5.8l v8 - VIN [g] Ford LTD Crown Victoria I

ENGINE IDENTIFICATION

Note. For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION section.

Engine may be identified from the Vehicle Identification Number. VIN is stamped on metal tab attached to instrument panel near windshield on driver's side of vehicle and is visible from outside. VIN number is also stamped on Safety Certification Decal, mounted on left front door lock face panel and on Engine Identification Label mounted on valve cover.

The VIN number contains 17 characters. The eighth character identifies engine and the tenth character establishes model year. The 5.8L HO engine is only available as a Police package.

ENGINE IDENTIFICATION CODES

HYDRAULIC VALVE LIFTER ADJUSTMENT

Note. Repeated valve seat and face reconditioning operations will decrease valve stem to rocker arm clearance to a point that if compensation is not made, valve lifters will cease to function.

Scheme 1

1. To compensate for any dimensional changes in valve mechanism, a.060" (1.52 mm) shorter or.060" (1.52 mm) longer replacement push rod is available.
2. To determine whether or not longer or shorter push rod is necessary, clearance between rocker arm and valve stem must be checked. Use lifter bleed down wrench and slowly collapse valve lifter until plunger is bottomed. NOTE: Valve lifter must be completely collapsed when checking valve clearance.
3. Hold lifter down while checking clearance. Procedure for checking valve clearance is as follows: COLLAPSED LIFTER CLEARANCE Allowable Desired 0.098-.198" (2.49-5.03 mm) 0.096-.146" (2.44-3.70 mm)
4. Rotate crankshaft until No. 1 piston is at TDC (point "A" in (Scheme 1) ) after compression stroke as indicated by timing mark on crankshaft damper and pointer. Make chalk mark on damper 180° (point "B") from TDC mark. Make chalk mark on damper 90° (point "C") clockwise from TDC mark. (Scheme 1): Positions to Place Crankshaft Damper When Making Hydraulic Lifter Adjustment Check to determine if longer or shorter push rod is necessary.
5. With damper at point "A", check valve clearances as shown in chart under "A". Rotate crankshaft 180° clockwise from point "A" so that point "B" is opposite pointer. Check clearances as listed for point "B" in chart. Rotate crankshaft 270° clockwise from point "B" so point "C" is opposite pointer. Check clearances for "C" as listed in chart. VALVE ADJUSTMENT CHART Dimension & Engine Adjust Valves Point "A" Intake Nos. 1, 4 and 8. Exhaust Nos. 1, 3 and 7. Point "B" Intake Nos. 3 and 7. Exhaust Nos. 2 and 6. Point "C" Intake Nos. 2, 5 and 6. Exhaust Nos. 4, 5 and 8.
6. If clearance is less than specified, install shorter push rod; if greater than specified, install longer push rod.

ENGINE

1. Drain cooling system and crankcase. Mark hinges for reinstallation and remove hood. Disconnect battery cables from engine block. Remove air cleaner and intake duct assembly. Remove upper and lower radiator hoses.
2. Disconnect transmission oil cooler lines from radiator. Remove fan shroud attaching bolts. Remove radiator, fan, spacer, belt pulley and shroud. Remove alternator bolts and position out of way.
3. Disconnect oil pressure sending unit wire from sending unit. Disconnect low oil level sensor wire (if equipped). Remove flexible fuel line at fuel tank and plug fuel tank line. Disconnect accelerator cable from carburetor. Disconnect TV rod on AOD transmissions. Disconnect speed control cable (if equipped).
4. Remove throttle valve vacuum line from intake manifold (if equipped). Disconnect transmission filler tube bracket from cylinder block. On air conditioning equipped vehicles, remove compressor. On power steering equipped vehicles, remove power steering pump bracket from cylinder head. Remove drive belt. Position power steering pump out of way.
5. Disconnect brake vacuum line from intake manifold. Remove heater hoses from water pump and intake manifold. Remove coolant temperature sending unit. Remove flywheel or converter housing-to-engine upper bolts. Disconnect primary wiring connector from ignition coil. Disconnect wiring-to-solenoid on left rocker arm cover. Remove wire harness from left rocker arm cover and position wires out of way. Remove ground strap from block.
6. Raise front of vehicle. Disconnect starter cable from starter. Remove starter. Remove muffler inlet pipes from exhaust manifolds. Disconnect engine support insulators from chassis. Disconnect downstream thermactor tubing and check valve from right exhaust manifold stud (if equipped).
7. Remove transmission cooler lines from retainer and remove converter housing inspection cover. Disconnect flywheel from converter. Secure converter assembly in housing. Remove remaining converter housing-to-engine bolts. Lower vehicle and support transmission. Attach engine lift sling. Hoist to lifting brackets on intake manifold.
8. Raise engine slightly and pull from transmission. Remove engine.

Removal

1. Disconnect negative battery cable and drain cooling system. Remove air cleaner, crankcase ventilation hose and intake duct assembly. Remove automatic choke heat tube.
2. Disconnect upper radiator hose at engine. Disconnect heater hose and water pump by-pass hose at intake manifold. Identify and disconnect all vacuum lines and electrical wires.
3. Remove distributor cap and wires as an assembly. Remove distributor. Disconnect fuel inlet line, accelerator cable and speed control linkage (if equipped) from carburetor.
4. Remove accelerator cable bracket. Disconnect fuel evaporative purge tube, if equipped. If vehicle is equipped with air conditioning, remove compressor from intake manifold brackets. Remove intake manifold bolts and manifold.

Note. Remove intake manifold and carburetor as an assembly.

Installation

1. Clean gasket mating surfaces. Apply oil resistant sealer at four junction points of seals and gaskets. Position front and rear seals on cylinder block and new gaskets on heads.
2. Make sure that holes in gaskets are aligned with holes in cylinder head. Position gaskets to interlock with seal tabs. Using guide pins, lower manifold in place.
3. Check for correct positioning of gaskets and seals before installing bolts. Remove guide pins. Install bolts and tighten, following sequence (Scheme 2) Reverse removal procedures to complete installation.
4. Start engine, check and adjust ignition timing. Operate engine until it reaches normal operating temperature, then retighten manifold bolts.

Intake Manifold Tightening Sequence Install intake manifold bolts and tighten in three steps. Scheme 2

1. On right side exhaust manifold, remove air cleaner, intake duct assembly and downstream air tube bracket (if equipped). Disconnect automatic choke heat tubes and exhaust pipe.
2. On left side manifold, remove oil dipstick, tube assembly, air cleaner and inlet duct assembly (if equipped). Remove speed control brackets, if equipped. Disconnect exhaust manifold from exhaust inlet pipe.
3. Remove spark plugs and wires. Disconnect exhaust gas oxygen sensor, if equipped. Disconnect exhaust manifold retaining bolts and remove manifolds.

1. Clean gasket mating surface mounting flange of exhaust manifolds and exhaust inlet pipes. Position exhaust manifolds on cylinder heads and install washers and retaining bolts.
2. Tighten retaining bolts from inside-to-outside in two steps. Install spark plugs and wires. Connect exhaust gas oxygen sensor, if equipped. To complete installation, reverse removal procedure.

CYLINDER HEAD

Note. Cylinder head should only be removed when engine is cold. Check cylinder head for warped gasket surface, nicks or damage. If cylinder head refinishing is needed, DO NOT machine more than .010" (.25 mm) from gasket surface. Replace head if cracked. Remove burrs or scratches with an oil stone.

1. Disconnect negative battery cable. Remove intake manifold and carburetor as an assembly. Remove valve covers. If equipped, discharge A/C compressor and disconnect refrigerant lines. Remove compressor.
2. If equipped, disconnect power steering pump and bracket. Remove drive belt from pump pulley and position to one side. Remove alternator mounting bracket bolt, air cleaner inlet duct, ignition coil and thermactor crossover tube (from rear of cylinder head).
3. If equipped, remove fuel line from clip at front of RH cylinder head. Disconnect exhaust inlet pipes at exhaust manifolds. Loosen rocker arm fulcrum bolts and rotate rocker arms to side. Remove push rods, keeping them in proper sequence for reinstallation in original positions.
4. On some engines it may be necessary to remove exhaust manifold to gain access to lower cylinder head bolts. Remove exhaust valve stem caps. Remove cylinder head bolts and cylinder head.

Note. If cylinder head is to be serviced, remove carbon deposits from combustion chamber with scraper and wire brush before removing valves. When disassembling, mark all valve components for proper reassembly.

1. Clean old gasket material from cylinder head and block. Check cylinder head and block gasket surface for warpage. Gasket surface maximum warpage is.003" (.08 mm) in any 6" (152 mm) and.006" (.152 mm) overall.
2. Position head gasket over dowels and onto block. Install cylinder head. Install bolts and tighten in 3 steps, following sequence (Scheme 3)
3. Clean push rods in solvent and blow out each oil passage with compressed air. Check ends of push rod for nicks, grooves or excessive wear. Ensure push rods are straight by checking with dial indicator and "V" block.
4. If runout exceeds.015" (.38 mm), replace push rod. DO NOT attempt to straighten push rod. Apply Ford Polyethylene Grease (DOAZ-19584-A) to rocker arm contact points and push rod ends during installation. Reverse removal procedures to complete installation.

Cylinder Head Tightening Sequence Tighten cylinder head bolts in 3 steps. Scheme 3

VALVE ARRANGEMENT

Note. When reconditioning valves, ensure interference angles of valve and seat are not lapped out. Remove all grooves and/or score marks from end of valve stem with an oil stone. DO NOT remove more than .010" (.254 mm) from end of valve stem.

E-I-E-I-E-I-E-I (Left bank, front-to-rear).

I-E-I-E-I-E-I-E (Right bank, front-to-rear).

VALVE GUIDE SERVICING

1. Valve guides are integral with cylinder head. Check valve stem-to-guide clearance. If clearance exceeds service limits, recondition valve guide. To check valve guide wear, insert tool (6505-E) onto valve stem until fully seated and tighten set screw. Permit valve to drop away from seat until tool contacts valve guide.
2. Attach dial gauge to cylinder head. Position gauge indicator against center portion of tool's spherical section at right angle. Move valve in guide and note guide wear shown on dial gauge. Divide reading by 2 (division factor for tool). Resulting measurement is valve stem clearance.
3. Maximum dial gauge reading for intake valve-to-guide clearance is shown in "Valves" specification table. Use valve guide cleaning tool for cleaning guides. To ream guides for installation of valves with oversize stems, use reamers in sequence and reface valve seat after valve guide is reamed.
4. Valve guide reamers are furnished in .003" oversize with standard diameter pilot, .015" oversize reamer with .003" oversize pilot and .030" oversize reamer with .015" oversize pilot.
5. If valve face is reground, check margin width dimension. Check valve seats for proper angle and seat width. Measure valve seat runout. Valve seat runout should be within .002" (.05 mm) for intake and exhaust. Valve seat must be refaced after guide has been reamed.
6. Intake and exhaust valve seat width is .060-.080" (1.52-2.03 mm). Use scraper to break (lightly chamfer or bevel) sharp top inside edge of guide. After valve guide repair, inspect valve stem end for wear before installation. Valve stem end may be reconditioned by grinding.

VALVE STEM OIL SEALS

1. If valve or valve seat has not been damaged, valve springs, seals and retainers may be replaced by holding affected valve against seat using air pressure. Cup or umbrella type seals are used on all valves. NOTE: An adapter can be constructed by welding an air hose connection to body of spark plug with porcelain removed.
2. Use Compressed Air Line Adapter (6513-ABA) installed in spark plug hole. A minimum of 140 psi (9.8 kg/cm 2 ) line pressure is required. If air pressure does not hold valve shut, valve is damaged or burnt and cylinder head must be removed for service.
3. With valve in head, install plastic seal protector cap over end of valve stem. Oil protector cap and start stem seal carefully over cap. Push seal down until seal jacket touches top of valve guide. Remove plastic seal protector cap. Using seal installer, bottom seal on valve guide.

1. Remove valve cover and spark plug on cylinder to be serviced. Be sure piston is at top of stroke with both valves closed. Install air line with adapter in spark plug hole. Apply minimum of 140 psi line pressure. NOTE: If air pressure fails to hold valve closed, remove cylinder head for inspection.
2. Remove required rocker arm and push rod. Use spring compressor to compress valve and remove retainer locks, sleeve, spring retainer and valve spring. Remove and discard valve stem seal. Do not remove air pressure as this will allow valve to fall into cylinder if piston has been moved to bottom of cylinder.
3. Check valve spring for out of square with 90° straight edge. Valve spring out of square service limit is .078" (1.98 mm) for intake and exhaust springs on all models. Check valve spring compression pressure and replace any spring not within specification.

1. Lubricate valve stem with engine oil and install new valve stem seal. Place spring in position over valve and install spring retainer. Compress valve spring and install locks. Check valve spring for proper installed height.
2. Remove air pressure and adapter and install spark plugs. Apply Ford Polyethylene Grease (DOAZ-19584-A) to ends of push rods and tip of valve stems. Install rocker arms and tighten.

VALVE SPRING INSTALLED HEIGHT

Installed height of valve spring must not exceed specification. Measure height from surface of cylinder head pad to underside of spring retainer. (Scheme 4) If height is greater than specified, install.030" (.76 mm) shim spacer on head under spring to bring height within limits.

Measuring Valve Spring Installed Height Check installed height and add spacer, if necessary. Scheme 4

VALVE SPRING INSTALLED HEIGHT

HYDRAULIC VALVE LIFTER ASSEMBLY

Note. Before replacing hydraulic lifter for noisy operation, be sure noise is not caused by improper collapsed lifter gap, worn rocker arms, push rods or valve tips. If lifter assembly is stuck in bore, use Hydraulic Lifter Puller (T70L-6500-A) or magnet.

1. Hydraulic lifter assemblies must be installed in original locations. Remove cylinder head and related parts. Using lifter remover or magnet, remove lifters. Clean and inspect but do not mix components or positions. Parts are select-fitted and are not interchangeable.
2. If lifter is sticking, disassemble and clean dirt, metal chips or varnish from components. If lifter check valve is not functional, obstructions may be preventing it from closing when cam lobe is moving lifter or check valve spring may be broken. Clean or replace components as necessary.
3. If plunger is not free in body of lifter, replace entire assembly. Plunger should drop to bottom of body by its own weight when assembled dry. Assemble lifter and check free operation by pressing down on cap. NOTE: If lifter has been disassembled and cleaned, be sure to fill with test fluid before installing in engine. New lifters already contain test fluid. When performing leakdown test, note that lifters cannot be checked with engine oil in them, only test fluid can be used.
4. Place lifter upright in Hydraulic Lifter Leak-Down Tester (6500-E), and check leakdown rate. Leak-down rate is 10-15 seconds measure at .0625" (1.59 mm) plunger travel, under 50 lb. (22 kg) load.
5. Inspect lifter base-to-cam lobe contact area. Surface must have smooth and convex contact face. Replace any lifter with flat or concave surface. Inspect related cam lobe for proper lobe lift, replace camshaft (and lifters if necessary) if any lobe is worn beyond specification.
6. Check lifter-to-bore clearance. Standard clearance is .0007-.0027" (.018-.069 mm). Service limit is .0050" (.130 mm) maximum. Standard diameter of lifter is .8740-.8745" (22.200-22.212 mm).

Exploded View of Valve Lifter Assembly Check lifter leakdown rate with test fluid in lifter. Scheme 5

HYDRAULIC ROLLER VALVE LIFTER ASSEMBLY

1. Remove intake manifold and related components. Remove valve covers and loosen rocker arm bolts. Rotate rocker arms out of way and remove push rods keeping them in order for reinstallation in original positions.
2. On 5.0L engines with roller lifters, push rods have a collar at upper end and can only be installed one way. Balls at each end of push rod are not identical.
3. Remove lifter guide retainer bolts. Remove retainer and lifter guide plates. Label guide plates for reinstallation in original position. Remove lifters. NOTE: Roller lifters must be installed in original position and orientation in bore so that roller rotates in same direction.
4. To install, reverse removal procedure. Lubricate lifter, lifter bore, rocker arms and fulcrum seats with engine oil. Apply Ford Polyethylene Grease (DOAZ-19584-A) to valve stem tips and push rod ends.

OIL PAN

1. Remove air cleaner, disconnect accelerator and kickdown rods at carburetor and remove accelerator mounting bracket. (With EEC, remove EGR valve and cooler.) Remove fan shroud bolts and position shroud over fan. Disconnect wiring from harness and remove wiper motor.
2. Disconnect windshield washer hose and remove wiper motor mounting cover. Remove dipstick and dipstick tube retaining bolt at exhaust manifold. With EEC, remove thermactor air dump tube retaining clamp and thermactor crossover tube at rear of engine.
3. On all models, raise vehicle and drain crankcase. With EEC, remove filler tube and drain transmission. Disconnect starter wiring, remove starter. On all models, disconnect fuel line from fuel pump and inlet pipes from exhaust manifold. CAUTION: Before disconnecting fuel lines on vehicles equipped with a high pressure electric fuel pump, relieve pressure at Schrader valve on fuel charging assembly.
4. With EEC, remove exhaust gas oxygen sensor from exhaust manifold and thermactor secondary air tube-to-converter housing clamps. Disconnect exhaust pipes to catalytic converter outlet. Remove catalytic converter secondary air tube and inlet pipes to exhaust manifold.
5. On all models, remove rear engine mount through bolts and shift crossover bolts at transmission. Disconnect transmission kickdown rod. Remove flywheel access cover. Remove brake line retainer from front crossmember. Using a jack, raise engine as far as possible.
6. Place support blocks between engine mounts and chassis brackets. Remove jack. Disconnect low oil sensor from oil pan, if equipped. Remove oil pan bolts and lower pan. Remove oil pump pickup tube assembly and place in oil pan. Remove oil pan.

Note. Vehicles equipped with dual sump oil pans require removal of both drain plugs to drain crankcase.

PISTON & ROD ASSEMBLY

Note. When removing ridge at top of cylinder bore, never cut into ring travel area more than .03125" (.794 mm). Before removing piston and connecting rod, ensure rod caps are marked to their related rods for proper reassembly. During removal, rotate crankshaft until piston assembly being removed is at bottom of stroke. DO NOT damage crankshaft journals or cylinder wall during removal.

1. With cylinder head and oil pan removed, inspect cylinder bores for ridges and/or deposits. Move piston to be removed to bottom of bore and cover with cloth to catch metal cuttings.
2. Remove ridge at top of cylinder bores (using ridge reamer) before removing pistons from block. Rotate crankshaft and inspect connecting rods and rod caps for cylinder identification. Mark them if necessary.
3. Remove rod nuts and cap. Install rubber sleeves on rod bolts and push each piston and rod assembly out top of cylinder bore. Take care not to nick crankshaft journal or cylinder wall. Remove bearing inserts from rod and cap and inspect for size, wear and damage. Install rod caps on mating rods.

Scheme 6

1. Check fit of new piston and/or rings in cylinder bore before assembling piston and pin to connecting rod. Check piston pin for clearance, etching or wear.
2. Oil piston rings and cylinder walls with light coat of engine oil. Ensure ring gaps are properly spaced on piston and install ring compressor on piston. (Scheme 6) (Scheme 6): Piston Ring Gap Spacing Check that ring gaps are properly spaced and manufacturers marks face up. NOTE: Notch or arrow on piston top should be toward front of engine.
3. Install rod bolt protectors before installing piston and rod assembly in bore. Tap gently with wooden handle to insert piston/rod assembly into cylinder bore. (Scheme 7)
4. After bearings have been inserted, apply oil to journals and bearings. Turn crankshaft throw to bottom of its stroke. Guide piston/rod assembly over crankshaft journal until rod bearing seats.
5. Match rod cap to rod and install cap. Tighten cap nuts in two steps. Repeat procedure for each piston assembly. After piston/rod assembly is installed, check side clearance between connecting rods on each crankshaft journal.

Piston and Connecting Rod Index Mark Locations With piston top arrow forward, numbers stamped on right of rod are for right bank and left for left bank. Scheme 7

FITTING PISTONS

1. Inspect pistons and replace any showing signs of excessive wear, wavy ring lands, or fractures. Replace piston if sponge-like or eroded surface is on edge of piston top (caused by detonation or pre-ignition).
2. Note if shiny surface on thrust side of piston is found, check for bent connecting rod. Replace piston and/or rod as necessary. Inspect connecting rods for signs of fracture and bearing bores for out of round and taper.
3. If bore exceeds recommended limits and/or rod is fractured, replace rod. Check pistons for fractures at ring lands, skirts and pin bosses. Check for scuffed, rough or scored skirts.
4. Check piston-to-cylinder bore clearance by measuring piston and bore diameters. Inspect cylinder walls for scoring, roughness or other signs of wear. Check bore for out-of-round and taper. Cylinder bore out-of-round should be .0015" (.038 mm) and service limit is .005" (.127 mm).
5. Cylinder bore taper should not be more than .010" (.25 mm). Measure diameter of cylinder bore at top, middle and bottom with gauge at right angle and parallel to centerline of engine. Measure outer diameter of piston at centerline of pin bore and 90° to pin bore axis.
6. If cylinder wall is severely marred and/or worn beyond specifications, refinishing will be necessary. Before any cylinder refinishing, ensure that main bearing caps are in place and tightened to specification to avoid distorting during refinishing operation.
7. After refinishing and before measurement, clean bore with soap/water solution and oil cylinder walls. Ensure piston and cylinder bore are clean, dry and at room temperature 70°F (21°C) during measurement. After any refinishing operation, allow bore to cool.

PISTON SIZE CODE CHART

FITTING PISTON RINGS

1. Clean ring grooves with ring groove cleaner or piece of broken ring. Ensure oil holes (or slots) in piston are clean. Measure piston ring side and end gap clearance for all pistons. Maximum piston ring side gap clearance is .006" (.152 mm).
2. Ring side clearance should be checked with feeler gauge between ring and piston lower ring land. Gauge should slide freely around entire circumference without binding. If step has formed around inner portion of lower ring land, piston must be replaced.
3. Using piston to position ring in cylinder bore, check ring end gap at least .63" (16 mm) from bottom of bore. Ring end gap service limit is .019" (.50 mm). Install rings on pistons with end gaps staggered at proper intervals. Ensure ring gap is not in line with thrust face of pin bore.
4. Be sure manufacturer's marks face up when rings are installed. Install oil ring expander first, followed by lower oil ring side rail and upper side rail. Do not use ring expander on side rails. When installing lower side rail, place one end between piston ring groove and expander.
5. Hold end firmly and press down portion to be installed until side rail is in position. Install upper side rail. Using ring expander, install intermediate and upper rings. Check that all components are within specifications.
6. If new piston rings are to be installed and no visible cross-hatch marks remain on cylinder walls, remove cylinder wall glaze using spring-type honing tool. After honing, clean bore and block with soap/water solution and oil cylinder walls.

FITTING PISTON PINS

Note. When removing or installing piston pin, connecting rod should be in firm contact with body of pin setting tool.

1. Remove bearing inserts from connecting rod and cap. Mark pistons, pins and inserts (if reusable) to assure assembly with same rod. Press piston pin from piston and connecting rod using arbor press and Piston Pin Remover/Replacer Tool (T68P-6135-A) or equivalent.
2. Inspect and replace any piston pin showing signs of fracture, etching or wear. Check piston pin-to-rod bore fit. Lubricate pin and small end of rod bore with engine oil.

1. Check piston to bore clearance before assembling piston and pin to connecting rod. Ensure connecting rod and cap numbers are on right side and arrow on top of piston faces front for right bank of cylinders. Rod and cap numbers are on left side and arrow faces front for left bank.
2. Standard piston pin diameter is.9119-.9124" (23.162-23.174 mm). Piston pin bore diameter is.9124-.9127" (23.174-23.182 mm). Connecting rod pin bore diameter is.9112-9096" (23.144-23.103 mm). Piston pins are available in.001" and.002" oversize. Pin length is 3.010-3.040" (76.45-77.21 mm).
3. Start piston pin in piston and connecting rod. Using guide bar and push rod, press pin through both piston and rod until pin is centered in piston. (Scheme 8) After pilot hub bottoms, DO NOT exceed 5000 lbs. (2275 kg) pressure with press. Make certain piston floats during pin installation operation.

Tool Layout to Remove and Install Piston Pin Check specifications of all components of piston assembly before installation. Scheme 8

CONNECTING ROD BEARINGS

Note. Following procedures are with oil pan and cylinder head removed. Selective fit bearings are used in this engine. DO NOT scrape gum or varnish deposits from bearing shells. Clean inserts and caps thoroughly in solvent. DO NOT file or lap bearing caps or use bearing shims to obtain proper bearing clearance.

Scheme 9

1. Remove connecting rod bearing caps and mark rods and caps for proper installation. Inspect each bearing for peeling, melting, seizure or improper contact. Replace defective bearings. Use Plastigage method for bearing clearance check.
2. Measure outside diameter of crankshaft connecting rod bearing journals to determine if out-of-round or tapered. Journal out-of-round must not exceed.0006" (.015 mm) per inch. Journal taper must not exceed.0006" (.015 mm) per inch. CAUTION: If bearing is fitted to out-of-round crankpin, be sure to fit to maximum diameter of crankpin. If bearing is fitted to minimum diameter, interference between bearing and crankpin will result causing rapid bearing failure.
3. When checking connecting rod clearances, crankshaft does not have to be supported. Instead, turn crankshaft until connecting rod to be checked starts moving toward top of engine, thus unloading lower bearing.
4. Cut Plastigage to same length as width of rod bearing. Place in bearing cap, parallel with crankshaft (not over oil hole or groove). Install rod bearings and cap. Tightening in two steps to specifications. Always install caps with markings in original positions.
5. Do not turn crankshaft with Plastigage installed. Remove rod bearing cap from crankshaft and measure Plastigage at its widest part (using scale on Plastigage package). If clearance is found to be excessive, new bearing will be required. (Scheme 9) (Scheme 9): Using Plastigage to Check Bearing Clearance During clearance check, DO NOT turn crankshaft or Plastigage will smear.
6. Service bearings are available in standard size and.0005" and.0010" undersize for use with new and used standard size crankshafts. After inspection and/or replacement, coat bearing surfaces with heavy engine oil. NOTE: Connecting rod bearing cap and rod identification numbers must remain on same side. Always replace bearings in pairs. Never use new bearing in combination with used bearing.
7. Check for shiny surface on either side of piston pin boss, indicating bent connecting rod. Twisted rods will not create identifiable wear patterns, but will disturb the action of entire crankshaft assembly and may cause excessive oil consumption.
8. Check connection rod side clearance with dial indicator contact point resting against rod cap. Pull cap towards front of engine and zero dial indicator. Push cap towards rear of engine and compare reading to specification. If excessive, replace connecting rod and cap.
9. If side clearance is less than specification, remove rod and cap. Check for scratches, burrs, nicks or dirt between crankshaft and rod. Dress minor imperfections with oil stone.
10. During assembly, ensure oil hole in bearing aligns with oil hole in connecting rod. Check bearing tangs are seated in appropriate slots in rod and cap. Ensure connecting rod bolt heads are properly seated in connecting rod. Tighten connecting rod bearing caps in two steps.

MAIN BEARINGS

Note. Upper and lower main bearing halves are not interchangeable. Upper half is drilled and grooved for entry of oil.

1. Inspect each bearing for peeling, melting, seizure or improper contact. Replace defective bearings. If copper-lead bearing base is visible but is not showing in more than 20% of total area, bearing is not excessively worn.
2. Measure outside diameter of crankshaft main bearing journals in at least four places to determine out-of-round or taper. Journal out-of-round must not exceed .0006" (.015 mm). Journal taper must not exceed .0004" (.010 mm) per inch. Standard main bearing journal runout is .002" (.05 mm) and service limit is .005" (.13 mm). NOTE: Always replace bearings in pairs. Never use new bearing in combination with used bearing. Observe location of high spots on main bearings. If high spots are not in line, crankshaft may be bent and should be checked.
3. To check main bearings, shim adjacent main bearings to bearing being check. Alternate method is to position jack under counterweight adjoining bearing being checked so weight of crankshaft will not compress Plastigage and provide incorrect reading.
4. When checking No. 1 bearing, loosen accessory drive belts to prevent tapered reading on Plastigage. DO NOT position jack under crankshaft pulley. Crankshaft post damage will result. With all bearing caps (other than one being checked) tight, check clearances using Plastigage method. NOTE: If undersize bearings are used on more than one journal, position in cylinder block rather than bearing cap. Do not turn crankshaft with Plastigage installed.
5. If standard and undersize bearing combinations do not bring bearing clearance within specified limits, crankshaft will have to be refinished and undersized bearings installed. If journal will not clean up to maximum undersize bearing, replace crankshaft.
6. If journals are remachined, ensure same journal shoulder radius is reproduced. Too small a radius will result in fatigue failure of crankshaft. Too large a radius will result in bearing failure due to radial ride of bearing.
7. When journals are refinished, chamfer oil holes and polish journals with No. 320 grit polishing cloth and engine oil. After chamfer and polish operations, clean crankshaft thoroughly in solvent and blow out oil passages with compressed air.
8. Oil new upper bearing and insert plain (unnotched) end between crankshaft and notched side of block. Insert Main Bearing Remover/Installer Tool (No. 6331) into oil hole in crankshaft and rotate bearing (opposite of engine rotation) into place.
9. Oil new lower bearing and install in bearing cap. Install main bearing cap so that arrow faces front of engine. Install new rear main bearing seal in rear main bearing cap and cylinder block. Tighten all main bearing caps to specifications in two steps.

THRUST BEARING ALIGNMENT

Install all main bearing caps except thrust bearing cap and tighten. Install thrust bearing cap with bolts, tighten finger tight. Pry crankshaft to front of engine. Then pry thrust bearing cap to rear of engine. While holding crankshaft forward, tighten main bearing cap bolts. Check crankshaft end play. Crankshaft end play service limit is .012" (.31 mm).

One Piece Rear Main Oil Seal Check position of seal is near flush with rear face of block. Scheme 10

1. With transmission and related components removed, punch hole into seal metal surface between seal lip and engine block with a sharp awl.
2. Screw in threaded end of Slide Hammer Tool (T82L-6701-A) or equivalent. Use slide hammer to remove seal. Use caution to avoid scratching or damaging oil seal surface.

1. Lubricate seal and seal mating surface with engine oil. Install oil seal on Seal Installer Tool (T82L-6701-A) or equivalent with spring side toward engine. Position tool and seal on rear of engine.
2. Alternate bolt tightening to properly seat seal. Install seal with rear face of seal within.005" (.13 mm) of rear face of block. If bolts are not available with installer tool, engine flywheel bolts may be used. (Scheme 11) Reverse removal procedure to complete installation.

1. Drain cooling system and crankcase. Remove fan, spacer, radiator shroud and all hoses or brackets attached to water pump. Remove crankshaft pulley and remove vibration damper using universal puller. Disconnect fuel pump outlet line from fuel pump.
2. Remove fuel pump bolts and lay pump to one side (with fuel line attached). Remove front cover bolts and cut oil pan gasket flush with cylinder block. Remove front cover and water pump as an assembly. If front cover is replaced, remove water pump from old cover. Install on new cover with new gasket.

Note. Cover front oil pan opening while cover assembly is off to prevent dirt or gasket material from entering oil pan.

1. Clean all gasket surfaces. Cut and position required sections of new gasket on oil pan using contact cement. Apply RTV silicone sealer to corners and gasket junctions.
2. Install new front cover seal. Use Pilot (T61P-6019-B or 6059-F) to center front cover on crankshaft. Use care when installing cover to avoid seal damage or possible gasket mislocation.
3. With front cover in place, it may be necessary to force cover downward to slightly compress pan gasket. Install retaining bolts and tighten. Apply polyethylene grease to oil seal rubbing surface of vibration damper inner hub to prevent seal damage.
4. Apply polyethylene grease to front of crankshaft for damper installation. Line up damper keyway with key on crankshaft and install damper. Install fuel pump with new gasket. Reverse removal procedures to complete installation.

Remove front cover. Using pin punch, drive out front cover oil seal. Use care to avoid damaging oil seal surfaces.

Coat seal with grease and drive into cover using Seal Driver (T53L-200-A and T58P-6700-B). Check seal to ensure it is fully seated and spring is positioned properly. Install front cover.

1. With crankshaft pulley, front cover and related components removed, align timing marks. (Scheme 11) Remove camshaft sprocket cap screw, washer, fuel pump eccentric and spacer (if equipped).
2. Slide both sprockets with timing chain forward and remove them as an assembly. Inspect timing chain and sprockets for worn gear teeth, stretched chain or damaged components.

Timing Chain Sprocket Alignment Align timing marks before removing old chain. Scheme 11

Inspection

1. With front cover removed, rotate crankshaft in counterclockwise direction to take up slack on left side of chain. Establish reference point on engine block and measure from this point to chain.
2. Rotate crankshaft in opposite direction to take up slack on right side of chain. Force left side of chain out and measure difference between reference point and chain. If deflection exceeds .500" (12.70 mm), replace timing chain.

1. Position timing chain on sprockets with timing marks aligned. (Scheme 11) Slide both sprockets and timing chain onto engine as an assembly. Install spacer (if equipped), fuel pump eccentric, washer and sprocket cap screw.
2. Tighten sprocket bolt. Oil timing chain and sprockets. Clean gasket area and install new oil seal as necessary. Install front cover, new gaskets and related components.

1. Drain cooling system and remove radiator, A/C condenser and grille components, as necessary. Remove engine front cover, fuel pump and gaskets. Remove sprockets and timing chain as an assembly.
2. Remove intake manifold and related parts. Remove crankcase ventilation tube and tubes from valve covers. Remove EGR cooler, if equipped. Remove valve covers and loosen rocker arm fulcrum bolts. Rotate rocker arms to the side and remove push rods (identify for proper installation).
3. Remove and identify valve lifters for proper installation. Remove camshaft thrust plate. Carefully pull camshaft toward front of engine and remove. Use caution to avoid damage to camshaft bearings.

1. Check camshaft journals for out-of-round condition. If journals exceed .0005" (.013 mm) out-of-round, replace camshaft. Check camshaft end play. Standard end play is .0010-.0070" (.025-.178 mm). End play service limit is .0090" (.228 mm). Replace thrust plate if clearance is excessive.
2. Check camshaft journal runout. Runout limit is .005" (.013 mm). Check camshaft for alignment. Use "V" block and dial indicator. If dial gauge reads more than .0015" (.040 mm), replace camshaft. Check camshaft journal-to-bearing clearance. Service limit is .006" (.15 mm).
3. Check camshaft lobe lift. Attach dial indicator with a ball/socket attachment to camshaft carrier or "V" block. Measure lobe lift. Allowable lobe lift loss is .005" (.013 mm). If not to specification, replace camshaft.

1. Oil camshaft journals with engine oil and apply Lubriplate to camshaft lobes. Carefully slide camshaft through bearings and install camshaft thrust plate with groove toward cylinder block.
2. Lubricate lifters and lifter bores with oil and install in same order as removal. Apply polyethylene grease or Lubriplate to push rod ends and install in proper positions. Lubricate rocker arms and install.
3. If any valve train components have been replaced, perform valve clearance adjustment. Install other components previously removed to complete installation.

1. With camshaft, flywheel and crankshaft removed from engine, push pistons to top of cylinders. Remove camshaft rear bearing bore plug. Using Camshaft Bearing Driver/Puller (T65L-6250-L), remove camshaft bearings.
2. During inner bearing removal, wrap cloth around threads of puller to protect front bearing or journal. To remove front bearing, install puller from rear of cylinder block.

1. Bearings are available prefinished to size for standard and .015" undersize journal diameters. Bearings are not interchangeable from one bore to another. When installing new bearings, oil holes must be aligned.
2. Ensure pulling plate and puller screw are centered to avoid damage to bearing. Front bearing must be installed .005-.020" (.13-.51 mm) below front face of cylinder block. Apply sealer to outside diameter and install camshaft bearing bore plug. To complete installation, reverse removal procedure.

CAMSHAFT END THRUST

1. When checking end play, back off rocker arm adjusting bolts to relieve tension on camshaft. With engine front cover removed, push camshaft toward rear of engine and install dial indicator so indicator stylus is on camshaft sprocket cap screw. Zero dial indicator.
2. Position large screwdriver between camshaft sprocket and block. Pull camshaft forward and release it. If dial indicator reading is not within specifications, replace thrust plate. Readjust valve clearance. Ensure lifters have enough time to bleed down before starting engine.

CAM LOBE LIFT

1. Check lift of each camshaft lobe in consecutive order as follows: Remove rocker arms and make sure each push rod is in valve lifter socket. Install dial indicator so ball socket adapter of indicator rests on end of push rod and in same plane as push rod movement.
2. With an auxiliary starter switch connected to starter solenoid and ignition switch "OFF", bump crankshaft until tappet is on base circle of camshaft lobe. This is push rod's lowest point.
3. Zero dial indicator and continue to rotate crankshaft until push rod is in fully raised position (highest indicator reading). Compare total lift from indicator readings with specifications.
4. To check accuracy of dial indicator readings, continue to rotate crankshaft until indicator reads zero. If lift on any lobe is .005" (.13 mm) less than specifications, valve lifters are operating on worn lobes. Replace camshaft and lifters as necessary.

Oil from main gallery enters main bearings through drilled passages in block.

Engine Oiling Circuit During engine rebuild, ensure oil passages in block and crankshaft are clean and open. Scheme 12

CAMSHAFT BEARINGS

Passages are drilled from each main bearing to each camshaft bearing.

TIMING CHAIN

Oil is forced through drilled passage from oil pump intermediate shaft to groove in thrust plate and passes around camshaft. It then flows through two grooves in timing chain sprocket and is deflected onto timing chain.

Crankshaft is drilled from main bearings to connecting rod bearings.

VALVE LIFTERS, PUSH RODS

Oil passages drilled from main oil gallery to each lifter gallery. Oil hole in valve lifter is indexed to lifter oil gallery and oil flows into lifter. Oil from lifter is metered through disc metering valve and flows up hollow push rod. Drilled hole in push rod is indexed to hole in rocker arm and oil lubricates the upper valve train and bearings. Excess oil is returned to oil pan through drain back holes at each end of cylinder head and block.

1. Disconnect negative battery cable and drain cooling system. Remove carburetor air inlet tube. Remove fan shroud and position shroud over fan. Remove fan and spacer from water pump shaft. Remove shroud and all accessory drive belts.
2. Remove all accessory brackets attached to water pump. Remove water pump pulley. Disconnect radiator lower hose, heater hose and water by-pass hose at water pump. Remove bolts that attach water pump to front cover. Remove pump and discard gasket.

Note. If installing new water pump, transfer pulley from old pump.

1. Clean all surfaces of gasket material to ensure good seal. Apply sealant to water pump sealing surface. Apply sealer to new gasket and install.
2. While sealer is wet, install water pump and tighten attaching bolts. Install pulley, brackets and drive belts. Adjust drive belts to specified tension. Reverse removal procedure to complete installation.

Note. For further information on cooling system capacities and other cooling system components, see ENGINE COOLING SYSTEMS article.

CRANKCASE CAPACITY

Crankcase capacity is four quarts (3.8L) W/O filter. Add one quart (.9L) with filter change.

NORMAL OIL PRESSURE (HOT)

Normal oil pressure is 40-60 psi (2.8-4.2 kg/cm 2 ) @ 2000 RPM.

PRESSURE REGULATOR VALVE

Pressure regulator valve is located in oil pump body and is not adjustable.

Force feed with rotor type oil pump. All oil from pump flows through full flow oil filter before entering the engine. (Scheme 12) From oil filter, oil flows to main oil gallery located on right side of camshaft, lubricating engine components as follows

OIL PUMP

Note. When draining engine oil, ensure both drain plugs are removed from dual sump oil pan. Failure to remove both plugs will result in incorrect oil level reading after crankcase refill.

1. Disconnect negative battery cable. Remove fan shroud attaching bolts and reposition shroud back over fan. Remove dipstick and tube assembly. Raise vehicle and drain crankcase.
2. Disconnect steering flex coupling. Remove 2 bolts attaching steering gear to main crossmember. Set steering gear aside away from oil pan. Remove nuts and washers attaching engine mounts to No. 2 crossmember. Disconnect transmission oil cooler lines and related components.
3. Raise engine and support with blocks between engine mounts and crossmember. Remove converter inspection plate. Remove 4 attaching bolts and rear "K" braces. Remove the oil pan and related parts. Remove oil inlet tube and screen assembly. Remove the oil pump attaching bolts and remove the oil pump and intermediate drive shaft.

Scheme 13

1. Remove cover bolts and cover from pump. Remove inner rotor and shaft assembly, then remove outer race. (Scheme 13) (Scheme 13): Exploded View of Oil Pump Assembly Ensure drive shaft hex is aligned with distributor shaft during installation.
2. Drill small hole and insert self-threading sheet metal screw into oil pressure relief cap and pull from chamber. Remove spring and plunger.

Note. Identification mark (dimple) on outer race must face outward and on same side as identification mark on rotor. Rotor and shaft assembly and outer race are serviced as an assembly and parts must be replaced together.

Reassembly

1. Clean, inspect and oil all parts thoroughly. Install relief valve plunger, spring and new cap. Install outer race and inner rotor and shaft assembly.
2. Install oil pump end cover and tighten bolts. Install oil inlet tube on pump.

1. Prime oil pump by filling either inlet or outlet port with oil. Rotate pump shaft to distribute oil within pump body.
2. Position intermediate drive shaft into distributor socket. With shaft firmly seated in socket, stop on shaft should touch roof of crankcase. If necessary, remove shaft and reposition stop.
3. With stop properly positioned, insert intermediate drive shaft into oil pump. Install pump and shaft as an assembly. Tighten oil pump attaching bolts. Reverse removal procedures to complete installation.

OIL PUMP SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

VALVE SPECIFICATIONS

VALVE SPECIFICATIONS

PISTON/PIN/RING SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

BEARING SPECIFICATIONS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECS

VALVE SPRING SPECIFICATIONS

VALVE SPRINGS SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

See also:
• ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION