21-01-1 General Gasoline Engine Service 21-01-1

GROUP
GASOLINE ENGINES 21
(6000 &
9000)
SECTION TITLE PAGE SECTION TITLE PAGE
General Gasoline Engine Service . 21-01-1 5.0L (302 CID) V-8 and
4.9L (300 CID) Six-Cylinder Engine 21-11-1 5.8L (351 CID) W-V-8 Engines 21-21-1
7.5L (460 CID) V-8 Engines .... 21-24-1

SECTION
General Gasoline Engine Service
21-01

SUBJECT PAGE SUBJECT PAGE

CLEANING AND INSPECTION CLEANING AND INSPECTION (Cont’d.)
Camshaft 21-01-19 Oil Pump 21-01-22
Connecting Rods 21-01-21 PCV System, Hoses and Tubes 21-01-16
Crankcase Breather Cap — Clean . 21-01-16 Pistons, Pins and Rings 21-01-21
Crankcase Ventilation System 21-01-16 Push Rods 21-01-17
Crankshaft 21-01-20 Timing Chain and Sprockets 21-01-19
Crankshaft Vibration Damper Timing Gears 21-01-19
and Sleeve 21-01-19 Valve Rocker Arm 21-01-17
Cylinder Block 21-01-22 Valve Rocker Arm Covers 21-01-17
Cylinder Heads 21-01-17 DESCRIPTION
Cylinder Head Flatness 21-01-17 Vehicle and Engine Identification 21-01-2
Valve Face Runout 21-01-18 DIAGNOSIS AND TESTING
Valve Seat Runout 21-01-17 Camshaft End Play 21-01-7
Valve Seat Width 21-01-17 Camshaft Lobe Lift 21-01-6
Valve Spring Pressure 21-01-18 Compression Test 21-01-4
Valve Spring Squareness 21-01-18 Crankshaft End Play 21-01-8
Valve Stem Clearance 21-01-18 Dynamic Valve Train Analysis
Valves 21-01-17 Valve Train Analysis 21-01-6
Exhaust Heat Control Valve 21-01-16 Engine Oil Leaks 21-01-3
Exhaust Manifolds 21-01-19 Flywheel Clutch Face Runout —
Flywheel — Automatic-Transmission 21-01-20 Manual-Shift Transmission 21-01-8
Flywheel — Manual-Shift Flywheel Runout —
Transmission 21-01-20 Automatic Transmission 21-01-8
Hydraulic Valve Tappets 21-01-19 Hydraulic Valve Tappet 21-01-4
Intake Manifold 21-01-19 Positive Closed-Type Crankcase
Main and Connecting Rod Bearing . 21-01-20 Ventilation System 21-01-3
Oil Change 21-01-23 Static Engine Off Valve Train Analysis
Oil Filter Change 21-01-23 (Rocker Arm Cover Removed) 21-01-5
Oil Pan 21-01-22 Timing Chain Deflection 21-01-7
21-01-2 General Gasoline Engine Service 21-01-2

General Gasoline Engine SECTION

Service (Cont’d.) 21-01
SUBJECT____________________ PAGE SUBJECT______________________ PAGE
DIAGNOSIS AND TESTING (Cont’d.) OVERHAUL (Cont’d.)
Timing Gear Backlash 21-01-8 Pistons, Pins and Rings (Cont’d.)
OVERHAUL Fitting Pistons 21-01-14
Camshaft Repair 21-01-13 Fitting Rings 21-01-14
Crankshaft 21-01-13 Valves 21-01-13
Refinishing Journals 21-01-13 Refacing Valves 21-01-13
Cylinder Block Select Fitting Valves 21-01-13
Refinishing Cylinder Walls 21-01-15 REMOVAL AND INSTALLATION
Repairing Engine Castings Having Core Plugs 21-01-10
Sand Holes or Being Porous... 21-01-15 Cup-Type 21-01-10
Cylinder Head 21-01-12 Expansion Type 21-01-10
Reaming Valve Guides 21-01-12 Crankshaft Rear Oil Seal — Split-Up . 21-01-10
Refacing Valve Seats 21-01-12 Crankshaft Rear Oil Seal — One Piece 21-01-10
Fitting Main or Connecting Rod EGR Valve 21-01-10
Bearings with Plastigage 21-01-13 21-01-8
Interpretation of “Service Exhaust Control Valve — 4.9L Engine
Limit" Specifications 21-01-11 Flywheel Ring Gear — 21-01-11
Pistons, Pins and Rings Manual-Shift Transmission 21-01-11
Fitting Piston Pins 21-01-15 PCV Valve Replacement 21-01-25
SPECIAL SERVICE TOOLS

DESCRIPTION obtained. The codes contain all pertinent information

All gasoline engines covered in this manual
incorporate positive closed type crankcase ventilation
systems and appropriate exhaust emission controls. The
emission control systems are covered in detail in the
Engine/Emissions Diagnosis Manual and in Section
50-29 of the Truck Pre-Delivery, Maintenance and
Lubrication Shop Manual.
This Section covers tests, adjustments, repair
procedures, cleaning and inspections that are generally
common to all or most gasoline engines covered in this
manual. When performing tests, adjustments and
repairs, it is essential to follow the procedures and
specifications provided. Specifications are listed at the
end of each pertinent engine Section.
Vehicle and Engine Identification
Vehicle identification, the location of the vehicle rating
and data plates and engine code information is fully
covered in Section 20-00, Identification Codes. For
specific and exact engine identification a decal label (Fig.
1) is located on the front of the valve rocker cover on 6
cylinder engines and on the front of the right rocker cover
on V-8 engines. Exceptions will occur if brackets or
equipment would obscure the view of the label. On
vehicles over 6000 GVWR the label is on the same
engine component as the Emission Certification decal.
Always refer to this label when replacement parts are
required or when checking engine calibrations. Engine
parts often are not the same within a CID family. The
identification codes will insure that the proper parts are
relating to dates, optional equipment and revisions. The
Ford Master Parts Catalog contains a complete listing of
the codes and their application.
DIAGNOSIS AND TESTING
Engine Oil Leaks
When diagnosing engine oil leaks, it is important that
the source and location of the leak be positively
identified before any repairs are made. The following
procedure has been found to be very effective and
requires only a minimum of equipment available in most
dealerships. Prior to using this procedure, it is important
to clean the cylinder block, cylinder head(s), rocker
cover(s), oil pan and flywheel housing areas with a
suitable solvent to remove all traces of oil.
To perform oil leak diagnosis use Rotunda Model 072-
00003 (Fig. 2) or equivalent, or fabricate the following
tool:
1. Air supply and air hose.
2. Air pressure gauge that registers pressure in one psi
increments.
3. Air line shut-off valve.
4. Appropriate fittings to attach the above parts to the
oil fill and PCV valve grommet holes.
5. Appropriate plugs (bolts, rubber plugs) to seal all
other openings leading to the crankcase, such as,
oil level indicator (dipstick), tube, etc.
21-01-3 General Gasoline Engine Service 21-01-3

YEAR 50 S 49 S CANADA CALIF A — AIR/CONDITIONING

0 0 A L S B — NON AIR/CONDITIONING
1 1 B M T C — INDUSTRIAL & MARINE
2 2 C N U D — EXPORT
3 3 D P W BASE E — OVER 6000 LBS/NON THERM
4 4 E R X DISPLACEMENT F — THERMACTOR WITHOUT A/C
5 5 F L s VEHICLE APPLICATION G — A/C OR NON A/C ENGINES
6 6 G M T INERTIA WEIGHT H — POWER STEERING
7 7 H N u AXLE RATIO J — THERMACTOR WITH A/C
8 8 J P w TRANSMISSION K — THERMACTOR A/C OR NON A/C
9 9 K R X L — OVER 6000 LBS/THERM

S RD45000
DESIGN LEVEL
+60° A — USED TO INDICATE INITIAL RELEASE

VCALIB & REVISION LEVEL

A — USED TO INDICATE INITIAL RELEASE
—CAL IB R-123-345

.INITIAL TIMING
(PLANT OPTION)

ENGINE
BUILD*
DATE CALIBRATION
NUMBER BAR CODE 1

DENOTES PLANT SOURCED TO PRODUCE ENGINES

D — DEARBORN ENGINE PLANT
C1 — CLEVELAND ENGINE PLT 1
C2 — CLEVELAND ENGINE PLT 2
W1 — WINDSOR ENGINE PLT 1
W2 — WINDSOR ENGINE PLT 2

A8713-2A

FIG. 1 Engine Identification

6. A solution of liquid detergent and water to be liquid detergent and water over the areas for the
applied with a suitable type applicator such as a formation of bubbles, which indicates leakage. The
squirt bottle or brush. areas to examine are:
Fabricate the air supply hose to include the air line Under Hood
shut-off valve and the appropriate adapter to permit the
air to enter the engine through the PCV valve opening. a. Rocker cover gasket.

Fabricate the air pressure gauge to a suitable adapter b. Cylinder front cover gasket.
for installation on the engine at the oil fill opening. c. Intake manifold gaskets.
Testing Procedure d. Front and rear intake manifold end seals.
1. Open the air supply valve until the pressure gauge e. Cylinder head gasket.
registers 5 psi (maintain 5 psi pressure). f. Rubber grommets.
2. Inspect the sealed and/or gasketed areas for leaks Fuel pump seal and/or mounting gasket.
g-
by applying Snoop Pressure Check or a solution of
h. Distributor O-ring.
i. Oil level indicator (dipstick) tube connection.
j. Oil pressure sending unit.
4 k. Cup plugs and/or pipe plugs at the end of oil
passages.
Under Engine—With Vehicle on Hoist
a. Oil pan gasket.
b. Front and rear oil pan end seals.
C. Cylinder front cover gasket.
d. Front crankshaft seal.
e. Oil filter seal and/or adapter gasket.
f. Oil cooler mounting gasket and/or cover plate
gasket.
With Transmission and Flywheel Removed
A6531-1A a. Rear crankshaft seal.
Air leakage in the area around a rope rear
FIG. 2 Leak Test Kit crankshaft oil seal does not necessarily
21-01-4 General Gasoline Engine Service
indicate a rear seal leak. However, if no other
cause can be found for oil leakage (air leaking
from the rear oil pan seal, rear main bearing cap
parting line, cup plugs, etc.) it can be assumed
that the rope seal is the cause of the oil
leakage.
A moderate amount of air leakage past the
service split lip seal is also acceptable.
b. Rear main bearing cap parting line.
c. Rear main bearing cap end seals.
d. Flywheel mounting bolt holes.
e. Rear cup plugs and/or pipe plugs at the end of
oil passages.
Oilleaks at crimped seams in sheet metal parts
and cracks in cast or stamped parts can be
detected when pressurizing the crankcase.
NOTE: Light foaming (similar to beer foam)
equally around rocker arm cover bolts and
crankshaft seals is not detrimental and no
corrections are required in such cases.
Positive Closed-Type Crankcase Ventilation
System
A malfunctioning closed crankcase ventilation system
may be indicated by loping or rough engine idle. Do not
attempt to compensate for this idle condition by
disconnecting the crankcase ventilation system and
making carburetor adjustments. The removal of the
crankcase ventilation system from the engine will
adversely affect the fuel economy and engine
ventilation with resultant shortening of engine life.
To determine whether the loping or rough idle condition
is caused by a malfunctioning crankcase ventilation
system, refer to Emission System testing and diagnosis
in the Engine/Emissions Diagnosis Manual.
Compression Test
The following procedure is to be used on all engines
when checking compression:
Be sure the crankcase oil is of the correct viscosity
1.
and make sure that the battery is properly charged.
Operate the engine for a minimum of 30 minutes at
1200 rpm, or 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 in the wide open
position.
Install a compression gauge in No. 1 cylinder.
3.
4. Crank the engine (with the ignition switch Off) at
least five pumping strokes and record the highest
reading indicated. Note the approximate number of
compression strokes required to obtain the highest
reading.
5. Repeat the check on each cylinder cranking the
engine approximately the same number of
compression strokes.
Test Conclusion
The indicated compression pressures are considered
normal if the lowest reading cylinder is within 75 percent
of the highest. Refer to the quick reference chart, (Fig. 3),
for pressure limits between cylinders. Variations
exceeding 75 percent implies an improperly seated valve
or worn or broken piston rings. If one cylinder reads low,
squirt approximately one tablespoon of engine oil on top
21-01-4
of the pistons in the low reading cylinders. Repeat
compression pressure check on these cylinders.
a. If compression improves considerably, the
piston rings are at fault.
b. If compression does not improve, valves are
sticking or seating poorly.
c. If two adjacent cylinders indicate low
compression pressures and squirting oil on the
pistons does not increase the compression, the
cause may be a cylinder head gasket leak
between the cylinders. Engine oil and/or
coolant in the cylinders could result from this
problem.
Example
After checking the compression pressures in all
cylinders, the highest reading obtained was 965 kPa (140
psi) and the lowest pressure reading was 689 kPa (100
psi). By locating 965 (140) in the Maximum column it is
seen that the lowest allowable pressure listed in the
Minimum column is 723 kPa (105 psi). Since the lowest
cylinder reading was 689 kPa (100 psi), the engine is not
within specifications and the compression is not
considered satisfactory.
Hydraulic Valve Tappet
Hydraulic tappet noise may be caused by any of the
following:
1. Excessive collapsed tappet gap.
2. Sticking tappet plunger.
3. Tappet check valve not functioning properly.
4. Air in lubrication system.
5. Leakdown rate too rapid.
6. Excessive valve guide wear.
Excessive collapsed tappet gap may be caused
by loose rocker arm fulcrum bolts, incorrect initial
adjustment, or wear of tappet face, pushrod, rocker
arm, rocker arm fulcrum or valve tip. With tappet
collapsed, check gap between valve tip and rocker
arm to determine if any other valve train parts are
damaged, worn, or out of adjustment.
A sticking tappet plunger may be caused by dirt, chips,
or varnish inside the tappet. The sticking can be
corrected by disassembling the tappet and removing the
dirt, chips or varnish that is causing the condition.
A tappet check valve that is not functional may be
caused by an obstruction such as dirt or chips preventing
it from closing when the cam lobe is lifting the tappet, or it
may be caused by a broken check valve spring.
Air bubbles in the lubrication system will prevent the
tappet from supporting the valve spring load and may be
caused by too high or too low an oil level in the oil pan, or
by air being drawn into the system through a hole, crack,
or leaking gasket on the oil pump pickup tube.
If the leakdown time is below the specified time for
used tappets, noisy operation may result. If no other
cause for noisy tappets can be found, the leakdown rate
should be checked and any outside the specification
should be replaced.
Assembled tappets can be tested with Tool 6500-E to
check the leakdown rate. The leakdown rate
specification is the time in seconds for the plunger to
move a specified distance of its travel while under a
22.68 kg (50 lb) load. Test the tappets as follows:
21-01-5 General Gasoline Engine Service 21-01-5

Maximum Minimum Maximum Minimum Maximum Minimum

kPa (PSI) kPa (PSI) kPa (PSI) kPa (PSI) kPa (PSI) kPa (PSI)

923 (134) 697 (101) 1199 (174) 903 (131) 1475 (214) 1103 (160)
937 (136) 703 (102) 1213 (176) 910 (132) 1489 (216) 1116 (162)
951 (138) 717(104) 1227 (178) 917 (133) 1503 (218) 1123 (163)
965 (140) 723 (105) 1241 (180) 930 (135) 1516 (220) 1137 (165)
979 (142) 737 (107) 1254 (182) 937 (136) 1530 (222) 1144 (166)
992 (144) 744 (108) 1268 (184) 951 (138) 1544 (224) 1158 (168)
1006 (146) 758 (110) 1282 (186) 965 (140) 1558 (226) 1165 (169)
1020 (148) 765 (111) 1296 (188) 972 (141) 1572 (228) 1179 (171)
1034 (150) 779 (113) 1310 (190) 979 (142) 1585 (230) 1185 (172)
1048 (152) 786 (114) 1323 (192) 992 (144) 1599 (232) 1199 (174)
1061 (154) 792 (115) 1337 (194) 999 (145) 1613 (234) 1206 (175)
1075 (156) 806 (117) 1351 (196) 1013 (147) 1627 (236) 1220 (177)
1089 (158) 813 (118) 1365 (198) 1020 (148) 1641 (238) 1227 (178)
1103 (160) 827 (120) 1379 (200) 1034 (150) 1654 (240) 1241 (180)
1116(162) 834 (121) 1392 (202) 1041 (151) 1668 (242) 1247 (181)
1130 (164) 848 (123) 1406 (204) 1054 (153) 1682 (244) 1261 (183)
1144 (166) 854 (124) 1420 (206) 1061 (154) 1696 (246) 1268 (184)
1158 (168) 868 (126) 1434 (208) 1075 (156) 1709 (248) 1282 (186)
1172 (170) 875 (127) 1447 (210) 1082 (157) 1723 (250) 1289 (187)
1185 (172) 889 (129) 1461 (212) 1089 (158)

CA1005-2B

FIG. 3 Quick Reference Compression Pressure Limit Chart

1. Disassemble and clean the tappet to remove all
traces of engine oil.
NOTE: Do not mix parts from different tappets. Hi
Parts are select-fitted and are not interchangeable.
Tappets cannot be checked with engine oil in
them. Only the testing fluid can be used. ADJUSTING NUT

2. Place the tappet in the tester, with the plunger HYDRAULIC TAPPET
facing upward. Pour hydraulic tappet tester fluid into LEAKDOWN TESTER
the cup to a level that will cover the tappet (TOOL-6500-E)
assembly. The fluid can be purchased from the 4

I
manufacturer of the tester. Using kerosene or any ■SOW
other fluid will not provide an accurate test. ■ PT
3. Place the 5/16-inch steel ball provided with the
■
A2916-1D
tester in the plunger cap (Fig. 4).
4. Adjust the length of the ram (Fig. 5) so that the FIG. 5 Adjusting the Ram Length
pointer is 1.59mm (1/16 inch) below the starting
mark when the ram contacts the tappet plunger, to 5. Work the tappet plunger up and down until the
facilitate timing as the pointer passes the Start tappet fills with fluid and all traces of air bubbles
Timing mark. have disappeared.
Use the center mark on the pointer scale as the
Stop Timing point instead of the original Stop 6. Allow the ram and weight to force the tappet
Timing mark at the top of the scale. plunger downward. Measure the exact time it takes
for the pointer to travel from the Start Timing to the
Stop Timing marks of the tester.

7. A tappet that is satisfactory must have a leakdown

rate (time in seconds) within the minimum and
maximum limits specified in the specific engine
Section in this Manual.

---- 8. If the tappet is not within specifications, replace it

HYDRAULIC TAPPET with a new tappet. It is not necessary to
LEAKDOWN
TESTER TOOL / disassemble and clean new tappets before testing,
because the oil contained in new tappets is test
fluid.

9. Remove the fluid from the cup and bleed the fluid
[A2915-1C from the tappet by working the plunger up and
down. This step will aid in depressing the tappet
FIG. 4 Placing Steel Ball in Valve Tappet Plunger plungers when checking the valve clearance.
21-01-6 General Gasoline Engine Service
Static Engine Off Valve Train Analysis
(Rocker Arm Cover Removed)
Rocker Arm Cover Removal
1. Remove air cleaner.
2. Disconnect and remove any hoses, wires, spark
plug leads and components that would interfere
with the removal of the rocker arm cover.
3. Remove the rocker arm cover bolts.
4. Remove the rocker arm cover.
Valve Train Analysis
Check for damaged and/or severely worn parts, for
correct assembly and assure use of correct parts by
proceeding, as follows, with the static engine analysis.
1. Rocker Arm Assemblies—individually mounted:
a. Check for loose mounting stud and nut or bolt.
b. Check for plugged oil feed in the rocker arm.
2. Push Rods:
Check for bent push rods.
3. Valve Spring Assembly—With or Without Damper
Spring:
Check for broken or damaged parts.
4. Retainer and Keys—Both two piece and one piece
retainers:
Check for proper seating of keys on valve stem and
in retainer.
5. Positive Rotator and Keys:
Check for proper seating of keys on valve stem in
the positive rotator.
6. Valves and Cylinder Head
a. Check the cylinder head gasket for proper
installation.
b. Check for plugged oil drain back holes.
c. Check for worn or damaged valve tips.
d. Check for missing or damaged valve stem oil
seals.
e. Check collapsed tappet gap—hydraulic tappet
applications.
f. Check installed spring height.
7. Overhead Cam Follower Arm and Lash Adjuster
Assemblies:
Check for broken or severely worn parts.
Check for "soft" lash adjuster with hand pressure
on rocker arm (arm on base circle of camshaft).
8. Camshaft—Overhead Camshaft Applications:
a. Check for plugged oil feed.
b. Check for correct cam lift.
Static checks (engine off) are to be made on the
engine prior to the following dynamic
procedure.
Dynamic Valve Train Analysis
Valve Train Analysis
CAUTION: Do not perform dynamic analysis on
overhead camshaft engines because of oil splash.
21-01-6
Start the engine and while running at idle, check for
proper operation of all parts. Check the following items
under firing engine operating conditions:
1. Rocker Arm Assemblies—Individually mounted:
a. Check for plugged oil feed in rocker arm.
If a condition of insufficient oiling is suspected,
accelerate the engine to 1200 rpm ±100 rpm with the
transmission in Neutral and the engine at normal
operating temperature. Oil should spurt from the rocker
arm oil holes such that valve tips and rocker arms are
well oiled and/or, with the rocker arm cover off, oil splash
may overshoot rocker arm. If oiling is insufficient for this
condition to occur, check oil passages for blockage.
2. Push Rods:
a. Check for bent push rods.
b. Check for proper rotation of push rods.
3. Positive Rotator and Keys:
Check for proper operation of positive rotator.
4. Valves and Cylinder Head:
a. Check for plugged oil drain back holes.
b. Check for missing or damaged valve stem oil
seals for guide mounted oil seals.
Rocker Arm Cover Installation
1. Remove old gasket from cover, if necessary, 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.
2. Install a new gasket and replace the cover on the
engine.
3. Install the rocker arm cover bolts and tighten in
sequence to specification in the specific engine
Section in this manual.
4. Connect all hoses, wires, spark plug leads, and
components.
Camshaft Lobe Lift
Check the lift of each lobe in consecutive order and
make a note of the readings.
1. Remove the fresh air inlet tube and the air cleaner.
Remove the heater hose and crankcase ventilation
hoses. Remove valve rocker arm cover(s).
2. 4.9L uses Stamped Rocker arm (same as 5.0L). On
5.0L (302 CID) V-8, and 5-8L (351 CID) 7.5L engine
("or all V-8 engines") W-V-8 engines, remove the
fulcrum bolts, fulcrum seat and rocker arm.
3. Make sure the push rod is in the valve tappet
socket. Install a dial indicator D78P-4201-B (or
equivalent) so that the actuating point of the
indicator is in the push rod socket (or the indicator
ball socket adapter Tool 6565-AB is on the end of
the push rod) and in the same plane as the push rod
movement (Fig. 6 or 7).
4. Disconnect the brown lead (I terminal) and the red
and blue lead (S terminal) at the starter relay. Install
an auxiliary starter switch between the battery and
S terminals of the starter relay. Crank the engine
with the ignition switch Off.
Turn the crankshaft over until the tappet is on the
base circle of the camshaft lobe. At this point, the
push rod will be in its lowest position.
21-01-7 General Gasoline Engine Service 21-01-7

a
p x CUP SHAPED
8. Remove the dial indicator and auxiliary starter
switch.
ADAPTER TOOL
A a (USE WITH BALL­
On 4.9L (300 CID) I-6, 5.0L (302 CID) V-8, and
END PUSH RODS) 5.8L (351 CID) (460 CID) 7.5L V-8 W-V-8 install the
rocker arm, fulcrum seat and fulcrum bolts. Check
SA the valve clearance. Refer to specific engine
Section in this Manual. Adjust if required (refer to
DIAL INDICATOR TOOL
procedure in this Section).
9. Install the valve rocker arm cover(s) and the air
cleaner.
SOLID TAPPET-TYPE
PUSH ROD
Camshaft End Play
On all 6 and 8 cylinders engines, prying against the
aluminum-nylon camshaft sprocket, with the valve train
load on the camshaft, can break or damage the sprocket.
"x ■4s Therefore, the rocker arm adjusting nuts must be backed
1 [I off, or the rocker arm and shaft assembly must be
loosened sufficiently to free the camshaft. After checking
IV’ ' J the camshaft end play, check the valve clearance. Adjust
if required (refer to procedure in this Section).
Push the camshaft toward the rear of the engine.
DIAL INDICATOR
Install a dial indicator (Tools D78P-4201-F, -G or
BRACKETRY TOOL' equivalent so that the indicator point is on the camshaft
sprocket attaching screw (Fig. 8). Zero the dial indicator.
BE SURE TO PLACE Position a large screwdriver between the camshaft gear
INDICATOR TIP
IN CENTER OF'
and the block. Pull the camshaft forward and release it.
Compare the dial indicator reading with the
sk:
PUSH ROD SOCKET
WK specifications listed at the end of the applicable engine
A4166-1C
Section.
FIG. 6 Typical Camshaft Lobe Lift Hydraulic Tappet— If the end play is excessive, check the spacer for
V-8 Engines
correct installation before it is removed. If the spacer is
correctly installed, replace the thrust plate.
DIAL INDICATOR
TOOL Remove the dial indicator.
rf 1
X 7 ■'
Timing Chain Deflection
„?s
1. Rotate the crankshaft in a counterclockwise
direction (as viewed from the front) to take up the
«S
slack on the left side of the chain.
L \ CUP SHAPED ADATER TOOL
2. Establish a reference point on the block and
L 1 measure from this point to the chain (Fig. 9).
3. Rotate the crankshaft in the opposite direction to
ZLai take up the slack on the right side of the chain.
Force the left side of the chain out with the fingers

u TOOL
D78P-4201-F AND G

ira A2919-1C

FIG. 7 Typical Camshaft Lobe Lift—4.9L (300 CID) 1-6 ■ I

Engines
5. Zero the dial indicator. Continue to rotate the
crankshaft slowly until the push rod is in the fully ■

raised position.
6. Compare the total lift recorded on the indicator with
specification listed in the specific engine Section in
IJj L
1
this Manual.
7. To check the accuracy of the original indicator
reading, continue to rotate the crankshaft until the few
indicator reads zero. If the lift on any lobe is below
specified wear limits listed in the specific engine
Section of this Manual, the camshaft and the valve aEg< a A1374-1EI
tappet operating on the worn lobe(s) must be
replaced. FIG. 8 Checking Camshaft End Play
21-01-8 General Gasoline Engine Service 21-01-8

"s

f IF1
■w

wz
• al
I

fit I
TOOL-D78P-4201
F AND G
Ml
■lit
r * '«»JET XT
I I1 ■:?

■ ■ ■
M
T ♦
$

A2987-1E

I PI
i
FIG. 11 Checking Crankshaft End Play

♦ \ — n i 3. Zero the dial indicator. Push the crankshaft forward

REFERENCE POINT
»1
FIG. 9 Checking Timing Chain Deflection
and measure the distance between the reference
point and the chain. The deflection is the difference
between the two measurements.
If the deflection exceeds specifications listed in
the specific engine Section in this Manual, replace
the timing chain and sprockets.
Timing Gear Backlash
Install a dial indicator (Tools D78P-4201-F, -G or
equivalent) on the cylinder block (Fig. 10). Check the
backlash between the camshaft gear and the crankshaft
gear with a dial indicator at six equally spaced teeth. Hold
the gear firmly against the block while making the check.
Refer to specifications in the specific engine Section of
this Manual for the backlash limits.
Crankshaft End Play
1. Force the crankshaft toward the rear of the engine.
2. Install a dial indicator (Tools D78P-4201-F, -G or
equivalent) so that the contact point rests against
the crankshaft flange and the indicator axis is
parallel to the crankshaft axis (Fig. 11).
A2952-1C
4.
and note the reading on the dial.
If the end play exceeds the wear limit listed in the
specific engine Section in this Manual, replace the
thrust bearing. If the end play is less than the
minimum limit, inspect the thrust bearing faces for
scratches, burrs, nicks, or dirt. If the thrust faces are
not damaged or dirty, they probably were not
aligned properly. Lubricate and install the new
thrust bearing and align the faces following the
procedure recommended under Main Bearing
Replacement in the specific engine Section. Check
the crankshaft end play.
Flywheel Clutch Face Runout—Manual-Shift
Transmission
Remove the spark plugs.
Install a dial indicator (Tools D78P-4201-F, -G or
equivalent) so that the indicator point bears against the
flywheel face (Fig. 12). Turn the flywheel making sure
that it is full forward or rearward so that crankshaft end
play will not be indicated as flywheel runout.
If the flywheel clutch face runout exceeds
specifications listed in the specific engine Section in this
Manual, remove the flywheel and check for burrs
between the flywheel and the face of the crankshaft
mounting flange. If no burrs exist, check the runout of the
crankshaft mounting flange. Replace the flywheel or

■■

^TIMING GEAR
%SK
gj&Kg.
n
4 0

if
r &
TOOL -D78P 4201
FANDG

■■
J f«

f # -J /
M J 4 ||

3
A3111-1B
TOOL
D78P-4201-F AND G
A2923-1 F
FIG. 12 Checking Flywheel Face Runout—Manual
FIG. 10 Checking Timing Gear Backlash Transmission
21-01-9 General Gasoline Engine Service 21-01-9

machine the crankshaft-flywheel mounting face if the

mounting face flange runout is excessive. If the ring gear SHAFT AND COUNTERWEIGHT
ASSEMBLY -9A430
EXHAUST CONTROL
VALVE-9460
runout exceeds specifications listed in the specific
engine Section in this Manual, check installation of the
gear to the flywheel flange. If it is not properly seated,
re-install it to the flywheel. If it is properly seated, replace
it. Refer to Ring Gear Replacement in this Section for the VALVE
TENSION
proper procedure. SPRING
9A469
Flywheel Runout—Automatic Transmission nl /O
Remove the spark plugs. ■T

Install a dial indicator so that the indicator point rests STOP PIN
on the face of the ring gear adjacent to the gear teeth. SPRING
BUSHING
9A458
9462
Push the flywheel and crankshaft forward or backward
THERMOSTATIC
as far as possible to prevent crankshaft end play from SPRING - 9449
FLAT WASHER
EXPANSION PLUG
375484-S
being indicated as flywheel runout. STOP PIN
9463
3 79367-S

BUSHING
Set the indicator dial on the zero mark. Turn the 9462
A23041B
flywheel one complete revolution while observing the
total indicator reading (TIR). If the TIR exceeds
specifications, the flywheel and ring gear assembly must FIG. 14 Exhaust Manifold Assembly
be replaced.
5. Remove the valve plate, shaft and flat washer.
Exhaust Control Valve—4.9L Engine 6. Remove the expansion plug from the control valve
shaft bushing bore.
Removal
7. Remove the exhaust control valve bushings from
4.9L (300 CID) I-6 engines utilize a thermostatic spring the manifold using soft drift punch and hammer.
and counterweight type exhaust control valve which is These bushings come in two sizes each, both front
integral with the exhaust manifold, (Fig. 14). Service and rear. To determine which bushings should be
procedures are covered in the Engine/Emission used, measure the outside diameter of the removed
Diagnosis Manual and Section 50-26 of the Truck, Pre­ bushings. Replace with the proper parts (Fig. 15).
Delivery, Maintenance and Lubrication Shop Manual.
1. Separate the intake and exhaust manifolds. Installation
2. Remove the valve tension spring and the 1. Install the new control valve bushings using soft
thermostatic spring from the exhaust control valve drift punch and hammer. The inner end of the
shaft (Fig. 14). smaller bushing should be 0.254-0.381 mm (0.010-
0.015 inches) below the inner surface of the
3. Remove the stop pin spring from the manifold. exhaust manifold. The inner end- of the larger
4. Using an acetylene torch inside the manifold, cut bushing should be 0.508mm (0.020 inch) above the
the shaft on both sides of the valve plate. inner surface of the exhaust manifold.
2. Ream the bushings to 6.375-6.426mm (0.251-0.253
inches) ID.
II 3. Slide the new shaft into the bushing, flat washer and
valve plate. The flat washer must be between the
valve plate and the large bushing.
4. Install a new stop pin spring on the stop pin.
p it
w
- // \5 ♦ >
5. Position the exhaust control valve at an 84 degree
angle with the top surface of the manifold (Fig. 16).
a-
& ; //MU’ __ TOOL - T79T-6527-B 6. Rotate the counterweight and shaft assembly
F0R 4 9L (30°CID> 1-6 clockwise until the counterweight contacts the stop
pin spring. Place a 0.76mm (0.030 inch) feeler

I gauge between the counterweight and manifold to

maintain the specified clearance while welding.

I If I

fl
Outside Inside Diameter
Part Number Bushing Olamater of Buahing Bore
ol Bushins In Manifold
(Front — Std )__________ C5AZ-9462~ 0 3070-0 3065 0 3061-0 3051
(Rear—Std )__________ C5AZ-9462-B 0 6255-0 6250 0 6246-0.6236

■
(Front —0 010 O S )_______ C5AZ-9462-C 0 3170-0.3165

’ di
0 3161-0 3151
(Rear —0.010 OS)_______ C5AZ-9462-0 0 6355-0 6350 0 6346-0.6336
Note Dimensions are in inches
*8POSITIVE STOP TYPE STUD CA1026-2B
A3723-1D

FIG. 13 Installing Rocker Arm Stud—4.9L (300 CID) I-6 FIG. 15 Exhaust Control Valve Bushing Sizes—4.9L
Engine (300 CID) I-6 Six-Cylinder Engine Only
21-01-10 General Gasoline Engine Service 21-01-10

the plug and pry it out with a small pin punch. Clean and
WELD VALVE TO SHAFT
WITH COUNTERWEIGHT
inspect the plug bore.
/ TOUCHING BUT NOT
84° < DEFLECTING STOP Prior to installing a core plug the plug bore should be
THERMOSTATIC SPRING i
\ .. PIN SPRING inspected for any damage that would interfere with the
/ proper sealing of the plug. If the bore is damaged it will be
necessary to true the surface by boring for the next
(--- specified oversize plug.
77 I i
Ur I /
I / Oversize (OS) plugs are identified by the OS stamped
I'xJ in the flat located on the cup side of the plug.
1 /
7 I /
N.
STOP PIN SPRING
Coat the plug and/or bore lightly with an oil-resistant
(oil galley) or water-resistant (cooling jacket) sealer
i/\ (B5A-19554-A or equivalent and install it following the
1/ procedure for cup type or expansion type below:
VALVE TENSION SPRING
EXPANSION PLUG
FLAT WASHER Cup-Type
Cup-type core plugs (Fig. 17) are installed with the
1 flanged edge outward. The maximum diameter of this
plug is located at the outer edge of the flange. The flange
on cup-type plugs flares outward with the largest
diameter at the outer (sealing) edge.
-k.
• __ CAUTION: It is imperative to pull the plug into the
machined bore by using a properly designed tool.
Under no circumstances is the plug to be driven into
0.030 INCH
the bore using a tool that contacts the flange. This
"COUNTERWEIGHT method will damage the sealing edge and will result
TO MANIFOLD
CLEARANCE
in leakage and/or plug blow out.
WELD
A23O5 IB The flanged (trailing) edge must be below the
chamfered edge of the bore to effectively seal the
FIG. 16 Valve Plate Position and Counterweight plugged bore.
Clearance
If the core plug replacing tool has a depth seating
7. With the plate and counterweight in position, use surface, do not seat the tool against a non-machined
stainless steel welding rod to tack-weld the valve (casting) surface.
plate to the shaft.
Expansion-Type
8. Move the assembly back and forth to check for a
binding condition. If there is no binding condition, Expansion-type core plugs (Fig. 17) are installed with
securely weld the valve plate to the shaft. the flanged edge inward. The maximum diameter of this
plug is located at the base of the flange with the flange
9. Install the expansion plug in the manifold bushing flaring inward.
bore.
CAUTION: It is imperative to push or drive the plug
10. Position the new thermostatic spring on the shaft into the machined bore using a properly designed
and counterweight assembly so that it will be tool. Under no circumstances is the plug to be driven
necessary to wind the spring approximately 1 /2 turn using a tool that contacts the crowned portion of the
in the clockwise direction to hook the open end over plug. This method will expand the plug prior to
the stop pin. Use a 7.94mm (5/16 inch) ID piece of installation and may damage the plug and/or plug
tubing to slide the thermostatic spring on the shaft bore.
and counterweight assembly. Wind the spring
clockwise and hook it over the stop pin. When installed the trailing (maximum) diameter must
be below the chamfered edge of the bore to effectively
11. Install a new valve tension spring on the exhaust seal the plugged bore.
control valve shaft and the stop pin.
If the core plug replacing tool has a depth seating
EGR Valve surface, do not seat the tool against a non-machined
(casting) surface.
CAUTION: Do not strike or pry on the valve
diaphragm housing or supports, as this may damage Crankshaft Rear Oil Seal—One-Piece
the valve operating mechanism and/or change the The one-piece crankshaft rear oil seal is used on the
valve calibration. Refer to the Engine/Emissions
4.9L, 5.0L, 5.8L, 7.5L engines.
Diagnosis Manual.
If the crankshaft rear oil seal replacement is the only
Core Plugs operation being performed, it can be done in the vehicle
as detailed in the following procedure. If the oil seal is
Removal and Installation being replaced in conjunction with a rear main
To remove a large core plug, drill a 12.70mm (1/2 bearing replacement, the engine must be removed
inch) hole in the center of the plug and remove with a from the vehicle and installed on a work stand.
universal Impact Slide Hammer T59L-100-B and T50T- Removal
100-A or pry it out with a large drift punch. On a small
core plug, drill a 6.35mm (1 /4 inch) hole in the center of 1. Remove the starter.
21-01-11 General Gasoline Engine Service 21-01-11

SEALING
SEALING EDGE
EDGE BEFORE
BEFORE INSTALLATION
INSTALLATION

CUP TYPE CORE

PLUG REPLACER TOOL
I
IX*X*X*X*X*X*K*K*X*X*M*X*X*X*M*X<X>X*X4
XXX X XX X XX XXXXXX X XX X X X XX XXXXXXXXXXXXX1 Ixxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxl

N
MT EXPANSION TYPE CORE
CUP TYPE EXPANSION TYPE PLUG
PLUG REPLACER TOOL
PLUG

A3217-2B

FIG. 17 Typical Core Plugs and Installation Tools

2. Remove the transmission from the vehicle,
following the procedures in Group 16 (Manual
Transmission) or Group 17 (Automatic
Transmission) in the Body/Chassis/Electrical
Manual.
3. On a manual-shift transmission, remove the
pressure plate and cover assembly and the clutch
disc following the procedure in Section 16-02,
Clutch.
4. Remove the flywheel attaching bolts and remove
the flywheel and engine rear cover plate.
Using a sharp awl, punch one hole into the seal
metal surface between the lip and block. Screw in
the threaded end of slide hammer Tool T77L-9533-
B or equivalent. Use the slide hammer to remove
the seal. Use caution to avoid scratching or
damaging the oil seal surface.
5. Clean the oil seal recess in the cylinder block and
main bearing cap.
Installation
1. Clean, inspect and polish the rear oil seal rubbing
surface on the crankshaft, following the procedures
in Section 21 -01, General Gasoline Engine Service.
Coat a new oil seal and the crankshaft with a light
(Automatic Transmission). Do not adjust the
transmission linkage.
Flywheel Ring Gear—Manual-Shift
Transmission
Removal
To replace a damaged or worn ring gear, heat the ring
gear with a blow torch on the engine side of the gear, and
knock it off the flywheel. Do not hit the flywheel when
removing the ring gear.
Installation
Heat the new ring gear evenly until the gear expands
enough to slip onto the flywheel. Make sure the gear is
seated properly against the shoulder. Do not heat any
portion of the gear to a temperature higher than
260°C (500°F). If this limit is exceeded, the hardness
will be removed from the ring gear teeth.
PCV Valve Replacement
1. Disconnect hose(s) and remove PCV Valve.
NOTE: If a high flow PCV Valve is scheduled for
installation, consult the Vehicle Emission Control
REAR OIL SEAL

I
REPLACER TOOL
film of engine oil. Start the seal in the recess with z\
the seal lip facing forward and install it with the Tool
(T65P-6701-A or equivalent) as shown in Fig. 18.
dkW1
II
Keep the tool straight with the centerline of the
crankshaft and install the seal until the tool contacts
the cylinder block surface. Remove the tool and
inspect the seal to be sure it was not damaged ) /
during installation. 1

2. Install the engine rear cover plate. Position the

flywheel on the crankshaft flange. Coat the threads
of the flywheel attaching bolts with oil-resistant
sealer (D8AZ-19554-A or equivalent) and install the
'i. W
bolts. Tighten the bolts in sequence across from
each other to 102-115 N-m (75-85 ft-lbs).
(at I
3. On a manual-shift transmission, install the clutch
disc and the pressure plate assembly following the
procedure in Section 16-02, Clutch.
1 Ww I

A2166-1B
i

4. Install the transmission, following the procedure in

Group 16 (Manual Transmission), or Group 17 FIG. 18 Installing One-Piece Crankshaft Rear Oil Seal
21-01-12 General Gasoline Engine Service 21-01-12

Information Decal for the correct high flow PCV

Valve part number.
If replacement PCV Valve requires a plastic fitting
for additional vacuum lines, soak the new plastic
fitting (furnished in PCV Valve Replacement Kit), in
hot water prior to installing on new PCV Valve.
Proceed to Step 2.
2. Install new PCV Valve and connect hose(s).
3. Check curb idle speed in accordance with
recommended procedures. (Refer to the Engine/
Emissions Diagnosis Manual Section 4).

OVERHAUL
Interpretation of "Service Limit" BREAK SHARP CORNER
Specifications
"Service Limit" specifications are intended to be a
guide only to be used when overhauling or reconditioning
II
an engine or engine component. A determination can be
made as to whether a component is suitable for
continued service or should be replaced for extended
service while the engine is disassembled.
In the case of "Valve Stem to Valve Guide
Clearance," the "Service Clearance" is intended as an
aid in diagnosing engine noise only, and does not
constitute a failure or indicate need for repair. However,
when overhauling or reconditioning a cylinder head, the
service clearance should be regarded as a practical
working value, and used as a determinant for installing IV
,V
the next oversize valve to assure extended service life.
Cylinder Head
Replace the head if it is cracked. Do not plane or
Af
b
grind more than 0.254mm (0.010 inch) from the ■■ ■■■

cylinder head gasket original surface. Remove all

burrs or scratches with an oil stone. I
Reaming Valve Guides A2910 1C

If it becomes necessary to ream a valve guide (Fig. 19) FIG. 19 Reaming Valve Guides
to install a valve with an oversize stem, a reaming kit is
available which contains the following reamer and pilot specifications. Refer to specific engine Section in this
combinations: a 0.015 inch OS reamer with a 0.003 inch Manual.
OS pilot, and a 0.030 inch reamer with a 0.015 inch OS
If the valve seat width exceeds the maximum limit,
pilot. remove enough stock from the top edge and/or bottom
When replacing a standard size valve with an oversize edge of the seat to reduce the width to specifications
valve always use the reamer in sequence (smallest refer to specific engine Section in this Manual.
oversize first, then next smallest, etc.) so as not to
overload the reamers. Always re-face the valve seat On the valve seats of all engines use a 60 degree
after the valve guide has been reamed, and use a angle grinding wheel to remove stock from the bottom of
suitable scraper to break the sharp corner (ID) at the
top of the valve guide. TO REMOVE STOCK FROM
TOP OF SEAT,.
TO REMOVE STOCK FROM
BOTTOM OF SEAT,
USE 30° WHEEL\ USE 60° WHEEL
Refacing Valve Seats
45°
Refacing of the valve seat should be closely
coordinated with the refacing of the valve face so that
the finished seat and valve face will be concentric and
the specified interference fit will be maintained. This is
important so that the valve and seat will have a
compression tight fit. Be sure that the refacer grinding
Al
11 f
WIDTH
wheels are properly dressed.
Grind the valve seats of all engines to a true 45 degree
angle (Fig. 20). Remove only enough stock to clean up
pits and grooves or to correct the valve seat runout. After
the seat has been refaced, use a seat width scale or a A2897-1C
machinist scale to measure the seat width (Fig. 21).
Narrow the seat, if necessary to bring it within FIG. 20 Refacing Valve Seat
21-01-13 General Gasoline Engine Service
SEAT WIDTH SCALE
H
O :
( FOR DIMENSIONS
A2909-1B
FIG. 21 Checking Valve Seat Width
the seats (raise the seats) and use a 30 degree angle
wheel to remove stock from the top of the seats (lower
the seats) (Fig. 20).
The finished valve seat should contact the
approximate center of the valve face. It is good practice
to determine where the valve seat contacts the face. To
do this, coat the seat with Prussian blue and set the valve
in place. Rotate the valve with light pressure. If the blue is
transferred to the center of the valve face, the contact is
satisfactory. If the blue is transferred to the top edge of
the valve face, lower the valve seat. If the blue is
transferred to the bottom edge of the valve face, raise
the valve seat.
Valves
Minor pits, grooves, etc., may be removed. Discard
valves that are severely damaged, or if the face runout
cannot be corrected by refinishing or if stem clearance
exceeds specifications. Refer to specific engine Section
in this Manual.
Discard any worn or damaged valve train parts.
Refacing Valves
The valve refacing operation should be closely
coordinated with the valve seat refacing operations so
that the finished angles of the valve face and of the valve
seat will be to specifications and provide a compression
tight fit. Be sure that the refacer grinding wheels are
properly dressed.
If the valve face runout is excessive and/or to remove
pits and grooves, reface the valves to a true 44 degree
angle. Remove only enough stock to correct the runout
or to clean up the pits and grooves. If the edge of the
valve head is less than 0.794mm (1/32 inch) thick after
grinding (Fig. 22), replace the valve as the valve will run
too hot in the engine. The interference fit of the valve
and seat should not be lapped out.
Remove all grooves or score marks from the end of
the valve stem, and chamfer it as necessary. Do not
remove more than 0.254mm (0.010 inch) from the
end of the valve stem.
If the valve and/or valve seat has been refaced, it will
be necessary to check the clearance between the rocker
arm pad and the valve stem tip with the valve train
assembly installed in the engine.
Select Fitting Valves
If the valve stem to valve guide clearance exceeds the
service limit, ream the valve guide for the next oversize
valve stem. Valves with oversize stem diameters of
21-01-13
K DO NOT REMOVE MORE
s-:i ■THAN 0.254 mm (0.010 INCH)
FROM THE END
CHECK FOR BENT STEM
REFER TO SPECIFICATIONS
DIAMETER
VALVE
(1/32 inch) MINIMUM
I FACE ANGLE
THIS LINE PARALLEL
0.794mm
■u WITH VALVE HEAD
1
t 1 A3453-1E
FIG. 22 Critical Valve Dimensions
0.003, 0.015 and 0.030 inch are available for service.
Always reface the valve seat after the valve guide
has been reamed. Refer to Reaming Valve Guides.
Camshaft Repair
Remove light scuffs, scores or nicks from the
camshaft machined surfaces with a smooth oil stone.
Crankshaft
Dress minor scores with an oil stone. If the journals are
severely marred or exceed the service limit, they should
be refinished to size for the next undersize bearing.
Refinishing Journals
Refinish the journals to give the proper clearance with
the next undersize bearing. If the journal will not clean up
to maximum undersize bearing available, replace the
crankshaft.
Always reproduce the same journal shoulder radius
that existed originally. Too small a radius will result in
fatigue failure of the crankshaft. Too large a radius will
result in bearing failure due to radius ride of the bearing.
After refinishing the journals, chamfer the oil holes;
then polish the journal with a No. 320 grit polishing cloth
and engine oil. Crocus cloth may also be used as a
polishing agent.
Fitting Main or Connecting Rod Bearings
with Plastigage
1. Clean crankshaft journals. Inspect journals and
thrust faces (thrust bearing) for nicks, burrs or
bearing pick-up that would cause premature
bearing wear. When replacing standard bearings
with new bearings, it is good practice to fit the
bearing to minimum specified clearance. If the
desired clearance cannot be obtained with a
standard bearing, try one half of a 0.001 or 0.002
inch undersize in combination with a standard
bearing to obtain the proper clearance.
21-01-14 General Gasoline Engine Service 21-01-14

2. If fitting a main bearing, position a jack under
counterweight adjoining bearing which is being
checked. Do not place jack under front post of
crankshaft. Support crankshaft with jack so its
weight will not compress Plastigage and provide an
erroneous reading.
3. Place a piece of Plastigage or it's equivalent, on
bearing surface across full width of bearing cap and
about 6.35mm (1/4 inch) off center (Fig. 23).
4. Install cap and tighten bolts to specifications. Refer
to specific engine Section in this Manual. Do not
turn crankshaft while Plastigage is in place.
5. Remove cap. Using Plastigage scale, check width
of Plastigage at widest point to get minimum
clearance. Check at narrowest point to get
maximum clearance. Difference between readings
is taper of journal.
6. If clearance exceeds specified limits, try a 0.001 or
0.002 inch undersize bearing in combination with
the standard bearing. Bearing clearance must be
within specified limits. If 0.002 undersize main
bearings are used on more than one journal, be
sure they are all installed in cylinder block side of
bearing. If standard and 0.002 inch undersize
bearing does not bring clearance within desired
limits, refinish crankshaft journal, then install
undersize bearings.
7. After bearing has been fitted, apply light coat of
engine oil to journal and bearings. Install bearing
cap. Tighten cap bolts to specifications. Refer to
specific engine Section in this Manual.
8. Repeat procedures for remaining bearings that
require replacement.
Pistons, Pins and Rings
Fitting Pistons
For specifications refer to specific engine Section in
this Manual.
Pistons are available in standard size or oversize for
service. Refer to the Ford Parts Master Catalog for
available oversize pistons.
CHECK WIDTH OF
PLACE PLASTIGAGE FULL \ PLASTIGAGE
WIDTH OF JOURNAL
ABOUT 6.35mm
f-s.
(’4 INCH) OFF CENTER \x
The standard size pistons are color coded red, blue, or
yellow or have 0.003 OS stamped on the dome. Refer to
the Specifications for standard size piston dimensions.
Measure the cylinder bore, (Fig. 24) and select the
piston to assure the proper clearance. When the bore
diameter is in the lower one third of the specified range, a
red piston should be used. When the bore diameter is in
the middle one third a blue piston should be used. When
the bore diameter is the upper one third, the yellow or
0.003 OS piston should be used.
Measure the piston diameter to ensure that the
specified clearance is obtained. It may be 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 a piston has been fitted, mark it for
assembly in the cylinder to which it was fitted.
If the taper, out-of-round and piston to cylinder bore
clearance conditions of the cylinder bore are within
specified limits, new piston rings will give satisfactory
service. If new rings are to be installed in a used
cylinder that has not been refinished, remove the
cylinder wall glaze (refer to Cylinder Block,
Refinishing Cylinder Walls). Be sure to clean the
cylinder bore thoroughly with soap and water.
1. Calculate the size piston to be used by taking a
cylinder bore check. Follow the procedures outlined
under Cleaning and Inspection.
2. Select the proper size piston to provide the desired
clearance (refer to the specifications). Measure the
piston diameter in line with the centerline of the
piston pin and at 90 degrees to the piston pin axis.
3. Make sure the piston and cylinder block are at room
temperature (21.1 °C or 70 degrees F). After any
refinishing and washing operation allow the cylinder
bore to cool, and make sure the piston and bore are
clean and dry before the piston fit is checked.
Fitting Rings
1. Select the proper ring set for the size cylinder bore.
2. Position the ring in the cylinder bore in which it is
going to be used.
A

B B
■a.

s, /

A
IL \
A — At right angle to center line of engine
B — Parallel to center line of engine
Top Measurement: Make 12.70mm (1/2 inch) below top of block deck

r
Bottom Measurement: Make within 12.70mm (1/2 inch) above top of
piston-when piston is at its lowest travel (B.D.C.)
MEASURING Bore Service Limit: Equals the average of "A” and "B" when measured
PLASTIGAGE at the center of the piston travel.
0.0015" (D81L-6002-B)
CLEARANCE Taper: Equals difference between "A" top and “A" bottom.
INSTALLING
Out-of-Round: Equals difference between "A” and "B" when measured
PLASTIGAGE
at the center of piston travel.
A2868-1C Refer to Specification tables at end of each engine section.
A4165-1F

FIG. 23 Installing and Measuring Plastigage—Engine

Installed FIG. 24 Cylinder Bore Measurement
21-01-15 General Gasoline Engine Service
3. Push the ring down into the bore area where normal
ring wear is not encountered.
4. Use the head of a piston to position the ring in the
bore so that the ring is square with the cylinder wall.
Use caution to avoid damage to the ring or cylinder
bore.
5. Measure the gap between the ends of the ring with
a feeler gauge (Fig. 25). Ring gap in a worn cylinder
is normally greater than specification. If the ring gap
is greater than the specified limits, try another ring
set listed in the specific engine Section in this
Manual.
6. Check the ring side clearance of the compression
rings with a feeler gauge inserted between the ring
and its lower land according to specification in the
applicable engine Section (Fig. 26). 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.
Fitting Piston Pins
Install the piston pin following the procedure under
Piston Assembly in the applicable engine Section in this
Shop Manual.
Cylinder Block
Refinishing Cylinder Walls
Honing is recommended for refinishing cylinder walls
only when there is no visible sign of cross hatching (hone
pattern) remaining, the walls have minor scuffs or
scratches, or for fitting pistons to the specified
I
4 hatch finish on the cylinder bore. The cross-hatch
Yd
A2902 IB
FIG. 25 Checking Piston Ring Gap
■ metallic plastic). Do not repair cracks with this
V
i ■
i I1020 1B
FIG. 26 Checking Piston Ring Side Clearance
21-01-15
clearance. The grade of hone to be used is determined
by the amount of metal to be removed. Follow the
instructions of the hone manufacturer. If coarse stones
are used to start the honing operation, leave enough
material so that all hone marks can be removed with the
finishing hone which is used to obtain the proper piston
clearance. Thoroughly clean the cylinder bore walls with
detergent and water solution after honing.
Cylinder walls that are severely marred and/or worn
beyond the specified limits should be refinished. Before
any cylinder is refinished, all main bearing caps must
be in place and tightened to specification, so that the
crankshaft bearing bores will not become distorted
from the refinishing operation. Refer to specific
engine Section in this Manual.
Refinish only the cylinder or cylinders that require it. All
pistons are the same weight, both standard and oversize;
therefore, various sizes of pistons can be used without
upsetting engine balance.
Refinish the cylinder with the most wear first to
determine the maximum oversize. If the cylinder will not
clean up when refinished for the maximum oversize
piston recommended, replace the block.
Refinish the cylinder to within approximately 0.0015
inch of the required oversized diameter. This will allow
enough stock for the final step of honing so that the
correct surface finish and pattern are obtained.
For the proper use of the refinishing equipment, follow
the instructions of the manufacturer. Only experienced
personnel should be allowed to perform this work.
Use a motor-driven, spring pressure-type hone at a
speed of 300-500 rpm. Hones of grit sizes 180-220 will
normally provide the desired bore surface finish. When
honing the cylinder bores, use a lubricant mixture of
equal parts of kerosene and SAE No. 20 Motor Oil.
Operate the hone in such a way as to produce a cross­
pattern should be at an angle of approximately 30
degrees to the cylinder bore.
After the final operation in either of the two refinishing
methods described and prior to checking the piston fit,
thoroughly clean the cylinder walls with detergent and
water solution, dry thoroughly and oil the cylinder walls.
Mark the pistons to correspond to the cylinders in which
they are to be installed. When the refinishing of all
cylinders that require it has been completed and all
pistons are fitted, thoroughly clean the entire block and
oil the cylinder walls.
Repairing Engine Castings Having Sand Holes or
Being Porous
Porosity or sand hole(s) which will cause oil seepage
or leakage can occur with modern casting processes. A
complete inspection of engine should be made. If the
leak is attributed to the porous condition of the cylinder
block or sand hole(s), repairs can be made with metallic
plastic (Epoxy Resin) (C6AZ 19554-A or an equivalent
material. Repairs with this metallic plastic (Epoxy
Resin) must be confined to those cast iron engine
component surfaces (Fig. 27) where the inner wall
surface is not exposed to engine coolant pressure or
oil pressure. For example:
a. Cylinder block surfaces extending along the
length of the block, upward from the oil pan rail
to the cylinder water jacket but not including
machined areas.
21-01-16 General Gasoline Engine Service 21-01-16

2. Mix the Epoxy Resin base and hardener as directed

on the container. Stir thoroughly until uniform.
FRONT AND LEFT SIDE
TYPICAL FOR 1-6 ENGINES

B 1 .................................... '-■-'■-’•■xem

SHADED AREAS MAY BE REPAIRED WITH EPOXY

3.

4.
Apply the repair mixture with a suitable clean tool
(putty knife, wood spoon, etc.) forcing the metallic
plastic into the hole or porosity.
Allow the repair mixture to harden. This can be
accomplished by two methods; heat cure with a 250
watt lamp placed 254mm (10 inches) from the
repaired surface, as directed on the package label,
or air dry for 10-12 hours at temperatures above
(!) 10°C (50°F).

-
0 REAR AND RIGHT SIDE
5. Sand or grind the repaired area to blend with the
general contour of the surrounding surface.
6. Paint the surface to match the rest of the block.
NOTE - PORTIONS OF THE REAR
SURFACE THAT ARE NOT MACHINED
OR NOT PART OF THE WATER
CLEANING AND INSPECTION
JACKET ARE REPAIRABLE
SHADED AREAS MAY BE REPAIRED The cleaning and inspection procedures are for a
WITH EPOXY complete engine overhaul; therefore, for partial engine

FRONT AND LEFT SIDE

op overhaul or parts replacement, follow the pertinent
cleaning or inspection procedure.
Crankcase Ventilation System
TYPICAL FOR V-8 ENGINES Refer to the Truck Pre-Delivery, Maintenance and
Lubrication Manual for the correct mileage interval for
NOTE - PORTIONS OF THE FRONT maintenance. Service, following procedures in the
SURFACE THAT ARE NOT MACHINED
OR NOT PART OF THE WATER
Engine/Emissions Diagnosis Manual.
JACKET ARE REPAIRABLE
SHADED AREAS MAY BE REPAIRED PCV System, Hoses and Tubes—Clean
WITH EPOXY
1. Remove the PCV system components, filler cap,
PCV valve, hoses, tubes, fittings, etc. from the
engine.
2. Clean the rubber ventilation hose(s) by passing a
suitable cleaning brush through each of them.
REAR ANO RIGHT SIDE
3. Thoroughly wash the rubber hoses in a low volatility
petroleum base solvent and dry with compressed
SHADED AREAS MAY BE REPAIRED WITH EPOXY A6428-1C
air.
4. Thoroughly wash the crankcase breather cap, if so
FIG. 27 Typical Cast Iron Cylinder Block Areas
Repairable with Metallic Plastic (Indicated by equipped, in a low volatility petroleum base solvent
Shaded Areas) and shake dry. Refer to the following procedure
under Crankcase Breather Cap—Clean.
b. Lower rear face of the cylinder block. 5. Thoroughly clean tubes, fittings and connections to
c. Intake manifold casting. Repairs are not assure unobstructed flow of emission gases.
recommended to the intake manifold exhaust Crankcase Breather Cap—Clean
crossover section since temperature can
exceed the recommended temperature limit of 1. Remove breather cap (oil filler) from rocker arm
260°C (500°F). cover.
d. Cylinder front cover on engines using cast iron 2. Remove cap from connecting hose.
material. 3. Wash cap in a low volatility—petroleum base
e. Cylinder head, along the rocker arm cover solvent.
gasket surface. 4. Shake dry; do not dry with compressed air.
The following procedures should be used to repair 5. Check cap for cracks and/or physical damage—
porous areas or sand holes in cast iron: replace if necessary.
1. Clean the surface to be repaired by grinding or 6. Reinstall breather cap to rocker arm cover and
rotary filing to a clean bright metal surface. Chamfer attach connecting hose.
or undercut the hole or porosity to a greater depth Exhaust Heat Control Valve—Bimetal Type
than the rest of the cleaned surface. Solid metal
must surround the hole. Openings larger than Application: 4.9L (300 CID)
6.35mm (1/4 inch) should not be repaired using
metallic plastic (Epoxy Resin). Openings in excess 1. Inspect valve assembly for any abnormal condition.
of 6.35mm (1/4 inch) can be drilled, tapped and Repair or replace as necessary.
plugged using common tools. Clean the repair area 2. Check valve and thermostatic spring operation by
thoroughly. Metallic plastic will not stick to a dirty or manually rotating the valve shaft. Valve must be
oily surface. free and return to the closed position when cold
21-01-17 General Gasoline Engine Service
(Rotunda choke tester or equivalent may be used if
necessary to cool bimetal spring). If valve cannot be
freed or closed, valve must be replaced.
3. Lubricate the valve with C0AZ-19A501-A or D7AZ-
19A501-A graphite lube or equivalent.
Exhaust Heat Control Valve—Vacuum
Operated—5.0L (302 CID) V-8
1. Inspect the valve assembly for any abnormal
condition. Service as necessary.
2. Remove the engine vacuum line from the valve.
Apply 33.77 to 67.54 kPa (10-20 inches Hg) of
vacuum to the vacuum motor using a hand vacuum
pump, and hold for 50 seconds. The valve must
close and not leak more than 6.75 kPa (2 inches Hg)
of vacuum. The valve must open when the vacuum
is released. If the valve fails either of these tests,
replace it.
3. Lubricate the valve and linkage with C0AZ-19A501-
A or C4AZ-19A501-A graphite lube or equivalent.
Intake Manifold Heat Control Valve—5.0L
(302 CID) V-8
1. Inspect the valve assembly for any abnormal
condition. Service or replace as necessary.
2. Remove the engine vacuum hose from the valve.
Apply 33.77 to 67.54 kPa (10-20 inches) of vacuum
to the vacuum motor using a hand vacuum pump.
Hold for 10 seconds. The valve must open and not
leak more than 3.38 kPa (one inch Hg) of vacuum.
The valve must close when the vacuum is released.
If the valve fails either one of these tests replace it.
3. Install the engine vacuum hose on the valve
assembly.
Valve Rocker Arm
Cleaning
Clean all the parts thoroughly. Make sure that all oil
passages are open.
On spherical and cylindrical fulcrum seat rocker arms,
make sure the oil passage in the push rod end of the
rocker arm is open.
If necessary, remove the plugs from both ends of the
rocker arm shaft to thoroughly clean the shaft passages.
Inspection
Inspect the pad at the valve end of the rocker arms for
indications of scuffing or abnormal wear. If the pad is
grooved, replace the rocker arm. Do not attempt to true
this surface by grinding.
On spherical and cylindrical fulcrum seat rocker arms,
check the fulcrum seat for excessive wear, cracks, nicks
or burrs. Check rocker arm studs and nuts for stripped or
broken threads, or looseness.
Valve Rocker Arm Covers
Check the gasket surfaces for damage caused by
over-tightened bolts. Straighten the surface as required
to restore original flatness.
21-01-17
Push Rods
Cleaning
Clean all push rods in a suitable solvent. On push rods
with an oil passage, blow out the passage with
compressed air.
Inspection
Check the ends of the push rods for nicks, grooves,
roughness or excessive wear.
The push rods can be visually checked for
straightness while they are installed in the engine by
rotating them with the valve closed. They also can be
checked with a dial indicator D78P-4201 -G or equivalent
(Fig. 28).
Cylinder Heads
Cleaning
With the valves installed to protect the valve seats,
remove deposits from the combustion chambers and
valve heads with a scraper and a wire brush. Be careful
not to damage the cylinder head gasket surface.
After the valves are removed, clean the valve guide
bores with a valve guide cleaning tool. Using cleaning
solvent to remove dirt, grease and other deposits, clean
all bolt holes; be sure the oil transfer passage is clean
(V-8 engines).
Remove all deposits from the valves with a fine wire
brush or buffing wheel.
Inspection
Inspect the cylinder heads for cracks or excessively
burned areas in the exhaust outlet ports.
Check the cylinder head for cracks and inspect the
gasket surface for burrs and nicks. Replace the head if it
is cracked.
On cylinder heads that incorporate valve seat inserts,
check the inserts for excessive wear, cracks or
looseness.
The following inspection procedures are for a cylinder
head that is to be completely overhauled. For individual
repair operations, use only the pertinent inspection
procedure.
Cylinder Head Flatness
When a cylinder head is removed because of gasket
leaks, check the flatness of the cylinder head gasket
surface (Fig. 29) for conformance to specifications
according to specific engine Sections. If necessary to
refinish the cylinder head gasket surface, do not plane or
grind off more than 0.254mm (0.010 inch) from the
original gasket surface.
DIAL -
INDICATOR, r
TOOL
A
L* J
TOO
♦l
HOLDING FIXTURE PUSH ROD
A1003-1D
FIG. 28 Checking Push Rod Runout
21-01-18 General Gasoline Engine Service 21-01-18

condition and the end of the stem for grooves or scores.

•13
CHECK DIAGONALLY
®8 CHECK ACROSS CENTER
Check the valve head for signs of burning or erosion,
1 warpage and cracking. Minor pits, grooves, etc., may be
removed. Discard severely damaged valves.
2
Inspect the valve springs, valve spring retainers, locks
and sleeves and discard any visually damaged parts.
iwf
hk Valve Face Runout
Check the valve face runout. It should not exceed the
IP- specified service limit. If the runout exceeds the service
limit, the valve should be replaced or refaced as outlined
V A2895-1A
under Refacing Valves in this Section.

Valve Stem Clearance

FIG. 29 Checking Cylinder Head Flatness—Typical
Valve Seat Runout
Check the valve seat runout with an accurate gauge
(Fig. 30). Follow the instructions of the gauge
manufacturer. If the runout exceeds the service limit,
reface the valve and valve seat.
Valve Seat Width
Measure the valve seat width (Fig. 21). Reface the
valve seat(s) if the width is not within specifications.
Refer to specific engine Section in this Manual.
Valves
The critical inspection points and tolerances of the
valve are illustrated in Fig. 26. Refer to specifications for
service limits. Refer to specific engine Section in this
Manual.
Inspect the valve face and the edge of the valve head
for pits, grooves or scores. Inspect the stem for a bent
Check the valve stem to valve guide clearance of each
valve in its respective valve guide with Tool-6505-E (111
32 valves) or the equivalent shown in Fig. 31. Use a flat
end indicator point.
Install the tool on the valve stem until it is fully seated,
and tighten the knurled set screw firmly. Permit the valve
to drop away from its seat until the tool contacts the
upper surface of the valve guide.
Position the dial indicator with its flat tip against the
center portion of the tool's spherical section at
approximately 90 degrees to the valve stem axis. Move
the tool back and forth in line with the indicator stem.
Take a reading on the dial indicator without removing the
tool from the valve guide upper surface. Divide the
reading by two, the division factor for the tool. If valve
stem to valve guide clearance exceeds the wear limit,
ream the valve guide for the next oversize valve stem as
previously described in this Section under "Valves".

DIAL INDICATOR
RUNOUT GAUGE
(TOOL—D81P-6002-E)

X.

* o
a
L

-'J.

X
as.
/
as
VALVE STEM CLEARANCE
TOOL
A7124IB
A1400-1D

FIG. 30 Checking Valve Seat Runout FIG. 31 Checking Valve Stem Clearano ■Typical
21-01-19 General Gasoline Engine Service 21-01-19

Valve Spring Pressure Intake Manifold

Check the valve spring for proper pressure (Fig. 32) at Cleaning
the specified spring lengths using Tool-6513-DD or Remove all gasket material from the machined
equivalent. Weak valve springs cause poor performance; surfaces of the manifold. Clean the manifold in a suitable
therefore, if the pressure of any spring is lower than the solvent and dry it with compressed air.
service limit, replace the spring.
Inspection
Valve Spring Squareness Inspect the manifold for cracks, nicked gasket
surfaces, or other damage that would make it unfit for
Check each spring for squareness using a steel further service. Replace all studs that are stripped or
square and a surface plate (Fig. 33). Stand the spring otherwise damaged. Remove all filings and foreign
and square on end on the surface plate. Slide the spring matter that may have entered the manifold as a
up to the square. Rotate the spring slowly and observe result of repairs.
the space between the top coil of the spring and square.
If the spring is out of square more than 1.984mm (5/64 Exhaust Manifolds
inch), replace it. Cleaning
Follow the same procedure to check new valve Remove all gasket material from the manifold(s).
springs before installation. Inspection
Make certain the proper spring (color coded) is On the 4.9L (300 CID) I-6 engine and 5.0L (302 CID)
installed. V-8 engine, check the exhaust control valve for freedom
from binding throughout the valve travel. If necessary,
free the shaft with exhaust control valve solvent. If the
solvent does not eliminate the binding condition, replace
the component parts. Refer to Exhaust Control Valve
APPLY TORQUE UNTIL
Replacement—4.9L Engine in this Section.
CLICK IS HEARD, READ
TORQUE WRENCH AND
Inspect the manifold(s) for cracks, damaged gasket
MULTIPLY READING surfaces, or other wear or damage that would make them
BY TWO / unfit for further service. Inspect the cylinder head joining
1 // flanges of the exhaust manifold(s) for evidence of
. /' exhaust gas leaks.
VALVE SPRING
TESTER
TOOL-6513-DD
Hydraulic Valve Tappets
The valve tappet assemblies should be kept in proper
■■ ■ sequence so that they can be installed in their original
.VALVE SPRING position. Inspect and test each tappet separately so as
not to intermix the internal parts. If any part of the
__ SET KNOB TO tappet assembly needs replacing, replace the entire
COMPRESSED
LENGTH OF SPRING
assembly.
Cleaning
A2917-1E Thoroughly clean all the parts in clean solvent and
wipe them with a clean, lint-free cloth.
FIG. 32 Checking Valve Spring Pressure Inspection
Inspect the parts and discard the entire tappet
assembly if any part shows pitting, scoring, galling or
evidence of non-rotation. Replace the entire assembly if
the plunger is not free in the body. The plunger should
drop to the bottom of the body by its own weight when
assembled dry.
CHECK SPECIFICATION
Assemble the tappet assembly and check for freeness
CLOSED COIL END DOWNWARD
of operation by pressing down on the push rod cup. The
tappets can also be checked with a hydraulic tester to
test the leak-down rate. Follow the instructions of the
test unit manufacturer or the procedure in this Section.
4* Camshaft
Clean the camshaft in solvent and wipe it dry. Inspect
the camshaft lobes for scoring and signs of abnormal
wear. Lobe wear characteristics may result in pitting in
the general area of the lobe toe. This pitting is not
detrimental to the operation of the camshaft; therefore,
the camshaft should not be replaced unless the
A2900-1F
camshaft lobe lift loss has exceeded specifications.
The lift of camshaft lobes can be checked with the
FIG. 33 Checking Valve Spring Squareness camshaft installed in the engine or on centers. Refer to
21-01-20 General Gasoline Engine Service
Camshaft Lobe Lift under Diagnosis and Testing in this
Section.
Replace the camshaft if the distributor drive gear is
broken or has chipped teeth.
Check the fuel pump eccentric (if so equipped) for
excessive wear.
Timing Chain and Sprockets
Cleaning
Clean all parts in solvent and dry them with
compressed air.
Lubricate the timing chain with engine oil before
installing it on the engine.
Inspection
Inspect the chain for broken links. Inspect the
sprockets for cracks and worn or damaged teeth.
Replace all the components of the timing chain and
sprocket assembly, if any one item needs replacement.
Inspect the fuel pump drive eccentric assembly for
scores, nicks and excessive wear. If the eccentric is
scored, replace it.
Timing Gears
Cleaning
Clean the gears in solvent and dry them with
compressed air.
Inspection
Inspect the gear teeth for scores, nicks, etc. Note the
condition of the teeth contact pattern. If the teeth are
scored, replace the gears.
It is necessary to replace the gears in sets. Also,
check backlash and runout.
Crankshaft Vibration Damper and Sleeve
Cleaning
Clean the oil seal contact surface on the 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, burrs or other imperfections which might damage
the oil seal during installation or cause premature seal
wear. Do not use crocus cloth to the extent that the
seal surface becomes polished. A finely polished
surface may produce poor sealing or cause
premature seal wear.
Inspection
Inspect the crankshaft damper or sleeve oil seal
surface for nicks, sharp edges or burrs that might
damage the oil seal during installation or cause
premature seal wear.
Crankshaft
Cleaning
Handle the crankshaft with care to avoid possible
fractures or damage to the finish surfaces. Clean the
crankshaft with solvent, and blow out all oil passages
with compressed air.
On a 4.9L engine, clean the oil seal contact surface at
the rear of the crankshaft with solvent to remove any
corrosion, sludge or varnish deposits. Excess deposits
that are not readily removed with solvent may be
21-01-20
removed with crocus cloth. Use crocus cloth to remove
any sharp edges, burrs or other imperfections which
might damage the oil seal during installation or cause
premature seal wear. Do not use crocus cloth to the
extent that the seal surfaces become polished. A
finely polished surface may produce poor sealing or
cause premature seal wear.
Inspection
Inspect the main and connecting rod journals for
cracks, scratches, grooves or scores.
Measure the diameter of each journal at least four
places to determine out-of-round, taper or undersize
condition (Fig. 34).
On an engine used with a manual shift transmission,
check the fit of the clutch pilot bearing in the bore of the
crankshaft. A needle roller bearing and adapter
assembly is used as a clutch pilot bearing. It is inserted
directly into the engine crank shaft. The bearing and
adapter assembly cannot be serviced separately. The
needle bearing clutch pilot can only be installed with the
seal end of the bearing facing the transmission. The
bearing and seal are pre-greased and do not require
additional lubrication. A new bearing must be installed
whenever a bearing is removed.
Inspect the pilot bearing, when used, for roughness,
evidence of overheating or loss of lubricant. Replace if
any of these conditions are found.
On the 4.9L (300 CID) I-6 engines, inspect the rear oil
seal surface of the crankshaft for excessively deep
grooves, nicks, burrs, porosity, or scratches which could
damage the oil seal lip during installation. Remove all
nicks and burrs and polish the chamfered edge and oil
seal contact surface with crocus cloth.
Check the runout of the flywheel mounting flange with
a dial indicator (Tools D78P-4201-F, -G or equivalent).
Flywheel
Automatic Transmission
Inspection
Inspect the flywheel for cracks or other damage that
would make it unfit for further service. Inspect the starter
ring gear for worn, chipped or cracked teeth. If the teeth
are damaged, replace the flywheel assembly.
A VSB = VERTICAL TAPER
C VS D = HORIZONTAL TAPER
A VS C AND B VS D = OUT OF ROUND
CHECK FOR OUT-OF-ROUND AT EACH END OF JOURNAL
TA /
B
/
I
I D
I
I
X
A2901-1C
FIG. 34 Crankshaft Journal Measurement
21-01-21 General Gasoline Engine Service
With the flywheel installed on the crankshaft, check
the gear face runout of the flywheel (refer to Diagnosis
and Testing for the proper procedure).
Flywheel
Manual-Shift Transmission
Inspection
Inspect the flywheel for cracks, heat checks, or other
damage that would make it unfit for further service.
Machine the friction surface of the flywheel if it is scored
or worn. If it is necessary to remove more than 1.143mm
(0.045 inch) of stock from the original thickness, replace
the flywheel.
Inspect the ring gear for worn, chipped, or cracked
teeth. If the teeth are damaged, replace the ring gear.
With the flywheel installed on the crankshaft, check
the flywheel face runout, following the procedure under
Diagnosis and Testing in this Section.
Main and Connecting Rod Bearing
Cleaning
Clean the bearing inserts and caps thoroughly in
solvent, and dry them with compressed air. Do not
scrape gum or varnish deposits from bearing shells.
Inspection
Inspect each bearing carefully. Bearings that have a
scored, chipped, or worn surface should be replaced.
Typical examples of bearings that should be replaced
and the causes are shown in Fig. 35. The copper-lead
bearing base may be visible through the bearing overlay
in small localized areas. This may not mean that the
bearing is excessively worn. It is not necessary to
replace the bearing if the bearing clearance is within
recommended limits. Check the clearance of bearings
that appear to be satisfactory with Plastigage or it’s
equivalent. Fit new bearings following the recommended
procedure in this Section.
Connecting Rods
Cleaning
Remove the bearings from the rod and cap. Identify
the bearings if they are to be used again. Clean the
connecting rod in solvent, including the rod bore and the
back of the bearing inserts. Do not use a caustic
cleaning solution. Blow out all passages with
compressed air.
Inspection
The connecting rods and related parts should be
carefully inspected and checked for conformance to
specifications. Various forms of engine wear caused by
these parts can be readily identified.
A shiny surface on the pin boss side of the piston
usually indicates that a connecting rod is bent or the
piston pin hole is not in proper relation to the piston skirt
and ring grooves.
Abnormal connecting rod bearing wear can be caused
by either a bent connecting rod, an improperly machined
journal, or a tapered connecting rod bore.
Twisted connecting rods will not create an easily
identifiable wear pattern, but badly twisted rods will
disturb the action of the entire piston, rings, and
connecting rod assembly and may be the cause of
excessive oil consumption.
21-01-21
•si
BRIGHT (POLISHED)
CRATERS OR POCKETS
SECTIONS
FATIGUE FAILURE IMPROPER SEATING
s \
SCRATCHES
DIRT IMBEDDED OVERLAY
J
INTO BEARING MATERIAL WIPED OUT
SCRATCHED BY DIRT LACK OF OIL
OVERLAY GONE
FROM ENTIRE SURFACE
RADIUS RIDE
TAPERED JOURNAL RADIUS RIDE
A2903-1A
FIG. 35 Typical Bearing Failures
Inspect the connecting rods for signs of fractures and
the bearing bores for out-of-round and taper. If the bore
exceeds the maximum limit and/or if the rod is fractured,
it should be replaced.
Check the ID of the connecting rod piston pin bore.
Install oversize piston pin if the pin bore is not within
specifications. Replace worn or damaged connecting
rod nuts and bolts.
After the connecting rods are assembled to the piston,
check the rods for bends or twists on a suitable
alignment fixture. Follow the instructions of the fixture
manufacturer. If the bend and/or twist exceeds
specifications, the rod must be straightened or replaced.
Pistons, Pins and Rings
Remove deposits from the piston surfaces. Clean gum
or varnish from the piston skirt, piston pins and rings with
solvent. Do not use a caustic cleaning solution or a
wire brush to clean pistons. Clean the ring groove with
a ring groove cleaner (Fig. 36). Make sure the oil ring
slots (or holes) are clean.
Inspection
Carefully inspect the pistons for fractures at the ring
lands, skirts, and pin bosses, and for scuffed, rough, or
scored skirts. If the lower inner portion of the ring
grooves have high steps, replace the piston. The step
will interfere with ring operation and cause excessive ring
side clearance.
Spongy, eroded areas near the edge of the piston top
are usually caused by detonation or pre-ignition. A shiny
surface on the thrust surface of the piston, offset from
the centerline between the piston pin holes, can be
caused by a bent connecting rod. Replace pistons that
show signs of excessive wear, wavy ring lands or
fractures, or damage from detonation or pre-ignition.
21-01-22 General Gasoline Engine Service
7
RING GROOVE CLEANER
(TOOL—D81 L-6002-D)
I J
V listed in the specific engine Section of this Manual, but
A2918-1C
FIG. 36 Cleaning Ring Grooves—Typical
Check the piston to cylinder bore clearance by
measuring the piston and bore diameters. Refer to the
specifications in the specific engine Section in this
Manual for the proper clearance. Refer to Cylinder Block
Inspection in this Section for the bore measurement
procedure. Measure the OD of the piston with
micrometers at the centerline of the piston pin bore
and at 90 degrees to the pin bore axis. Check the ring
side clearance following the procedure under Fitting
Piston Rings in this Section.
Replace piston pins showing signs of fracture, etching
or wear. Check the piston pin fit in the piston and rod.
Refer to Piston and Connecting Rod Assemblies, in the
specific engine Section.
Check the OD of the piston pin and the ID of the pin
bore in the piston. Replace any piston pin or piston that is
not within specifications.
Replace all rings that are scored, chipped or cracked.
Check the end gap and side clearance. It is good
practice to always install new rings when overhauling an
engine. Rings should not be transferred from one piston
to another regardless of mileage.
Cylinder Block
Cleaning
After any cylinder bore repair operation, such as
honing or deglazing, clean the bore(s) with soap or
detergent and water. Then, thoroughly rinse the
bore(s) with clean water to remove the soap or
detergent, and wipe the bore(s) dry with a clean, lint-
free cloth. Finally, wipe the bore(s) with a clean cloth
dipped in engine oil. If these procedures are not
followed, rusting of the cylinder bore(s) may occur.
If the engine is disassembled, thoroughly clean the
block in solvent. Remove old gasket material from all
machined surfaces. Remove all pipe plugs that seal oil
passages; then clean out all the passages. Blow out all
passages, bolt holes, etc., with compressed air.
Make sure the threads in the cylinder head bolt holes
are clean. Dirt in the threads may cause binding and
result in a false torque reading. Use a tap to true-up
threads and to remove any deposits.
Inspection
After the block has been thoroughly cleaned, check it
for cracks. Minute cracks not visible to the naked eye
may be detected by coating the suspected area with a
mixture of 25 percent kerosene and 75 percent light
engine oil. Wipe the part dry and immediately apply a
coating of zinc oxide dissolved in wood alcohol. Avoid
21-01-22
use of methanol substitute rubbing alcohol. If cracks are
present, the coating will become discolored at the
cracked area. Replace the block if it is cracked.
Check all machined gasket surfaces for burrs, nicks,
scratches and scores. Remove minor imperfections with
an oil stone. Check the cylinder block for flatness of the
cylinder head gasket surface following the procedure
and specifications recommended for the cylinder head.
The cylinder block can be machined to bring the cylinder
head gasket surface within the flatness specifications
not to exceed 0.254mm (0.010) inch stock removal
from the original gasket surface.
Replace all expansion-type plugs that show evidence
of leakage.
Inspect the cylinder walls for scoring, roughness, or
other signs of wear. Check the cylinder bore for out-of­
round and taper. Measure the bore with an accurate 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 angles
and parallel to the centerline of the engine (Fig. 28). Use
only the measurements obtained at 90 degrees to the
engine centerline when calculating the piston to cylinder
bore clearance.
Refinish cylinders that are deeply scored and/or when
out-of-round and/or taper exceed the service limits.
If the cylinder walls have minor surface damage, but
the out-of-round and taper are within limits, it may be
possible to remove such damage by honing the cylinder
walls and installing new service piston rings providing the
piston clearance is within specified limits listed in the
specific engine Section of this Manual.
To remove the cylinder wall glaze or to refinish a
cylinder bore, follow the honing procedure described
under Cylinder Block-Refinishing Cylinder Walls in this
Section.
Oil Pan
Cleaning
Scrape any dirt or metal particles from the inside of the
pan. Scrape all old gasket material from the gasket
surface. Wash the pan in a solvent and dry it thoroughly.
Be sure all foreign particles are removed from below the
baffle plate.
Inspection
Check the pan for cracks, holes, damaged drain plug
threads, and a loose baffle. Check the gasket surface for
damage caused by over-tightened bolts. Straighten the
surface as required to restore original flatness.
Replace the pan if repairs cannot be made.
Oil Pump
Cleaning
Wash all parts in a solvent and dry them thoroughly
with compressed air. Use a brush to clean the inside of
the pump housing and the pressure relief valve chamber.
Be sure all dirt and metal particles are removed.
Inspection
Refer to the specifications for the specific engine for
clearances and service limits.
Check the inside of the pump housing and the outer
race and rotor for damage or excessive wear or scoring.
21-01-23 General Gasoline Engine Service 21-01-23

Check the mating surface of the pump cover for wear. 2. Bring engine to normal operating temperature and
If the cover mating surface is worn, scored or grooved, turn off.
replace the pump.
Measure the inner rotor tip clearance (Fig. 37). 3. Remove oil drain plug and drain engine oil.

With the rotor assembly installed in the housing, place 4. Clean oil drain plug and inspect gasket. Replace
a straight edge over the rotor assembly and the housing. gasket if damaged.
Measure the clearance (rotor end play) between the
straight edge and the rotor and outer race (Fig. 38). Refer 5. Verify that gasket is properly located. Correct as
to specific engine Section for specification. required.
Check the drive shaft to housing bearing clearance by
6. Reinstall oil drain plug and tighten to specification.
measuring the OD of the shaft and the ID of the housing
bearing.
NOTE: If the oil filter is not to be changed, remove
Detail components of the oil pump are not serviced. If the oil filter cap and fill the crankcase with the
any part of the oil pump requires replacement, replace specified amount, type and grade of oil.
the complete pump assembly.
Inspect the relief valve spring for a collapsed or worn Reinstall the oil filler cap; start the engine and
condition. Check the relief valve spring tension inspect for oil leak(s). Correct as required.
according to specifications for specific engine.
Engine Oil Filter Change
Check the relief valve piston for scores and free
operation in the bore. 1. Disposable type oil filter change:
Engine Oil Change
A. Remove oil filter and discard.
1. Apply parking brake and block wheels.
B. Clean the gasket sealing surface at the cylinder
block or adapter.

C. Coat the gasket on the filter with a light film of

oil; screw the filter onto the adapter or cylinder
block, until the gasket contacts the sealing
surface; then, advance it an additional 1 /2 turn.

2. Replaceable element type oil filter change:

O
A. Place a drip pan under the filter. Remove the
o filter center bolt; then, remove the filter
o
assembly and gasket. Discard the gasket.

B. Remove the filter element, neoprene gasket,

spring and seat; then remove the center bolt
NOTE: INNER TO OUTER ROTOR
TIP CLEARANCE MUST NOT from the container and the fiber gasket from the
EXCEED 0.305mm (0.012 INCH) WITH
FEELER GAUGE INSERTED 12.7mm
bolt.
(1/2") MINIMUM AND ROTORS
REMOVED FROM PUMP HOUSING. C. Wash all parts in solvent. Make sure the
A576B-1C
openings in the bolt are clean.

FIG. 37 Checking Inner Rotor Tip Clearance D. Install the new filter element in the housing,
following the instructions furnished with the
STRAIGHT EDGE new element.
I £
4
E. Clean the cylinder block filter recess. Install a
new gasket.

F. Place the filter assembly in position and thread

1,/
/ ' <
the center bolt into the adapter, finger tight.
v - i
G. Rotate the filter assembly slightly, in each
direction, to make sure the gasket is seated
evenly.

O ** H. Tighten the filter center bolt to specification.

CAUTION: Make sure not to over-tighten the

) center bolt.

Remove the oil filler cap and fill the crankcase with the
specified amount, type and grade of oil. (Fig. 2).
FEELER GAUGE
* A1027 1B
Re-install the oil filler cap; start the engine and inspect
FIG. 38 Checking Rotor End Play for oil leak(s). Correct as required.
21-01-24 General Gasoline Engine Service 21-01-24

APPROXIMATE ENGINE OIL CAPABILITY

Engine U.S. Quarts U.S. Quarts Imp. Quarts Imp. Quarts Liters Liters
Displacement With Filter Without Filter With Filter Without Filter With Filter Without Filter
Change Change Change Change Change Change
4.9L (300 CID) I-6 6 5 5 4.1 5.6 4.7
5.0L (302 CID) V-8 6 5 5 4.1 5.6 4.7
5.8L (351 CID) W-V-8 6 5 5 4.1 5.6 4.7
7.5L (460 CID) V-8 6 5 5 4.1 5.6 4.7
CA1415-2J

FIG. 39 Engine Oil Capacities

TRANSMISSION GEAR
IGNITION TIMING FAST IDLE RPM POSITION DURING
SPECIFICATION ENGINE VACUUM HOSE
SPECIFICATION CURB IDLE RPM ADJUSTMENT
ROUTING (TYPICAL)
SPECIFICATION
/
FORD MOTOR COMtpXNY VACUUM HOSE ROUTING

VEHICLE EMISSION CONTROL IlWRMATIOtf vcv B 5X -

V REST til
SET FORKING BRAKE AND BLOCK WHEELS. MAKE CURB IDLE — PUT TRANSFUSION IN DRIVE —
>5 5
ALL ADJUSTMENTS WITH ENGINE AT NORMAL/ 1 - NON-A/C OR AC OFF\— KITH DASHPOT rVCV]
OPEF1ATING TEMPERATURE. ACCESSORIES AftD
HEAllLlGHTS OFF. PUT AIR CLEANER IN POSITION
COLLAPSED. ADJUSTVrO 600 RPM BY TURNING
SOLENOID BRACKET ADJUSTING SCREW. (525
•t
8!

w
WHEN CHECKING ALL ENGINE SPEEDS. / RPM FOR VEHICLE WI1H LESS THAN 100 MILES).
2 - A/C ON - PLACE A/C SELECTOR TO MAX. COOL­ Q
IGItfj

HOtc. WITH
____
* TIMING-^
DISCjONNECT AND PLUG DISTRIBUTOR VAC/jUM
MTK TRANS. IN NEUTRAL, ADJUST/HMING
ING POSITION AND DISCONNECT THE A/C ELEC­
TRO-MAGNETIC
i nvmnuni. i iv vlu i vr>.VlTH
CLUTCH v»i i n THE DASHPOTi
i nc unonrv
COLLAPSED. ADJUST TO 675 RPM BY TURNING
(T SA-FV
h
TO 3° BTDC, 800 RPM MAX. RECONNECT l/OSE. THE HEX NUT ON THE DASHPOT (600 RPM FOR
fast idle - Disconnect
__ And rmu plug v V:uum
v»> uum VEHICLE WITH LESS THAN 100 MILES). RECON­ o (egf?
HOSES AT Th _= C/'D
L1ACCC AT TL : EGR VALVE
WAI
__.............. AllA AT
X/C A1ID THE/'URGE
AT TUC
................. 111 lO/IC CV.
._____ NECT AC CLUTCH WIRE.
PUT FAST ICX E SCREW ON TAB HIGHER STEP OF
Tl\E HIGHE!
SEE SHOP MANUAL FOR CHOKE AND IDLE MIXTURE 'carb'
THE FAST 101 E CAM AND ADJUST TO 2250 RPM ADJUSTMENT INFORMATION
with trans IN NEUTRAL. '
1AL. (21(0 RPM FOR ENGINE
WITH LESS 1 -IAN 1( IILES). RECONNECT HOSES
ihFWis? VAC

n ____I

JJ-oCBch-J
I

i tw n____ '
THIS VEHICLE CONFORMS TO3U.U S E PA. REGULATIONS
APPLICABLE TO• 1983
1$
IPL
VEHICLES COMPLIANCE
YEAR NEW MOTOR
MOOEL YE>
DEMONSTRATED AND DE­
Uh rF)
s
SIGNED FOR PRINCIPAL USE BELOW 4000 FEET. FOR l____ -J
NEW VEHICLE COMPLIANCE ABOVE 4000 FEET, SEE cc
SERVICE PUBLICATIONS.
LL

E3AE-9CI45- SPARK PLUG: ASF-42 GAP .042- 046 AIR BPV VCV
OKS CATALYST 5.0L/3DM — SING^HJANK3DQ — DUAL TANK
DFM5.dW.AAF5 — EGJSAIP'OC FRONT OF VEHICLE c
SPARK PLUG
GAP SPECIFICATION
TRANSMISSION GEAR TYPE
TIMING RPM POSITION DURING ENGINE TYPE
SPECIFICATION ADJUSTMENT
TYPICAL VEHICLE EMISSION CONTROL INFORMATION DECAL V4225-2A
21-01-25 General Gasoline Engine Service 21-01-25

SPECIAL SERVICE TOOLS

GENERAL GASOLINE ENGINE SERVICE

Tool Number Description Tool Number Description
D79P-100-A Impact Slide Hammer T58T-6306-A Crankshaft Sprocket Remover
T50T-100-A Impact Slide Hammer T65L-6306-A Camshaft Gear Replacing Adapter
T59L-10O-B Impact Slide Hammer T58P-6316-D Crankshaft Damper Remover
T58L-101-A Puller Attachment T79T-6316-A Damper Remover/Replacer Tool
T72J-1177- Bearing Housing Seal Replacer T00L-6331- Upper Main Bearing Insert Remover & Replacer
T75L-4201-A & -B Clutch Housing Alignment Adapter T74P-6375-A Flywheel Holding Tool
D78P-4201-B Dial Indicator with Mag. Base T70L-6500-A Hydraulic Lifter Puller
D78P-4201-F, G Dial Indicator with Bracketry TOOL-650O-E Hydraulic Tappet Leakdown Tester
T00L-4201-C Dial Indicator with Bracketry T65T-6505-H Valve Stem Clearance Tool
T70P-6000- Engine Lifting Brackets T65P-6513-A Valve Spring Compressor
T75T-6000-A Engine Lifting Plate T70P-6513-A Tappet Bleed Down Wrench
D81P-6002-D Piston Ring Groove Cleaner T71B-6513-B Tappet Bleed Down Wrench
D81P-6002-E Valve Seat Runout Gauge T71 P-6513-A Tappet Bleed Down Wrench
T64L-6011-EA Cylinder Ringe Reamer TOOL-6513-ABA Valve Holdup Air Adapter
T70P-6011-A Camshaft Bearing Plug Installer T00L-6513-DD Valve/Clutch Spring Tester
T73L-6011-A Cylinder Hone Set T00L-6513-K Tappet Bleed Down Wrench
T61P-6019-B Front Cover Aligner T79T-6527-A Rocker Arm Stud Remover
T68P-6019-A Front Cover Aligner T79T-6527-B Rocker Arm Stud Replacer
T79T-6019-A Front Cover Aligner T62F-6565-A Valve Spring Compressor
T69P-6049-D Rocker Arm Stud Replacer TOOL-6565-AB Cup Shaped Adapter
T70P-6049-A Valve Spring Compressor T73L-6600-A Pressure Gauge
T76T-6049-A Compression Test Adapter D79P-6666-A Spark Plug Boot Puller
T79T-6070-A Front Seal Remover Adapters T74P-6666-A Spark Plug Wire Remover
T58P-6085-B Valve Guide Reamer Kit T75L-6666-A Plug Boot Installation Tool
T60K-6085-B Valve Guide Reamer Kit T65P-6701-A Rear Oil Seal Replacer
T68P-6135-A Piston Pin Remover/Replacer D79L-6731-A Oil Filter Wrench
D79L-6250-A Heavy Duty Reversible Ratchet D79L-6731-B Oil Filter Wrench
D79L-6250-B Ratchet Handle T65P-6A527-A Rocker Arm Stud Replacer
D79L-6250-C Ratchet Adapter T70P-6B070-A Front Cover Seal Replacer
D79L-625O-D Ratchet Adapter T70P-6B070-B Front Cover Seal Remover
T65L-625O-A Camshaft Bearing Set T62F-6A527-B3, B5 Rocker Arm Stud Replacer
T52L-6306-AEE Crankshaft Damper & Sprocket Replacer T77L-9533-B Plug Puller
CA6855-2D

ROTUNDA EQUIPMENT
Tool Number Description
072-00003 Rotunda Oil/Coolant Leak Tester
CA6526-1C