Start the engine and compare the engine idle condition to the prior idle condition. Check the crankcase ventila- 2. If the system is not restricted, further engine component diagnosis will have to be conducted to find the malfunction.
They also can. Clean the manifold in a suitable solvent and dry it with compressed air. Inspection Inspect the manifold for cracks, damaged gasket sur- faces, or other damage that would make it unfit for further FIG.
Replace all studs that are stripped or otherwise damaged. Cleaning With the valves installed to protect the valve seats, remove deposits fbm the combustion chamber and valve heads with a scraper aud a wire brush. Using cleaning solvent to remove dirt, grease and other Inspection deposits, clean all bolt holes. Remove all deposits from the valves with a fine wire Check the exhaust control valve for freedom from bind- 0 brush or buffing wheel.
If the solvent does not Inspection eliminate the binding condition, replace the component parts0 c Inspect the cylinder heads for cracks or excessively Inspect the manifold s for cracks, damaged gasket sur- burned areas in the exhaust outlet ports. Replace the head if it is the exhaust manifold s for evidence of exhaust gas leaks.
Make sure that all oil When a cylinder head is removed because of gasket passages are open leaks, check the flatness of the cylinder head gasket surface Make sure the oil passage in the push rod end of the Figure 9 for conformance to specifications. If necessary to rocker arm is open. Inspect the pad at the valve end of the rocker arms for indications of scufing or abnormal wear.
If the pad is grooved9 replace the rocker arm Do not attempt to true this surface by grinding, Check the rocker arm adjusting,screws and the push rod end of the rocker arms for stripped or broken threads, and the ball end of the adjusting screw for nicks, scratches, or excessive wear,.
Check the rocker arm stud and nut for stripped or broken A A threads. Follow the instructions of the gauge manufacturer. If Clean the push rods in a suitable solvent.
Blow out the oil the runout exceeds the wear limit, reface the valve and valve passage in. Runout Gouge mately 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. Weak valve springs cause poor performance; therefore, if the pressure of any spring is lower than the wear limit, replace the spring.
Reface the valve seat s if the width is not within specifications. Refer to specifications for wear FIG. Inspect the valve face and the edge of the valve head for pits, grooves or scores. Inspect the stem for a bent condition and.
Minor pits, grooves, etc. Stand the spring and square on end on the surface piate. Slide the spring up to the square. If the spring is out-of- Check the valve face runout. It should not exceed the square more than inch, replace it. If the runout exceeds the wear limit, the Follow the same procedure to check new valve springs valve should be replaced or refaced as outlined under Refac- before installation.
Make certain the proper spring color coded is installled. Use a flat end indicator point. Install the tool on the valve stem until it is fully seated, THAN 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. ERS The valve lifter assemblies should be kept in proper sequence so that they can be installed in their original posi- tion.
Inspect and test each lifter separately so as not to intermix the internal parts. If any part of the lifter assembly FIG. Cleaning operation of the camshaft; therefore, the camshaft should Thoroughly clean all the parts in cleaning solvent and not be replaced unless the camshaft lobe lift loss has ex- wipe them with a clean, lint-free cloth.
The lift of the camshaft lobes can be checked with the camshaft installed in the engine or on centers. Refer to Camshaft Lobe Lift. Check the distributor drive gear for broken or chipped Snspection teeth. Inspect the parts and discard the entire lifter assembly if any part shows pitting, scoring, galling or evidence of non- rotation.
The plunger should drop to the bottom of the body by its own weight when assembled dry. CRANKSHAfl Assemble the l[ifter assembly and check for freeness of Cleaning operation by pressing down on the push rod cup, The lifters Handle the crankshafi with care to avoid possible frac- can also be checked with a hydraulic tester to test the tures or damage to the finished supfaces.
Clean the crankshaft leak-down rate0 Follow the instructions of the test unit man- with solvent, and blow out all oil passages with compressed ufacturer or the procedure in this manual. Clean the oil seal contact surface at the rear of the crankshaft with solvent to remove any corrosion, sludge or varnish deposits. A finely polished surface may produce psor sealing QFcause prexna- ture seal wear. Note the condition of the teeth contact pattern.
Measure the diameter of each journal in at least four places to determine out-of-round, taper or undersize condi- tion Figure 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.
Inspection Inspect the crankshaft damper or sleeve oil seal surface FIG. The bushing is pressed into the crankshaft and Clean the camshaft in solvent and wipe it dry. Inspect the should not be loose, Inspect the inner surface of the bushing camshaft lobes for scoring and signs of abnormall wear for wear or a bell-mouth condition. Check the ID of the Lobe wear characteristics may result in pitting in the general bushing Figure Replace the bushing if it is damaged or area of the lobe toe, This pitting is not detrimental to the the ID is not within specifications.
Inspect the pilot bearing, when used, for roughness, Check the ID of the connecting rod piston pin bore. Replace if any Reolace the connecting rod if the pin bore is not within of these conditions are found. Replace defective connecting rod nuts and Inspect the rear oil seal surface of the crankshaft for bolts.
Remove all nicks and burrs and polish the chamfered fixture. Follow the instructions of the fixture manufacturer. 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 ciean pistons. Clean the ring groove with a ring groove cleaner Figure Make sure the oil ring slots or holes are clean.
Machine the friction surface of the flywheel if it is scored or FIG. If it is necessary to remove more than 0. Inspection Inspect the ring gear for worn, chipped, or cracked teeth. Carefully inspect the pistons for fractures at the ring If the teeth are damaged, repiace the ring gear, lands, skirts and pin bosses, and for scuffed, rough, or With the flywheel installed on the crankshaft, check the scored skirts.
If the lower inner portion of the ring grooves flywheel face runout, following the procedure under Diag- have high steps, replace t-he piston. The step will interfere nosis and Testing. A shiny sur- Cleaning face on the thrust surface of the piston, offset from the Remove the bearings from the rod and cap.
Identify the centerline between the piston pin holes, can be caused by a bearings if they are to be used again. Clean the connecting bent connecting rod. Replace pistons that show signs of rod in solvent, including the rod bore and the back of the excessive wear, wavy ring lands or fractures, or damage inserts.
Do not use a caustic cleaning solution. Blow out all from detonation or pre-ignition. Check the piston to cylinder bore clearance by measur- ing the piston and bore diameters. Refer to the specifications Inspection for the proper clearance. Refer to Cylinder Block Inspection The connecting rods and related parts should be care- for the bore measurememt procedure.
Measure the QD of the fully inspected and checked for conformance to specifica- piston tith micrometers at the centerjline of the piston bore tions Various forms of engine wear caused by these parts and at! Check the piston pin fit in the piston and rod.
Refer to grooves. Pistons and Connecting Rods Assembly in the pertinent Abnormal connecting rod bearing wear can be caused by engine section. Replace any piston pin or piston that is not Twisted connecting rods will not create an easily identi- within specifications. Check the end gap and side clearance. Rings should not be transferred from one Inspect the connecting rods for signs of fractures and the piston to another regardless of miieage.
Replace Clean the bearing inserts and caps thoroughly in solvent, the connecting rod if the bushing is so worn that it cannot be and dry them with compressed air. Do not scrape gum or reamed or honed for an oversize pin. Inspect the cylinder walls for scoring, roughness9 or Inspect each bearing carefully. Bearings that have a other signs of wear. Check the cylinder bore for out-of- scored, chipped, or wofar surface should be replaced.
Typi- round and taper. Measure the bore with an accurate bore cal examples of bearings that should be replaced and the gauge following the instructions of the manufacturer. Mea- causes are shown in Figure The copper-lead bearing base sure the diameter of each cylinder bore at the top9 middle may be visible through the bearing overlay.
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. 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 lugs that seal oil passages; then clean out all the passages. Make sure the threads in the cylinder head bolt holes are clean. Dirt innthe 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 FIG.
If cracks are present, the coating will become discolored at the cracked area. Replace the block if it is Cleaning cracked. Scrape any dirt or metal particles from the inside of the Check all machined gasket surfaces for burrs, nicks, pan, Scrape all old gasket material from the gasket surface.
Remove minor imperfections with an Wash the pan in a solvent and dry it thoroughly. Be sure all oil stone. Check the cylinder block for flatness of the cylin- foreign particles are removed from below the baffle plate. The cylinder Inspection block can be machined to bring the cylinder head gasket Check the pan for cracks, holes, damaged drain plug surface within the flatness specifications, but not to exceed threads, and a loose baffle. Check the gasket surface for 0.
Straighten the sur- Replace all expansion-type plugs that show evidence of face as required to restore original flatness. Replace the pan if repairs cannot be made. Basic Engine Use a brush to clean the inside of the pump housing and the pressure relief valve chamber. Be sure all dirt and metal particles are removed. Inspection Refer to the specifications for clearances and wear limits. Check the inside of the pump housing and the outer race and rotor for damage or excessive weti or scoring.
Check the mating surface of the pump cover for wear. If the cover mating surface is worn, scored or grooved, replace the cover. Measure the outer race to housing clearance Figure With the rotor assembly installed in the housing, place a straight edge over the rotor assembly and the housing.
Mea- A Inspect the relief valve spring for a collapsed or worn conditiona Check the relief valve spring tension. The oil filler tube breather cap, located on the valve rocker arm cover, should be cleaned at the proper mileage interval.
Remove the cap and wash it in a low-volatility, petroieuti-base solvent. Shake the cap dry and install it. Do FIG. The outer race, shaft and rotor are replaceable only as an Clean the crankcase ventilation system connection s on assembiy. This is important so that the more than 0. Be sure that Remove all burrs or scratches with an oil stone.
Remove only enough stock to clean up If it becomes necessary to ream a valve guide Figure 2 1 pits and grooves or to correct the valve seat runout. After to install a valve with an qversize stem. The finished valve seat should contact the approximate center of the valve face.
To do this, coat the Refacing the valve seat should be closely coordinated seat with Prussian blue and set the valve in place. Rotate the with the refacing of the valve face so that the finished seat valve with light pressure. If the blue is transferred to the and valve face will be concentric and the specified interfer- center of the valve face, the contact is satisfactory.
If the blue is transferred to the bottom edge of the The valve refacing operation should be closely coordi- valve face, raise the valve seat. Be sure that the refacer grinding wheels are properly dressed. Remove only enough stock to correct the runout or to clean up the pits and grooves. The Metier- ence fit of the valve and seat should not be lapped outc Remove afl grooves or score marks from the end of the valve stem, and chamfer it as necessary.
Do not remove more than 0. If the journals are severely marred or exceed the wear limit, they should be refinished to size for the next undersize bearing. If the journal will not clean up to maximum undersize bearing available, replace the FIG. Too large a radius will result in Minor pits, grooves, etc. Discard bearing failure due to radius ride of the bearing. Crocus cloth may also be used as a polishing Discard any worn or damaged valve tram parts.
Measure the cylinder bore and select the piston to assure the proper clearance. When the bore diameter is in the lower one-third of the specified range, a red piston should be used. When the bore diameter is in the middle one-third a biue piston should be used. When the bore diameter is in the upper one-third, the 0. Measure the piston diameter to ensure that the specified clearance is obtained. It may be necessary periodically to use another piston red or blue that is either slightly larger or smaller to achieve the specified clearance.
If none can be fitted, reftih 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.
Follow the procedures outlined under Clean- ing and Inspection. Measure the piston 1. Clean crankshaft journals. When replac- Make sure the piston and cylinder block are at room ing standard bearings with new bearings, it is good prac- temperature 70 degrees F. After any refinishing opera- tice to fit the bearing to minimum specified clearance.
If tion allow the cylinder bore to cool, and make sure the the desired clearance cannot be obtained with a standard piston and bore are clean and dry before the piston fit is bearing, try one half of a 0. If fitting a main bearing, position a jack under counter- 1. Select the proper ring set for the size cylinder bore.
Do not 2. Position the ring in the cylinder bore in which it is going to place jack under front post of crankshaft. Support be used, crankshaft with jack so its weight will not compress 3. Push the ring down into the bore area where normal ring Plastigage and provide an erroneous reading.
Place a piece of Plastigage on bearing surface across full 4. Use caution Install cap and torque bolts to specifications. Do not turn 5. Measure the gap between the ends of the ring with a crankshaft while Plastigage is in place. If the ring gap is less or greater 5. Remove cap. Using Plastigage scale, check width of Plas- than the specified limits, try another ring set.
Check 6 Check the ring side clearance of the compression rings at narrowest point to get maximum clearance. Difference with a feeler gauge inserted between the ring and its between readings is taper of journals lower land Figure 27 The gauge should slide freely 6.
If clearance exceeds specified limits, try 0. Bearing clearance must be within specified portion of the lower land. If the lower lands have high limits. If standard and 0. Install bearing cap. Torque cap bolts to specifications. Repeat procedure for remaining bearings that require replacement.
The standard size pistons are color coded red or blue, or have JO3 O. Refer to the Speciflca- tions for standard size piston dimensions. Only experienced per- piston pin bore and bushing in the connecting rod. Pistons sonnel should be allowed to perform this work.
The piston pins should not be speed of rpm. Hones of grit sizes will nor- interchanged. When honing the cylinder bores, use a lubricant mixture of equal parts of kerosene and SAE No.
If the pad at the valve end of the rocker arm has a After the final operation in either of the two refinishing grooved radius, replace the rocker arm.
Do not attempt to methods described and prior to checking the piston fit, true this surface by grinding. Mark the pistons to correspond to the cylinders in which they are to be in- stalled. 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.
A com- FIG. If the leak is attributed to the porous condition of the cylin- der block or sand hole s , repairs can be made with metallic plastic Part No. Do not repair cracks with this materiak Repairs with this metallic plastic must be Following the procedures under Push Rod Inspection, confined to those cast iron engine component surfaces check the push rods for straightness.
Do not attempt to straighten push rods. Lower rear face of the cylinder block. Intake manifold casting. I-Ioning is recommended for refinishing cylinder walls 4, Cylinder front cover on engines using cast iron material.
Cylinder head,, along the rocker arm cover gasket fitting pistons to the specified clearance. The grade of hone surface. Follow the instructions of the hone manufacturer. Clean the surface to be repaired by grinding or rotary en0u material so that all hone marks can be removed with filing to a clean bright metal surface. Chamfer or un- the finishing hone which is used to obtain the proper piston dercut the hole or porosity to a greater depth than the clearance, rest of the cleaned surface.
Before any repaired using metallic plastic. Openings in excess of cylinder is refmished, ail main bearing caps must be in place inch can be drilled, tapped and plugged using and tightened to the proper torque so that the crankshaft common tools Clean the repair area thoroughly. Mix the metallic plastic base and hardener as directed Refinish only the cylinder or cylinders that require it, All on the container.
Stir thoroughly until uniform. Apply the repair mixture with a suitable clean tool therefore, various sizes of pistons can be used without up- putty knife, wood spoon, etc. Refinish the cylinder with the most wear first to deter- d.
Allow the repair mixture to harden. This can be ac- mine the maximum oversize. If the cylinder will not clean up complished by two methods: heat cure with a when refinished for the maximum oversize piston recom- degree watt lamp placed 10 inches from the repaired mended, replace the block.
This will allow e. Sand or grind the repaired area to blend with the enough stock for the final step of honing so that the correct general contour of the surrounding surface.
Paint the surface to match the rest of the block. With No. Loosen the rocker arm stud nut until 1. Install an auxiliary starter switch. Space the marks approximately degrees apart so push rod with the fingers as the stud nut is tightened that, with the timing mark, the damper is divided into Figure Rotate the crankshaft until No. Check the breakaway 6.
Operate the engine and check for rough engine idle or a torque torque required to turn nut in a counterclockwise noisy lifter s. Valve clearance set too tight will cause direction of each stud nut. Replace the stud nut if the rough idle and valve clearance set too loose will cause a breakaway torque does not meet specifications. If, after noisy lifter s. If it has been determined that these condi- replacing the stud nut, the breakaway torque still is not tions are caused by improper valve clearance, readjust within specifications, replace the stud.
Remove the air cleaner. Connect the air inlet hose to the oil fill cap and carburetor 2. Grasp the crankcase ventilation regulator valve and pull air cleaner. Install the air cleaner. Operate the engine and check for 3. Remove the regulator valve from the vent hose and re- leaks. ARM 4. Remove the inlet tube from the intake manifold. Remove the air inlet hose from the oil fill cap and car- Removal buretor air cleaner.
Disconnect the inlet air hose at the oil fill cap. Disconnect the throttle rod from the carburetor throttle Installation lever. Remove the cable retracting spring. Remove the 1. Install the inlet tube in the intake manifold. Instail the hose on the inlet tube in the intake manifold.
Install the regulator valve in the hose. Remove the crankcase ventilation regulator valve from 3. Insert the regulator valve into the rocker arm cover the valve rocker arm cover, if so equipped.
Remove the mounting grommet. Removal Inspect the rocker arm cover bolts for defective seals under the bolt heads and replace as necessary. If removal of Remove the air cleaner. Disconnect the choke cable at the rocker arm stud is necessary, refer to the procedure in the carburetor. Disconnect the throttle rod from the car- this section. The valve rocker arm assembly is shown in Figure Disconnect the fuel inlet line and the distributor vacuum line from the carburetor.
Lift the manifold assemblies from the 6A engine. Remove and discard the gaskets. To separate the manifolds, remove the nuts --joining the intake and exhaust manifolds. If one of the manifolds is to be replaced, remove the tube FIG. Also install new studs in Installation the new manifold. Apply Lubriplate to the top of the valve stem and at the 3. If the intake-and exhaust manifolds have been separated, push rod guide in the cylinder head.
Install the valve manifold. Install the lock washers md nuts. Tighten them rocker d studnut, Adjust the valve finger tight. InstaN a new intake manifold gasket. Clean the valve rocker arm cover id the cylinder head Place the manifold assemblies in position against the gaske pply oil-resistant sealer to one side of a cylinder head. Make sure that the gaskets have not become new 6 Lay the cemented side of the gasket in dislodged.
Make sure the If the intake and exhaust manifolds were separated, gasket seats evenly allt around the head. Partially tighten tighten the nuts joining them. Connect the crankcase vent hose to the intake manifold Then torque the bolts to specifications in the same inlet tube and position the hose clamp.
Connect the fuel inlet line and the distributor vacuum line 1 the mkcase ventilation regulator valve in the to the carburetor. Apply Lubriplate to the rocker arm fulcrum seat and the Removal fulcrum seat socket in the rocker arm. Position the rocker arms and tighten the stud nuts just enough to If the cylinder head is to be replaced, follow the proce- hold the push rods in position.
Adjust the vaive clear- dures under Cylinder Head Disassembly and Assembly. Transfer all valves, springs, seals, spark plugs, etc. Coat one side of a new cylinder head. Clean and inspect all parts, reface the new valve rocker arm cover gasket with oil-resistant valves and check valve guide clearances before assembling sealer.
Lay the cemented side of the gasket in place in the used parts to the new cylinder head. Position the cover, making sure that the 1. Drain the cooling system. Install the 2. Remove the crankcase ventilation regulator valve, if so center to specifications. Disconnect the Connect the spark plug wires to the spark plugs. Connect the crankcase vent hose to the inlet tube in the 4. Disconnect and remove the carburetor fuel inlet line and intake manifold.
Install the crankcase ventilation reg- the distributor vacuum line. Disconnect the choke cable at the carburetor and posi- Position the fuel inlet line and the distributor vacuum tion the choke cable and housing out of the way.
Connect the distributor vacuum line 6. Disconnect the throttle rod from the carburetor throttle to the distributor and carburetor. Connect the car- lever. Disconnect the radiator upper hose at the coolant outlet Connect the throttle rod to the carburetor throttle lever. Connect the choke cable to the carburetor. Remove the coil bracket attaching bolt and position the Connect the radiator upper hose to the coolant outlet coil out of the way.
Remove the valve rocker arm cover. Loosen the rocker Fill and bleed the cooling system. Operate the engine until engine temperatures have Remove the valve push rods in sequence and identify stabilized. Adjust the engine idle speed and idle fuel mixture. Check for fuel, oil and coolant leaks. Disconnect the spark plug wires at the spark plugs. Remove the cylinder head bolts.
Install the cylinder head lifting eyes in the locations shown in Figure Lift the cylinder head and intake Broken valve springs or defective valve stem seals and and exhaust manifolds assembly off the engine. Do not retainers may be replaced without removing the cylinder pry between the head and block as the gasket surfaces head providing damage to the valve or valve seat has not may become damaged.
Disconnect the throttle rod from the carburetor throttle lever. Disconnect the choke cable at the carburetor. Remove the crankcase ventilation regulator valve from the valve rocker arm cover and remove the valve rocker arm cover. Remove the applicable spark plug. Install an air line adapter in the spark plug hole Figure. Installation 33 and connect the air line. Clean the cylinder head and cylinder block gasket - sur- faces. Clean the exhaust pipe.
If the cylinder head was removed for a cylinder head dw Tool-6SABA1 gasket replacement, check the flatness of the head and block gasket surfaces.
Position the gasket over the dowel pins on the cylinder block. Install lifting eyes on the cylinder head in the location shown in Figure 32 and use a floor crane and lifting sling to lift the cylinder head over the cylinder block. Lower it carefully until it is properly positioned on the block and dowel pins. Remove the hoist and lifting eyes. Coat the threads of the cylinder head bolts with engine oil. Install the bolts. The cylinder head bolts are tightened in three progres- sive steps.
Follow the sequence shown in Figure Torque the bolts to specifications. Apply Lubriplate to both ends of the push rods. Install the push rods in their original bores, positioning the lower end of the rods in the valve lifter sockets.
Install the stud Removal nut and position the compressor tool as shown in Figure 1. Remove the crankcase ventila- Remove and dis- 2.
Discon- card the valve stem seal Figure 34 nect the throttle cable at the carburetor, 3. Remove the coil. Remove the valve rocker arm cover, 5. Disconnect the spark plug wires at, the spark plugs and the secondary high tension wire from the coil. Remove the distributor cap and spark plug wire assembly. Loosen the rocker arm stud nut s until the rocker arm s can be disengaged from the push rod s.
Remove the push rod s. Remove the valve lifter s with the tool shown in Figure If more than one push rod and valve lifter is removed, do it in sequence and place the parts in a rack so they can be installed in their original locations.
If this condition occurs9 remove the 2. Apply Lubriplate to the cam lobe contact surface of the cylinder head for further inspection. Coat the rest of the valve lifter s with If air pressure has forced the piston to the bottom of the engine oil.
Install the valve lifters with the tool shown in cyihder, any removal of air pressure will allow the valve to Figure Rotate-the valve and check the valve stem tip for eccentric movement during rotation. Move the valve up and down through normal travel in valve guide and check the stem for binds. Installation A A. Apply Lubriplate to both ends of the push rod s. Install Compress the valve spring and install the valve spring the push rod s in sequence Engage the rocker arm s retainer locks, Remove the compressor tool and stud nut.
Apply Lubriplate to both ends of the push rod. Install the sufficiently to hold the push rod s in place. Apply Lubriplate to the Mcrum seat and socket Install 4.
Adjust the valve clearance, following the procedure the valve rocker arm, fulcrum seat and stud nut. Adjust given on page f Coat one side of new gaskets with oil-resistant sealer and page l under Valve Clearance Adjustment. Turn off the air and remove the air line and adapter. Instail the push rod cover and the Install the spark plug and connect the spark plug wire.
Torque the cover screws in sequence 5. Clean the valve rocker arm cover. Coat one side of a new to specifications. Install the crankcase regulator valve in gasket with oil-resistant sealer. Position the gasket on the the rocker arm cover. Install the cover, making sure that the gasket seats attaching bolt. Install the cover bolts 7.
Install the distributor cap and spark plug wire assembly. Connect the throttle cable to the carburetor. Connect the Connect the choke cable to the carburetor. Install the crankcase ventilation regulator valve in the 9. Start the engine and adjust the valve rocker arm cover. Loosen the alternator adjust- ing arm bolt and remove the alternator drive.
Remove the fan and pulley. Disconnect the radiator lower hose and radiator supply line at the water pump. Remove the bolts attaching the water pump to the block. Remove the pump and gasket. Installation Before a water pump is re-installed, check it for damage. If it is damaged and requires repair, replace it with a new pump or install a rebuilt pump obtained from a Ford- Authorized Reconditionei.
If a new water pump is to be installed, remove the fittings from the old pump and install them on the new pump. Position a new gasket, coated on both sides with sealer, 2, Clean the cylinder front cover and the gasket surfaces of on the water pump. Coat the gasket surface of the block and cover with oil-resistant sealer. Position a new gas- Install the pump body on the block.
Install the pump attaching bolts, coated with sealer and torque the bolts to ket on the block. Connect the radiator lower hose, and radiator supply in the bore of the cover. Position the cover and pilot assembly over the end of the crankshaft and against the line.
Install the pulley and fan. Install the alternator belt block Figure 38 , being careful to align the cover flush and adjust the belt tension.
Fill and bleed the cooling system. Operate the engine and check for leaks. Install the alternator adjusting arm and cylinder front cover bolts. Removal 1, Drain the cooling system and crankcase. Remove the radiator. Remove the alternator adjusting arm bolt, loosen the drive belt and swing the adjusting arm out of the way. Remove the fan and drive belts.
Lubricate the crankshaft with a white lead and oil mix- ture to facilitate installation and removal of the damper. Lubricate the front oil seal rubbing surface on the damper inner hub and the inner surface sealing area of FIG.
Remove the oil pan and crankshaft. Install the damper on the crankshaft as related parts by following the procedure under Oil Pan shown in Figure Remove the oil pump screen and inlet tube assembly.
Remove the cylinder front cover and discard the gasket. It is good practice to replace the oil seal each time the cylinder front cover is removed. Drive out the old seal with a pin punch.
Clean out the recess in the cover. Installation 1. Coat a new seal with grease and install the seal Figure Drive the seal in until it is fully seated in the recess. After installation, check to be sure the seal is properly A A Toed-TWA positioned in the cover and the spring is properly posi- tioned in the seal.
Install the washer and cap screw. Torque the cap screw 6. Disconnect the spark plug wires at the spark plugs and to specifications. Apply oil-resistant sealer to the cavities between the tion coil.
Remove the distributor cap and spark plug rear main bearing cap and cylinder block Figure 40 wires assembly. Install a new oil pan rear seal in the rear main bearing 7. Disconnect the fuel outlet lines at the fuel pump. Re- cap and apply a bead of oil-resistant sealer to the ta- move the fuel pump mounting bolts and position the fuel pered ends of the seal. Install new side gaskets on the oil pan with oil-resistant 80 Disconnect the vacuum line at the distributor and the sealer Figure Position a new cylinder front cover primary wire at the coil.
Remove the distributor. Loosen the rocker 9. Clean and install the oil pump screen and inlet tube arm stud nuts, move the rocker arms to one side and assembly. Install the oil pan and related parts following remove the push rods in sequence. Place the push rods the procedure under Oil Pan Installation. Install the oil in a rack so they can be installed in their original level dipstick.
Install the water pump pulley, drive belts and fan. Ad- Remove the valve push rod cover; then remove the just all drive belt tensions to specifications. Install the valve lifters in sequence, using the tool shown in Figure radiator. Place the valve lifters in a tray or rack to facilitate Fill the crankcase. Operate the engine at fast idle and check all hose con- removed, nections and gaskets for leaks, Remove the cap screw and washer from the end of the crankshaft.
Remove the damper Figure Remove the oil pan and related parts by following the procedure under Qil Pan Removal. Check the camshaft end play, the timing gear backlash and the timing gear runout Turn the crankshaft to align the timing marks as shown in Figure Drain the cooling system and the crankcase.
Disconnect the throttle rod fkom the carburetor throttle lever. Disconnect the throttle at the carburetor and position out Remove the camshaft thrust plate screws Figure Remove the camshaft.
Avoid damaging the uxmskaft 4. Remove the radiator, lobes during removaL Press the camshaft out of the gear 5.
Loosen the alternator adjusting arm bolt and remove the in an arbor press Figure Remove the key, thrust drive belt. Clean the valve push rod cover ;ind cylinder block gas- ket surfaces. Apply oil-resistant sealer to one side of a new gasket and place the gasket on the push rod cover with the cemented side next to the cover.
Install the cover and torque the bolts in sequence to specifications. Apply Eubriplate to the valve pad on the rocker arms. Oil the valve stems with heavy SE engine oil. Align the valve rocker arms with the valves and push rods Tighten the rocker arm stud nuts sufficiently to hold the push rods in place. Adjust the valve clearance following instructions given in this part under Valve Clearance Adjustment.
Clean the valve rocker arm cover and cylinder head gasket surface. Apply oil-resistant sealer to one side ofa AA new gasket and install the gasket on the cover sealer side against cover. Install the cover and torque the FIG. Set the distributor rotor so-the points are about to open for No. Install the distributor. Check the points. If the camshaft timing marks are still aligned step 6 above , the points should be fully open in Installation No.
Install the distributor and hold-down clamp. Clean the fuel pump and cylinder block gasket surfaces. Oil the camshaft bearing journals and apply Lubriplate Install the fuel pump with a new gasket. Torque the to all the lobes. Install the camshaft and thrust plate. Torque the thrust plate attaching screws to 14, Install the distributor cap and spark plug wires as an specifications.
Connect the spark plug wires to the plugs and 4. Position the camshaft gear on the camshaft. Align the the secondary high tension wire to the coil. Connect the shoulder on the camshaft. Connect the 5. Crank the engine until the timing marks are aligned. Do choke cable and the hand throttle cable. Install the water pump pulley, cooling fan and drive iIl! Adjust the belt tension to specifications.
Clean the cylinder front cover and cylinder block gasket Install the radiator. Connect the radiator upper hose to surfaces. Install a new oil seal in the cylinder front the thermostat housing cover. Connect the lower hose cover. Clean the crankshaft damper and inspect it, fol- to the water pump. Fill the crankcase and cooling system. Start the engine and check for oil, coolant and fuel 7. Clean the oil pump screen. Clean the oil pan and the leaks. Adjust the ignition timing.
Connect the dis- gasket surfaces of the cylinder block. Install the oil tributor vacuum line to the distributor. Adjust the car- pump screen and inlet tube and oil pan, following the buretor idle speed and fuel mixture. Lubricate the valve lifters with heavy SE engine oil and install the lifters Figure 35 in the same bores from which they were removed.
Be sure the rotate the camshaft or crankshaft in the engine without the push rods were seated in the valve lifter sockets. Install the cylinder front cover, oil pan and related parts. Removal e following the procedures under Camshaft Installation.
Drain the cooling system and crankcase. Remove the cylinder front cover and oil pan, following 4. Fill the crankcase and the cooling systems. I've been looking for it for hours.
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