3
NO. 3 CROSSMEMBER REAR
REAR FLANGEFLANGE
5C246
HUB OF
OF
PITMAN ARM
ARM
75
I .75
5C246
(2 REQ'D.) {
.75l~REO'~~L
FRAME
It;~
-~I~O5E259"'~5E25~tj'i~
SECTION A
CONVERTERS
WITH CONVERTERS
.82
SECTION C
<
':T
INLET PIPE - 5246

\
SHIELD-5E258
~
~~:~~~J~
~~-- n-L/ ~\~~.U>~
~(P
--1-L
I U
J
VIEWW
C
-+
U't
VIEW Y - ^ M U F F L E R - 5230
40980-S2
40980-S2
(4 REO'D.)
(4
REQ'D.)
/15-25
FT-LB
/ 15-25 FT-LB
'-,
AUXILIARY VIEW
PAN
"-.5230
SECTION B
4"\.~~
CD-- ---
CONVERTER
C-6 TRANSMISSION
TRANSMISSION
HOUSING
,,;::p-~~
FRONT
~~~FLOOR
T
T~'
3.30
CENTER
CENTER FLOOR
FLOOR PAN
PAN REINF.
REINF
TWO CONVERTERS
-A-U-X-IL-I-A-R-Y-V-I-E-W-'
NO CONVERTERS
NO.4
CROSSMEMBER
NO.
4 CROSSMEMBER
ONE CONVERTER
"'-~~' ~ ~
0j~""---(j
.-.-.'A',~
'~VJ:..
\
'
J
'-
386302-S2
//(4REO'D.l
(4 REQ'D.)
9
9 FT-LB
FT-LB MAX
MAX.
~ ~CONVERTER
~N
~
CONVERTER
CONVERTER
SHIELD
5E258
SHIELD --5E258
r-V-I-EW-R-I
~-----

\)'
1.64
FROM SURFACE
OF
FLANGE
J)' ~ /X" 1.56
1
56 MANIFOLD
MANIFOLD
,j/ ~~'" .
1\..-----. ---/ /
386271-S2
5B266-FOR460-4VP.1.0NLY
5B266-FOR
460^V P.I. ONLY
5F2O8-FOR 460^V ONLY
"--(~.~~Y~5E212ASSY ~':,~~Q~~~AX ~;~~,;:~~R4604VONLY
~)
"C)l~1
~
I
'--- -'\~1+~
@12-20
VIEW X
:~~~~~~:~D
RIGHT SIDE SHOWN

.:.----.. .:---.. RIGHT
BRACKET AND
INSULATOR-INSULATOR
5230
,'"
~,Sl:2;f1ij'~'-":
5230
"-.:7~"J./ ~f_l~
'~- .I .-.= ~OUTLET
rl~
5E212 ASSY.
5246 ASSY.
ASSY.
381877:S2
PIPE
5246
387040-S2
-*OUTLET PIPE
387040-S2
1/1 I:>
45358-S7G
(4 REO D.)
::.',
45358-S7G
44 REQ'D.
FT-LB
~'
REO'D._
.-/
VIEW U
'\ tt>,
) I,~
(4 REO'D.)
(4 REQ'D.)
25-35 FT-LB
25-35 FT LB
94
20-30 FT-LB
FT-LB
WHEN ASSEMBLED .96 CLEARANCE
9
4 .......... / /'-:... ~A/l2) 1----0/ 20-30
WHEN
ASSEMBLED .96 CLEARANCE
TORQUE
/
TOROUE TO
TO SPECIFICATION
SPECIFICATION WHILE
WHILE HOLDING
HOLDING THE
THE
'86
;..,....,
'li _ ~
BETWEEN MUFFLER REAR SUPPORT
86
BETWEEN MUFFLER REAR SUPPORT
SPECIFIED
CLEARANCE TO NO. 3 CROSSMEMBER.
SPECIFIED CLEARANCE TO NO.3 CROSSMEMBER.
FROM
SURFACE
OF
AND REAR SUSPENSION UPPER ARM
AND REAR SUSPENSION UPPER ARM
TIGHTEN MANIFOLD FLANGE PRIOR TO TIGHTEN- F R 0 M S ^ F _ A C E 0 F
VIEWP
TIGHTEN MANIFOLD FLANGE PRIOR TO TIGHTEN- CONVERTER
COLANNVGERE.TER ASSY
ASSY.
VIEW P
MOUNTING BRACKET.
BRACKET.
VIEW P
MOUNTING
.NG"U"BOLT.
. H . SHOWN.
F
FLANGE.
ING "u" BOLT. Ll.H.
SHOWN, R.H.
R.H. SYM.
SYM. OPPOSITE
OPPOSITE
L.H. SHOWN, R.H. SYM. OPPOSITE
U1586-A
VIEWP
L.H. SHOWN, R.H. SYM. OPPOSITE
U1586 A
"0--
FIG. 9 Exhaust SystemFord/Mercury

System-Ford/Mercury Sedan With 460 and 460 PI V-8
V-B (1975/76)
BACK TO GROUP INDEX

5299
2 REO'D.
NO. 4CR0SSMEM6ER
5E212 R.HI REF.
15E214 L.HT
5C258 L.H.
5C257
ASSY. REF
1.64
L.H. & R.H.
~ft<~a::::arn~
386271-S2
30 FT.LB. MAX
FRAME REF.
40980-S2
4 REO'D.
15-25 FT_LB
5C257
R.H.
5C257 ASSY.
ASSY.R.H
5C258
5C258 L.H.
L.H. ASSY
ASSY
EXHAUST
MANIFOLD REF.
4 REQ'D.
15-25 FT-LB
375636-S7
4 REQ'D.
25-35 FT-LB
45358-S7G
20-30 FT-LB
VIEW V WITHOUT
RESTRICTOR
RESTRICTOR 5F208
2REQ/D.
y
REMOVE PAPER BACKING AND
INSTALL WITH ADHESIVE SIDE
ADJACENT TO CONVERTER FLANGE
386302-S22
386302-S2 2 REO'D.
REQ'D.
108
MAX.
108 IN.
IN. LB.
LB.MAX.
5E212
R.H.
5E212R.H.
5E214L.H.
5E214
L.H.
T OF
ACKET PAR
BRACKET
PART OF
BR
TER
ASSY.
CONYER
CONVERTER ASSY.
V~EW
VIEWT
5E258REF.
5E258
REF.
5E259REF.
5E259
REF.
VIEW Z
381877-S2
8-14 FT-LB
44 REO'D.
REQ'D.
8-14
8-14 FT-LB
FT-LB
5E212 R.H.
5E214 L.H.
il
386302-S2
386302-S2
~ 108
108 IN.
IN. LB.
LB. MAX.
MAX
VIEWS
VIEWS
VIEW V WITH RESTRICTOR

RESTRICTOR
VIEW V WITH EPT AS SHOWN
TYPICAL EXC
EXCEPT AS SHOWN
5C257 ASSY. R.H.
E
5E258 ASSY. R.H.
CLAMP MUST BE P A R A L L E L ^
TO GROUND LINE WITHIN 10
.94
^
P
.50
.75
MUFFLER ASSY. REF
|MAIN VIEW - TWO CONVERTERS
NO. 3CROSSMEMBER
\
ONE CONVERTER
SECTION D - D
PITMAN ARM
~~~~~~~44P1TM~
REAR FACE
OF BLOCK ^ 1
^ \
SECTION
SECTION A
A
44
1.46
~~OIL
OIL PAN
PAN REF.
RE .
75,
.TRANSMISSION
TRANSM ISS '~N
~~~~ RE~.H.
..9;50 C)
MAXIMUM
STRG
MAX. M
l
GEAfl TRAVEL
& RAJH.
SPRING
SPRING POCKET
POCKET
REF.
REF
SECTION C
UM STRG
SECnON B
'..
SSY R.H. REF.
5C257
5C257 ASSY.
A
Y' R.H.
L H REF.
REF
5C258 ASS .L.H.
. . REF
5C258ASSY.
SECTION F
SECTION B
GEAR TRAVE
--.
nemal
SECTION
F
IV (1975/761
Mark
Nt
f
SECTION G
U1572-B
FIG.
Mark IV (1975/78)
System-Thu nderbird/ContI
FIG. 10
10 Exhaust
Exhaust System-Thundefbird/Cantinefrtal
BACK TO GROUP INDEX

1.06R.H.
1.38 L.H.
SIDE RAIL REF.
1.64 FROM SURFACE

S
1.64
1.56 MANIFOURFACE OF
OF
1.56
/ \MANIFOLD
LD FLANGE
FLANGE
SECTION E
EXHAUST
MANIFOLD
5C257 ASSyL:
. .H. REF.
REF
5246 R.H. REF.
5E212RH
5E212
5E214 R.H.
L:H: REF.
~~~. .. (CALIFORNIA
(CALIFORNIA ONLY)
ONLY)
5E214 L.H. REF.
..J;.:-.
~~MBER
376699-S2
4 REO'D.
NO 4 CRorME
r~~g~2 ~~~~-'~{)~..
375636-57
25-35 FT-LB
4 FT-LB
SYM
L.H. SHOWN VIEW
R.H. SYM.
OPPOSITE
Z
. OPPOSITE
VIEWZ
UPPER SUSPE
BRACKE~S~~~
___
40980-52
~:2~O;~~LB
(l)CD
i / A S S Y 2 REQ'O
50203 ASSY
'7
50204 ASSY
~:~:
';E RAIL REF.
45358-S7G
20-30
FT.LB
._~__
1.28
L.H. & R.H.
/5A246
UPPER SUSPENSION
ARM BRACKET REF.
ARM
5246 ASSY. REF.
5232 ASSY
~NGPOCKET
5A289 ASSY. REF.
5C257 ASSY. REF
R.H. SHOWN - L.H. SYMMETRICALLY OPPOSITE

VIEWU
SIO
386302-S2
2 REQ'O
1081N-LB
MAX .
~SE212R.H
~,
IT
5232 ASSY. REF.'
R.H. SHOWN L.H . VIEW

SYMMETRIC
V
ALLY OPPOSITE
&5E214L.H
5E2~RJdt
386271-S2
30FT.LB. MAX.
5E212 A5SY
30 H.LB. MAX
5E212 ASSY. R.H. REF.
5E214 ASSY' ~.HH REF.
. . REF.
5E214 ASSY..L.H.REF.
5E259
L.H. SHOWN
SHOWN,,R.H.
R.H. SYMMETRICALLY
REFJ--~~
VIEWR
CALIFORNIA ONLY
VIEWY
~5C264
---JJ'~,
-;;;;:n
o
5E2~REF.~\'
~
r
\
5E258 REF.
5E259
REF.
5E259REF.
2 REQ'O.
5246 ASSY.
REF.
MAIN VIEW (CALIFORNIA ONLY)
~
-ooo"""""'386302.S2
-3863O2-S2
~
2REO'D
2 REQ'D.
ONL~08
108 IN. LB. MAX.

CALIFORNIA
IN. LB. MAX.
CALIFORNIA ONLY
VIEWS
SEAT
BELTREF
FLOOR PAN
PAN REF
REF
.75,
1.14
,r!}\ ()" 1.\
~I
5C257 ASSY. REF

5232 ASSY. REF ..
5E259 ASSY. L.H.
J'---S':'AFT
~'"1/
L.H. \ORIVE
\ DRIVE SHAFT REF.}
REF /H ' H
^ 55246
2 4 6 ASSY.
ASSY. REF
R E F . / R.H.
SECTIONC
SECTION C
~,
5E259REF~IJZ
<i
CALIFORNIA
5E259REF./
NLY
CALIFORNIA ONLY
'000\
INo.3CROSSMEMBER
LH
L.H
5246 ASSY REF .

SECTION B
/75
~
'\,t~
" 5E258 REF

..
R H CALIFORNIA
"'
ONLY
ltf
5252 ASSY
25-35 FT-LB
11-:~ 5246~r

49
SAME AS MAIN
AND CANADA
SAME AS MAIN VIEW EXCEPT AS
AS SHOWN
SHOWN
Ii\
0 I | M0
10
A.H. SHOWN L H
'0
100
. . SYMMETRICALLY
R.H. SHOWN L.H.
VIEW W
OPPOSITE
VIEWW
U1573-A
U1573-A
FIG. 11
11 Exhaust System-Lincoln
SystemLincoln Continental (1975)
(1975)
BACK TO GROUP INDEX

27-00-1
27-00-1
Cooling System
GROUP
Cooling System
PART 27-05
PAGE
27-01
PART 27-111
General Cooling System Service
27
PAGE
Fan Drive Clutch . .
27-01-1
27-01-1
27-05-1
27-05-1
PART 27-06
PART 27-03
Radiators
27-06-1
27-06-1
Ford Flex-Blade Fan

Fan
27-03-1
27-03-1
PART 27-01
27-01 General Cooling System Service
Applies to
to All
All Models
Models
COMPONENT INDEX
Page
01-1
01-1
GENERAL INFORMATION
COMPONENT INDEX
Page
REMOVAL AND
AND INSTALLATION
INSTALLATION
Four and
and Six-Cyli
Six-Cylinder
nder
TESTING
Procedures . . . . . . . . . . . . .
General Test Procedures.
Cooling System Pressure Test.
Test . . . . . . . . .
Radiator Cap
Cap Pressure
PressureTest.
Test . . . .. .. .. .
Thermostat Test - Thermostat
Removed
Fan Drive Clutch Test
01-1
01-1
01-2
01-2
Fan
Engine Cooling Fan
01-3
Fan
V-8 Engine Cooling Fan
01-3
Fan Drive Belt
01-4
01-2
Radiator
Rad
iator Hose
01-3
Thermostat
01-4
.
01-4
CLEANING AND
AND INSPECTION
Cleaning Cooling System
ADJUSTMENTS
Drive Belts . . . . . . . . . . . . . . . . . . . . . . . .
01-3
01-5
SPECIFICATIONS
SPECiFiCATIONS....................
01-6
NOTE: The information in this Part applies to both 1975 and 1976 luodel
NOTE:
CR1966-A
GENERAL INFORMATION
This part covers general cooling
system service. For
For cooling system
component
component removal, disassembly,
disassembly,
assembly, installation
installation and
and repair
procedures and specifications, refer to the

pertinent Part of this Group.
TESTING
GENERAL TEST PROCEDURES
Visual Inspection
A. Check for leakage at:

at:
All hoses and
and hose connections.
1. All
2. Radiator seams, radiator core,
and radiator drain petcock.
BACK TO GROUP INDEX
All block core plugs

plugs and
and drain
3. All
plugs.
4. Edges of all
all cooling system gaskets.
5. Transmission oil cooler.
6. Vehicle heating system comcomponents.
7. Water pump shaft

shaft and
and bushing.
for evidence of
B. Examine oil dipstick for
of
coolant contaminated engine oil.
oil
C. Check radiator for evidences of oil
at transmission
in coolant (leakage at
cooler).
oil cooler)o
27-01-2
27-01-2

RADIATOR CAP
COOLING SYSTEM PRESSURE

TEST
off. To prevent loss
1. Shut the engine off.
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 clotll
cloth over the cap
cap and rotate
rotate
counterclockwise
the cap SLOWLY coullterclockwise
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 sending unit from the manifold.
With the radiator cap installed and
the cooling system pressure reof
lieved, only a small amount of
coolant will be lost when the
removed.
sending unit is removed.
4. Install an adapter fitting (male
thread on one end, and a hose
connector on the other end to
accommodate the tester hose tightmanifold or
ly into the intake manifold
cylinder head in place of the sending unit.
5. Remove the radiator overflow hose
from the retainer clips. Make sure
the hose is firmly installed on the
radiator overflow tube and is in
good condition. Insert the free end
of the overflow hose into a containerofwater.
er of water.
6. Attach the pressure pump and
gauge (Fig. I)
1) to the adapter fitting
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.
satisfactory at the
If the system is satisfactory
lower limit, gradually increase the
system pressure until a slight stream
of bubbles appears in the water
container. This is the upper limit of
of
the pressure cap under test.
Replace any
any radiator
radiator cap
cap that
that exReplace
exceeds the
the specified
specified UPPER
UPPER LIMIT
LIMIT
ceeds
pressure without
pressure
without discharging
discharging bubbubbles.
bles.
7. If the radiator cap does not hold
pressure, remove and wash the cap
in clean water to dislodge all foreign
particles from the gaskets. Check
the sealing surface in the radiator
filler neck.
BACK TO GROUP INDEX
RADIATOR CAP PRESSURE

TEST ADAPTOR
PRESSURE TEST PUMP

(ROTUNDA WRE-500-851
WRE-500-85)
FILLER NECK SEAL
FILLER NECK ADAPTOR
FIG. 1 Pressure Test Pump

and Attachment
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.
Pressure should not drop during this
time.
RESULTS:
RESULTS: If the pressure drops,
check for leaks at the engine to
hoses, engine to
to radiator
heater core hoses,
valve hose
hose
hoses, bypass hose, water valve
(If applicable), thermostat housing
gasket, radiator and heater core,
etc. Also refer to Engine System
leak cannot
cannot be
belocated
locatedin
in
checks if aa leu
the cooling system. Any leaks
which are found must be corrected
and the
the system rechecked.
rechecked.
If the
the system
system holds
holds pressure
pressure proIf
proceed to
to step
step 9.
9.
ceed
9O 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
WRE-SOQ-85 Radiaof the Rotunda WRE-500-85
tor Cap Pressure Test Adapter.
NOTE: The adapter is designed to
NOTE:
accept both deep and shallow neck
caps.
radiator caps.
3. Iinmerse
Immerse the filler neck seal in water
30
and install in the filler neck adapter.
NOTE:
NOTE: The filler neck seal is
reversible so that it may be used on
either aa deep or shallow radiator
filler neck. It will also fit either end
0
QUICK DISCONNECT
FITTINGS
Q1401A
Q1401-A
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
disconnect
pump to the male quick pisconnect
fitting of the filler neck adapter.
60
6. SLOWLY depress the plunger of the
pressure test pump until the pressure gauge reading stops increasing
and note the highest pressure readobtained.
ing obtained"
NOTE: If the plunger of the pump
NOTE:
is depressed too fast, an erroneous
pressure reading will result.
7. Release the pressure by turning the
pressure relief
relief screw counterclockwiseo
wise. Then tighten the pressure
relief
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
of
the radiator cap and is not erratic.
Refer to Specifications.
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 212F.
If the problem being investigated is
insufficient
insufficient heat, the thermostat should
be checked for leakage.
leakage. This may be done
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
27-01-3
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:
follows:
Minimum Slip Fan Drive

Requirement Test
1.
1. Using a suitable marker, mark the
water pump pulley hub, one of the fan
attaching bolts and the
blade attaching
crankshaft pulley.
crankshaft
2. Connect a tachometer to the engine.
3. Install a throttle adjusting tool.
4. Connect a Sun Strobe Light. This can
be a SLT-lor
SLT-1 or SLT-2 Strobotach or a
STA-1 Strobe Trigger adapter for the
STA-I
Sun Distributor Test Stand.
5. Start the engine and run it at
approximately 1500 rpm until engine
temperature has normalized.
6.
6. Adjust
Adjust the engine to the specified
engine testing speed (Part 27-03).
7.
7. Operate the Strobe Light at 2000 rpm
and aim it at the water pump pulley.
Adjust the engine speed until the light
27-01-3

flashes and the water pump pulley
mark are synchronized.
8.
8. Aim the timing light at the fan blade
attaching bolts. Adjust
Adjust the Strobe
Light until it is synchronized with the
fan blades (fan blade appears to stand
still).
9.
9. The fan speed must not be greater
than the specified minimum fan test
speed at 2000 water pump rpm.
10.
10. Turn
Turn the
the engine
engine off.
off.
11. If the fan speed was greater than the
specified minimum fan test speed,
check for proper parts usage.
If
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.
12. If
If the
the Maximum
Maximum Slip
Slip Fan
Fan Drive
Drive
Requirement Test is going to be
performed, do not remove the
performed,
tachometer, Strobe Light or throttle
adjusting tool.
If a Maximum Slip Fan Drive
13. If
Requirement Test is not going to be
performed, remove the tachometer,
adjusting
Strobe Light and Throttle adjusting
tool.
tool.
Maximum Slip Fan

Fan Drive
Requirement Test
1.
1. If
If the Minimum Slip Fan Drive
Requirement Test was not performed,
2.
2.
3.
4.
4.
5.
6.
6.
7.
7.
8.
8.
9.
9.
thru 55under
underMinimum
Minimum
follow steps 1 thru
Slip Fan Drive Requirement Test.
Block off
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
maximum speed.
the fan to operate at maximum'speed.
Place the air conditioning selector to
the maximum position and the blower
switch to the high position.
Adjust the Strobe Light to 2000 rpm.
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.
off the air conditioning blower
Turn off
switch.
Synchronize the timing light with the
marked fan to clutch attaching bolts.
The fan speed must meet or exceed
the specified maximum slip fan test
speed at 2000 water pump rpm.
If the fan speed was less than the
specified maximum slip fan test
specified
speed, check for proper parts usage.
If the correct parts are used,
If
replace the fan drive clutch.
If the part(s) are not the correct
ones, replace the part(s) and perform
the test again.
ADJUSTMENTS
DRIVE BELTS
The fan drive belt(s) should be
properly adjusted
adjusted at all times.
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
ve belts
Properly tensioned
tensioned dri
drive
minimize the noise and also prolong
service life of the belt. Therefore, it is
recommended that a belt tension gauge
adjust the belt
be used to check and adjust
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.
Belt Tension
1. Install the belt tension tool on the
1.
drive belt (Fig. 2) and check the
tension following the instructions of
manufacturer.
the tool manufacturer.
2.
2. If adjustment
adjustment is necessary, loosen the
alternator mounting and adjusting
adjusting
alternator
arm bolts. Move the alternator
toward or away from the engine until
the correct tension is obtained.
Remove the gauge. Tighten the
alternator adjusting
adjusting arm and
alternator
bolts. Install the tension
mounting bolts.
gauge and check the belt tension.
3. Follow similar procedures for
for
adjusting Thermactor air pump, air
conditioner compressor and power
steering pump drive belts.
Tool-T63L-8620-A
Too1-T63l-862Q-A
Q1039-A
FIG. 22 Checking Drive Belt Tension

FOUR AND SIX-CYLINDER ENGINE
COOLING FAN
Remoysl
Removal
Loosen the fan belt. Remove the
capscrews and lock washers attaching the
fan to the water pump hub.'
hub. Remove the
fan.
BACK TO GROUP INDEX
Installation
Installation
Position the fan on the water pump
hub. Install the lock washers and
capscrews and torque the capscrews to
specifications. Adjust the fan belt tension
to specifications.
V-8 ENGINE COOLING FAN

v-a
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-tofan spacer.

27-01-4
27-01-4
General Cooling
Cooling System
System Service
Service
General
Removal
1. Remove the radiator
radiator upper
upper support
support
the
and fan guard or shroud. Loosen the
fan belt. Remove the capscrews and
and
and
lock washers attaching the fan and
spacer (or drive clutch) to the water
water
pump hub. Remove the fan and
spacer (or drive clutch).
If equipped with a fan drive clutch,
2. If
remove the attaching capscrews and
lock washers and separate the fan
from the drive coupling.
RADIATOR HOSE
HOSE
RADIATOR
Removal
Removal
. Radiator
Radi~tor hoses
hoses should
should be
be replaced
replaced as
as
directed in the
the pertinent
pertinent car
car Maintenance
directed
Schedule or
or whenever
whenever they
they become
become
Schedule
rotted or
or have
have aa tendency
tendency to
to
cracked, rotted
collapse.
the
Drain the radiator; then loosen the
of the
the hose
hose to
to be
be
clamps at each end of
the hose off
off the
the radiator
radiator
removed. Slide the
connecti.on and the radiator
radiator supply tank
tank
connection
connection (upper
(upper hose) or the water
water
connection
hose).
pump connection (lower hose).
with
On Mustang vehicles equipped with
the. optional 302 CID V-8 engine, the
the
radiator filler is inserted in the upper
radiator top tank and
hose, between the radiator
cylinder block. When
the engine cylinder
replacing these two hoses, remove four
clamps and remove the hoses from
radiator,
ra~iator, radiator cap adaptor and engine
cylinder
cyhnder block connections.
Installation
Installation
1.
1. Position the replacement fan on the
drive clutch and install the lock
washers and capscrews. Torque the
capscrews evenly and alternately to
specifications.
2. Position the fan and spacer (or drive
clutch) on the water pump hub and
install
install the lock
lock washers and
capscrews. Torque the capscrews
evenly
e v e n l y and
and alternately
a l t e r n a t e l y to
specifications. Adjust
Adjust the fan belt
tension to specifications. Then, check
the fan drive clutch flange-to-water
flange-to-water
pump hub for proper mating. Install
the radiator upper support and fan
guard or shroud.
FAN DRIVE BELT

Removll1
Removal
If equipped with power steering andl
and/
or air conditioning and Thermactor
Thermactor
exhaust emission control system it will be
be
necessary to
to loosen and remove the drive
belts before the fan drive belt can be
removed.
removed.
1.
1. On aa car with power steering
steering
(except Lincoln Continental),
loosen the power steering pump at
the mounting bracket and remove
the
drive belt
beltoo
the drive
On
On aa car
car with
with an
an air conditioner,
conditioner,
remove
remove the
the compressor
compressor drive
drive belt.
belt.
2.
2. Loosen
Loosen the
the alternator
alternator mounting
mounting and
adjusting
adjusting arm
arm bolts.
bolts. Move the
the
alternator
alternator toward
toward the
the engine.
engine. Remove
Remove
the
the belt(s)
belt(s) from
from the
the alternator
alternator and
crankshaft
crankshaft pulleys,
pulleys, and
and lift
lift them
them over
the
the fan.
fan.
Installation
Installation
L1. Place
Place the
the belt(s)
belt(s) over
over the
the fan.
fan. Insert
Insert
the
the belt(s)
belt(s) in
in the
the water
water pump
pump pulley,
pulley,
crankshaft
crankshaft pulley
pulley and
and alternator
alternator
pulley
pulley grooves.
grooves. Adjust
Adjust the
the belt
belt
tension
tension to
to specifications.
specifications.
On aa car
car with
with an
an air
air conditioner
conditioner,
2.2. On
install
install and
and adjust
adjust the
the compresso;
compressor
drive belt
belt to
to specifications.
specifications.
drive
3.3. On
On aa car
car with
with power
power steering
steering
(except Lincoln
Lincoln Continental),
Continental), inin(except
stall the
the power
power steering
steering pump
pump drive
drive
stall
belt and
and tighten
tighten the
the pump
pump at
at the
the
belt
mounting bracketo
bracket. Adjust
Adjust the
the drive
drive
mounting
belt tension
tension to
tospecifications.
specifications.
belt
BACK TO GROUP INDEX
Installation
Installation
1/8 inch
Position the clamps at least 1/8
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
~Iamps
clamps are beyond the bead and placed
In
of
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.
leaks.
THERMOSTAT (REFER TO FIGS.
3,4
3, 4 AND
AND 5)
5)
V-6 engines,
engines, the thermostat is
On V-6
on the bottom of the water pump
hOUSing.
housing. The thermostat
thermostat housing
housing
connects to the radiator lower hose,
as is
is customary on
rather than the upper, as
all other engines.
engines.
all
located
locate~
27-01-4
27-01-4
Removal
Removal
1.
1. Drain
Drain the
the radiator
radiator so
so that
that the
the coolant
coolant
level
is below
below the
the thermostat.
thermostat.
level is
2.
2. Remove
Re":l0~e the
the coolant
coolant outlet
outlet housing
housing
retaining
retaining bolts.
bol~s. Pull
Pull the
the elbow
elbow away
away
from
from the
the cylinder
cyhnder head
head or
or manifold
manifold
(water
(water pump
pump on
on V-6)
V-6) sufficiently
sufficiently to
to
provide
provide access
access to
to the
the thermostat.
Remove
Remove the
the thermostat
thermostat and
and gasket.
gasket.
Installation
Installation
Check the
the thermostat
thermostat before
Check
before
installing it,
it, following
following the
the procedure
procedure
installing
under Thermostat
Thermostat Test,
Test, Part
Part 27-01,
27-01
under
Section 1.
1.
'
Section
1. Clean
Cle~n the coolant
coolant outlet
outlet housing
housing and
and
cylinder
cyhnder head
head or
or manifold
manifold gasket
gasket
surfaces. Coat
Coat a new
new gasket
gasket with
with
water resistant
resistant sealer. Position
Position the
the
gasket on the cylinder
cylinder head opening.
opening.
The gasket must be positioned on the
cylinder head or the intake manifold,
manifold,
before the thermostat is installed,
installed,
except on 351M, 400 and 460 CID
CID
engines, where the thermostat
thermostat is
is
installed
installed in the block
block (351M
(351 M and
400) or intake manifold
manifold (460) first,
and then the gasket is installed.
To prevent incorrect installation of
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
and 4)
4) in
in the
the outlet
outlet
section (Figs.
(Figs. 3
3 and
casting.
thermostat
casting. Turn
Turn the
the thermostat
clockwise to
the
clockwise
to lock
lock it
it in
in position
position on
on the
flats cast
cast into
into the
the outlet
outlet elbow.
elbow.
flats
2. Position the coolant outlet elbow
against the cylinder head, or the
manifold. Install and torque
intake ~~nifold.
the retaining bolts to specifications.
3. Fill the cooling system with the
Antifreeze
recommended Permanent Antifreeze
and water mixture. If equipped with
a crossflow radiator, follow the
special instructions
instructions in
in Part
Part 27-03
special
regarding checking
checking cool~nt
coolant level.
level.
regarding
Check for
for leaks
leaks and
and proper
proper coolant
coolant
Check
level after
after the
the engine
engine has
has reached
reached
level
normal operating
operating temperatures.
temperatures.
normal
RECESS
14-21 FT-LB
FT-LB
14-21
~.-o
FLATS
OUTLET CONNECTION
CONNECTION
OUTLET
-8594
-8594
THERMOSTAT - 8575
(OUTLET SIDE TO
RADIATOR)
B29S2-A
B2952A
Q1271-A
Q1271-A
FIG. 3 Installing
Installing Thermostat-Typical
ThermostatTypical
FIG.3
In-Line 66 and
and V-8
V-8
In-line
FIG. 4 4-Cylinder
4-Cylinder Thermostat
Thermostat and
and
FIG.4
HousingDisassembled View
View
Housing-Disassembled
27-01-5
27-01-5
Vehicle
Application
Mustang/Pinto/
Bobcat, Maverick/
Comet
WATER PUMP ---~

8591
Specified Cap
Cap
Pressure (PSI)
(PSI)
Lower Limit (PSD

(PSI)
(Must Retain)
Upper Limit (PSI)

(PSI)
(Must Relieve)
13
11
11
17
16
16
13
19
19
HOUSING
8592
Ford/Mercury,
To
rino/Montego/
Torino/Montego/
Cougar/Elite,
Thunderbird/
Continental/Mark
Co
nti nental/Mark
IV, and Lincoln
Continental
CQ1402-A
CQ1402A
01124-8
Q1124-B
FIG.
and Housing
F I G . 5 V-6
V-6 Thermostat and
CLEANING AND
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
c o o l i n g efficiency
efficiency and
and avoids
avoids
cooling
BACK TO GROUP INDEX
Always remove the

ooverheating.
v e r h e a t i n g . Always
to pressure flushing. A
thermostat prior to
A
pulsating or reversed direction of
flushing water flow will loosen sediment
in the
the
more quickly than aa steady flow in
normal direction of coolant flow. In
severe cases where cleaning solvents will

not properly clean the cooling system for
for
efficient
efficient operation, it will be necessary to
use the
the pressure flushing method.
Various types of flushing equipment are
are
available.

27-01-6
27-01-6
SPECIFICATIONS
SPECIFICAliONS
COOLING SYSTEM CAPACITIES
Quantity - Qts.*
(U.S. Measure)
Vehicle/Engine
Pinto/Bobcat
2.3
2.3
2.8
2.8
Non/AC
AC
Non/AC
AC
8.7
9.0
12.5
13.2
Mustang
2.3
2.3
2.8
2.8
302
Non/AC
AC
Non/AC
AC/Ralley Pack
Non/AC and AC
8.5
9.1
9.1
12.3
13.2
16.3
200
200
Non/AC
AC
250
250
302
302
Non/AC
AC
Non/AC
AC
8.7
8.9
9.7
9.7
13.5
14.1
14.1
200
(All)
Granada/Monarch
250
250
302
302
351W
351W
Non/AC
AC
Non/AC
AC
Non/AC
AC
10.5
10.7
14.4
14.6
15.7
16.7
To
rino/Montego/Elite/
Torino/Montego/Elite/
Ranchero/Cougar
351M
351M
351M
351W
351W
400
400
400
460
460
460
Non/AC
AC/Police
AC/Trailer Tow (Medium)
Non/AC
AC
Non/AC
AC/Police and Trailer Tow (Heavy)
Non/AC
AClTrailer
/ Police
AC/Trailer Tow (Heavy)
(Heavy)/Police
17.1
17.1
18.0
17.5
15.9
16.2
17.1
17.1
17.5
18.0
19.2
19.7
19.2
Ford/Mercury/Meteor
Ford/Mereu
ry/Meteo r
351M
351M
400
400
460
460
460
460
460
Non/AC
AC/3.25:
AC/3.25:11 Ratio Axle
Non/AC
AC/Trailer Tow (Medium) 3.25:
3.25:11 Ratio Axle
AC and Non/AC
AClTrailer
AC/Trailer Tow (Heavy)
AC/Police Interceptor
A/C Station Wagon
17.1
17.1
17.6
17.1
17.1
17.6
18.5
19.0
20.0
20.0
19.0
Continental Mark IV
460
460
AC/Trailer
AC/T railer Tow
AC and Sierracin Heated Window
19.8
19.9
Thunderbird
460
460
460
AC/Trailer Tow
AC
{:l.C
AC and Sierracin Heated Window
19.8
19.3
19.4
Lincoln Continental
460
AC
19.7
Maverick/Comet
9.9
NOTES
* Figures represent calculated volume.

volume. Actual coolant capacities may vary
10% from these amounts.
amounts,
Measure, multiply the quantities shown by .83.
a To convert to Imperial Measure,
Above capacities include heater and
and coolant reservoir,
reservoir, where
where applicable.
applicable.
Above
a Service refill recommendations are

are a 50/50 mix of water and
and permanent coolant/anti-freeze fluid (Ford SPEC
SPEC ESE-M97818-C).
ESE-M97B18-C).
a
be 50%
50% of above specification - for each
each application.
Material required will be
Closed cooling systems with coolant reservoir require an
an additional 1 qt. (approx.) of mixture for r~servoir
reservoir - material required is
is approx. 1 pt. of permanent
a Closed
anti-freeze fluid.
CQ115J-C
CQ1153-C
BACK TO GROUP INDEX

27-01-7
TORQUE VALUES (ALL CARS)

NOTE: All specifications are given in ft-Ibs
ft-lbs unless otherwise noted.
Fan shroud assembly to
radiator
where
applicable
24-48 in-Ibs
to
in-lbs
Fan to
12-18
to pulley hub (All engines)
12-18
Radiator hose clamps (200 CIO
CID
in-lbs
Maverick-Comet standard radiator)
16-24 in-Ibs
in-lbs
(All others)
20-30 in-Ibs
Transmission oil cooler tubes to
9-12
to oil
oil cooler - all engines.
engines . . . . . . . . . .. 9-12
SPECIAL SERVICE TOOLS (ALL CARS)
Description
Ford Tool No.

T63L-8620-A
Belt Tension Gauge

RADIATOR PRESSURE CAP
Vehicle
Cap Specified
Pressure
Pressure (PSI)
(PSI)
Acceptable Test
Gauge Re"ing
Reading (PSI~
(PSIH
Mustang/Pinto/Bobcat,
Maverick/Comet
13
11-17
11-17
Ford/Mercury, Torino/Montego/Elite/
Ranchero,Thunderbird/Continental
Ranchero,
Thunderbird/Continental
Mark IV, Lincoln Continental, Granada/
Monarch
16
13-19
13-19
BACK TO GROUP INDEX
DRIVE BELT TENSIONS (lbs.)

Newly Installed
(1)
50-80
1/4"
1/4"
27-01-7
Used
Size
Except 1/4"
1/4"
120-160
Up
to 10 Min.
UptoiOMin.
40-80 (2)
(2)
Over
10 Min.
OveMQMin.
40-60 (2)
(2)
90-160
(3)
90-160(3)
75-120
(4)
75-120(4)
(1) Read tension immediately after belt is

seats in
in pulley grooves.
to 40-60 pounds.
to 90-120 pounds.
to 90-120 pounds.
THERMOSTATS
Starts to Open F
F
Fully Open
.. 188-195
188-1950
212.215
..212-215
CQ1090-F
CQ10g0F

27-03-1
27-03-1
Radiators
27-03-1
27-03-1
27 -03 Radiators
PART 27-03
All Models so Equipped
Applies to All
Page
COMPONENT INDEX
COMPONENT
Page
COMPONENT
COMPONENT INDEX
......................
Constant-Full Cooling System ........
03-1
Filling Cooling System ...............
03-1
03-1
Radiator
Rad iator ..........................
03-1
Crossflow Radiators .................
03-1
REMOVAL AND
AND INSTALLATION
03-2
........................ .
03-2
Automatic
Automatic Transmission Oil
Oi I Cooler .....
03-3
Down Flow Radiator ................
03-1
Radiator ..........................
03-2
DESCRIPTION
Diagnosis
The information
infonnation in this Part applies to both 1975 and 1976 model year vehicles unless otherNOTE: The
wise specified.
CR1966-A
CR1966-A
DESCRIPTION
RADIATOR
Standard and
and extra-cooling radiators
but service
are installed in production, but
are usually of the
replacement radiators are
the
extra cooling type.
~
\
DOWN FLOW RADIATORS

These radiators are
are the
the tube and
and slitfin-core type with the
the tubes arranged for
vertical flow of the coolant. The radiator
bottom header tank on
on automatic
automatic
transmission
transmission cars contains aa heat
exchanger for
for cooling the
the transmission
oil.
CROSSFLOW RADIATORS
These radiators are
and
are of the
the tube and
slit-fin-core type with the tubes arranged
horizontally for
for crossflow of the coolant.
Two header tanks,
tanks, one on each side of the
radiator, provide uniform distribution of
of
to the
the cross-flow tubes.
tubes. The
The
the coolant to
or chamber, on
on the
the left side
header tank, or
of the radiator contains aa heat exchanger
the transmission fluid.
for cooling the
fluid.
Special Filling
Instructions.:Crossflow
Instructions-Crossflow Radiators
Radiators
be accurately
Coolant level cannot be
checked while
while the
the engine is
is running,
running, due
due
to the
the construction of this radiator.
radiator.
Check the
the level while
while the
the engine is
is cold
and fill to
to about 22 1/24
1/2-4 inches below the
fill
fill cap
cap seat (Fig.
(Fig. 1).
1).
FILLING COOLING SYSTEM
SYSTEM
On initial fill
fill or
or refilling the
the cooling
system,
system, the following procedures must be
followed to
to prevent air
air entrapment and
inadequate coolant levels.
levels. This
This does
does not
apply to
to cooling systems
systems equipped with
coolant recovery or constant full
full systems.
systems.
1.
1. Check all
all hose
hose clamps for
for proper
BACK TO GROUP INDEX
CONSTANT-FULL COOLING
SYSTEM
82951.8
B2951-B
LevelCrossflow
FIG. 11 Cold Fill level-Crossflow
Radiator
2.
2.
3.
3.
4.
4.
5.
5.
tightness.
tightness. Be
Be sure radiator drain cock
is
is closed.
closed.
Position heater temperature selector
the maximum heat position.
position.
in the
Fill cooling system to
to 22 1/2-4
1/2-4 inches
thefill
capseat
seat(cross-flow)
(cross-flow)or
or
below the
fill cap
1/2 inches
inches below
below the
the fill
fill cap
cap seat
seat
11 1/2
(down-flow).
Leave
Leave radiator cap ofT
off and run engine
until thermostat opens
opens (hot
(hot coolant
flows through
through radiator
radiatorupper
upperhose).
hose).
flows
Stop
Stop engine
engine and add
add coolant to
to 11 1/2
cap seat (cross(crossinches below fill cap
flow) or
or 1/4
1 /4inch
inchbelow
belowfill
fillcap
capseat
seat
flow)
(down-flow). Install radiator cap.
cap.
This system is based around a 13

13 PSI
PSI
pressure cap
cap (vehicles with downflow
16 PSI
radiators), or aa 16
PSI pressure cap
cap
and aa
(vehicle with downflow radiators) and
plastic reservoir and
and hose, except the
following vehicles equipped with the 460
V-8, which uses aa 16
16 PSI
PSI pressure
pressure
CID V-8,
(1) Continental Mark IV-all;
IVall; (2)
(2)
cap: (1)
ThunderbirdClass III
III Trailer Towing
Thunderbird-Class
P aacckkaaggee;; a
an
nd
d (( 3
3 ))
P
Torino/Montegopolice. When the
Torino/Montego-police.
in the
the radiator expands to
to the
coolant in
overflow point, it passes through the
cap and
and into the
the plastic
pressure cap
the coolant in
in the
reservoir. When the
and therefore
therefore
radiator cools down and
contracts, it pulls coolant from the
reservoir through aa vacuum relief valve
the pressure cap,
cap, back into the
in the
radiator.
are the
the
The advantages of the system are
in the
the expansion
extra coolant carried in
and the
the fact that any
any air
air bubbles
tank and
trapped in
in the
the cooling system are
are vented
vented
the plastic reservoir, rather than
in the
causing excessive aeration of the coolant.
coolant.
the coolant level
level in
in the
the plastic
Check the
the engine at
at operating
reservoir with the
temperature. Do
Do not
not remove
remove the
thefill
cap
fill cap
temperature.
except to
to service the
the radiator.
radiator.
Filling Constant Full
Full Cooling
Cooling
Filling
System-Mustang
SystemMustang W/Optional
W/Optional
302
CID-V-8
302CID-V-8
1. Check all
all hose
hose clamps for
for proper
1.
tightness.
tightness. Be
Be sure
sure radiator drain cock
is closed.
closed.
is
2. Set
Set the
the heater temperature selector
2.
27-03-2
27-03-2
Radiators
lever to the maximum heat position.

3. Fill the cooling system through the
filler neck
neck inin the
the radiator
radiator upper
upper hose
hose
filler
until the coolant level is up to the
Fig. 3.)
bottom of the filler neck. (See Fig.
Install the
the radiator
radiator cap.
Install
4. Fill the plastic reservoir bottle to the
4.
HOT LEVEL mark. Install the
reservoir cap.
5. Start the engine and allow to warm to
normal operating temperature.
6.
6. Check the level of coolant in the
plastic reservoir. If the level is below
the HOT LEVEL mark, add coolant
to the plastic reservoir bottle only.
UNDER NO CIRCUMSTANCES
SHOULD
TOR
SHOULD THE
THE RADIA
RADIAT
OR
PRESSURE CAP BE REMOVED
WHILE
W H I L E THE
T H E ENGINE
E N G I N E IS
RUNNING.
Filling Constant Full Cooling
System-Except
SystemExcept Mustang
W/302 CID v-a
V-8
1. Check all hose clamps for proper
tightness. Be sure radiator drain cock
tightness.
is closed.
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.
4. Run engine until thermostat opens
(coolant flowing through radiator
upper hose becomes hot).
5.
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
change does not occur, check the system
follows:
as follows:
1.
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
unique; replace only
this system is unique;
with the proper cap.
2.
2. Rem
R e m o0 vvet
e t hher
e raa dd ii aa tor
tor
overflow-to-reservoir
overflow-to-reservoir hose at the
radiator filler
filler neck connection and at
the bottle.
3. Inspect the reservoir hose for
cuts. Replace
obstruction, cracks or cuts.
if necessary.
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.
6. Pressure test the system.
7. Replenish the coolant in the radiator
7.
and reservoir, as required.
8.
8. Reinstall the radiator pressure cap.
RADIATOR CAP - 8100
57644-S2 3/8-16X3/4"
(1 REQUIRED)
RADIATOR ASSEMBLY - 8005
COOLING SYSTEM
FI
LL CAP
FILL
A/C COMPRESSOR
SUCTION LINE
r
RADIATOR FI
LL ASSEMBLY
FILL
AND SUPPORT - 8C160
TRANSFER HOSE
\:;~,
RESERVOIR CAP
376025-S2
376025-S2
3/8-16
3/8-16 XX 1"
1'
(1 REO'DJ
VIEWZ
VIEW 2 1
UPPER RADIATOR
HOSE - 8 B 2 7 4
REMOTE
REMOTE FILLER
FILLER
TUBE
TUBE
RESERVOIR 8C045
RADIATOR FILLTUBE ASSEMBLY 8C153
""
FRONT
FRONT OF
OF ENGINE
ENGINE
12-16 FT-LB
(2 PLACES)
01269-A
Q1269-A
FIG. 2 Constant-Full Cooling

SystemFord/Mercury
System-FordlMercury
w/400
V-8 and Class III
wi
400 CID V-B
Trailer Towing Package
LOWER
RADIATOR HOSE
-8B273
RESERVOIR
ASSEMBLY - 8C045
HOLE & SLOT IN
FENDER
FENDER APRON
APRON
RADIATOR FAN
SHROUD SHOWN
OUT OF PLACE
FOR PURPOSE OF
RADIATOR
ILLUSTRATION.
'
I':
NOTE: TORQUE LOWER HOSE

CLAMP INTO POSITION BEFORE
FAN SHROUD IS INSTALLED.
NOTE:
NOTE:
POSITION SHROUD TO MAINTAIN A
MINIMUM OF .38 RADIAL CLEARANCE
CLEARANCE
TO THE FAN TIP
24-48 IN-LB
(6 PLACES)
01270-A
Q1270-A
v-a
FIG. 3 Constant Full Cooling System-Mustang

/Optional 302 CID V-8
SystemMustang W
W/Optional
Engine
INSTALLATION
REMOVAL AND INSlALLAliON
RADIATOR
Removal
Removal
1.
1. Drain the cooling system. Disconnect
the radiator upper and lower hoses
from the radiator.
BACK TO GROUP INDEX

disconnect the
transmission,
automatic transmission fluid cooler
inlet and outlet lines from the
radiator.
2. Crossflow radiators
a. If
If equipped with fan shroud,
remove two upper shroud attaching
bolts at radiator support. Lift fan
shroud sufficiently
sufficiently to disengage
27-03-3
retaining clips and lay
lower retaInIng
shroud back over fan.
fan.
shroud
b. Remove
Remove radiator
radiator upper
upper support
support
b.
attaching bolts
bolts and
and remove
remove
attaching
support(s). tift
Lift the
the radiator
radiator from
from
support(s).
vehicle.
vehicle.
3. Downflow
Downflow radiators
radiators
3.
a. If equipped with fan shroud,
shroud,
a.
remove four attaching bolts,
bolts, two
two at
remove
side of radiator.
radiator. Lay
Lay shroud
each side
fan.
back over fan.
b. Remove radiator attaching bolts,
b.
two at each side
side of radiator.
radiator. Lift
two
vehicle.
radiator from vehicle.
27-03-3
Radiators
Radiators
COOLER
COOLER ASSEMBLY
ASSEMBLY
COOLER ASSEMBLY
ASSEMBLY
COOLER
Installation
Insta//ation
1. If aa new
new radiator isis to
to be
be installed,
1.
2.
2.
3.
3.
4.
4.
5.
5.
6.
7.
remove the drain cock from the old

remove
radiator and install it on the new
radiator.
is to be
be installed on
If aa new radiator is
vehicles equipped with automatic
transmission, transfer the oil cooler
radiator,
line connectors to the new radiator,
sealer.
using oil resistant sealer.
Position the radiator assembly into
the vehicle.
a. On downflow radiators, install the
bolts, two on each
four attaching bolts,
side of the radiator.
b. On crossflow radiator, install upper
supports and secure with bolts.
Onn vvehicles
withh aut
a u t 0o mat
matic
0
e h i c I e s wit
transmissions, connect the oil cooler
lines.
lines.
Place fan shroud into clips on lower
radiator support
support of
of crossflow
crossflow
radiator
radiator. Secure to upper support
bolts. Position shroud to
with two bolts.
downflow radiator and secure with
two bolts each side of radiator.
Position shroud
shroud to maintain
maintain a
minimum of 0.38 inch minimum
radial clearance to fan blade tips.
Connect the radiator upper and lower
hoses.
hoses; Close the drain cock. Fill the
cooling system.
Operate the engine and check for
leaks at the hose connections and the
automatic transmission fluid cooler
lines. Check
automatic
Check the
the automatic
transmission and radiator fluid level.
AUTOMATIC TRANSMISSION OIL

COOLER
Replacement
Replacement of
of the automatic
transmission oil cooler in the radiator
tank, as given ~Jow,
b Jow, isis usually
usually performed
performed
by radiator specialty shops on a sub-let
basis. However, the operation can be
performed
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.
BACK TO GROUP INDEX
45221-S7 22 REO'D.
REQ'D. BEFORE
BEFORE
45221-S7
SOLDERING TOROUE
TORQUE
TO 20-50 IN-LB
IN-LB
SOLDER
SOLDER OIL
OIL COOLER
COOLER
FITTINGS
FITTINGS COMPLETELY
COMPLETELY
TO
TO TANK
TANK
(THREADED DESIGN)
SOLDER OIL COOLER
FITTINGS COMPLETELY
TO TANK
TYPICAL CROSSFLOW AND

AND
DOWNFLOW RADIATORS
RADIATORS
'
384173-S5 OR
374551-S5
22-REQUIRED
- REQUIRED
(BEAD DESIGN)
DESIGN)
83144-8
B3144-B
FIG. 4 Typical Radiator Oil Cooler Installation
be made
made to
to repair
No attempt should be
aa fractured radiator tank.
tank. Should a
fractured tank be
be encountered,
encountered, itit must
mustbe
be
replaced.
replaced. Tank repairs
repairs usually result in
repeat failures, due
due to
to the flexible nature
of the tank.
Removal
Removal
1.
2. Remove the radiator from the vehicle,
vehicle,
2.
following the procedure outlined
previously.
3. Thoroughly
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:
NOTE: Caution
should be exercised during the
disassembly and assembly solder
operation of radiator components.
Avoid excess heat concentration
which could result in burning through
through
the radiator sheet metal or loosening
an adjoining soldered area.
On downflow radiators, apply heat
to separate support tabs from lower
tanks.
4. Remove the radiator tank containing
the defective oil cooler.
5. Melt the puddled solder from the oil
cooler
cooler inlet and outlet
outlet fittings.
Remove the retaining rings from the
fittings.
6. Remove the defective oil cooler.
7. Clean the soldered surface areas and
inspect and tin as

as necessary to assure
proper solder bonding.
Installation
Installation
1.
1. Install the replacement oil cooler
assembly into the tank openings and
secure cooler with new retaining
rings. For threaded design, torque
retainer to 20-50 in-Ib;
in-lb; for bead
design, push ring past fitting bead.
Retaining ring tangs should point
away from tank (Fig.
(Fig. 4).
2. Puddle-solder the oil cooler fittings
completely to the tank.
3. Seat the tank assembly in the header
well and solder securely, completely
well. Use 40-60 solder with
filling the well.
either zinc chloride 30 (BAUME) or
S-B
5-B NALCO flux.
4. Resolder the supports in position on
downflow radiator.
off all excess acid, internally
5. Flush off
and externally.
Pressure-test the radiator assembly to
6. PressUre-test
14-16 PSI for leaks.
7. Paint as required.
8. Install the radiator and fan shroud to
the vehicle. Install the connectors in
cooler inlet
inlet and outlet
the oil cooler
connections and connect
connect the
connections
transmission oil cooler lines.
9. Connect the hoses to the radiator inlet
and outlet connections.
10. Flush
Flush the
the cooling
cooling system
system and
and refill
refill
of
with the recommended mixture of
Rotunda all season coolant.

27-05-1
27-05-1
27-01-1
27-05-1
Fan Drive Clutch
PART 27-05 Fan Drive Clutch

Applies
Equipped
Applies to
to Models
Models So
So Equipped
Page
Page
COMPONENT
COMPONENT INDEX
INDEX
FAN DRIVE CLUTCH
Description and
and Operation ............
05-1
05-1
Removal and
05-1
05-1
COMPONENT INDEX
COMPONENT
INDEX
Page
Page
SPECI
FICATIONS ....................
SPECIFICATIONS
05-2
NOTE:
information in
specified.
CR1966-A
CR1966-A

FAN DRIVE CLUTCH
The fan
3)
fan clutch (Figs. 1,
1, 22 and
and 3)
permits use
use of aa powerful fan
fan without
paying the penalty of power loss or
or noise.
noise.
It is
is basically a temperature-controlled
temperature-controlled
fluid coupling that regulates fan
fan speed
to the
the temperature of the air
air
according to
the radiator core and
coming through the
and
flowing around the bi-metal control valve

of the clutch.
located on the forward face of
ang slip-speeds are given
Pulley ratios ancl
Specification Section of this Part.
in the Specification
BIMETAL
BI-METAL STRIP
BIMETAL SPRING
BI-METAL
B1593-B
FIG. 11 Typical Fan

Fan Drive Clutch
FIG.
Installation
CONTROL PISTON
81932-C
B1932-C
B2631-B
2 Fan
Fan Drive Clutch With Flat
FIG. 2
Bi-Metal Spring
FIG. 3
3 Fan Drive Clutch With Coil
Bi-Metal Spring
INSTALLATION
FAN DRIVE CLUTCH
Removal
1. Remove the
the radiator upper support
1.
fan guard or
or shroud.
shroud.
and/or fan
2. Loosen the
the fan
fan belt. Remove the
2.
the
the fan
fan drive
capscrews attaching the
to water pump hub
hub (Fig. 1).
1).
clutch to
Remove the
the fan
fan drive clutch and
and fan
fan
an assembly.
assembly.
as an
BACK TO GROUP INDEX
3. Remove the attaching capscrews and

separate the fan from the drive clutch.
Installation
Installation
1. Position the
the fan
fan on
on the
1.
the drive clutch.
the capscrews and
and torque to
Install the
to
specifications.
the fan
fan drive clutch and
fan
2. Position the
and fan
assembly to the water pump hub (Fig.
1). Install and

and torque the
the attaching
capscrews evenly and
and alternately to
to
specifications. Then, check
fan
check the
the f~n
drive clutch flange-to-water
flange-to-water pump
purhp
hub for proper mating. Adjust the fan
to specifications.
belt tension to
3. Install radiator upper support and/or
fan guard or
or shroud.
27-05-2
Fan Drive Clutch
27-05-2
SPECIFICAliONS
SPECIFICATIONS
TORGUE
TORQUE VALUES (ALL
(ALL CARS) -- FT-LB
NOTE
f t . - l b s . unless
i nless otherwise
NOTE: All specifications (He
am given iini lUlls.
toted.
itherwise noted.
Filn
A/C) ~- All Engines
Fan to Fiw
Fan Clutch (With A/C)
Wiltel
Fan Clutch
Clinch to
to W
tei Pump
121H
12 1H | F,1I1
All Ellgines
Engines
12-1B
D R I V E CLUTCH SPECIFICATIONS
SPECIFICATIONS
FAN DRIVE
Fan Test Speed @ 2000 Water Pump RPM
Vehicle
Torino, Elite,
Montego, Cougar,
Thunderbird
Mark IV, Ford,
Lincoln
Mercury, Lincoln
Granada, Monarch (Ghia)
Engine
Cooling Option
Water Pump
Pulley Ratio
Engine RPM
RPM Required
To Run
Run Water Pump
2000 RPM
4GO
460
A/C
AIC
1.251
1.25:1
1GOO
1000
Minimum RPM
(Hot)
Minimum RPM
RPM
(Cold)
1600
bOO
SOO
3S1-W
351-W
A/C
1.131
1.13:1
1770
1600
500
Granada,
Monarch (Ghia)
302
302
STD
STO
A/C
.96
.96:11
1.13:
1.13:11
2040
1770
1600
1600
500
500
Mustang
302
A/C
Ale
1.251
1.25:1
1600
1600
500
Granada,
Monarch (Ghia)
250
250
STD
STO
A/C
1.04:1
1.041
1.181
1.18:1
1920
1690
1600
1600
500
SOO
500
CQ1095C
C01095-C
BACK TO GROUP INDEX

27-06-1
27-06-1
27-06-1
27-06-1
Ford Flex-Blade Fan

Fan
PART 27
-06 Ford Flex-Blade Fan
Fan
27-06
Applies to All Models
Page
COMPONENT INDEX
FAN-FLEX-BLADE
Description and
and Operation
...........................................................
06-1
NOTE:
NOTE: The
The information in
specified.
CR1966A
CR1966-A
DESCRIPTION
DESCRIPTION
The Ford Flex Blade Fan
1)
Fan (Fig.
(Fig. 1)
consists of aa spider stamping of either
5-blade or
or 7-blade configuration, to
which are
are riveted the
the flexible blade
assemblies. Other than the
the riveted
flexible blades,
in
blades, the fan
fan is
is conventional in
and is
is removed and
and replaced
appearance and
in
in the
the same manner as
as aa standard fan
(Part 27-01).
OPERATION
as engine rpm
Because the blades flex as
increases, the Ford Flex-Blade Fan tends
increases,
to use
use less
less power and
and to
to generate less
to
noise than does aa conventional rigid
fan of fixed pitch. This fan
cooling fan
to the engine speed without
adjusts itself to
use of
of complicated
complicated drive
drive mechanisms.
mechanisms.
the use
or adjustment
adjustment is
is therefore
therefore
No test or
the fan
fan drive
required, beyond keeping the
to the
the proper (standard)
belt adjusted to
tension.
tension.
B3143-A
B3143A
FIG. 1 Ford Flex-Blade Fan

FIG.
Fan
BACK TO GROUP INDEX

28-01-1
28-01-1
Starting System
28-01-1
28-01-1
GROUP
Storting System
PAGE
28-01
PART 28-01
Starting System General Service
28-01-1
. 28-01-1
PART 28-02
Positive Engagement Starter
28-02-1
. 28-02-'
PART 28-03
28
PAGE
Starter . . . . . . . . . . . . .. 28-03-1
Solenoid Actuated Starter.
28-03-1
PART 28-01 Starting System General Service

NOTE: The information in this Part applies to both 1975 and 1976 Illodel
CR1966-A
CR1966-A
INFORMATION
GENERAL INFORMAliON
The function
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
of
resistance in the starting circuit must be
kept to an absolute minimum to provide
BACK TO GROUP INDEX
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,
discharged the
the owner may have discharged
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
difficulty.
locate the cause of the starting difficulty.
The road service is not a part of the
diagnosis procedures.

28-02-1
28-02-1
28-02-1
28-02-1
PART 28-02 Positive Engagement Starter

Applies to
v-a
to All
All Engines Except 460 CJ.D.
C.I.D. V-8
COMPONENT INDEX
OESCR
IPTION
DESCRIPTION
Page
......................
02-1
02-1
TESTING
COMPONENT INDEX
Page
REMOVAL AND
AND INSTALLATION
INSTALLATION
Positive Engagement Starter ...........
02-4
Road
Road Service ......................
02-1
02-1
On
On Vehicle Testing ..................
02-2
Positive Engagement Starter ...........
02-4
.......................
02-3
SPECiFiCATIONS
02-8
Bench
Bench Tests
OVERHAUL
NOTE:
NOTE: The
The information in
specified.
CR1966-A
CR1966-A

POSITIVE ENGAGEMENT STARTER
The starting system includes the
the
an integral positivestarter motor with an
drive, the
the battery, aa remote
engagement drive,
control starter switch (part of the ignition
the neutral-start
neutral-start switch
switch
switch), the
shift
(automatic transmission with floor
floor shift
only), the starter relay,
relay, and heavy circuit
only),
wiring.
wiring.
of the
the ignition key
key to
to the
the
Turning of
the starter
START position actuates the
relay,
relay, through the starter control circuit.
The starter relay then connects the
the
to the
the starter.
starter.
battery to
an automatic
Vehicles equipped with an
and aa console or
or floor
floor
transmission and
mounted shift lever have aa neutral-start
in the
the starter control circuit,
switch in
which prevents operation of the starter if
is not in the N (neutral)
the selector lever is
position.
or PP (park) position.
an automatic
Vehicles equipped with an
and aa column shift do
do not
not
transmission and
use aa neutral-start switch.
switch. The
The ignition
use
switch mechanism in the steering column
is designed
designed so
so that
that the
the ignition
ignition switch
switch can
is
r
":'"
l---I ++
STARTER RELAY
BATTERY
BATTERY
* START SWITCH &

SAFETY SWITCHES
IN OPERATED POSITION
(PINTO/MAVERICK)
SEE VEHICLE WIRING DIAGRAM
DIAGRAM
* SEE
J1083-G
Jl083-G
FIG. 11 Starting Circuit
to the start position only when

be turned to
is in
in NEUTRAL or
or
the selector lever is
PARK.
is not
not in
in use, one of
When the starter is
of
is connected directly to
the field coils is
to
1).
ground through aa set of contacts (Fig. 1).
the
When the starter is first connected to
to the
battery, aa large currentflows
flows through the
grounded field coil, actuating aa movable
shoe. The
Thepole
poleshoe
shoeisisattached
attachedtotothe
the
pole shoe.
starter drive plunger lever and thus the

the
drive is
is forced into engagement with the
the
flywheel
ringgear.
gear.
flywheel ring
When the
the movable pole shoe is
is fully
seated, it opens the
the field coil grounding
contacts and the starter is then in normal
operation. A
A holding coil is
is used to
to
maintain the
the
the movable pole shoe in
in the
fully seated position during the time that
the starter is turning the engine.
of Battery Jumper Cables

Use of
The following instructions contain
be observed to
to
precautions that should be
injury to
avoid possible injury
to yourself
yourself or
or
to the
the vehicle.
damage to
CAUTIONUse only aa 12-volt
CAUTICN-Use
power supply. You can damage a 12-volt

starting motor and
and ignition system
extensively by
by connecting it to a 24-volt
power supply (two
(two 12-volt batteries in
in
series, or
or a
a 24-volt motor-generator set).
WARNINGBatteries
WARNING-Batteries contain
TESTING
ROAD SERVICE
calls, connect aa 1212On road service calls,
to the
the system for
volt booster battery to
for
cases of aa starter that will not
not crank the
cases
or aa starter that cranks the engine
engine or
very slowly.
slowly.
very
BACK TO GROUP INDEX

28-02-2
SULFURIC ACID. Shield your eyes
when working near the battery to protect
against possible spilled acid solution. In
case of acid contact with skin, eyes, or
IMMEDIATELY
clothing, FLUSH IMMEDIATELY
WITH WATER FOR A MINIMUM
MINIMUM
OF FIVE MINUTES. Get "on-the-spot"
medical attention immediately.
Hydrogen and oxygen gases are
produced during normal battery
produced
battery
operation. This gas mixture can explode
if flames or sparks are brought near the
battery. When charging or using a
battery in an enclosed space, always
provide ventilation.
Use particular care when connecting
a booster battery to prevent sparks. To
jump start: (1) remove vent caps from
discharged battery, (2) cover the top of
this battery with a clean dry cloth, (3)
(+))
connect ends of one cable to positive (+
terminals of each battery, (4) connect one
end of other cable to negative (-) terminal
(5) connect other end
of "good" battery, (5)
of cable to engine block on vehicle being
started (NOT TO NEGATIVE (-)
T E R M I N A L OF BATTERY). To
TERMINAL
prevent damage to other electrical
electrical
components on vehicle being started,
make certain that engine is at idle speed
before disconnecting jumper cables.
Replace vent caps and carefully dispose
of the cloth since it may now contain
sulfuric acid. REMOVE VENT CAPS
WHEN
WHEN CHARGING
CHARGING OR USING
USING
JUMPER CABLES.
If the starter does not turn the engine
over, even with the booster
booster battery
attached, refer to the following tests. Be
certain that correct battery polarity is
VOLTMETER
28-02-2

ON VEHICLE TESTING
@ ---"'/60.>~.,
\.
-.
STARTER
J1259-D
FIG. 2 Starter Cranking Circuit Test
observed when using a booster battery;

positive to positive, and negative to
negative connection of the jumper cables.
off and
Be sure that all lights are turned off
all doors are closed when using a booster
battery. The starter should not be
operated continuously for periods longer
than one minute at a time. An interval of
at least two minutes should be observed
between such cranking periods to protect
the starter from overheating.
Disconnect
D i s c o n n e c t vacuum
v a c u u m line
l i n e to
to
thermactor by-pass valve before
thermactor
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
If the engine
stops turning and the starter spins at high
speed, the drive is not operating properly
should be replaced. Whenever
Whenever
and should
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.
Alternate Starter Drive Test
1. Pull the push-on connector from the
I.
starter relay terminal.
2. Connect a remote control starter
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.
CARBON PILE RHEOSTAT

AMMETER
POSITIVE
LEAD
POSITIVE LEAD
TO OTHER CIRCUITS
TO IGNITION
SWITCH
STARTER RELAY
TO COIL
(PINTO AND
MAVERICK)
STARTER SWITCH
(ON IGNITION
IGNITION
SWITCH)
TO BATTERY
TO IGNITION
COIL
(PINTO AND
MAVERICK)
STARTER
StARTER
BATTERY
J1086-G
Jl086-G
FIG. 3 Starter Load

Load Test
BACK TO GROUP INDEX

28-02-3
28-02-3
4. Observe if the starter is cranking the

4.
if it
it continues to
to
dead engine and if
crank the engine until the remote
is released. If
If the
control switch is
not crank the dead
starter does not
slipping.
engine, the drive assembly is slipping.
5. Repeat the test at least three times in
5.
to detect intermittent
succession to
operation.
Starter Cranking Circuit Test
in the starter
Excessive resistance in
from the
the results
results
circuit can be determined from
of this test. Make the test connections as
Fig. 2.
2. Crank the engine with
shown in Fig.
OFF. This is accomplished
the ignition OFF.
by disconnecting the push-on connector
at the starter relay and by connecting aa
the
remote-control starter switch from the
battery terminal of the starter relay to the
of the relay.
"S"-terminal of
The voltage drop in the circuit will be
to 22 volt
indicated by the voltmeter (0 to
range). Maximum allowable voltage drop
range).
should be:
1.
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,
2,
connection 1).
2.
2. 0.1
0.1 volt with the voltmeter negative
lead connected to the battery terminal
of the starter relay and the positive
lead connected
connected to
to the
the positive
terminal of
2,
of the battery (Fig. 2,
connection 2).
of the starter relay and the positive
connected to
to the
the posItIve
positive
lead connected
of the battery (Fig. 2,
terminal of
2,
connection 3).
4.
4. 0.1
to the
the negative
lead connected to
of the battery and the
terminal of
the
positive lead connected to the engine
(Fig. 2,
2, connection 4).
ground (Fig.
Load Test
Starter Load
Connect the test equipment as shown
3. Be sure that no current is
in Fig. 3.
is
flowing through the ammeter and heavyduty carbon pile rheostat portion of the
c i r c u i t (rheostat
( r h e o s t a t at
at maximum
maximum
circuit
counterclockwise position).
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
starter switch
switch from
from the
the
remote-control
positive battery
battery terminal
terminal to
to the
the
positive
"S"-terminal of
of the
the starter
starter relay.
relay.
"S"-terminal
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
engine. The ammeter will indicate the
the engine.
starter current draw under load.
BENCH TESTS
Starter No-Load Test
Starter
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
at noload, on the test bench only.
Make the test connections as shown

in Fig.
Fig. 4.
4. The starter will run at no-load.
no current is
is flowing
flowing
Be sure that no
the ammeter (rheostat
(rheostat at
through the
at
maximum counterclockwise position).
on the
the
Determine the exact reading on
voltmeter.
Disconnect the
the
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
A
commutator for evidence of burning. A
caused
spot burned on the commutator is caused
by an
an arc
arc formed every time the
the
to the
commutator segment, connected to
open circuit winding, passes under aa
brush.
brush.
Armature and Field Grounded
Circuit Test
This test will determine if the winding
insulation has failed, permitting aa
conductor
to touch the
the frame or
cond
uctor to
or
armature core.
To determine if the armature
armature
windings are
are grounded, make the
the
as shown in
in Fig.
Fig. 5.
5. If
If the
connections as
voltmeter indicates any voltage, the
the
windings are grounded.
Grounded field windings can be
be
detected by making the connections as
as
Fig. 6.
6. If the voltmeter indicates
shown in Fig.
any voltage, the
the field windings are
are
grounded.
JUMPER LEAD-x
DO NOT CONNECT
LEAD TO BEARING
SURFACE
POSITIVE
LEADS
\
\
KEEP BOTH
FIELD BRUSHES
AND hOLUlNGCOIL
- GROUND LEAD
-'- AWAY FROM
FRAME
/
' /
/ /
/
STARTER
TERMINAL
NEGATIVE LEADS
DISCONNECT
HOLDING COIL
GROUND LEAD
BATTERY
J1087-E
FIG. 4
4 Starter No-Load Test on Test
Bench
Bench
BACK TO GROUP INDEX
VOLTMETER POSITIVE L E A D TOUCH TO COMMUTATOR
J1088-D
FIG. 5
5 Armature Grounded Circuit
Test
LEAD
LEAD
J1094-D
FIG. 66 Field Grounded Circuit Test

28-02-4
28-02-4
28-02-4
Positive
Positive Engagement
Engagement Starter
Starter
REMOVAL
INSTALLATION
POSITIVE
POSITIVE ENGAGEMENT
ENGAGEMENT STARTER
All
All Models
Models Except
Except Pinto,
Pinto, Bobcat
Bobcat
and
and Mustang
Mustang
1.1. Disconnect
Disconnect negative
negative battery
battery cable.
cable.
2.
2. Raise
Raise the
the vehicle
vehicle on
on aa hoist and
and
position
position stands
stands (models
(models with
with 8-cyl.
8-cyl.
engine
engine and
and Ford
Ford 6-cyl.).
6-cyl.).
3.
3. Disconnect
Disconnect the
the starter
starter cable
cable at
at the
the
starter
starter terminal.
terminal.
4. Remove
Remove the starter
starter mounting bolts.
bolts.
4.
5.
5. Remove
Remove the starter
starter assembly (Fig.
(Fig. 7).
7).
On
On some
some models it is
is necessary to turn
turn
the
the wheels
wheels to the left or right to
to
remove
remove the starter.
starter.
6. Position
Position the starter
starter assembly to the
the
6.
flywheel housing, and start the
the
flywheel
mounting bolts.
bolts.
7. Snug
Snug all bolts, while holding the
the
7.
starter squarely against its mounting
mounting
starter
surface and fully inserted into the
the
surface
to
pilot hole. Torque the bolts to
specification.
8. Connect the starter cable and lower
8.
vehicle. Connect battery cable.
cable.
vehicle.
Pinto, Bobcat and
and Mustang
Mustang
Pinto,
Removal
Remoysl
1. Remove ground cable from battery.
1.
2. Raise car on hoist and remove four
four
2.
under
bolts retaining crossmember under
housing.
bell housing.
Jj 1085
loss- B
FIG.
FIG. 77 Starter Mounting-2300cc
Mounting2300cc
Mustang,
Mustang, Bobcat and Pinto
J1640-A
Mounting
FIG. 88 Starter Cable Mounting
Pinto, Bobcat and
2800cc V-6 Pinto,
Mustang
3. Remove the flex

flex coupling clamping
screw at attachment point to steering
gear.
4. Remove (3) three nuts and bolts that
attach steering gear to crossmember.
crossmember.
5.
5. Disengage steering gear from flex
coupling and pull steering gear down
to provide access to starter motor.
6.
6. Disconnect starter cable from motor.
7.
7. Remove starter motor attaching bolts
(3) and remove motor.
Insts//stion
Installation
1.
1. Position starter motor to engine and
hold firmly in place against mounting
surface, then install (3) attaching
bolts.
2. Install starter cable to motor.
3. Position steering gear splined shaft
shaft to
flex coupling and steering gear to
crossmember.
crossmember. (Observe
(Observe line on
coupling at flat on shaft.)
shaft.)
4. Install (3) attaching bolts and nuts to
steering gear and crossmember.
5. Install
Install clamping
clamping screw
screw to flex
coupling.
6. Install crossmember
crossmember using (4) bolts
and nuts. Lower car to floor.
7. Connect battery ground
ground cable.
OVERHAUL
Disassembly
Dissssembly
Use the following procedure when it

necessary to completely
completely
becomes necessary
overhaul the starter. Figs. 9 and 10
illustrate a disassembled starter.
1.
1. Loosen
Loosen the brush
b r u s h cover
cover band
band
retaining screw and remove the brush
cover band and the starter
starter drive
plunger lever cover. Observe the lead
STARTER DRIVE
PLUNGER LEVER
PLUNGER RETURN
SPRING
^""*-
COVER
2.
3.
4.
r#
5.
6.
~
/@
BUSHING
7.
8.
~-
DRIVE END HOUSING
STARTER
DRIVE
STARTER DRIVE
<
,@
~
-----
1 (-,
/
~_-.
WASHER
WASH ER
---...J
GASKET
=-
POLES
J1644-B
J1644-B
FIG. 9 Positive Engagement Starter DisassembledExcept

Disassembled-Except 2800 V-6 Engines
BACK TO GROUP INDEX
9.
posItIons for assembly

assembly and
and then
positions
commutator brushes from
remove the commutator
the brush holders.
through bolts, starter
Remove the through
drive end housing, and the starter
plunger lever return
return spring.
drive plunger
retaining the
Remove the pivot pin retaining
starter gear plunger
plunger lever and remove
starter
the lever and the armature.
Remove the
the stop
stop ring
ring retainer.
Remove
Remove and
and discard
discard the stop
stop ring
retaining the starter
starter drive gear
gear to the
end of
of the armature
armature shaft,
shaft, and
and remove
the starter
starter drive gear
gear assembly.
Remove the brush
brush end
end plate.
Remove the two screws retaining
retaining the
ground
ground brushes to the frame.
On
On the field coil that
that operates
operates the
starter
starter drive
drive gear
gear actuating
actuating lever,
bend
bend the
the tab
tab up on
on the
the field coil
retaining sleeve
sleeve and
and remove
remove the
retaining
sleeve.
Remove
Remove the
the three
three coil
coil retaining
screws, using Tool
Tool 10044-A
l0044-A and
and an
an
arbor
arbor press (Fig. 11). The
The arbor
arbor press
prevents
the wrench
wrench from
from slipping
slipping out
out
prevents the
of
of the screw. Unsolder
Unsolder the
the field
field coil
coil
leads from
from the
the terminal
terminal screw, and
and
remove
remove the pole
pole shoes
shoes and
and coils
coils from
the frame. Use a 300-watt
300-watt iron.
Cut (or
(or unsolder)
unsolder) the
the insulated
insulated brush
brush
Cut
28-02-5
9. Replace starter drives and ring gears

9.
with milled, pitted or broken teeth or
evidence of inadequate engagement
(Fig. 13).
(Fig.
Assembly
Assembly
1.
1. Install the starter terminal, insulator,
washers, and retaining nut in the
frame (Fig.
(Fig. 14).
14). Be sure to position
the slot in the screw perpendicular to
the frame end surface.
STARTER DRIVE
PLUNGER LEVER
GROUND
BRUSH
FIELD COILS
~ I
k~FIELD
GROUND
BRUSH
BUS:~NG ~
FRAME
~_ ~
l i "~
I
@~
~ ~
'-~~_.~~
BRUSH
END
~ 1~~~E
BRUSH
DRIVE
DRIVE
END
HOUSING
BRUSH.C.OVER
/BAND
/-:7:
FIELD
~- ~
~-
BRUSH COVER
BRUSH
BUSHING
-~
<./
~ ~
THROUGH
@'~OLT
\
ri
Mr*
C.
~CO'L
COIL RETAINING FLANGE
A
j
~* ^
~~COIL
COIL RETAINING SLEEVE
RETAINING SLEEVE
oj
r ~~o
DRIVE
'~JI
THRUST
WASHER
POLE SHOES
POLE
SHOES
J1646-A
J1646A
Disassembled2800 V-6 Engines

FIG. 10 Positive Engagement Starter Disassembled-2800
oo/-70044-A
001-10044-A
USE Arbor
Arbor Press
Press TO HOLD
Tool IN SCREW SOCKET
and the two bearings for scoring and

wear. If the commutator is
excessive wear.
rough, or more than 0.005 inch outof-round, turn it.
Dial
Indicator
Dial Indicator
ROTATE
ARMATURE SHAFTS
O N BEARING SURFACES
BE SURE
IN SCREW SOCKET
"V"
JJ1059-D
1059D
FIG. 11
11 Pole Shoe Screw Removal
leads from the field

field coils, as close to
the field
field connection point as
as possible.
possible.
10.
10. Remove
Remove the
the starter
starter terminal
terminal nut,
nut,
washer, insulator and terminal from
the starter frame. Remove any excess
solder from the terminal slot.
Cleaningand
andInspection
Inspection
Cleaning
1. Use a brush or air to clean the field
field
1.
commutator,
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. 12).
12). Inspect the armature shaft
(Fig.
BACK TO GROUP INDEX
28-02-5
Blocks
J1091-C
FIG. 12 Commutator Runout Check
5. Check the brush holders for broken

springs and the insulated brush
holders for shorts to ground. Tighten
loose. Replace
any rivets that may be loose.
1/4 inch in
the brushes if worn to 1/4
length.
6. Inspect the field
6.
field coils for burned or
broken insulation and continuity.
7. Check the field
7.
field brush connections
and lead insulation. A brush kit and
available. All other
a contact kit are available.
assemblies are to be replaced rather
than repaired.
8. Examine the wear pattern on the
8.
starter drive teeth. The pinion teeth
must penetrate to a depth greater than
1/2 the ring gear tooth depth (Fig.
13), to eliminate premature ring gear
failure.
and starter drive failure.
2.
2. Position the coils and pole pieces,
with the coil leads in the terminal
screw slot, and then install the
(Fig. 11).
11). As the pole
retaining screws (Fig.
shoe screws are tightened, strike the
frame several sharp blows with a softfaced hammer to seat and align the
shoes, then stake the screws.
pole shoes,
3. Install the solenoid coil and retainer
and bend the tabs to retain the coils
to the frame.
frame.
4.
field coils and solenoid
4. Solder the field
wire to the starter terminal using
rosin core solder. Use a 300-watt iron.
5.
5. Check for continuity and grounds in
the assembled coils.
6. Position the new insulated field
6.
terminal.
brushes lead on the field
field coil 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
14). Use a 300-watt iron.
solder (Fig. 14).
7.
7. Position the solenoid coil ground
terminal over the nearest ground
screw hole.
8. Position the ground brushes to the
8.
starter frame and install the retaining
(Fig. 14).
screws (Fig.
9. Position the starter brush end plate to
9.
the frame with the end plate boss in
the frame slot.
10. Apply
Apply aa thin
thin coating
coating of
of Lubriplate
Lubriplate
10.
777 on the armature shaft splines.
Install the starter motor drive gear
assembly to the armature shaft and
ring. Install a new
install a new stop ring.
stop-ring retainer.
11. Position the fiber thrust washer
(except molded
commutator
(except
molded commutator
armatures) on the commutator end of
of
the armature shaft and position the
frame.
armature in the starter frame.
12. Position
Position the
the starter
starter drive
drive gear
gear plunger
plunger
12.
lever to the frame and starter drive
assembly, and install the pivot pin.
13. Partially
Partially fill
fill the
the drive
drive end
end housing
housing
bearing
b e a r i n g bore
b o r e with
w i t h grease
grease
1/4 full). Position the
(approximately 1/4
starter drive plunger lever return
spring and the drive end housing to
the frame and install and tighten the
(55 to
through bolts to specification (55
in-lbs.). Do not pinch the brush
75 in-Ibs.).
leads between the brush plate and the
frame. Be sure that the stop ring
retainer is seated properly in the drive
housing.
housing.
28-02-6
28-02-6
28-02-6
28-02-6
Positive
Positive Engagement
Engagement Starter
Starter
MILLED
MILLED CONDITION.
CONDITIONEXCESSIVE
EXCESSIVE WEAR
WEAR ON
ON
22OR
OR33TEETH
TEETH
MILLED
MILLED TOOTH.METAL
TOOTH-METAL
BUILD.UP
BUILD-UP WILL
WILL NOT
NOT
PERMIT
PERMIT ENGAGEMENT
ENGAGEMENT
NORMAL WEAR
WEAR PATTERN
PATTERN
NORMAL
SMALL WEAR
WEAR PATTERN
PATTERN
SMALL
MILLED
GEARS
MILLED GEARS
J 1372-A
1372-A
J
FIG. 13
13 Pinion
Pinion and
and Ring
Ring Gear Wear Patterns
FIG.
14. Install
Install the
the brushes
brushes in
in the
the brush
brush
14.
holders. Be
Be sure
sure to
to center
center the
the brush
holders.
brush
springs on
on the
the brushes.
springs
brushes.
15. Position
Position the
the drive
drive gear
gear plunger
plunger lever
lever
IS.
cover on
on the
the starter
starter and
and install
install the
cover
the
brush cover
cover band
gasket.
brush
band with
with a
a gasket.
Tighten the
the band
Tighten
band retaining
retaining screw.
screw.
16. Check
Check the
the starter
starter no-load
no-load current
current
16.
draw.
draw.
Starter
Replacement
Starter Drive
Drive Replacement
1.
1. Loosen
Loosen and
and remove
remove the
the brush
brush cover
cover
band
band and
and the
the starter
starter drive
drive plunger
plunger
lever
9 and
and 10).
10).
lever cover
cover (Figs.
(Figs. 9
2.
2. Loosen
Loosen the
the through
through bolts
bolts enough
enough to
to
allow
allow removal
removal of
of the
the drive
drive end
end
housing
housing and
and the
the starter
starter drive
drive plunger
plunger
lever
lever return
return spring.
spring.
3.
3. Remove
Remove the
the pivot
pivot pin
pin retaining
retaining the
the
starter
starter drive
drive plunger
plunger lever
lever and
and
remove
remove the
the lever.
lever.
4.
4. Remove
Remove the
the drive
drive gear
gear stop
stop ring
ring
retainer
retainer and
and stop
stop ring
ring from
from the
the end
end of
of
the
the armature
armature shaft
shaft and
and remove
remove the
the
drive
drive gear
gear assembly.
assembly.
5.
Apply
5. Apply aa thin
thin coating
coating of
of Lubriplate
Lubriplate
777
777 on
on the
the armature
armature shaft
shaft splines.
splines.
Install
Install the
the drive
drive gear
gear assembly
assembly on
on the
the
armature
armature shaft
shaft and
and install
install aa new
new stop
stop
ring.
ring.
6.
6. Position
Position the
the starter
starter gear
gearplunger
plungerlever
lever
on
on the
the starter
starter frame
frame and
and install
install the
the
pivot
pivot pin.
pin. Be
Be sure
sure that
that the
the plunger
plunger
lever
lever properly
properly engages
engages the
the starter
starter
drive
drive assembly.
assemmbly.
7.7. Install
Install aa new
new stop-ring
stop-ring retainer.
retainer.
BACK TO GROUP INDEX
GROUND B R U S H ^ : g j |
STARTER DRIVE \ , ^ f t f
ACTUATING COIL % Y>
AND HOLDING
*%W'
COIL "*
GROUND BRUSH
JT"
TERMINAL
* SCREW
I. \
FIELD
COIL
J 1092E
J1092-E
FIG.
FIG. 14
14 Field
Field Coil
Coil Assembly
Assembly
Partially
Partially fill
fill the
the drive
drive end
end housing
housing
bbearing
e a r i n g bbore
o r e wwith
i t h ggrease
rease
(approximately
(approximately 1/4
1/4full).
full). Position
Positionthe
the
starter
starter drive
drive plunger
plunger lever
lever return
return
spring
spring and
and drive
drive end
end housing
housing to
to the
the
starter
starter frame,
frame, and
and then
then tighten
tighten the
the
through
through bolts
bolts to
to specifications
specifications (55
(55 to
to
75
75 in-lbs.).
in-Ibs.).
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.
Brush Replacement
Replace the starter
starter brushes
brushes when
when they
1/4 inch. Always install aa
are worn to 1/4
complete set of
of new
new brushes.
brushes.
brush cover
cover
1. Loosen and remove the brush
band, gasket,
gasket, and
and starter
starter drive
drive
band,
pI unger lever
lever cover.
cover. Remove
Remove the
the
plunger
brushes from
from their
their holders.
holders.
brushes
2. Remove
Remove the
the two
two through
through bolts
bolts from
from
2.
the starter
starter frame.
frame.
the
3. Remove
Remove the
the drive
drive end
end housing,
housing, and
and
3.
the plunger
plunger lever
lever return
return spring.
spring.
the
4. Remove
Remove the
the starter
starter drive
drive plunger
plunger
4.
lever pivot
pivot pin
pin and
and lever,
lever, and
and remove
remove
lever
the armature.
armature.
the
5. Remove
Remove the
the brush
brush end
end plate.
plate.
5.
6. Remove
Remove the
the ground
ground brush
brush retaining
retaining
6.
screws from
from the
the frame
frame and
and remove
remove the
screws
brushes.
brushes.
Cut the
the insulated
insulated brush
brush leads
leads from
from
7.7. Cut
the field
field coils,
coils, as
as close
close to
to the
thefield
field
the
connection point
point as
as possible.
possible.
connection
Clean and
and inspect
inspect the
the starter
starter motor.
motor.
8.8. Clean
Replace the
the brush
brush end
end plate
plate ifif the
the
9.9. Replace
insulator between
between the
the field
field brush
brush
insulator
holderand
andthe
theend
endplate
plateisiscracked
crackedor
or
holder
broken.
broken.
10. Position
Position the
the new
new insulated
insulated field
field
10.
brushes lead
lead on
on the
the field
field coil
coil
brushes
connection. Position
Position and
and crimp
crimp the
the
connection.
thebrushes
brushesto
tohold
hold
clipprovided
providedwith
withthe
clip
the brush
brush lead
lead to
to the
the connection.
connection.
the
28-02-7
Solder the lead, clip, and connection
together, using rosin core solder (Fig.
14). 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
16. Partially fill the drive end housing
bbearing
e a r i n g bbore
o r e with
w i t h grease
grease
(approximately 1/4
return spring on the plunger lever,
and the drive end housing to the
starter frame. Install the through
bolts and tighten to specified
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
commutator brushes in the
Center the brush
brush holders. Center
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.
Armature Replacement
1. Loosen
Loosen the
t h e brush
b r u s h cover
cover band
band
1.
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.
BACK TO GROUP INDEX

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.
bearing
b e a r i n g bore
b o r e with
w i t h grease
grease
(approximately 1/4
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
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.
Starter Terminal
Removal
Removal
1. Loosen
Loosen the brush
b r u s h cover
cover band
band
1.
starter drive
cover band and the starter
plunger lever cover. Observe the lead
positions for assembly and then
commutator brushes from
from
remove the commutator
the brush holders.
2. Remove the through bolts, starter
drive end housing, starter
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.
28-02-7
4. Unsolder the field coil and solenoid
wire leads from the terminal screw.
Use a 300-watt
3OO-watt soldering iron.
5. Remove the starter
starter terminal nut,
from
washer, insulator and terminal from
the starter frame.
frame.
Ins/a//a/ion
Installation
1.
1. Install the new starter
starter terminal,
insulator, washers, and retaining nut
in the frame (Fig. 9). Be sure to
position
position the slot
slot in the screw
screw
perpendicular to the frame
perpendicular
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
bearing
b e a r i n g bore
b o r e with
w i t h grease
grease
(approximately 1/4
starter drive plunger lever return
spring and the drive end housing to
the frame and install and tighten the
through bolts to specification
specification (55 to
75 in-Ibs.).
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 screw.
10. Check the starter no-load current
draw.

28-02-8
28-02-8
SPECIFICATIONS
STARTER
Dia.
Dia.
(Inches)
Positive Engagement Starter Motor

Normal
Min.
Current Draw
Engine
Stall
Max.
Under Normal Cranking
Torque
load
Load
@5
(Amps)
load
Speed
Speed
@5 Volts
Load
(Amps)
(rpm)
(Ft-Lbs)
Starter Brushes
No.
load
Load
(Amps)
Mfg.
length
Length
(Inches)
Wear
limit
Limit
(Inches)
(Inches)
Spring
Tension
(Ounces)
1802~0
70
90
460
050 - - f - -0.25
180 250
70
40
9.0
-----1150-290
~O- 290
15.~
670
80
050
15.5
80
0.25
80
M(JXIr11LJrn
voltage drop
drop (battery
(battery positive terminal
terminal to
to starter
M a x i m u m COnllT1Llld!Of
Commutator fl!f)()lJt
runout IS
is 0005
0.005 /[lch
inch. Maximum
M a x i m u m starting circuli
circuit voltage
terminal)
terminal) (jt
at 110lll1dl
nnimal fmljlrle
nnqme tell1perdtLJre
temperature IS
is 05
0.5 volt
volt.
44
4-1/2
4-1/2
l~D 200
150 180
----- - f - - - 150-200
SPECIAL TOOLS
Ford
Ford Tool No.
TOOL 10044 A
55- 75
55-75
55-75
55-75
Mounting
Bolt Torque
(FtLbs)
(Ft-Lbs)
15-20 - 15-20
BACK TO GROUP INDEX
Through
Bolt
Torque
(InL
bs)
(In
Lbs)
Former No.
10044-A
Description
Generator Pole
Screw Wrench
CJ1430-C

28-03-1
28-03-1
Solenoid Actuated Starter

i
PART 28-03 Solenoid Actuated Starter

This Information Applies to All 460 C.I.O.
CJ.D. Engines
Page
COMPONENT INDEX
COMPONENT INDEX
Page
Bench Tests .......................

OPERATION
Description ........................
03-1
03-1
Operation .........................
03-2
TESTING
03-4

INSTALLATION
So leno id Actuated Starter ............
Solenoid
03-4
OVERHAUL
OVERHAUL
Road Service ......................
03-2
On-Vehicle Testing ..................
03-3
. ...........
03-5
SPECiFiCATIONS
03-7
NOTE:
Inodel year vehicles unless otherNOTE: The information in this Part applies to both 1975 and 1976 model
specified.
wise specified.
CR1966-A
CR1966-A

DESCRIPTION
Starter
Major assembly components of the
frame
solenoid actuated starter are the frame
and field coil assembly, armature
armature
assembly, brush plate assembly, drive
assembly, shift lever assembly, drive
housing assembly and starter solenoid
(Fig. 1).
assembly (Fig.
is aa four-brush, four-field,
four-field,
The motor is
unit.
four-pole wound unit.
is mounted to
The solenoid assembly is
on the
the starter
starter drive
drive housing.
housing. The
The
aaflange
flange on
entire shift lever mechanism and the
solenoid plunger are enclosed in the drive
from
housing, thus protecting them fronl
exposure to dirt and road splash.
A metal heat shield protects the
A
solenoid from heat radiated by the
exhaust pipe and manifold. Without this
shield, plastic .parts of the solenoid
could be damaged by excessively high
temperatures, and the solenoid could
fail.
fail.
Always install a heat shield whenever
aa starter
starter has
has been
been removed and repaired
or replaced, or whenever the shield has
fallen off or has been damaged.
damaged.
The solenoid incorporates two
windings:
windings: aa pull-in winding and hold-in
winding. Together they provide the
magnetic attraction to pull the solenoid
plunger into the solenoid.
solenoid.
BACK TO GROUP INDEX
SOLENOID
SOLENOID TERMINAL
HEAT SHIELD
BATTERY
TERMINAL
SHIFT FORK
PINION
BRUSH-
OVER-RUNNING
OVERRUNNING CLUTCH
J1414-B
J1414B
FIG. 1 Starter-Cross
StarterCross Section
FIG.

28-03-2
OPERATION
Solenoid
Engine cranking occurs when the
solenoid on the starter is energized
through the starter control (ignition)
switch. When energized, the solenoid
shifts the starting motor pinion into mesh
with the engine flywheel ring gear.
of
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
lever to disengage the starter drive from
the engine flywheel ring gear.
The starting motor is protected from
short duration excessive speed by an
overrunning clutch incorporated in the
drive. The overrunning clutch
starter drive.
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.
engine.
Connector
Link
Con
nector Li
nk
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
function is handled by
starter, this function
contacts in the solenoid. In vehicle
production, however, a starter relay is
installed on vehicle lines with either type
of starter. This simplifies vehicle building
in the assembly plants.
The solenoid actuated starter is
installed in vehicles with a starter relay,
is installed on
a special "connector link" is
the solenoid (Fig.
(Fig. 3).
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
current operates the solenoid and then
the starter through solenoid internal
contacts.
When replacing starters or starter
solenoids, be sure to replace the link. If
If
a link is
is not used on aa starter relay
equipped vehicle, the vehicle will not
start.
28-03-2
SOLENOID LINK
BATTERY
r l---
I+
STARTER RELAY
TO
IGNITION
COIL
STARTER
START SWITCH AND SAFETY

SWITCHES IN CLOSED
POSITION*
POSITION"
(PINTO, MAVERICK)
MAVERICK)
"SEE VEHICLE WIRING DIAGRAMS BOOK
J1642-B
FIG. 2 Starter Circuit-With

CircuitWith Starter Relay
LINK
/-----.~
.......
STARTER
WITH
RELAY
J1641-C
FIG. 3 Solenoid Connector Link

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.
slowly. If the starter does
BACK TO GROUP INDEX
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
positive-to-positive
a booster battery; positive-to-positive
and negative-to-negative connection of
the auxiliary cables.
28-03-3
28-03-3
ON VEHICLE
VEHICLE TESTING
Starter Cranking Circuit Test

These tests will determine whether or
not there is excessive resistance in the
cranking circuit. Make each test
4. While
connection as shown in Fig. 4.
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).
range). Maximum allowable voltage drop
should be:
CONNECTIONS FOR TESTS 1,2,3

1,2,3 AND 4
VOLTMETER
POSITIVE LEAD
VOLTMETER
NEGATIVE LEAD
STARTER
J1413-B
J1413-B
FIG. 4 Starter Cranking Circuit Test

FIG.

battery positive terminal (Fig. 4,
connection 1).
battery terminal of
of the starter
starter
solenoid (Fig.
(Fig. 4,
4, connection 2).
lead connected to the battery terminal
of the starter solenoid and the positive
lead connected
connected to the positive
terminal of the battery (Fig. 4,
connection 3).
4. 0.1
lead connected
ti ve
connected to the nega
negative
terminal of the battery and the
positive lead connected to the engine
ground (Fig.
(Fig. 4,
4, connection 4).
Starter Load
Load Test
Connect the test equipment as shown
in Fig. 5.
5. Be sure that no current is
flowing through the ammeter and heavyduty carbon pile rheostat portion of the
c i r c u i t (rheostat
( r h e o s t a t at maximum
maximum
circuit
Crank the engine with the ignition
OFF, and determine the exact reading on
OFF,
the voltmeter. This test is accomplished
by disconnecting and grounding the high
tension lead from the
the ignition coil,
coil, and
tension
by connecting a jumper from the battery
the starter
starter solenoid to the
terminal of the
ignition switch "S"
" S " terminal of the
solenoid.
BATTERY STARTER TESTER
CARBON PILE RHEOSTAT
VOLTMETER
AMMETER
POSITIVE LEAD
REMOTE CONTROL
STARTER SWITCH
'------=--'-'-"'--'-=..:.~~/_-__:ii_
TO IGNITION SWITCH
Red- Blue
STARTE R
J1415-B
FIG. 5 Starter Load Test

FIG.
BACK TO GROUP INDEX

28-03-4
Actuated Starter
Starter
Solenoid Actuated
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.
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
Starter No-Load Test
This test will uncover such faults as
open or shorted windings, rubbing
armature, and bent armature.
shown
Make the test connections as shown
starter will run at no load.
in Fig. 6. The starter
that no current
current is flowing
Be sure that
through the ammeter
ammeter (rheostat
(rheostat at
through
maximum counterclockwise
Determine the exact reading on the
voltmeter.
Disconnect the starter
starter from
from the
Disconnect
of the
battery, and reduce the resistance of
rheostat until the voltmeter
voltmeter indicates the
same reading as that obtained while the
starter was running. The ammeter will
will
indicate the starter no-load current draw.
Armature Open Circuit Test
circuit armature
armature may
An open circuit
sometimes be detected by examining the
A
commutator for evidence of burning. A
spot burned on the commutator is caused
formed every time the
by an arc formed
28-03-4
28-03-4
commutator segment, connected
connected to
to the
the
commutator
circuit windings,
windings, passes
passes under
under aa
open circuit
brush.
brush.
Armature and Field Grounded
Circuit Test
Circuit
test will
will determine ifif the
the winding
winding
This test
insulation has failed,
failed, permitting
permitting aa
insulation
cond uctor to touch
touch the
the frame
frame or
or
conductor
armature core.
core.
determine if
if the
the armature
To determine
armature
windings are
are grounded,
grounded, make
make the
windings
If the volt
volt
connections as shown in Fig. 7. If
meter indicates any voltage, the windings
are grounded.
Grounded field
field windings can
can be
be
Grounded
detected by making the connections as
as
shown in Fig. 8. If
If the voltmeter
voltmeter indicates
field windings are
any voltage, the field
grounded.
BATTERY
STARTER
TESTER
BATTERY STARTER TESTER
~.-.'-'~
~.".' p,.".'.'.
~r:~~~~j
~
..... t. . . . . . .
"t
c=l.: l~l -
------ARE-T6:31
BENOi
BENCH TEST
TEST
J1417-A
J1417A
J1416-B
FIG.
FIG. 66 Starter No-Load
No-Load Test on
on Test
Bench
Bench
FIG. 7 Armature Grounded Circuit

FIG.
Test
J1418-A
J1418A
FIG. 8 Field Grounded Circuit Test
INSTALLATION
SOLENOID ACTUATED STARTER
SOLENOID
Removal
RemoJ'sJ
1.1. Disconnect the
the battery ground cable,
cable,
raise the
the vehicle
vehicle on
on aa hoist.
hoist.
and raise
2. Disconnect the
the cable and wires
wires at the
2.
terminals on
on the
the solenoid.
solenoid.
terminals
3. On Thunderbird and Continental
Continental
3.
Mark IV-loosen
IVloosen the
the two
two front brace
Mark
attaching bolts.
bolts. Remove all other
other
attaching
brace attaching
attaching bolts
bolts and
and allow
allow brace
brace
to hang.
hang.
to
4. Turn
Turn the
the front wheels
wheels fully to
to the
the
4.
right. Remove
Removethe
thetwo
twobolts
boltsattaching
attaching
right.
the
the steering
steering idler
idler arm
arm to
to the
the frame.
frame.
BACK TO GROUP INDEX
5. Remove the starter mounting bolts

5.
and
and remove
remove the
the starter
starter assembly.
assembly.
Instlll/stion
Installation
1.
1. Position
Position the
the starter
starter assembly
assembly to
to the
the
starter
starter mounting
mounting plate
plate and
and start
start the
the
mounting bolts.
bolts.
2.
2. Snug the starting motor mounting
bolts while holding the starter
starter
squarely against the mounting surface
surface
and fully inserted into the pilot hole.
hole.
Torque the mounting bolts to
to 15
15toto20
20
ft.-Ibs.
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.
95
4. Install and tighten the brace attaching
4.
b o l t s on Thunderbird
T h u n d e r b i r d and
and
bolts
Continental Mark IV models.
5. Install the steering idler arm bracket
5.
to the car frame. Tighten the bolts to
28 to
to 35
35 ft-Ibs
ft-lbs torque,
torque, lower
lower the
the
28
vehicle, and connect the battery
ground cable.
28-03-5
28-03-5

LINK
'J1434-B
FIG. 9 Starter Cable Connections
OVERHAUL
SOLENOID
Disassembly
Disassembly
1. Disconnect the copper strap from the
1.
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
starter
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.
5. Remove the solenoid plunger and
shift
shift fork assembly. If either the
plunger or fork is to be replaced, they
can be separated by removing the roll
pin.
6.
6. Remove the armature and drive
assembly from the frame. Remove the
drive stop ring and slide the drive
assembly off
off the armature shaft.
7.
7. Remove the drive stop ring retainer
from the drive housing.
Cleaning and Inspection

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

2.
broken or burned insulation and
unsoldered connections.
3. Check the armature for open circuits
and grounds.
ASSEMBLY-11390
SOLENOID ASSEMBLY
-11390
BRUSH END PLATE

ASSEMBLY-11049
BAUSHSPAIN~
~ ~~J
........
"'A"
...
LINK
I)
~BUSHING'1~
BRUSH END PLATE
"
BRUSH COVER
BAND-11126
PLUNGER 11393
ST~R FRAME
/'
A~E
THAUST,
WASHER-11036
/
SOLENOID LINK
INSTALLED
AAMAT~5
IfIIP
/,
FIELD COLL
ASSEMBLY11082
SHIFT FOAKOll061_A
FORK-11067
DRIVE ASSEMBLY
OAIVEASSEMBLY
-11350
11350
-~I
SEAL
~"@O
~
...
DRIVE STOP RING-11222

DRIVESTOPRING-11222/'/
I~
DRIVE STOP RING RETAINER

-11223
WASHER-11036
DRIVE PINION THRUST WASHER11036
POLE SHOE RETAINING

SCREW-11415
J1403E
J1403-E
FIG. 10 Starter Disassembled
BACK TO GROUP INDEX

28-03-6
28-03-6
4. Check the commutator for runout

11). Inspect the armature shaft
(Fig. 11).
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
of
If the
commutator is rough, or more than
0.005 inch out-of-round, turn it down.
Dial Indicator
ROTATE
ARMATURE SHAFTS
O N BEARING SURFACES
"V" Blocks
Jl091-CJ1091-C-
FIG. 11
11 Commutator Runout Check
5.
5. Check the brush holders for broken
springs and the insulated brush
holders for shorts to ground. Tighten
loose. Replace
any rivets that may be loose.
the brushes if worn to 1/4
1/4 inch in
length.
6.
6. Check the brush spring tension.
Replace the springs if the tension is
not within specified limits (80 ounces
minimum).
minimum).
7.
7. Inspect the field
field coils for burned 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
8.
starter drive teeth. The pinion teeth
must penetrate to a depth greater than
1/2 the ring gear tooth depth (Fig.
1/2
12), to eliminate premature ring gear
failure.
and starter drive failure.
9. Replace starter drives and ring gears
9.
with milled, pitted or broken teeth or
evidence of inadequate engagement
(Fig.
(Fig. 12).
Assembly
Assembly
1. Install a small amount ofLUbriplate
of Lubriplate
1.
splines. Install
on the armature shaft splines.
the drive assembly on the armature
shaft and install a new stop ring (Fig.
10).
2.
a small amount o(Lubriplate on
2. Apply
ApplyasmallamountofLubriplateon
the shift lever pivot pin.
pin:-Position
Position the
shift lever
solenoid plunger and shift
assembly in the drive housing.
3. Place a new retainer in the drive
housing. Apply a small amount of
of
Lubriplate 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. Applya
Apply a small
small amount ofLubriplateon
of Lubriplate on
the commutator end of the armature
shaft.
5. Position the frame and field

field assembly
5.
to the drive housing. Be sure that the
frame is properly indexed to the drive
housing assembly.
6. Position the brush plate assembly to
6.
the frame assembly. Be sure that the
brush plate is properly indexed to the
frame. Install the through-bolts and
45 to 85
85 in-lbs.
tighten to 45
in-Ibs.
7. Place the brushes in their holders.
7.
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

8.
the solenoid mounting and the upper
outside surface of the frame. Position
the starter solenoid with metal gas (if
(if
used), and install the solenoid
mounting screws.
9. Connect the copper strap to the
9.
starter terminal on the solenoid.
10. Position
Position the
the cover
cover band
band and
and tighten
tighten
10.
the retaining screw.
MILLED CONDITIONEXCESSIVE WEAR ON

2 OR
OR 3 TEETH
MILLED TOOTH-METAL
BUILD-UP WILL NOT
PERMIT ENGAGEMENT
PATTERN
NORMAL WEAR PATTERN
SMALL WEAR PATTERN

PATTERN
MILLED GEARS
JJ 1372.A
1372-A
FIG. 12 Pinion and Ring Gear

Gear Wear
Wear Patterns
BACK TO GROUP INDEX

28-03-7
Brush
Brush Replacement
Replacement
Replace the starter brushes when they
are worn to 1/4 inch.
inch. Always install a
complete set of new
new brushes.
1.
1. Disconnect the copper strap from the
2.
2. Loosen the retaining screw and slide
the brush cover band back on the
starter frame for access to the
brushes.
brushes.
3.
3. Remove the commutator brushes
from their holders.
holders. Hold each spring
away from the brush with a hook,
while sliding the'
the brush out of the
holder.
holder.
4.
4. Remove the through-bolts and
separate the drive end housing,
housing, starter
frame and brush end plate assemblies.
5.
5. Remove the ground brush retaining
screws from
from the
the frame
frame and
and remove
remove the
the
brushes.
brushes.
6.
6. Cut the insulated brush leads from
the field coils,
coils, as
as close to the field
connection point as possible.
7.
7. Clean and inspect the starter motor.
8.
8. Replace the brush end plate, if the
insulator between the field brush
holder and the end plate is cracked or
broken.
9.
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.
iron.
10.
10. Install
Install the
the ground
ground brush
brush leads
leads to
to the
the
frame with the retaining screws.
11. Clean the commutator with 00 or 000
sandpaper.
12.
12. Apply
Applyaasmall
smallamount
amountof
ofLubriplate
Lubriplateon
on
the commutator end of the armature
shaft.
13.
13. Position
Position the
the rubber
rubber gasket
gasket over
over the
the
solenoid plunger lever, then position
the frame to the end housing so that
the frame clears the
the wide slot in the'
28-03-7
plunger lever and the end housing
dowel is indexed with its frame slot.
14. Position
Position the
the brush
brush plate
plate assembly
assembly to
to
the frame assembly. Be sure that the
brush plate is properly indexed to the
frame. Install the through-bolts,
making certain that the insulated
brush lead is not between
between the
brush
through-bolt and the frame, and
through-bolt
in-Ibs.
tighten to 45 to 85 in-lbs.
15. Place
Place the
the brushes in
in their holders.
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
prevent possible
components to prevent
shorts.
16. Slide
Slide the
the cover
cover band
band into
into position
position and
tighten the retaining screw.
17. Connect
Connect the
the copper
copper strap
strap to
to the
the
18. Connect
Connect the
the starter
starter to
to aa battery to
to
SPECIFICATIONS
STARTER
Bolt Torque
Solenoid Actuated Starter Motor
(Ft.L bs.)
Starter Brushes
(Ft.-Lbs.)
Through
5/16
5/16 in.
in.
Normal
Bolt Three
Bolt
Wear
Spring
Wear
Mfg.
Engine
No.
Current Draw
Hole Mfg.
Limit
Torque
Length
Tension
Under Normal
Cranking
Load
Oia.
Dia.
(Inches)
(InLbs)
(Inches)
Speed (rpm)
(In-Lbs)
(Inches)
(Amps)
(Ounces)
Load
Speed
Load (Amps)
(Inches)
@70F.
45-85
15-20
70
40
0.25
4-1/2
180-210
70
0.50
140-170
Maximum Commutator runout is
is 0.005 inch. Maximum starting circuit voltage drop (battery positive terminal to starter
MaximulTl
terminal) ell
at normal engine temperature is
is 0.5 volt.
terrnilHlI)
TOOLS
SPECIAL TOOLS
Ford Tool No.
Ford
10044-A
TOOL 10044-A
Former No.
10044-A
10044A
Description
Generator Pole
Screw Wrench
CJ 1452-B
1452-8
BACK TO GROUP INDEX

29-00-1
29-00-1
29-00-1
Engine Emission Control Systems
GROUP
Engine Emission Control

Systems
29
29
29-01
PART 29-01
General Service.
Service . . . . . . . . . . . . . . . . . . . .
PAGE
29-01-1
29-01-1
PART 29-07
EGR System
PAGE
29-07-1
29-07-1
PART 29-02
Engine Diagnosis and Service
29-02-1
29-02-1
PART 29-10
CTAV System
29-10-1
29-10-1
PART 29-03
Thermactor System
29-03-1
29-03-1
PART 29-01 Emission Systems General Service

COMPONENT INDEX
GENERAL INFORMATION
INFORMATION
Air Cleaner Temperature Switch
Cold Start Spark Advance (CSSA)
Cold Weather Modulator
Coolant Spark Control (CSC)
Delay Valve Bypass (DVB)
Dual Signal Spark
Advance (OSSA)
(DSSA)
Electric Assisted Choke
Page
.
.
.
.
.
01-7
01-2
01-6
01-2
01-4
.
.
01-3
01-1
01-1
COMPONENT INDEX
Page
Exhaust Heat Control Valve (HCV)

.
Electric Ported Vacuum Switch (PVS) . . .
Fuel Deceleration Valve
.
Identification
.
PCV Valve and Crankcase Vent Cap
.
Ported Vacuum Switches (PVS)
.
Spark Delay Valve (SDV)
.
Speed Modulated Fuel
Decel System
.
01-6
01-5
01-1
01-1
01-1
01-1
01-5
01-1
01-1
01-5
01-1
01-1
NOTE: The infonnatiol1

information in this Part applies to both 1975 and 1976 model year vehicles unless otherwise specified.
CR1966A
CR1966-A
INFORMATION
GENERAL INFORMATION
Emission Control
Control
The Engine Emission
of this Manual is
Systems section of
designed to cover those adjustments and
service operations required to meet
factory specifications for passenger cars.
General information
information for emission
reduction systems
systems and
and miscellaneous
miscellaneous
reduction
emission related parts will be covered in
Part 29-01,
29-01, while
while service
service for
for the
the various
Part
components
will be
carred in
in the
the
com
ponen ts will
be carred
individual Parts.
Parts. Engine
Engine Diagnosis
Diagnosis is
individual
is
covered in
in Part
Part 29-02.
covered
29-02.
IDENTIFICATION
Each passenger car is equipped with
a decal containing emission control data
specifically to that vehicle
that applies specifically
and engine. This data is critical to the
(Fig. 1).
servicing of the emission systems (Fig.
When performing services listed in
29-02, refer to this decal located
Part 29-02,
either on the engine or, in the case of
of
Pinto and Bobcat, on the inside front of
of
the engine compartment hood.
BACK TO GROUP INDEX
EMISSION-RELATED FUEL SYSTEM

COMPONENTS
Fuel Deceleration Valve
Deceleration
Deceleration valves are used to
provide enriched mixture on engine
(Figs. 2
deceleration with closed throttle (Figs.
and 3).
3). When this occurs with closed
throttle, the valve provides momentary
fuel/air flow, bypassing the carburetor.
fuel/air
The deceleration valve is used with two
Motorcraft 5200 2V
2V used
used
carburetors, the Motorcraft
used
on the 2.3L engine and the 2150 2V used
on the
the 2.8L V-6.
on
The deceleration valve has two ports
and a threaded base that attaches to the
manifold of the engine. The
intake manifold
operation of
of the
the valve
valve is
is controlled
controlled by
operation
application of
of vacuum
vacuum to
to the
the smaller
smaller of
application
of
the two
two side
side ports.
When the
the vacuum
vacuum is
the
ports. When
is
applied to
to the
the control
control port,
the valve
applied
port, the
valve
opens and
and pulls
fuel/air mixture
mixture from
from
opens
pulls aa fuel/air
the carburetor
carburetor deceleration
deceleration system
system into
into
the
the intake
intake manifold
manifold (Fig.
(Fig. 3).
the
3).
On the conventional system, control

vacuum is applied directly from the
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.
figure.
Speed Modulated Fuel Decel
Valve
On Mustang vehicles with the 2.8L
V-6 engine, the fuel deceleration system
(Fig. 4).
4). In this
is tied into vehicle speed (Fig.
from
way the system is prevented from
operating when the vehicle is in a
11 mph, and
deceleration mode below 11
allowed to operate when the vehicle is in
11 mph.
mph. The
a deceleration mode above 11
interlock is designed to prevent the
deceleration system from acting upon
11 mph.
engine idle speed below 11
Electric Assisted Choke

All passenger cars use an electricallyassisted choke thermostatic spring heater
29-01-2
Emission Systems General Service
...
VEHICLE EMISSION CONTROL INFORMATION 1
^ ^
ENGINE
ENGINE FAMILY
FAMILY
SPARK
PLUG
SPARKPLUG
. MAKE
MAKE ALL
ALL ADJUSTMENTS
ADJUSTMENTS WITH
WITH ENGINE
ENGINE AT NORMAL
NORMAL
OPERATING TEMPERATURES, A/C AND HEADLIGHTS OFF.
302
302 CATALYST EGR/AIR (2CMF)
302
302 CID
CID
ENGINE
ENGINE DISPLACEMENT
DISPLACEMENT CID
CID
ARF42
ARF42
CURB
IDLE-ADJUST
WITH
THROTTLE
SOLENOID
IDLE-ADJUST
ON, ALL
POSITIONER ENERGIZED, THERMACTOR AIR ON,
VACUUM HOSES CONNECTED AND AIR CLEANER IN
POSITION. WHENEVER CURB IDLE IS RESET,
RESET CHECK AND
ADJUST THE DECEL VALVE ACCORDING TO THE SERVICE
MANUAL.
.042-.046
.042.046
GAP
GAP
-DISTRIBUTOR-BREAKER
LESS
DISTRIBUTOR-BREAKERLESS
CHOKE
CHOKE HOUSING
HOUSING
MAN/TRANS
MAN/TRANS
NOTCH
NOTCH SETTING
SETTING
AUTO/TRANS
AUTO
NEUTRAL
NEUTRAL
TRANSMISSION
TRANSMISSION
RPM
RPM
MANUAL
NEUTRAL
0 BTDC
88BTDC
IGNITION
IGNITION TIMING
TIMING
TIMING
TIMING RPM
RPM
CURB
CURB IDLE
IDLE
33 RICH
RICH
AUTO
DRIVE
500
500
A/C
A/C
700
700
INO
NO A/C
A/C
INITIAL TIMING-ADJUST
TIMING-ADJUST WITH HOSES DISCONNECTED
AND PLUGGED AT THE DISTRIBUTOR.
DISTRIBUTOR.
IDLE
IDLE MIXTURE-ARTIFICIAL
MIXTURE-ARTIFICIAL ENRICHMENT
ENRICHMENT
RPM
RPM GAIN
GAIN
RPM
RPM RESET
RESET
IDLE MIXTURE-PRESET
MIXTURE-PRESET AT THE FACTORY, DO NOT
REMOVE THE LIMITER CAP(SI.
CAP(S). CONSULT THE SERVICE
MANUAL FOR DESCRIPTION OF ARTIFICIAL ENRICHMENT
METHOD OF IDLE MIXTURE ADJUSTMENT TO BE USED
ONLY DURING TUNE-UPS
TUNE UPS AND MAJOR CARBURETOR
REPAIRS.
REPAIRS. IDLE MIXTURE MUST BE
BE MEASURED WITH
THERMACTOR AIR OFF_
OFF.
15-80
15-70
|
j
"B"
"B"
THIS
THIS VEHICLE
VEHICLE REQUIRES
REQUIRES MAINTENANCE
MAINTENANCE SCHEDULE
REFERENCE TO
TO A/C,
A/C, THROTTLE SOLENOID, THERMACTOR AIR AND DECEL VALVE APPLICABLE ONLY IF THE
ENGINE
EQUIPPED.
IS
SO
SERVICE
CONSULT
IS
SO
PUBLICATIONS FOR FURTHER INSTRUCTIONS ON TIMING
AND IDLE SET.
THIS
VEHICLES_
THIS VEHICLE
VEHICLE CONFORMS
CONFORMS TO
TO U.S.E.P.A. REGULATIONS APPLICABLE TO 1975 MODEL YEAR NEW MOTOR VEHICLES.
THIS
THIS VEHICLE
VEHICLE ALSO
ALSO CONFORMS TO
TO THE STATE OF
OF CALIFORNIA CERTIFICATION STANDARDS APPLICABI.E
APPLICABLE TO 1975
MODEL YEAR NEW MOTOR VEHICLES.
929
VEHICLES.
D5DE-9C385-TA
FORD
FORD MOTOR
MOTOR COMPANY
COMPANY
D5DE 9C385TA
CALIFORNIA
PaR| VEHICLE
VEHICLE EMISSION CONTROL
CONTROL INFORMATION
INFORMATION
ENGINE
ENGINE FAMILY
FAMILY
302
302 "A"
" A " CATALYST EGR/AIR (1
(1 CEF)
ENGINE DISPLACEMENT
DISPLACEMENT CID
CID ..
ENGINE
SPARKPLUG
SPARK
PLUG
ARF-42
302
302 CID
IDLE-ADJUST
WITH
THROTTLE
SOLENOID
IDLE-ADJUST
CURB
ON, ALL
POSITIONER ENERGIZED, THERMACTOR AIR ON,
VACUUM HOSES CONNECTED AND AIR CLEANER IN
POSITION. WHENEVER CURB IDLE IS RESET, CHECK AND
ADJUST THE DECEL VALVE ACCORDING TO THE SERVICE
MANUAL.
GAP .042-.046
.042.046
GAP
CHOKE
CHOKE HOUSING
HOUSING
MAN/TRANS
MAN/TRANS
NOTCH SETTING
SETTflNG
NOTCH
AUTO/TRANS
TRANSMISSION
TRANSMISSION
AUTO
NEUTRAL
NEUTRAL
INDEX
INDEX
33 RICH
RICH
AUTO
DRIVE
550
TIMING RPM
RPM
TIMING
CURB IDLE
IDLE
CURB
RPM
RPM
MANUAL
NEUTRAL
0 BTDC
66BTDC
IGNITION TIMING
TIMING
IGNITION
A/C
A/C
900
NO A/C
INOA:C
INITIAL TIMING-ADJUST
TIMING-ADJUST WITH HOSES DISCONNECTED
AND PLUGGED AT THE DISTRIBUTOR.
DISTRIBUTOR.
10-100
10 100
10-60
TO A/C,
A/C, THROTTLE SOLENOID, THERMACREFERENCE TO
TOR AIR AND DECEL VALVE APPLICABLE ONLY IF THE
IS
SO
EQUIPPED.
EQUIPPED.
SERVICE
CONSULT
IS
SO
ENGINE
PUBLICATIONS FOR FURTHER INSTRUCTIONS ON TIMING
AND IDLE SET.
THIS VEHICLE
VEHICLE REQUIRES
REQUIRES MAINTENANCE
MAINTENANCE SCHEDULE
THIS
FORD MOTOR
MOTOR COMPANY
COMPANY
FORD
MIXTURE-PRESET AT THE FACTORY, DO NOT

IDLE MIXTURE-PRESET
CAP(S). CONSULT THE SERVICE
REMOVE THE LIMITER CAP(SI.
MANUAL FOR DESCRIPTION OF ARTIFICIAL ENRICHMENT
METHOD OF IDLE MIXTURE ADJUSTMENT TO BE USED
METHOL>
ONLY DURING TUNE-UPS
TUNE UPS AND MAJOR CARBURETOR
REPAIRS. IDLE MIXTURE MUST BE
BE MEASURED WITH
REPAIRS.
THERMACTOR AIR
AIR OFF.
OFF.
THERMACTOR
900
IDLE MIXTURE-ARTIFICIAL
MIXTURE-ARTIFICIAL ENRICHMENT
ENRICHMENT
IDLE
RPM
RPM GAIN
GAIN
RPM RESET
RESET
RPM
MAKE ALL ADJUSTMENTS WITH ENGINE AT NORMAL

OPERATING TEMPERATURES, A/C AND HEADLIGHTS OFF.
"A"
"A"
TO U.S.E.P.A. REGULATIONS
THIS VEHICLE CONFORMS TO
TO 1975 MODEL YEAR NEW MOTOR VEHICLES.
APPLICABLE TO
D5TE 9C485 AEA
D5TE-9C485-AEA
CANADA
948
A4056-B
FIG.l Typical Emission

Emission Control Decals-California,
DecalsCalifornia, 49 States and
FIG.1
Canada1975 Shown,
Shown, 1976 Similar
Canada-1975
as an aid to fast choke release and better

as
emission characteristics during engine
(Figs. 5 and 6).
6). The heaters are
warm-up (Figs.
types: temperature sensitive (all
of two types:
5200 2V)
2V) and constant operating
except 5200
2V). Both types operate from
from
(5200 2V).
current supplied from the center tap of
the alternator when the engine is running
(Fig.
7).
(Fig. 7).
The temperature sensitive electric
choke assist system consists of a choke
cap, thermostatic spring, a bibi-metal
cap,
metal
(switch), and a
temperature sensing disc (switch),
ceramic positive temperature coefficient
coefficient
heater. The current to operate the
(PTC) heater.
system isis supplied from the center tap of
the alternator to the temperature sensing
switch.
switch.
is grounded through a
The system is
BACK TO GROUP INDEX
ground strap connected to the carburetor

t e m p e r a t u r e s below
body. At temperatures
approximately 60 degrees F, the switch
is open and no current is supplied to the
ceramic heater located within the
t h e r m o s t a t i c spring.
s p r i n g . Normal
Normal
thermostatic
thermostatic spring choking action then
temperatures above
occurs. At temperatures
approximately 60 degrees F, the
approximately
temperature sensing switch closes and
current is supplied to the ceramic heater.
As the heater warms, it causes the
thermostatic spring to pull the choke
1-1/2 minutes.
plates open within 1 to 1-1/2
The electric assist choke system used
on the 5200 2V carburetor is installed
between the choke thermostatic spring
and the choke casting and heats
whenever the engine is running.
29-01-2
EMMISION RELATED SPARK
CONTROL COMPONENTS
Ported Vacuum Switches
Switches (PVS)
These switches are used in several
places in emission control and other
of twoengine systems. They consist of
three- or four-port coolant temperature
A
operated vacuum switching devices. A
typical three-port PVS is used in the
cooling system to increase engine idle
8).
rpm when the engine overheats (Fig. 8).
When cold, the 3-port PVS provides
a path through the top and center ports.
When hot, only the center and bottom
ports are connected. In the case of the
cooling PVS, this provides carburetor
venturi vacuum to the distributor
vacuum advance under normal (cool)
conditions and switches to engine
manifold vacuum for increased idle speed
when the engine is abnormally hot. As
ofT, carburetor
soon as the engine cools off,
venturi vacuum is once again selected
and the idle speed decreases as the spark
is retarded again.
Cooling PVS-Vent Retard System
The cooling PVS-Vent Retard System
distributor retard spark
switches the distributor
signal from intake manifold
manifold vacuum to
specified coolant
atmosphere at a specified
temperature (Fig. 9).
Coolant Spark Control (CSC)

System
The Coolant Spark Control (CSC)
System is used to prevent distributor
vacuum advance when the engine is
below a specified operating temperature.
When the engine
engine is below
below this
When
distributor vacuum
temperature, the distributor
advance diaphragm
diaphragm is vented
vented to
atmospheric pressure, preventing
atmospheric
advance (Fig. 10).
Cold Start Spark Advance
(CSSA)
On some engines, a Cold Start
Start Spark
Advance System (CSSA) is added to the
ADJUSTER
A4075-A
FIG.
FIG. 2 Adjustable Fuel Deceleration
Valve
29-01-3
distributor spark control system (Fig.
11
).
11).
This system provides intake manifold
vacuum to the distributor spark advance
diaphragm when the engine coolant
temperature is below 125
1250 F. The
vacuum path is from the intake manifold
tap, through the Distributor
Distributor Retard
Control Valve (DRCV), through the
CSSA PVS
PVS and to the distributor.
At 125
1250 F.
F. and above,
above, the CSSA PVS
is operated. Vacuum then reaches the
distributor as follows: from
from the
distributor
carburetor
carburetor spark port, through the
cooling PVS,
PVS, through the SDV, through
PVS and to the distributor.
the CSSA PVS
Above 235
2350 F., the cooling PVS
operates, directing intake manifold
manifold
vacuum to the distributor through the
SDV and CSSA PVS. In an overtemperature situation at idle, this will
increase engine rpm by providing
increased vacuum. When the engine
temperature decreases, spark will once
more be controlled from the spark port
of the carburetor.
Dual Signal Spark Advance
(OSSA)
(DSSA) System
vance
The Dual Signal Spark Ad
Advance
(DSSA) System uses a spark delay valve
(SDV) and a one-way check valve to
EGR
provide improved spark and EG
R
function during mild acceleration (Fig.
12).
12).
The check valve prevents spark port
vacuum from reaching the EGR valve
and causing excessive EGR valve flow. It
also prevents EGR port vacuum from
diluting spark port vacuum, which could
result in improper spark advance due to
weakened signal. The SDV permits
application of full EGR vacuum to the
distributor vacuum advance diaphragm
during mild acceleration. During steady
speed or cruise conditions, EGR port
vacuum is applied to the EGR valve and
spark port vacuum is applied to the
distributor vacuum advance diaphragm.
CARBURETOR
BACK TO GROUP INDEX
MIXTURE FLOWS INTO INTAKE

MANIFOLD.
FUEL/AIR
MIXTURE HOSE
"INTA
K E MANIFOLD
INTAKE
MANIFOLD
WHEN MANIFOLD VACUUM IS

HIGH, VALVE OPENS.
0)
V
HOSE CARRIES FUEL-AIR MIXTURE

MIXTURE
FROM CARBURETOR TO VALVE.
FUEL
DECEL VALVE
A4076-A
FIG. 3 Conventional Fuel Deceleration System (2150 Carburetor Shown)
11 MPH
OPERATION BELOW 11
SOLENOID IN VACUUM
VALVE IS ENERGIZED.
3) VALVE CLOSES
4j
NORMALLY OPEN
DECEL VALVE
IS INOPERATIVE
WITH NO VACUUM.
ELECTRONIC
MODULE
~.SPEEDOMETER
SPEEDOMETER
CABLE
P E E D SENSOR
SENSOR
"X ^ ". ""^ SSPEED
------------,
j NO VACUUM IS
~:~~G~ET,?OR
CARBURETOR
CD
SENSOR SENDS
SENDS
BELOW 11 MPH,
H . SENSOR
DECELERATION
G E SIGNAL TO THE
DECELERATION
DECELERATION
CIRCUIT
B E L 0 W 11 M p
A V0LTA
A VOLTAGE .SIGNAL
THE
. C L 0 s p . TO
THE
"CLOSE" THE
M0DU|_E TQ
~I~~~~~. TO
CIRCUIT.
OPERATION AT 11
11 MPH OR HIGHER
SOLENOID IN VACUUM
3} ~~~~NE~~D~~TV:~~~G~~
VALVE IS NOT ENERGIZED.
Electric Ported Vacuum Switch

(PVS)
The electric PVS is used in som~
some
Thermactor equipped engines that have
catalytic converters in the exhaust
system. It is a combined
combined vacuum
switching device and electric signalling
device that is used in two versions:
normally closed electric contacts and
normally open electric contacts (Fig.
(Fig. 13).
Spark Delay Valves (SOV)
(SDV)
Spark delay valves are installed on
many engines to permit closer control of
of
operated emission related
vacuum operated
equipment. All 1975/76 mono-delay
SVD's have an internal sintered orifice to
SYD's
slow air flow
flow in one direction, a check
29-01-3
2) NO CURRENT
FLOWS IN
SOLENOID
CIRCUIT
NORMALLY OPEN
DECELVALVE
OPERATES NORMALLY.
--
FROM
CARBURETOR
FUEL-AIR MIXTURE FROM

CARBURETOR DECEL CIRCUIT
ENTERS INTAKE MANIFOLD.
ELECTRONIC
MODULE
~
7 ) AT 11
11 MPH OR HIGHER, THE
CD
SENSOR SENDS A VOLTAGE
SIGNAL TO THE MODULE TO
"OPEN" THE CIRCUIT.
A4077-A
FIG. 4 Speed Modulated Fuel

Fuel Decel System

29-01-4
valve to allow free airflow
flow in the opposite
direction, and a filter. They can be
installed on previous model year vehicles
(Fig.
(Fig. 14).
For 1976,
1976, a dual-delay SDV is used,
with two connections on one side and a
single connection on the other side (Fig.
15).
dual-delay SDV provides
provides
The dual-delay
of emissions by
improved control of
delaying the vacuum spark advance
during some vehicle acceleration modes
and providing extra spark advance
during some deceleration modes.
During mild acceleration, the transfer
of spark port vacuum to the distributor
vacuum advance diaphragm is delayed
delayed by
by
the high flow resistance of the sintered
metal disc in the SDV valve. During
steady cruising conditions, there is no
change in vacuum and no flow
flow occurs.
During heavy acceleration, when intake
manifold vacuum decreases, the pressure
difference across the restrictor disc
difference
reverses and causes the check valve to
open. With no restriction in the line, the
vacuum signal is quickly passed to the
distributor.
29-01-4

HEATER
TEMPERATURE
SENSITIVE
BIMETALLIC DISC
SILVER
CONTACTS
QUICK-DISCONNECT
TERMINAL
GROUND STRAP
STRAP
GROUND
V1595-B
V1595B
FIG. 5 Temperature Sensitive Type Electric Assisted Choke
Delay Valve Bypass (DVB) System
This system allows full spark port

vacuum to the distributor
distributor vacuum
advance diaphragm below the PVS
opening temperature. It uses a vacuum
check valve, spark delay valve (SDV),
and 4-port PVS
PVS (Fig.
(Fig. 16).
Above the PVS
PVS opening temperature
PVS close,
close,
the two top ports of the 4-port PVS
routing the spark port vacuum signal
through the spark delay (SDV) to the
distributor vacuum advance diaphragm.
Cold Temperature Retard
Control System
Cold Temperature Retard Control
may be used with a dual diaphragm
distributor and a normally closed air
cleaner temperature switch to prevent
distributor retard below the opening
temperature of the air cleaner switch
(Fig.
(Fig. 17).
When the aircleaner
air cleaner switch reaches
operation temperature and opens, the
solenoid opens and creates a path for
vacuum to the distributor spark retard
diaphragm.
EMISSION RELATED
lELATED
MISCELLANEOUS COMPONENTS
PCV Valve and Crankcase Vent
Cap
All engines
engines are
are equipped with aa closed
closed
emission control system that
features a filler cap ventilated to the
vacuum-operated
crankcase and a vacuum-operated
Positive Crankcase Ventilation (PCV)
(Fig. 18).
valve (Fig.
V2132-A
FIG. 6 Constant Operating Type Electric Assisted Choke
When the engine is running, vapors

that may escape past piston rings are
manifold,
pulled back into the intake manifold,
causing
fresh air to flow in
into
ca
using .fresh
to the
crankcase through the filler cap. Periodic
maintenance is required to keep system
operating properly.
~rankcase
cJrankcase
BACK TO GROUP INDEX
Exhaust Heat Control Valve

(HCV)
If fuel condenses on the cold surfaces
of the fuel induction system, fuel/air
fuel/air
ratios fluctuate. These variations can

cause uneven acceleration and increased
emission levels.
levels. The exhaust heat control
valve (Fig. 19) is designed to provide
quick induction system warm-up and
better cold engine fuel/air ratio control.
For 1975,
1975, all passenger car engines,
except the 2300cc
23OOcc and 460 CID, have a
vacuum-operated heat control valve
vacuum-operated
mounted between the exhaust pipe and
the exhaust manifold. For 1976, some
passenger car engines have this heat
29-01-5
29-01-5
ELECTRIC
CHOKE
CAP
TO INTAKE MANIFOLD
MANIFOLD
PVS
CENTER TAP OF
ALTERNATOR
(BLACK IDENTIFICATION RING)
V2133-A
V2133A
VENT T ( T
ATMOSPHERE
FIG. 77 Typical Electric Assisted

Choke Wiring-Temperature
WiringTemperature
Sensitive Type Shown
A4098-A
A4098A
FIG. 99 Cooling PVS-Vent Retard System
VENT TO ATMOSPHERE
3104-A
B 3104A
SPARK PORT
PVSTypical
FIG. 88 Cooling PV5-Typical
control valve while others are equipped

with aa spacer in
in this location. The
The
function of the HCV is
is to
to preheat the
the
of
fuel-air mixture by directing a portion of
the exhaust gas upward through passages
the intake manifold
manifold during engine
in the
warm-up.
On cold starts, manifold vacuum is
is
directed to the heat control valve (HCV)
the top
top two ports in
in the
the HCV
HCV
through the
PVS (ported vacuum switch), closing the
HCV valve against the
the spring in
in the
the
vacuum motor. When the engine coolant
reaches aa certain temperature, the
the PVS
PVS
off the vacuum supply, venting the
seals ofT
HCV vacuum motor to
to the
the atmosphere
and allowing the spring to open the HCV
(Fig. 20).
butterfly valve (Fig.
A separate PVS
PVS is
is used for
for each of
of
systems. They can be identified as
three systems.
as
follows:
follows:
PVS IDENTIFICATION CHART
PVS Body Color
Opening
Opening Temp.
Temp. (OF.)
(F.)
Black
92
9 2 - 998
8
Blue
125
1 2 5- 1131
31
Purple
157
1 5 7-- 1163
63
CA1428-A
CA1428A
BACK TO GROUP INDEX
COLD
PVS
A4099A
A4099-A
FIG. 10 Coolant Spark Control (CSC) System
AIR CLEANER MOUNTED

SWITCHES
Weather Modulator
Modulator (Fig.
Cold Weather
21
21))
is aa
The Cold Weather Modulator is
vacuum modulator located in
in the
the air
air
cleaner on some models. During engine
operation in
in cold ambient temperait prevents the
the air
air cleaner duct
tures, it
door from opening to
to non-heated
intake air. When available air from the
"fresh air" intake is

"fresh
is above 55F.,
55 0 F., the
cold weather modulator does not
not
operate.
be
Normally, the
the duct air
air door will be
closed to
to outside air
air any time vacuum
closed.
is applied. This
from the bimetal sensor is
the outside
outside temperature
temperature isis
occurs when the
to require heated air
air for
for
low enough to
carburetor intake. When the
the vacuum is
is
off, the door will open. This occurs
cut ofT,
when temperature rises high enough to
to
the bi-metal sensor. It
It also
operate the
29-01-6
in cold
happens during acceleration in
conditions. When this situation is
is
encountered, the
the Cold Weather
Weather
encountered,
in the
the vacuum line
Modulator, inserted in
between the
the bi-metal sensor and
and the
the
vacuum duct motor, will close the
the
to- the motor and hold the duct
vacuum .to'
door open.
DRCV
OR CHECK VALVE
SPARK PORT
29-01-6
DIST.
INTAKE MANIFOLD
VACUUM TAP
CSSA PVS
COOLANT PVS
(OPTIONAL)
A4063-B
A4063-8
FIG. 11
11 Cold Start Spark Advance (CSSA) System-Typical
SystemTypical
EGR PORT
CHECK VALVE
Air Cleaner Temperature Switch

(Fig.
(Fig. 22)
22)
Engines with Cold Temperature
Temperature
Actuated Vacuum systems (CTAV), and
Thermactor systems
systems
those with Thermactor
containing one
one or
or more catalytic
catalytic
containing
converters, also are
are equipped with aa
in the
the air
air cleaner.
temperature switch in
This switch consists of aa ho-using
housing
mounted in
in the
the air
air cleaner
cleaner which
which
mounted
contains a bimetal switch that isis operated
by temperature
temperature changes.
changes. They
They are
are of
of two
types, each
each identified
identified by
the connector
connector to
types,
by the
to
the wiring
wiring harness
harness (Fig.
(Fig. 22).
22). Type
Type 11 has
has
the
contacts that
that are
are normally
normally closed;
closed; Type
contacts
Type
has contacts
contacts that
that are
are normally
normally open.
open.
22 has
Refer to
to the operation of the CTAV
for the
the system
system
and Thermactor systems for
function of these temperature switches.
SPARK PORT
SPARK DELAY VALVE
A4100-A
FIG. 12
12 Dual Signal Spark Advance (OSSA)
(DSSA) System
BACK TO GROUP INDEX

29-01-7
29-01-7
CONTACTS OPEN
WITH HOT COOLANT (235F.)
CONTACTS CLOSED
WITH COLD COOLANT
NORMAL PVS OPERATION
I"*"
CONTACTS CLOSED WITH

HOT COOLANT (235F.)
-ENGINE COOLANT OPERATED

CONTACTS OPEN WITH
COLD COOLANT
NORMALLY CLOSED (COLD)
NORMALLY OPEN (COLD)
ENGINE COOLANT OPERATED
A4078-A
A4078A
FIG. 13
13 Electric Ported Vacuum Switches
FILTER PACK
.~--,
-SINTERED
SINTERED ORIFICE
SINTEREO ORIFICE
SINTERED ORIFICE
FILTER PACK
CHECK VALVE
V1826-A
FIG. 14 Spark Delay Valve (SDV)-Mono Delay Shown
CHECK VALVE
CHECK VALVE
,.------,
r-- ---,
:[
~
I
TO
DISTRIBUTORl
DISTRIBUTORL
!
I
I
I
TO
PORTED
VACUUM
-;:::::_...r...-..1---~~~1~~
~
T 0
TO
DiSTRIBUTOR
I
I
I
I
TO PORTED
VACUUM
--..- _ _I=---1_~
L__ ~
ORIFICE
MONO-DELAY TYPE
TO INTAKE
MANIFOLD
ORIFICE
DUAL-DELAY VALVE
DUAL-DELAY
A4101-A
A4101A
15 Spark Delay Valve (SDV) Schematics

FIG. 15
BACK TO GROUP INDEX

29-01-8
29-01-8
29-01-8
29-01-8
Emission Systems
Systems General
General Service
Service
Emission
TO
TO SPARK
SPARK PORT
PORT
ON
ON CARBURETOR
CARBURETOR
TO
EGR VALVE
VACUUM
CHECK VALVE
TO VACUUM
AMPLIFIER
SPARK
DELAY VALVE
A4102-A
A4102A
DISTRIBUTOR
DISTRIBUTOR
FIG. 16
16 Delay
Delay Valve Bypass (DVB) System
B+(IGN)
B+OGN)
NORMALLY
NORMALLY
CLOSED
SOLENOID VALVE
DISTRIBUTOR
DISTRIBUTOR
TO INTAKE
INTAKE
MANIFOLD VACUUM
VACUUM
TEMPERATURE SWITCH
LOCATED IN AIR CLEANER
(NORMALLY CLOSED)
A4103-A
A4103A
FIG. 17 Cold Temperature Retard Control System

CRANKCASE VENT
TUBE EXTENSION HOSE
CRANKCASE VENT
HOSE
CRANKCASE VENT
TUBE H O S E 6A664
PCV VALVEVALVE PCV
6A666
.71 1.0.
GROMMET
GROMMET.58 I.D.
OIL FILLER
CAP - 6766
CRANKCASE
VENT T U B E - 6 7 5 9
A4070-B
A4070-B
FIG.
FIG. 18
18 Typical
Typical PCV
PCV System
System
BACK TO GROUP INDEX

29-01-9
29-01-9
Emission
Emission Systems
Systems General Service
Service
VACUUM
VACUUM
~~-- CONNECTION
CONNECTION
BUTTERFLY
VALVE
A4061-A
FIG. 19 Vacuum Operated Exhaust

Heat Control Valve
ON INTAKE MANIFOLD
MANIFOLD
VACUUM TAP ON
HCV PVS
HCV (351W
SHOWN)
FILTERED
ATMOSPHERIC
VENT
A4062-A
FIG. 20 HCV System Schematic
BACK TO GROUP INDEX

29-01-10
29-01-10

TO DUCT VALVE
VACUUM MOTOR
TO BI-METAL SENSOR
O-RING SEAL
COLD START OPERATION

MODULATOR
0MODULATOR
BI-METAL SEATS. -
_ _..l1l:...I
VACUUM MOTOR
DUCT
JLJVALVE OPEN FOR FULL HEAT

(BLOCKS FRESH AIR INLET).
0MANIFOLD
MANIFOLD VACUUM I
IS S /
HIGH (ABOVE 8 INCHES).
INCHES)
CHECK VALVE OPENS.

0CHECK VALVE OPENS.
F.
ACCELERATION (MODULATOR TEMPERATURE BELOW 55 F.)
BI-METAL
REMAINS SEATED.
F U L L VACUUM'
TO MOTOR.
HEATED AIR FROM HEAT SHROUD
O-RING SEAL
.....
Cl), VACUUM IS TRAPPED.
SJVALVE STAYS ON FULL HEAT

(BLOCKS FRESH AIR INLET).
CD1) MANIFOLD
VACUUM IS
LOW (BELOW 8 INCHES).
o
@
"Iff
SEATS.
CHECK VALVE SEATS.
HEATED AIR
AIR FROM HEAT SHROUD
WARM
WARM ENGINE (MODULATOR
(MODULATOR TEMPERATURE ABOVE 55
55 F.)
F.)
CD MANIFOLD VACUUM
MANIFOLD VACUUM
ABOVE 8 INCHES.
BI-METAL UNSEATED.
VALVE
CHECK VALVE
REMAINS SEATED.
O-RING SEAL
0CONTROLLED VACUUM
TO MOTOR.
VALVE CLOSES TO ALLOW

ENTRY OF FRESH AIR.
NORMAL TEMPERATURE
6
6J CONTROL.
HEATED AIR FROM HEAT SHROUD
A4079-A
FIG. 21
21 Cold Weather Modulator Operation
BACK TO GROUP INDEX

29-01-11
29-01-11
General Service
Emission Systems General
Sf-METAL CONTACT
CONTACT
BI-METAL
49-55 F. RANGE
OPERATES IN 49-55
B
~ CONNECTOR
CONNECTOR IDENTIFIES:
TYPE1TYPE
1 NORMALLY CLOSED
CLOSED
NORMALLY
TYPE 2 ~TYPE2
NORMALLY OPEN
NORMALLY
A4080-A
Cleaner Temperature Switch

FIG. 22 Air Cleaner
BACK TO GROUP INDEX

29-02-1
29-02-1
29-02-1
29-02-1
Engine Diagnosis and

and Service
PART 29-02 Engine Diagnosis and

and Service
All Engines, All Vehicles
COMPONENT INDEX
Page
COMPONENT INDEX
Page
GENERAL INFORMATION ............

DIAGNOSIS CHARTS .................
Diagnosis Chart Index ...............
02-1
02-1
02-2
02-2
DIAGNOSIS PROCEDURES ............

Procedure
Proced
ure Index ....................
SPECiFiCATIONS
02-54
02-54
02-78

NOTE:
information in this Part applies to both 1975 and 1976 Inodel
CR1966-A
CR1966-A
GENERAL INFORMAliON
INFORMATION
The following information comprises
and Service
the Engine Diagnosis and
to emission system
procedures related to
related components. The
and
The diagnosis and
related service routines provided here are
the only authorized service procedures
1975 and
and 1976 Ford Cars.
Cars. Refer to
for 1975
Volume 5 of tthis
his M
a n u a l for
Volume
Manual
Maintenance Procedures.
BACK TO GROUP INDEX

29-02-2
29-02-2
29-02-2
DIAGNOSIS CHARTS
DIAGNOSTIC CHARTS
ENGINE DIAGNOSTIC
CONDITION
PAGE
101 -- Engine will not crank -- starter

starter spins
Routine 101
02-3
Crank
Routine 102 -- Engine Will Not Crank
02-4
024
Routine 103 -- Engine Cranks Slowly
02-5
Normally - Will Not Start

Routine 104 - Engine Cranks Normally
02-6
Normally - Starts Hard When Cold

02-8
Normally - Starts Hard When Hot

02-9
Routine 107 - Engine Idles Rough - Misses (Warm or Cold Engine)
02-11
02-11
Routine 108 - Engine Idle Speed Varies
02-13
Speed
Routine 109 - Engine Misses at High Speed
02-16
~ngine Misses at Low Speed

Routine 110 - Engine
02-18
111 - Engine Stalls At Idle - Engine Cold

Routine 111
02-20
Routine 112 - Engine Stalls At Idle - Engine Hot
02-22
Routine 113 - Engine Stalls During Deceleration Or On Quick Stop
02-24
Routine 114 - Engine Hesitates - Stalls During Acceleration
02-25
Routine 115 - Engine Has Poor Acceleration

Routine 116 - Engine Has Less Than Normal Power
02-27
02-29
Routine 117 - Exhaust System Backfire

Routine 118 - Engine Surges
02-32
Routine 119 - Excessive Fuel Consumption
02-34
02-31
02-31
Routine 120 - Excessive Oil Consumption
02-37
Routine 121
121 - Engine Diesels - Continues To Run After Shut Off
Routine 122 - Engine Noise
Routine 122A - Spark Knock or Pinging
02-39
02-42
Routine 123 - Engine Vibration
02-43
02-41
02-41
Routine 124 - Engine Fails To Reach

Reach Normal Operating Temperature
02-44
Routine 125 - Loss of Coolant Or Engine Overheating
02-45
Routine 126 - Smoke From Vehicle Exhaust System

Routine 127 - High Floor Pan
Pan Temperatures
02-47
DIAGNOSTIC CHART REFERENCE ONE

DIAGNOSTIC CHART REFERENCE TWO
02-50
02-49
02-51
02-51
CA1421B
CA1421B
BACK TO GROUP INDEX

29-02-3
29-02-3

and Service
ROUTINE NO.
NO. 101
101
ENGINE WILL NOT
NOT CRANK - STARTER SPINS
VERIFY THE
THE CONDITION PER
PER SHOP MANUAL STARTER DRIVE TEST
REMOVE STARTER AND

AND INSPECT FOR
FOR BROKEN OR
OR WORN STARTER
DRIVE
NOT OK
OK
REPLACE STARTER DRIVE.

DRIVE. INSPECT
FLYWHEEL ASSEMBLY AND REPAIR AND //OR
OR
REPLACE AS REQUIRED.
REQUIRED.
NOT OK
+
REPAIR AND
/ OR REPLACE STARTER
AND/OR
ASSEMBLY AS
AS REQUIRED.
REQUIRED.
OK
t
PERFORM
STARTER BENCH TESTS.
TESTS.
PERFORM STARTER
OK
REPAIR AND/OR
AND / OR REPLACE FLYWHEEL
AND RING GEAR ASSEMBLY.
CA1357-A
CA1357-A
BACK TO GROUP INDEX

29-02-4
29-02-4

and Service
ROUTINE NO. 102
ENGINE WILL NOT CRANK

VERIFY THE CONDITION
OK
I4
CHECK SEAT BELT
INTERLOCK SYSTEM
AND THE
TRANSMISSION
NEUTRAL SWITCHES
FOR PROPER
FUNCTION.
NOT OK
NOTOK
_----&.-1---__
REPLACE OR REPAIR
AS
AS REQUIRED.
OK
I
CHECK CABLE
CONNECTIONS AT
AT
BATTERY AND AT
AT
STARTER TERMINAL.
TERMINAL.
I
NOTOK
NOT OK
-------.1...-_-----.
CLEAN AND TIGHTEN
CLEAN AND TIGHTEN
CONNECTIONS.
OK
PERFORM BATTERY
CAPACITY TEST
I
NOTOK
NOT OK
OK
\
CHARGE THEN RETEST

BATTERY.
NOTOK
NOT OK
t
REPLACE BATTERY.
CONNECT
VOLTMETER NEGATIVE
LEAD TO NEGATIVE
POST OF BATTERY.
OK
OK
CONNECT A
A 12-VOLT
TEST LIGHT IN
IN SERIES
WITH BATTERY POSITIVE
POST AND BATTERY
CABLE. LIGHT SHOULD
NOT GLOW.
K
- - - - - - - - - - -.........- - O O
K
NOTOK
NOT OK
INVESTIGATE ELECTRISYSTEM. REPAIR/

CAL SYSTEM.
REPLACE AS
AS REQUIRED
OK
t
CONT'D. ON NEXT PAGE.
OBSERVE VOLTAGE
OK
t
LESS THAN 10
10 VOLTS
- EXAMINE CABLE
FROM RELAY TO
TO
STARTER FOR
FOR
CHAFING OR
OR
ABRASION RESULTI.NG
RESULTING
IN SHORT TO GROUND.
NOT OK
NOT OK
....t......
REPLACE RELAY.
'"""'1
OK
t
VOLTAGE REMAINS
SAME - MOVE
VOLTMETER POSITIVE
LEAD TO TERMINAL
STUD IN
IN STARTER.
NOTOK
NOT OK
REMOVE NUT AND

WASHER FROM
TERMINAL STUD.
CLEAN OR REPLACE
AS REQUIRED.
BACK TO GROUP INDEX
OK
VOLTAGE REMAINS
SAME-REMOVE
SAME
- REMOVE
AND REPAIR STARTER
,-----.. . 1 -------.
4
REPLACE OR REPAIR
AS
AS REQUIRED.
------'
OK
REMOVE STARTER
AND PERFORM
BENCH TESTS.
I
NOT OK
. TURN IGNITION KEY

KEY
TO START POSITION
FOR
AND LISTEN FOR
CLICK. RELAY
CLICK..
SHOULD CLICK
NOTOK
NOT OK
t
VOLTAGE REMAINS
SAME - MOVE
VOLTMETER POSITIVE
LEAD TO STARTER
TERMINAL OF RELAY.
. CONNECT
VOLTMETER POSITIVE
LEAD TO POSITIVE
POST OF BATTERY.
NOT OK
NOTOK
OK
tt
REPAIR OR ADJUST
AS REQUIRED.
PER
FORM TESTS
PERFORM
FOR ENGINE SEIZING
AND/OR LOCK-UP.
1
CA1358-B
CA1358-B1

29-02-5
29-02-5
ROUTINE NO. 103
ENGINE CRANKS SLOWLY

VERIFY
CONDITION
PERFORM BATTERY CAPACITY TEST
NOT OK
BATTERY.
RECHAFCGE
RECHARGE AND RETEST
RETEST BATTERY.
NOTOK
NOT OK
OK
REPLACE BATTERY.
CONNECT A 12-VOLT
12-VOLT TEST LIGHT
IN SERIES WITH BATTERY
BATTERY
BATTERY
POSITIVE POST AND BATTERY
CABLE. LIGHT SHOULD NOT GLOW.
OK
CONNECT VOLTMETER NEGATIVE LEAD

TO STARTER TERMINAL STUD AND
VOLTMETER POSITIVE LEAD TO THE
THAT
I
BATTERY POSITIVE POST. INSURE THAT
OK
~----OK------II
THE CHOKE PLACE IS FULLY OPENED
DISCONNECT
(VERTICAL POSITION) AND DISCONNECT
COIL PRIMARY WIRE (BATTERY SIDE).
CRANK THE ENGINE AND OBSERVE
VOLTMETER READING. IT SHOULD NOT
EXCEED 0.5 VOLTS.
I
I
NOT OK
NOTOK
...
1i
r--
INVESTIGATE ELECTRICAL SYSTEM.

REPAIR OR REPLACE AS NECESSARY.
OK
NOTOK
NOT OK
I
r----------1a..-------_
DISCONNECT AND CLEAN CONNECTION AT
POSITIVE BATTERY POST, RELAY AND AT
STARTER TERMINAL.
TERMINAL.
CONNECT VOLTMETER NEGATIVE LEAD TO

BATTERY POST, AND VOLTMETER
VOLTMETER
NEGATIVE BATTERY
POSITIVE LEAD TO STARTER MOUNTING BOLT
OR ENGINE GROUND. INSURE THAT THE CHOKE
PLATE IS FULLY OPENED (VERTICAL POSITION)
(BATTERY
AND DISCONNECT COIL PRIMARY WIRE (BATTERY
SIDE). CRANK THE ENGINE AND OBSERVE
VOLTMETER READING. IT SHOULD NOT EXCEED
0.1 VOLTS.
0.1
I
NOT OK
OK
DISCONNECT AND CLEAN CONNECTIONS AT

NEGATIVE BATTERY POST AND GROUND CABLE
CONNECTIONS AT ENGINE BLOCK.
REMOVE STARTER AND PERFORM BENCH TESTS.
NOT OK
OK
~--
---II
-----,
REPAIR AND/OR REPLACE AS REQUIRED.
PERFORM ENGINE CHECKS FOR SEIZING,

HIGH FRICTION, OR OVER HEATING.
I
I
NOT OK
NOTOK
1I
CA1359-B
BACK TO GROUP INDEX

29-02-6
29-02-6
Engine Diagnosis
Dragnosis and Service
ROUTINE NO. 104

ENGINE CRANKS NORMALLY - WILL NOT START
VERIFY THE CONDITION USING THE CORRECT STARTING
FLOOOlNG.
PROCEDURE AND CHECK FOR FLOODING.
INSPECT VACUUM HOSES.

WIRING. FUEL SYSTEM AND
HOSES, ELECTRICAL WIRING,
AIR CLEANER FOR LEAKS,
LEAKS, DAMAGE.
DAMAGE, BLOCKAGES, AND PROPER
CONNECTIONS. ALSO CHgCK
CHECK FOR FUEL IN TANK.
I
NOT OK
OK
CHECK FOR WEAK OR NO SPARK AT ANY

SPARK
PLUG. (SEESSD-14)
(SEE SSO-14)
SPARKPLUG.
REPAI,R
/ OR REPLACE AS
REQUIRED.
REPAIR AND
AND/OR
AS REQUIRED.
OK
O
K --GGOOD
O O D SPARK
NO SPARK OR WEAK SPARK

PERFORM
COIL RESERVE
PERFORM STEP"
STEP II OF 550-14
SSD-14COIL
VOLTAGE CHECK (PERFORM THIS TEST
WHILE CRANKING).
CRANKING).
NOT OK
REPAIR AND
/ OR
AND/OR
REPLACE AS
AS
REQUIRED.
REQUIRED.
CHECK IGNITION
WIRES,
WIRES, CAP AND
ROTOR FOR
DAMAGE.
DAMAGE. CHECK
FOR MOISTURE
ON ROTOR.
ROTOR, CAP,
ON
SPARK PLUGS
AND WIRE
CONNECTIONS.
CRANK ENGINE
TO VERIFY
DISTRIBUTOR
OPERATION.
OPERATION.
NOT OK
OK
REPAIR AND
/ OR
AND/OR
REPLACE AS
REQUIRED.
CRANK ENGINE
WITH CHOKE
HELD OfeOSED
~sED AND
CHECK FOR FUEL
WETTING IN THE
DISCHARGE AREA.
OK
OK
NOT OK
PERFORM STEP
11A OF
REFERENCE TWO.
I
I
OK
t
AND/OR
REPAIR AND
/ OR
REPLACE AS
AS
AEPLACE
REQUIRED.
AEQUIHED.
OK
r--------I~J--.....-..-_...,
NOT OK
550-12 AUTOMATIC
PERFORM STEP I OF SSD-12
CHOKE CHECK PROCEDURE.
NOT OK
PERFORM STEP IV
SSD-14
OF 85014SPARK PLUG
REQUIRED
VOLTAGE.
VOLTAGE.
(PERFORM THIS
TEST WHILE
CRANKING.)
REPAIR AND/OR
REPLACE AS
REQUIRED.
REQUIRE
D.
OK
OK
i
NOT OK
AND/OR
REPAIR AND
/ OR
AS
REPLACE AS
REQUIRED.
REQUIRED.
i
NOT OK
AND/OR
REPAIR AND
/ OR
AS
REPLACE AS
REQUIRED.
REQUIRED.
BACK TO GROUP INDEX
NOT OK
PERFORM STEPS
2, 21, AND 22 OF
2,21,
REFERENCE TWO.
OK
CONTINUED ON NEXT PAGE

CA1360-A1

29-02-7
29-02-7
and Service
NO. 104
ROUTINE NO.
104
ENGINE CRANKS NORMALLY
- WILL NOT
NOT START -CONTINUED
CONTINUED
OK
OK
OK
OK
PERFORM STEPS 11,12,13,14,15,16,17

11, 12, 13, 14, 15, 16, 17 AND
AND
19 OF
TWO (INTERNAL).
OF REFERENCE TWO
I
OK
NOT OK
OK
JL
REPAIR AND
/ OR REPLACE AS
AS REQUIRED.
AND/OR
CHECK BASIC TIMING WHILE CRANKING.
NOT OK
OK
,..-
fa.-
---,
REPAIR AND
lOR REPLACE AS REQUIRED.
AND/OR
REQUIRED.
....--
OK
+
CHECK FOR WEAK, OR NO SPARK, AT ANY
SPARK PLUG. (SEE SSD-14,
550-14, STEP II)
III
NOT OK
OK
OK
OK
REQUIRED.
AS REQUIRED.
REPAIR AND
I OR REPLACE AS
AND/OR
NOT OK
CHECK PCV
PCV SYSTEM FOR
FOR PROPER
OPERATION.
I
OK
OK
.--------*------------,
REQUIRED.
REPAIR
/ OR REPLACE AS
AS REQUIRED.
REPAIR AND
AND/OR
CHECK TO SEE THAT THE EGR VALVE WILL

CLOSE. PERFORM
PERFORM STEPS IC,
IC, 1,
1, 2
CLOSE.
2 AND 3
3 OF
SSD-1.
SSO-1.
NOT OK
REPAIR
REPAIR AND // OR
OR REP
REPLACE
AS REQUIRED.
REQUIRED.
LACE AS
OK
OK
PERFORM CYLINDER COMPRESSION AND / OR

(WET AND
AND DRY).
DRY).
LEAKAGE TEST (WET
NOT OK
OK
NOT
REPAIR AND
AND/OR
REPLACE
AS REQUIRED.
REQUIRED.
LACE AS
/ OR REP
REPAIR
PERFORM
SSD 17.
17.
PER
FORM VALVE TRAIN ANALYSIS SSD
AS REQUIRED.
REPAIR AND/OR REPLACE AS
CA1360-B2
BACK TO GROUP INDEX

29-02-8
29-02-8
ROUTINE NO. 105

ENGINE CRANKS NORMALLY-STARTS
NORMALLY STARTS HARD WHEN COLD
VERIFY THE CONDITION 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
.....-
t'.1--
AND/OR
REPAIR AND
I OR REPLACE AS REQUIRED.
----,
.....-
AND/OR
REPAIR AND
...-
23,7,14,17,24
11 OF
PERFORM STEPS 23,
7, 14, 17, 24 AND 11
REFERENCE TWO (EXTERNAL).
NOT OK
---J~L---
OK
OK
---,
OK
t
CHECK STEPS 10,22,13
10, 22, 13 REFERENCE ONE
SSD-14 STEP II
IN COMBINATION WITH SSD~14
IGNITION
COIL
IGN
ITION SYSTEM COl
L RESERVE VOLTAGE,
STEP IV SPARK PLUG REQUIRED VOLTAGE.
NOT OK
OK
,L---
AND/OR
REPAIR AND
REQUIRED.
----,
Jft
PERFORM
SSD-1 PART II
PERFORM EGR SYSTEM CHECK SSD-1
BAND
V.
B AND C 1,
1, 4,
4, 55 AND PART V.
NOT OK
OK
REPAIR AND
AND/lOR
OR REPLACE AS REQUIRED.
SSD-11 PART 11 A,
A, B,
B, C
C,l D.
D,
CHECK PCV SYSTEM SSD-11
NOT OK
OK
_--------tt-------------,
AND/I OR REPLACE AS REQUIRED.
REPAIR AND
NOT OK

LEAKAGE TEST.
OK
OK
t
REPAIR AND
AND/OR
PERFORM VALVE TRAIN ANALYSIS SSD

SSD 17.
CA1361-B
BACK TO GROUP INDEX

29-02-9
29-02-9
ROUTINE NO. 106
ENGINE CRANKS NORMALLY -STARTS

STARTS HARD WHEN HOT
I VERIFY
THE CONDITION USING PROPER STARTING PROCEDURES.
,
.NSPECT
FUEL. SYSTEMS,
INSPECT VACUUM SYSTEMS, ELECTRICAL SYSTEMS, FUEL
SYSTEMS,
LEAKS, BLOCKAGE AND PROPER CONNECTIONS.
NOT OK
t
r------------~.L-----------....,
REPAIR AND/OR
AND lOR REPLACE AS REQUIRED.
OK
t
PERFORM STEPS 17, 23A AND D THRU K, 24,
11
11 AND 14 OF REFERENCE TWO (EXTERNAL).
I
NOT OK
r------------~----------....,
t
REQUIRED.
REPAIR AND/OR
AND I OR REPLACE AS REQUIREd.
OK
PERFORM
PERFORM EGR SYSTEM CHECK SSD-1
PART II SAND
B AND CC 1,1,4,4,55AND
AND PART
PART V.V.
I
I
OK
NOT OK
t
REPAIR AND/OR
AND I OR REPLACE AS REQUIRED.
CHECK FOR OVERHEATING.
NOT OK
t
_--------t------------....,
PERFORM ROUTINE 125 AND REPAIR
AND/OR REPLACE AS REQUIRED.
OK
CHECK STEPS 10, 13 REFERENCE ONE IN

COMBINATION WITH SSD-14 STEP \III
RESERVE VOLTAGE,
IGNITION SYSTEM COIL RE:SERVE
I
NOT OK
NOT
r---
tt
AND/OR
REPAIR AND
...,
OK
ft
SSD-11 PART II
CHECK PCV SYSTEM SSD-11
A, S,
A,
B, C.
C. D.
D.
I,
NOT OK
OK
~-------_~L---------.....,
AND/OR
REPAIR AND
CHECK EXHAUST HEAT CONTROL VALVE

SSD-10 AND RESTRICTED EXHAUST SYSTEM.
I
NOT OK
OK
If
REPAIR AND/OR

CA1362-A1
CA1362-A1
BACK TO GROUP INDEX

29-02-10
29-02-10
ROUTINE NO. 106

ENGINE CRANKS NORMALLY - STARTS
HARD WHEN HOT
- CONTINUED
HOT
,
I
OK
10,13,14 AND 16 OF
PERFORM STEPS 10,13,14
REFERENCE TWO (INTERNAL).
NOT OK
AND/OR
REPAIR AND
I
I
OK
PERFORM CYLINDER COMPRESSION AND I/ OR

LEAKAGE TEST.
I
NOT OK
t
AND/OR
REPAIR AND
OK
PERFORM VALVE TRAIN ANALYSIS SSD-17.

CA1362-A2
BACK TO GROUP INDEX

29-02-11
29-02-11
29-02-11
29-02-11
ROUTINE 107
107
ENGINE IDLES ROUGH I/MISSES
MISSES (WARM
(WARM OR COLD ENGINE)
ENGINE)
CONDITION
VERIFY THE CONDITION;
((
OK

EVAPORATIVE CONTROL SYSTEM,
SYSTEM, AIR
AIR CLEANER FOR
FOR DAMAGE,
LEAKS, OR IMPROPER CONNECTIONS.
I
I
NOT OK
OK
OK
--------~~---------,
AND/OR
AS REQUIRED.
REPAIR AND
lOR REPLACE AS
t
WITH ENGINE RUNNING REMOVE LINE FROM
TO AIR
AIR
EVAPORATIVE EMISSION CANISTER TO
CLEANER.
H
OK
t
J_
I
I
NOT OK
OK
_______
----'~L--
___,
REPLACE EVAPORATIVE CANISTER.
CHECK THE
THE INTEGRITY OF
OF ALL
ALL VACUUM
AND CHECK FOR
FOR INTAKE MANIFOLD
SYSTEMS AND
LEAKS.
LEAKS.
,
t
NOT OK
OK
r-----------:~I----------__,
AND/OR
AS REQUIRED.
REPAIR AND
I OR REPLACE AS
OK
PERFORM REFERENCE TWO

TWO STEPS 9,11,24.
(EXTERNAL)
I
NOT OK
OK
OK
t~
___,
AND/OR
AS REQUIRED.
REPAIR AND
I OR REPLACE AS
REQUIRED.
PERFORM AIR
AIR CLEANER TEMPERATURE
AND DELAY VALVE DIAGNOSIS SSD-9.
CONTROL AND
NOT
OK
NOT OK
_ _ _ _ _ _ _ _t..l.---
___,
REPAIR AND
lOR REPLACE AS
REQUIRED.
AND/OR
AS REQUIRED.
I
OK
CHECK STEPS
STEPS IN
IN REFERENCE ONE
ONE STEPS
STEPS 21,
22,10,11,7,8
22, 10, 11,7, 8 AND 17
17 IN
IN COMBINATION WITH
SSD-14 STEP
STEP \III IGNITION SYSTEM
SYSTEM COIL RESERVE
AND STEP
STEP IV
IV SPARK PLUG REQUIRED VOLTAGE.
NOT OK
r-------------,L..----------.
AND/OR
REPAIR AND
/ OR REPLACE AS
AS REQUIRED.
REQUIRED.
,
I
OK
PERFORM EGR SYSTEM SSD-1

SSD-1 PART
PART II "CHECK
"CHECK
OF EGR VALVE
ENGINE"
VALVE WHEN ON THE
THE ENGINE"
B AND C STEPS
STEPS 1,
1, 4,
4, 5.5.
PROCEDURE BAND
1
NOT OK
OK
tf
AND/OR
REPAIR AND
/ OR REPLACE AS
AS REQUIRED.
ON NEXT PAGE
CONTINUED ON
CA1363-B1
CA1363-B1
BACK TO GROUP INDEX

29-02-12
29-02-12

and Service
ROUTINE 107
107
ENGINE IDLES ROUGH I/ MISSES -CONTINUED
CONTINUED
OK
i
PERFORM VACUUM AMPLIFIER SSD-1
V-SSD-1 PART V
"EGR VENTURI VACUUM AMPLIFIER DIAGNOSTIC
PROCEDURE"
NOT OK
OK
r--
REPAIR AND I/OR

AS REQUIRED.
OR REPLACE AS
. .,
II
OK
OK
PERFORM POSITIVE CRANKCASE VENTI

LATION
VENTILATION
SYSTEM SSD-11
SSD-11 PART A
A - "CHECK
"CHECK PCV SYSTEM
FUNCTION" 1,2,3,4.
1,2,3,4.
I
I
NOT OK
OK
OK
REPAIR AND
I OR REPLACE AS
AND/OR
AS REQUIRED.
REQUIRED.
CHECK FOR RESTRICTED EXHAUST SYSTEM.

SYSTEM.
CHECK
NOT OK
~_------r---------...,
AS REQUIRED.
REQUIRED.
AND/OR
REPAIR AND
lOR REPLACE AS
OK
+
PERFORM CARBURETOR
CARBURETOR SSD-13
MIXTURE -ADJUST
ADJUST
IDLE
FUEL
OK
NOT OK
OK
r---------~L-..---------...,
REPAIR AND
AND/OR
REQUIRED.
rL_..__
REPAIR AND
I OR REPLACE AS REQUIRED
AND/OR
REQUIRED
PERFORM CARBURETOR
CARBURETOR REFERENCE TWO
TWO
15, 16, 17, 18, 23, 19. (INTERNAL)
STEPS 15,16,17,18,23,19.
,
I
I
NOT OK
OK
,.....--
t
I
OK
...,
CYLINDER
PERFORM COMPRESSION AND /I OR CYLI
NDER
LEAKAGE TEST.
I
I
NOT OK
AND/OR
AS REQUIRED
REPAIR AND
I OR REPLACE AS
I
OK
OK
550-17.
AS REQUIRED.
CA1363-B2
BACK TO GROUP INDEX

29-02-13
29-02-13
ROUTINE NO. 108

ENGINE IDLE SPEED VARIES
CONDITION I
I VERIFY THE CONDITION

SYSTEM, AND AIR CLEANER FOR DAMAGE,
LEAKS, BLOCKAGE OR IMPROPER CONNECTIONS.
I
NOT OK
r-----------J~i----------____,
AND/OR
REPAIR AND
NOT OK
tL.t
r---
OK
+
WITH ENGINE AT OPERATING TEMPERATURE
CHECK IDLE SPEEDS. PERFORM STEP 7 OF
REFERENCE ONE.
OK
WITH ENGINE RUNNING REMOVE LINE FROM

EVAPORATIVE EMISSION CANISTER TO AIR
CLEANER.
ADJUST SPEEDS AS REQUIRED.
I
I
NOT OK
t
__--------~L.--------~
REPLACE EVAPORATIVE CANNISTER.
,
---,
AND/OR
REPAIR AND
PERFORM STEPS 7, 9, 10, 14, 17, 19, 23 A,

24, 26,
26, AND 28 OF REFERENCE TWO
(EXTERNAL).
I
tt""'---
__
OK
PERFORM SSD-7
- FUEL DECELERATION
SSD-7FUEL
DECELERATION
VALVE CHECK.
REQUIRED.
REQUIRED.
II
NOT OK
OK
trL.-
......-
OK
- IJ
NOT OK
REPAIR AND
AND// OR REPLACE AS
AS
CHECK CARBURETOR SOLENOID THROTTLE

POSITIONER FOR PROPER FUNCTION.
I
tt
.-
t
I
NOT OK
.--
OK
--.,
AS REQUIRED.
REQUIRED.
REPAIR AND //OR
OR REPLACE AS
CHECK STEPS 10, 11

11 OF REFERENCE ONE
IN COMBINATION WITH SSD-14 STEP II
IGNITION SYSTEM COIL RESERVE VOLTAGE
VOLTAGE,
STEP IV SPARK PLUG REQUIRED VOLTAGE. '
NOT OK
r---------~L.-.-.--------.,
REPAIR AND/OR
CA1364-B1
CA1364-B1
BACK TO GROUP INDEX

29-02-14
29-02-14
NO. 108
ROUTINE NO.
108
ENGINE IDLE SPEED VARIES CONTINUED
- CONTINUED
I
OK
+
REMOVE VACUUM HOSE FROM DISTRIBUTOR
AT IDLE.
i
.t
II
OK
NOT OK
OK
PERFORM SSD-3.
SSD-3. REPAIR AND/OR
AND / OR REPLACE
PERFORM
REQUIRED.
AS REQUIRED.
PERFORM EGR
EGR SYSTEM SSD-1
SSD-l PART I1 CHECK OF
OF EGFj
EGA VALVE WHEN ON
ON THE
THE
ENGINE B
AND C STEPS 1,
BAND
1, 4,
4, 5.
5.
,-------------------------Il
NOT OK
OK
t.L.--
r--
---.,
AND / OR REPLACE AS
AS REQUIRED.
REQUIRED.
REPAIR AND/OR
OK

SSD-l PART
V EGR
EGR VENTURI AMPLIFIER DIAGNOSTIC
PROCEDURE
,
I
NOT OK
OK
,..------------~----------.,
REPAIR AND/OR
AND / OR REPLACE AS
AS REQUIRED.
NOT OK
OK
r--
- - -__--.,
REPAIR AND/OR
AND lOR REPLACE AS
AS REQUIRED.
OK
PERFORM POSITIVE CRANKCASE VENTILATION

SYSTEM SSD-11
PART A CHECK PCV
PCV FUNCTION
SSD-11 RART
1,2,3,4.
I
I
OK
SSD-13
PERFORM CARBURETOR 880-13IDLE FUEL MIXTURE -ADJUST.
ADJUST.
J
NOT OK
OK
t
---------~------------,
OK
11, 13,
13, 15,
15, 16,
16, 18,
18, 23
23 AND
PERFORM STEPS 11,
AND
OF REFERENCE TWO.
27 OF
TWO.
REPAIR AND
/ OR REPLACE AS
AND/OR
AS REQUIRED.
REQUIRED.
NOT OK
OK
jt
r--
REPAIR AND
/ OR REPLACE AS
AND/OR
AS REQUIRED.
--.,
ok
OK
t

TEMPERATURE
PERFORM AIR
AND RELAY S8.o-9.
SSO-9.
CONTROL AND
I
OK
NOT OK
OK
REPAIR AND
/ OR REPLACE AS
AND/OR
AS REQUIRED.
REQUIRED.
ENGINE FOR
FOR OVERHEATING
CHECK ENGINE
NOT OK
OK
PERFORM ROUTINE 125.

125.
OK
CONTINUED ON
ON NEXT PAGE
C.L\1364-B2
CA1364-B2
BACK TO GROUP INDEX

29-02-15
29-02-15
29-02-15
Engine
Engine Diagnosis
Diagnosis and
and Service
ROUTINE NO.
NO. 108
ENGINE IDLE SPEED VARIES
- CONTINUED
VARIES
CONTINUED
OK
I
PERFORM CYLINDER COMPRESSION

AND/OR LEAKAGE TEST.
TEST.
OK
OK
REPAIR AND/OR REPLACE

REPLACE AS
AS REQUIRED.
REQUIRED.
REPAIR
NOTOK
NOT OK
PERFORM VALVE TRAIN ANALYSIS

SSD
SSD 17.
17. REPAIR AND/OR REPLACE
AS
AS REQUIRED.
CA1364-A3
CA1364-A3
BACK TO GROUP INDEX

29-02-16
29-02-16
ROUTINE 109
ENGINE MISSES AT HIGH SPEED
I VERIFY THE CONDITION I

if
HOSES, ELECTRICAL WIRING, FUEL SYSTEM,

INSPECT VACUUM HOSES,
AIR CLEANER, DUCT, VALVE, ELEMENT, EVAPORATIVE SYSTEM
FOR LEAKS, DAMAGE OR IMPROPER CONNECTIONS.
NOT OK
OK
*
r---------~'J-.---------_..
AND/OR
REPAIR AND
/ OR REPLACE COMPONENTS
AS REQUIRED.
INSPECT DUCT DOOR TO VERIFY THAT IT

IS IN THE FULLY OPEN POSITION WITH
WARMED UP ENGINE.
r
NOT OK
OK
OK
t
---------,-----------INSPECT, TEST, REPAIR AND / OR REPLACE
550-9.
AS OUTLINED IN SSD-9.
CHECK STEPS 10, 11,

11. 12, 13, 17,22
17, 22 OF
REFERENCE ONE IN COMBINATION
COMBINATION
WITH SSO-14
SSD-14 STEP II IGNITION SYSTEM
COl
L RESERVE VOLTAGE, STEP IV
COIL
SPARK PLUG REQUIRED VOLTAGE.
r
NOT OK
OK
--------_.----------.........
PERFORM SPARK DELAY VALVE DIAGNOSIS

550-2.
PROCEDURE SSD-2.
REPAIR AND
/ OR REPLACE AS REQUIRED.
AND/OR
NOT OK
1r
r--
OK
__
REPLACE COMPONENTS AS NECESSARY.
f
PERFORM STEPS 7,
7, 9,
9, 10,
10, 14, 17, 19,
19, AND
26 OF REFERENCE TWO (EXTERNAL).
I
I
NOT OK
OK
t
PERFORM
PERFORM STEP 20
20 OF REFERENCE TWO.
TWO.
AND/OR
REPAIR AND
NOT OK
r--
OK
OK
__
PERFORM STEPS 21
21 AND 22 OF REFERENCE
/ OR REPLACE AS
TWO. REPAIR AND
AND/OR
REQUIRED
PERFORM STEPS 25,

25, 11,
11, 12,
12, 13,
13, 15,
15, 16,
16, 18
AND 27 OF REFERENCE TWO (INTERNAL).
NOT OK
OK
t
AND/OR
REPAIR AND
,t

CA1365-B1
CA1365-B1
BACK TO GROUP INDEX

2t-02-17
29-02-17
29-02-17

and Service
ROUTINE 109
109
ENGINE MISSES AT
CONTINUED
AT HIGH SPEED -CONTINUED
OK
CHECK ENGINE OPERATING

OPERATING TEMPERATURE
TEMPERATURE
FOR OVE'RHEATING.
OVERHEATING.
I
NOT OK
OK
ti
PERFORM ROUTINE NO. 125.

125.
I
OK

LEAKAGE TEST.
NOT OK
OK
OK

REPAIR AND
/ OR REPLACE AS NECESSARY.
AND/OR
NECESSARY.

AS REQUIRED.
CAl365-B2
CA1365-B2
BACK TO GROUP INDEX

29-02-18
29-02-18

and Service
ROUTINE NO.
NO. 110
110
ENGINE MISSES AT
AT LOW
LOW SPEEDS
THE CONDITION
CONDITION
VERIFY THE
1
AIR CLEANER FOR DAMAGE,
EVAPORATIVE CONTROL SYSTEM AND AIR
LEAKS, BLOCKAGE, AND IMPROPER CONNECTIONS.
,I
NOT
OK
NOT OK
r-----------~L----------.....,
REPAIR AND
/ OR REPLACLAND/OR
REPLACE AS
AS REQUIRED.
REQUIRED.
I
..,
OK
f
JL
AS REQUIRED.
REPAIR AND I/OR
OR REPLACE AS
INSPECT HIGH TENSION WIRING FOR

FOR PROPER
ROUTING AND
AND CONNECTIONS
CONNECTIONS
CHECK STEPS 10, 17

17 A'\ID
AND 22
22 OF REFERENCE
IN COMBINATION WITH SSO-14
SSD-14 STEP II
ONE IN
IGNITION SYSTEM COIL RESERVE VOLTAGE,
OK
NOT OK
OK
~L--
OK
REROUTE, REPAIR AND / OR REPLACE

AS REQUIRED.
..-
CHECK INTEGRITY OF
ALL VACUUM SYSTEMS,
OF ALL
AND CHECK FOR
FOR INTAKE MANIFOLD LEAKS.
r---
r-----------~L----------.....,
NOT OK
OK
t~
OK
NOT OK
OK
AND/OR
AS REQUIRED.
REPAIR AND
/ OR REPLACE AS
.....,
PERFORM STEPS 9,10,14,17,19,24

9, 10, 14, 17, 19, 24AND
AND2626
REFERENCE TWO
TWO (EXTERNAL).
,
I
OK
NOT OK
OK
r - - - - - - - - - - ' L -j - - - - - - - - - . . . . . ,
PERFORM
PERFORM EGR SYSTEM
SYSTEM DIAGNOSIS
PROCEDURE SSD-1
SSD-1 PART II BAND
B AND C STEPS
1,
V.
1, 4
4 AND 5
5 AND PART V.
ADJUST, REPAIR AND

AND/OR
ADJUST,
/ OR REPLACE
REQUIRED.
AS REQUIRED.
NOT OK
r----------~L----------.....,
AND/OR
REQUIRED.
REPAIR AND
,
I
NOT OK

125.
OK
CHECK ENGINE OPERATING

OPERATING TEMPERATURE
TEMPERATURE
FOR OVERHEATING.
OVERHEATING.
I
I
OK
CONTINUED ON
ON NEXT PAGE
CA1366-B1
CA1366-B1
BACK TO GROUP INDEX

29-02-19
29-02-19
Engine
Engine Diagnosis
Diagnosis and
and Service
ROUTINE NO.
NO. 110
ENGINE MISSES AT LOW SPEEDS -CONTINUED
CONTINUED
,
I
OK
PERFORM
PERFORM CARBURETOR SSD-13 -IDLE
IDLE FUEL
FUEL
MIXTURE
ADJUST.
MIXTURE -ADJUST.
NOT OK
..--
'L--
__
AND/OR
REQUIRED.
REPAIR AND
OK

LEAKAGE TEST.
TEST.
1
NOT OK
AND/OR
REQUIRED.
REPAIR AND
OK
PERFORM VALVE TRAIN ANALYSIS 550-17.
SSD-17.
AS REQUIRED.
REQUIRED.
CA1366-A2
BACK TO GROUP INDEX

29-02-20
29-02-20
ROUTINE NO. 111

111
ENGINE COLD
ENGINE STALLS AT IDLE -ENGINE

CONDITION I
+
INSPECT VACUUM SYSTEMS,

LECTR ICAL SYSTEMS,
UE L SYSTEMS,
SYSTEMS, E
ELECTRICAL
SYSTEMS, F
FUEL
---,
NOTOK
NOT OK
EPLACE AS REQUIRED.
REPAIR AND/OR R
REPLACE
OK
CHECK CHOKE FOR PROPER OPERATION BINDING, STICKING AND/OR IMPROPER

ADJUSTMENT. PERFORM SSD-12 PART I.
NOT OK
PERFORM STEP 23 - REFERENCE II

REPAIR, REPLACE AND/OR ADJUST CHOKE
MECHAN
ISM TO SP
ECI F ICATIONS.
MECHANISM
SPECIFICATIONS.
CHECK FOR CARBURETOR ICING.
NOT OK
NOTOK
OK
OK
THAW CARBURETOR AND ADD ANTI-ICING

ADDITIVE TO FUEL.
NOTOK
NOT OK
PERFORM STEPS 5,8,9

5, 8, 9 AND 24 OF
REFERENCE TWO.
OK

SSD-1 PART I "CHECK
OF EGR VALVE WHEN ON
ON THE ENGINE" B
AND C
C STEPS 1,45.
1,4 5.
--------1
'--1
NOT OK
NOT OK
I REPAIR AND/OR REPLACE AS REQUIRED. I
OK
PERFORM SSD-1
SSD-1 PARTS II AND II I II..
OK

VENTILATION
SYSTEM SSD-11
SSD-11 PART I, CHECK PCV SYSTEM
FUNCTION A, B, C,
C, D.
NOT OK
NOTOK
CA1367-B1
CA1367-B1
BACK TO GROUP INDEX

29-02-21
29-02-21
29-02-21
29-02-21

and Service
ROUTINE NO.
NO. 111
111
ENGINE STALLS AT
ENGINE COLD -CONTINUED
CONTINUED
AT IDLE -ENGINE
I
OK
OK
~~~~~~~~~~~~~~~~C_H_E_C_K~H_EA_T~C_O_N_iROL
I
SSD~O
CHECK HEAT CONTROL VALVE SSD-10
_.
OK
NOT OK
OK
r-------------J~L___
VALVE
___,
REPAIR AND/OR
AND J OR REPLACE AS
AS REQUIRED.
PERFORM CARBURETOR SSD-13

IDLE FUEL MIXTURE -ADJUST.
ADJUST.
I
NOT OK
OK
OK
r - - - - - - - - - - ' I -i - - - - - - - - - _ _ ,
17, 19,,23
19, 23 OF
PERFORM STEPS 17,
OF
TWO (EXTERNAL).
REFERENCE TWO
REPAIR AND
/ OR REPLACE AS
AND/OR
REQUIRED.
AS REQUIRED.
NOT OK
OK
REQUIRED.
AS REQUIRED.
REPAIR AND
/ OR REPLACE AS
AND/OR
PERFORM STEPS 16
OF
16 AND
AND 18
18 OF
REFERENCE TWO
TWO (INTERNAL).
-------1
" " - - 1
NOT OK
OK
t_
r---------~--------__,
AND/OR
AS REQUIRED.
REPAIR AND
J OR REPLACE AS
OK
REQUIRED.
REPAIR AND
/ OR REPLACE AS
AS REQUIRED.
AND/OR
PERFORM SPARK CONTROL DIAGNOSIS SSD-3.
REQUIRED.
AS REQUIRED.
AND/OR
REPAIR AND
J OR REPLACE AS
....,
PERFORM
PERFORM AIR
CONTROL AND DELAY SSD-9.
SSD-9.
l
I
NOT OK
OK
r----------~L---------~
AND/OR
AS REQUIRED.
REPAIR AND
J OR REPLACE AS
OK
NOT OK
t~L--
CHECK STEPS 10, 11,12

ONE
11, 12 OF
OF REFERENCE
REFERENCE ONE
IN COMBINATION WITH SSD-14 STEP II
IGNITION SYSTEM COIL RESERVE VOLTAGE,
NOT OK
OK
.----
OK
JL
t
OK
COMPRESSION
AND
/ OR LEAKAGE TEST.
AND/OR
NOT OK
OK
AND/OR
AS REQUIRED.
REPAIR AND
/ OR REPLACE AS
OK
AS REQUIRED.
CA1367-A2
BACK TO GROUP INDEX

29-02-22
29-02-22
2'-12-22
ROUTINE 112
ENGINE STALLS AT IDLE -ENGINE
ENGINE HOT

OK
WITH ENGINE RUNNING, REMOVE LINE FROM
EVAPORATIVE EMISSION CANISTER TO AIR
CLEANER.
I
NOT OK
_____________tL-
OK
INSPECT VACUUM SYSTEMS, ELECTRICAL

ELECTRICAL
SYSTEMS, FUEL SYSTEMS, EVAPORATIVE
EVAPORATIVE
SYSTEM, AIR CLEANER FOR
CONTROL SYSTEM,
CONNECTIONS.
DAMAGE, LEAKS OR IMPROPER CONNECTiONS.
REPLACE CANISTER.
NOT OK
OK
AND/OR
REPAIR AND
VERIFY CHOKE PLATE IS OPEN.
NOT OK
---.
r---
OK
AND/OR
APJUST CHOKE
REPAIR, REPLACE AND
/ OR ADJUST
MECHANISM TO SPECS. STEPS 5, 2323
REFERENCE TWO.
PERFORM REFERENCE TWO STEPS 4,

4, 7,
7, g,
9,
24, 23 (EXTERNAL).
NOT OK
1.t
I
_ _ _ _ _ _ _ _ _'t.1--..-
OK
AND/OR
REPAIR AND
/ OR REPLACE.

SSD-1 PART I;
CHECK OF EGR VALVE WHEN ON ENGINE
B &
& C
C STEPS 1,
1, 4,
4, 5.
5.
NOT OK
----..J~L...--
r---
Tt
OK
---.___,
REPAIR AND
REQUIRED.
AND/OR
SSD-1 PART V
EGR VENTURI VACUUM AMPLIFIER
DIAGNOSTIC PROCEDURE
I
NOT OK
OK
AND/OR
REQUIRED.
REPAIR AND
/ OR REPLACE AS R~QUIRED.

SSD-11 PART I. CHECK PCV SYSTEM
SYSTEM SSD-11
FUNCTION PARTS A, B, C, D.
NOT OK
AND/OR
REPAIR AND

CA13
8- 1
CA1368-B1
BACK TO GROUP INDEX

29-02-23
29-02-23

and Service
ROUTINE 112
112
ENGINE STALLS AT
ENGINE HOT -CONTINUED
CONTINUED
AT IDLE -ENGINE
I
OK
i+
CHECK HEAT CONTROL VALVE SSD-10 AND
AND
CHECK EXHAUST SYSTEMS FOR
FOR
RESTRICTIONS.
,
J
NOT OK
OK
,...--
f,.0.--
AND/OR
AS REQUIRED.
REPAIR AND
I OR REPLACE AS
--,
OK
PERFORM CARBURETOR SSD-13

-IDLE FUEL
SSD-13IDLE
MIXTURE -ADJUST.
ADJUST.
I
NOT OK
OK
t
.----------~Io____---------,
OK
PERFORM STEPS 10,

15
10, 16,
16, 17,
17, 18,
18, 19,
19, 13E,
13E, 15
REFERENCE TWO
TWO (INTERNAL).
AND/OR
REQUIRED.
REPAIR AND
I
NOT OK
r----------~L------------,
REQUIRED.
REPAIR AND
AND/OR
OK
CHECK REFERENCE ONE - STEPS 10

10 AND 11
11 IN
II IGNITION
IGNITION
COMBINATION WITH SSD-14 STEP II
SYSTEM COIL RESERVE VOLTAGE AND STEP
IV "SPARK PLUG REQUIRED VOLTAGE". PERFORM
22, REFERENCE ONE.
STEP 22,
,
I
NOT OK
OK
t
,...---------,&......-_---------,
AND/OR
AS REQUIRED.
REPAIR AND
I OR REPLACE AS
OK
PERFORM AIR CLEANER TEMPERATURE

TEMPERATURE
CONTROL AND DELAY VALVE PROCEDURE SSD-9.
SSD-9.
I
I
NOT OK
OK
OK
f
AND/OR
AS REQUIRED.
REPAIR AND
I OR REPLACE AS
CHECK ENGINE FOR

FOR OVERHEATING.
NOT OK
OK

125.
CA
1368-B2
CA1368-B2
BACK TO GROUP INDEX

29-02-24
29-02-24
ROUTINE 113
ENGINE STALLS DURING DECELERATION OR ON QUICK STOP
OK
OK

SYSTEMS, ELECTRICAL SYSTEMS, FUEL SYSTEMS,
SYSTEM, AIR CLEANER FOR DAMAGE,
LEAKS OR IMPROPER CONNECTIONS.
NOT OK
.----
-JrL-
AND/OR
REPAIR AND
----,
.----
rL-
AND/OR
REPAIR AND
t
_JL
PERFORM REFERENCE TWO STEPS 4, 7, 9 AND
28. (EXTERNAL)
I
I
NOT OK
OK
----,
1
OK
JLt
PERFORM
REFERENCE ONE
ONE STEPS
STEPS 10,
PERFORM REFERENCE
1 0 , 11,
11,7
AND8.
AND
8.
,
I
NOT OK
.---
trL_.._
--,
13,15,18,
PERFORM REFERENCE TWO STEPS 13,
15, 18,
17.
17. (INTERNAL)
AND/OR
REPAIR AND
.----
OK
OK
NOT OK
OK
OK
t~L_.._
AND/OR
REPAIR AND
NOT OK
---,
t
LEAKAGE TEST.
OK
OK
AND/OR
REPAIR AND

CA1369-B
BACK TO GROUP INDEX

29.02-25
29-02-25
29-02-25
Engine Diagnosis anq

and Service
ROUTINE 114
ENGINE HESITATES I/ STALLS DURING ACCELERATION
VERIFY THE CONDITION I
I VEFUFY
I
OK
I
SYSTEMS, ELECTRICAL SYSTEMS, FUEL SYSTEMS,
SYSTEM, AIR CLEANER FOR DAMAGE,
j
NOT OK
OK
r----------------I~-----------___.
REPAIR AND
AND/OR
PERFORM REFERENCE TWO STEPS 6, 7, 9, 10,

14, 17, 19, 11,
11, AND 23 (EXTERNAL).
NOT OK
,...-
----1't
OK
f
----.
AND/OR
REPAIR AND
101'1 REPLACE AS REQUIRED.
CHECK STEPS IN REFERENCE ONE 10, 11,

11, 12,
12,
13,22,26,
13, 22, 26, IN COMBINATION WITH SSD-14
STEP II - "IGNITION SYSTEM COIL RESERVE
"SPARK PLUG
VOLTAGE" AND STEP IV "SPARK
REQUIRED VOLTAGE."
VOLTAGE."
I
OK
NOT O'K
OK
REPAIR AND
AND/OR
REQUIRED.
I OR REPLACE AS fqEQUIRED.
fiitPAIf'
Nor
NOT Of(
OK
,...-
t.r-.-
P~RFORM REFERENCE TWO STEP 20.

PERFORM
OK
----,
21 AND 22
PERFORM REFERENCE TWO STEPS 21
- REPAIR AND I/OR
OR REPLACE AS REQUIRED.
13,15 AND
PERFORM REFERENCE TWO STEPS 13,15
16 (INTERNAL)
NOT OK
OK
I
,...---------~I--_----------,
AND/OR
REPAIR AND
I OR REPLACE AS
t
PERFORM EGR SYSTEM SSD 1 PART I
- "CHECK
OF EGR VALVE WHEN ON THE ENGINE"
B AND C STEPS 1,
PROCEDURES BAND
1, 4, 5.
REQUIRED.
REQ'UIRED.
,...-....-
NOT OK
trl--
REPA(R AND
AND/OR
REPAIR
OK
----,
PERFORM VACUUM AMPLIFIER

AMPLIFIER SSD 1 PART V
V-"EGR VENTURI VACUUM AMPLIFIER
AMPLIFIER DIAGNOSTIC
PROCEDURE"
,
I
NOT OK
OK
AND/OR
REPAIR AND
L..--
CONTINUED
ON NEXT PAGE
C_O_N_T_IN_U_E_D_O__N_N_E_X_T_PA_G_E
I
CA1370-B1
BACK TO GROUP INDEX

29-02-26
29-02-26
ROUTINE 114
ENGINE HESITATES /I STALLS DURING ACCELERATION
- CONTINUED
I
CHECK
CHECK FOR RESTRICTED EXHAUST
EXHAUST SYSTEM
AND EXHAUST
OPERATION
EXHAUST CONTROL
CONTROL VALVE OPERATIONSSD-10.
I
OK
NOT OK
r---
oL.-

REQUIRED.
REPAIR AND/OR
-----,
I
PERFORM AIR CLEANER
CLEANER TEMPERATURE
PERFORM
SSD-9.
CONTROL SYSTEM PROCEDURE SSD-9.
I
I
NOT OK
~-------__I
I L--------_
REQUIRED.
REPAIR AND/OR
OK
II
CYLINDER COMPRESSION AND/OR
PERFORM CYLINDER
LEAKAGE TEST.
I
NOT OK
OK
,-----------,"-------------,
II
REPAIR AND/OR
AND I OR REPLACE AS
AS REQUIRED.
REQUIRED.
NOT OK
REQUIRED.
REPAIR AND
lOR REPLACE AS
AS REQUIRED.
AND/OR
REPLACE DEFECTIVE SPARK PLUGS.
OK
CA1370-B2
BACK TO GROUP INDEX

29-02-27
29-02-27
ROUTINE NO.
NO. 115
115
HAS POOR ACCEl:ERATION
ACCELERATION
ENGINE HAS

~
SYSTEMS, ELECTRICAL SYSTEM,
SYSTEM, FUEL SYSTEM,
EVAPORATIVE CONTROL SYSTEM AND
AND AIR
AIRCLEANER
CLEANER FOR
FORDAMAGE
DAMAGE,
'
I
I
NOT OK
OK
.--
rL-
__
AS REQUIRED.
OK
OK
t
CHECK STEPS IN
IN REFERENCE ONE 10, 11,
11, 12,
12,
13, 7, 8, 26, 27 AND 22
22 IN
IN COMBINATION WITH
13,7,8,26,27
II - "IGNITION SYSTEM COIL
SSD-14 STEP II
RESERVE VOLTAGE" AND STEP IV SPARK
PLUG REQUIRED VOLTAGE.
I
I
NOT OK
OK
.-
t"---
__
PERFORM SSD-3
SSD-3 AND
AND REPAIR AND //OR
OR REPLACE
REPLACE
PERFORM
AS REQUIRED.
REQUIRED.
OK
PERFORM STEPS 7,
7, 9,
9, 10, 11,
11, 17, 19, 23,
23, 26.
26,REFERENCE TWO
TWO (EXTERNAL)
I
I
NOT OK
OK
,-
itL-
__
AND/OR
AS REQUIRED.
REPAIR AND
/ OR REPLACE AS
OK
CHECK EGR
BAND
EGR SYSTEM SSD-1
SSD-1 STEPS 1IB
AND
C 1,
1, 4,
4, 55 and
and STEP V.
Y.
I
NOT OK
OK
OK
OK
,---------.&.--1----------.
AS REQUIRED.
+
CHECK AIR
AIR CLEANER AND
AND DELAY VALVES
SSD-9
NOT OK
OK
,..----------. J---------_
REPAIR AND /OR
/ OR REPLACE AS
AS REQUIRED.
OK
OK
CHECK FOR
FOR STUCK HEAT CONTROL VALVE
SSD-10 AND
AND RESTRICTED EXHAUST SYSTEM.
I
I
NOT OK
OK
OK
r-----------'.L-----------..
AND/OR
AS REQUIRED.
REPAIR AND
/ OR REPLACE AS
,
I
NOT OK
IF STEP 20
21,
20 IS
IS NOT
NOT OK
OK PERFORM STEPS 21,
22
2 2 - REFERENCE TWO
TWO AND
AND REPAIR AND / OR
AS REQUIRED.
REPLACE AS
PERFORM
PERFORM STEPS 20,
20, 14,
14, 15,
15, 16,
16, 2727
REFERENCE TWO.
TWO.
,
I
OK
ON NEXT PAGE
CONTINUED ON
CA
1371-B1
CA1371-B1
BACK TO GROUP INDEX

29-02-28
29-02-28
ROUTINE NO.
115
NO. 115
ENGINE HAS
HAS POOR ACCELERATION - CONTINUED
Ii
OK
OK
CHECK FOR
FOR OVERHEATING
NOT OK
OK
OK
r----------+.&..----------PERFORM ROUTINE 125.

125.
VISUALLY CHECK BELT DRIVEN COMPONENTS

FOR ROTATION.
NOT OK
OK
OK
,..----------,----------------.,
tt
REPAIR AND
lOR REPLACE AS
AND/OR
AS REQUIRED.
CHECK FOR
FOR PARTIALLY LOCKED OR
OR
DRAGGING
DRAGGING BRAKES.
BRAKES.
OK
NOT OK
NOT,
OK
,..----------
REPAIR AND
I OR REPLACE AS
AND/OR
AS REQUIRED.
OK
NOT OK
OK
r---
&.--
----.
AS REQUIRED.
REPAIR AND/OR
AND I OR REPLACE AS
AND TIMING CHAIN

CHECK VALVE TIMING AND
OR BELT.
NOT OK
OK
---,
r---
CHECK FOR
OR
FOR CLUTCH SLIPPAGE (MIT)
(M/T) OR
MALADJUSTED A/T.
AlT.
.L---
AND/OR
AS REQUIRED.
REPAIR AND
lOR REPLACE AS
OK
t
OR
LEAKAGE TEST.
I
NOT OK
OK
_--------,r,...------------.
AND/OR
AS REQUIRED.
REPAIR AND
I OR REPLACE AS
OK
f
IF NOT
REPLACE DEFECTIVE SPARK PLUGS IF
NOT
PREVIOUSLY DONE.
OK
NOT OK
REPAIR AND/OR
AND I OR REPLACE AS
AS REQUIRED.
REQUIRED.

AS REQUIRED.
CA1371-B2
BACK TO GROUP INDEX

29-02-29
29-02-29
ROUTINE NO. 116

ENGINE HAS LESS THAN NORMAL POWER
CONDITION I
+
LEAKS OR IMPROPER CONNECTIONS.
NOT OK
tr
r--
----,
r--
t
CHECK AUTOMATIC TRANSMISSION FLUID
LEVEL.
-IOKI
NOT OK
OK
CHECK FOR CLUTCH SLIPPAGE (MIT),

(M/T), OR
MALADJUSTMENT
MALADJUSTMENT OF TRANSMISSION (A/T).
NOT OK
OK
__- - - - - - - - t - -t - - - - - - - - - - - ,
23, 20,
20, 24,
24, 21-D,
PERFORM STEPS 9, 7, 14, 23,
21-0,
26
2 6 - REFERENCE TWO EXTERNAL.
OK
NOT OK
__- - - - - - - - t L -t- - - - - - - - - - - - ,
IF STEP 20 IS NOT OK PERFORM STEPS 21,
22
21,22
- REFERENCE TWO AND REPAIR AND / OR
t
PERFORM STEPS 10,
10, 11,
11, 12,
12, 13,
13, 16,
16, 18,
18, 26,
26,
27 -REFERENCE
ONE.
27
REFERENCE ONE.
1
OK
NOT OK
__- - - - - - - - t - -t- - - - - - - - - - - ,
PERFORM EGR SSD-l

SSD-1 STEPS I-B AND C 1, 4, 5
ANDV.
AND Y.
NOT OK
OK
NOT OK
__--------L--~------------,
PERFORM SSD-ll
SSD-11 STEPS 1-0,
I-D, ]I
H AND
tt
SSD-11 STEPS I-A, B, (C, D.

PERFORM PCV SSD-11
OK
t
CHECK AIR CLEANER AND DELAY VALVE
SSD-9.
NOT OK
OK
CA1372-B1
CA1372-B1
BACK TO GROUP INDEX

29-02-30
29-02-38
29-02-30

and Service
ROUTINE NO.
NO. 116
116
ENGINE HAS
CONTINUED
HAS LESS THAN NORMAL POWER -.
CONTINUED
CHECK
CONTROL VALVE SSD-10 AND
CHECK HEAT CONTROL
FOR RESTRICTED EXHAUST SYSTEM.
SYSTEM.
I
NOT OK
r-----------~--------------..,.-......,
REQUIRED.
OK
PERFORM STEPS 10,

13, 16,
16, 17,
17, 19,
19, 15,
15, 27
2710, 13,
REFERENCE TWO
TWO (INTERNAL).
I
NOT OK
OK
OK
AN~OR REP~:_A_C_E_A_S_._R_E_Q_U_IR_E_D_'~~~.~~~~~~_C_H_E_C_K~F_O~R~VERHEATIN&

REPAIR
NOT OK
OK
_________+
CHECK FOR OVERHEATING.
. . .,
OK
t
__
VISUALLY CHECK BELT DRIVEN COMPONENTS
VISUALLY
FOR ROTATION.

125.
NOT OK
OK
~--------t~~~-~~-~---,
OK
CHECK FOR PARTIALLY LOCKED OR

CHECK
DRAGGING
DRAGGING BRAKES.
BRAKES.
REPAIR AND
I OR REPLACE AS
AND/OR
AS REQUIRED.
NOT OK
OK
t
~-------_.---~~~~~~~---,
OK
CHECK VALVE TIMING AND

AND TIMING CHAIN
OR BELT.
REPAIR AND
I OR REPLACE AS
AND/OR
AS REQUIRED.
NOT OK
OK
r--
~_~~~~---,
AS REQUIRED.
OK
OK
PERFORM CYLINDER COMPRESSION AND

AND/OR
pERFORM
I OR
LEAKAGE TEST.
I
NOT OK
OK
tr......-~~~~~~~---,
r--
R~PLACE
AS REQUIRED.
NOT OK
OK
AS REQUIRED.
OK
REPLACE DEFECTIVE SPARK

SPARK PLUGS
OK
;t

AS REQUIRED.
CA1372-A2
BACK TO GROUP INDEX

29-02-31
29-02-31
29-02-31
29-02-31
ROUTINE 117
EXHAUST SYSTEM BACKFIRE

INSPECT VACUUM SYSTEMS & IGNITION WIRING FOR LEAKS
AND/OR IMPROPER ROUTING.
NOT OK
AND/OR
REPAIR AND
OK
*
PERFORM STEPS 10, 11,

11, 12, AND 13 OF
REFERENCE ONE.
, - - - - - - - - - - - ' - - - - - - - - - - - - - 1I
NOT OK
~_---L....--~---___,
AND/OR
REPAIR AND
+
PERFORM PROCEDURE B OF SSD-4
(NON-CATALYTIC) OR SSD-5 (CATALYTIC)
NOT OK
r - - - - - - -_ _---l~L---
__,
AND/OR
REPAIR AND

LEAKAGE TEST
-,
INSPECT FOR STICKING OR BURNED VALVES.

AND/OR
REPAIR AND
PERFORM SSD-7 AND STEP 18 REFERENCE

TWO.
OK
t .---------.,
r----------,L
trL.-
NOT OK
NOT OK
OK
REPAIR AND/OR
r---
OK
OK
VERIFY PROPER CAMSHAFT TIMING AND/OR

NOT OK

REPAIR AND
AND/OR
CA1373-B
BACK TO GROUP INDEX

29-02-32
29-02-32
and Service
ROUTINE 118
118
ENGINE SURGES

~
INSPECT VACUUM SYSTEMS, ELECTRICAL SYSTEMS, FUEL SYSTEM,
EVAPORATIVE CONTROL SYSTEM, AND
AND AIR
AIR CLEANER FOR
FOR DAMAGE,
BLOCKAGES, LEAKS, AND
AND PROPER CONNECTIONS.
,
NOT OK
OK
r - - - - - - - - - - - ' L1. . - - - - - - - - - - - .
AND/OR
REPAIR AND
/ OR REPLACE AS
AS REQUIRED.
,
i
OK
OK
CHECK STEPS IN
IN REFERENCE ONE 10,11,12,13,
10, 11, 12, 13,
19,20
19, 20 AND 22
22 IN
IN COMBINATION WITH 550-14
SSD-14
STEP II
II -- "IGNITION SYSTEM COIL RESERVE
VOLTAGE" AND STEP IV
IV "SPARK PLUG REQUIRED
VOLTAGE."
I
NOT OK
OK
r---------------.;~~-----------.
OK
t
PERFORM COMPRESSION BALANCE (ELECTRICAL)
STEP 17
ONE.
17 REFERENCE ONE.
REPAIR AND
/ OR REPLACE AS
AND/OR
AS REQUIRED.
NOT OK
OK
OK
t
I---------~~-----------,
AND/OR
PERFORM CYLINDER COMPRESSION AND
/ OR
LEAKAGE TEST.
PERFORM SSD-3 SPARK CONTROL SYSTEMS

AND SPARK DELAY VALVE.
OK
NOT OK
OK
r-----------'~I.--------------.
JL
PERFORM STEP 25
25 OF
OF REFERENCE TWO
TWO AND
AND
REPAIR AND
/ OR REPLACE AS
AND/OR
AS REQUIRED.
SSD-1 PARTS I,
IV, AND
AND VV
PERFORM SSD-1
I, III,I, IV,
EGR SYSTEM DIAGNOSIS.
AND/OR
AS REQUIRED.
I OR REPLACE AS
REPAIR AND
OK
NOT OK
OK
r - - - - - - - - - - - - 't, " - - - - - - - - - - - .
PERFORM
PERFORM SSO-II
SSD-II STEPS I-D,
I-D, AND
AND n.
II.
AND/OR
REPAIR AND
/ OR REPLACE AS
AS REQUIRED.
REQUIRED.
I
NOT OK
OK
23 OF
OF REFERENCE TWO
TWO (IF
PERFORM STEP 23
(I F
AND REPAIR AND / OR REPLACE
APPLICABLE) AND
AS REQUIRED.
,
I
NOT OK
OK
PERFORM SSD-11
SYSTEM"
SSD-11 PART A
A "PCV SYSTEM'
1,2,3,4.
I
I
OK
t
PERFORM STEPS 17,
17, 9,
9, 14,
14, 23A,
23A, AND
AND 26
26
PERFORM
OF REFERENCE TWO.
TWO. (EXTERNAL)
(EXTERNAL)
I
I
OK
tt
CONTINUED ON
ON NEXT PAGE
CA1374-B1
CA1374-B1
BACK TO GROUP INDEX

1'-12-33
29-92-33
29-02-33
ROUTINE 118
118
ENGINE SURGES -CONTINUED
CONTINUED
I
OK
20 OF
OF REF.
REF. TWO.
TWO.
PERFORM STEP 20
NOT OK
OK
I
OK
PERFORM STEPS 21
21 & 22
22 OF
OF REF.
REF. TWO
TWO
AS
AND REPAIR AND / OR
OR REPLACE AS
REQUIRED.
PERFORM SSD-13 IDL~

ADJUST
IDLE FUEL MIXTURE. -ADJUST
NOT OK
OK
-----Jr~
T
r---
___,
-----Jr~
AS REQUIRED.
REPAIR AND/OR
AND I OR REPLACE AS
NOT OK
OK
SSD-9, AIR
PERFORM 880-9,
CONTROL &
& DELAY VALVE.
REPAIR AND/OR
fltEPAIR
AND / OR REPLACE AS
AS REQUIRED.
t--
OK
___,
OK
+
PERFORM STEPS 10,
AND 27
27
10, 13,
13, 15,
15, 16,
16, 19,
19, AND
OF REFERENCE TWO.
TWO. (INTERNAL)
I
I
NOT OK
OK
----.,;t~
r--
REPAIR
AIPAtR AND/OR
AND I OR REPLACE AS
AS REQUIRED.
___,
REPAIR AND/OR
AND / OR REPLACE AS
AS REQUIRED.
CHECK FOR
FOR RESTRICTED EXHAUST SYSTEM
5SD-10.
AND PERFORM
PERFORM SSD-10.
t
----------~'---------------.
NOT OK
OK
NOT OK
OK
AND/OR
REPAIR AND
I OR REPLACE AS
AS REQUIRED.
OK
OK

LEAKAG
E TEST:
LEAKAGE
TEST!
I
OK
t
550-17.
AS REQUIRED.
CA1374-A2
BACK TO GROUP INDEX

29-02-34
29-02-34
ROUTINE NO. 119

EXCESSIVE FUEL CONSUMPTION

I
LEAKS, AND IMPROPER CONNECTIONS.
NOT OK
OK
OK
AND/OR
REPAIR AND
CHECK TIRES FOR PROPER PRESSURE.
_t
,
NOT OK
t
r----------......;~'---------INFLATE TIRES TO PROPER SPECIFICATIONS.
OK
CHECK TO SEE THAT AIR CLEANER DOOR

IS IN OPEN POSITION.
OK
NOT OK
PERFORM SSD-9
INSPECT AIR CLEANER FILTER ELEMENT.
NOT OK
OK
REPLACE AS REQU
IRED.
REQUIRED.
1C, 23 A, H, I, J, K, 10, 17,

PERFORM STEPS 1C,
9, OF REFERENCE TWO (EXTERNAL).
...---------,
OK
NOT OK
~----~
AND/OR
REPAIR AND
CHECK STEPS 10, 11,

11, 12, 13, 17 OF REFERENCE
SSO-14-ONE IN COMBINATION WITH STEP II OF SSD-14
IGNITION SYSTEM COIL RESERVE VOLTAGE AND
STEP IV - SPARK PLUG REQUIRED VOLTAGE.
I,
OK
NOT OK
LACE AS
AND/OR
REPLACE
REPAIR AND
/ OR REP
REQUIRED.
PERFORM EGR SYSTEM SSO-1

SSD-1 PART 1 -"CHECK OF EGR VALVE WHEN ON THE
ENGINE" BAND
C; 1,4,5.
B ANDC;
1,4,5.
OK
NOT~ OK
,.
PLACE AS REQUIRED.
AND/OR
REPLACE
REPAIR AND
/ OR RE

CA
1375-B 1
CA1375-B1
BACK TO GROUP INDEX

29-02-35
29-02-35
and Service
NO. 119
ROUTINE NO.
119
CONTINUED
EXCESSIVE FUEL CONSUMPTION -CONTINUED
I
OK
+
PERFORM VACUUM AMPLIFIER
AMPLIFIER SSD-1
SSD-1 PART V
V
EGR VENTURI VACUUM AMPLIFIER
DIAGNOSTIC
DIAGNOSTIC PROCEDURE.
---lrl.---
AND I OR REPLACE AS
AS REQUIRED.
REPAIR AND/OR
OK
tL--
AND I OR REPLACE AS
AS REQUIRED.
REPAIR AND/OR

SYSTEM SSD-11 PART I. CHECK
CHECK PCV
PCV SYSTEM
FUNCTION PARTS A,
A, B,
B, C,
C, D.
D.
OK
NOT OK
...---
,
II
NOT OK
OK
OK
PERFORM STEPS 12,11,13,14,15,16,18,

12, 11, 13, 14, 15, 16, 18,
23B,
AND
23 B, C,
C, AND
AND 27
27 OF
OF REFERENCE TWO
TWO AND
SSD-13 IDLE FUEL MIXTURE
- ADJUST.
NOT OK
OK
OK
t
PERFORM
20 OF REFERENCE TWO.
PERFORM STEP 20
TWO.
REPAIR AND/OR
AND / OR REPLACE AS REQUIRED.
REQUIRED.
NOT OK
,..--
r.l-.-
REPAIR AND
I OR REPLACE AS
AND/OR
AS REQUIRED.
----.
OK
PERFORM HEAT VALVE SSD-10

SSD-10 AND CHECK
PERFORM
SYSTEM.
FOR RESTRICTED EXHAUST SYSTEM.
NOT OK
OK
. 1.--
OK
---.
REPAIR AND
/ OR REPLACE AS
AND/OR
AS REQUIRED.
REQUIRED.
CHECK FOR PARTIALLY LOCKED OR

DRAGGING
DRAGGING BRAKES.
BRAKES.
NOTIOK
NOT OK
OK
,
I
REPAIR AND
/ OR REPLACE AS
AND/OR
AS REQUIRED.
REQUIRED.
NOT OK
OK
REPAIR AND
/ OR REPLACE AS
AND/OR
AS REQUIRED.
REQUIRED.
FOR CLUTCH SLIPPAGE (M

( M /ITT),
) , OR
CHECK FOR
OR
IMPROPER TRANSMISSION OPERATION AND
AND
( A IT).
/T).
FLUID LEVEL (A
OK
t
J_
CONTINUED ON
ON NEXT PAGE
PAGE
CA1375-A2
BACK TO GROUP INDEX

29-02-36
29-02-36
ROUTINE NO. 119

EXCESSIVE FUEL CONSUMPTION -CONTINUED
CONTINUED
ojcI
OK

AN
D/OR LEAKAGE TEST.
AND/OR
,
NOTOK
NOT OK
PERFORM VALVE TRAIN ANALYSIS

SSD
SSD 17. REPAIR AND/OR REPLACE
AS
AS REQUIRED.
CA1375-A3
BACK TO GROUP INDEX

29-02-37
29-02-37
29-02-37
ROUTINE NO. 120

EXCESSIVE OIL CONSUMPTION

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:
AND / OR OIL.
A. STEAM CLEAN THE ENGINE (IF NECESSARY) TO REMOVE ACCUMULATED DIRT AND/OR
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.)
SSD-11 PART I A, B, C, D.
D. PERFORM POSITIVE CRANKCASE VENTILATION SYSTEM SSD-11
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 LEAKAGE).
F.
SHUT OFF ENGINE AND CHECK FOR LEAKAGE AT:

1.
2.
3.
4.
5.
6.
7.
8.
9.
VALVE ROCKER ARM COVER GASKETS.

OIL PAN GASKET.
CYLINDER BLOCK FRONT COVER GASKET.
CYLINDER BLOCK TO FUEL PUMP GASKET AND FUEL PUMP AIR VENT.
INTAKE MANIFOLD SEALS.
CRANKSHAFT SEALS.
DISTRIBUTOR HOUSING O-RING.
OIL FILTER
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 NUMBER 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 REINSPECT 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 OUTLINED BELOW.
NOTE: A NEW ENGINE MAY REQUIRE UP TO 6,000 MILES OF OPERATION IN ORDER TO PROPERLY SEAT (BREAK IN) THE
RINGS. FOR THIS REASON,
REASON, THE ENGINE SHOULD NOT BE CONDEMNED AS LONG AS OIL ECONOMY IS IMPISTON RINGS.
ACCUMULATION
PROVING WITH MILEAGE ACCUMULATION. IF OIL ECONOMY CEASES TO IMPROVE WITH MILEAGE ACCUMULATION
CORRECTIVE ACTION SHOULD BE TAKEN.
CA1376-A1
CA1376-A1
BACK TO GROUP INDEX

29-02-38
29-02-38
ROUTINE NO. 120 -CONTINUED

CONTINUED
LEAKAGE TEST.
I
NOT OK
I
OK
DISASSEMBLE ENGINE. MAKE REPAIRS AS

NECESSARY TO CORRECT LOW OR ERRATIC
COMPRESSION.
,--
DRIVE VEHICLE UNDER NORMAL CONDITIONS

UNTIL ENGINE IS AT NORMAL OPERATING
TEMPERATURE. STOP ENGINE. REMOVE AND INSPECT SPARK PLUGS FOR "WET" OIL DEPOSITS.
I
NOT OK
it.a..-
I
---.
CHECK FOR EXCESSIVE VALVE STEM TO GUIDE CLEARANCE, WORN,

LOOSE, OR DAMAGED VALVE STEM SEALS, CRACKED INTAKE
MANIFOLD, LEAKING INTAKE MANIFOLD GASKET, AND I/ 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.
AND/OR
MAKE ALL NECESSARY REPAIRS AND
I OR REPLACEMENTS.
OK
!
CA1376-A2
BACK TO GROUP INDEX

29-02-39
29-02-39
121
ROUTINE NO. 121
DIESELS
ENGINE DIESELSCONTINUES TO RUN AFTER SHUT OFF

+
EVAPORATIVE CONTROL SYSTEM, AND AIR CLEANER FOR DAMAGE,
BLOCKAGES, LEAKS, AND PROPER CONNECTIONS. CHECK TO
INSURE THAT PROPER GRADE OF FUEL IS BEING USED.
I
NOT OK
...--
-----"tL--
OK
----.
REPAIR AND/OR
CHECK THE POSITION OF THE AIR CLEANER

DUCT DOOR TO INSURE THAT IT IS IN THE
WARM ENGINE (OPEN) POSITION.
,
I
NOTIOK
NOT OK
___________t.L..-
OK
PERFORM SSD-9 AND REPAIR AND / OR

CHECK THE INTEGRITY OF ALL VACUUM

SYSTEMS AND CHECK FOR INTAKE
MANIFOLD LEAKS.
NOT OK
OK
t~L--
.--
AND/OR
REPAIR AND
PERFORM STEPS
REFERENCE ONE
TWO AND CHECK
POSITIONER FOR
P'OSITIONER
10, 11,
11, 7,
7, AND 8 OF
STEP 28 OF REFERENCE
THROTTLE SOLENOID
PROPER FUNCTION.
OK
NOT OK
i+
REPAIR AND/OR
AND / OR REPLACE AS REQUIRED.
RECHECK FOR DIESELING.
7, 9..
9, 17, 24 AND 26
ST~PS 3, 4, 7,
PERFORM STEPS
OF REFERENCE TWO (EXTERNAL).
IF ENGINE STILL DIESELS
NOT OK
r---------------:~L---------____.
REPAIR AND/OR
OK
JL
+
PERFORM CARBURETOR SSD-13 IDLE FUEL
MIXTURE -ADJUST.
ADJUST.
I
NOT OK
AND / OR RE
REPAIR AND/OR
REPLACE
PLACE AS REQUIRED.
I
NOT OK
REPLACE
REPAIR AND/OR
AND / OR RE
PLACE AS REQUIRED.
OK
f
PERFORM SSD-7 -FUEL
FUEL DECELERATION
DECELERATION
VALVE DIAGNOSTIC.

CA1377-A1
CA1377-A1
BACK TO GROUP INDEX

29-02-40

and Service
29-02-40
ROUTINE 121
121
ENGINE DIESELSDIESELS
CONTINUES TO
CONTINUED
TO RUN
RUN AFTER SHUT OFF -CONTINUED
Ii
L
I
NOT OK
________---'JL--
OK
OK
FOR OVERHEATING.
OVERHEATING.
CHECK ENGINE F;OR
,t
OK
PERFORM EGR SYSTEM SSD-1,

SSD-1, PART II
B &
5..
& C STEPS
STEPS 1,
1, 44 AND 5

125.
NOT OK
OK
OK
OK
REPAIR AND
/ OR REPLACE AS
AND/OR
AS REQUIRED.
PERFORM VACUUM AMPLIFIER SSD-1, PART V.

V.
NOT OK
OK
OK
r-----------~~-------_
t
AND/OR
AS REQUIRED.
REPAIR AND
lOR REPLACE AS
PERFORM STEPS 17,

OF
17, 18,
18, 19,
19, 27
27 AND
AND 15
15 OF
REFERENCE TWO
TWO (INTERNAL).
NOT OK
OK
OK
LACE AS
AND/OR
REPLACE
AS REQUIRED.
/ OR REP
REPAIR AND
CHECK EXHAUST HEAT CONTROL VALVE

AND CHECK FOR
FOR RESTRICTED
PER SSD-10 AND
EXHAUST SYSTEM.
NOT OK
OK
REPAIR AND
/ OR RE
PLACE AS REQUIRED.
AND/OR
REPLACE
REQUIRED.
NOT OK
REPAIR AND
/ OR REPLACE AS
AND/OR
AS REQUIRED.
OK
~----_---t--------....,
SSO-17.
AS REQUIRED.
CA1377-A2
BACK TO GROUP INDEX

29-02-41
29-02-41
Engine
and Service
29-02-41
29-02-41
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 INBE A MATTER OF INDIVIDUAL
INDIVIDUAL INTERPRETATION. THEREFORE, IF THE MOST LIKELY STEP ,FAILS
FAILS TO CORRECT
DEED MAY BE
SO ON UNTIL THE CONDITION IS CORRECTED.
THE CONDITION, PROCEED TO THE NEXT LIKELY STEP,
STEP, AND SO
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. IF CONDITION PERSISTS,
PERSISTS, INSPECT FOR WORN OR MALFUNCTIONING VALVE
VALVE
TRAIN COMPONENTS. PERFORM SSD-17.
SSD-17. IF NO FAILURE IS DETECTED CHECK FOR EXCESSIVE VALVE STEM TO
VALVE GUIDE WEAR BY EXERTING SIDE PRESSURE VALVE STEM.
STEM. IF NOISE IS CORRECTED EXCESSIVE WEAR
IS INDICATED. IF VALVE IS ELIMINATED AS A POSSIBLE CAUSE,
CAUSE, CHECK FOR ACCESSORY COMPONENT NOISE
BY LOOSENING AND/OR REMOVING DRIVE BELTS ONE AT A TIME UNTIL NOISE STOPS.
STOPS. INVESTIGATE FUEL
PUMP AND/OR PUMP DRIVE POSSIBLE CAUSE.
NOTE: IIF
F NOISE IS ISOLATED TO THERMACTOR SYSTEM,
SYSTEM, PERFORM SSD-4 OR 5.
C. SHARP RAPPING - VARIES WITH ENGINE SPEED
USUALLY CAUSED BY MALFUNCTIONING 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. INSPECT FOR CARBURETOR GASKET LEAKS.
NOTE: IF NOISE IS ISOLATED TO THERMACTOR SYSTEM,
E. SHARP SNAPPING NOISE DURING ACCELERATION
ACCELERATION
PERFORM STEPS 21,22
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.
H. RINGING, GRINDING OR COMBINATION OF BOTH
CHECK FOR LOOSE,
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,
I. BUZZING OR WHISTLING DURING ENGINE OPERATION
PERFORM RADIATOR CAP FUNCTIONAL CHECK AND VERIFY PROPER CAP SEALING IF ENGINE OVERHEATING IS
INDICATED. CHECK FOR INTERFERENCE WITH THE FAN OR FRONT END DRIVE COMPONENTS BY FOREIGN MATELOOSE, OR BROKEN SURROUNDING PARTS.
PARTS. CHECK FOR LOOSE CARBURETOR MOUNTING. CHECK FOR
RIAL OR LOOSE,
VACUUM LEAKS, CHECK POWER STEERING.
CA1378-C
BACK TO GROUP INDEX

29-02-42
29-02-42
ROUTINE NO.
122A
NO. 122A
OR PINGING
SPARK KNOCK OR
CONDITION
WITH OWNER AS
AS TO GRADE OF
OF
CHECK WITH
FUEL
USED.
FUEL BEING
BEING USED.
OK
NOT OK
OK
ADVISE OWNER OF
OF PROPER GRADE OF
OF FUEL.
CHECK ENGINE
ENGINE FOR OVERHEATING.
OVERHEATING.
NOT OK
OK
OK

125.
USE ROTUNDA ENG.

ENG. SYSTEM ANALYZER
USE
OR
OR EQUIVALENT TO CHECK STEPS
STEPS IN
IN REF.
ONE
10,11,12,13,20
ONE 10, 11, 12, 13, 20 AI'ID
AND 22
22 IN
IN COMBINA
COMBINATION WITH SSD14
SSD-14 STEP"
STEP II "IGNITION SYSTEM COIL RESERVE VOLTAGE" AND STEP
TEM
IV "SPARK PLUG REQUIRED VOLTAGE".
OK
NOT OK
OK
PERFORM COMPRESSION BALANCE (ELECTRICAL) STEP

STEP 17 OF
OF REFERENCE ONE.

AS REQUIRED.
OK
NOT OK
OK
PERFORM "SPARK CONTROL SYSTEM AND

AND
SPARK DELAY VALVE" SSD-3.
PERFORM CYLINDER COMPRESSION AND/

OR
OR LEAKAGE TEST.
OK
NOTOK
NOT OK
IA, B,
B, C,
C, PCV
PCV SYSTEM
PERFORM PART lA,
SSD-11.
SSD-11.

AS REQUIRED.
OK
NOTOK
NOT OK
PERFORM SSD-11
SSD-11 STEPS
STEPS 1-0
1-D AND IIII REPAIR
AND/OR REPLACE AS
AS REQUIRED.
REQUIRED.
PERFORM STEPS
9,14,
STEPS9,
14, 23A AND 26
26 OF
OF REF.
TWO
TWO (EXTERNAL).
NOTOK
NOT OK
OK
STEP 23
23 OF
OF REF.
REF. TWO
TWO (IF
(IF APPLIPERFORM STEP
AS
CABLE) AND REPAIR AND/OR REPLACE AS
REQUIRED.
REQUIRED.
SSD-9, "AIR
"AIR CLEANER TEMP.
PERFORM SSD-9,
CONTROL AND DELAY VALVE".
OK
OK
[\lOT
NOT OK
OK

AS REQUIRED.
STEPS 10,
10, 13,
13, 15,
15, 16,
16, 19 AND 27
PERFORM STEPS
27
OF
OF REF.
REF. TWO
TWO (INTERNAL).
NOTOK
NOT OK
OK

AS REQUIRED.
SUBSTITUTE KNOWN
KNOWN GOOD FUEL PUMP.
NOTOK
NOT OK
OK
REINSTALL ORIGINAL FUEL PUMP.

INSTALL KNOWN
KNOWN GOOD
GOOD DISTRIBUTOR.

AS REQUIRED.
OK
NOTOK
NOT OK
I
AS REQUIRED.
BACK TO GROUP INDEX
I
REINSTALL ORIGINAL DISTRIBUTOR. PERFORM
CYLINDER LINKAGE AND/OR COMPRESSION
AS REQUIRED.
CHECK. REPAIR AND/OR REPLACE AS
CA1378-B1
CA1378-B1

29-02-43
29-02-43
and Service
ROUTINE NO.
NO. 123
123
ENGINE VIBRATION

CHECK INTEGRITY OF
OF MOTOR MOUNTS, VIBRATION DAMPER
AND FAN
FAN
NOT OK
OK
REPAIR AND/OR
AND I OR REPLACE AS
AS REQUIRED.
OK
CYCLE ENGINE ACCESSORY COMPONENTS.
NO CHANGE
~
LOOSEN DRIVE BELTS ONE
AT A TIME AND
AND
ONE AT
OPERATE ENGINE TO
ASCERTAIN. IF
TO ASCERTAIN
VIBRATION IS
IS CAUSED BY
BY ACCESSORY
COMPONENTS.
NOT OK
OK
REQUIRED.
REPAIR AND/OR
I
OK
CHECK ALL
ALL MOVING INTERNAL ENGINE
COMPONENTS FOR PROPER OPERATION.
NOT OK
REQUIRED.
REPAIR AND/OR
CA1379-A
BACK TO GROUP INDEX

29-02-44
29-02-44
ROUTINE NO. 124

ENGINE FAILS TO REACH NORMAL OPERATING TEMPERATURE
VERIFY THE CONDITION BY THE USE OF A THERMOMETER

THERMOMETER
NOT OK
OK
II
REPLACE THERMOSTAT
CHECK OPERATION OF TEMPERATURE SENDING

UNIT, GAUGE OR LIGHT.
1 --------
r---
L.-
NOT OK
I
REPAIR
REPAIR AND
A N D /I OOR
R REPLACE AS REQUIRED.
REQUIRED.
CA1380-A
BACK TO GROUP INDEX

29-02-45
29-02-45

and Service
Service
Engine
ROUTINE NO.
NO. 125
LOSS
LOSS OF COOLANT OR ENGINE OVERHEATING
OVERHEATING
I VERIFY
CONDITION
THE CONDITiON
1+
AND CONDITION,
CONDITION, REPLACE REQUIRED
REQUIRED
CHECK COOLANT LEVEL AND
CLEAN RADIATOR CAP SEAL AND SEAT,
SEAT.
COOLANT AND CLEAN
,
i
COOLANT)
NOT OK (LOSS OF COOLANT)
LEAKS.
CHECK FOR OBVIOUS EXTERNAL LEAKS.
CHECK ENGINE OIL FOR CONTAMINATION BY
COOLANT.
,
i
Ii
OK
OK
NOT OK
REPAIR AND
AND/OR
R'EPAIR
lOR
REQUIRED.
OK (ENGINE OVERHEATS)
OVERHEATS)
INSPECT FAN
FAN BELT WEAR AND TENSION,
TENSION,
DAMAGE.
RADIATOR FINS FOR DIRT OR DAMAGE.
AND
CHECK FOR OBVIOUS COOLANT, AIR AND
RESTRICTIONS.
EXHAUST FLOW RESTRICTIONS.
NOT OK
r-------'a.-------.
PRESSURE TEST CHECK

LEAKS
FOR EXTERNAL LEAKS
CAP, IN
IN RADIATOR CAP,
COOLING AND HEATING
SYSTEM.
ADJUST, REPAIR
AND/OR
AND
I OR REPLACE AS
REQUIRED.
REQUIRED.
OK
REPAIR AND
AND/OR
lOR
PRESSURE TEST CHECK

FOR INTERNAL LEAKS.
_JL
CHECK COOLANT
COOLANT
CIRCULATION BY
REMOVING CAP AND
OPERATING AT 2000
RPM. CHECK FLOW AT
FILLER NECK AFTER
ENGINE WARMS UP.
NOT OK
Ii
OK
OK
NOT
NOT OK
OK
OK
OK
REPLACE THERMOSTAT.
CHECK OPERATION OF
FAN CLUTCH IF
APPLICABLE.
1
NOT OK
1
REPLACE WATER PUMP.
II
OK
j
NOT OK
DISASSEMBLE ENGINE
TO THE EXTENT
REQUIRED TO
DETERMINE THE
CAUSE AND TO
REPAIR INTERNAL
LEAKAGE.
SEE ENGINE
OVERHEATS
PROCEDURE.
NOT" OK
NOT
REPAIR AND/OR REPLACE

COOLING PVS TEMPERATURE
SENDING UNIT AND/OR
WARNING LIGHT
LIGHT AS REQUIRED.
NOT OK
OK
PERFORM FAN CLUTCH

DRIVE TEST AND
REPLACE FAN CLUTCH
IF REQUIRED.
CHECK TEMPERATURE
SENDING UNIT, GAUGE
AND I OR WARNING
AND/OR
LIGHT. (IF EQUIPPED
WITH COOLING PVS,
CHECK FOR VACUUM
AT PVS OUTLET WITH
ENGINE IN OVERHEAT
CONDITION AT IDLE.
OK
lO,
11, 13 OF REFERENCE
ONE.
-..
CONTINUED ON
NEXT PAGE
CA1381-A1
BACK TO GROUP INDEX

29-02-46
29-02-46
ROUTINE NO. 125

LOSS OF COOLANT OR ENGINE OVERHEATING CONTINUED
...---,- - I
NOT OK
OK
PERFORM SSD-3 AND

I OR
REPAIR AND
AND/OR
CHECK
CHECK FOR RESTRICTED
EXHAUST, PERFORM
SSD-10.
OK
I
NOT OK
,.....-----t
I OR
REPAIR AND
AND/OR
NOT OK
_---~L-----""""
REMOVE RADIATOR,
I OR
CLEAN AND
AND/OR
NOT OK
CLEAN SYSTEM WITH

MANUFACTURERS
MANUFACTURERS
RECOMMENDED
COOLING SYSTEM
CLEANER.
I
OK
REMOVE WATER PUMP

AND CHECK FOR
DAMAGED IMPELLER
ETC.
I
OK
REPLACE WATER PUMP.
RADIATOR,
DISCONNECT RADIf-TOR,
REMOVE THERMOSTAT
AND PRESSURE FLUSH
BLOCK AND HEAD
COOLANT PASSAGES.
NOT OK
DISASSEMBLE ENGINE
AND CHECK FOR
COOLANT
BLOCKED COOLANT
PASSAGES. REPAIR
REQUIRED.
AS REQUIRED.
CA1381-A2
BACK TO GROUP INDEX

29-02-47
29-02-47
ROUTINE NO. 126

SMOKE FROM VEHICLE EXHAUST SYSTEM


LEAKS, BLOCKAGE AND PROPER CONNECTIONS.
NOT OK
--'~L...-
AND/OR
REPAIR AND
OK
....,
r----------~L...--------.....,
PERFORM SSD-11
SSD-11 STEPS A1, 2,
2, 3 & 4
PCV SYSTEM DIAGNOSIS.
OK
REPAIR AND/OR
PERFORM STEPS 11,

11, 19A,
19A. AND 23 OF
REFERENCE TWO (EXTERNAL).
NOT OK
r---------~----------.....,
OK
ON AUTOMATIC TRANSMISSION VEHICLES,

APPLY 16" HG. VACUUM TO TRANSMISSION
TRANSMISSION
MODULATOR (BOTH PRIMARY AND
SECONDARY ON D.A.D. TRANSMISSIONS.)
NOT~
NOT OK
OK
,---------REPAIR AND/OR
OK
NOT OK
REPAIR AND/OR
CHECK CONDITION OF AIR CLEANER AND

AIR CLEANER FILTER ELEMENTS FOR
CLOGGING AND CONTAMINATION.
NOT OK
REPAIR AND/OR
OK
CHECK THE INTEGRITY OF ALL VACUUM

SYSTEMS AND CHECK FOR INTAKE
MANIFOLD LEAKS.
NOT OK
OK
REPAIR AND/OR
CA1382-B1
CA1382-B1
BACK TO GROUP INDEX

29-02-48
29-02-48
ROUTINE NO. 126

SMOKE FROM VEHICLE EXHAUST SYSTEM
- CONTINUED
SYSTEM
,
I
OK

11, 13, 15, 16, 18, 19 AND
27 OF REFERENCE TWO (INTERNAL).
NOT OK
r-
----,
REPAIR AND/OR
NOT OK
REPAIR AND/OR
OK

LEAKAGE TEST.
I
OK

CA1382-B2
BACK TO GROUP INDEX

29-02-49
29-02-49
29-02-49
NO- 127 HIGH FLOOR PAN TEMPERATURES

ROUTINE NO
(CATALYST EQUIPPED VEHICLES ONLY)
1. PERFORM SSD-5 PART C, STEPS 1-5.
DISCONNECT WIRING TO SOLENOID
SOLENOID VALVE.
2. DISCONNECT
FINGER OVER
OVER OPEN END OF VACUUM HOSE TO BY3. WHILE THE ENGINE IS AT IDLE CONDITION, PLACE FINGER
IT DOES, REPLACE SOLENOID.
PASS VALVE. NO VACUUM SHOULD ATTRACT YOUR FINGER. IF IT
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:
GRANADA AND MONARCH FRONT SEAT OF VEHICLE

ON PINTO, MUSTANG, MAVERICK, COMET, GRANADA
MUST BE REMOVED TO REPLACE THE FLOOR PAN SWITCH. ON A
ALL
L L OTHER VEHICLES, SWITCH
IS LOCATED ON THE TOEBOARD.
CA1450-A
BACK TO GROUP INDEX

29-02-50
29-02-50
ELECTRICAL SYSTEM DIAGNOSIS

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.
8. Check fast idle speed.
9. Check engine idle manifold vacuum.
10. Check basic timing - per 550-15.
SSD-15.
11. Check retard timing - per SSD-15.
550-15.
12. Check mechanical advance - per
per 5S0-15.
SSD-15.
SSD-15.
13. Check total advance at 2500 RPM - per 550-15.
14. Check ignition coil primary voltage 1000 RPM (measured at "Bat"
" B a t " terminal).
15. Check battery voltage - 1000 RPM.
SSD-14 (loaded or on quick acceleration).
16. Check spark plug firing voltage per 550-14
*17.
17.
Check compression balance 1-8 cylinders (electrical - no EGR).
*18.
18.
Check ignition system coil reserve voltage - 1000 RPM,

550-14.
RPM, per SSD-14.
*19.
19.
550-14.
Check distributor
distributor rotor high voltage gap drop, per SSD-14.
20.
Check coil and spark plug wire resistance, per SSD-14.

550-14.
21.
Inspect coil and spark plug wires and connections.
22.
of cap and rotor.

Check condition of
23. Check ignition coil condition and operation, per SSD-14.

550-14.
24. Check primary wiring in ignition system, per SSD-14.
550-14.
25.
Check charging rate to battery with engine operating at approximately

approximately 1000 RPM.
26. Check spark delay valve for correct operation (5S0-2).

(SSD-2).
27.
Use auxiliary vacuum source to check integrity of

of vacuum advance and retard diaphragnl.
diaphragm.
distributor dwell at normal engine idle and at 2500 RPM.

28. Check distributor
NOTE: Check and adjust fuel decel valve to specifications after any idle speed adjustment is performed.
* On catalyst equipped vehicles,
vehicles, do not perform Steps 17,18,
17, 18, and 19 until vehicle passes 5tep
Step 16.
CA1419-B
CA
1419-8
BACK TO GROUP INDEX

29-02-51
29-02-51
29-02-51
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
AND/OR
REPAIRED, ADJUSTED, CLEANED AND I/ OR REPLACED AS REQUIRED. IDLE MIXTURE SHOULD BE VERIFIED AND
lOR
ADJUSTED AFTER CARBURETOR INTERNAL REPAIRS.
1. CHECK FUEL SUPPLY IN FUEL TANK

A.
B.
C.
D.
CHECK
CHECK
CHECK
CHECK
FOR
FOR
FOR
FOR
FUEL AVAILABILITY
CONTAMINATION
FUEL CONTAMINATION
FUEL LEAKS IN TANK AND FUEL LINES
DAMAGED PARTS IN TANK AND FUEL LINES
2. CHECK FUEL DELIVERY TO CARBURETOR

A.
B.
C.
D.
D.
E.
F.
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
FOR
FOR
FOR
FOR
FOR
FOR
FUEL DELIVERY TO FILTER PRIOR TO REMOVING FILTER FROM CARBURETOR

FUEL DELIVERY THROUGH FILTER(S) TO CARBURETOR
FUEL PUMP LEAKS
DAMAGE, LEAKS, BLOCKAGES AND/OR PROPER CONNECTIONS.
CONTAMINATION
CONTAMINATION
DAMAGED PARTS
3. CHECK CARBURETOR VACUUM HOSES, FUEL LINES, AND PCV LINE

A.
B.
C.
D.
CHECK
CHECK
CHECK
CHECK
FOR
FOR
FOR
FOR
LEAKS
DAMAGED PARTS
PROPER ASSEMBLY
CONTAMINATION
CONTAMINATION
4. CHECK ELECTRICAL CONNECTIONS

A. CHECK FOR PROPER ASSEMBLY
B. CHECK FOR SHORTED CIRCUIT
C. CHECK FOR DAMAGED PARTS
5. CHECK CHOKE HEAT SUPPLY SYSTEM
A.
B.
C.
D.
D.
CHECK
CHECK
CHECK
CHECK
FOR
FOR
FOR
FOR
AIR LEAKS
DAMAGED PARTS
PROPER ASSEMBLY
MISSING PARTS (EXTERNAL ONLY)
6. CHECK AIR CLEANER

A.
B.
C.
D.
CHECK
CHECK
CHECK
CHECK
FILTER ELEMENT(S) 'FOR

FOR CONTAMINATION
CONTAMINATION
HEAT CONTROL VALVE FOR FUNCTION (SSD-9)
FOR DAMAGED PARTS
FOR PROPER ASSEMBLY
7. CHECK THROTTLE LINKAGE AND THROTTLE PLATES
A.
B.
C.
D.
E.
CHECK
CHECK
CHECK
CHECK
CHECK
FOR
FOR
FOR
FOR
FOR
BINDING
FULL TRAVEL
PROPER ASSEMBLY
CONTAMINATION
CONTAMINATION
DAMAGED PARTS
8. CHECK ENGINE SPEED ADJUSTMENTS

A. CHECK LOW IDLE SPEED WI
W/ AND WIO
W/O TSP (NOTE: WHEN TSP-OFF SPEED IS ADJUSTED,
ALSO ADJUST FUEL BOWL VENT CLEARANCE PER SSD-16)
B. 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
AND I OR MECHANICAL PROBLEMS HAVE
BEEN PROPERLY CORRECTED - THEN FINAL ADJUSTMENTS SHOULD BE MADE ACCORDING TO SPECCA1420-B1
IFICATION.
CA1420-B1
BACK TO GROUP INDEX

29-02-52
29-02-52
9.
9. CHECK SECONDARY THROTTLE LINKAGE AND CHOKE LOCKOUT LINKAGE
A.
A.
B.
B.
C.
C.
D.
D.
CHECK
CHECK
CHECK
CHECK
FOR
FOR
FOR
FOR
LINKAGE BINDING
BINDING
DAMAGED PARTS
PROPER ASSEMBLY
CONTAMINATION
CONTAMINATION
10. CHECK AIR VALVE PLATE,

PLATE, METERING NEEDLES AND / OR JETS
A.
A.
B.
B.
C.
C.
D.
D.
CHECK
CHECK
CHECK
CHECK
FOR
FOR
FOR
FOR
BINDING
BINDING
DAMAGED PARTS
PROPER ASSEMBLY
ASSEMBLY
CONTAMINATION
CONTAMINATION
11. CHECK ACCELERATOR PUMP SYSTEM

A.
A.
B.
B.
C.
C.
D.
D.
E.
E.
F.
F.
G.
G.
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FUEL DISCHARGE
DISCHARGE
BINDING
BINDING
PROPER ADJUSTMENT
ADJUSTMENT
FUEL LEAK
CONTAMINATION
CONTAMINATION
PROPER ASSEMBLY
ASSEMBLY
DAMAGED PARTS
12. CHECK FOR FUEL IN FUEL BOWL

A.
A.
B.
B.
C.
C.
USE FUEL GAUGE TO CHECK FOR FUEL IN BOWL (WHEN GAUGE IS AVAILABLE)
CHECK FOR CONTAMINATION AND,
550-18
AND, IF REQUIRED, CLEAN CARBURETOR PER SSD-18
DISASSEMBLE AND CHECK ITEM # 113
3 AS REQUIRED
COMPONENTS
13. CHECK FUEL INLET SYSTEM COMPONENTS
A.
A.
B.
B.
C.
C.
D.
D.
E.
E.
F.
F.
G.
G.
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
FOR CONTAMINATION AND,

AND, IF REQUIRED, CLEAN CARBURETOR PER SSD-18
FOR BINDING
BINDING
DAMAGE
FOR DAMAGE
FOR PROPER ASSEMBLY
FOR FUEL LEVEL
FOR FLOAT ALIGNMENT
ALIGNMENT
FLOAT FOR LEAKS
14. CHECK FUEL BOWL VENTS
A.
A.
B.
B.
C.
C.
D.
D.
CHECK
CHECK
CHECK
CHECK
FOR
FOR
FOR
FOR
RESTRICTION
RESTRICTION
ADJUSTMENT
PROPER ADJUSTMENT
ASSEMBLY
PROPER ASSEMBLY
BINDING
BINDING
& MAIN)
15. CHECK FUEL METERING SYSTEMS (IDLE &
A.
A.
B.
B.
C.
C.
D.
D.
E.
E.
F.
F.
G.
G.
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
FOR
FOR
FOR
FOR
FOR
FOR
FOR
CONTAMINATION
CONTAMINATION
LEAKS
FUEL LEAKS
AIR LEAKS
RESTRICTIONS
RESTRICTIONS
ASSEMBLY
PROPER ASSEMBLY
DAMAGED PARTS
PROPER IDLE FUEL MIXTURE (SSD-13)
16. CHECK FUEL ENRICHMENT SYSTEM
A. CHECK FOR AIR LEAK

A.
B. CHECK FOR FUEL LEAK
B.
C. CHECK FOR RESTRICTIONS
RESTRICTIONS
C.
D. CHECK FOR DAMAGED PARTS
D.
E. CHECK FOR PROPER ASSEMBLY
ASSEMBLY
E.
F. CHECK FOR CONTAMINATION
CONTAMINATION
F.
CA1420-B2
BACK TO GROUP INDEX

Engine
Engine Diagnosis
Diagnosis and
and Service
Service
29-02-53
29-02-53
29-02-53
29-02-53
17. CHECK
CHECK ALTITUDE
ALTITUDE COMPENSATOR
COMPENSATOR
17.
A.
A.
B.
B.
C.
C.
D.
D.
E.
E.
F.
F.
G.
G.
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
BINDING
BINDING
AIR LEAK
LEAK
AIR
FUEL LEAK
LEAK
FUEL
CONTAMINATION
CONTAMINATION
DAMAGED PARTS
PARTS
DAMAGED
PROPER ASSEMBLY
ASSEMBLY
PROPER
PROPER ADJUSTMENT
ADJUSTMENT
PROPER
18. CHECK
CHECK FUEL
FUEL DECELERATION
DECELERATION SYSTEM
SYSTEM
18.
A.
A.
B.
B.
C.
C.
D.
D.
E.
E.
F.
F.
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
CONTAMINATION
CONTAMINATION
RESTRICTION
RESTRICTION
PROPER ASSEMBLY
ASSEMBLY
PROPER
DAMAGED PARTS
PARTS
DAMAGED
PROPER ADJUSTMENT
ADJUSTMENT
PROPER
AIR LEAKS
LEAKS
19. CHECK VENTURI VALVE SYSTEM

SYSTEM
19.
A.
A.
B.
B.
C.
C.
D.
D.
E.
E.
CHECK
CHECK
CHECK
CHECK
CHECK
FOR
FOR
FOR
FOR
FOR
FOR
FOR
BINDING
BINDING
CONTAMINATION
CONTAMINATION
ASSEMBLY
IMPROPER ASSEMBLY
LEAKS
LEAKS
PARTS
DAMAGED PARTS
DELIVERY
20. CHECK FUEL PUMP FUEL DELIVERY
A.
A.
B.
B.
C.
D.
CHECK
CHECK
CHECK
CHECK
PRESSURE AND VOLUME WITH ORIGINAL FILTER

PRESSURE AND VOLUME WITH NEW FILTER
CONTAMINATION
FOR CONTAMINATION
FOR FUEL LEAK
21. CHECK FUEL TANK
A.
B.
C.
D.
CHECK
CHECK
CHECK
CHECK
FOR LEAKS
FOR SOURCES WHERE DIRT OR WATER MAY ENTER
TANK FILTER AND PICK-UP FOR FUNCTION
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
23. CHECK CHOKE SYSTEM
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
PER SSD #
1 2 PART #
1 (LINKAGE)
#12
#1
PER SSD ##12
1 2 PART #
2 (HEAT)
#2
PER SSD ##12
1 2 PART ##3
3 (ELECTRIC)
FOR PULLDOWN
FOR DECHOKE
CAM CLEARANCE
CHOKE PLATE ALIGNMENT
CHOKE CAP INDEX
INDEX SETTING
FOR PROPER
PROPER ASSEMBLY
FOR DAMAGED
DAMAGED PARTS
FOR CONTAMINATION
24. CHECK
CHECK HOT
HOT IDLE
IDLE COMPENSATOR
COMPENSATOR
A.
A.
B.
B.
C.
C.
D.
D.
E.
E.
F.
F.
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
FOR
FOR DAMAGED
DAMAGED PARTS
FOR
FOR AIR
AIR LEAK
LEAK
PROPER
PROPER TEMPERATURE
TEMPERATURE CALIBRATION
FOR
FOR CONTAMINATION
FOR
FOR PROPER
PROPER ASSEMBLY
ASSEMBLY
FOR
FOR RESTRICTION
BACK TO GROUP INDEX
CA1420-B3

29-02-54
25.
25. CHECK
C H E C K SPARK
SPARK PORT,
PORT, EGR
E G R PORT,
PORT, AND
AND
A.
A.
B.
B.
C.
C.
D.
D.
E.
E.
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
AND
A N D GASKET
G A S K E T SURFACE
SURFACE
AIR
AIR LEAKS
LEAKS
FUEL LEAKS
LEAKS
PROPER ASSEMBLY
DAMAGED PARTS
27.
27. CHECK
C H E C K INTERNAL
INTERNAL GASKET
GASKET
A.
A.
B.
B.
C.
C.
D.
D.
E.
E.
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
I/OR
OR ELA
ELAVENTURI
VENTURI PORT
PORT
RESTRICTION
RESTRICTION
CONTAMINATION
CONTAMINATION
PROPER
PROPER ASSEMBLY
ASSEMBLY
DAMAGED PARTS
AIR
AIR LEAKAGE
26.
26. CHECK
C H E C K EXTERNAL
EXTERNAL GASKET
GASKET
A.
A.
B.
B.
C.
C.
D.
D.
29-02-54
AND
A N D GASKET
GASKET SURFACE
SURFACE
AIR
AIR LEAKS
LEAKS
FUEL LEAKS
LEAKS
PROPER ASSEMBLY
ASSEMBLY
PROPER
DAMAGED PARTS
CONTAMINATION
CONTAMINATION
28.
28. CHECK DASHPOT AND
AND BRACKET
BRACKET
A.
A.
B.
B.
C.
C.
D.
D.
CHECK
CHECK
CHECK
CHECK
FOR
FOR
FOR
FOR
FOR
FOR
FOR
FOR
PROPER ADJUSTMENT
ADJUSTMENT
PROPER ASSEMBLY
PARTS
DAMAGED PARTS
CONTAMINATION
CONTAMINATION
CA1420-A4
CA1420-A4
EMISSION CONTROL SYSTEM DIAGNOSIS AND SERVICE PROCEDURES

SERVICE/DIAGNOSIS PROCEDURE
PAGE
SSD-1
SSD-1
EG
R System
EGR
02-56
SSD-2
Spark Delay Valve
02-60
02-61
02-61
SSD-3
Spark Control Systems and Spark Delay Valve
SSD-4
Thermactor System - Non-catalytic
02-63
SSD-5
Thermactor System - Catalytic
02-65
SSD-7
Fuel Decel Valve
0267
02-67
SSD-9
Air Cleaner Temperature Control and

and Delay Valve
02-68
SSD-10 Exhaust Heat Control Valve
02-70
SSD-11 PCV System

SSO-11
02-70
SSD-12 Automatic Choke

SSO12
SSO-13
Ie Fuel Mi
xture
SSD-13 Id
Idle
Mixture
02-71
02-71
02-74
SSD-14 Ignition System Diagnosis
02-76
SSD-15 Ignition and

and Timing
02-79
SSO-16
SSD-16 Fuel Bowl Vent Clearance
02-79
SSD-17 Valve Train Diagnosis
02-79
02-80
SSO-18
SSD-18 Carburetor Cleaning Procedures
CA1422-A
SSD-l-EGR
SSD-1EGR SYSTEM
DIAGNOSIS-EGR
DIAGNOSISEGR VALVE AND
VENTURI VACUUM AMPLIFIER
EGR valve removal and cleaning
procedures can be found in Parts VI, VII
and VIII of this system diagnosis.
BACK TO GROUP INDEX
The EGR delay valve diagnosis is

described under Spark Delay Valve
Diagnosis SSD-2.
I. Check of EGR Valve When On
The Engine
A. Start the engine and warm it up until
A.
engine coolant temperature is above

the calibrated temperature of the
EGR PVS
PVS valve as indicated below
according to the color code of the
PVS valve.
B. Check all vacuum hoses in the
29-02-55
29-02-56
COLOR COnE
CODE
Green Top
Top
Black Top
Plain Dichromate or
Blue Top

and Service
TEMPERATURE (F.)
(OF.)
Above 680
68 0
1000
Above 100
133 0
Above 133
CA1387-A
CA1387A
system to be
be sure they are
are open and
and
not broken, split or cracked and
and fit
fit
snugly onto connectors. Remove the
EGR vacuum supply hose from the
and hook a vacuum hose
EGR valve and
EGR valve to an
an external,
from the
the EGR
gaged, variable vacuum source with
increments of one in. Hg, 0.10 in. Hg
Hg
graduations and minimum 10
10 in.
Mercury capacity.
C. Gradually apply vacuum to the EGR

valve and simultaneously observe the
movement of the EGR
EGR valve stem.
1.
1. The stem should visually be
observed to start to move within
1.0 in. Hg of the Diaphragm Signal
Vacuum as noted in Specifications.
To ease observation of valve stem,
mark stem prior to observation.
2. If the
EGR valve does not meet
2.
the EGR
"start
"start to open" specification,
specification,
the valve.
replace the
Hg
3. With engine off, apply 8 in.
in. Hg
vacuum to EGR
EGR valve and trap.
Vacuum should remain within 11
in. Hg for a minimum of 30
seconds. Replace the EGR
EGR valve if
seconds.
is out of specification.
it is
4. With engine at idle, apply vacuum
to EGR
EGR valve of at least 8 in.
in. Hg.
Hg.
The valve should move to the
the full
extent of its travel and engine
should roughen, rpm should
decrease and/or stop completely.
If idle quality doesn't change there
E G R flow
flow and
a n d if
if
is no EGR
specifications of Step 3 have been
met something is plugging the
Perform cleaning
EGR system. Perform
procedure to determine problem.
5.
5. With hose routings properly
connected, restart engine and
stabilize temperature. If the engine
is not acceptable, the
idle quality is
EGR valve may
may not be sealing
properly. If this condition is
encountered, install a new
new EGR
valve and new gasket. Recheck the
idle condition of the engine. If
If
there is
is no
no improvement in idle
quality, the
the problem is elsewhere.
EGR valve should be
The original EGR
re-installed and further
further engine
diagnosis should be performed to
ddetermine
e t e r m i n e tthe
h e offending
offending
ccomponent.
o m p o n e n t . If
If there
t h e r e is
improvement in idle quality,
improvement
change EGR
EGR valve.
change
BACK TO GROUP INDEX
To Check The
The Carburetor EGR
II. To
EGR
The Following
Port, Perform The
Steps:
Steps:
A. Attach a vacuum gage directly to the
EGR port on the carburetor using a
suitable hose.
B. With the engine running, open the
carburetor throttle quickly and
carburetor
momentarily to at least the 1/2
1/2 open
position. While performing this step,
avoid overspeeding the engine.
C. Observe the vacuum gage for a quick
rise and fall as the throttle is opened
and closed. (Absolute vacuum value
If a vacuum is
is not a criteria.) If
evident, the EGR port is open and
If no vacuum is evident, the
OK. If
EGR
carburetor is
EG
R port in the carburetor
plugged or restricted and should be
cleaned.
III. EGR PVS Functional Check
A. Verify that the EGR valve, external
vacuum passages, and/or solenoid
valve (if so equipped) are functional.
functional.
PVS With
B. PVS
With Two
Two Connectors
Connectors
1. Disconnect both vacuum hoses at the
PVS valve. Connect vacuum gage to
either connector
connector on the PVS.
either
Connect manifold
Connect
manifold vacuum
vacuum or
auxiliary vacuum source of at least
10 in. Hg. to other connector.
2. Start engine and warm it up until
the calibration temperature of the
EGR PVS as previously indicated.
a. If no reading is noted on vacuum
gagePVS has failed and should
gage-PVS
be replaced.
noted-PVS is OK.
b. If vacuum is notedPVS
C. PVS
With Three
Three Connectors
Connectors
C.
PVS With
1. Disconnect EGR vacuum hose at
carburetor and connect manifold
manifold
carburetor
vacuum or auxiliary vacuum source
to hose.
2. Disconnect EGR vacuum hose at
EGR valve and connect a vacuum
gage to the hose.
NOTE: If
If available, chassis
chassis
dynamometer diagnostic equipment
is beneficial
beneficial when checking EGR
valve function.
a. If no reading is noted on vacuum
gage-PVS
gagePVS has failed and should
be replaced.
noted-PVS is OK.
b. If vacuum is notedPVS
D. PVS
With Four
Connectors
PVS With
Four Connectors
1. Disconnect vacuum hoses at the PVS
valve. Connect a vacuum gage to
either of the two ports marked D and
M. Connect a vacuum supply to the
other.
29-02-55
a. If there is no vacuum reading
readingthat portion of the PVS is OK.
noted-the PVS is
b. If
If vacuum is notedthe
defective and should be replaced.
3. Connect the gage to either one of the
bottom two ports marked E and S
and the vacuum supply to the other.
a. If vacuum is notedthe
noted-the PVS is
OK.
b. If there is no vacuum reading-the
readingthe
PVS is defective and should be
replaced.
FOR 1975
IV. STEP DELETED FOR
V.(1) EGR
EGR Venturi Amplifier
Procedure(Dual Vacuum Plug
Procedure-(Dual
Design)
A. After
After the basic components of the
EGR system-EGR
systemEGR valve, EGR/
EGR/
PVS valve, vacuum hose routings
etc. are checked, the vacuum
vacuum
amplifier system should be checked
as follows. These system checks and/
or maintenance procedures must be
done in sequenced order.
1. Remove output hose that connects
amplifier
amplifier to EGR
EGR valve from
from
amplifier. Connect output hose to
vacuum gage.
2. Remove reservoir vacuum hose
and "tee" this hose with the source
vacuum line. Connect the source
hose to a manifold vacuum.
NOTE: On
On some applications, a
NOTE:
vacuum
solenoid valve
valve or
oraavacuum
vacuum
vacuum solenoid
operated switch is connected
between the
and EGR
EGR
the amplifier and
valve. On
On these applications, they
and the
should be bypassed and
vacuum gage connected to the
amplifier output hose.
3. Depress accelerator and release
after engine
engine has reached
reached
after
1500/2000 rpm.
rpm. After engine has
has
returned
returned to curb idle speed,
remove vacuum hose at carburetor
venturi. The
The vacuum gage reading
in. Hg
Hg of
should be within .3
. 3 in.
of
specified bias value. Zero bias may
read from 0 to .5
.5 in.
in. Hg.
Hg. If bias
vvacuum
a c u u m vvalue
a l u e is out
o u t of
of
specification, replace amplifier.
amplifier.
Refer to Specifications.
after engine
after
engine has reached
reached
1500/2000
rpm. If output
1500/2000 rpm.
output
vacuum gage reading shows an
in. Hg
increase of greater than I1 in.
during the
the acceleration period, the
amplifier should be
be replaced.
5. Hook
Hook up vventuri
e n t u r i hose to
carburetor. If an increase in output
vacuum of more than .5
.5 in.
in. Hg
above Step 3 isisobserved,
observed,check
checkidle
idle
speed. High idle speed could
29-02-56
increase output vacuum due to
venturi vacuum increase. Reset
idle speed to specifications
if
specifications if
necessary. Refer
Refer to Vehicle
Emission Control Decal.
6. Observe vacuum gage connected to
6.
to
EGR
hose. Depress accelerator
EG
R hose.
rapidly to 1500/2500 rpm.
Vacuum should increase to above
in. Hg during accelerations and
4 in.
return to the vacuum bias noted in
idle. If out
Step 3 or less at curb idle.
amplifier.
of specification, replace anlplifier.
7.
7. Connect "R" nipple to a manifold
vacuum. Connect US"
"S" to a spark
port vacuum. Connect "V" nipple
to venturi vacuum. Connect "C"
"c"
nipple to a vacuum gage.
gage. Depress
accelerator and release after engine
speed has reached 1500/2000
1500/2000
rpm. After engine has returned to
curb idle speed, remove vacuum
hose at venturi. Check spark port
vacuum. Vacuum greater than 2
amplifier
in. Hg could increase amplifier
output vacuum. The vacuum gage
.5 in.
reading should be less than .5
Hg for all amplifiers. If out of
of
specification, replace amplifier.
8.
8. Check external amplifier vacuum
reservoir as follows:
follows:
a. If external reservoir does not use
an external
external check
check valve,
disconnect reservoir to amplifier
hose. Charge reservoir with
external vacuum source to 14
14 in.
in.
Hg and trap. Vacuum should
remain within 1 in. Hg for 11
if out of
minute. Replace if
of
specification.
b. If external reservoir utilizes an
external check valve,
valve, an external
vacuum source of 15
15 in.
in. Hg
Hgmust
must
be applied at the tee between
check valve and reservoir at the
amplifier
amplifier side of the tee and
trapped. Vacuum should remain
within 11 in.
in.Hg
Hgfor
for 11minute.
minute.IfIf
out of specification, proceed to
next step.
Remove hose to reservoir at tee
and charge reservoir to 15
15 in.
in. Hg
Hg
and trap.
trap. Vacuum must remain
within 11 in.
in. Hg for 11 minute.
minute.IfIf
out of specification-replace.
If
specificationreplace. If
reservoir checks good proceed to
next step.
Inspect check valve by removing the hose to check valve at
the tee and applying external
15 in. Hg and
and
vacuum source of 15
trap. Vacuum reading should
remain within one in. Hg for
specificaone minute. If out of specification replace.
NOTE: In all cases where check

valve or reservoir is replaced,
repeat check with new part.
BACK TO GROUP INDEX

V.(2) EGR Venturi Vacuum
Amplifier Diagnostic
Procedure-(Single
Procedure(Single Vacuum Plug
Design)
A. After the basic components of the
EGR system-EGR
systemEGR valve, EGR/
EGR/
PVS
PVS valve, vacuum hose routings,
etc. are checked, the vacuum
amplifier should be system checked
follows. These
These system checks
checks and/
and/
as follows.
or maintenance procedures must be
done in sequenced order for Ranco
systems.
systems.
1.
1. Remove output hose that connects
amplifier
amplifier to EGR valve from
from
amplifier. Connect output hose to
vacuum gage.
2.
2. Check that vacuum source hose
from amplifier
amplifier is connected to
manifold
manifold vacuum nipple. Some
engines have vacuum source
connected to EGR carburetor port
vacuum. For this application, the
vacuum hose should be connected
to manifold for this test.
NOTE:
NOTE: On some applications, a
vacuum solenoid
solenoid valve
valve or
oraavacuum
vacuum
vacuum
operated switch is connected
between the amplifier and EGR
valve.
In these applications, they
valve. In
should be bypassed and the
vacuum gage connected to the
amplifier output hose.

after
after engine
engine has reached
reached
RPM. After engine has
1500/2000 RPM.
returned to curb idle speed,
remove vacuum hose at carburetor
venturi. The vacuum gage reading
should be within .3 in. Hg of
of
specified bias value for other than
zero bias. Zero bias may read from
in. Hg.
Hg. If bias
bias vacuum valve
o0 to .5.5 in.
specification, replace
is out of specification,
amplifier. Refer to Specifications.
4.
after
after engine
engine has reached
reached
1500/2000
1500/2000 RPM. If
If output
output
vacuum gage reading shows an
increase greater than 1 in. Hg
during the acceleration period, the
amplifier should be replaced.
5. Hook
Hook up venturi
v e n t u r i hose to
5.
carburetor. If an increase more
than .5
.5 in. Hg. above Step 3 in
output vacuum is observed, check
idle speed. High idle speed could
increase output vacuum due to

venturi vacuum increase. Reset
idle speed to specifications, if
if
necessary. Refer
Refer to Vehicle
6.
6. Observe vacuum gage connected to
EGR
hose. Depress accelerator
EG
R hose.
1500/2500 rpm.
rapidly to 1500/2500
Vacuum should increase to above
4 in.
in. Hg during accelerations and
return to the vacuum bias noted in
29-02-56
Step 3 or less at curb idle.
idle. If out
of specification, replace amplifier.
7.
7. Check external amplifier vacuum
reservoir as follows:
follows:
a. If external reservoir does not use
external check
check valve,
an external
disconnect reservoir to amplifier
hose. Charge reservoir with
external vacuum source to 14
14 in.
in.
Hg and trap. Vacuum should
remain within 1 in. Hg for 1I
minute. Replace if out of
of
specification.
b. If external reservoir utilizes an
external check valve,
valve, an external
vacuum source of 15
15 in.
in. Hg
Hgmust
must
be applied at the tee between
check valve and reservoir at the
amplifier
amplifier side of the tee and
trapped. Vacuum should remain
in. Hg
Hgfor
for 11minute.
minute.IfIf
within 1 in.
out of specification, proceed to
next step.
Remove hose to reservoir at tee
15 in.
in.Hg
Hg
and charge reservoir to 15
and trap.
trap. Vacuum must remain
in. Hg
Hgfor
for 11minute.
minute.IfIf
within 11 in.
out of specification, replace.
If
replace. If
reservoir checks good proceed to
next step.
Inspect check valve by removing
and
hose to check valve at the tee and
applying external vacuum
source of 15
15 in. Hg and trap.
Vacuum reading should remain
within one in. Hg for one
minute. If out of specification,
specification,
replace.
replace.
NOTE: In all cases if check
valve or reservoir is replaced,
repeat check with new
new part.
VI. Poppet And Internal Tapered
Stem EGR Valves
P r o c e d u r e for cleaning
cleaning and
Procedure
conditions for replacing EGR valve.
NOTE: Sequence
NOTE:
Sequence of
of maintenance
maintenance can
can
be varied to suit individual engine
characteristics.
A. EGR Valve
A.
Valve Removal
Removal
1.
1. Remove the EGR valve for cleaning.
CAUTION:
CAUTION: DO NOT STRIKE OR
OR
PRY
P R Y ON
ON THE
T H E VALVE
VALVE
DIAPHRAGM HOUSING OR
SUPPORTS, AS THIS MA
Y
MAY
DAMAGE
D A M A G E THE
T H E VALVE
VALVE
OPERATING
OPERATING MECHANISM
MECHANISM
AND/OR CHANGE THE VALVE
CALIBRATION.
2.
2. Check orifice hole in the EGR valve
deposits. A small hand drill
body for deposits.
may be used to clean the hole if
if
taken
plugged: Extreme care must be taken
to avoid enlarging the hole, or
damaging the surface.
If The
B. If
The Valve
ValveIsIs Not
Not To
ToBe
Be Taken
Taken
Apart For
For Cleaning:
Cleaning:
1.
1. Prior to cleaning, if the orifice plate
29-02-57
is less than a .450 in. dia. hole, it
must be removed. Caution must be
used in removing the orifice to
deforminguse a hook type
prevent deforming-use
tool for removal.
2.
2. To clean the valve seat and poppet,
first apply 15
15 in. Hg vacuum to
retract the diaphragm.
3. Preferred cleaning method
Where facilities for blast cleaning
metal parts are available the
following procedure should be
followed:
a. Apply masking tape to diaphragm
for protection.
b. Direct the blaster stream against
the valve poppet until the poppet
appears free of deposits.
deposits. Remove
debris with shop air.
CAUTION: DO NOT DIRECT
BLASTER STREAM AGAINST
THE VALVE DIAPHRAGM.
c. C lI e aannor
o r iiffiice
c e pIa
p l a ttea
e and
c.
nd
counterbore in valve body.
counterbore
Reinstall orifice by using a small
amount of contact cement to retain
plate in place while assembling the
valve to the carburetor spacer.
CAUTION: Apply cement only to
CAUTION:
edges of
oforifice
orifice plate
plateto
toavoid
avoid
outer edges
restriction to orifice.
4. Alternate cleaning method
a. The passages and cavities of the
valve body can be cleaned by
scraping or utilizing a short length
of speedometer cable driven by a
drill motor. Insert cable up into
valve cavity and with slight force
move cable back and forth while
drill motor is in motion.
b. To clean the valve seat and poppet,
insert cable between poppet and
seat. Turn on drill motor and allow
cable to move around the valve
seat area in a circular motion. Care
should be used to avoid removal of
of
metal and damaging valve seat or
poppet.
c.
c. Remove all debris with shop air.
d. C lI e aannor
o r iiffiice
c e p lI aate
t e and
and
counterbore
Reinstall orifice by using a small
amount of contact cement to retain
plate in place while assembling the
valve to the carburetor spacer.
CAUTION:
edges of
oforifice
orifice plate
plateto
toavoid
avoid
outer edges
c:
If The
C. If
The Valye
ValveIsIsTo
ToBe
BeTaken
TakenApart
Apart
For ClelJJ1ing:
For
Cleaning:
1.
1. Separate the diaphragm section from
the main mounting body.
2.
2. Clean the valve plate, stem, and the
mounting plate using a small power
driven rotary type wire brush taking
care not to damage the parts.
3. Remove deposits between stem and
valve disc by using a steel blade or
BACK TO GROUP INDEX
steel shim (.028 thick) in a sawing

motion around the stem shoulder at
both sides of the disc. The poppet
must be free to wobble and move
axially before re-assembly.
4. Clean the cavity and passages in the
4.
main body section with a small
power driven rotary type wire brush
taking care not to damage the valve
seat.
5. Remove all loosened debris using
5.
shop air.
6. Re-assemble the diaphragm section
6.
on the main body using a new gasket
between them. Torque the attaching
screws 23-33
23-33 in-lbs.
in-Ibs.
7. Clean
Clean orifice
orifice plate and the
the
7.
body. Re-install
orifice by using a small amount of
of
contact cement to retain plate in
place while assembling the valve to
carburetor spacer.
CAUTION:
outer edges of orifice plate to avoid
D. EGR Supply
Supply Tube
Tube And
AndSpacers
Spacers
1.
carburetor and
carburetor spacer.
2.
2. Clean supply tube with a small
or blast cleaning equipment.
3. Clean the exhaust gas passages and
cavities in the spacer using a suitable
and/or scraper. The
wire brush and/or
machined holes in the spacer can be
cleaned by using a suitable round
wire brush. Hard encrusted material
should be probed loose first, then
brushed out. The center passage in
4V spacers incorporates a stainless
steel tube. This tube should be
removed for cleaning.
E. Exhaust
Exhaust Gas
E.
GasChannels
Channels
1.
1. Clean the exhaust gas channel,
channel, where
where
applicable, in the intake manifold
using a suitable carbon scraper.
Clean the exhaust gas entry port in
the intake manifold by hand passing
a suitable drill bit thru the holes to
deposits. Do not use a
auger out the deposits.
wire brush.
CAUTION: The manifold riser
bore(s) should be suitably plugged
during the above action to prevent
from entering the
any of the residue from
induction system.
2.
2. The 200 and 250 CID valve is
mounted on the side of the cylinder
head below the carburetor pad.
pad. After
removal of the EGR valve, inspect
the passages with a small light. If
If
deposits are present in the exhaust
passage (left hand side),
side), remove with
a wire brush or aa suitable drill bit.
bit.
The re-entry passage (right hand
side) can be cleaned with a suitable
drill bit hand operated. Remove all
foreign particles prior to reassembly.
29-02-57
CAUTION: Do not allow pieces to
CAUTION:
get into re-entry passage (right hand
An electric drill should NOT
side). An
be used to remove deposits.
F. STEP DELETED
DELETED FOR
F.
FOR1975
1975
G.
G. Check
Check of
ofEGR
EGR Valve
ValveFunction
Function
When
WhenOff
OffThe
TheEngine
Engine
1.
After cleaning valve connect a
1. After
vacuum hose from EGR valve to an
externally gauged variable vacuum
source with minimum 10 in. Hg
capacity. Start at vacuum less than
in. Hg
Hg and
and vary
vary vacuum
vacuum steadily
steadily up
up
2 in.
to lOin.
10 in. Hg.
Hg. The valve stem must
move smoothly without apparent
sticking, binding, or chattering
noisy
action. The valve should not be noisy
or exhibit excessive vibration due to
If erratic
the above operation. If
motion or vibration as described
above is detected, replace valve.
Valve stem may cease to move above
7 in.
in. Hg
Hg of applied vacuum.
vacuum. This is
not cause for replacement. Remove
vacuum and use a felt-tip pencil to
mark stem position closest to the
valve main body. Re-install valve
and related components on engine
using new gaskets.
VII. Modulating EGR Valves
Procedure
P r o c e d u r e for
for cleaning
cleaning and
Sequence of maintenance can be
individual engine
engine
varied to suit individual
characteristics.
A. EGR Valve
ValveRemoval
Removal
1.
OR
CAUTION:
P R Y ON
ON THE
T H E VALVE
VALVE
PRY
SUPPORTS, AS THIS MAY
D
A M A G E THE
T H E VALVE
VALVE
DAMAGE
OPERATING
OPERATING MECHANISM
MECHANISM
CALIBRATION.
body for deposits.
plugged. Extreme care must be taken
taken
to avoid enlarging the hole, or
If The
B. If
The Valve
ValveCannot
CannotBeBeTaken
Taken
Apart (Assembled
(AssembledWith
WithDrive
DriveRivets):
Rivets):
1. Do not attempt to clean it - it must
1.
be replaced.
c:
If The
Apart:
C. If
The Valve
ValveCIJJ1
CanBeBeTaken
Taken
Apart:
1.
1. Separate the diaphragm section from
the main mounting body.
2. Clean the valve plates, stem, and the
mounting plate using a small power
driven rotary type wire brush taking
care not to damage the parts.
3. Remove deposits between stem and
valve disc by using a steel blade or
steel shim .028 thick in a sawing
motion around the stem shoulder at
both sides of the disc.
disc. The poppet
290258
29-02-58
must be free to wobble and move
axially before re-assembly.
re-assembly.
4.
4. Clean the cavity and passages in the
main body section with a small
taking care not to damage the valve
seat. To clean orifice port side of
seat.
valve, the orifice plate must be
less than a .450
removed when it has less
in. dia.
dia. hole.
in.
hole.
5.
5. Remove all loosened debris using
shop air.
air.
6.
6. Re-assemble the diaphragm section
on
on the main body using a new gasket
between them.
them. Torque the attaching
specifications.
7.
7. Clean orifice
orifice plate and the
the
body. Re-install
orifice by using a small amount of
contact cement to retain plate in
place while assembling the valve to
spacer.
carburetor spacer.
CAUTION:
CAUTION: Apply
Apply cement to
to outer
edges of orifice plate to avoid
to orifice.
restriction to
D. EGR
EGR Supply
Supply Tube
TubeAnd
AndSpacers
Spacers
1.
carburetor and
and
carburetor spacer.
spacer.
2.
3.
3. Clean the exhaust gas
gas passages and
in the spacer using a suitable
cavities in
wire brush and/or scraper. The
should be
be probed
probed loose
loose first,
first, then
then
should
brushed out.
out. The center passage in
4V spacers
spacers incorporates
incorporates aa stainless
stainless
4V
steel tube.
tube. This
This tube
tube should
should be
be
steel
removed for
for cleaning.
cleaning.
removed
E. Exhaust
ExhaustGas
GasChannels
Channels
E.
1. Clean the exhaust gas
gas channel,
channel, where
where
1.
manifold
gas entry port in
Clean the exhaust gas
suitable drill
drill bit thru the
the holes
holes to
aa suitable
auger out the deposits.
deposits. Do not use a
wire brush.
brush.
wire
bore(s) should be
be suitably plugged
bore(s)
during
any of the
the residue from
from entering the
any
induction system.
2.
pad. After
head below the carburetor pad.
removal of the EGR valve,
valve, inspect
passage (left
(left hand
hand side)
side) remove
remove with
passage
wire brush or aa suitable drill bit.
bit.
aa wire
The re-entry
re-entry passage
passage (right
(right hand
hand
The
side) may
may be
be cleaned
cleaned with
with aa suitable
suitable
side)
drill bit
bit hand
hand operated.
operated. Remove
Remove all
drill
all
BACK TO GROUP INDEX
290258
29-02-58
CAUTION: DO NOT DIRECT

BLASTER STREAM AGAINST
THE DIAPHRAGM.
4. Remove debris with shop air with the
diaphragm retracted.
C.
If
Cleaning Facilities
C. If No Blast Cleaning
Facilitiesare
are
Available
Available
The valve should be replaced if
if it
becomes clogged or causes a rough idle
condition.
D. EGR Supply
Supply Tube
Tube and
andSpacers
Spacers
carburetor and
1.
carburetor spacer.
3. Clean the exhaust gas passages and
cavities in the spacer using a suitable
and/or scraper. The
wire brush and/or
be
should be probed loose first, then
brushed out. The center passage in
4V spacers incorporates a stainless
should be
steel tube. This tube should
removed for cleaning.
Exhaust Gas
E. Exhaust
GasChannels
Channels
1.
1. Clean the exhaust gas channel, where
Clean the exhaust gas entry port in
a suitable drill bit thru the holes to
auger out the deposits. Do not use aa
wire brush.
bore(s) should be suitably plugged
any of the residue from entering the
induction system.
head below the carburetor pad. After
removal of the EGR valve, inspect
If
passage (left hand side), remove with
a wire brush or a suitable drill bit.
The re-entry passage (right hand
side) may be cleaned with a suitable
drill bit hand operated. Remove all
B. Where
WhereFacilities
Facilitiesfor
forBlast
BlastCleaning
Cleaning
are Available
Available
Metal Parts are
get into the re-entry passage (right
The following procedure should be
hand side). An electric drill should
followed:
not be used to remove deposits.
1. Apply masking tape to diaphragm
1.
F.
FOR 1975
1975
F. STEP DELETED
DELE"TED FOR
protection and plug valve
for protection
vacuum nipple when exposed.
SSD-2SPARK
SSD-2-SPARK DELAY VALVE
2. Clean the exposed part of the plunger
2.
To determine if
if a delay valve is
by directing the blaster stream
operating
correctly,
use the following
operating'
against it.
procedure:
3. To clean the valve seat and the rest
Equipment Required:
of the plunger apply 15 in. Hg
(a)
Model
vacuum to retract
retract the valve
(a) Vacuum
Vacuum GaugeUSG
Gauge-USG Model
12121-1 2 inches
inches dia.,
dia., 0-30
0-30 inches
inches Hg
Hg
12121-1
diaphragm then direct the blaster
vacuum gage with 3/16 inch OD
stream between the plunger and seat.
00
CAUTION:
get into re-entry passage (right hand
hand
side). An
An electric drill should NOT
be used to remove deposits.
F.
DELETED FOR
F. STEP DELETED
FOR1975
1975
G.
G. Check
Check of
ofEGR
EGR Valve
ValveFunction
Function
When
WhenOff
OffThe
TheEngine
Engine
1. After cleaning valve connect a
vacuum hose from EG
R valve to an
EGR
externally gaged variable vacuum
source with minimum lOin.
10 in. Hg
capacity. Start at vacuum less than
in. Hg
Hg and
and vary
vary vacuum
vacuum steadily
steadily up
up
2 in.
10 in.
in. Hg.
Hg. The valve stem must
to 10
move smoothly without apparent
sticking, binding, or chattering
noisy
action. The valve should not be noisy
or exhibit excessive vibration due to
the above
above operation.
operation. If
If erratic
erratic
the
motion or
or vibration
vibration as
as described
described
motion
above is
is detected,
detected, replace
above
replace valve.
valve.
Valve stem
stem may
may cease
cease to
Valve
to move
move above
above
in. Hg
Hg of
of applied
applied vacuum.
vacuum. This
This is
is
77 in.
not cause
cause for
for replacement.
replacement. Remove
not
Remove
vacuum and
and use
vacuum
use aa felt-tip
felt-tip pencil
pencil to
to
mark stem
stem position
position closest
closest to
the
mark
to the
valve main
main body.
body. Re-install
Re-install valve
valve
valve
and related
related components
components on
on engine
and
engine
using new
new gaskets.
using
gaskets.
VIII.
VIM. Tapered Stem Valves
(Exposed Plunger Type)
P r o c e d u r e for cleaning
cleaning and
Procedure
Sequence of maintenance can be
varied to suit individual
individual engine
characteristics.
ValveRemoval
Removal
A. EGR Valve
1.
OR
CAUTION:
PRY
THE
P R Y ON
ON T
H E VALVE
VALVE
SUPPORTS, AS THIS MAY
D A M A G E THE
T H E VALVE
VALVE
DAMAGE
OPERATING MECHANISM
MECHANISM
OPERATING
CALIBRATION.
2.
body for deposits.
if
plugged. Extreme care must be taken
to avoid enlarging the hole or

29-02-59
29-02-59
Engine Diagnosis
Diagnosis and Service
Service
Engine
vacuum hose
hose nipple
nipple adaptor and
and 24
24
vacuum
inches of 3/16 inch
inch ID
ID Distributor
inches
Vacuum Hose
Hose or equivalent.
equivalent.
Vacuum
(b) Stop watch or wrist watch with a
(b)
sweep second hand.
hand.
sweep
(c) External vacuum source capable of
(c)
maintaining aa minimum constant 10
inches Hg
Hg vacuum.
vacuum.
inches
NOTE: The
The vacuum
vacuum gage
gage must
must have
NOTE:
small internal
internal volume
volume and
and be
be
aa small
EXTERNAL
FREE FROM EXTERNAL
LEAKAGE.
LEAKAGE.
(d) Prevent vacuum from being

being
(d)
to CARB nipple while
while
applied to
applying 10
10 inches
inches Hg
Hg vacuum
vacuum to
to
applying
side of valve.
valve.
black side
(e)
(e) Apply vacuum to the CARB
CARB
nipple
nipple and observe
observe time
time in
in seconds
for gage
gage to
to read
read from
from 0-8
0-8inches
inchesHg
Hg
10 inches Hg
Hg
with aa constant 10
source.
vacuum source.
2.
2. The minimum and maximum time
the valve
valve to
to reach 88 inches
inches Hg
for the
be as
as follows:
follows:
should be
Procedure:
Procedure:
/. Mono
Mono Delay
Delay Va/ye
Valve
L
1. (a)
(a) Set external vacuum source to 10
1.
Hg.
inches Hg.
(b) Connect black side of delay valve
(b)
source.
to vacuum source.
(c) Connect the 24 inch section of
(c)
vacuum hose to gage and to
delay valve.
colored side of delay
(d) Apply vacuum and observe time in
in
(d)
seconds for gage to read from 0-8
inches Hg with a constant 10
inches Hg vacuum source.
2.
for the valve to reach 8 inches Hg
as follows:
follows:
should be as
I.D.No.
1.0.
No.
Color
5
10
10
15
15
20
20
2
20
20
and White
Black and
and Yellow
Black and
and Blue
Black and
and Green
Black and
and Brown
White and
and Green
Green
White and
Time in
in Seconds
Max.
Min.
Max.
12
12
14
14
16
16
20
20
2
20
20
4
5.8
7
9
2
9
CA1383-A
When checking the delay valve,

valve, care
must be exercised to prevent oil or
dirt from getting into the delay valve
functioning.
as this will impair the functioning.
Diagnosis
DiagnosisGuide
Guide
Replace
Replace delay
delay valve
valve if itit fails
fails any
any of
the
the above
above tests.
tests.
Il':
IV. Air Cleaner
CleanerDelay
DelayValve
Valve
Procedure:
Procedure:
1.
1. (a)
(a) Set
Set external vacuum source
source to
to 10
inches
inches Hg.
Hg.
(b)
(b) Connect colored side
side of
of delay valve
to
to vacuum source.
source. Note:
Note: .20
.20 inch
OD to
to .27
.27 inch OD adapter may
be
be required to connect colored side
of valve
valve to
to vacuum source.
source.
(c)
(c) Connect the 24 inch section of
vacuum hose
hose to gauge
gauge and to
to white
side of delay valve.

in
seconds for gauge to read from 0
inches to 88 inches Hg with a
constant 10
10 inch Hg vacuum
source.
source.
2.
should be as follows:
follows:
Diagnosis
DiagnosisGuide
Guide
Color
Time in Seconds
I.D.
1.0.
No.
No.
Minimum
Maximum
MlXimum
1
2
5
10
10
15
15
20
30
40
1
2
4
5.8
7
9
13
13
15
4
5
12
12
14
14
16
20
24
28
28
Black and Gray
Black and Brown

Black and White
Black and Yellow
Black and Blue
Black and Green
Black and Orange
Black and Red
CV1382-A
CV1382A
When checking
checkIng the delay valve, care
dirt from getting into the valve as
this will impair the functioning.
Diagnosis
Guide
Diagnosis Guide
//.
Delay Valve
IL Dual Delay
Valve
1. (a) Set external vacuum source to 10
10
inches Hg.
(b) Connect
Connect the 24 inch section of
of
vacuum hose to gage and to DIST
nipple of
of delay valve.
(c) Connect black side of delay valve
and CARB nipple of
of delay valve to
vacuum source.
BACK TO GROUP INDEX
1.0.
No.
I.D.No.
IlL Retard Delay Valve

///.
Valve
1. (a) Set external vacuum source to 10

1.
inches Hg.
(b) Connect colored side of delay valve
to vacuum source.
(c) Connect the 24 inches section of
of
vacuum hose to gage and to white
side of delay valve.
in
seconds for gage to read from 0-8
inches with a constant 10 inches
Hg vacuum source.
should be as follows:
Time in Seconds
Seconds
I.D.No.
1.0. No. Min. Max.
Color
Color
White/Brown
White/Green
Black/White
Black/Yellow
Black/Yellow
Black/Blue
Black/Green
BlacVGreen
CNI
Replace delay valve if it fails any of

of
the preceding tests.

of
the above tests.
II
20
5
10
10
15
20
2
9
4
5.8
7
9
5
20
12
14
16
20
20
CA1384-A
When checking the delay valve, care

this will impair the functioning.
White/Red
40
40
Time in Seconds
Min.
Max.
28
28
15
15
CA1434A
CA1434-A
When checking the delay valve care

this will impair its function.
Diagnosis Guide
of
the above tests.
SSD-3-SPARK CONTROL
SSD-3SPARK
SYSTEMS AND SPARK DELAY
VALVE
Spark Control Systems
A. Spark
L Non-Thermal
Non-Thermal Control
/.
ControlSystem
System
(1) Remove air cleaner. Remove SDV ifif
so equipped and check per the delay
valve procedure SSD-2. Install a
connector in place of
of the SDV in
connector
order to carry out system checks.
(2) Install "T" fitting and vacuum gage
at distributor.
(3) With engine at normal operating
29-02-60
temperature and with transmission
in neutral, momentarily
momentarily open
throttle half way.
(4) Observe the vacuum gage for a quick
and closed. If a vacuum is evident,
the system is OK. If no vacuum is
evident, check the vacuum lines,
lines, "T"
(if applicable) and port in carburetor
for plugging and correct.
(5) For vehicles with a cooling PVS,
check vacuum reading at distributor
at normal idle and engine operating
temperature. If vacuum reading is 2
If
in. Hg or less, the PVS is OK. If
vacuum reading is greater than 2 in.
Hg, remove the top vacuum line that
PVS. If
If
goes to the carburetor at PVS.
vacuum reading is still greater than
2 in.
in. Hg,
Hg, PVS
PVS is
is leaking and should
be replaced.
(6) Remove the vacuum gage, "T"
"T"
fitting, connector (where used),
used), reinstall SDV (where used), and reconnect all vacuum lines.
(7) Re-install air cleaner and torque
wing nut to specifications.
IL Cold
//.
Cold Lock-Out
Lock-OutSpark
SparkSystem
System
(1) Remove air cleaner. Remove SDV if
if
so equipped and check per delay
valve procedure SSD-2. Install
of SDV for system
connector in place ofSDV
checks.
checks.
(2) Install "T" fitting and vacuum gage
in primary side of distributor.
(3) With engine at normal operating
temperature and transmission in
neutral, momentarily
momentarily open the
throttle half way.
evident, check vacuum lines, cold
lock-out PVS ports and carburetor
port for plugging and leaks and
correct.
(5) Remove vacuum gage, "T" fitting,
connector (if used) and install SDV
(if used) and re-connect all vacuum
lines.
lines.
wing nut to specification.
specification.
III. Dual
DelaySystem
System
TIL
Dual Delay
(1) Remove air cleaner. Remove dual
(3 port) and check per
delay SDV (3
dual delay valve procedure SSD-2.
the spark
spark
Install a connector between the
port line and the distributor line.
Connect a vacuum gage to the line
manifold port
removed from the manifold
(black side) of the dual delay valve.
2) Start engine and note if vacuum
'2)
reading is obtained. If vacuum is
evident, vacuum
vacuum lines and
evident,
connections to intake manifold are
OK. If no vacuum is evident, check
lines, "T"s and manifold fitting for
BACK TO GROUP INDEX
Engine'
plugging and leaks and correct.
(3) Remove gage from line
line and plug
plug line.
line.
of
Install "T" fitting at primary side of
distributor and connect vacuum
gage.
gage.
(4) With
With engine
e n g i n e running
r u n n i n g and
and
transmission in neutral, momentarily
open throttle half way.
lines, and
evident, check the vacuum lines,
the spark port for plugging or leaking
and correct.
(6) Remove gage and "T" fitting from
distributor and
primary side of distributor
install on secondary side. With
engine running vacuum should be
noted. If no vacuum, check vacuum
" T " for
line and connection to "T"
plugging and correct.
(7) Remove "T" fitting,vacuum gage,
plug, and connector. Install dual
reconnect all
delay valve and reconnect
vacuum lines.
specification.
wing nut to specification.
IV. Cold
IV.
Cold Start
Start Spark
SparkAdyance
AdvanceSystem
System
NOTE:
thru five
five
NOTE: Perform steps one thru
only if engine complaint is spark knock
or pinging.
CAUTION:
C A U T I O N : Do not leave
leave
drive during
duringStep
Steptwo
twoand
and
transmission in drive
four for longer than 15 seconds.
1.
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.
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.
4. Remove vacuum advance line from
distributor and plug.
plug. Restart engine
and repeat step two (see Caution
above) to recorded rpm.
5.
5. If spark knock or pinging reoccurred
with
with vacuum
vacuum advance
a d v a n c e line
line
disconnected, stop engine and
proceed to next step.
step. If spark knock
or pinging did not reoccur, the
system has a faulty CSSA PVS
PVS andl
and/
or retard delay valve or check valve
(if so equipped). Repair and/or
and/or
(if
replace as required.
6. Remove air cleaner. Remove SDV ifif
6.
so equipped and check per delay
valve procedure (SSD-2). Install
connector in place of SDV.
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
29-02-60
7.
7.
8.
8.
9.
9.
10.
10.
11.
12.
12.
13.
13.
14.
14.
15.
15.
16.
16.
place of check valve or retard delay

valve.
valve.
Install "T" fitting and vacuum gage
at distributor primary.
Remove vacuum line from bottom
port of Cold Start PVS and cap.
With engine at normal operating
temperature and at idle, the vacuum
reading should be zero.
zero. If vacuum is
not zero, the Cold Start PVS is
Remove cap and reconnect the
removed line to the bottom port of
of
the Cold-Start PVS.
Remove vacuum line from top port
of the Cold-Start PVS and plug.
For vehicles with a Cooling PVS,
check vacuum reading at distributor
at normal idle.
idle. If vacuum reading is
2 in.
in. Hg or less,
less, the Cooling PVS
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
If vacuum reading is still
greater than 2 in.
in. Hg, Cooling PVS
is leaking and should be replaced.
With
With engine
e n g i n e running
r u n n i n g and
and
open the controls (1/2 open).
Observe vacuum gauge for a quick
and closed. If vacuum is evident, the
spark advance system is OK. If no
evident, check
check the
the vacuum
vacuum is evident,
lines, ports in the Cold-Start and
Cooling PVS's, and the carburetor
vacuum port for plugging and
correct.
Remove "T" fitting, vacuum gauge,
plug and connectors. Install SDV
and check valve or retard delay valve
(if used) and reconnect all vacuum
lines.
lines.
Re-install air cleaner and torque
wing nut to specifications.
V.
By-Pass
System
(PVS
V.Delay
DelayValye
Valve
By-Pass
System
(PVS
Operated)
Operated)
1. Remove air cleaner.

1.
2.
2. Remove SDV and check per Delay
Valve Procedure SSD-2.
SSD-2. Install a
connector in place of SDV.
SDV. Remove
vacuum line at distributor and install
a T-fitting and vacuum gauge.
3. With engine idling at normal
operating temperature and with
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
evident, check
check the
the vacuum
vacuum is evident,
lines, T's and port in carburetor for
plugging. Correct as required.
5.
5. Shut engine otT.
off.
6.
6. Remove vacuum gauge, "T" fitting,
29-02-61
7.
7.
8.
8.
9.
9.
10.
10.
11.
12.
12.
13.
13.
and connector. Reinstall SDV and

reconnect vacuum hoses.
Remove vacuum check valve and
check per Vacuum Check Valve
Check Procedure.
Reinstall check valve in hose to
distributor.
Install connector and vacuum gauge
in vacuum hose from PVS to check
valve.
valve.
With engine running at normal
operating
o p e r a t i n g temperature
t e m p e r a t u r e and
open throttle (1/2 open).
Observe the vacuum gauge for
evidence of vacuum. If
If vacuum
reading is two
two inches
inches Hg
Hg or
or less,
less, PVS
PVS
is OK. If vacuum reading is greater
than two inches Hg the PVS is
Remove vacuum gauge, connector
and plugs (where used), reinstall
check valve and reconnect all
vacuum hoses.
Reinstall air cleaner and torque to
specifications.
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 Gage with 3/16 inch OD
vacuum hose nipple adaptor.
(b) Vacuum Source
Procedure:
1. For checking function:
function:
1.
in. Hg.
(a) Set vacuum source at 5 in.
(b) Apply vacuum to the check side of
the check valve and trap.
trap. After 30
seconds the vacuum should not be
less than 4 in.
in. Hg.
Hg. If it is,
is, replace
the valve.
2.
2. For flowing function:
function:
in. Hg.
(a) Set vacuum source at 5 in.
(b) Connect gage to check side which
is the same side the vacuum source
was connected to in Step 1 of
ofthis
this
procedure.
(c) Apply vacuum to the opposite side
used in Step 1.
1. Reading on gage
should be same as source.
source. If it is
not, replace the valve.
SSD-4THERMACTOR NONSSD-4-THERMACTOR
CATALYTIC CONVERTOR
EMISSION SYSTEM CHECK
The thermactor non-catalyst system
consists of
of the following
following major
major
components:
1. Belt-driven air supply pump
1.
2. Air By-Pass Valve
3. Check Valve(s)
4. Internal or external air manifolds(s)
5.
5. Air supply tubes
6.
6. Crossover tube to connect RH and
BACK TO GROUP INDEX

LH air manifolds (internal system
only)
Special Tool Required:
Gauge. Use
Thermactor Pump Test Gauge.
Rotunda Tool T7SL-9486-A
T75L-9486-A or
Rotunda
equivalent, including a pressure gauge
15 PSI
PS Iminimum
minimum
with a reading of 0 to 15
1/4 PSI increments.
and readable in 1/4
Procedure:
A. Air Pump
Supply Test
Test
Pump Supply
1.
p e c t aall
11 hhoses
0 s e san
0 se
2. Ins
Inspect
andd hhose
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
adjust to specifications.
specifications. See
Procedure "B"
" B " of this system
diagnosis procedure.
4. With the transmission in neutral or
park and the parking brake on, warm
the engine to normal operating
temperature. If
If an objectionable
objectionable
noise complaint can be isolated to
to the
the
air pump,
pump, replace the air pump.
5. Stop the engine and disconnect the
5.
air supply hose(s) from the air pump
to the air by-pass valve at the air bypass valve.
6. Insert the Thermactor Pump Test
6.
T75L-9486-A
Gauge, Rotunda Tool T7SL-9486-A
in the end of the hose disconnected
from the by-pass valve.
valve. Clamp the
hose securely to the air supply tester
to prevent it from blowing out.
C A U T I O N : Position
P o s i t i o n the
the
CAUTION:
Thermactor Pump Test Gauge so
that the air blast emitted will be
harmlessly dissipated.
7.
8a.
8a. Slowly increase engine speed to 1000
rpm and observe the pressure
produced at the test gauge.
gauge. The air
pump pressure must be 2.25 PSI
minimum.
8b.
8b. If Rotunda Tool T7SL-9486-A
T75L-9486-A is not
not
available, increase engine speed to
1500 rpm and place hand over the
open hose.
hose. Air flow should be heard
felt.
and felt.
9.
9. If air flow does not comply with
minimum requirements listed in Step
8a, install a new air pump and repeat
test.
10. Turn off
off the engine.
engine. Remove all test
10.
equipment and reconnect the air
supply hose to the air by-pass valve
clamp. Torque
and tighten the hose clamp.
if
the air cleaner nut to specification if
the cleaner was removed.
Belt
B. Thermactor
ThermactorAir
AirPump
PumpDriye
Drive
Belt
Adjustment
Adjustment
1.
1. Install
Install the belt tension gage
T63L-8620-A
T63L-862O-A or equivalent on the
drive belt and check the tension
29-02-61
following the instructions of the tool
manufacturer. Compare the belt
tension to the specified belt tension
and adjust as necessary.
2.
2. If adjustment
adjustment is necessary,
necessary, loosen
loosen the
the
air pump mounting and adjusting
adjusting
arm bolts. Move the air pump
the correct tension is obtained. Use
Rotunda Tool T75L-9480-A or
equivalent to hold belt tension while
tightening the mounting bolts.
gage. Tighten the air
Remove the gage.
pump adjusting arm and mounting
bolts. Install the tension gage and
check the belt tension.
CAUTION: Do not use aa pry bar to
CAUTION:
move air pump.
move
pump.
3. Check all air pump pulleys and
mounting bolts and torque to
Specifications
specifications. Refer to Specifications
contained in appropriate engine part.
CAUTION: Any belt that has
operated for aa minimum of ten
minutes is considered aa used belt;
and when adjusted, it must be
to the tension shown in the
adjusted to
specifications for used belts.
C.
C. Air By-Pass Valye
Valve Functional
FunctionalTests
Tests
(Non-Conyerter
(Non-ConverterType)
Type)
Determine if the air by-pass valve is
functioning properly by performing the
following operation:
1.
1. If necessary, warm the engine to
normal operating temperature with
the transmission in neutral or park
and the parking brake on.
2.
2. Stop the engine and remove the air
by-pass valve-to-air manifold check
valve hose at the by-pass valve.
valve. For
a tee system, remove both hoses
connecting the by-pass valve to the
check valves.
valves. Install a tachometer on
the engine.
park and the parking brake on, start
the engine.
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.
4. With transmission in neutral or park
and parking brake on, accelerate to
1500 rpm. With hand held over the
connection for
for
by-pass valve connection
approximately 5 to 8 seconds, pinch
off the vacuum hose to the by-pass
off
valve to duplicate the air by-pass
cycle. Release the pinched vacuum
cycle.
hose. Air flow thru the by-pass valve
hose.
should be felt and heard to diminish
should.
or stop for a short period of time,,
time,
then resume normal air flow. The
length of time required to resume
normal flow cannot be specified since
the time
time interval
interval is
is dependent
dependent on
the
on
engine vacuum
vacuum and
and length
length of
of time
engine
time
29-02-62
the vacuum line is
is pinched off. Air
will
will be
be discharged thru the exhaust
ports in the side of the valve silencer
cover.
cover. If this complete cycle does not
occur, the valve is defective and it
must be
be replaced.
replaced.
5.
5. Perform the following test ONLY if
the air pump supply tester is
available:
available:
Install the Thermactor Pump Test
Gauge Rotunda Tool T75L-9486-A
or equivalent to the air by-pass valve
outlet using aa short length of
of
appropriate diameter hose.
hose. If the air
by-pass valve has two outlets, plug
the one without the tester. Increase
1000 rpm.
rpm. Observe
engine speed to 1()()()
the pressure produced at the test
gauge. The air pressure must be 2.25
gauge.
(2 1/4)
1/4) rSI
PSI minimum. If the air
(2
pressure is
is not
not within
within specifications,
specifications,
pressure
replace the
the valve.
replace
valve.
6.
6. Tum
Turn off the engine,
engine, remove all test
equipment and connect the air
supply hose(s) to the air by-pass
valve(s), and tighten all clamps.
valve(s),
Determine if the air by-pass valve
controls are functioning properly by
performing the following operations:
D. Check
Check Valye
ValveTest
Test
1.
1. With the engine stopped, inspect the
hose(s)
hose(s) from the check valve to the
by-pass valve for any leaks due to
cracks,
cracks, splits,
splits, holes,
holes, etc.
etc. Replace if
required. -.
required.
2.
2. Inspect the hose clamp(s) at the
check valve for being properly
positioned and tightened. Correct,
position, tighten or replace as
required.
required.
3.
3. Disconnect the thermactor hose(s)
valve
from check valve to the by-pass valve
at the by-pass valve end.
end.
4.
4. Connect the check valve tester,
equivalent, to the open end of the
valve hose.
hose. Position the hose
check valve
specification.
clamp and tighten to specification.
5. Squeeze the rubber bulb on the tester
5.
to force as
as much air from the bulb as
to
possible. Quickly release the bulb
possible.
timing. The bulb should
and start timing.
remain collapsed and not return to
its original free shape for at least 15
seconds.
seconds.
6. If the test bulb does not return to its
6.
15 seconds,
original free shape for 15
the check valve and hose are good.
Remove the check valve tester from
the end of the hose and reinstall the
hose on
on the
the by-pass
by-pass valve.
valve. Position
Position
hose
and tighten
tighten the
the hose
hose clamp
clamp to
to
and
specification.
specification.
7. If the test bulb returns to its original
7.
15 seconds
secondsor
or less,
less,both
both
free shape in 15
c h e c k valve are
are
hose and check
questionable.
questionable.
8. Remove the test bulb from the end
8.
BACK TO GROUP INDEX

of the hose.
hose. Remove the hose from
the check valve.
valve. Install a 6 to
to 18
18inch
inch
length of appropriate diameter hose
to the check valve and test bulb.
of
Position a hose clamp at each end of
the hose and tighten to specification.
Repeat Step 5 above.
9.
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
hose from
from the
the check
check valve and
test
test bulb.
bulb. Install
Install aa new hose of the
test
proper part
part number,
number, to
proper
to the
the check
check
valve and
and test
test bulb.
valve
bulb. Position
Position aa hose
hose
clamp at each end of the hose and
tighten to specification. Repeat Step
5 to be
be sure the new hose does not
leak. After
After the
the test,
test, remove
leak.
remove the
the hose
hose
clamp and
and test
test bulb.
Install the
clamp
bulb. Install
the hose
hose
on the
the by-pass
by-pass valve
valve nipple.
on
nipple. Position
Position
the hose
hose clamp
clamp and
and tighten
to
the
tighten to
specification.
specification.
10.
free shape (Step 7) in 15
15 seconds or
less, the check valve is defective and
less,
is to be replaced.
11. Test the new check valve for leaks
before installing on the engine.
18 inch length of
Connect a 6 to 18
of
appropriate diameter hose to the new
check valve and test bulb. Position
specification a hose
and tighten to specification
clamp at each end of the hose.
Repeat Step
Step 55 above.
Repeat
12. Remove the hose from the check
12.
valve. Install the new check valve on
valve.
t h e engine
e n g i n e and
and ttorque
o r q u e to
the
specification. Visually inspect the
specificati9n.
surface
original hose for any surface
condition that
that would cause a
condition
problem in
in the
the near
near future.
future. Replace
problem
with a new hose if required. Install
the hose
hose on
on the
the check
check valve and bythe
pass valve
valve nipples.
nipples. Route
Route the
pass
the hose
hose as
as
required. Position
Position aa hose
required.
hose clamp
clamp at
at
each end
end of
of the
the hose
and tighten
each
hose and
tighten to
to
specification.
specification.
FOR 1975
1975
D (II).
(II). STEP DELETED
DELETED FOR
SSD-5THERMACTOR
SSD-5-THERMACTOR
CATALYTIC CONVERTER
EMISSION SYSTEM CHECK
The thermactor catalytic converter
system consists of the following major
components:
components:
1.
1.
2.
2.
3.
4.
4.
5.
5.
6.
6.
Belt-drive air 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)
7. Differential
Differential vacuum valve (Decel)
7.
29-02-62
8. Air
Air cleaner
cleaner temperature
temperature sensor
sensor
8.
9. Solenoid
Solenoid vacuum
vacuum valve
valve
9.
Special Tool Required:
Thermactor Pump Test Gauge. Use
Use
Rotunda Tool T75L-9486-A
T75L-9486-A or
Rotunda
equivalent, including a pressure gauge
with a reading of 0-15 PSI minimum
and readable in 1
1/4
/4PSI
PSIincrements.
increments.
Procedure:
A. Air Pump
Pump Supply
A.
SupplyTest
Test
1.
Ins pee tall
h 0 s e san
0 se
2. Inspect
all hoses
andd hhose
connections in the system for any
abnormal conditions and correct
and/or repair and/or
and/or replace as
and/or
necessary.
3. Check the air pump belt tension and
adjust to specifications.
specifications. See
adjust
Procedure "B" of this Diagnostic
Procedure.
park and the parking brake on, warm
the engine to normal operating
If an objectionable
temperature. If
noise complaint can be isolated
isolated to
to the
the
air pump, replace the air pump
regardless of pump performance.
5. Stop the engine and disconnect the
air supply hose(s) from the air pump
to the air by-pass valve at the air bypass valve.
6. Insert the thermactor
thermactor pump test
gauge in the end of
of the hose
disconnected from the by-pass valve.
Clamp the hose securely to the
thermactor
thermactor pump test gauge to
prevent it from blowing out.
CAUTION: Position the test gauge
so that the air blast emitted will be
be
harmlessly dissipated.
8a. Slowly increase engine speed to 1000
rpm and observe the pressure
produced at the test gage. The air
pressure must be 2.25 (2 1/4)
1/4) PSI
minimum.
8b. If
If the Rotunda tool is not available,
increase the engine speed to 1500
rpm, place hand over the open hose.
Air flow
flow should be heard and felt.
9. If
If air flow does not comply with
minimum requirements listed in Step
8a, install a new air pump and repeat
test.
10. Turn off
ofT the engine. Remove all test
equipment and reconnect the air
valve and tighten the hose clamp(s).
Torque the air cleaner
cleaner nut to
specification
specification if
if the
the air
air cleaner
cleaner was
was
removed.
removed.
B. Thermactor
AirPump
PumpDriye
DriveBelt
Belt
Thermaetor Air
Adjustment
Adjustment
1. Install
1.
Install the belt
belt tension
tension gage
T63L-8620-A or equivalent on the
drive belt and check the tension
29-02-63
following the instructions of the tool

manufacturer. Compare the belt
tension to the specified belt tension
and adjust as necessary.
2.
2. If adjustment is necessary,
necessary, loosen
loosen the
the
air pump mounting and adjusting
adjusting
arm bolts. Move the air pump
the correct tension is obtained. Use
equivalent to hold belt tension while
tightening the mounting
mounting bolts.
bolts. Install
Install
the tension gage and check the belt
tension.
CAUTION: Do not use aa pry bar to
CAUTION:
move air pump.
pump.
3. Check all air pump pulleys and
mounting bolts and torque to
Specifications
specifications. Refer to Specifications
in appropriate Engine Part.
CAUTION: Any belt that has
operated for aa minimum of ten
minutes is considered aa used belt;
and when adjusted, it must be
adjusted to the tension shown in the
specifications for used belts.
C
By-Pass Valve
Tests
C. Air By-Pass
ValveFunctional
Functional
Tests
(Catalytic
(Catalytic Converter
ConverterType)
Type)
Determine if the air by-pass valve is
functioning properly by performing the
following operations:
1.
and the parking brake on.
6.
6. If
If available, install the air pump
tester, Rotunda Tool T75L-9486-A
valve
or equivalent, to the air by-pass valve
outlet using
using aa short
short length
length of
outlet
of
appropriate
diameter hose.
hose. If
If the
the air
appropriate diameter
air
by-pass valve
valve has
has two
two outlets,
outlets, plug
by-pass
plug
the one
without the
the tester.
tester. Start
Start the
the
one without
the
engine and
and speed
speed to
to 1000
1000 rpm.
rpm.
engine
Observe the
the pressure
pressure produced
produced at
Observe
at the
the
test gage.
gage. The
The air
air pressure
pressure must
must be
test
be
2.25 (2
1/4) PSI
PSI minimum.
minimum. If
If the
the
2.25
(2 1/4)
pressure is
is not
not within
within specification,
specification,
pressure
replace the valve.
replace
2.
by-pass valve-to-air manifold check
valve. For
a tee system, remove both hoses
connecting the by-pass valve to the
check valves.
valves. Install a tachometer on
the engine.
park and the parking brake on, start
the engine.
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.
heard and felt.
4. Remove the vacuum hose from the
off the
by-pass valve and plug off
vacuum hose.
hose. With the engine at
1500 rpm
rpm and
and hand
hand held
held over
over the
the bybypass valve connection, there should
be virtually no air flow felt or heard.
Air flow will be discharged thru the
exhaust ports in the end of the valve
silencer cover.
If air flow is felt or heard thru the
by-pass valve connection, the valve
is defective and should be replaced.
5.
5. Stop the engine. Remove the plug
from the vacuum hose and reinstall
the vacuum hose on the by-pass valve
valve
nipple.
nipple.
BACK TO GROUP INDEX
7.
otT the engine, remove all test
7. Turn off
equipment and connect the air
valve and tighten all hose clamp(s).
Determine if the air by-pass valve
controls are functioning properly by
p e r f o r m i n g tthe
h e following
following
performing
operation(s).
C
Valve
C. (LJ
(I.) Differential
DifferentialVacuum
Vacuum
Valve
(Decel)
(Decel)Functional
FunctionalCheck
Check
1.
and parking brake on.
2.
by-pass valve to air manifold check
valve. For
hoses.
a tee system, remove both hoses.
Install a tachometer on the engine.
3. Start the engine. With hand held
outlet
over the by-pass valve outlet
c o n n e c t i o n s accelerate
a c c e l e r a t e to
connections
rpm. Release
Release the
the
approximately 2500 rpm.
throttle for a normal return to engine
idle rpm. During the deceleration
period, the air flow in the valve outlet
and/or heard to
should be felt and/or
momentarily diminish or stop and
then resume as before (normal air
flow). Air flow will be discharged
thru the exhaust ports in the end of
of
the by-pass valve silencer cover.
The air flow interruption during
deceleration cannot be specified due
variations in the rate of
of
to variations
deceleration and manifold vacuum.
4.
4. If the by-pass valve meets its test
requirements, but does not function
function
3, check to be
as described in Step 3,
sure the decel valve is receiving a
signal. If the decel valve is
vacuum signal.
receiving a signal, then the decel
valve
defective
val
ve is defecti
ve and is to be
replaced.
5.
5. Turn off
off the engine.
engine. Remove all test
equipment and reconnect all related
of the thermactor
thermactor
components of
system.
C
C. (IL)
(II.) Applies
Appliestoto Truck
TruckOnly
Only
29-02-63
C.
C. (IlL)
(III.) A.
A. Thermae/or
ThermactorSystem:
System:
Solenoid
(Norma//y
Solenoid Vacuum
VacuumValve
Valve
(Normally
Closed, Type
TypeI)I)
Closed,
Note: A Normally closed Type I,
Solenoid Vacuum Valve is used in
conjunction with a Type II air cleaner
temperature switch which is identified
according to the Vehicle Specifications.
See Procedure SSD-9: Air Cleaner
and Delay Valve,
Temperature Control and
8.
Step No.
No.8.
la. Determine that engine air cleaner

1a.
ambient temperature is above 65F.
1b.
lb. Engine must be at normal operating
temperature.
2.
2. While the engine is at idle condition,
disconnect vacuum
vacuum hose to
disconnect
thermactor air by-pass valve.
thermactor
Thermactor air should dump to
Thermactor
atmosphere thru the exhaust ports in
the end of the valve silencer cover.
Re-connect vacuum hose.
If thermactor
dumps
a. 1ft
her mac tor air dum
pstto
0
atmosphere, the solenoid hose
connections are correct.
NOTE: Vacuum supply always
goes to the bottom vacuum fitting
on the solenoid vacuum valve.
on
b. Disconnect vacuum supply hose at
the solenoid valve.
valve. Place finger
over end of open vacuum hose.
Your finger should be attracted to
the hose opening by the vacuum
If
supplied by the engine manifold. If
vacuum supply is not observed,
and/or repair vacuum
check and/or
sources as required. Re-connect
vacuum hose.
3. Disconnect
Disconnect wiring to solenoid
vacuum valve.
a. Determine which wire has B+
voltage when the ignition switch is
in the run position.
b. Connect wire which has B+
B+
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. Thernlactor
Thermactor air
should not dump to atmosphere.
4b. Connect wire removed in Step 3a to
solenoid vacuum valve.
valve. Thermactor
air should
should not be dumped to
atmosphere.
5. Replace solenoid vacuum valve if it

5.
does not function
function as detailed in
statement
statement 4a, re-install related
system components.
29-02-64
C.
C. (IlL)
(III.) B.
B. Thermactor
ThermactorSystem;
System;
Solenoid
Normally
Solenoid Vacuum
VacuumValye
Valve
Normally
Open,
Open, Type
Type 2
Note: A normally open, Type 2,
solenoid vacuum valve is used in
conjunction with aa Type 2 air cleaner
temperature switch which is identified
according to the Vehicle Specification.
(See Diagnostic Procedure SSD-8, Air
Cleaner Temperature Control and
and Delay
Valve, Step No.
No.9.)
9.)
la. Determine that engine air cleaner
ambient temperature is above 65F.
Ilb.
b. Engine must be at normal operating
temperature.
2a.
disconnect
disconnect vacuum
vacuum hose to
thermactor
thermactor air by-pass valve.
Thermactor
Thermactor air should dump to
atmosphere thru the exhaust ports in
the end of the valve silencer cover.
2b. 1ft
If t hher
erm
a c ttor
o r air dum
dumps
mac
pstto
0
2b.
atmosphere, the solenoid hose
connections are correct. Re-connect
vacuum hose.
NOTE: Vacuum supply always goes
NOTE:
to black input nozzle on solenoid
valve.
valve.
3. Discon
nect wiring to solenoid
Disconnect
vacuum valve.
in the run position.
b. Connect wire which has B+
B+
voltage to solenoid vacuum valve.
4a.
ground the other exposed terminal
on the solenoid vacuum valve to
Thermactor air
chassis ground. Thermactor
should be dumped to atmosphere.
4b.
4b. Connect wire removed in Step 3a
solenoid vacuum valve.
valve. Thermactor
air should
should not be dumped to
atmosphere.
5.
5. Replace solenoid vacuum valve ifif
Step 4b results in air being dumped
to atmosphere. Re-install related
system components.
C.
C. (IV.)
(IV.) Vacuum
VacuumReseryoir
Reservoir
Check-{Required
some
catalytic
Check(Requiredonon
some
catalytic
converter
convertercontrol
controlsystems)
systems)
a. Dis
con nee t va
c u u mho
s eon
Disconnect
vacuum
hose
on
reservoir which connects to electric
solenoid valve vacuum nipple.
b. Connect 10 to 30 inches vacuum
gage with suitable length of 3/16
vacuum hose to reservoir.
c.
c. Remove manifold vacuum hose from
reservoir and connect external
nipple. Charge
vacuum source to this nipple.
14 inches Hg vacuum
reservoir to 14
from external source and trap.
Vacuum on gage Step (b) should not
inchininone
oneminute.
minute.
drop more than 11 inch
Replace reservoir
reservoir if
if out of
of
specification.
specification.
d. Remove all test equipment, reinstall
vacuum lines to the reservoir and
BACK TO GROUP INDEX

torque all clamps and air cleaner to
specification.
D. (L)
(I.) Check
Check Valye
Valve Test
Test
1.
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.
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 by-pass valve
at the by-pass valve end.
4. Connect the thermactor-check valve
tester (Rotunda Tool T75L-9487-A
or equivalent) to the open end of the
hose. Position the hose
check valve hose.
clamp and tighten to specification.
specification.
5. Squeeze the rubber bulb, on the
5.
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.
15
6.
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.
valve. Position
and tighten the hose clamp to
specification.
7.
15 seconds
seconds or
or less,
less,both
both
free shape in IS
and check
c h e c k valve
valve are
are
hose and
questionable.
8.
8. Remove the test bulb from the end
of the hose.
hose. Remove the hose from
the check valve.
valve. Install a 6 to
to 18
18inch
inch
length of appropriate diameter hose
to the check valve and test bulb.
Position and tighten to specification,
hose clamp at each end of the hose.
a hose
hose.
9.
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.
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
hose. Repeat Step
at each end of the hose.
5 to be
be sure the new
new hose does
does not
After test remove the hose
leak. After
clamp and test bulb.
bulb. Install the hose
nipple. Position
on the by-pass valve nipple.
and tighten the hose clamp to
specification.
10.
free shape (Step 8) in 15
15 seconds or
29-02-64
less, the check valve is defective and
is to be replaced.
II.
11. Test the new check valve for leaks
before installing on the engine.
Connect a 6 to 18
of
18 inch length of
appropriate diameter hose to the new
new
check valve and test bulb. Position
and tighten to specification
specification a hose
clamp at each end of the hose.
12.
12. Remove the hose from the check
valve.
valve. Install the new check valve on
on
the
and torque
t h e eengine
n g i n e and
t o r q u e to
to
specification. Visually inspect the
original hose for any surface
surface
condition
condition that would cause a
problem in the near future'.
future. Replace
with a new hose if required. Install
the hose on the check valve and bynipples. Route the hose as
pass valve nipples.
required. Position and tighten to
specification a hose clamp at each
specification
end of the hose.
E Floor
Floor Pan
System
E.
PanThermal
ThermalSwitch
Switch
System
Check
Check
1.
1. Disconnect wiring to the vacuum
solenoid valve.
in the "on" position.
b. Connect a test light in series with
ground.
c.
c. Start the engine.
d. Test light should glow at all times
while the engine is running.
e.
e. If test light glows,
glows, wiring and floor
pan switch are satisfactory, except
for condition in Step 3.
2. If test light does not glow:
2.
a. Inspect fuses in the fuse panel.
i.i. If a fuse is blown, check circuits
for shorts. Repair
Repair and/or
and/or
replace as necessary.
ii.
ii. Check for electric continuitycontinuity
test light should glow.
b. If
If fuses in the fuse panel are
satisfactory,
satisfactory, check for "open
circuits" in the circuitry:
i.i. Check the integrity of the wires,
loose connections, cracks,
broken wires,
wires, etc.
etc. Repair and/or
ii.
ii. Check connector, at air cleaner
switch, for any physical damage
and proper connection(s).
connection(s).
Repair aand/or
n d / o r replace as
necessary.
iii.
iii. Check connector, at floor pan
switch, for any physical damage
connection(s).
and proper connection(s).
Repair and/or
a n d / o r replace as
necessary.
iv. Check intermediate connector,
iv.
at dash panel, for any physical
d a m a g e and
a n d proper
proper
damage
connection(s). Repair and/or
3. Thermal floor pan switch check
29-02-65
(vehicle may be hot enough to
activate the system)
a.
a. Determine the location of floor
pan switch.
switch.
b.
floor pan switch, with freon,
b. Cool floor
freon,
from under the floor
floor pan until the
floor
floor isis cold to the touch.
touch.
c.
c. With the test light connected,
connected,
according to Step 11 (above) the
light should glow.
glow.
d.
d. If test light does not glow,
glow, replace
the floor
floor pan switch.
switch.
SSD-7-FUEL
SSD-7FUEL DECELERATION
DECELERATION
VALVE CHECK
Note:
Note: For
For vehicles equipped with
transmission interlocked fuel decel
system
system see
see Appendix A.
A. For
For MIT
M/T 2.8L
engines
engines with
with fuel decel control system,
see
see Appendix
Appendix B.
Procedure-Marvel-Schebler
ProcedureMarvel-Schebler
Valve (Two hose
hose connections)
For vehicles equipped with a PVS
interlocked fuel decel system, ensure
ensure that
that
manifold idle vacuum is
is available at the
the
decel valve
valve with the engine at normal
fuel decel
manifold
operating temperature. If manifold
is evident, the PVS
PVS and vacuum
vacuum is
lines are OK. If no or low vacuum is
evident, check vacuum lines,
lines, PVS
PVS ports
evident,
and intake manifold fitting for plugging
leaks and correct.
correct.
and leaks
1.
1. Engine must be
be at normal operating
temperature.
temperature.
2.
2. Connect tachometer and timing
light.
light.
3.
3. Ignition timing and engine idle rpm
must be at specification. Refer to
Decal. Correct as
necessary.
necessary.
4. Remove
Remove air cleaner.
cleaner.
4.
5. Visually inspect
inspect the hoses,
hoses,
5.
connections and valve for any
abnormal conditions. Repair or
as necessary.
necessary.
replace as
6. Check for leaking diaphragm by
6.
15 in.
in. Hg.
Hg. vacuum in the
trapping 15
cavity. Vacuum must not
diaphragm cavity.
10 in. Hg.
Hg. in 5 seconds.
drop below lOin.
Otherwise, replace valve.
Otherwise,
7. Disconnect the rubber hose that
7.
connects the carburetor to the fuel
decel valve at the carburetor and
plug the hose.
hose.
8. With transmission in neutral and
8.
increase
parking brake applied, increase
engine speed to 3000 rpm and hold
for five seconds.
seconds. Release the throttle
immediately
and note if engine immediately
returns to normal idle speed. If
does not return, check
engine speed does
for linkage hang-up and correct
before proceeding to the next step.
9. Remove plug from hose and install
9.
"T" and aa vacuum gage
gage into the
a "T"
hose between the valve and the
carburetor.
BACK TO GROUP INDEX

Note:
Note: The ID of the "T" connector
must be at least 11/4
14 inch for those
legs of the "T" not connected to the
vacuum gauge.
CAUTION: On vehicles equipped
with FVD override devices, check
the function of the device 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
temperature at idle,
manifold
urn should
manifold vacu
vacuum
should be
approximated on the gauge.
gauge. Remove
the vacuum gauge and leave the
device deactivated while performing
Step 10.
10.
10. Increase engine speed to 3000 rpm
and hold for five seconds. Measure
the time required for the vacuum to
drop to zero when the throttle is
released.
This time should
should be within
within
specifications. If
of
If time is out of
specification, do the following:
following:
a.
a. Ensure that vacuum is available
from the 3/16
3/16 inch vacuum
control hose
b. Adjust
Adjust decel valve until time is
within specification. If dece1
decel valve
cannot be adjusted
adjusted to
time cannot
specification, or the decel valve is
a non-adjustable valve,
valve, replace the
decel valve and check the new
valve time to ensure 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 PDV
FDV hose at carburetor.
B2.8L ENGINE
SSD-7 APPENDIX B-2.8L
FUEL DECEL VALVE CONTROL
SYSTEM
1. To perform the system test, install a

1.
"T" fitting and vacuum gauge with
a long hose into the vacuum line
between the solenoid valve and the
valve. With the rear wheels
decel valve.
raised, start engine and engage
transmission in drive.
2. If the vacuum gauge reading is not
2.
indicated below 11
11 mph
mphcut-in
cut-inspeed,
speed,
continue with SSD-7.
If vacuum reading does not occur
before cut-in speed, check solenoid
by connecting jumper wires from its
terminals to the battery and to
ground. Operate the engine in
NEUTRAL at about 1500 rpm.
There should be no vacuum reading
If there is a vacuum
indicated. If
valve. Remove
reading, replace the valve.
jumper wires.
3. With ignition switch on, check for
B+ voltage to solenoid. IfB+ voltage
29-02-65
is not indicated, test back to power
source for an open circuit.
4. Check for proper ground. Check the
speed sensor for continuity with an
ohmmeter between
between the leads.
ohmmeter
Resistance should be 40 ohms.
SSD-8 STEP DELETED FOR 1975
SSD-9-AIR
SSD-9AIR CLEANER
TEMPERATURE CONTROL AND
DELAY VALVE
Procedure:
Note: For A/C
AIC System with delay
valve, perform system diagnosis
procedure SSD-2.
Thermostat Operated System
Thermostat
Temperature Method
A. Air Temperature
Method
1. Remove necessary items to visually
1.
see the duct door. Remove the air
cleaner cover.
2. With a cold engine and ambient air
t'05F or less, the
temperature of 105F
duct valve should be in the "heat on"
position or closed. If the duct valve
is opened, cool the thermostat by
spraying liquid from a small can of
of
R-12 refrigerant
refrigerant and ZRE-6271 can
adapter or equivalent.
CAUTION: DO NOT SPRAY
THERMOSTAT WITH LIQUID
ENGINE IS RUNNING. IF R-12
REFRIGERANT
DRAWN
REFRIGERANT IS DRA
WN
INTO THE CARBURETOR
CARBURETOR
WHILE THE ENGINE
ENGINE IS
WHILE
RUNNING,
R
U N N I N G , POISONOUS
POISONOUS
PHOSGENE
PHOSGENE GAS WILL BE
A
REA. C
O N D U C T THIS
THIS
AREA.
CONDUCT
PROCEDURE ONLY IN A WELL
WELL
VENTILATED AREA.
3. Place a magnetic based temperature
indicator as near as possible to the
thermostat. Use Rotunda
Rotunda Tool
T75L-9601-A or comparable tool.
4. Re-install the air cleaner
cleaner cover
without installing the wing nut(s).
Start the engine and allow to run at
idle rpm.
5. As the engine warms up, observe the
duct valve door. When the duct valve
door opens (heat-off-position),
(heat-off-position),
remove the air cleaner cover and note
the temperature
temperature reading of
of the
temperature
temperature indicator
indicator at the
tthermostat.
h e r m o s t a t . It
h o u l d be
It sshould
o
approximately 130 to
to 150
150F.
Replace
P. Replace
as required.
6. Remove instruments and re-install
related system components. Torque
ccarb.uretor
a r b u r e t o r wing
u t ( s ) to
wing n
nut(s)
specifications.
B. Water
Water Immersion
ImmersionTest
Test(Alternate
(Alternate
Method)
Method)
1. Disconnect duct and valve assembly
1.
from air cleaner and heat stove and
remove.
29-02-66
2. Insert unit in
in water so
so that bulb
bulb end
2.
wax pellet is
is submerged, and
of wax
valve.
check for operation of valve.
3. With water temperature
t e m p e r a t u r e at
at
3.
95F-105F, duct and valve
valve should
95F-105F,
be closed. Allow 55 minutes for
for
stabilization.
temperature stabilization.
4. Wit
Withh w
water
t e m per
p e r a t uurrea
e att
4.
ate r tern
13OF-15OF, duct and valve
valve should
130F-150F,
be open (allow 55 minutes for
for
stabilization).
temperature stabilization).
NOTE: Open
Open means
means that the
the duct
NOTE:
and valve
valve door
doorisis open
opento
tofresh
fresh (cold)
(cold)
and
air.
air.
5. Replace unit if defective.
defective.
5.
6. Re-install unit in vehicle and
6.
reconnect to heat stove and air
cleaner.
cleaner.
Vacuum Operated Systems
CAUTION: DO NOT IMMERSE
CAUTION:
ANY PART OF THE VACUUM
OPERATED DUCT AND VALVE
WATER. If
ASSEMBLY SYSTEM IN WATER.
the temperature sensor switch vacuum
opens, water
waterwill
willbe
beintroduced
introducedinto
into
bleed opens,
the vacuum system. This can
permanently damage the temperature
sensor switch.
and Valve
ValveSystem
SystemFunctional
Functional
A. Duct and
Test
Test
NOTE: On
On vehicles equipped with
with a
NOTE:
cold weather modulator, bypass the
connecting the
the vacuum
vacuum line
line
modulator by connecting
from sensor directly to the vacuum
motor.
1. Remove necessary items to visually
1.
see the duct door. Remove the air
cleaner cover.
2. Check to see that the duct valve door
2.
(heat-off, no vacuum)
is in the open (heat-otT,
position when the engine is not
running. If the duct valve door is
closed, check for binding and
sticking. Repair and/or replace as
necessary.
3. Place a magnetic based temperature
indicator as near as possible to the
temperature sensor on the air inlet
side. Use Rotunda Tool T75L-9601T75L-9601A or a comparable tool.
4. Note color code on sensor.
a. If
If coded blue, yellow or green:
Start the engine. With a cold
eengine
n g i n e aand
n d an ambient
ambient
temperature below 75F, the duct
and valve door should be in the
closed or full heat-on position. If
If
the door is closed, proceed to Step
5. If
If the duct valve door is not
closed, turn off
off the engine. Cool
the temperature
temperature sensor
sensor to a
temperature
temperature below 75F by
spraying with liquid from a small
can of
of R-12 refrigerant
refrigerant and aa
ZRE-6271 can
can adapter
adapter or
equivalent.
CAUTION: DO NOT COOL
T
H E TEMPERATURE
TEMPERATURE
THE
BACK TO GROUP INDEX
Engine
and Service
S E N S O R WHILE
W H I L E THE
THE
SENSOR
ENGINE IS
IS RUNNING.
RUNNING. IF
IF R-12
R-12
ENGINE
IS DRAWN
REFRIGERANT IS
INTO THE CARBURETOR
CARBURETOR
IS
WHILE THE ENGINE IS
RUNNING, POISONOUS
POISONOUS
GAS WILL BE
PHOSGENE GAS
INTO THE
THE TEST
TEST
EXHAUSTED INTO
THIS
AREA. CONDUCT THIS
PROCEDURE ONLY
ONLY IN
IN A
PROCEDURE
A
WELL VENTILATED
VENTILATED AREA.
AREA.
WELL
Restart the
the engine.
engine. If
If the
the duct
duct
Restart
valve door
door is
is closed,
closed, proceed
proceed to
to
valve
Step 5.
5. If
If door
door isis open
open during
during idle,
idle,
Step
check related
related vacuum
vacuum system
system per
per
check
Appendix "A"
"A" of
of this
this procedure.
procedure.
Appendix
Repair or
or replace
replace as
as necessary.
necessary,
Repair
b. If
If coded
coded orange:
orange: At
At room
room
b.
temperature the
the duct
duct and
and valve
valve
temperature
door will
will be
be either
either partially
partially or
or
door
completely in
in the
the open,
open, or
or full
full
completely
cold, position.
p o s i t i o n . Cool
Cool the
the
cold,
t e m p e r a t u r e sensor
s e n s o r to
to aa
temperature
temperature below
below 45F
45F with
with
temperature
liquid
from
a
small
can
of
R-12
liquid from a small can of R-12
refrigerant and
and ZRE-6271
ZRE-6271 can
can
refrigerant
adapter,
or
equivalent.
adapter, or equivalent.
CAUTION: DO
DO NOT
NOT COOL
COOL
CAUTION:
T
H
E
T
E
M
P
E
R
A
T
URE
THE TEMPERATURE
S E N S O R WHILE
W H I L E THE
THE
SENSOR
ENGINE
IS
RUNNING.
IF
R-12
ENGINE IS RUNNING. IF R-12
REFRIGERANT IS
IS DRAWN
DRAWN
REFRIGERANT
INTO THE
THE CARBURETOR
CARBURETOR
INTO
WHILE
THE
ENGINE IS
IS
WHILE THE ENGINE
RUNNING, POISONOUS
POISONOUS
RUNNING,
AREA. CONDUCT THIS
AREA. CONDUCT THIS
PROCEDURE ONLY IN A
PROCEDURE
ONLAREA.
Y IN A
WELL
VENTILATED
WELL
VENTILATED
AREA.
Start the engine. If the duct valve
If the duct
valve
Start is
theclosed,
engine.proceed
door
to Step
5.
is
closed,
proceed
to
Step
5.
door
If door is open during idle, check
If door is vacuum
open during
idle, check
related
system
per
related vacuum
system
per
Appendix
"A" of this
procedure.
Appendix
"A" of as
this
procedure.
Repair or replace
necessary.
Repair or replace as necessary.
5. Re-install the air cleaner cover
without installing the wing nut(s).
6. Start engine if necessary. As the
sensor warms up, observe the duct
valve door. When it starts to open to
heat-otT position, remove the air
the heat-off
cleaner cover
cover and
and note the
cleaner
reading of
of the
ttemperature
e m p e r a t u r e reading
temperature indicator. It should be
within the following specifications:
a. For sensors color coded blue,
yellow and green: temperatures
o
should not exceed 110F.
110 P.
b. For sensors color coded orange:
temperatures should not exceed
80F.
If
If the duct valve door does not
open, replace the temperature
sensor switch. After
After completion of
of
this test, turn off
otT the engine.
on
7. Cold Weather Modulator (Only on
applicable models)
29-02-66
a.
a. Cool
Cool the
the cold weather modulator
to
to 40F
40F or less.
less. The
The modulator can
be
be cooled by
by spraying
spraying with
with liquid
R-12
R-12 refrigerant and aa ZRE-6271
ZRE-6271
equivalent. Allow
can adapter or equivalent.
sufficient time for the modulator
temperature to stabilize and the
modulator valve
valve to close.
close.
CAUTION: DO NOT COOL
CAUTION:
THE COLD WEATHER
WEATHER
THE
MODULATOR WHILE THE
ENGINE IS
IS RUNNING.
RUNNING. IF
IF R-12
R-12
ENGINE
REFRIGERANT IS
IS DRAWN
DRAWN
REFRIGERANT
INTO THE
THE CARBURETOR
CARBURETOR
INTO
WHILE THE
THE ENGINE
ENGINE IS
IS
WHILE
RUNNING, POISONOUS
POISONOUS
RUNNING,
PHOSGENE GAS
GAS WILL
WILL BE
BE
PHOSGENE
EXHAUSTED INTO
INTO THE
THETEST
TEST
EXHAUSTED
AREA. CONDUCT
CONDUCT THIS
THIS
AREA.
PROCEDURE ONLY
ONLY IN
IN A
PROCEDURE
A
WELL VENTILATED
VENTILATED AREA.
WELL
AREA.
b.
b. Using an external vacuum source,
apply a minimum of 16
16 inches of
vacuum to the vacuum motor side
trap. The
of the modulator and trap.
14 in.
in.
modulator must hold at least 14
Hg vacuum for 60 seconds.
Otherwise, replace the modulator.
If the modulator does not hold
vacuum, it must be replaced.
c.
c. Warm the modulator to 70F or
above.
above. The modulator should not
hold vacuum at or above 70F
ambient temperature. If the cold
weather modulator
modulator does not
function as indicated, it must be
replaced.
8.. Cold Temperature Actuated
Actuated
Vacuum System (Only on applicable
models).
models). Refer to Specifications or
Vehicle Emission Control Decal.
Temperature Switch Functional Test
(Type 1).
(Type 1).
1). Refer to Specifications or
a. Disconnect the connector from the
wiring harness.
Connect the leads from
from an
b. Connect
self-powered test
ohmmeter or self-poweied
light to the temperature switch
connector terminals.
c. Cool the switch to a temperature
below 40F. The switch can be
cooled by spraying liquid from a
small can of R-12 refrigerant
refrigerant with
a ZRE-6271 can adapter
adapter or
equivalent.

THE SWITCH WITH LIQUID
THE ENGINE IS RUNNING. IF
R-12
R-12 REFRIGERANT
REFRIGERANT IS
D
R A W N IINTO
N T O THE
THE
DRAWN
CARBURETOR
CARBURETOR WHILE THE
ENGINE
RUNNING,
ENGINE IS RUNNING,
POISONOUS
POISONOUS PHOSGENE
GAS WILL BE EXHAUSTED
29-02-67
INTO THE TEST AREA.
CONDUCT
THIS
CONDUCT
THIS
PROCEDURE ONLY IN A
WELL
WELL VENTILATED AREA.
When the switch is
is cooled below
40F,
40F, the internal switch contacts
should be open. The ohmmeter
should read maximum resistance
and the test light should not light.
If the switch does
does not open below
40F, the switch should be
replaced.
replaced.
d.
d. Increase the switch temperature
until the temperature is above
70F.
70F. The switch temperature can
be
be increased by placing the palm
of the hand on the metal surface of
the switch or by starting the engine
and allowing the exhaust manifold
heat to increase the intake air
temperature. When the switch
o
temperature is above 70
p, the
70F,
switch contacts should be closed.
The ohmmeter should read zero
resistance or the test light should
light.
light.
If the switch does
does not close,
close, or if
the ohmmeter
ohmmeter indicates
indicates a
resistance of 11 ohm or more,
more, the
switch should be replaced.
replaced.
e.
e. If it is
is necessary to replace the
switch,
switch, check the operation 'of
of the
new
new switch before connecting the
wiring harness connector.
9.
9. Cold Temperature
Temperature Actuated
Actuated
Vacuum System (Only on applicable
models). Refer to Specifications or
models).
Vehicle Emmision Control Decal.
Temperature Switch Punctional
Functional Test
(Type 2).
2).
(Type 2)
Refer to Specifications Vehicle
a. Disconnect the connector from the
a.
harness.
wiring harness.
b. Connect the leads from an
b.
self-powered test
ohmmeter or self-powered
light to the temperature switch
terminals.
connector terminals.
c. Cool the switch to a temperature
c.
o
40F.
P. The switch can be
below 40
cooled by spraying liquid from a
small can R-12 refrigerant with a
can adapter, or
ZRE-6271 can
equivalent.
CAUTION:
THE SWITCH WITH LIQUID
THE
THE ENGINE
ENGINEIS
ISRUNNING.
RUNNING.IF
IF
THE
REFRIGERANT IS
R-12 REFRIGERANT
D R A W N INTO
I N T O THE
THE
DRAWN
CARBURETOR WHILE THE
ENGINE IS RUNNING,
RUNNING,
PHOSGENE
POISONOUS PHOSGENE
GAS WILL BE EXHAUSTED
GAS
AREA.
INTO THE TEST AREA.
BACK TO GROUP INDEX
29-02-67

CONDUCT
THIS
CONDUCT
THIS
PROCEDURE ONLY IN A
A
WELL
WELL VENTILATED AREA.
When the switch is cooled below
o
4O
P, the internal switch contacts
40F,
should be closed. The ohmmeter
should read zero resistance and the
test light should light. If the switch
o
is cooled below 40
p, or if the
40F,
ohmmeter indicates a resistance
value of 11 ohm
ohmor
ormore,
more,the
theswitch
switch
should be replaced.
d. Increase the switch temperature
until the temperature is above
o
70
P. The switch temperature can
70F.
be increased by placing the palm
of the hand on the metal surface of
of
the switch or by starting the engine
and allowing the exhaust manifold
heat to increase the intake air
temperature. When the switch
o
70F,
temperature is above 70
p, the
switch contacts should be open.
The ohmmeter should indicate
maximum resistance and the test
If the switch
light should not light. If
contacts do not open, the switch
should be replaced.
e.
e. If it is necessary to replace the
switch, check the operation of the
new switch before connecting the
wiring harness connector.
10.
10. Air Cleaner Delay Valve. Check
valve, if equipped, Per SSD-2,
delay valve,
Step IV.
SSD-9APPENDIX "A"
"A"
SSD-9-APPENDIX
Vacuum Motor Test

A. Check the duct valve door for
A..
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.
B. Disconnect the vacuum hose from
B.
the vacuum motor connector tube.
C. Connect an external vacuum source
C.
16 inches
inches Hg
Hg to
to the
the vacuum
vacuum motor
motor
of 16
if door does not close.
D. 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
seconds.
motor assembly.
SSD-10 EXHAUST HEAT
SSD-10-EXHAUST
CONTROL VALVE
Bimetal Type
1. Visually inspect valve assembly for
1.
any abnormal condition repair or
2. Check valve and thermostatic spring
2.
operation by manually rotating valve
shaft. Valve must be free and return
position when cold
to closed position
(Rotunda choke tester or equivalent

may be used if necessary to cool
If valve cannot be
bimetal spring). If
freed
freed or closed, valve must be
replaced.
val ve wit
3. L u b rric
i c aate
t e tthe
h e valve
withh
C4AZ-19A501COAZ-19A501-A or C4AZ-19A501COAZ-19A5O1-A
A graphite lube or equivalent.
SSD-l0(b)-VACUUM OPERATED
SSD-lO(b)VACUUM
EXHAUST HEAT CONTROL VALVE
1.
1. Inspect exhaust heat control valve
for any abnormal condition. Repair
and/or replace as necessary.
2. Inspect vacuum hoses, connections,
manifold vacuum port
port for
and manifold
and/or proper
blocks, leakages and/or
connections. Repair and/or replace
as required.
3. If vacuum system is equipped with aa
vacuum check valve, perform SSD-3
Vacuum Check Valve Procedure.
4. Substitute tee for vacuum valve.
Remove vacuum line from heat
control valve and connect Rotunda
vacuum gauge or equivalent. With
engine idling at normal operating
temperature, gauge should register
If not, replace
less than 3 inches Hg. If
PVS valve.
5. Check
Check valve
valve assembly
assembly operation
operation with
with
5.
aa vacuum
vacuum source
source (Rotunda
(Rotunda hand
hand
vacuum pump
pump or
or equivalent
equivalent may
may be
be
vacuum
used). The
The valve
valve must
must close
close (see
(see note
note
used).
below) when
when 15-20
15-20 inch
inch Hg
Hg vacuum
vacuum
below)
or more
more is
is applied
applied and
and trapped
trapped for
for 60
60
or
seconds to
to the
the valve
valve vacuum
vacuum motor
motor
seconds
actuator motor.
motor. Valve
Valve must
must not
not leak
leak
actuator
more than
than 2
2 in.
in. Hg
Hg vacuum.
vacuum. Valve
Valve
more
if valve
valve
assembly must
must be
be replaced
replaced if
assembly
does not
not close
close when
when 15
15 in.
in. Hg
Hg
does
vacuum is
is applied
applied and/or
and/or leaks
leaks more
more
vacuum
than 2
2 in.
in. Hg
Hg vacuum.
vacuum.
than
Start
Start Closing
CID
CID
351W
All Other
Applications
Vacuum)
Vacuum)
Completely
Completely
Closed* (In. Hg.
Hg.
Vacuum)
Vacuum)
1-3
66 or less
3-6
10 or
or less
at (In. Hg.
*NOTE: Valve is closed if the shaft lever comes

within .065 (Feeler Gauge) of the stop.
CA1385-B
CA 1385-8
Valve must return to open position

when the valve vacuum actuator
motor is vented to the atmosphere by
removing the vacuum source. If
If
valve does not open, the valve
assembly must be replaced.
NOTE: Valve is closed if the shaft
lever comes within 0.065 (feeler
gauge) of the stop.
6. Check valve assembly operation to
vacuum specification. If
If valve does
not
l o s e within
within
not open
open or
or cclose
29-02-68
specifications, valve assembly must
be replaced.
7. Re-install engine vacuum line on the
7.
valve assembly.
8. L u b rric
i c aate
t e the
t h e val
v a l vvee wit
with
COAZ-19A501-A
C0AZ-19A501-A or C4AZ-19A501A graphite lube or equivalent.
SSD-11PCV SYSTEM, HOSES

SSD-ll-PCV
TUBESCHECK AND CLEAN
AND TUBES-CHECK
Application
Application and Requirements
Requirements
(noting any difference
difference between car lines):
ALL VEHICLES-ALL
VEHICLESALL ENGINES
PCV System Function:
A. Check PCV
1. With
Engine Idling
With The
The Engine
a. Remove oil filler cap.
b. Hold approved Ford PCV valve
tester over the opening in the valve
cover, making sure there is a positive
seal between the tester and cover.
NOTE: If the No. V-44 PCV Tester
NOTE:
is not applicable, use Alternate A-2.
c. Start the engine and allow it to
operate at the idie
idle speed.
d. If the ball settles in the good (green)
area, the system
system is functioning
functioning
properly. If
If the ball settles in the
repair (red) area, servicing of the
system is needed.
2. With
With Vehicle
Vehicle At
At Normal
Normal Operating
Operating
Temperature
Temperature
a. Remove the PCV valve from its
mounting. If
If the valve is functioning
functioning
properly and not plugged, a hissing
air noise will be heard as the air
passes through
through the valve, and a
strong vacuum should be felt when
a finger is placed over the valve inlet.
inlet.
While finger is over the valve inlet,
check for vacuum leaks in the hose
line and at all connections.
b. Re-install
Re-install the PCV valve, then
remove the crankcase air inlet hose
at the air cleaner connection. Loosely
hold a small piece of stiff
stiff paper (such
as a 3 x 5 memo card or parts tag
card) over the opening at the end of
of
the inlet hose.
The paper should be sucked against
the hose opening with a noticeable
force after sufficient
sufficient time has lapsed
for the crankcase pressure to lower
(usually about a minute or more).
3. For 2.3L Engines
Engines Only
a. Remove PCV valve from engine.
Install a known good PCV valve. If
If
idle quality improves, the original
valve was not functioning normally.
4.
Engine Stopped
4. 'With
With The
The Engine
a.
a: Remove the PCV valve from its
mounting and shake it. A metallic
clicking noise should
should be heard,
heard,
indicating the valve is free.
free.
If the ventilation system passes the
above tests, the system is functioning
, and no further service is required. If
it fails any of the tests, replace the
BACK TO GROUP INDEX
29-02-68
PCV valve and clean the PCV

system per Step 2.
B.
B. Clean PCV
PCV System:
1.
1. Remove
R e m o v e the
t h e PCV
P C V System
System
components, filler cap, PCV valve,
hoses, tubes, fittings, etc. from the
engine.
2. Soak the rubber ventilation hose(s) in
a low volatility petroleum base
solvent.
3. Clean the rubber ventilation hose(s)
by passing a suitable cleaning brush
through them.
4. Thoroughly wash the rubber hoses in
a low volatility petroleum base
solvent and dry with compressed air.
5. Thoroughly
Thoroughly wash the crankcase
crankcase
breather cap if so equipped in a low
volatility petroleum base solvent and
shake dry. Do NOT dry with
compressed
compressed air, damage to the
filtering media may result.
6. Thoroughly
Thoroughly clean tubes, fittings,
fittings,
connections to assure unobstructed
flow of emission gases.
7.
7. Install a new PCV valve and reinstall previously removed hoses,
tubes, fittings, etc. to their proper
location.
8. Replace any system component that
of damage, wear or
shows signs of
deterioration as required.
9. Replace any hose or tube that cannot
be cleaned satisfactorily.
satisfactorily.
specification, remove and proceed to

Section III.
4. If the flowmeter reading is not within
specification
specification clean, repair or replace
as required
r e q u i r e d to
t o meet
m e e t flow
flow
specifications.
///.
Choke Function
and
IlL Electric Choke
Function and
Choke
Pu//down Check
I.
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
If light does not glow, either the
alternator or choke wire is defective.
4. Place test light in series with choke
terminal and stator lead. If light does
not
not glow, replace
replace choke
choke cap
cap
assembly. If
If light glows, turn off
off
engine. Remove light.
5. Manually open throttle and set on
fast
fast idle
idle cam.
c a m . Remove
R e m o v e (see
(see
CAUTION in Step 10) the hot air
supply tube at the choke housing and
install a choke tester (Rotunda LRE
34618 or equivalent). Cool choke
housing p
e r choke
c h o k e tester
tester
housing
per
manufacturer's instructions until
manufacturer's
bimetal closes choke plate lightly in
airhorn. NOTE: Do not use choke
testers manufacturer's
manufacturer's time
time
testers
specifications.
SSD-12AUTOMATIC CHOKE
SSD-12-AUTOMATIC
CHECK PROCEDURE
2150 2V Carburetor (2.8,
(2.8, 302,
351, and 400 CID
CID Engines)
/.
of Linkage and System
System
L Freedom
Freedom of
Integrity
Integrity Check
With the engine off,
perform the
off, perform
1. Remove air cleaner, verify that the
1.
hold-down wingnut has not been
A/C
over-torqued thus causing the AIC
housing to interfere with the choke
plate operation. Also confirm
confirm that
vacuum hoses, solenoid and electric
choke wires are properly connected
and intact. Correct as required.
2. Check the following for freedom of
of
operation: throttle system, choke
plate, all linkages, fast idle cam, etc.
Correct as required.
L Freedom
Freedom Of
/.
Of Linkage And System
System
Integrity Check
Integrity
perform the
off, perform
1.
1. Remove air cleaner and verify that
vacuum hoses, solenoid and electric
choke wires are properly connected
of
operation: throttle system, choke
plate and shaft, all linkages, fast idle
cam, etc. Correct as required.
IL Choke
//.
Choke System Leakage And Flow
1. Disconnect the choke clean air hose
1.
(rubber) from the carburetor
carburetor air horn
and attach flow meter to the hose.
Disconnect and plug EGR vacuum
hose at EGR valve and distributor
vacuum advance hose.
2. Warm
Warm the engine
engine to normal
normal
operating
operating temperature.
t e m p e r a t u r e . Place
Place
transmission in neutral. Bring engine
up to 900-1000 rpm and observe flow
meter reading.
If flow meter reading is within
3. If
specifications, remove flow meter.
Specifications or
Refer to applicable Specifications
Reconnect the clean air hose to the
carburetor, EGR hose to EGR valve,
distributor advance hose to
and distributor
distributor primary. Proceed
Proceed to
distributor
Section III.
IL Choke
//.
Choke Heat System
System Leakage and
Meter (Except 351M,
Flow and Flow Meter
400)
1. Connect choke flow meter (Rotunda
1.
Tool
No.
Tool N
o . T75L-9850-A
T 7 5 L - 9 8 5 O - A or
or
equivalent) to choke cold air supply
tube.
2. Warm engine to normal operating
temperature
temperature and, at curb idle,
observe flowmeter reading.
3. If
If flowmeter
flowmeter reading is within
within
1V Carburetor (200 And

YFA 1V
250 CID
CID Engines)

29-02-69
4. If
If the flow meter reading is not
4.
specification, refer
refer to
Appendix HA"
"A" of this procedure.
///.
Choke Functional
FunctionalTests
Tests
IlL Choke
1.
in series with the stator lead and
ground.
2. The test light should glow with the
2.
engine running.
3. If light does not glow, either the
alternator or choke wire is defective.
4.
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
off
engine. Reconnect choke terminal
and alternator stator lead.
5.
5. Remove the hot air supply tube at
carburetor choke housing.
the carburetor
Attach Rotunda
Rotunda choke tester
tester
LRE-34518 or equivalent. Manually
set fast idle cam on high step.
step. Cool
choke housing until choke plate just
closes.
closes.
CAUTION: Use extreme care in
removing, reinstalling and
and checking
for leaks in the choke hot air supply
tube.
tube. The
The retaining
retainingnut
nutandlor
and/orchoke
choke
housing can
can easily be cross threaded.
threaded.
6.
6. Check for choke resistance by
securing an ohmmeter across the
securi~g
choke cap terminal and choke
ground strap.
7.
7. This valve should
should be within
within
specification. Refer to applicable
Specifications. If range is exceeded,
replace choke cap and repeat III
beginning with Step 4.
8. Recool choke housing until choke
8.
plate just closes. If choke plate is
closed, this step should not be
performed.
9. Remove Rotunda
Rotunda choke tester
9.
LRE-34518 or equivalent.
10. With heat tube removed, choke plate
10.
closed, and fast idle screw positioned
on high step of cam, start engine
without touching throttle and see
that choke opens to a vertical
position with electrical assist only.
come-off time.
time. Refer
Record choke come-ofT
to applicable Specifications. If choke
does not open with electrical assist
only, replace choke cap and repeat
III beginning with Step 4 of this
procedure.
CAUTION: Use extreme care in
and checking
tube. The
The retaining
retainingnut
nutandlor
and/orchoke
choke
tube.
housing can
can easily
easilybe
becross-threaded.
cross-threaded.
BACK TO GROUP INDEX

11. Stop engine. Remove instruments
and reinstall
reinstall related
related system
system
carburetor
components. Torque carburetor
wingnut (in air cleaner)
cleaner) to
wingnut
specification.
specifi
cation.
IV. Choke
IV.
Choke Plate
PlatePul/down
Pulldown
1.
1. Remove the air cleaner assembly,
then remove the choke thermostatic
t~len
spring housing and gasket from the
carburetor.
2.
2. Bend a 0.026 in.
in. diameter wire gage
at a 90 degree angle approximately
1/8-inch from one end. Insert the
bent end of the gage between the
choke piston slot and the right hand
slot in the choke housing. Rotate the
choke piston lever counterclockwise
until the gage is snug in the piston
slot as shown in Fig.
Fig. 1.
3. Exert a light pressure on the choke
piston lever to hold the gage in place,
place,
then use a drill with a diameter equal
to the specified pulldown clearance
between the lower edge of the choke
carburetor bore to
plate and the carburetor
check clearance.
4. To adjust the choke plate pulldown
4.
clearance, bend the choke piston
lever as required to obtain the
specified setting as shown in Fig.
Fig. 1.
lever, be careful
When bending the lever.
not to distort the piston link.
5.
5. Install the choke thermostatic spring
housing and gasket. Set the housing
to specifications. Refer to Engine
Emission Decal.
.026 DIAMETER
WIRE GAUGE
----,~I....II-BEND HERE
A1386-A
FIG. 1.
1. Choke Plate Pulldown
Adjustment
V.
V. Dechoke
Dechoke
1.
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
thin
If the clearance is not wi
within
specification, adjust by bending the
29-02-69
arm on the choke trip lever. Refer to
applicable Specifications. Bending
the arm downward will increase the
clearance, and bending it upward
will decrease the clearance. Always
recheck the clearance after making
any adjustment.
adjustment.
4.
4. If the choke plate clearance and fast
adjustment was
idle cam linkage adjustment
performed with the carburetor on the
engine, adjust the engine idle speed.
Adjust the dashpot if so equipped.
VI.
FastIdle
IdleCam
CamIndex
Index
Setting
VL Fast
Setting
1. Position the fast idle screw on the
1.
kickdown step of the fast idle cam
against the shoulder of the high step.
2.
2. Adjust
Adjust by bending the choke plate
connecting
connecting rod to obtain
obtain the
specified clearance between lower
specified
edge of the choke plate and the
carburetor bore.
bore. Refer to applicable
Specifications.
2S Carburetor (2.3L
5200 25
Engine)
L Freedom
Freedom of
System
/.
ofLinkage
Linkageand
and
System
Integrity Check
Integrity
Check
off, perform
perform the
1.
vacuum hoses,
hoses, solenoid and electric
choke wire are properly connected
2.
of
operation: primary and secondary
throttle systems, choke plate, all
linkages, fast idle cam, etc.
etc. Correct
as required.
//.
Choke Functional
FunctionalCheck
Check
IL Electric
Electric Choke
1. Disconnect the stator lead at the
1.
choke cap terminal or at lead
connector and connect it to one lead
of a test light.
2. Connect the second test light lead to
ground.
with the engine running.
4. If the light does not glow, either the
alternator is not functioning or the
automatic choke wire from the stator
is an open circuit and should be
repaired as necessary.
5. If the light glows,
glows, disconnect the test
5.
lead from "ground" and connect it
to the choke lead connector.
6.
6. If necessary, warm up the engine to
normal operating temperature:
a. Verify
Verify the engine coolant
coolant is
flowing through choke housing.
Housing should get hot. If not,
check hoses for restriction.
b. The choke unit should operate and
the test light should glow.
glow. If not,
the choke unit is defective and
should be replaced.
7.
7. If
If the light glows, an additional
electrical check must be performed
as outlined below. Remove test light.
29-02-70
a. Stop the engine, release cooling
system pressure and disconnect the
water hoses to the automatic choke
housing.
b. Adapt the Rotunda choke tester
LRE-34618, or equivalent, to one
LRE-34618,
of the hose connections of the
automatic choke housing.
c.
c. Cool the choke housing per the
manufacturer's
choke tester manufacturer's
instructions until the bimetal
closes the choke plate lightly in the
air horn (maintain 1/4
1/4 throttle
opening while
while using
using choke
choke tester).
opening
If choke plate is not lightly closed
after five
five minutes,
minutes, tap
tap plate
after
plate lightly
lightly
and continue.
continue. If
If choke
choke plate
plate does
does
and
not close
close in
in 10
10 minutes,
minutes, recheck
recheck
not
for binding
and correct
correct as
as
for
binding and
required.
required.
d. Check electrical
tin ui ty
electrical con
continuity
between the choke cap terminal or
lead connector and ground at the
choke bimetal housing with an
ohmmeter. Be sure above
above
ohmmeter.
conditions are met and that
adequate connections are made
with the ohmmeter leads.
e.
e. The resistance should be within
If
specs. Refer to Specifications. If
not, the electric choke unit should
be replaced. Repeat electric
continuity check with new choke
cap and correct as required.
8. Reinstall related system components
8.
Refer to applicable
applicable
to specs. Refer
Specifications. Check coolant level if
if
required.
4350 4V Carburetor (460 CID
Engines)
Engines)
L
Freedom Of
/. Freedom
OfLinkage
LinkageAnd
AndSystem
System
Integrity Check
Integrity
Check
off, perform the
1.
the vacuum hoses, solenoid and
electric choke wires are properly
connected and intact. Correct as
required.
2.
of
operation: primary and secondary
throttle system, air valve, choke
plate, all linkages, fast idle cam, etc.
IL Choke
//.
Choke Heat
HeatSystem
SystemLeakage
LeakageAnd
And
Flow Meter
Flow
Meter
1.
1. Disconnect the choke clean air hose
from the carburetor air horn and
attach a flow meter to the hose.
2.
2. Warm engine to normal operating
temperature and observe flow meter
reading.
3. If
specification, remove the flow meter.
Refer to applicable Specifications.
Reconnect the clean air hose to the
carburetor and proceed to Section
III.
BACK TO GROUP INDEX
4. If the flow meter reading is not

4.
specification, refer
refer to
Appendix A of this procedure.
///.
Choke Functionsl
FunctionalChecks
Checks
IlL Choke
1.
in series with ground.
2.
while engine is running.
3. If light does not glow, either the
alternator or choke wire is defective
and should be replaced as necessary.
4.
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
off
engine.
engine.
5.
5. Remove the hot air supply tube at
the choke housing and install a choke
choke
tester Rotunda
Rotunda LRE-34618 or
equivalent. Cool choke housing per
choke tester
tester manufacturer's
manufacturer's
instruction until bimetal closes choke
choke
plate lightly in air horn.
CAUTION:Use extreme care in
and checking
tube. The retaining nut could be
easily damaged.
6.
6. Check for choke resistance by
adequately securing an ohmmeter
across the choke cap terminal and
choke ground strap.
7.
7. This value should
should be within
specifications.
s p e c i f i c a t i o n s . Refer
R e f e r to
to
S p e c i f i c a t i o n s . If
If out
out of
of
Specifications.
specifications, replace choke cap
assembly. Remove ohmmeter.
8.
8. Apply external vacuum 16
16 in 2 in
Hg to pulldown control diaphragm.
Measure choke plate opening at
lower edge.
edge. Pulldown setting should
be within specifications for minimum
choke plate opening. Refer
Refer to
Specifications.
Specifications. If
If choke plate
minimum opening is met, continue
with Diagnosis. Reset pulldown if
if
found to be out of specification.
9.
9. Re-install the hot air supply tube.
CAUTION: Exercise
Exercise extreme
extreme care
CAUTION:
care
in removing,
removing, reinstalling
reinstalling and
in
and
checking for
for leaks
leaks in
in the
the choke
choke hot
checking
hot
air supply
supply tube
tube as
as its
its retaining
retaining nut
air
nut
could be
easily cross-threaded.
could
be easily
cross-threaded.
10. Start the engine without touching
10.
following:
throttle and observe the following:
a. If diaphragm retracts.
b. On applicable models, the fast idle
cam should rotate and throttle
should move to kickdown step of
of
cam in specified time.
c. Choke plate should open within
c.
specified time.
If any of these conditions are not
met, repair
repair and/or
and/or replace
replace
according to Appendix A.
11. Install shop air of specified
specified PSI or
less to cold air inlet side of choke
29-02-70
heat system. Use snoop or equivalent to check air leakage at heat
tube nut to choke housing. No
acceptable Repair or releakage acceptable,
place as necessary.
12.
12. Stop engine. Remove instruments
and reinstall
reinstall related
related system
system
components. Torque carburetor air
cleaner wingnut to specifications.
specifications.
Specifications
Refer to 1975 Car Specifications
Book.
IV.
ChokePlate
PlatePul/down
PulldownCheck
Check
IV. Choke
1.
1. Remove the choke thermostatic
spring housing assembly.
2.
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 gage at
a 90
90 degree angle approximately 1/8
1/8
inch from its end. Insert the bent end
of the gage between the choke piston
edge of the rightslot and the upper .edge
hand slot in the choke housing as
shown in Fig.
Fig. 1 on page 29-02-69.
4.
4. Rotate the choke thermostat lever
counterclockwise until the gage is
snug in the piston slot. Hold the gage
gage
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.
linkage.
5.
5. Using a drill gage or equivalent,
check initial choke pulldown
clearance by placing the gage against
the inner wall of the choke air horn
downstream side at
on the downstream
approximately the longitudinal
longitudinal
carburetor and
centerline of the carburetor
check clearance from wall to edge of
choke plate.
6. If the measured clearance is not
6.
within specification, adjust clearance
by turning the hex head lock screw
on the choke shaft
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.
7. Hold the drill gage with diameter
equal to specified
specified pulldown
pulldown
clearance between the lower edge of
of
the choke plate and air horn wall,
maintaining light closing force on
choke plate.
8.
8. With choke piston snug against the
gage, the top of the
0.036 inch wire gage,
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
gage, tighten the hex head screw on
gage,
the choke shaft.
9.
9. Reinstall the choke thermostatic
spring housing assembly.
29-02-71
Appendix A
Diaphragm
FailsToTo
Retract
Diaphragm Fails
Retract
1. Check for binding of linkage.
linkage. Repair
1.
if necessary.
2.
2. Check for cracked vacuum hose.
hose. On
carburetor with external vacuum
supply, check vacuum supply to
diaphragm.
3. Check for plugged vacuum channel
(2V carb.).
carb.). Remove vacuum hose at
diaphragm. Connect a Rotunda
hand vacuum pump or equivalent to
the hose. If a vacuum reading is
maintained, the system is plugged.
Clean, repair and/or replace as
required.
4. Check for vacuum leak at gasket
4.
surfaces or ruptured diaphragm.
5.
5. Check for loose attachment. Correct,
repair or replace as required.
Fllst Idle Cam
Fast
Cam Does
DoesNot
Not Rotate
Rotate Or
Or
Minimum Timing
Does Not Meet Minimum
Timing
Specification
Specification
1.
1. Check adjustment
adjustment and reset as
required to insure that fast idle screw
rests on fast idle cam K.D. step when
diaphragm is fully retracted.
2. Check for leaks in diaphragm
diaphragm
2.
assembly if timing is excessive.
3. Replace diaphragm assembly if
if
restriction cannot be cleared.
Choke
Choke Plate
PlateDoes
DoesNot
Not Open
OpenToTo
VerticalPosition
PositionInInSpecified
SpecifiedTime
Time
Vertical
I.
1. Check for binding linkage.
2. If plate does not rotate to vertical
position in prescribed time, replace
choke thermo assembly. For
prescribed time, refer to 1975 Car
Specifications
Specifications Book or Vehicle
Choke
Choke Heat
HeatSystem
SystemFlow
FlowNot
NotWithin
Within
Specifications
Specifications
1. Check for leaks.
leaks. Tighten connections
1.
in the hot air circuit.
2.
2. Disconnect the hot air tube from the
choke housing.
3. Connect flow meter to hot air
connection on the choke housing.
4. If
specifications, check air supply
system. For flow meter reading, refer
to Specifications or Vehicle Emission
Con
trol Decal. Clean, repair or
Control
5. If flow meter reading is not within
specification, clean, repair or replace
as necessary.
Choke
Choke Pul/down
PulldownAdjustment
Adjustment
1.
1. Make certain that choke plate is
lightly closed in carburetor airhorn.
(If engine is warm use choke tester,
LRE-34618 or equivalent, to cool
choke until choke plate lightly closes
in the airhorn.)
2. Note index position of bimetal cap

and wrap choke cap 90 in the rich
BACK TO GROUP INDEX
3.
4.
5.
5.
6.
6.
direction (CCW) from that position

and secure.
Activate pulldown motor manually
or with external vacuum if the
pulldown motor has an external
vacuum tube.
specified MEAN choke plate
Set specified
opening between choke plate and the
carburetor airhorn
center of the carburetor
nearest to the fuel bowl by turning
the adjusting screw at the back of the
pulldown motor.
After the adjustment
adjustment is made apply
"Loctite 290"
290" to the threads of the
adjusting screw where it enters the
pulldown motor.
Return choke cap to its original
Refer to applicable
applicable
position. Refer
Specifications.
STEP DELETED FOR

SSD-13(a) STEP
1975
SSD-13(b)-ARTIFICIAL
SSD-13(b)_ARTIFICIAL
ENRICHMENT IDLE FUEL MIXTURE
APPLICABILITY: All vehicles
according to Engine Emission Decal.
NOTE: Remove and re-install air
cleaner when necessary to perform
adjustments.
CAUTION:
CAUTION: Depress brake pedal or
when vehicle is in drive.
block wheels when
1.
1. Stabilize engine temperature by
running at fast idle in neutral until
thermostat opens and the radiator
top tank is warm. Install tachometer.
2.
2. Disconnect the evaporative emission
purge hose from air cleaner. When
applicable, disconnect and cap PCV
fresh air connection at air cleaner.
3. Adjust
A d j u s t curb
c u r b idle speed
speed to
specification. Refer
Refer to Vehicle
specification.
E m i s s i o n Control
C o n t r o l Decal.
Decal.
Emission
(Transmission should be in drive for
automatic transmission
transmission vehicles
vehicles and
in neutral for manual transmission
vehicles.)
CAUTION: Every time curb idle
adjusted, thermactor must
speed is adjusted,.
be connected and
and air
air cleaner
cleaner must
mustbe
be
pla-ce for final reading. Air
in place
cleaner must be in place for final
reading.
4. Remove thermactor system air hose
from the air by-pass valve to check
check valve
valve(s) at the check
connection(s).
5. Plug Rotunda carburetor
carburetor Idle
5.
Adjustment
Adjustment Tool T75L-9600-A into
the air cleaner purge nipple.
nipple. With the
adjust the
engine idling, slowly adjust
Rotunda valve to obtain maximum
engine speed. Note the amount of
of
speed increase and compare to
specification. Continue opening
drops. If
Rotunda valve until speed drops.
If
29-02-71
29-02-71
speed does not drop with valve full
open, check bottle-gas supply.
NOTE: EVERY TIME THE
ARTIFICIAL ENRICHMENT
ENRICHMENT
S U B SS TTAN
A N CCEE
SUB
II S
A D M I N I S T E R E D , PLACE
PLACE
ADMINISTERED,
TRANSMISSION IN SPECIFIED
MODE ACCORDING
A C C O R D I N G TO
MODE
SPECIFICATIONS
VEHICLE SPECIFICATIONS
OR ENGINE EMISSION DECAL.
pee din
ere a s e iiss wit
hin
6A.
6A. IIff sspeed
increase
within
specification, proceed to Step 7.
th artifical
6B. If speed increase wi
with
artifical
enrichment is high:
a. Richen the mix
ture wi
thou t
mixture
without
artificial enrichment substance by
turning the mixture screws
counterclockwise in equal
equal
counterclockwise
amounts until the rpm increases
the approximate amount deemed
in excess in the first
first evaluation (i.e.
if the increase
increase in the first
first
if
evaluation was 80 rpm and the
desired increase is 50 rpm, the
mixture screws should be turned
rich to attain a 30 rpm increase).
b. If idle mixture limiter(s) is already
at maximum rich, close and
remove Rotunda valve. Also,
limiters using
remove idle limiters
R o t u n d a T75L-9500-A
T75L-9500-A or
Rotunda
equivalent limiter cap(s) removal
tool.
c.
c. Re-adjust
Re-adjust the curb idle speed to
specification after each adjustment
adjustment
of the mixture screw(s).
d. Run engine at kickdown speed for
one minute before each speed
recheck.
e.
e. Note speed increase with artificial
enrichment substance-rich
substancerich or
lean to attain proper speed gain
when adding artificial enrichment
s u b s t a n c e (thermactor
(thermactor
substance
disconnected).
f. If
ters were
If idle mixture limi
limiters
removed and speed increase is
within specification, install service
(Blue) limiters at the maximum
rich stop. If idle mixtures were not
within specification, proceed to
Step 7.
g.
g. When applicable, check speed
increase after installation of blue
limiters to be sure that installation
of the limiters did not disturb the
If setting is within
setting. If
specification, proceed to Step 7.
6C.
6C. If
If speed increase with artificial
artificial
enrichment substance is low:
a. Lean the mixture without artificial
enrichment gas by turning the
mixture screw(s) clockwise in
equal amounts until the rpm
decreases the approximate amount
difference
required to attain the difference
between the observed and desired
29-02-72
speeds (i.e.
(i.e. if the observed increase
was "0"
"0" rpm and the desired speed
gain is 20 rpm the mixture screws
should be turned lean until a 20
rpm loss).
b. If idle mixture limiter(s) is already
at maximum lean, close and
remove Rotunda valve. Also
rem
G v e iidle
dIe 1limiters
im i t e r sus
ing
remove
using
Rotunda
Rotunda T75L-9500-A
T75L-9500-A or
equivalent limiter cap removal
tool.
tool.
c.
c. Re-adjust
Re-adjust the curb idle speed
(thermactor
(thermactor connected)
connected) to
specification after each adjustment
adjustment
of the mixture screw(s).
d. Run engine at kickdown speed for
one minute before each speed
recheck.
e.
e. Note speed increase with artificial
enrichment
enrichment substarice
substance and
continue to adjust rich or lean to
attain proper speed gain when
artificial enrichment
enrichment
adding artificial
s u b s t a n c e (t
( ther
h e r mac
m a c to
tor
substance
disconnected).
f. If
If idle mixture limiters were
within specification, install service
(Blue) limiters at the maximum
rich stop.
stop. If idle mixture limiters
were not removed and speed
increase is within specification,
specification,
proceed to Step 7.
g.
g. Check speed increase after
after
installation of Blue Limiters to be
sure that installation of the limiters
did not disturb the setting. If
If
specification,
setting is within specification,
proceed to Step 7.
7. Remove Rotunda tool from air
7.
cleaner purge nipple and re-install
erhission hose.
evaporative emission
8. Remove tachometer.
8.
SSD-14IGNITION SYSTEM
SSD-l4-IGNITION
DIAGNOSIS
To properly diagnose the ignition
system the following steps must be taken:
Note: 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 the
distributor high tension wire.
Caution: On catalytic converter
equipped vehicles, a spark plug wire
should be removed for no more than 30
seconds for the coil reserve and rotor air
gap tests combined. Engine rpm should
be increased to measurement speed
before spark plug wire removal to keep
the test time to a minimum.
High Voltage Portion
I. Visually
Visually inspect
inspect all wires,
connections and related system
components for any abnormal
abnormal
conditions. Repair and/or replace as
required.
BACK TO GROUP INDEX

II. Measure the Ignition System Coil
Reserve Voltage Specification: 28
KV minimum.
To make this measurement, connect
any diagnostic instrument, capable
of displaying high voltage 3;nd
and engine
rpm readings to the vehicle. Its
"clamp on" voltage pickup must be
connected to the coil to distribUtor
distributor
high tension wire.
wire. With the engine
running at 1000 rpm observe engine
operation and observe scope pattern
for any abnormal conditions. Correct
as required before proceeding. With
engine running at 1000 rpm (see
Caution in Note 2 and below),
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.
scope.
Caution:
Caution: For
Forthis
thistest,
test,do
donot
notremove
remove
the following while engine is
running:
running:
No.11 or No.
No.88 Wire on V-8
No.
Engines
No. 3 ~r
prNo.5
No. 5Wire
Wireonon1-6
1-6Engines
Engines
No.11 or No.
No.4
No.
4 Wire on V-6
Engines
No.33 Wire on 4 CyI.
No. 11 or No.
Cyl.
Engines
If this reading fails, the problem may
be in the system module, the ignition
coil, the primary wiring circuits or in
the coil to the distributor
distributor high
voltage wire.
wire. Do SSD-I4--Step
SSD-14Step VI.
Repair or replace as required.
///.
theDistributor
DistributorRotor
Rotorand
and
IlL Measure
Measure the
Cap High
HighVoltage
VoltageDrop
Drop
Cap
Specification 88 KV.
KV. max.
max.
Specification
A.
A. To make this measurement connect
instrument high
the diagnostic instrument
voltage probe to the coil-todistributor high voltage wire.
distributor
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.
wire.
B.
B. If this test fails, the problem will be
either the distributor rotor or the
distributor cap, or both. First replace
the rotor and re-run the test. If the
test again fails, replace the
distributor cap.
IV. Measure
Measure Spark
IV.
SparkPlug
PlugRequired
Required
Voltage
Voltage
Specification 8-20 KV.
A. To make this measurement connect
A.
instrument high
the diagnostic instrument
voltage probe to the coil to
distributor
distributor high voltage wire.
Momentarily bring engine to
Momentarily
approximately 2,000 rpm, and read
29-02-72
the highest spark plug high voltage
requirement for each cylinder.
B.
B. 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
on individual plug wires the
minimum specification is reduced to
6 KV.
KV.
Remove the spark plug from any
cylinder having a required voltage
less than
KV.and/or
than approximately
approximately 66KV.and/or
significantly lower voltage than other
cylinders during acceleration and
inspect for closed gap,
gap, bridged gap,
fouled insulator nose, or cracked
ceramic. Repair or replace as
required.
C.
C. If
If required voltage is more than
approximately
approximately 20 KV. and/or
and/or
significantly
significan
tly (50%) higher than
other cylinders, use the same
other
procedure as shown above (B) to
locate the problem cylinder. Check
both the spark plug and the high
voltage spark plug wire. Remove
spark plug and inspect
inspect for
for
spark
excessively worn or burnt electrodes,
or high
high resistance
resistance between
between terminal
terminal
or
and center
center electrodes.
electrodes. Repair
Repair or
or
and
replace as
as required.
required.
replace
V.
Cap,
Rotor
& Spark
V.Distributor
Distributor
Cap,
Rotor
& Spark
Plug Wires-Inspect
WiresInspect
1.
1. Remove distributor cap (remove air
cleaner if necessary).
2. Visually inspect cap for cracks.
2.
3. Wipe distributor cap inside and out
with a clean, dry rag.
4. Remove the rotor and check for
4.
cracks or a deformed spring arm, or
sign of dielectric failure. Replace as
necessary.
5.
5. Clean and re-install rotor.
6.
6. Without removing from the engine,
visually inspect wires (one at a time)
for physical damage; i.e., cuts,
pinches, cracks, and torn boots.
boots. Do
not remove wires from dist. cap.
7.
7. Replace wires that are physically
damaged.
8.
8. Check ignition wire resistance
through the distributor cap.
Note:
N
o t e : Do not
n o t under
u n d e r any
any
circumstances probe or puncture an
ignition
ignition wire. Usage of
of any
commercial
commercial probing device is
positively prohibited.
9. If the resistance of a wire exceeds
9.
5000 ohms per inch, the assembly is
suspect.
Note:
Note: If a wire(s) is suspected to be
defective, it should be completely
removed from the spark plug and
distributor cap and be checked
individually for wire resistance.
Replace a spark plug wire when
29-02-73
resistance exceeds 5000 ohms per
inch.
10. Be sure that all wires are firmly
firmly
seated at the spark plug, coil and
distributor terminals.
Note: Torn or damaged boots should
If wire is satisfactory,
satisfactory,
be replaced. If
carefully
carefully cut
cut and
and remove
remove the
the
damaged boot. (Used spark plug
assy, tooL)
tool.) Use a small amount
boot assy.
of silicone lubricant
lubricant as an aid to
of
install the new boot.
R e c o n n e c t related
r e l a t e d system
system
11. Reconnect
components.
SOCKET NO.6
NO. 6
SOCKET NO.3
NO. 3
SOCKET NO.1
NO. 1
"HARNESS
"HARNESS SIDE"
SIDE"
SOCKET NO.7
NO. 7
SOCKET NO. 4
SOCKET NO.8
NO. 8
SOCKET
SOCKET NO.5
NO. 5
B349S-C
B3495-C
FIG. 2 Electronic Module Connectors-Harness

ConnectorsHarness Side
TEST VOL
TAGE BETWEEN
VOLTAGE
KEY
ON
ON
CRANKING
Socket # 4 and
and Engine Ground
SHOULD BE
BE
Battery Voltage
Module Bias Test
0.1
0.1 Volt
Socket # 1 and Engine Ground
Battery Voltage
0.1 Volt
0.1
Battery Source Test
# 5 and Engine
Socket #
Engine Ground
8 to 12 volts
Cranking Test
# 1 toto #4P-8 8
Jumper #
Read#
Read # 6
more than 6 volts
Starting Circuit Test
Pin
Pin # 7 and
and Pin
Pin # 33
1/2 volt minimum A.C.

or any D.C. volt wiggle
Distributor
Hardware Test
TEST VOL
TAGE BETWEEN
VOLTAGE
KEY
OFF
IF NOT, CONDUCT
Socket #
Socket #
Socket #
Socket #
77 and
8 and
and
7 and
and
3 and
## 3
SHOULD BE
BE
IF NOT, CONDUCT
400 to 800 ohms

o0 ohms
more than 70,000 ohms
Magnetic Pick-up
(Stator) Test
Socket #
#= 4 and Coil Tower
Socket # 1 and
and Pin #^ 6
7000 to 13000 ohms

1.0 to 2.0 ohms
Coil Test
Socket #
4fc 1 and
andEngine
EngineGround
Ground
more than 4.0 ohms
Short Test
Socket # 44 and Pin ## 6
1.0 to 2.0 ohms
Resistance Wire Test
Engine Ground
Ground
Engine Grou
nd
Engine Ground
CB 16030
1603-D
CB
FIG. 3 Primary (Low Voltage) Tests-1975

Tests1975
BACK TO GROUP INDEX
29-02-73
VL
Primary (Low Voltage) Portion
VI. Primary
Port/on
NOTE:
information is intended to
1. This information
supplement Part 23-01
2. An accurate volt-ohmmeter
voltohmmeter is
required.
3. Battery must be in a good state of
charge.
Ensure that the ignition coil high
t e n s i o n wire
w i r e is good.
g o o d . Then
Then
tension
disconnect the three-way and fourfourway connectors as shown in Fig. 2 at
the electronic module and make the
tests shown in Fig. 3 at the harness.
If
If the results are not what they
should
should be, conduct
conduct the trouble
trouble
isolation tests shown below. Figs. 5
and
a n d 6 are
a r e schematic
s c h e m a t i c of
of the
the
breakerless ignition system.
If the above checks are OK, substitute
If
the known good module (ground not
required).
1.
1. If
If the substitution
substitution corrects the
malfunction,
malfunction, reconnect the original
module to verify that no intermittent
or repair elsewhere in the system was
t h e problem
p r o b l e m cause.
c a u s e . If
If the
the
the
malfunction still exists, replace the
malfunction
original module.
If the substitution module does not
2. If
correct the problem, reconnect the
original
original module
module and make the
the
appropriate repairs elsewhere in the
system.
Module Bias Test
Module
Measure the voltage at Socket 4 to
ground with the ignition key
engine gtound
If the voltage observed is less than
"on". If
battery voltage, repair the voltage feed
module for running
running
wiring to the module
conditions.
Battery
Source Test
Test
Battery Source
1. Connect the voltmeter leads from the
1.
battery terminal at the coil to engine
ground, without disconnecting the
coil.
2. Install a jumper wire from the DEC
terminal of the coil to a good ground.
off.
3. Turn the lights and accessories otT.
4. Turn the ignition switch on.
5. If
If the voltmeter reading is between
4.9 and 7.9 volts, the primary circuit
from the battery
battery to the coil is
from
satisfactory.
6. If the voltmeter reading is less than
4.9 volts, check the following:
following:
The primary
p r i m a r y wiring
wiring for
for worn
worn
insulation, broken strands, and loose
or corroded terminals.
The resistance wiring for defects.
7. If
If the voltmeter reading is greater
than 7.9 volts, the resistance wire
after verifying
verifying
should be replaced after
defect.
Cranking Test
Measure the voltage at Socket 5 to
engine ground with the engine cranking.
If the voltage observed is not 8 to 12
If
29-02-74
volts,
the
volts, repair the
the voltage feed to
to the
module
module for
for starting conditions.
conditions.
Starting Circuit
Circuit Test
Test
StIlrting
the reading isis not
not more
more than
than 66volts,
volts,
If the
is open or
the ignition by-pass circuit is
the starter solenoid
grounded from either the
the ignition switch to
to Socket 55 or
or the
at the
the coil.
coil. Repair
primary connections at
or replace as
as required.
required.
DistributorHsrdwsre
HardwareTest
Test
Distributor
Engine
and Service
Short Test
Test
Short
If the
the resistance
resistance from Pin
Pin 55 to
to engine
engine
ground is
is less
less than 44 ohms,
ohms, check for
short to
to ground at
at the
the DEC
DEC terminal of
the
the ignition coil
coil or
or in
in the
the primary wiring
to
to the
the coil.
coil.
Resistance Wire
Wire Test
Test
Resistance
out of
Replace resistance wire if out
specification.
two parallel blades in

in the
between two
the
distributor connector
connector must be
distributor
400-800 ohms.
the third blade
Resistance between the
and the
the distributor bowl
(ground) and
be zero ohms.
must be
Resistance between either parallel
blade and
and engine ground must be
be
greater than 70,000 ohms.
If any test fails, the distributor stator
assembly is
and must be
be
is defective and
replaced.
If above readings are not the same as
measured in
in the
the original test, check
for defective harness. If readings are
are
the same, proceed.
If the
the above checks OK,
OK, the
the signal
generator portion of the
the distributor
is OK.
OK.
SSD-15IGNITION TIMING
TIMING
SSD-15-IGNITION
and Requirements
Requirements
Application and
any differences
differences between car
(noting any
lines):
lines):
LINESALL
ALL VEHICLE LINES-ALL
ENGINES.
ENGINES.
A. Basic Timing
Timing
A.
1.
1. Clean the
the surface and
and place aa white
mark on
on
on the
the proper degree line on
and pointer
pointer
the front damper and
according to
on
to specification noted on
decal.
engine decal.
2. Disconnect the vacuum line(s)
line(s) at
at the
2.
and plug.
distributor and
3. Connect aa snap-on type timing light
3.
No. 1 cylinder spark plug wire.
to No.1
4. Connect aa tachometer.
4.
5. Start engine, warm up,
up, and
and set
5.
timing idle speed to
to specifications.
specifications.
to Vehicle Emission Control
Refer to
Decal.
Decal.
6. Check engine initial timing.
timing. If within
6.
2
2 of the
the specification
specification on
on the
Emission Decal, Do
Not Reset.
Do Not
7.
7. If more than 2,
2, loosen
loosen distributor
distributor
hold down bolt and
and adjust
adjust initial
to specification
by rotating
timing to
specification by
the distributor against rotor rotation
to advance timing, or with rotor
rotation to
to retard timing. When the
the
white mark (Step 1)
1) isis directly
directly in
in line
line
with pointer, ignition timing is
is then
correct. Torque hold down bolt.
Recheck timing when hold down
bolt is
is torqued.
B. Centrifugal Advance
1. Check centrifugal
centrifugal advance by
by
1.
accelerating engine in neutral to 2500
rpm. If ignition timing advance is
is
noted during acceleration, the
the
centrifugal
centrifugal advance mechanism is
is
functional. If not, replace.
Ignition
CoilTest
Test
Ignition Coil
The breakerless ignition coil must be
be
diagnosed separately from the rest of the
ignition system.
1. Primary resistance must be
be 1.0-2.0
1.0-2.0
ohms.
2. Secondary
Secondary resistance
resistance must be
be
7000-13,000 ohms.
3. If coil is still suspected, test on coil
ttester
e s t e r by ffollowing
o l l o w i n g tthe
he
manufacturer's
manufacturer's instructions, using aa
standard coil.
If
If reading above differs
differs from the
the
original test, check for defective
harness.
C. Total Advance
1. Install a vacuum gage in the vacuum
line from the carburetor source to the
vacuum advance diaphragm (outer
diaphragm
diaphragm on dual diaphragm
distributors). Increase engine speed
to 2500 rpm
rpm to verify
verify available
vacuum. If no vacuum is available
within 60 seconds vacuum system is
is
at fault, perform
perform SSD-3. If a vacuum
is available, perform
C-2.
perform Step C-2.
2. Install
Install distributor
distributor vacuum line
(without spark delay valves) to outer
diaphragm (on dual diaphragm
diaphragm
1. Disconnect three-wire weatherproof

1.
at distributor pigtail.
pigtail.
connector at
2. Connect aa D.C.
D.C. voltmeter on 2.5
2.5 volt
volt
2.
scale to
to two
two parallel blades.
blades. With the
engine cranking, the
the meter needle
should oscillate.
oscillate.
3.
3. Remove distributor cap
cap and
and check
for visual damage or
or misassembly.
misassembly.
a.
a. Sintered iron armature (4,
(4, 66 or
or 8
toothed wheel) must be
be tight on
sleeve,
sleeve, and
and the
the roll pin
pin aligning
to sleeve must be
be in
armature to
position.
position.
b.
b. Sintered iron stator must not
not be
be
broken.
c. Armature must rotate when engine
c.
is cranked.
4. If the hardware is OK, but the meter
4.
doesn't oscillate, replace the
magnetic pick-up assembly.
Magnetic Pick-up
Pick-upTest
Test
Magnetic
1. Resistance of pickup coil measured
1.
2.
2.
3.
4.
5.
6.
BACK TO GROUP INDEX
29-02-74
distributor).
distributor). Accelerate engine to
to
2500
2500 rpm.
rpm. Total
Total advance
advance should now
be greater than in
in Part "B"
" B " if
advance
advance mechanism isis functional. If
not, replace vacuum advance
advance
components as
as required.
required.
D.
D. Vacuum Retard
Retard (Dual
(Dual
Diaphragm Distributor)
Distributor)
1.
1. Unplug and
and install vacuum gage
gage in
vacuum line
line from intake manifold.
manifold.
With the
the engine at
at idle verify
verify
available vacuum.
vacuum. If vacuum isis not
not
available,
available, vacuum system isis at
at fault.
fault.
as required. If vacuum is
Correct as
D-2.
available perform Step 0-2.
2.
2. Remove the
the vacuum gage and
reinstall the
the vacuum line on
on the
on dual
retard (inner diaphragm on
diaphragm distributors). Ignition
retard. If no
timing should indicate retard.
retard is
is indicated, replace
replace
retard
distributor vacuum advance
advance
distributor
as required.
required.
components as
SSD-l6-FUEL
SSD-16FUEL BOWL VENT
CLEARANCE
CLEARANCE
I.I. 2150
2150 Carburetors
Carburetors
1.
1. Inspect the
the valve'and
valve and linkage for
damage leaks and/or
a n d / o r proper
proper
connections.
connections.
2.
2. Check for
for plugged bowl vent tube by
by
connecting aa Rotunda vacuum hand
pump or
or equivalent to
to the bowl vent
tube.
tube. If the valve maintains a vacuum
vacuum
reading the
the tube is
is plugged. Clean,
repair and/or replace as
as required.
to normal
3. If necessary, bring engine to
4.
4. Check TSP-off
TSP-off speed (for 2.8L which
not have a solenoid check curb
does not
to
idle speed) to specifications. Refer to
1975 Specifications Book. Adjust as
as
required.
(at curb idle
5. With TSP de-energized (at
2.8L) and
and vent valve plunger
for 2.8L)
the clearance
depressed, measure the
the vent valve plunger and
and
between the
the actuating lever.
C I ear a n c e should
s h 0 u I d be wit
hin
6. Clearance
within
Refer
sspecifications.
pecifications. R
e f e r to
Specifications. Bend actuating lever
the specified
as required to obtain the
clearance.
II. 4350 Carburetors

for
1. Inspect the valve and linkage for
damage leaks
leaks aand/or
damage
n d / o r proper
connections.
and TSP
TSP de2. Check curb idle speed and
deenergized speed to specifications.
Specifications Book
Refer to 1975 Specifications
and Vehicle Emission Decal. Adjust
as required.
3. Set throttle to curb idle position.
clearance between tip of
of
4. Gauge clearance
adjusting screw on bowl vent arm
arm
adjusting
and tang on acceleration pump drive
lever.
29-02-75
29-02-75
5.
5. If measured clearance is
is not within
specification, turn adjusting screw to
obtain required clearance.
clearance. Refer to
1975
1975 Specifications Book.
6.
6. Check for movement of bowl vent
when TSP is
is de-energized. Repair
and/or replace as
as required.
required.
III.
III. YFA Carburetors
Carburetors
1. Check curb idle rpm to spec with
1.
Adjust as
solenoid activated. Adjust
required.
required.
2.
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 (Fig.
(Fig. 7).
4.
4. Close throttle and measure the travel
of the fuel bowl vent rod at point
"A" from open throttle position
(Step No.3
id~e position
No. 3 above) to idle
TEST VOLTAGE BETWEEN

KEY
Socket No.4
No. 4 and
and Engine Ground
SHOULD BE
IF NOT,.CONDUCT
NOT, CONDUCT
Battery Voltage
Battery Source Test
No.22 above).
(Step No.
above). Travel
Travel of the
the fuel
fuel
bowl vent rod at point "A" should
.010.
be .020 .010.
5. If out of spec, bend throttle vent
indentation to obtain
lever at indentation
required travel.
SSD-17-PROCEDURE
SSD-17PROCEDURE FOR VALVE
TRAIN ANALYSIS
I. Removal of Rocker Cover
A. Remove air cleaner.
B. Disconnect and remove any hoses,
spark plug
plug leads
leads and
wires, spark
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.
II. Static Valve Train Analysis
Check for damaged and/or severely
worn parts, for correct assembly and
assure use of correct parts, then proceed
as follows with static engine analysis.
Shaft Assemblies
AssembliesA. Rocker Arm Shaft
individually mounted.
1.
1. Check for loose mounting stud and
nut or bolt.
2. Check for plugged oil feed in
rocker arm.
Shaft Assemblies
B. Rocker Arm Shaft
1.
1. Check for loose mounting bolt(s).
2. Check for plugged oil feeds.
C. Push Rods
1.
1. Check for bent push rods.
Assembly-with or
D. Valve Spring Assemblywith
without damper spring
1.
1. Check for broken or damaged
parts.
Keys-both 2 piece
E. Retainer and Keysboth
and 1 piece retainers
1.
1. Check for proper seating of keys
on valve stem and in retainer.
F. Positive Rotator and Keys
1.
1. Check for proper seating of keys
on valve stem and in positive
rotator.
G. Valves and Cylinder Head
+ 0.1
0.1 Volt
Volt
ON
ON
Socket No.1
No. 1 and
andEngine
EngineGround
Ground
Battery Voltage
Battery Source Test
0.1 Volt
0.1
CRANKING
Socket No.5
No. 5 and
and Engine Ground
8 to 12
12 volts
Check Supply Circuit

(starting) through
Ignition Switch
Jumper No.1
No. 1 totoNo.8
No. 8
more than 6 volts
Starting Circuit Test
Read
Read NO.6
No. 6
Pin
Pin NO.3
No. 3and
andPin
PinNo.8
No. 8
1/2 volt minimum A.C.
Distributor
or any D.C. volt wiggle
Hardward Test
TEST VOLTAGE BETWEEN
SHOULD BE
IF NOT, CONDUCT
KEY
No. 8 and
and No.3
No. 3
Socket No.8
400 to 800 ohms
Magnetic Pick-up
OFF
OFF
No. 7 and
and Engine Ground
Socket No.7
aOohms
ohms
(Stator) Test
No. 8 and
and Engine Ground
Socket No.8
704000 ohms
more than 70~000
No. 3 and
and Engine Ground
Socket No.3
701000 ohms
more than 70\000
No. 4 and
and Coil Tower
Socket No.4
13,0(D0ohms
7000 to 13,OlDO
ohms
Coil Test
CoilTest
No. 1 and
andEngine
EngineGround
Ground
Socket No.1
more than 4.0 ohms
Short Test
CB 1603E
1603-E
CB
FIG. 4 Primary (Low Voltage) Test-1976

Test1976
FIG.
" ,-~ _N_I~_6_1~_N
. .....r
-~6=--
R_-.........._V\.,V.v-....
:--;.~ ~-:-~--...
t-7
I 44 RED
S
6 BLUE
BAT
55 WHITE
GREEN
1 GREFN
3 ORANGE
NOTE
WIRE SEQUENCE
HAS BEEN ARRANGED
ARRANGED
TO SIMPLIFY
SCHEMATIC.
WIRES WILL NOT
NECESSARILY
NECESSARI L Y BE IN
THIS ORDER ON
PRODUCTION
MODULES.
C~.rn~_"';;'8.; ;.B.; .;LA. ;.;C;.;.K~_. J
* ^
PURPLE
8 BLACK
77 PURPLE
B3738-A
B3738-A
FIG. 5 Electronic Module Schematic-Breakerless

SchematicBreakerless Ignition (1975)
FIG.
BACK TO GROUP INDEX

29-02-76
1. Check cylinder head gasket for
1.
(For 2.8L
proper installation. (For
Engines ensure there are 3 fingers
left cylinder
visible on front of left
head and 3 fingers on rear of right
cylinder head.)
2. Check for plugged oil drain back
holes.
3. Check for worn or damaged valve
tips.
4.
4. Check for missing or damaged
valve stem oil seals or guide
mounted oil seals.
5.
5. Check valve lash-mechanical
lashmechanical
tappet applications.
6.
gap6. Check collapsed tappet gap
hydraulic tappet applications.
7.
7. Check installed spring height.
H.
H. Overhead Cam Follower Arm and
Lash Adjuster Assemblies
1.
1. Check for broken or severely worn
parts.
I. Camshaft-Overhead
CamshaftOverhead Camshaft
Camshaft
Applications
1.
1. Check for plugged oil feed.
feed.
2.
2. Check for correct cam lift.
The above static checks are to be
made on the engine prior to the following
dynamic procedure.
III.
III. Dynamic Valve Train Analysis
CAUTION: DO NOT USE THIS
CAUTION:
OVERHEAD
PROCEDURE FOR OVERHEAD
CAMSHAFT ENGINES.
Start the
the engine and while
while running at
idle check for proper operation of all
parts.
parts. Check the following items under
firing engine operating conditions:
conditions:
A.
r mAs
A. Roc
R o c k eerA
r Arm
A s s e m b llie
i e ss
individually mounted
1.
1. Check for plugged oil feed in
rocker arm.
arm.
B.
B. Rocker Arm Shaft Assemblies
1.
1. Check for plugged oil
oil feeds.
feeds.
2.
2. Check for proper overhead valve
train lubrication.
lubrication. If aa condition of
insufficient
insufficient oiling is
is suspected,
suspected,
accelerate engine to 1200 rpm
100
100 rpm with transmission in
normal
neutral and engine at normal
temperature. Oil
Oil should
spurt from rocker arm oil holes
spurt
such that valve
valve tips and rocker
such
arms are
are well
well oiled and/or, with
arms
oil splash
rocker arm cover off, oil
may overshoot
overshoot rocker arm.
arm. If
may
oiling is
is insufficient
insufficient for this
this
oiling
condition to occur, check oil
passages for blockage.
blockage.
passages
C. Push
Push Rods
Rods
C.
1. Check
Check for
for bent push
push rods.
rods.
1.
2. Check
Check for
for proper rotation of push
2.
rods.
rods.
D. Positive
Positive Rotator
Rotator and
and Keys
Keys
D.
Check for
for proper
proper operation
operation of
1.1. Check
positive rotator.
rotator.
positive
E. Valves
Valves and
and Cylinder
Cylinder Head
E.
Check for
for plugged
plugged oil
oil drain
drain back
1.1. Check
holes.
holes.
BACK TO GROUP INDEX
Diagnosis and
and Service
Engine Diagnosis
or damaged
2. Check for missing or
stem oil seals or
or guide
valve stem
seals.
mounted oil seals.
IV. Reinstallation of Rocker
Cover
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 ifif necessary.
C. Install a new gasket and replace the
cover on the engine.
D. Reinstall the rocker arm cover bolts
tigh ten in recommended
and tighten
specified torque. See
sequence to specified
appropriate Engine Part. Use a 1/4inch-drive handle
handle and
and 10mm
inch-drive
universal socket to provide clearance
for distributor when tightening rear
cover bolts.
E. Reconnect all hoses, wires, spark
plug leads and components that were
removed in Part 1.
SSD-18CARBURETOR CLEANING
SSD-18-CARBURETOR
PROCEDURE
4350
4 3 5 0 Carburetor
performed if
if
This procedure is to be performed
contamination must be removed from the
carburetor.
1. Clean carburetor in the following

1.
sequence:
sequence:
Clean with lead-free
lead-free fuel
fuel or
equivalent.
A. Remove external connections, air
A.
horn hold down screws, and air
cleaner
cleaner stud. Lift
Lift air horn
assembly
assembly vertically
v e r t i c a l l y from
from
carburetor and place on a flat
surface.
B.
B. Clean fuel bowl.
C. Clean air horn assembly.
C.
D. Remove and clean float assembly.
D.
E. Rem
R e m o0 vvee p rrim
i m aa rryy and
and
E.
supplementary inlet needle and
assemblies. Remove fuel inlet
seat assemblies.
gasket.
filter and gasket.
2. If further
further cleaning is required,
required,
2.
remove external connections, remove
and:
carburetor from vehicle and:
A. Separate main body and throttle
A.
assemblies.
body assemblies.
B. Remove and clean accelerator
accelerator
B.
ball.
pump weight and pump check ball.
C. Clean carburetor bodies.
C.
3. Replace fuel inlet assemblies, inlet
3.
filter and gasket with new
filter
components.
components.
4. Set dry float level to specifications
specifications
4.
and qualify
qualify supplementary
supplementary inlet
inlet
and
valve.
valve.
5. Reassemble carburetor on vehicle
5.
using new
new retainers at choke rod and
using
pump rod.
rod.
pump
6. Manually check operation of air
6.
valve and
and choke
choke linkage to
to ascertain
valve
29-02-76
29-02-76
freedom of
of movement.
movement. Repair
Repair and/
and/
freedom
or replace as required.
external connections
connections to
to
7. Make all external
carburetor on vehicle.
vehicle.
carburetor
8. Check all idle speeds and idle fuel
Adjust as
as
mixture to specifications. Adjust
required.
5200 Carburetor
Carburetor
5200
performed ifif
This procedure is to be performed
contamination
carburetor.
carburetor from
from the
vehicle.
which
2. Remove the following: (Note which
items were removed from
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
limiter cap and
and idle
f. Remove limiter
adjustment
adjustment screw (Note number of
of
otT seat)
turns off
3. Clean the fuel bowl and all of
of the
items removed in Step 2 using lead
free fuel or equivalent.
4. Using compressed air, blow
out the
blowout
following main body channels in the
listed order:
Primary idle
idle channel
channel from
a. Primary
adjustment screw opening.
adjustment
Primary and secondary
secondary idle
b. Primary
channels from idle jet opening.
primary and
c. Fuel bowl and primary
secondary main metering
metering jet
secondary
channels.
d. Primary and secondary main well
channels.
5.
off the
5. Using compressed air, dry off
items removed in Steps 2b, c, d, e,
and f.
6.
6. Install new fuel filter.
7.
Adjust dry float setting (See Part
7. Adjust
24-05).
8.
8. Reassemble the carburetor using a
new air horn gasket.
9.
9. Check and reset as necessary:
a.
a. Choke pull down
b. Cam setting
10. Reinstall carburetor on vehicle.
10.
11. Check all idle speeds and idle fuel
mixture to specification. Adjust
Adjust as
required.
2150
Carburetor
21
50 Ca
rbu retor
This procedure is to be performed ifif
carburetor.
1. Disassemble
Disassemble and
and clean
clean carburetor
carburetor in
1.
the following sequence:
Clean all
all parts
parts with
with lead
lead free
free fuel
fuel or
Clean
or
equivalent.
A. Remove
Remove airhorn.
airhorn.
A.
B. Note position on idle limiter caps.
B.
C. Clean
Clean fuel
fuel bowl.
bowl. Remove
Remove and
and clean
C.
float, inlet needle and seat, inlet
filter screen.
screen.
filter
29-02-77
29-02-77
IGNITION
SWITCH
4 RED
NOTE
BAT
~~~~TION (1)
WIRE SEQUENCE
HAS BEEN ARRANGED
TO SIMPLIFY
SCHEMATIC.
5 WHITE
1 GREEN
DEC
WIRES WILL NOT

NECESSARILY BE IN
NECESSARILY
THIS ORDER ON
PRODUCTION
MODULES.
3 ORANGE
ORANGE
~\tp
CJ)
8 BLACK
7 PURPLE
83738- B
8
B3738-
FIG. 6 Electronic Module Schematic-Breakerless

SchematicBreakerless Ignition (1976)
2.
2. If further
further cleaning is required,
remove carburetor from vehicle and:
A.
A. Clean fuel bowl.
bowl. Remove and clean
booster hold down screw, booster
assembly, pump weight, pump
check ball.
B.
B. Remove and clean accelerator
pump cover, pump spring, power
valve cover, enrichment valve,
main metering jets.
3.
3. Using compressed air dry all parts,
blowout
blow out all channels in booster
assembly (if applicable), main body
and airhorn.
4.
4. Reassemble carburetor in reverse
two. Use
order of steps one and/or two.
new gaskets for the following as
required.
5.
6.
7.
8.
Enrichment Valve
Enrichment Valve Cover
Booster Assembly
Accelerator Pump Diaphragm
Install new fuel filter.
If required, reinstall assembled
If
carburetor to specifications
specifications on
carburetor
vehicle using new gaskets.
specifications and
Check fuel level to specifications
adjust as required.
CAUTION: For safety purposes,
temporarily secure airhorn to start
engine. Remove for float level check.
Reinstall airhorn to specifications
with new gasket.
Check all idle speeds and idle fuel
Adjust as
mixture to specifications. Adjust
required.
V1976-A
Fuel Bowl Vent Valve

FIG. 7 Fuel
AdjustmentYFA 1-V
1-V
Adjustment-YFA
BACK TO GROUP INDEX

29-02-78
29-02-78

and Service
SPECIFICATIONS
EGR VALVE STARTTOOPEN
START-TO-OPEN SPECIFICATIONS
Basic
Basic No.
No.
90475
9D475
Type
D3AE-LA
03VE-AA
D3VE-AA
04AE-AA
D4AE-AA
04AE-BA
D4AE-BA
D4AE-CA
D4AE-DA
D4AE-EA
D4AE-FA
D4AE-GA
D4DE-AB
D4DE-EA
D4DE-FA
D4DE-GA
D4DE-HA
D40E-AA
D40EAA
D40E-BA
D40E-CA
D40E-DA
D40E-EA
D4TE-AA
D4TE-BA
D4TE-DA
D4TE-EA
04TE-EA
D4TE-FA
D4TE-HA
D4TE-JA
D4TE-KA
D4UE-AA
D4UE-BA
D4UE-CA
D4ZE-AA
D4ZE-BA
D4ZE-CA
D42E-AG
Start-toO
pen
Start-to-Open
Inches HG
HG
TS
TS
TS
TS
P
P
P
M
P
P
P
P
P
P
TS
TS
TS
TS
P
P
P
P
P
P
P
P
P
TS
TS
P
TS
TS
TS
TS
P
P
P
M
M
M
TS
TS
2.5
2.5
2.9
2.9
2.9
2.0
3.6
3.6
2.9
2.9
2.0
2.9
2.9
2.9
2.7
2.5
3.0
3.0
2.9
2.9
2.9
2.9
2.9
2.7
4.8
2.9
2.9
2.7
1.7
1.7
2.5
2.5
2.5
2.5
3.0
3.0
3.0
3.0
2.9
2.0
2.0
2.0
3.6
3.6
3.6
3.6
3.6
3.6
2.8
TS - Tapered
Tapered Stem
PP - Poppet
Basic
Basic No.
No.
90475
9D475
Type
P
TS
TS
TS
TS
P
TS
TS
P
TS
TS
TS
TS
P
TS
TS
TS
TS
TS
TS
TS
TS
P
TS
TS
TS
TS
TS
TS
P
P
P
TS
TS
P
P
TS
TS
TS
TS
TS
TS
TS
TS
TS
TS
TS
TS
TS
TS
TS
TS
TS
TS
TS
TS
TS
TS
D42E-BB
042E-CO
D42E-CD
042E-OB
D42E-DB
D42E-OC
D42E-DC
D42E-EB
D42E-FA
D5AE-AA
D5DE-AA
D5EE-CA
D5ME-BA
D50E-AA
D5TE-CA
D5TE-CB
D5TE-DA
D5TE-EA
D5TE-FA
D5UE-BA
D5UE-CA
D5VE-CA
D5VE-DA
D5VE-EA
D5VE-FA
05VE-GA
D5VE-GA
D5ZE-AA
D52E-DA
D52E-EA
D52E-FA
D52E-GA
D52E-HA
D52E-JA
D52E-JS
D52E-KA
D52E-LA
D58E-AA
Startto-Open
Start-to-Open
Inches tfG
HG
2.7
2.8
4.7
4.7
2.7
2.8
2.9
3.5
3.5
2.5
2.0
2.5
3.0
3.0
2.5
2.9
2.5
3.0
3.0
3.0
3.0
3.5
3.5
2.0
2.5
2.5
2.5
2.5
2.5
2.0
2.8
2.8
4.7
2.8
2.6
4.7
4.7
3.8
3.8
3.0
3.0
2.9
M - Modulator
CA1440B
CA1440-B
VACUUM AMPLIFIER CODING

Part Number
Prafiv &
& Qnffiv
Prefix
Suffix
rreiix at OUTTIX
(Basic No. 9E451)
Code
Number
Code Number
on Unit
on
Amplification
Ratio of Unit
Bias
Bias Rating
of Unit (In.
Hg.)
(In. Hg.)
Service Bias
Specification
"Yellow""
Stamped in "Yellow
D52E-B1A,-B2A,-B3A
052E-Bl
A, -B2A, -B3A
D52E-A1A,-A2A,-A3A
052E-A1A,
-A2A, -A3A
D5TE-A1A,-A2A,-A3A
05TE-A
1A, -A2A, -A3A
D5TE-B1A,-B2A,-B3A
05TE-Bl
A, -B2A, -B3A
D5OE-A1A,-A2A,-A3A
050E-A1
A, -A2A, -A3A
10-0
10-5
10-1
10-1
10-15
10-2
10:
10:11
10:1
10:1
10:
10:11
10:
10:11
10
10:11
0
.5
.5
1.0
1.0
1.5
2.0
0-.5
0-.5
.2 - ..88
.7
. 7 - 1.3
1.2
1.2-- 1.8
1.7
- 2.3
1.7-2.3
Stamped
Stamped in "White"
D5DE-A1A,-A2A,-A3A
050E-A 1A, -A2A, -A3A
D5DE-B1A,-B2A,-B3A
050E-B1
A, -B2A, -B3A
D5TE-C1A,-C2A,-C3A
051'E-Cl
A, -C2A, -C3A
D5AE-A1A,-A2A,-A3A
05AE-A1A, -A2A, -A3A
14-0
14-1
14-1
14-2
14-3
14:1
141
14:11
14:
14:11
14:
14:1
141
0
1.0
2.0
2.0
3.0
3.0
0-.5
0-.5
.7
. 7 - 1.3
1.7
- 2.3
1.7-2.3
2.7 - 3.3
Stamped in "Red"
"Red"
D5TE-D3A
18-0
181
18:1
0-.5
0-.5
(Basic No. 9E451)
Notl:
Note: The
The different numerals in
in the
the suffix denote alternate vendor sources:
sources: "1"
" 1 " for Fram,
Fram, "2"
"2" for Marvel Scheblor, "3"
" 3 " for Ranco.
BACK TO GROUP INDEX
CA1441-A
29-03-1
29-03-1
29-03-1
Thermactor System
Thermactor
PART 29-03 Thermactor System

Page
Page
INFORMATION
GENERAL INFORMATION
Air Supply Pump ...................
Air Bypass Valve ...................
Vacuum Differential Valve (VDV) ......
..
Differential Valve Delay Valve (DVDV) ..
Exhaust Check Valve ................
03-1
03-1
03-1
03-1
03-2
03-2
03-2
Page
Page
COMPONENT INDEX
Cold Engine Lockout -Catalytic Converter
Equipped .....................
Normally Closed (Type I) Switches .....
Normally Open (Type II) Switches ......
Vacuum Check Valve ................
CD CD CD CD
CO CO CO CO
CO CO CO CO
COMPONENT
COMPONENT INDEX
03-3
03-3
03-3
03-3

information in this Part applies to both 1975 and 1976 model year vehicles unless otherwise specified.
CR1966-A
GENERAL INFORMAYION
INFORMATION
A "Thermactor"air injection system
is installed
installed on all vehicles. The
Thermactor Exhaust Control System
1) reduces carbon monoxide and
(Fig. 1)
hydrocarbon content of combustion byproduct 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
drilled-passages in
in the
the
"internal"
cylinder head
or exhaust
exhaust manifold.
manifold. The
cylinder
head or
The
oxygen in
the fresh
air, plus
the heat
oxygen
in the
fresh air,
plus the
heat of
of
the
causes further
further
the exhaust
exhaust gases,
gases, causes
oxidation
oxidation (burning),
(burning), which
which converts
converts the
the
exhaust gases
into carbon
carbon dioxide
dioxide and
exhaust
gases into
and
water.
water.
The major components (Fig. 11 and
and2)2)
of a typical Thermactor system include:
a. Air supply pumpbelt
pump-belt driven from
crankshaft
pulley or from
crankshaft pulley
from
alternator
b. Air bypass valve
c. Vacuum differential
differential valve (VDV)
-some
somesystems
systems
d. Air supply system-external
systemexternal or
internal
e.
e. Cylinder heads with air passages to
exhaust ports
f. Air supply check valves
reservoir-some models
g. Vacuum reservoirsome
h. Air supply pump mufflerh.Air
muffler
Mustang, Granada and Monarch
with 302 or 351
351 CID V-8
The air supply pump does not have a

pressure relief valve, this function being
valve. The
controlled by the air bypass valve.
pump also incorporates larger ports for
reduced outlet air temperature (Fig.
(Fig. 3).
AIR BYPASS VALVE

Three air bypass valves are used for
1975 and 1976, one type for non-catalytic
systems and two for catalytic converter
equipped systems (Figs. 4 and 5).
The timed bypass valve used with

1975 non-catalytic systems and some
1976 non-catalytic systems operates as
follows: During normal operation,
vacuum is equ&lized
equalized on both sides of the
diaphragm (Fig. 4). The diaphragm
return spring btolds
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
CHECK VALVE
HOSE INLET HOSE9B466
AIR CHECK
VALVE
VACUUM HOSE
TO VDV
TOVDV
AIR BYPASS
VALVE _----i'~
9B289
VACUUM
DIFFERENTIAL
DIFFERENTIAL
VALVE (VDV) -9E441
-9E441
AIR BYPASS VALVE

BRACKET - - 9B466
AIR BYPASS VALVE

INLET HOSEHOSE 9F287
AIR SUPPLY PUMP

The belt driven air pump (Fig. 3)
takes air in through an impeller-type
centrifugal air filter fan, thus eliminating
centrifugal
the need for a separate air filter.
filter. Dust and
dirt particles cannot enter the pump
because
heavier-than-air
because these heavier-than-air
contaminants are thrown from the air
centrifugal force.
force.
intake by centrifugal
BACK TO GROUP INDEX
AIR SUPPLY PUMP
A4084B
A4084-B
FIG. 1 Typical Thermactor System ComponentsCatalytic

Components-Catalytic
29-03-2
29-03-2
Thermactor System
System
AIR SUPPLY
SUPPLY CHECK
CHECK
AIR
VALVE - VALVE
AIR BYPASS
BYPASS VALVEVALVE
AIR
9B289
9B289
ATTACHING
BANJO NUTS
VACUUM
CONNECTION
AIR BYPASS VALVE

INLET HOSE - 9F287
AIR SUPPLY
PUMP
AIR SUPPLY
PUMP
PUMP MUFFLER
MUFFLER 9F449
MUFFLER INLET
INLET
MUFFLER
HOSE
- 9F451
HOSE-9F451
A4085-A
FIG. 22 Mustang 302 CIO

CID v-a
V-8 Thermactor System-Non-catalytic
SystemNon-catalytic
FIG.
A4086-A
FIG. 3 Thermactor Air Supply Pump
pressure and pulls the valve downward.

Thermactor air is then diverted to the
atmosphere
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 is the
same for 1975 and 1976 systems, and
operates as follows: During normal
operation,
operation, engine intake manifold
vacuum applied through the VDV holds
the normally-closed
normally-closed valve upward,
allowing thermactor
thermactor air to flow to the
cylinder head(s) and blocking the vent
port
port (Fig. 5). When engine intake
manifold
manifold rises or drops sharply (such as
during acceleration or deceleration, or
BACK TO GROUP INDEX
system blockage or failure), the VDV

operates and momentarily cuts off
off the
vacuum to the bypass valve. The spring
pulls the stem down, seating the valve to
cut off
off pump air to the exhaust manifold,
and opening the dump valve at the lower
end of the bypass valve to momentarily
divert
divert the
the pump
pump air
air to
to the
the atmosphere.
atmosphere. In
In
the
the case
case of
of excess
excess pump
pump volume
volume or
or aa
downstream
downstream restriction,
restriction, the
the excess
excess
pressure
pressure will
will unseat
unseat the
the valve
valve in
in the
the lower
lower
portion
of the
the bypass
bypass valve
valve and
and allow
allow aa
portion of
partial
the
partial flow
flow of
of pump
pump air
air to
to the
atmosphere.
atmosphere. At
At the
the same
same time,
time, the
the valve
valve
in
in the
the upper
upper part
part of
of the
the bypass
bypass is
is still
still
unseated,
unseated, allowing
allowing aa partial
partial flow
flow of
of pump
pump
air
air to
to the
the exhaust
exhaust manifold
manifold to
to meet
meet
system requirements.
A
A new
new air
air by-pass
by-pass valve
valve isis used
used with
some 1976
1976 catalyst and non-catalyst
non-catalyst
thermactor systems
6).
systems (Fig.
(Fig. 6).
This by-pass valve contains an
integral vacuum differential function and
vacuum vent.
vent. A
A separate
separate VDV
VDV isis not
not
aa vacuum
this valve.
valve. When
When the
the vent
required with this
is
is blocked,
blocked, the
the valve
valve functions as
as aa timed
by-pass valve just as
as was
was used in past
years with
with aa VDV.
VDV. When the vent isis open
open
years
to atmospheric pressure,
pressure, however,
however, and a
to
4" Hg
Hg or more isis applied to
vacuum of 4"
goes
the source port, the valve goes
to the "dump"
"dump" mode.
mode.
immediately to
VACUUM DIFFERENTIAL VALVE

(VDV)-CATALYST
(VDV)CATALYST SYSTEMS
The vacuum differential valve (VDV)
controls the operation of the new bypass
valve used with catalytic converter
converter
equipped systems (Fig.
(Fig. 7).
The VDV
VDV is
is inserted in the vacuum
control line to the bypass
bypass valve
valve and
and serves
serves
to cut off the vacuum and de-energize the
bypass valve. The differential
differential valve
consists of a diaphragm connected to a
dump valve that controls the vacuum to
the bypass valve. During normal
normal
operation, vacuum is equalized on both
sides of the diaphragm and the spring
holds the dump valve closed. When
sudden higher than normal vacuum is
encountered, such as under deceleration
conditions, vacuum is higher on the
dump valve side of the diaphragm and
the diaphragm operates the dump valve.
As the dump valve operates, the vacuum
signal to the bypass valve is diverted
through the
the built-in
built-in filter
filter system
system to
to
through
atmosphere. When the vacuum bleeding
through the bypass timing orifice in the
VDV has equalized on both sides of the
.diaphragm, the diaphragm return spring
once again closes the dump valve and
applies vacuum to the bypass valve,
which again directs pump air to the
exhaust
exhaust ports.
ports.
DIFFERENTIAL VALVE DELAY
VALVE (DVDV)
This delay valve is used to delay air
bypass during periods of low engine
manifold vacuum. The DVDV is
manifold
8).
installed in series with the VDV (Fig. 8).
This installation of a delay valve in
of
the sense vacuum line delays operation of
differential valve during
the vacuum differential
sudden drops in manifold
manifold vacuum such
as during hard acceleration. During
sudden
sudden deceleration, however, the
sudden rise in intake manifold
manifold vacuum
opens the check in the delay valve,
passing the signal along instantly.
EXHAUST CHECK VALVE (FIGS. 9
AND 10)
The exhaust gas check valve allows
thermactor air to enter the exhaust port

29-03-3
29-03-3
29-03-3
Thermactor System
Thermactor
BY-PASS TIMING
ORIFICE
INTAKE
INTAKE
MANIFOLD
MANIFOLD
VACUUM
VACUUM
DIAPHRAGM
CHECK VALVE
BY-PASS TIM ING

ORIFICE
DIAPHRAGM
DIAPHRAGM RETURN
RETURN
SPRING
INTAKE MANIFOLD
INTAKE
VACUUM
~_r..:. ,",,",~__ l
....
~~::=:::::~
l-.r---.......
~~m:!~~~(,~~!!.~~~
TO CHECK
VALVE
AIR PASSAGE
TO ATMOSPHERE
AIR
AIR SILENCING
SILENCING
CHAMBER
--
FROM
AIR
rUMP
NORMAL
VACUUM
AIR PASSAGE
AIR
TO
ATMOSPHERE
PARTIAL VACUUM
PARTIAL
"v-?J
[:~:;;:>d
HIGH VACUUM
t--_1
THERMACTOR AIR
THERMACTOR
---------------------------------------------------------------------------------
BY-PASS POSITION
NORMAL POSITION
POSITION
V1837-B
V1837-B
FIG.
FIG. 44 Timed Bypass Valve-Non-Catalytic
ValveNon-Catalytic System Type
drillings,
flow of
drillings, but prevents the reverse flow
exhaust gases
gases in the event of improper
operation of system components. The
valve isis located between the bypass valve
valve
and the exhaust port drillings, either
mounted on the external air manifold or
engine.
directly on the engine.
COLD ENGINE LOCKOUTLOCKOUT

THERMACTOR SYSTEM WITH
WITH
CONVERTER(S)
CATALYTIC CONVERTER(S)
Cold Engine Lockout for systems

equipped with catalytic converters is
provided by an electrically operated
vacuum solenoid installed in the
vacuum circuit to the bypass valve
(Fig. 11).
11).
(Fig.
Two distinct systems are used:

used: a
(Fig.
system of normally closed switches (Fig.
12), and aa system
system of normally open
12),
switches (Fig.
(Fig. 13).
13).
switches
Normally Closed
Closed (Type
(Type I)I)
Normally
Switches (Fig.
(Fig. 12)
12)
Switches
When the
the engine
engine is
is at
at normal
normal
When
operating temperature,
temperature, with all
all
operating
components functioning
functioning normally,
normally, an
components
electrical path isis provided from battery
electrical
through the
the solenoid
solenoid vacuum valve
valve
through
BACK TO GROUP INDEX
windings, through the closed contacts

of the air cleaner temperature sensor,
through closed contacts of the floor
pan temperature sensor (on some
vehicles) to ground. This provides a
vacuum path from the vacuum source
through the operated solenoid vacuum
valve, through the vacuum differential
differential
valve,
valve (VDV) to the bypass valve,
allowing thermactor
thermactor air
air to
to flow
flow in
in the
the
allowing
system.
If any of the normally closed switches
operates, due
due to
to low
low intake
intake air
air tempertemperoperates,
ature, or overheated floor pan (some
vehicles), the solenoid vacuum valve
vehicles),
will release, breaking the vacuum path
and causing the bypass valve to dump
thermactor air to the atmosphere.
Open (Type II)

Normally Open
(Fig. 13)
Switches (Fig.
normal
When the engine is at normal
all
operating temperature, with all
components functioning normally, the
is not operated.
solenoid vacuum valve is
This provides aa vacuum path through the
This
non-operated solenoid vacuum valve,
differential valve
through the vacuum differential
(VDV) to
to the bypass valve,
valve, allowing
(VDV)
thermactor air
air to
to flow
in the
the system.
system.
thermactor
flow in
When the ambient air is cold, the air

cleaner temperature sensor operates,
closing the solenoid windings through
to ground. If
If the electric PVS operates
due to overheated engine it closes the
windings of the solenoid vacuum valve
through to ground.
If
If the solenoid
solenoid vacuum
vacuum valve
operates, it breaks the vacuum path to the
VDV and bypass valve, causing
thermactor air to be diverted to the
atmosphere instead of being injected
injected into
the exhaust system ports.
THERMACTOR VACUUM CHECK

VALVE
In some thermactor
thermactor systems, a
vacuum check valve may be installed in
the line between the inlet side of the
solenoid switch and the fitting on the
(Fig. 14).
intake manifold (Fig.
This check valve installation prevents
thermactor air bypass during all vehicle
modes except cold vehicle operation. The
normally open
open solenoid
solenoid incoporates
incoporates a
normally
small vacuum bleed which, when the
solenoid closes,
closes, prevents
prevents aa vacuum
vacuum lock
solenoid
lock
between the
the solenoid
solenoid and
and the
the air
air bypass
between
bypass
valve.
valve.
29-03-4
29-03-4
Thermactor System
NORMAL OPERATION
CONTROL
VACUUM
PORT
AIR INLET
FROM
THERMACTOR
PUMP
M A N I F O L D VACUUM
. / G)MANIFOLD
PULLS DIAPHRAGM UP.
VALVE IS UNSEATED
AIR FROM THERMACTOR

PUMP FLOWS FREELY TO
EXHAUST MANIFOLD.
AIR OUTPUT
TO
TO EXHAUST
EXHAUST
MANIFOLD
SILENCER AND
VENT OPENINGS
VENT PORT
SEALED OFF.
PRESSURE RELIEF OPERATION
"DUMP" OP[RATION
OPCRATION
CD WHEN
VACUUM SIGNAL
DROPS
WHEN VACUUM SIGNAL
DROPS
4 ) VALVE SEATS AND

BLOCKSTHERMACTOR
BLOCKS THERMACTOR
AIR FLOW TO EXHAUST
MANIFOLD.
G)
I) PARTIAL THERMACTOR
AIR FLOW TO EXHAUST
PARTIAL THERMACTOR
AIR FLOW TO EXHAUST
MANIFOLD TO MEET
SYSTEM REQUIREMENTS.
EXCESSIVE
PRESSURE
UNSEATS
RELI
EF
RELIEF
VALVE.
fJ\ VALVE OPENS
2J SPRING PULLS
STEM DOWN
SPRING PULLS ........ 1~0~:u~-U-~1!i

STEM DOWN
VTO
TO ALLOW
THERMACTOR
AIR FLOW TO
ATMOSPHERE.
PARTIAL
PARTIAL THERMACTOR
THERMACTOR
AIR
AIR FLOW
FLOW TO
TO ATMOSPHERE.
ATMOSPHERE.
, ,
w
f
A4087-A
FIG. 5 Bypass Valve-Normally

ValveNormally Closed-Catalytic
ClosedCatalytic System Type (1975 and 1976)
BACK TO GROUP INDEX

29-03-5
29-03-5
29-03-5
29-03-5
Thermactor System
System
Thermactor
VACUUM VENT
"
SPRING
SPRING
CONNECTS TO
TO VACUUM
VACUUM
CONNECTS
SOLENOID
SOLENOID OR
OR VACUUM
VACUUM
SWITCH
SWITCH
MAIN POPPET
SENSE VACUUM
(INT. MAN.)
AIR OUTLET
AIROUTLET~
AIR INLET
~A'R'NLET
RELIEF
RELIEF VALVE
VALVE
A4175-A
FIG. 6 Timed Air By-Pass Valve With Integral Vacuum Differential Function
DIAPHRAGM
3 ) DIAPHRAGM
RETURN SPRING HOLDS DIAPHRAGM
UPWARD, CLOSING DUMP VALVE
CUT-CFF
CUT-OFF OPERATION
UPWARD, CLOSING DUMP VALVE
BYPASS TIMING
ORIFICE
ORIFICE
( 2 ) VACUUM EQUALIZED ON BOTH
SIDES OF DIAPHRAGM, THROUGH

W
SIDES OF DIAPHRAGM, THROUGH

BYPASS TIMING ORIFICE
/s
DIAPHRAGM
(*)
DIAPHRAGM IS
IS MOMENTARILY
MOMENTARILY
PULLED
DOWN.
PULLED DOWN.
3 ) ORIFICE DELAYS INCREASE

ABOVE DIAPHRAGM.
2 )
.. t>::;
FROM SOLENOID
VACUUM VALVE
VACUUM
G)VACUUM TO
TO
~_l~~--..
~~~II~~:s:9~HAN
BYPASS
VALVE
BYPASS VALVE
o5) VACUUM
IN BYPASS VALVE'
LINE IS DUMPED TO ATMOSPHERE

NORMAL
NORMAL OPERATION
THROUGH FILTER, CAUSING

VALVE TO DUMP
BYPASS VALVE
THERMACTOR AIR.
THERMACTOR
NORMAL
VACUUM FROM
FROM SOLENOID
SOLENOID
VACUUM
VACUUM VALVE
VALVE DURING
DURING
VACUUM
ENGINE
DECELERATION.
ENGINE DECELERATION.
VACUUM IN BYPASS VALVE

LINE IS DUMPED TO ATMOSPHERE
VACUUM VALVE
VALVE DUMP
VACUUM
INCREASES
BELOW
DIAPHRAGM
VACUUM DUMP VALVE

OPENS MOMENTARILY.
A4088-8
FIG. 77 Vacuum Differential

Differential Valve
Valve (VDV)Catalyst
(VDV)-Catalyst Systems Only
BACK TO GROUP INDEX

29-03-6
29-03-6
Thermactor System
VACUUM DIFFERENTIAL
DIFFERENTIAL
VALVE
___________e~t~~ \.
DELAY
VALVE
INTAKE MANIFOLD
_ _ _IN_T_A_K_E_M_A_N_IF_O_L_D
-41}-AIR BY-PASS
VALVE
A4176-A
A4176
A
Fig. 8 Differential Valve Delay Valve
CHECK VALVE
VALVE
CHECK VALVE
CHECK VALVE
CROSS
CROSS SECTION
CHECK VALVE
CROSS SECTION
A4089-A
A4089-B
Valve1975
FIG. 9 Exhaust Check Valve-1975
Valve1976
FIG. 10 Exhaust Check Valve-1976
NORMALLY OPEN SENSOR

CONTACTS CAUSE SOLENOID
TO REMAIN UN-OPERATED.
IF ALL CONTACTS CLOSE,
SOLENOID WILL CLOSE
NORMALLY CLOSED SENSOR

SOLENOID
CONTACTS HOLD SOLENOID
OPERATED. VALVE CLOSES

OPERATE~VALVECLOSES
WHEN ANY SWITCH
ONLY WHEN
OPENS
OPENS
SWITCHES
CLOSED
VACUUM
PATH
PATH
NORMALLY
OPEN
OPEN
VACUUM
SOLENOID VACUUM
VALVE FOR
FOR NORMALLY
NORMALLY
VALVE
CLOSED (TYPE 1)
SYSTEMS
SYSTEMS
VACUUM
PATH
NORMALLY
OPEN
PLUNGER
OPEN
PLUNGER
UP
SOLENOID VACUUM
VALVE FOR
FOR NORMALLY
NORMALLY
OPEN (TYPE 2)
SYSTEMS
SYSTEMS
V4090-B
11 Solenoid Vacuum Valves for Normally Open and Normally Closed

FIG. 11
Type Systems
BACK TO GROUP INDEX

29-03-7
(2)
0
@
29-03-7
Thermactor System
Thermactor
NOTE: SOME EARLY PRODUCTION

UNITS HAVE POWER (B+)
(B+) CONNECTED
TO SOLENOID VACUUM VALVE AND
AND
ARE GROUNDED THROUGH THE
THE
TEMPERATURE SWITCHES
SOLENOID IS
IS
ENERGIZED
WHEN ALL
ALL
SWITCHES
ARE CLOSED
B+
APPLIED
VACUUM APPLI
ED
VALVE
TO BY-PASS VALVE
PAN SWITCH
FLOOR PAN
(ON SOME CARS ONLY)
CLOSED,
IS CLOSED
VALVE
OPENS
FROM~~~fJ=
PUMP
U,
TO MANIFOLD
THERMACTOR AIR
AIR
FLOWS FREELY TO
TO
EXHAUST MANIFOLD
MANIFOLD
MANIFOLD
VACUUM
0
CD
SWITCH
TEMPERATURE SWITCH
AIR CLEANER IS
IN AIR
IS
NORMALLY CLOSED
NORMALLY
ABOVE 65F
(1975 VEH
ICLES)
VEHICLES)
NORMAL ENGINE AND FLOOR PAN TEMPERATURE
(D
VDV
VDV
SOLENOID IS
IS
DE-ENERGIZED
ANY
WHEN ANY
SWITCHES OPEN
---------~II'
OR FLOOR PAN
OR
PAN
SWITCH OPENS
(SOME VEHICLES)
~B+
VACUUM IS
BLOCKED
" .......
1'-/
I
-' OB+
BY-PASS VALVE
DUMPS THERMACTOR
AIR TO
TO ATMOSPHERE
MANIFOLD
VACUUM
CD
OR OVERHEATED FLOOR PAN
COLD AMBIENT AIR OR
PAN
SYSTEM (SOME VEHICLES)
~~
TEMPERATURE SWITCH
IN AIR
AIR CLEANER OPENS
BELOW 65F
(1975 VEH
ICLES)
VEHICLES)
A4091-B
FIG. 12
12 Cold Engine Lockout System-Normally
SystemNormally Closed Switches
BACK TO GROUP INDEX

29-03-8
29-03-8
Thermactor
Thermactor System
VDV
V
DV
B+
"\---
.....
() VACUUM
APPLIED
TO BY-PASS
VALVE
SOLENOID
IS DE-ENERGIZED
FROM
MANIFOLD
VACUUM
TO MANIFOLD
(g) TEMPERATURE
SWITCH IN AIR
CLEANER IS
OPEN ABOVE
65
65FF
() THERMACTOR AIR
FLOW TO EXHAUST
MANIFOLD
CD
(?) ELECTRIC COOLING PVS

IS BELOW OPERATING
TEMPERATURE AND
CONTACTS ARE OPEN.
NORMAL ENGINE TEMPERATURE

(AND NORMAL AMBIENT AIR
TEMPERATURE)
VDV
VDV
(5)
VACUUM CUT
OFF TO
BY-PASS VALVE
VALVE
MANIFOLD
VACUUM
( D OR TEMPERATURE
o
SWITCH IN AIR
OR TEMPERATURE
SWITCH IN AIR
IS
CLEANER IS
CLOSED BELOW
BELOW 490F
49F
CLOSED
() VALVE DUMPS
DUMPS
THERMACTOR
AIR TO
TO ATMOSPHERE
ATMOSPHERE
CD
IF ENGINE OVERHEATS,
OVERHEATS,
IF
CLOSING ELECTR!C
ELECTRIC CONTACTS
CONTACTS
CLOSING
IN PVS
PVS
IN
COLD
COLD AMBIENT AIR
AIR
OR
OR OVERHEATED
OVERHEATED
ENGINE
ENGINE
(SOME
(SOME VEHICLES)
VEHICLES)
A4092-B
FIG. 13 Cold
Cold Engine Lockout System-Normally
SystemNormally Open Switches
Switches
BACK TO GROUP INDEX

29-03-9
29-03-9
Thermactor System
System
AIR
AIR BY-PASS
BY-PASS
VALVE
VALVE
THERMACTOR VACUUM
VACUUM
THERMACTOR
CHECK VALVE
VALVE
CHECK
INTAKE MANIFOLD
MANIFOLD
INTAKE
J~-OUTLET
NORMALLY
NORMALLY
OPEN
OPEN
SOLENOID
VALVE
-.J
...,.I
NO:MALLY
NORMALLY OPEN
OPEN
TEMPERATURE SWITCH
SWITCH
LOCATED IN
IN AIR
AIR CLEANER
CLEANER
(ALL CATALYST VEHICLES)
VEHICLES)
A4177-A
FIG. 14
14 Thermactor Vacuum Check Valve Installation
BACK TO GROUP INDEX

29-07-1
29-07-1
29-07-1
29-07-1
Gas Recirculation System

Exhaust Gas
Gas Recirculation System

PART 29-07 Exhaust Gas
All
All Models
Models So
So Equipped
Equipped
Page
COMPONENT INDEX
COMPONENT INDEX
GENERAL INFORMATION
EGR
EG
R Valve ........................
Spacer Entry EGR System ............
Page
Page
Venturi Vacuum Amplifier ............

EGR Backpressure Transducer .........
EGR/CSC
EG
RI esc System ...................
07-1
07-1
07-1
07-1
07-1
07-1
07-1
07-1
07-2
NOTE: The
The infonnation
information in
1976 model
model year
year vehicles
vehicles unless
CR1966A
CR1966-A
GENERAL INFORMAliON
INFORMATION
The Exhaust Gas
Gas Recirculation
Recirculation
System (EGR)
re(EGR) is
is designed to
to reintroduce small amounts of
gas
of exhaust gas
into the combustion cycle, thus reducing
of nitrous oxides (NOX).
the generation of
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
are
in Fig.
Fig. 1.
shown in
1.
EGR VALVE
The EGR valve (Fig.
(Fig. 2)
2) isisaavacuumvacuumoperated unit that attaches to
to aa spacer
that fits under the
the
the carburetor. When the
valve is open, exhaust gas is
is permitted to
enter the intake manifold passages. When
When
the valve is
is closed, internal or
or external
sealing takes place, preventing the
the flow
of exhaust gases into the intake passages.
SPACER ENTRY EGR
EGR SYSTEM
On this type of system, exhaust gases
are routed to
is
to the
the EGR
EGR valve,
valve, which is
attached to
to aa spacer mounted between
the carburetor and
and the
the intake manifold
(Fig.
(Fig. 3).
3).
VENTURI VACUUM AMPLIFIER
(VVA)
The EGR
EGR Venturi
V e n t u r i Vacuum
Vacuum
Amplifiers (Figs. 44 and
and 5)
5) use
use aa
Amplifiers
in
relatively weak venturi vacuum signal in
of the
the carburetor to
to shape aa
the throat of
strong intake manifold vacuum signal to
to
the EGR
EGR valve.
valve. This makes it
operate the
it
possible to
to achieve an
an accurate,
accurate,
repeatable and
and almost exact proportion
between venturi air flow and
and EGR
EGR flow.
it assists in
in controlling oxides of
of
Thus, it
nitrogen emissions with minimal sacrifice
in vehicle driveability.
to aa vacuum
The amplifier connects to
and contains aa check valve to
reservoir and
to
maintain adequate vacuum supply
in engine
regardless of variations in
manifold vacuum.
A relief valve is
is also used to
to "dump"
"dump"
or cancel the
the output
output EGR
EGR signal
BACK TO GROUP INDEX
EGR-PVS
VALVE
RESERVOIR
VACUUM
OUTPUT
VACUUM
VENT
~--~li
L---.J
VENTURI
VACUUM
VACUUM
CARBURETOR
RES:::~;:~ ~""'----------L~N~:~~~:C~E':~O--L~--'-"---_r-'---.-/
~
VACUUM
EGR
VALVE
WITH SINGLE CONNECTOR VVA

VVA (1974 TYPE)
RESERVOIR
VACUUM
"
CHECK
VALVE
AMPLIFIER
VENTU~IS ~
VACUUM"
L
VACUUM
RESERVO'/
EGR-PVS
VALVE
VENT
ii'
"I
!
iI
I I!
.~
I
\
V0
OUTPUT
VACUUM
CONNECTOR
~ L_-==--_-~
SPARK OR
EGR PORT
VACUUM
,,--.---,.--__....
CARBURETOR
EGR SPACER
INTAKE MANIFOLD
MANIFOLD
VACUUM
V1846-B
FIG. 11 Typical EGR

EGR System Components
the venturi vacuum signal is

whenever the
is
to, or
or greater than, the
the intake
equal to,
the EGR
EGR
manifold vacuum. This allows the
to close at
at or
or near wide-open
valve to
throttle acceleration, when maximum
power is
is required from the
the engine.
EGR BACKPRESSURE
TRANSDUCER
For 1976,
1976, some EGR systems employ
a Backpressure Transducer connected to
to
the EGR
EGR valve and
an adapter between the
and
TheAUTO
The
transducer
DAVE GRAHAM
LITERATURE, INC.
29-07-2
29-07-2
System
Exhaust Gas Recirculation System
INTERNAL
INTERNAL TAPERED
TAPERED STEM
STEM TYPE
TYPE
POPPET TYPE
EXTERNAL
EXTERNAL TAPERED
TAPERED STEM
STEM TYpE
TYpE
./VACUUM
~ NIPPLE
SPRING
VACUUM
VACUUM NIPPLE
NIPPLE
SPRING
ANGLE BACKSTOP
STROKE LIMITER
VALVE SEAT
DIAPHRAGM
DIAPHRAGM
~~~~~~~l,... VALVE
VALVE SEAT
SEAT
POPPET VALVE
RESTRICTOR ORIFICE^ 'f'

USED TO CONTROL F LOW
BELOW APPROX. 10.0 CFM
I~
c=Y
~~
~
DIAPHRAGM
'-----'
OUTLET
VALVE SEAT'
/
VALVE'
V1875-B
Valve
FIG. 2 Typical EGR Valye
modulates EGR flow by varying the

EGR valve vacuum signal according to
exhaust backpressure. The exhaust
is sensed in the pressure cavity
pressure is
of the transducer spacer (Fig.
(Fig. 6).
EGR/CSC SYSTEM
The EGR/CSC System (Fig. 7)
regulates both distributor spark advance
and EGR valve operation according to
coolant temperature, by sequentially
switching vacuum signals.
major EG
EGR/CSC
system
The major
R/CSC system
components are:
EGRPVS valve
a. 95F EGR-PVS
b. Spark Delay Valve (SDV)
c. Vacuum Check Valve
c.
When the engine coolant temperature
is below 82F, the EGR-PVS
EGRPVS valve
admits carburetor EGR port vacuum
(occurring at about 2500 rpm) directly to
the distributor advance diaphragm,
through the one-way check valve (Fig. 8).
8).
At the same time, the EGR-PVS
EGRPVS
valve shuts off
ofT carburetor EGR vacuum
to the EGR valve and transmission
diaphragm.
When engine coolant temperature is
95F and above (Fig. 9), the EGRPVS
EGR-PVS
valve is actuated and directs carburetor
EGR vacuum to the EGR valve and
transmission instead of the distributor.
At temperatures between 82F and 95F,
the EGRPVS
EGR-PVS valve may be open,
closed or in mid-position.
The SDV valve delays carburetor
spark vacuum to the distributor advance
diaphragm by restricting
restrictin~ the vacuum
signal through the SDV valve for a
predetermined
predetermined time. During
Durin.g normal
acceleration, little or no vacuum is
admitted
admitted to the distributor
distributor advance
diaphragm
diaphragm until
until acceleration
acceleration is
completed, because of
of (1) the time delay
of
of the SDV valve and (2) the re-routing
of
of EGR
EGR port
port vacuum, if
if the engine
BACK TO GROUP INDEX
CARBURETOR
CARBURETOR
EGR
EGR VALVE
VALVE
UPPER
GASKET
CARBURETOR
SPACER
MOUNTING PADS
PADS ON
ON
VALVE ARE REVISED.
VALVES ARE
ARE NOT
INTERCHANGEABLE
WITH 1974
LOWER
~----GASKET
GASKET
EXHAUST GAS
FROM
CROSSOVER
PASSAGE
INTAKE
MANIFOLD
V2040-A
FIG. 3 Spacer Entry EGR System
coolant temperature is 95 degrees F or

higher.
The check valve blocks off
off vacuum
signal from the SDV to the EGRPVS
EGR-PVS
so that carburetor spark vacuum will not
be dissipated when the EGRPVS
EGR-PVS is
actuated above 95F.
The 235F PVS is not part of
of the
EGR/CSC system, but is connected to
the distributor
distributor vacuum
vacuum advance to
prevent engine overheating while idling
(as on previous models). At idle speeds,

no vacuum is generated at either the
carburetor spark port or EGR port and
engine timing is fully retarded. When
engine coolant
coolant temperature
temperature reaches
235F, however, the valve is actuated to
admit intake manifold
manifold vacuum to the
distributor
distributor advance diaphragm. This
advances engine timing and speeds up the
engine. The increase in coolant flow
flow and
fan speed lowers engine temperature.
29-07-3
29-07-3
VENT - MUST NOT

NOT BE
BE RESTRICTED
RESTRICTED AA
VENT
AMPLIFIED OUTPUT O
CONNECTOR
ASSEMBLY
AMPLIFIER CODED FOR

FOR
PORT CONNECTIONS:
SHEET METAL SCREW
O - OUTPUT TO
TO EGR
EGR VALVE
VALVE
0CARBURETOR VENTURI
VENTURI V
V R
R _- FROM
FROM RESERVOIR
RESERVOIR
M OR
OR S
S -- MANIFOLD
MANIFOLD VACUUM
VACUUM
M
R
VACUUM RE~iERVOIR
RESERVOIR R
N T U R I VACUUM
V --V E
VENTURI
A - ATMOSPHERE
V1851-B
4 Venturi Vacuum AmplifierSingle

FIG. .4
Amplifier-Single Connector Type
AMPLIFIER CODED FOR

FOR PORT
PORT CONNECTIONS:
CONNECTIONS:
O- OUTPUT TO
TO EGR
EGR VALVE
VALVE
0
R - F FROM
R O M RESERVOIR
R
S -- VACUUM SOURCE
(SPARK OR EGR PORT)
VENTURIVACUUM
V - VENTURI
VACUUM
A - ATMOSPHERE (VENT)
MARVEL-SCHEBLER
MARVEl-SCHEBlER
V2041-A
5 Venturi Vacuum AmplifierDual

FIG. 5
Amplifier-Dual Connector Type
BACK TO GROUP INDEX

29-07-4
29-07-4
AIR FILTER
TO EGR
EGR VALVE
EGR VALVE
TO EGR VACUUM
SOURCE VIA EGR
PVS VALVE
EXHAUST
PRESSURE PROBE
EGR TRANSDUCER
ADAPTOR
EXHAUST GAS TO
INTAKE MANIFOLD
EXHAUST GAS
ENTRANCE FROM CROSSOVER
A4178-A
FIG. 66 EGR
EGR Valve Exhaust Backpressure Transducer
--------
235
PVS
SPARK PORT
_ _ _ TO INTAKE
MANIFOLD
-"""'11..--
J~I
CARBURETOR
EGR PORT
----~
-~--I
"T"
_____
TOTRANS.
TO TRANS.
DUAL
DUAL AREA
AREA
DIAPHRAGM
V1853-A
V1853A
FIG. 77 Schematic of EGR/CSC System
BACK TO GROUP INDEX

29-07-5
29-07-5
Exhaust Gas Recirculation

Recirculation System
System
Exhaust
235 0L
PVS
I
TO INTAKE
MANIFOLD
SPARK
SPARK PORT
PORT
---~---~
~ALVE
CARBURETOR
"T"
,.~CHECKVALVE
EGR PORT
--~
I
I
50
~
PVS
._-._J
- --- ~
( EGR
----l~y
- -- - -
TO TRANS.
TRANS.
DUAL AREA
DIAPHRAGM
V1854A
V1854 A
FIG. 88 EGR/CSC System

System Operation-Below
OperationBelow 82
82 degrees F.
fiG.
f.
SPARK PORT
CARBURETOR
~CHECKVALVE
EGR PORT
~---I
~
50
PVS
'--_J--@
-~ -
-- -
--~
EGR
VALVE
TO TRANS.
DUAL AREA
DUAL
DIAPHRAGM
V1855A
V1855
A
FIG.
fiG. 9 EGR/CSC System OperationAbove
Operation-Above 95 degrees F.
F.
BACK TO GROUP INDEX

29-10-1
29-10-1
29-10-1
Cold Temperature Actuated Vacuum System (CTAV)
PART 29-10 Cold Temperature Actuated

Vacuum System CTAV
All
All Models
Models So
So Equipped
Equipped
COMPONENT
COMPONENT INDEX
INDEX
Page
Page
COMPONENT INDEX
COMPONENT
INDEX
Page
Page
GENERAL INFORMATION ............
10-1
10-1
OPERATION ........................
10-2
NOTE:
Illodel year vehicles unless otherNOTE: The information in this Part applies to both 1975 and 1976 model
wise specified.
specified.
CR1966-A
CR1966A
GENERAL INFORMAliON
INFORMATION
The CTAV system is used to more
accurately match spark advance to
engine requirements under cold outside
conditions. The system can
temperature conditions.
two vacuum sources for spark
select from two
advance, depending on the temperature
advance,
of air in the air cleaner assembly.
assembly. If the
is below 49F,
ambient air temperature is
49P,
the system will select spark port vacuum
for distributor
distributor modulation,
modulation, and,
and, if
if the
the
for
temperature is above 6Sop,

65F, the system
will select EGR vacuum. In between
these two temperatures, the system will
select either port, depending on the cycle
it is in.
The CTA
V system consists of an
CTAV
ambient temperature switch, a three-way
vacuum switch, an in-line vacuum bleed,
and a latching relay (Fig. 1).
Vacuum from both the spark port and

the EGR port is supplied to the threeway solenoid
solenoid valve. The ambient
temperature switch
switch provides the signal
that determines which of the sources will
be selected. The latching relay provides
for only one cycle each time the ignition
switch is turned on.
B+ (IGN)
r-------.,
OPEN
(NOT USED)
I
I
SWITCH
OPEN
TEMPERATURE SWITCH
LOCATED IN AIR CLEANER
_________ J I
LATCHING RELAY
TOP
- - -
--r-
-\LJ'"""---,
------'
SPARK PORT
EGR PORTt:
CARBURETOR
')
DISTRIBUTOR
DISTRIBUTOR
r//
TEE,
//
J$s~~~
----~-_.~/
IN-LINE BLEED
IN-LINE
V1859-B
V1859B
FIG. 1 Schematic of CTAV System Below 49 degrees FF
BACK TO GROUP INDEX

29-10-2
29-10-2
Cold
Cold Temperature Actuated
Actuated Vacuum
Vacuum System
System (CTAV)
(CTAV)
OPERATION
OPERATION
The temperature switch
switch activates
activates the
the
The
solenoid. It
It isis calibrated to open at
at 49p
49F
solenoid.
below, and
and to
to close at
at 65p
65F and
and below,
and
above. In
In between,
between, itit may be
be either open
above.
closed. Thus,
Thus, at
at air
air temperatures
temperatures
or closed.
the air
air cleaner below 49p,
49F, the
within the
the
is inoperative and the
the distributor
distributor
system is
receives carburetor spark port
diaphragm receives
while the
the EGR valve
valve receives
receives
vacuum, while
vacuum (Pig.
(Fig. 1).
carburetor EGR port vacuum
1).
When the
the temperature switch closes
closes
When
(above
(above 65p),
65F), current from the
the battery
the 3-way solenoid vacuum
energizes the
valve and
and carburetor EGR port vacuum
valve
is delivered to
to the
the distributor advance
is
as well
well as
as the
the EGR
EGR valve
valve
diaphragm, as
(Pig.
(Fig. 2).
2).
The
The latching relay
relay (normally OFF)
OFF) isis
also
also energized by
by the
the closing of
of the
temperature switch.
switch. However,
However, once
once ON,
ON,
it receives
receives its
its energy through the
the ignition
switch and
and stays
stays ON
ON until the
the ignition
switch is
of
is turned OFF,
OFF, regardless of
whether the
the temperature switch is
or closed.
closed.
opened or
S+ OGN)
r-------.,
OPEN
(NOT USED)
I
SWITCH
SWITCH
CLOSED
I
I
I
I
,--
I ~EMPERATURE
~OCATED
TEMPERATURE SWITCH
SWITCH
LOCATED IN
IN AIR
AIR CLEANER
CLEANER
.JI
;-------
LATCHING RELAY
ABOVE 65F
TOP
CARBURETOR
--- -
---------.,;;:---....r---l--
SPARK PORT
3 -WAY
SOLENOID
VALVE
/'
~'-----
DISTR
I SUTOR
DISTRIBUTOR
-~--~-_./'
_y
IN-LINE
IN-LINE BLEED
,/
>
--l
E:PORT~1
EGRPORT
TO EGR SYSTEM
V1861B
FIG.
FIG. 2 Schematic of CTAV
CTAV System Above 65 degrees FF
BACK TO GROUP INDEX

1975-76 Ford Car Shop Manual Volume II Engine

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1975-76 Ford Car Shop Manual Volume II Engine

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Aut

I Clutch and Manual Transmission

Instruments, Clusters and Controls

I Speed Control and Sure-Track Brake System

Stationary Window Glass

I Doors, Hood, Luggage Compartment Door & Tailgate

The Ford Shop Manuals consist of five Volumes: 1 - Chassis, 2

Ford Parts and Service Division

DAVE GRAHAM AUTO LITERATURE, INC.

The official Vehicle Identification

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number indicates the model year. The

The BODY code is two numerals and

DAVE GRAHAM AUTO LITERATURE, INC.

Car Identification Codes

BODY SERIAL CODE

VEH. )DENT. NO.

THIS VEHICLE CONFORMS TO

ASSEMBLY PLANT CODE

BODY COLOR CODE

THIS VEHICLE CONFORMS TO ALL

VEH. IDENT. NO. I|

BODY I COLOR I TRIM I TRANS. I AXLE I DSO

( j j ) REAR AXLE CODE

ACCESSORY RESERVE LOAD

FIG. 1 Vehicle Identification and

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DAVE GRAHAM AUTO LITERATURE, INC.

1975 IDENTIFICATION CODES

Car Identification Codes

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(RPO) UNIQUE COLORS (NON POLISH)

Dk. Copper Met.

Brt. Blue Met.

5070-A . ... Med. Red Met.

(RPO) DIAMOND FLARE (POLISH)

Silver Blue Met.

DAVE GRAHAM AUTO LITERATURE, INC.

4-Dr. Sedan Hardtop

Station Wagon <2)

2-Dr. Pillar Hardt

4-Dr. Pillar Hardtop@)

4-Dr. Pillar Hardtop

2-Dr. Pillar Hardtop

4-Dr. Pillar Hardtop

4-Dr. Pillar Hardtop

Also available w/Dual

o Also Available w/Rear

Cross Hatch Full 2-Door

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DAVE GRAHAM AUTO LITERATURE, INC.

Car Identification Codes

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DAVE GRAHAM AUTO LITERATURE, INC.

Car Identification Codes

INTERIOR TRIM CODES - Continued

Whitt Trim with Color Components.

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.... ..... .....

***100% Nylon Fabric - Cashmere like appearance.

DAVE GRAHAM AUTO LITERATURE, INC.

Car Identification Codes

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.... .... ....