Werkstatthandbuch Book 1 · Seiten 901–1000

21-21-5 5.OL/5.SL 3O2/35 11W1’ CID V-S Engines 21-21-5 Granada, Monarch and Versailles Removal SHIELD- 1. Support the engine using a jack and wood block 6C060 L. H. ONLY placed under the oil pan. 2. Remove the nut and through bolt attaching the 68032 ASS?. ILK. insulator to the insulator support bracket Fig. 4. 6038 ASSY. RH. 3. Raise the engine slightly with the jack. 4. Remove the engine insulator and bracket assembly 38323 282 to cylinder block attaching bolts. Remove the 5800. 38 2400-S 2 engine insulator assembly and the heat shield, if so

_________ 21-21-6 5.OL/58L 302/351 "W" CID V-S Engines - 21-21-6 34 794-52 382802-Sr 2 REOD.I 12 REQD.I 382802 -82 RH- SIDE ONLY 2D-30 PT-LB 6038 VIEW 4 REQD.I

21-21-7 5.OL/5.8L 302/351 "WI’ CID V-S Engines 21-21-7 through-bolts Remove the supporting jack, install the nuts and washers attaching the support to the crossmember and torque the nuts to specifications 7659 ASSY. IRE 4. On LTD II, Cougar and Thunderbird models, install the support insulator to crossmember attaching nuts. Tighten the nuts to specifications. MUSTANG II. FAIRMONT AND ZEPHYR P Removal 1. Place a block of wood and a jack under the transmission. 5573&52

21-21-8 5.01/5.81 302/351 "W" CID V-8 Engines 21-21-8 NOTE If the rocker arm cover is not being EON COOLER removed, remove only the 1/2-inch attaching BRACKET screws at the top of the bracket to disconnect the cooler assembly. 2. Cut the cooler exhaust inlet and outlet tube clamps one at the front of the cooler and one at the EGR valve using Tool T78P-9481-A or equivalent follow tool manufacturer’s instructions. Rotate the cooler by hand to separate the tubes after the clamps are cut. 4. Disconnect inlet and outlet coolant hoses and remove the cooler assembly. Installation 1. Install the coolant hoses. Align the bracket and cooler assembly. 2. Position the exhaust inlet and outlet tubes-front and rear-to the cooler assem

21-21-9 5.01/5.81 302/351 "W" CID V.8 Engines 21-21-9 rocker covergasket in each cover, making sure that the tabs engóge the notches in the cover. 5. Position the covers on thecylinder heads. Install the bolts and wire loom clips on left hand cover. The cover is tightened in two steps. Torque the bolts to specifications. Two minutes later, torque the bolts to the same specifications. Install the crankcase ventilation hoses in the covers. Install the automatic chske heat tube and connect the automatic choke heat chamber air inlet hose at the air cleaner. 6. Install the spark plug wires and bracket assembly on the rocker arm attaching stud. Connect the spark plug wires. See Part 23-01 for special instructions. Inst

21-21-10 5.01/5.81 302/351 "W" CID V-8 Engines 21-21-10 HEATER FCSE FITTING MANIFOLD-TO-HEAD GASKET 9441 MANIFOLD-TO-BLOCK REAR SEAL 9A424 WATER TEMPERATIJA SENDING UNIT / I4K :* ;,

21-21-11 5.OL/5.81 302/351 "W" CID V-B Engines 21-21-11 Installation 1. If the intake manifold assembly was disassembled, install the temperature sending unit threads coated with electrical conductive sealer, ignition coil, gasket, spacer and carburetor, Install the EGR back-pressure transducer and valve using a new gasket. Position the thermostat in the coolant outlet housing. Coat the thermostat gasket with water- resistant sealer and position it on the coolant outlet housing. Install the coolant outlet housing. Connect -C 0- all vacuum hoses. 2. Clean the mating surfaces of the intake manifold, cylinder heads and cylinder block. Use a solvent such as lacquer thinner, chiorothane or tri-chior ethylene.

21-21-12 5.01/5.81 302/351 ,‘W" CID V-B Engines 21-21-12 14. Start the engine and check and adjust the ignition Installation timing. Connect the distributor vacuum hoses to the Tappets and bares are to be lubricated with heavy distributor. engine oil SE before installation. 15. Operate the engine at fast idle and check all hose 1. Clean outside of tappets and install in the bares connections and gaskets for leaks. When engine from which they were removed. If a new tappet is temperatures have stabi

21-21-13 5.0L/5.8L 302/351 "W" CID V-8 Engines 21-21-13 -At 594 1B FIG. 21 Removing Valve Push Rod FIG. 23 Cylinder Head Bolt Torque Sequence 5. Apply Lubriplate or equivalent to bath ends of the push rods. Install the push rods in their original positions. Apply Lubriplate or equivalent to the

21-21-14 5.01/5.81 302/351 "W’ ‘ CID V-8 Engines 21-21-14 2. Position the exhaust manifold on the cylinder head CYLINDER FRONT COVER AND TIMING and install the heat shields and the attaching bolts CHAIN and washers. Working from the center to the ends, torque the bolts to specifications. Install the spark Removal plugs and spark plug wires. See Part 23-01 for 1. Refer to Water Pump Removal. Perform all steps special installation procedure. except removal of the pump. l.eave it attached to 3. Position the muffler inlet pipe to the manifold. the front cov

21-21-15 5.OL/5.8L 302/351 "W,’ CID V.8 Engines 21-21-15 S - TIMING MARKS A2131-1R 42132-IS FIG. 25 Aligning Timing Marks FIG. 26 Removing or Installing Timing Chain Installation 1. Position the sprockets and timing chain on the camshaft and crankshaft simultaneously Fig. 26. Be sure the timing marks on the sprockets are positioned as shown in Fig. 25. 2. Install the fuel pump eccentric, washers and camshaft sprocket cap screw. Torque the sprocket coj, screw to specifications. On 5.8L 351 CID engines, install the crankshaft front oil slinger Fig. 2

21-21-16 5.01/5.81 302/351 "W" CID V-8 Engines 21-21-16 can be facilitated by using a suitable tool at the 16. Fill the crankcase with the proper grade and front cover attaching hale locations. quantity of engine oil. 10. Coot the threads of the attaching screws with oil 17. Fill and bleed the coaling system. resistant sealer and install the screws. While 18. Operate the engine at fast idle and check far pushing in on the alignment tool, tighten the oil pan coolant and oil leaks. Check and adlust the ignition to cover attaching screws to specifications Fig. 28. timing and engine idle speed. - Tighten the cover to black attaching screws to specifications. Remove the pi

21-21-17 5.01/5.81 302/351 "W" CID V-B Engines 21-21-17 TIMING CHAIN - 6286 ANO 8 EAR [N CS CAMSHAFT SPROCKET - 6256 6263 6261 THRUST F LAT CAMSHAFT REAR BEARING7 BORE PLUG -

21-21-18 5.OL/5.81 302/351 "W" CD V-8 Engines 21-21-18 cover and related parts following procedures under 2. To check flywheel face runout or replace flywheel Cylinder Front Cover and Timing Chain Installation. ring gear far manual-shift transmissions, refer to 9. On vehicles equipped with air conditioning, install Part 21-01. the air conditioning condenser. 3. Remove the flywheel attaching bolts and remove Position the fan shroud, if so equipped, over the the flywheel. fan. Install the radiator and connect the upper and Installation lower radiator hoses. 1. Coat the threads of the fly

21-21-19 5.OL/5.8L 302/351 "W" CID V.8 Engines 21-21-19 On a vehicle with a manual transmission, install the clutch pressure plate, disc and the transmission following the procedures in Group 16. On a vehicle with an automatic transmission, install the transmission and converter housing following the procedure in Group 17. OIL PAN MUSTAN

21-21-20 5.OL/5.8L 302/351 "WI’ CID V-8 Engines 21-21-20 5. Remove two 2 bolts attaching steering gear to installation main crossmember and let steering gear rest on 1. Clean the gasket surfaces of the block and oil pan. frame away from oil pan. The oil pan has a two-piece gasket, 6. Remove the bolts attaching the engine mounts. 2. Clean the oil pump pick up tube and screen. 7. Raise the engine and place two 2 wood blacks ç2’ 3. Coat the block surlace and the oil pan gasket with x 4" between the engine mounts and the vehicle sealer. Position the oil pan gaskets an the cylinder frame. block Fig. 34. 8. Remove rear "K" braces 4 bolts.

21-21-21 5.OL/5.81. 302/351 "W" CD V-8 Engines 21-21-21 5. Position the oil pan rear seal on the rear main 5. Clean and install the oil pump inlet tube and screen bearing cap Fig. 34. Be sure the tabs an the seal assembly Fig. 35. are aver the oil pan gasket. 6. Position the oil pan side gaskets on the cylinder 6. Position the oil pan to the cylinder block. Install the block using contact cement Part B9AE-19B508-A attaching bolts and torque to specifications. or equivalent. See Fig. 34. 7. Position the idler arm bracket to the chassis and 7. Position the oil pan front seal on the cylinder front install the attaching bolts. Torque to

21-21-fl 5.OL/5.8L 302/351 "W" CID V-B Engines 21-21-22 CRANKSHAFT REAR OIL SEAL A split-lip type crankshaft rear oil seal is used for replacement on oh engines. if replacement is necessary, this type of seal must be used. The complete seal can be replaced without removing the crankshaft. Refer to Crankshaft Rear Oil Seal. Replacement in Part 2 1-01 for replacement procedures. MAIN BEARING The main bearing inserts are selective fit. Refer to procedures under Fitting Main and Connecting Rod Bearings in Part 21-01. Removal 1. Drain the crankcase Remove the oil level dipstick. Remove the oil pan and related parts by following steps under Oil Pan Removal. 2. Remove the oil pump inlet tube assembly and the oil pump.

21-21-23 5.OL/5.BL 302/351 "W" CID V-B Engines 21-21-23 PRY FORWARD HOLD CRANKSHAFT PRY CAP FORWARD 4 BACKWARD THRUST BEARING THRUST BEARING - Il rr PRy cRANKSHAFT FORWARD PRY CAP BACKWARO TiGITN CAP

21-21-24 5.OL/5.81 302/351 "W" C1D V.8 Engines 21-21-24 ‘- PISTON RI 0 CO PRESSOR 5. Remove the connecting rod nuts and cap. ‘I’ Ia 6. Push the connecting rod and piston assembiy out the tap of the cylinder with the handle end of a L hammer. Avoid damage to the crankshaft journal or the cylinder wail when removing the piston and rod. 7. Remave the bearing inserts from the connecting rod and cap. 8. Install the cap o

21-21-25 5.0L/5.8L 302/351 "W" CD V-8 Engines 21-21-25 FLYWF-IP.PL - 6375 BEARING INSERTS bOLT FIG. 40 Crankshaft and Related Parts 13. Install the intake manifold following procedures 2. Remove the fuel pump and oil filter. Slide the water under Intake Manifold Installation. pump by-pass hose clamp toward the water pump. 14. Fill and bleed the cooling system. Fill the crankcase Remove the alternator and mounting brackets. with the proper grade and quantity of engine oil. 3. Remove the crankshaft pulley from the crankshaft 15. Start

21-21-26 5.OL/5.81. 302/351 "W" CID V-8 Engines 21-21-26 9. Carefully lift the crankshaft out af the block so that following the procedure under Fitting Main and the thrust bearing surfaces ore not damaged. ConnecHng Rod Bearings in Part 21.01. Handle the crankshaft with care to avoid 19. After the connecting rod bearings have been fitted, possible fracture or damage to the finished apply a light coat of engine oil to the journals and surfaces. bearings. Ta refinish journals, dress minor imperfections, 20. Tur

21-21-27 5.O1/5.8L 302/351 ‘W" CID V-8 Engines 21-21-27 EXI’ARUING MANDREL DETAIL -1 -2 DR -2 BACK-UP NUT THRUST BEARING GETAIL-l-2EXPANDING CDLIOR-S ET DETAIL-S PULLING NUI H.: PULLER SCRFW CAMSHAFT BEARING ILOOSEI PULLING PLAT

21-21-28 5.OL/5.81 302/351 "w" CID V-8 Engines 21-21-28 DISASSEMBLY AND ASSEMBLY When installing nuts or bolts that must be torqued 6. Depress the plunger, and position the closed end refer to Specifications, oil the threads with light weight of the lock ring in the groove of the tappet body. engine oil. Do not oil threads that require oil- With the plunger still depressed, position the open resistant or water-resistant sealer. ends of the lack ring in the groove. Release the Refer to Part 21-01 for Cleaning and Inspection plunger, and then depress it again to fully seat the procedures. lock ring.

2b21..29 5.01/5.81 302/351 ‘W" CID V-B Engines 21-21-29 LOCKS - 6518 Fig. 47. Check the dividers against a scale. If the assembled height is greater than specifications, RETAINER install the necessary 0.030 inch thick spacers -6514 4’ I----_____._,__ SLEEVE-- 6517 between the cylinder head spring pad and the valve spring to bring the assembled height to the recommended height. SPRPNG

_____________________ 21-21-30 5.OL/5.8L 302/351 ‘W" CID V-B Engines 21-21-30 LOWER UPPER COMPRESSION COMPRESSION RING RING OIL RING ASSEMBLY

21-21-31 5.OL/5.BL 302/351 ‘,W’, ClO V-8 Engines 21-2141 SPECIFICATIONS GENERAL SPECIFICATIONS CAMSHAFT LIFT OISPLACEMENT CL/SOt 002 00/351 CIOI LOSE Intake 0.2373 5.OL 302 CIDI NUMBEROFCYLINDERS

_____________________________ 21-21-fl 5.OL/5.81 302/351 "W" CID V-8 Engines 21-21-32 CRANKSHAFT AND FLYWHEEL - -- - - COI4NECTIR4G ROD 0551088 fuND RttrICS -1 SAl N SEAR IloG JOUR SAL 014/A ETER 2.2482-2.240t 5.01 302 CIOI 2.9994-3.0002 5.81 1351 6101 CONNECTING ROD Dot-Of- Rtuibd Limrl -. 0.0006 Moo. Pinto Pier Bole Diamelor 0.9096-0.9102 Taper Limil - 0.0006 Max.

21-21-33 5.OL/5.81 302/351 IWCl CID V-B Engines 21-21-33 LUBRICATION SYSTEM TORQUE SPECIFICATIONS - General Application U.S. THREAD SIZES TORQUE OIL PUMP Relieb Valse Spring Teriion I Lbs al Spec, Length - 00.0- tZ2 A 0.704 5.01 302 CIOI 014-20 6-9 t&2-20.2 A 2.49 5.81 035? CIOl 506-10 12-to Dnixe Sliafn-Ta-Hoann

21-fl-i 5.8L/66L 351 "M"/400 CID V-8 Engines 21-22-1 5.8L/6.6L 351 "M"/400 CID 21-22 V-8 Engines Ford, Mercury, LTD II, Cougar, Thunderbird, Lincoln Continental, Continental Mark V SUBJECT PAGE SUBJECT PAGE DESCRIPTION REMOVAL AND INSTALLATION Cont’d. Crankcase Ventilation System 22-1 Cylinder Heads 22-9 Engine 22-1 Engine 22-2 Exhaust Emission Control System 22-1 Engine Front Supports 22-3

21-22-2 5.BL/6.6L 351 "M"/400 CID V-B Engines 21-22-2 44071 -2C FIG. 1 Right Front View-Typical REMOVAL AND INSTALLATION 10. Remove the power steering pump brackets and position the pump out of the way in an upright position to prevent fluid loss. Caution: Do not operate engine with hood open 11. On vehicles equipped with air conditioning, isolate until fan has been first examined for possible and remove the compressor as outlined in Group cracks and separation.

21-224 5.8L/6.6L 351 "M"/400 CID V-8 Engines 21-223 21. Remove the engine front support through bolts and 15. Connect the battery ground wire to the right front the starter cable clomp at the engine right front of cylinder block. Connect the heater hoses to the support. water pump and cylinder block. 22. Remove the converter inspection cover and 16. Install the alternator and bracket. Connect the disconnect the flexplate from the converter. alternator ground wire to the cylinder block. Remove the downshift rod. 17. On a vehicle with air conditioning, install the air Remove the four converter lower housing-to. conditioning compressor and brackets as outlined

21-22-4 5.SL/6.6L 351 "M"/400 CID V-B Engines 21-22-4 4. Install the fan shroud attaching bolts. ENGINE REAR SUPPORT 305759-82 The rear support is located at the transmission 363232-S2 extension housing Figs. 5, 6 and 7. Whenever self- 35-60 FT-LB INSULATOR ASS?- - locking mounting bolts and nuts are removed, they 6SO32 1.11.1 must be replaced with new self-locking bolts and 385757-52

21-22-5 5.8L/6.6L 351 ‘4M"/400 CID V-B Engines 21-22-5 3. Remove the air cleaner and intake duct assembly. 4. Disconnect the cTankcose vent hose trom the carburetor. 6028 2 REOD. 5. Pull the PCV valve out of the oil fill cap. 6. Remove the crankcase ventilation filter from the air 4 386242-S 100 cleaner body. 2 REQ’D.

21-22-6 5.8L/6.6L 351 "M"/400 CUD V-B Engines 21-22-6 Installation 4. Position the covers on the cylinder heads. Make sure the gasket seats evenly all around the head, All rocker arms and fulcrum seats are to be lubricated Install the bolts. The cover is tightened in two steps. with heavy engine oil SE before installation. Tighten the bolts to specification. Two minutes 1. Apply Lubriplate or equivalent to the top of the later, tighten the bolts to the same specification. valve stem. Lu

21-fl-i 5.8L/6.6L 351 "M"/400 CID V-8 Engines 21-22-7 OIOKE HEATER ASSEMBLY - 90869 9 FIG. 12 Removing or Installing Valve Stem Seal Installation 1. Inspect the valve stem for damage. Rotate the valve and check the valve stem tip for eccentric movement during rotation. Move the valve up and down through normal travel in the valve guide and check the stem for binds. If the valve has been damaged, it will be necessary to remove the cylinder head for repairs as outlined in Part 21-01. 2. If the condition of the valve proves satisfactory,

21-22-8 5.8L/6.6L 351 "M"/400CID V-8 Engines 21-22-8 SEAL MOUNTING SURFACE 7. Rotate the crankshaft damper until the No. 1 piston is on TDC at the end of the compression stroke. Position the distributor in the block with the rotor at the No. 1 firing position. Install the hold down clamp and connect the distributor wiring harness. 8. Instal

21-22-9 5.8L/6.6L 351 "M"/400 CID V-S Engines 21-22-9 2. Apply graphite grease to the mating surface of the exhaust manifold. 3. Position the exhaust manifold on the head and install the attaching baIts. Working from the center to the ends, tighten the bolts to specification. Install the spark plug heat shields.

21-22-10 5.BL/6.6L 351 "M"/400 CID V-8 Engines 21-22-10 If the left cylinder head was removed on a vehicle with an air conditioner, install the compressor as outlined in Group 36. If the left cylinder head was removed, install the drive belt and power steering pump bracket. Install

21-22-11 5.8L/6.6L 351 4’M"/400 CID V-8 Engines 21-22-11 9. Connect the radiator lower hose at the water pump. 0. Connect the heater hose at the water pump. TIMING MARKS 1. Connect the battery cable. Fill and bleed the cooling system. Operate the engine until normal operating temperature has been reached and check for leaks. CYLINDER FRONT COVER PLATE AND TIMING CHAIN Removal 1. Refer to Water Pump Removal. Perform Steps 1 thru 9, but leave the water pump attached to the front cover plate. 2. Remove the heater hose and lower radiator hose from the water pump. 3. Remove the crankshaft pulley from the crankshaft vibration damper. Remove the vibration damper attaching scr

21-22-12 5.8L/6.6L 351 "M"/400 CID V-B Engines 21-22-12 TOOL T,op-e 6070-a A3252-lB A3249-IA FIG. 22 Fuel Pump Eccentric Installed 2. Install the two-piece fuel pump eccentric, washers and camshaft sprocket cap screw Fig. 22. Torque the sprocket cap screw to specification. Be sure the outer eccentric sleeve rotates freely.

21-22-13 5.8L/6.6L 351 "M"/400 CID V-8 Engines 21-22-13 TOOL - T52L 6306-ABE A 5. Place the front seal removing tool onto the front OR 6306 AJ cover plate over the front seal as shown in Fig. 23. Tighten the two through bolts to force the seal puller under the seal flange. 6. Alternately tighten the four puller bolts a half turn at

21-22-14 5.8L/6.6L 351 "M"/400CID V-B Engines 21-22-14 Removal 13. Place the radiator shroud over the fan. Install the 1. Drain the coaling system. Disconnect the upper and radiator and connect the hoses. Connect the lower radiator hoses at the radiator. Disconnect the transmission oil cooler lines at the radiator. On oil cooler lines at the radiator. If equipped with air vehicles so equipped, install the radiator shroud conditioning, remove the condenser. attaching bolts. 2. Remove the cylinder front cover plate, fuel pump 14. Raise the vehicle. Remove the oil pan and install and the timing chain following the procedure under new gaskets and s

21-22-15 5.8L/6.6L 351 "M"/400 CID V-8 Engines 21-22-15 2. Remove the fan shroud attaching bolts and position 10. lower the vehicle. the fan shroud and air inlet tube over the fan. 11. Install the fan shroud and air inlet tube attaching 3. Raise the vehicle. bolts. 4. Drain the crankcase. 12. Install the oil level dipstick. Fill the crankcase with 5. Remove the sway bar attaching bolts from the the proper grade and quantity of engine oil. Start chassis and lower the sway bar for clearance the engine and operate at idle speed until it reaches except Ford and Mercury. normal operating temperature. Check for oil leaks. 6.

21-22-16 5.SlJ6.6L 351 "M"/400CID V-B Engines 21-22-16 CRANKSHAFT REAR OIL SEAL install the bearing insert so that Tool 6331 can be inserted in the oil hole in the crankshaft. With Tool A split-up type crankshaft rear oil seal is used for 6331 positioned in the oil hole in the crankshaft, replacement an all engines. If replacement is necessary, rotate the crankshaft in the opposite direction of this type of seal must be used. The complete seal can engine rotation until the bearing insert seats itself. be replaced without removing the crankshaft. Refer to Remove the tool. Part 21-01 for removal and installation procedures.

21-fl-li 5.8L/6.GL 351 "M"/400 CID V-B Engines 21-fl-li Installation Installation 1. Be sure the bearing inserts and the bearing bare 1. If new piston rings are to be installed, remove the in the connecting rod and cap are clean. Foreign cylinder wall glaze using a spring type cylinder material under the inserts will distort the bearing hone only if there is no visible sign of cross hatch and cause a failure. markings on cylinder walls. Follow the instructions 2. Clean the crankshaft journal. of the tool manufacturer. After deglazing or honing 3. Install the bearing inserts in the connecting rod and cylinder wa

21-22-18 5.BL/6.6L 351 "M"/400 CID V-8 Engines 21-22-18 9. After the piston and connecting rod assemblies have been installed, check the side clearance between the connecting rods on each crankshaft journal Fig. 32. 10. D;abl, clean and assemble the oil pump see Part 21-01. Clean the oil pump inlet tube screen and the oil pan and block g

21-22-19 5.8L/6.GL 351 ‘M"/400 CID V-B Engines 21-22-19 MAIN BEARING INSERTS- CRANKSHAFT CRANKSHAFT SPROCKET MAIN REARING INSERTS OIL SSAL WASHER *MAIN BEARING CAPS

21-22.20 5.81_/6.GL 351 "M"/400 CID V-B Engines 21-22-20 PRY CAP PRY FORWARD HOLD CRANKSHAFT BACKWARD FORWARD ‘a if tIZNKSH A FT FOR WARD CAP SACKWARD

21-22-21 5.8L/6.6L 351 "M"/400 CID V-8 Engines 21-22-21 callet assembly in the camshaft bearing, and expanding collet can cause severe bearing tighten the back-up nut on the expanding mandrel damage. Be sure the front bearing is installed until the collet fits the camshaft bearing. the specified dktance below the front face of 4. Assemble the puller screw and extension if the cylinder block Fig. 36. necessary as shown and install on the expanding 2. Install the core plug as detailed in Part 21-01. mandrel. Wrap a cloth around the threads of the 3. Install the camshaft, crankshaft, flywheel and puller screw to prote

__ 21-22-22 5.8L/6.6L 351 "M"/400 CID V-8 Engines 21-22-22 to the underside of the spring retainer with dividers Fig. 411. Check the dividers against a scale. If the T7OP.SSOB-A assembled height is greater than specification, install the necessary 0.030 inch thick spacers between the cylinder head spring pad and the valve spring to bring the assembled height to the

21-22-23 5.BL/6.6L 351 "M"/400 CID V-B Engines 21-22-23 PUSH POD CUP MCTERING VALVE DISC CHECK VALVE SPRING I . Press ko CHECK VALVE Driver DetcsI 47 LOCK RING PLUNGER CHECK VALVE RETAINER FIG. 42 Hydraulic Tappet Assembly fbelm 3. Position the check valve retainer

21-22-24 5.8L/6.6L 351 "M"/400 CID V-8 Engines 21-22-24 4. Check the ring side clearance of the compressian procedures given in the Removal and Installation rings with a feeler gauge inserted between the ring section of this Part, and its lower land Part 2 1-01. The gauge should 4. Check all assembly clearances and correct as slide freely around the entire ring circumference necessary. without binding. Any wear that occurs will farm a step at the inner portion of the lower land. If the lower lands have high steps, the piston should CYLINDER BLOCK 6010 be replaced. before repacing a cylinder bock, determne It it is5. Be sure the bearing inserts, the b

o00606a008000039 93303 3 21-22-25 5.8L/6.6L 351 "M"/400 do V-8 Engines 21-22-25 SPECIFICATIONS GENERAL SPECIFICATIONS CAMSHAFT DISPLACEMEI5JI . 581.16.6L 35184/400 10 LOBE LIFT NUMSEROFCYLINDERS 8 Intake 1T2355.EL35CeIJI BOREANOSTROKE 4MOu3.5058L351C101 0.2474 S.6L 1400 101 4.00, 4.0066!. 1400 101

0 005 21-22-26 5.8L/6.6L 351 "M"/400 dID V-8 Engines 21-22-26 CRANKSHAFT ANO FLYWHEEL CONNECTING ROD, PISTDN ANO RINGS Conoineaedl MAIN BEARING JOURNAL DIAMETER 2.9994.3,0002 Put0 Groove WidIli Out-of- Round Limil 0.0006 Mat. C nineressmne ItupI 0.080-0.080 TapevLimin 0.0006Man. C nlnrtevvi on IBontumj 0 080.0.001 Journal Hsinous Limit

21-24-1 7.5L 460 CID V-8 Engines-Passenger And Police Interceptor 21-24-1 7.5L 460 CID Passenger and 21-24 Police Interceptor V-8 Engines Ford. Mercury, Lincoln Continental and Continental Mark V SUBJECT PAGE SUBJECT PAGE DESCRIPTION REMOVAL AND INSTALLATION Cont’d. Crankcase Ventilation System 24-1 Main Bearing 24-18 Engine 24-1 Oil Filter 24-22 Exhaust Emission Control System 24-1 Oil Filter Adapter Police Interceptor 24-4

21-24-2 7.51 460 CID V-8 Engines-Passenger And Police Interceptor 21-24-2 A2976-1O FIG. 1 3/4 Left Front View-7.5l. 460 CID V-8 Engine REMOVAL AND INSTALLATION CAUTION: Do not operate the engine with the CAUTION: Use 2 wrenches when disconnecting hood open until the fan has been first examined hoses to avoid damaging hose from twisting. for possible cracks and separation. 6. Remove the fan shroud attaching bolts. When installing nuts or bolts that must be torqued 7. Remove the cooling fan-to.water pump hub refer to torque specifications, oil the threads with light attaching

21-24-3 7.51 460 CID V-8 Engines-Passenger And Police Interceptor 21-24-3 cover, and positian the transmission filler tube out 6. Install the starter and connect starter cable. of the way. 7. With gaskets in place on inlet pipes, guide pipe 13. Disconnect all vacuum lines at the rear of intake ends into exhaust manifold flanges. Install nuts on manifold. flange studs and torque to specifications. On Police 14. Disconnect the speed control at carburetor if so Interceptor models, connect engine oil cooler hoses equipped. Disconnect the accelerator cable and to oil filter adaptor. Make sure and observe color secure out of way.

21-24-4 7.51. 460 CID V.8 Engines-Passenger And Police Interceptor 21-24-4 22. If equipped with air conditioning, recharge the twisted causing an oil leak or obstrucfion if bent system. too sharply. 23. Install the hood. Remove the masking tape and 4. Connect the water inlet hose to the upper fitting fender covers. on the oil cooler and the outlet hose to the lower fitting. Tighten the hose clamps. CRANKCASE OIL COOLER POLICE 5. Fill the cooling system with the specified coolant. INTERCEPTOR

________ 21-24-5 7.51 460 CID} V-8 Engines-Passenger And Police Interceptor 21-24-5 647050 L.H. 647038 n.H. I-.__-t_4jjj 383232.52’ T ONLVI 6038 ASSY. RH. 35-60 FT-LB CO1O RH. 385759-52 2 REOD. 20-35 FT-LB 385758-S 2 DIRECTION OF 383232-826 REOD. BOLT OPTIONAL 35-60 P

21-24-6 7.5L 460 CID V-8 Engines-Passenger And Police Interceptor 21-24-6 FORD. MERCURY. LINCOLN CONTINENTAL AND CONTINENTAL MARK V INSULATOR Removal ASSEMBLY-6O68 1. Remove the nuts and through bolt where 382B02.52’ applicable attaching the insulator to the No. 3 N 20-35 crossmember.

21-24-7 7.5L 460 CID V-B Engines-Passenger And Police Interceptor 21-24-7 3. Remove the valve rocker arm covers. 4. Remove the valve rocker arm bolt, oil deflector, fulcrum seat and rocker arm. FULCRUM BOLT-’ 6A529 Installation Apply Lubriplate or equivalent to the top of the valve stems, the rocker arm and fulcrum seats. OIL DEFLECTOR 2. Position the No. 1 piston on TDC at the end of the compression stroke in position 1 in Fig. 10 and install the rocker arm, fulcrum seat, oil deflector and bolt on the following valves: No. I Intake No. 1 Exhaust

21-24-8 7.5L 460 CID V-8 Engines-Passenger And Police Interceptor 21-24-8 3. Remove valve rocker arm bolts, oil deflectors, fulcrum seats, rocker arms, and pugh rods from affected cylinders. 4. Install air line with adapter in spark plug hole. Turn on air supply to hold valves closed. 5. Install Tool T7OP-6049-A Fig. 11 and compress valve spring. Remove retairter locks, spring retainer, and spring. Remove and discard valve stem seal Fig. 1 2. If air pressure fails to hold valve in closed position, valve damage affecting sealing is indicated. Remove and inspect cylinder head assembly. 6. Wrap rubber band, tape or string around end of valve stem to prevent valve from dropping into cylinder when air pressure in cylinder is shut off if pis

21-24-9 7.5L 460 CD V.8 Engines-Passenger And Police Interceptor 21-24-9 connector. Remove distributor and vacuum lines as an assembly. 7. Disconnect accelerator linkage at carburetor. Remove speed control linkage bracket, if so equipped, from intake manifold and disconnect it from the carburetor. Remove bolts holding accelerator cable bracket and position cable out of way. 8. Disconnect fuel line at carburetor. 9. Disconnect wiring harness at coil connector, engine temperature sending unit, oil pressure sending unit, and other connections as necessary. Disengage wiring harness from three clips at left valve rocker arm cover bolts, and position wiring harness out of way. 10. Remove coil and bracket assembly. Remove the

21-24-10 7.51 460 CID V-S Engines-Passenger And Police Interceptor 21-24- 10 VALLEY COVER AND GASKET ASSEMELY - 9D440 COOLANT OUTLET HOUSING -8 594 THERMOSTAT WATER TEMPERATURE SENDING UNIT-1D884

21-24-11 7.51 460 CID V-S Engines-Passenger And Police Interceptor 21-24-11 use plier.type Tool T7OP.14151 to remove them. Rotate tappets back and forth to loosen them from gum or varnish deposits. Refer to Part 21-01 for cleaning, inspection and -Itesting prodedure. If necessary to disassemble tappets, 1’ refer to Tappet Disassembly and Assembly in this Port. Installation 1. Clean the outside of tappets. Tappets and bores ore to be lubricated with heavy oil SE before installation. Install the tappets in their original bores. Check any new tappet for free fit in bore to which it is to be installed. 2. Install push rods in original positions. Apply Lubriplate or equivalent to valve stem tips an

21-24-12 7.51 460 CID V-B Engines-Passenger And Police Interceptor 21-24-12 Clean the oil passage in the push rods with a suitable solvent, and blow out with compressed air. 5. Install push rods in original positions. Apply Lubriplate or equivalent to valve stem tips and push rod ends. 6. Lubricate and install the rocker orms following the procedure under Valve Rocker Arm installation. Be sure lower ends of push rods remain seated in tappets. 7. Torque catalyst inlet pipe or muffler inlet pipe stud nuts to specification. FIG. 20 Right Exhaust Manifold Installation 8. Install intake manifold and carburetar assembly, following procedure under Intake Manifold Installation Installation.

21-24-13 7.5L 460 CID ‘1-8 Engines-Passenger And Police Interceptor 21-24-13 10. Loosen the by-pass hose clamp at the pump. 11. Remove remaining water pump attaching bolts and remove water pump from cylinder front cover. UNIVERSAL PULLER Remove cover plate from water pump. Discard gaskets. Installation 1. Remove any gasket material from water pump, cylinder front cover and pump cover. 2. Position new gaskets coated on both sides with water-resistant sealer. 3. Position water pump on cylinder front cover and install only those bolts not used to attach compressor bracket if installed and alternator bracket to water pump. Torque bolts to specification. tnstau the Thermactar par

21-24-14 7.5L 460 CID ‘1-8 Engines-Passenger And Police Interceptor 21-24-14 A 2953-lA FIG. 23 Removing or Installing Timing Chain FIG. 22 Aligning Timing Marks other as shown in Fig. 22. Install the chain and sprockets as an assembly to crankshaft and camshaft. Verify proper alignment of timing marks after installation. 2. Install the fuel pump eccentric, camshaft sprocket cap screw and washer. Torque cap screw to specification. Lubricate timing chain with engine oil. 3. Coat the gasket surface of the oil pan with sealer. Cut and position the required sections of a new seal on the oil pan. Apply sealer at the corners. 4. Coat the gasket surfaces of the block and cover with sealer, and po

21-24-15 7.51 460 CID V-S Engines-Passenger And Police Interceptor 21-24-15 TOO L--TB4T-6306-A A2957-lA FIG. 25 Installing Crankshaft Vibration Damper A2955-1A FIG. 26 Installing Front Oil Seal17. Adjust belt tensions to specification. Tighten alternator and air pump attaching bolts and compressor idler pulley, if so equipped, to specification. BEARINGS 18. Fill and bleed the cooling system. Fill the crankcase to the correct level with the recommended oil. 19. Run engine at fast idle and check for

21-24-16 7.5L 460 CID V-S Engines-Passenger And Police Interceptor 21-24-16 Installation the attaching screws to specification. Install screws 1. Oil the camshaft journals and apply Lubriplate or attaching shroud to the radiator. equivalent to the cam lobes. Carefully slide 19. Adjust the tension of drive belts to specifications camshaft into position. and tighten attaching screws. 2. Install camshaft thrust plate. Check camshaft end 20. Fill and bleed the cooling system and power play, following procedure in Part 21-01. If end play steering reservoir. Run engine at fast idle and check is excessive, replace the camshaft thrust plate. for leaks. 3. Insta

21-24-17 7.5L 460 CID V-S Engines-Passenger And Police Interceptor 21-24-17 bracket and frame. Lower the engine to allow the 5. Remove the oil pan attaching bolts and lower the blocks to support the engine. pan. Rotate the crankshaft to provide clearance 8. Remove the oil pan attaching bolts and lower the between the pan and crank throw or counterweight. pan to the No. 2 crossmember. Position rear 6. Remove the oil pan. crankshaft throw horizontally to ease pan removal. 7. Refer to Part 21 01 for cleaning and inspection 9. Remove the pan. procedures. Check the gasket surface for damage Refer to Part 2 1-01 for cleaning and inspection caused by over-tarqued bolts. S

21-24-18 7.5L 460 CID V-S Engines-Passenger And Police Interceptor 21-24-18 To align, rotate the intermediate shaft until it can be seated. Secure the oil pump to cylinder block and torque the screws to specifications. 4. Install the oil pan and related parts, following procedure under Oil Pan Installation. CRANKSHAFT REAR OIL SEAL A split-lip type crankshaft rear oil seal is used for replacement on all engines. If replacement is necessary, this type of seal must be used. The complete seal can be replaced without removing the crankshaft. Refer to Part 21-01 for removal and installation procedures. MAIN BEARING Main and connecting rod bearing inserts are selective fits. cRANKSHRFT JOURNAL A2962-IA

21-24-19 7.5L 460 CID V-B Engines-Passenger And Police Interceptor 21-24-19 3 TOHQUL CAP BOLTS 1.PRY CRANKSHAFT WHILE HOLDING FORWARD AND HOLD CRAOI<:-IHAFT FORWARD 2 F’HY FLAP DEARWAPO 0 a, ‘ 0 SN 0

21-24-20 7.5L 460 CID V-8 Engines-Passenger And Police Interceptor 21-24-20 8. Install the connecting rod cap. Be sure connecting OIL RING SPACER rod bolt heads are properly seated in the connecting rod. Torque the nuts to specifications. 9. After the piston and connecting rod assemblies have been installed, check the side clearance between the connecting rods on each crankshaft journal. 10. Disassemble, clean and assemble the oil pump. Clean the oil pump inlet tube screen, and oil pan and the block gasket surfaces. 11. Prime the oil pump by filling the inlet port with engine oil and rotating the pump shaft to distribute oil within the housing. Install the oil pump. Install the oil pan, following the procedure

21-24-21 7.5L 460 CID V-8 Engines-Passenger And Police Interceptor 21-24-21 MAIN BEADING INSERTS DEAR REARING FLYWHEEL -6375 CAP JOURNAL 6333 SEAL 5701

21-24-22 7.5L 460 CID V-S Engines-Passenger And Police Interceptor 21-24-22 26. Install the oil filter and fuel pump, and connect the damage. Align oil holes in bearings with oil holes fuel lines. in cylinder block before pressing them into block. 27. Install the spark plugs and connect the spark plug Be sure front bearing is installed specified distance wires below front face of cylinder block Fig. 34. 28. Install the engine in vehicle. 5. Install the bearing bore plug as detailed under "Care Plugs" in Part 21-01, CAMSHAFT BEARINGS

21-24-23 7.5L 460 CID V.8 Engines-Passenger And Police Interceptor 21-24-23 Installation PILTER ELEMENT 6231 1. Coat the gasket on a new filter with oil. Place a new filter on the adapter fitting. Hand tighten the filter until the gasket contacts the sealing surface then tighten 1 /2 turn more.

21-24-24 7.5L 460 CID V-B Engines-Passenger And Police Interceptor 2 1-24-24 2. Clean carbon from combustion chambers before removing valves. 3. Compress valve springs Fig. 37. Remove spring retainer locks and release springs. Remove retainers, springs, stem seals, and valves. Discard stem seals. Clean and inspect cylinder heads and related components, using pertinent procedures in Part 21- 01. Refer to Part 21-01 for repair procedures for cylinder heads and valves. Assembly Lubricate all valves, valve stems and valve guides with heavy oil SE. The valve tips are to have Lubriplate or equivalent applied. The lubricant is to be applied before installation. 1. Install each valve in port from which it was removed or

21-24-25 7.5L 460 CID V-8 Engines-Passenger And Police Interceptor 21-24-25 PRESS RAM RIGHT RANK LEFT BANK NOTCH IOWARC mONT OH ENGINE: OR IV ER UE1AII A-? INSERT TAPERED PILOT IN PISTON PIN POR PIN RP000AI

0 005 21-24-26 7.5L 460 CID V-8 Engines-Passenger And Police Interceptor 21-24-26 SPECIFICATIONS GENERAL SPECIFICATIONS CAMSHAFT PoliceInterceptor Peso. LOBE LIFT DISPLACEMENT 1.SL 460 CIV llstakp 0.278 - . . - 0.253 NUMSER OF CYLINDERSITYFE VB-OHV ExPanD 0.290 - . . - 0.218 BOREANOSTROKE

5U,00060060358 6 a6065 21-24-27 7.51 460 CD V-8 Engines-Passenger And Police Interceptor 21-24-27 CONNECTING ROD, PISTON AND RINGS TOROUE SPECIFICATIONS - SPECIAL APPLICATION CONNECTING ROD CAMSHAFT SPROCKET TO CAMSHAFT £4045 Piutrn Pis trr, Diameter 1.0386-t.B393 CAMSHAFT THRUST PLATE TO BLOCK - 9-12 Crankshaft Bearing Barn Die meter 2.6530-2.6522 CONNECTING ROD NUTS OR BOLTS 40-45 Out-Of- Rourd Limit

23-00-1 Ignition System 23-00-1 GROUP IGNITION SYSTEM 23 12000 CB351 O-2A PAm General Ignition Service 23-01 All Models Except Versailles with EEC System SUBJECT PAGE SUBJECT PAGE GENERAL INFORMATION REMOVAL AND INSTALLATION Cont’d. Centrifugal Advance 01-3 Fixed Base Hate 01-9 Circuit Operation

23-01-2 General Ignition Service 23-01-2 modules have the same exterior appearance Fig. 2. Altitude Compensation See Part 29-06 for operation and servicing of the An aneroid switch Fig. 2 provides an automaticEEC system components not covered in this Part. retard signal to the module at different altitudes, giving appropriate advanced timing at higher altitudes and Dual Mode Timing Ignition Module retard mode for spark knock control at lower altitudes. On some applications, a special Dura Spark II Economy Calibrations ignition module is used, with altitude compensotion ond

23-01-3 General Ignition Service 23-01-3 circuit, coil and ignition switch. Certain other service Retarding the timing during these periods helps control actions such as removing the distributor cap with the engine emissions. ignition switch "on" may also cause the system to fire. The distributor on four or six cylinder engines rotates For this reason, the ignition switch should remain in a clockwise direction. To advance timing; rotate the "off" during any underhood operations unless the distributor counterclockwise. The distributor on V-8 intent is to start the vehicle engine, or to perform engines rotates counterclockwise. To advance t

23-01-4 General Ignition Service 23-01-4 AMOUNT OF TRAVEL FOR RETARD DIAPHRAGM PLATE RESTING 0° RETARD RETARD DIAPHRAGM AT FULL RETARD PLATE RESTING ON STOP RETARD STOP SECONDARY ADVANCE DIAPHRAGM IN VACUUM FULL ADVANCE POSITION CON N E CT ID N RETARD SPRING

23-01-5 General Ignition Service 23-01-5 The secondary circuit consists of the: The high voltage flows through the coil high tension 1. Secondary windings of the ignition coil. lead to the distributor cap where the rotor distributes it to one of the spark plug terminals in the distrbutor2. Distributor rotor cap. This process is repeated for every power stroke of3. Distributor cap. the engine. 4. High tension spark plug wires. 5. Spark plugs.

CYLINDER NUMBERING AND CYLINDER NUMBERING AND CYLINDER NUMBERING AND CYLINDER NUMBERING AND DISTRIBUTOR LOCATION DISTRIBUTOR LOCATION DISTRIBUTOR LOCATION DISTRIBUTOR LOCATION p4p 0 DISTRIBUTOR

23-01-7 General Ignition Service 23-01-7 REMOVAL AND INSTALLATION DISTRIBUTOR-V-8 ENGINES the mark previously scribed on the distributor body and the marks on the distributor body and cylinder Removal block in alignment. 1. Remove the air cleaner. Disconnect the distributor 3. Install the distributor cap and wires. wiring connector from the vehicle wiring harness. 4. Connect the distributor wiring connector to the 2. Disconnect the vacuu

23-01-8 General Ignition Service 23-01-8 ROLL. PIN ARMATuRE -ARMATURE STOP RING MAGNETIC PICKUP ASSEMBLY STATOR ASSEMBLYI SYSTEM GROUND vAcuuM ADVANCE LINK FIXED BASE P LATE WIRE RETAINER WIRING HARNESS

23-01-9 General Ignition Service 23-01-9 Removal STATOR TOOTH MUST SE PERFECTLY 1. Remove the cap, rotor and adapter. ALIGNED WITH TIMING MARKS 2. Disconnect the vacuum lines. EACH 1/2 TOOTH ERROR IS 3. Remove the spring clip that secures the diaphragm DEGREESEOUAL TOTIMING7-3/4 ENGINEERROR link to the movable advance plate. 4. Remove the diaphragm unit attaching screws and carefully remove the unit by tilting downward to disengage the link from the post on the movable advance plate. Installation 1. Position the diaphrag

23-01-10 General Ignition Service 23-01-10 2. Slide the wiring grommet into the slot at the edge of the lower plate and install the ground screw. Install the washers and snap ring to secure the pickup coil assembly to the lower plate. TOO L-T74F-6666-A 3. Install the armature on the advance plate sleeve, making sure the roll pin is engaged in the matching slats. 4. Install the distributor rotor, adapter and cap and connect the distributor wiring plug to the vehicle harness. VACUUM ADVANCE UNIT Removal

23-01-11 General Ignition Service 23-01-11 the appearance of being a contaminant of the cap and rotor electrodes. This condition is normal and causes no performance loss. COIL CONNECTOR REPLACING SPARK PLUGS 10 ‘DEC TERMINAL Removal TRONICDISTRIBUTORCONTROLIELEC 1. Remove the wire from each spark plug by grasping the molded boot with Tool T74P-oooo.A Fig. 11. Twist the boot until it loosens and then pull it off the spark plug. Do nat pull on the wire, as the connection may become damaged. 2. Any wire damaged must be replaced. Each original spark plug wire is numbered for the cy

23-01-12 General Ignition Service 23-01-12 GAP BRIDGED OIL FOULED CARBON FOULED - --.4-z IDENTIFIED 5V DEPOSIT IDENTIFIED By WET BLACK DEP IDENTIFIED BY BLACK, BUILD-UP CLOSING GAP OSITS ON THE INSULATOR SHELL DRY FLUFFY CARBON BETWEEN ELECTRODES. BORE ELECTRODES CAUSED BY DEPOSITS ON INSULATOR CAUSED BY OIL OR EXCESSIVE OIL ENTERING COMBUS TIPS. EXPOSED SHELL CARBON FOULING. REPLACE TION

23-01-13 General Ignition Service 23-01-13 Clean the plugs on a sand blast cleaner, following wire part of 14401 wiring harness. The resistor wire the manufacture’s instruction. Do not prolong the use is fed from a circuit weld in the harness approximately of the abrasive blast as it will erode the insulator 3" from the connector to the ignition switch on the and electrodes. steering column, and is routed to the connector on the back of the fuse panel which connects with the 14398 Examine the plug carefully for cracked or broken engine comportment wiring harness on the left side ofinsulators, badl

23-01-14 General Ignition Service 23-01-14 14. Connect the free end of the new resistor wire to the 17. Start the vehicle and see if the engine will continue free end of the lumper, using a B7A-14487-A single running when the lock cylinder is released to the connector Fig. 18. RUN position. if not, check for proper voltage at 15. Reassemble the connector to the back of the fuse the ignition coil ION terminal. Voltage should be panel and connect it with the 14389 wiring harness about 6.4 volts, or resistance to ground should read at the dash panel. from 1.05.1.15 ohms at 75°F. The new resistor allows fa

23-01-15 General Ignition Service 23-01-15 WIRE RETAINING TANGS I UNLOCKING RIRE FROM RETAINER-CONNECTOR ASSEMBLY INSTALLING WIRE TERMINAL TO RETAINER-CONNECTOR ASSEMBLY K2591 -24 FIG. 17 Removing Female Terminal From Fuse Block Connector P ETA IN P CGN N ECTOR

23-01-16 General Ignition Service 23-01-16 SPECIFICATIONS DISTRIBUTOR GENERAL INFORMATION Distributor Gear Distributor Gear Shaft End Location j Shaft End location Engine Play 1 :i Engine Play Li 2. 2.3L 0.022-0033 2.220-2.230 5.8L 351 CID 0024-0035 4.0314038 2.OL - 0022-0.033

23-01-17 General Ignition Service 23-01-17 SPECIAL TOOLS cBlegB-ZF "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

_______________________________________ 24-01-1 Fuel System 24-01-1 - - GROUP FUEL SYSTEM 24 - 9500 PART TITLE