1981 FSM All Windsors
1981 FSM All Windsors
1981 FSM All Windsors
DESCRIPTION
WARNING: Do not operate the engine with the arms are individually bolt mounted. The valve lifters are
hood open until the fan has been first examinad hydraulic.
for possible cracks and separation.
The 4.2L (255 CID) V-8 is available on sorne F-1 00
ENGINE models. The 5.0l (302 CID) V-8 is used asan option on
so me F-1 00, F- 150, F-250 and Bronco models al so E-
The 4.2L (255 CID) V-8, 5.0L (302 CID) V-8 and 5.8L lOO, E- 150 and E-250. The 5.8l (351 CID) W-V-8 is
(351 CID) W-V-8 engines hove the same basic design. optional for E-l 00-E-350 and F-150, F-250 and
The cylinder block for these engines is special high Bronco California models. An aluminum intake manifold
grade cast iron, thin wall construction. The crankshaft is used on 4.2l (255 CID), 5.0l (302 CID) and 5.8l (351
has five main bearings and is precision cast nodular CID) W-V-8 engines. Refer to the Specification listed
iron. Pistons are alur:ninum alloy, tin plated. Valve rocker at the end of this Port.
21-21-2 4.2l (255 CID) V-8, 5.0l (302 CID) V-8 and 5.8l (351 CID) W-V-8 Engines 21-21-2
The illustrations shown in Figs. 1 and 2 are typical EXHAUST EMISSION CONTROL SYSTEM
and will serve as a reference for the procedures
outlined. The numbers and part descriptions shown in The exhaust emission control devices used on these
the illustration keys are basic part numbers engines are covered in Group 29 of this Manual.
corresponding with the Ford Master Parts Catalog.
CRANKCASE VENTILATION SYSTEM
LUBRICATION SYSTEM These engines are equipped with a positive closed-
A typical lubrication system is shown in Figure 3 . type crankcase ventilation system directing the
crankcase vapors to the intake manifold for combustion.
COOLING SYSTEM
A typical cooling system is shown in Figure 4.
60
44
--
~
1
~
1
w
57
41
TI GHTEN TO
2 1-24 N -m 115-18 FT -LBSI 39
01
VIEW FOR E-100, 150, 250 5.0L 1302 CID)
o,....
w
o
.....,
()
2
< 1
())
o
:::::1
a..
~
,....
())
w
01
17
()
2
~
< 1
())
62
31
m
:::::1
48 ce.
:::::1
CD
63 "'
TIGHTEN TUBE NUT
TO 21 -24 N ·m 115· 18 FT·LBSI
FAONT OF ENGINE
~
USE NO SEALER
1
1 6009 Cylinder Assy. - (lncludes 39 12106 Distributor- Cap .o.
interna! parts) 40 12127 Distributor Assy.
2 6019 Cover Assy.- Cylinder Front 41 12259 Wire Set- Spark Plug
3 6020 Gasket- Cylinder Front Cover 42 12270 Clamp- Distributor
4 6023 Pointer- Timing 43 12405 Spark Plug Assy.
5 6049 Head - Cylinder 44 18599 Elbow- Hot Water Connection
6 6051 Gasket- Cylinder Head 45 56126-S Bolt - Washer Head -
7 6065 Bolt- Cylinder Head 5/16-18 X 7/8"
8 6266 Plug- Camshaft Rear Bearing 46 20386-S Bolt- 5/16-18 x 1"
9 6375 Flywheel Assy. 47 383765-S Bolt - 5/16-18 x 3-5/8"
10 6392 Housing Assy. - Flywheel 300958-S Bolt- 5/16-18 x 5"
11 6582 Cover Assy. - Valve Rocker Arm
48
49 56128-S Bolt- 5/16-18 x 2-1/2"
-
12 6584 Gasket- Val ve Rocker Arm Cover 50 56126-S Bolt- 5/16-18 x 2" 01
13 68890 Elbow & Valve Assy.- P'ositive 51 376256-S Bolt or Screw- 5/16-18 x 1" or-
Crankcase Ventilation (P.C.V.)
14 6675 Pan Assy. - Oil
52
53
373564-S • Bolt- 5/16-18 x 1-7/8"
381731-S Bolt- 3/8-16 x 1-7/8"
w
o
15 6700 Seal - Cylinder Front Cover 54 35674s-s ¡ Bolt- 1/4-20 x 5/8"
1>,.)
1
Ul
!>--
1\,)
r-
'¡:::)
01
01
()
2
< 1
SX'
01
or-
w
ot-.)
()
o
63 <
Ca
o
::J
o.
01
(X)
r-
w
01
()
2
~
<1
(X)
m
::J
ce.
::J
~
"'
61
.,.,
33
A4941 ·2B
--.,.,
1
1
Ul
FIG. 2 Interna! Exploded View-4.2L (255 CID) V-8, 5.0L (302 CID) V-8 and 5.8L (351 CID) W-V-8
Engines
Ref. Buk: Ref. Baslc
Descrlptlon Descrlptlon
No. Part No. No. Part No.
1 6010 Block Assy. (Interna! parts not 34 6379 Bolt - Flywheel to Crankshaft
included) 35 6384 Gear - Flywheel Ring
2 6019 Cover Assy. - Cylinder Front 6500 Tappet Assy. - Hydraulic
36
3 6049 Head - Cylinder 37 6505 Valve- Exhaust
4 6108 Piston Assy. 6507 Valve - lntake
38 !>--
....,
5 6135 Pin- Piston 39 6513 Spring - Valve ,....
6 6148 Ring Set- Piston 40 6514 Retainer- Valve Spring '¡;:)
7 6200 Rod Assy. - Connecting 41 6518 Key- Valve Spring Retainer 01
6211 Bearing - Connecting Rod 01
8 42 6A528-A Fulcrum
Nut- Connecting Rod (')
9 6212 43 6571 Valve Stem Seal
10 6214 Bolt- Connecting Rod 44 6A53-1 Oil Deflector .2
11 6250 Camshaft 45 6A527-A Bolt- Rocker Arm Attach <
1
12 6251 Bearing Kit - Camshaft - Standard 46 6564 Arm - Valve Rocker (X)
A4942·2B
--
~
1
~
1
o.
FIG. 2A lnternal Exploded View-Key
21-21-7 4.2L (255 CID) V-8, 5.0L (302 CID) V-8 and 5.8L (351 CID) W-V-8 Engines 21-21-7
A5505 · 1A
ADJUSTMENTS
VALVE CLEARANCE 4.2L (255 CID) Y·B ANO 5.0L (302 CID) V·B
ENGINES
The valve arrangement of the left bank is E-1-E-1-E-1-
E-1 and on the right bank is 1-E-1-E-1-E-1-E. l. lnstall an auxiliary starter switch. Crank the engine
with the ignition switch OFF until the No. 1 piston
A 0.060 inch shorter push rod or a 0.060 inch longer is on TDC after the compression stroke.
push rod are available for service to provide a means 2. With the crankshaft in the positions designated in
of compensating for dimensional changes in the valve Steps 3, 4 and 5, position the tappet compressor
mechanism. Refer to the Master Parts list or the tool T71 P-6513-A or equivalent on the rocker arm
Specifications listed at the end of this Part for the (Fig. 5).
pertinent color code.
Slowly apply pressure to bleed down the tappet
Valve stem to valve rocker arm clearance should be until the plunger is completely bottomed (Fig. 5).
within specifications with the hydraulic tappet Hold the tappet in this position and check the
completely collapsed. Repeated valve reconditioning available clearance between the rocker arm and
operations (valve and/or valve seat refacing) will the valve stem tip with a feeler gauge.
decrease the clearance to the point that if it is not lf the clearance is less than specifications, install
compensated for, the hydraulic valve tappet will cease a shorter push rod.
to function and the valve will be held closed. lf the clearance is greater than specifications,
The positive stop rocker arm bolt eliminates the install a longer push rod.
necessity of adjusting the valve clearance. However, to 3. With the No. 1 piston on TDC at the end of the
obtain the specified valve clearance, it is important that compression stroke, POSITION 1 in Fig. 6, check
all valve components be in a serviceable condition and the following valves:
installed and torqued properly. No. 1 lntake No. 1 Exhaust
To determine whether a shorter ora longer push rod No. 7 lntake No. 5 Exhaust
is necessary, make the following check. No. 8 lntake No. 4 Exhaust
21-21-8 4.2L (255 CID) V-8, 5.0L (302 CID) V-8 and 5.8L (351 CID) W-V-8 Engines 21-21-8
POS ITI ON 1 -
NO . 1 A T T DC . A T
END OF COMPRESS IClN
STA OKE
POS IT ION 2 -
ROT A TE CRANKSHAFT
A3000 -1E 180° IONE -HALF
REVOL UTI ONI CL OCK WI SE,
FR OM POS ITI O N 1
FIG. 5 Checking Valve Clearance-Hydraulic POS ITI ON 3 -
Valve Lifters ROT A TE CRANKSHAFT
27 0° IT HRE E-QU A RT ER
REVOLUT IONI C LOCKW ISE,
4. Rotate the crankshaft to POSITION 2 in Fig. 6 and FROM POS IT ION 2 A3234 - 1E
check the following v_alves.
No. 5 lntake No. 2 Exhaust FIG. 6 Position of Crankshaft for Checking and
Adjusting Valve Clearance
No. 4 lntake No. 6 Exhaust
5. Rotate the crankshaftto POSITION 3 in Fig. 6 and 3. With the No. 1 piston on TDC at the end of the
check the following valves. compression stroke, POSITION 1 in Fig. 6 check the
following valves:
No. 2 lntake No. 7 Exhaust
No. 1 lntake No. 1 Exhaust
No. 3 lntake No. 3 Exhaust
No. 4 lntake No. 3 Exhaust
No. 6 lntake No. 8 Exhaust
No. 8 lntake No. 7 Exhaust
5.8L (351 CID) W-V-8 ENGINE 4. After these valves hove been .checked, rotate the
l. Disconnect the brown lead (1 terminal) and the red crankshaft to POSITION 2 in Fig. 6 and check the
and blue lead (S terminal) at the starter relay. following valves:
lnstall an auxiliary starter switch between the No. 3 lntake No. 2 Exhaust
battery and S terminals of the starter relay. Crank No. 7 lntake No. 6 Exhaust
the engi1:1e with the ignition switch OFF until the No. 5, After these valves hove been checked, rotate the
1 piston is on TDC on the compression stroke. crankshaft to POSITION 3 in Fig. 6 and check the
2. With the crankshaft in the positions designated in following valves:
Steps 3, 4 and 5, position the tappet compressor No. 2 lntake No. 4 Exhaust
tool on the rocker arm. Slowly apply pressure to
No. 5 lntake No. 5 Exhaust
bleed down the tappet until the plunger is
completely bottomed (Fig. 5). Hold the tappet in No. 6 lntake No. 8 Exhaust
this position and check the available clearance lf the clearance is less than specifications, install
between the rocker arm and the valve stem tip with a shorter push rod. lf the clearance is greater than
a feeler gauge. specifications, install a longer push rod.
17. lf so equipped, connect two A/C lines to the A/C evaporative emission hoses, where applicable, from
compressor (refer to Part 36-61, light Truck and front of carburetor pad and/or top of PCV valve.
Bronco Heater-Air Conditioning System). Disconnect hose at carburetor bowl vent and
18. lnstall the radiator (refer to Part 27-04 Radiators). vacuum hose from evaporative canister to vacuum
Connect the radiator upper and lower hoses. harness at the harness. Raise the vehicle on the
Connect the transmission oil cooler lines if so hoist, drain the crankcase and remove the oil filter.
equipped. lnstall the fan shroud. Disconnect the power brake booster vacuum hose,
if so equipped.
19. lf so equipped, install the A/C condenser to the
radiator (refer to Part 36-61, light Truck and 10. Disconnect the muffler inlet pipe at the exhaust
Bronco Heater-Air Conditioning System). manifolds. Remove two bolts retaining the
20. Connect the heater hose at the water pump. Fill and transmission filler tube bracket to the right cylinder
bleed the cooling system (refer to Part 27-02, head.
General Cooling System Service). Fill the crankcase 11. Remove the engine mount attaching bolts and nuts
with the proper grade and quantity of oil. Connect (Fig. 7). Remove the starter motor and disconnect
the power brake booster vacuum hose, if so the cable. On vehicles equipped with a manual
equipped. transmission, remove the housing to engine bolts.
21. Operate the engine at fast idle and check all On vehicles equipped with an automatic
gaskets and hose connections for leaks. transmission, remove the converter inspection cover
22. lnstall the air cleaner and intake duct assembly bolts.
including the crankcase ventilation hose and carbon
cannister hose. INSU L A T OR
23. Adjust idle speed and mixture to sp'ecifications on ASSEMBLY - 6038
Engine decal.
24. Evacuate and charge the A/C System (if so SUPPORT
intake manifold (attaching bolts). Remove two verter to the flex plate. lnstall the converter inspec-
converter housing-to-cylinder block upper bolts. tion cover (bolts).
19. Position a floor jack under the transmission for 1O. lnstall the starter motor and connect the cable.
support. Position a floor crane to the vehicle and lnstall the engine mount attaching bolts and nuts.
connect it to the lifting bracket which is attached Tighten to specifications.
to the intake manifold a nd carefully move engine 11. lnstall the two bolts that retain the transmission
forward in the engine compartment so that no filler tube bracket to the right cylinder head.
components are damaged. lnstall the engine on a
work stand. 12. Connect the muffler inlet pipe at the exhaust
manifolds (refer to torque specifications in Part 26-
20. Remove the engine from the vehicle. 01, Exhaust System General Service). lnstall the oil
filter.
lnstallation
13. Lower the vehicle on hoist. Position the carburetor,
1. On vehicles equipped with an automatic with gasket, to the intake manifold, install four
transmission, connect the floor crane to the engine. nuts, spacer (cast iron intake manifold only),
Raise the engine and position it into the vehicle connect the fuel line, choke line, vacuum lines and
aligning the transmission converter to the flywheel the choke lead wires. Reconnect evaporative
(or flex platel and the engine dowels to the canister hoses to carburetor bowl vent, vacuum
transmission. Lower the engine to the chassis harness and intake manifold or PCV valve.
brackets, and ali'gn the through-bolt holes on the
engine supports (Fig. 7). 14. Connect the throttle and transmission linkage and
On vehicles equipped with a manual the speed control linkage, if so equipped, at the
transmission, start the transmission main clutch carburetor. Connect the alternator lead wires to the
drive shaft into the clutch disc. alternator.
lt may be necessary to adjust the position of the 15. Position the power steering pump drive belt to its
transmission in relation to the engine if the input respective pulleys, adjust belt tension and tighten
shaft will not enter the clutch disc. lf the engine the retaining bolts (refer h.> Specifications at end
hangs up after the shaft enters, turn the crankshaft of this Part). lf so equipped, connect two A/C lines
slowly (transmission in gear) until the shaft splines at the A/C compressor (refer to Part 36-65, E-
mesh with the clutch disc splines. l 00--E-350 Air Conditioning System) and install
the accelerator cable bracket to the dash.
Align the housing on the engine and insert the
housing to engine bolts . Tighten bolts to 16. Position the radiator to the radiator support and
specifications. secure with four attaching bolts (refer to Part 27-
2. On vehicles equipped with an automatic 04, Radiators). lnstall the shroud and secure with
transmission, install two converter housing-to- four attaching bolts.
cylinder block lower bolts. Remove the lifting 17. Connect two oil cooler lines at the radiator, if so
bracket from the intake manifold. equipped.
3. Remove floor jack from under the transmission, and 18. Connect the radiator lower hose at the radiator.
position it out of the way. Connect the radiator upper hose at the radiator.
4. lf so equipped, connect the A/C compressor 19. lnstall the A/C condenser to radiator support, if so
magnetic clutch lead. (refer to Part 36-65, E-1 00-- equipped (refer to Part 36-65, E-1 00--E-350 Air
E-350 Air Conditioning System). Conditioning System. lnstall the grille upper support
5. Connect the flex tube to the exhaust manifold bracket, hood lock support and condenser upper
stove . Position the accelerator cable mounting mounting brackets.
bracket and the speed control servo to the intake 20. lnstall the grille assembly. Fill the crankcase. Fill the
manifold, and install three attaching bolts. cooling system (refer to Part 27-02, General
6. Position the engine wire harness in retainers and Cooling System Service).
connect at respective locations. Connect vacuum 21. Connect battery, start engine and check for leaks.
lines at the rear of the intake manifold. Connect the Adjust idle speed and mixture to specifications on
power brake booster vacuum hose, if so equipped. Engine Decal.
7. Connect two heater hoses, one at the heater core 22. Evacuate and charge the A/C system, if so
and one at the water valve. lf so equipped position equipped (refer to Part 36-30, Air Conditioning
the power steering front face bracket and the System General Service). lnstall the air cleaner
power steering pump to the water pump and the assembly.
left cylinder head. lnstall the six attaching bolts.
8. lnstall the fan assembly and spacer to the water 23. lnstall the engine cover.
pump shaft and position the shroud over the fan
assembly. ENGINE FRONT SUPPORTS
9. Raise the vehicle on a hoist . lnstall one bolt
attaching ground cable to cylinder block. lnstall The front supports are located on each side of the
four lower converter housing-to-cylinder block cylinder block. The procedures given apply to either a
bolts. lnstall the three adapter plate-to-converter right or left installation. However, a sheet metal shield
hou~ino bolts. lnstall four nuts retainina the con- on the left side only is used on F-Series trucks.
21-21-12 4.2L (255 CID) V-8, 5.0L (302 CID) V-8 and 5.8L (351 CID) W-V-8 Engines 21-21-12
F-100 and F-250 4. Replace the insulator to support nuts and tight€;·,
Removal to specifications. lnstall fan shroud and bolts.
l. Remove the bolts attaching the fan shroud to the
radiator and position the shroud over the fan.
ENGINE REAR SUPPORTS
2. Remove the nut and washer attaching the support The procedures given apply to F-100-F-250 and
insulator to the chassis bracket. Bronco and E- 100-E-350 center mount (Figs. 9 and
3. Raise the engine. 10}.
4. Remove the bolts and lock washers attaching the F-100-F-250 ANO BRONCO
support insulator to the cylinder block (Fig. 8} and
remove the insulator and hect shield; left side only. Removal
BRACKET l. Remove the support insulotor-to-crossmember
6061 attaching bolt ond locknut (Fig. 9}.
2. Remove the support insulotor-to-transmission
extension housing bolts and lockwashers.
3. Raise the transmission with a floor jack. Remove the
support insulator and retainer.
lnstallation
l. Position the support insulator and retainer on the
transmission extension housing (Fig. 9}.
2. lnstall the support insulator-to-transmission
extension housing bolts and lockwashers. Tighten
the bolts to specifications. Lower the transmission.
3. lnstall the support insulator-to-crossmember
attaching bolt and lock nut. Tighten the nut to
NUT
specifications.
NUT ANO WASHER
ASSEMBLY - 388049-52
N620483-S2
65 -88 N ·m
Check to see that the retainer does not
VIEW SHOWING INSTALLATION OF '.48-65 FT -LBSI contact the portian of the insulator which is
FRONT ENGINE MOUNTS FOR 302 C.I.D. ENGINE A4992 -1A attached to the crossmember.
FIG. 8 Engine Front Supports-F-1 00--F-250-- E-1 00-E-250
Bronco
Removal
lnstallation l. Raise the vehicle on a hoist.
l. Position the support insulator and hect shield, left 2. Remove the insulator support nuts securing the rear
side only to the cylinder block and install the insulator support to the frame crossmember (Fig.
attaching bolts an_d lockwashers loosely. 10}.
2. Carefully lower the engine, guiding the support 3. Raise the transmission with a jack so that the
insulator stud into the support bracket (Fig. 8}. insulator support clears the frame.
Tighten the insulator-to-engine bolts to
4. Remove the insulator support bolts securing the rear
specifications.
insulator support to the transmission, then remove
3. lnstall the insulator-to-chassis bracket nut and the insulator.
washer. Tighten the nut to specifications.
4. lnstall the fan shroud attaching bolts. lnstallation
l. Position the insulator support, then instoll the bolts
E-100-E-350 securing the insulator support to the tronsmission
Removal (Fig. 10}. Tighten the bolts to specifications.
l. Remove fan shroud bolts. Remove the insulator to 2. Lower the jack supporting the transmission and
support nuts (Fig. 7}. align the insulator support bolt holes with the holes
2. Position transmission jack under engine assembly. in the frame assembly.
Lift engine assembly and then remove starter (Part 3. lnstall the bolts and nuts securing the insulator
28-02, Starter}. support to the frame. Tighten to specification.
3. Remove insulator to engine bolts and alternator 4. Lower the vehicle.
splash shield. Remove the insulators (Fig. 7}.
lnstallation
EGR EXTERNAL COOLER
l. Clear slots in engine block of debris, using a 7/16- 5.0L (302 CID) and 5.8LW (351 CID) V-8 California
14 bottoming tap. Models Only
2. lnstall insulators to engine using new bolts and l. Drain the radiator.
tighten to specifications (Fig. 7}. 2. Disconnect the coolant lines to the EGR cooler.
3. lnstall starter (Part 28-02, Starter} and then lower 3. Loosen and remove the 5/16 inch and 3/8 inch nuts
the engine assembly. Move transmission jack out holding the EGR valve and cooler to the intake
of the way. manifold (Fig. 11 }.
21-21-13 4.2L (255 CID) V-8, 5.0L (302 CID) V-8 and 5.8L (351 CID) w~V-8 Engines 21-21-13
FRONT OF VEHICLE
SUPPORT - 5060
'"'·'"M~"--"'1 '
- - : : .-· ----1:
~ --~ b
-- ~
~~e>~
--~--~
:
~
'.
WAS HE R
OOU~M»
INSTALLATION WITH 3 SPD. MANUAL , 450 D SROD,
ABSORBER - 6A037 C4 AUTO., 3 SPD. MEO . DUTY F-100, 150, 250, 350 (4x2} ALL
CENTERLINE INSULATOR___
~
•
FRONT OF VEHICLE
ABSORBER - 6A061 ~~--:i--::--
~- o 'e::>'
:
----- '
-~--------=-=- ¿::»
1
A BOL T - 304726 S2
~~ " "''""'"'-'"'"
RETAINER ASSEMBLY - 6054
--::b...
INSTALLATION BRONCO , F-150, 250, (4x4}
NUT - 4 5350 S2
-,<~('<::~,,:: ,: · .~~~~~r::·~':c.
specification.
6. Connect water lines to the EGR cooler.
7. Close the radiator drain petcock and refill the
radiator, Part 27-01. Operate engine and check for
coolant or exhaust leaks.
~
VIEWA CRANKCASE VENTILATION SYSTEM
The crankcase ventilation system components for the
various applications are shown in Figs. 12 and 13. Any
modification of the system prior to the first sale
and registration of the vehicle is subject to Federal
(U.S.A.) law and to the penalties under the laws
"""i~:E~::::~¡:~~~~~.::: ~::
of some states thereafter.
F-100-F-250, BRONCO
neo" : :
ANO 5 .8L (351 CID} W V -8 ENGINE Removal
5.0L (302 CID} NUT -382400-52
l. Disconnect the crankcase vent rear hose from the
-·
59 71 N m 143 53 FT LBS}
_,,• A2782 -1H air cleaner. Pull the hose and elbow out of the
grommet in the valve rocker arm cover. Remove the
FIG. 10 Engine Rear Support-E-100--E-350 elbow from the vent hose.
2. Remove the air cleaner and intake duct assembly.
4. Carefully remove EGR valve, disconnect electrical
connection if necessary. 3. Disconnect the crankcase vent front tube from the
carburetor spacer and the PCV valve in the rocker
5. Remove EGR cooler from intake manifold. arm cover.
1nsta llation 4. Remove the cam-lock oil filler cap from the valve
rocker arm cover. Pull the PCV valve out of the
l. lnstall one gasket to manifold. grommet in the rocker arm cover.
2. lnstall EGR cooler in proper orientation to insure
1nstallation
short side to manifold and scallop in UP position.
l. lnsert the PCV valve into the grommet in the oil filler
3. lnstall second gasket between cooler and valve. cap. lnstall the oil filler cap in the valve rocker arm
4. lnstall EGR valve. cover and turn the cap to lock it into position.
21-21-14 4.2L (255 CID) V-8, 5.0L (302 CID) V-8 and 5.8L (351 CID) W-V-8 Engines 21-21-14
9424
9L438GASKET
/ '"""' """0'"
EG R COOL ER EXTERNAL
FRO NT O F ENGINE
A5008 -A
A4994 -2B
FIG. 12 Typical Crankcase Ventilation System-5.0L (302 CID) V-8 Shown, 4.2L (255 CID) V-8
2. Connect the crankcase vent front tube to the PCV 2. Remove the air cleaner and intake duct assembly.
valve and the carburetor spacer. lf so equipped, disconnect the oil filter pipe hose
3. lnstall the air cleaner and intake duct assembly. from the left rocker arm cover.
4. lnsert the elbow into the grommet in the valve 3. Disconnect the crankcase vent rear hose from the
rocker arm cover. Connect the crankcase vent rear carburetor spacer, at the rear of the carburator or
hose to the elbow and the air cleaner. front of intake manifold. Pull the hose and PCV
5. Start the engine and check for leaks. valve out of the grommet in the valve rocker arm
cover. Remove the PCV valve from the vent hose.
E-1 00-F-350
Removal lnstallation
l. Disconnect the crankcase vent front hose from the l. lnsert the PCV valve into the grommet in the valve
air cleaner. rocker arm cover. Connect the crankcase vent rear
21-21-15 4.2L (255 CID) V-8, 5.0L (302 CID) V-8 and 5.8L (351 CID) W-V-8 Engines 21-21-15
FRONT OF ENGINE
A4993 -2B
provided in the cover. Position the cover(s) on the 7. lnstall the PCV valve into the right rocker arm cover.
cylinder head(s). lnstall the bolts and tighten to 8. Reconnect evaporative canister hoses to the chassis
specifications. Two minutes later tighten the bolts tube harness.
to the sorne specifications. 9. Reconnect thermactor air supply hose at air pump
5. lnstalllow voltage wiring clips. lnsert the spark plug (5.8L-351 W only).
wires and bracket assembly on the attaching stud 1O. Connect the oil filler pipe hose to the left rocker arm
on the rocker arm cover(s) and connect the wires cover.
to the spark plugs.
11. lnstall the air cleaner and intake duct assembly,
6. lnstall the PCV valve into the oil filler cap in the including the crankcase ventilation hoses.
rocker arm cover. lnstall vacuum solenoid connect
vacuum harness and electric connectors. VALVE SPRING, RETAINER AND STEM SEAL
7. lnstall air cleaner and intake duct assembly,
including the crankcase ventilation hoses. Removal
E-1 00-E-350 Broken valve springs or damaged valve stem seals
Removal
and retainers may be replaced without removing the
cylinder head, provided damage to the valve or valve
l. Remove a ir cleaner and intake duct assembly, seat has not occurred.
including the crankcase ventilation hoses.
1. Refer to Valve Rocker Arm Cover in this section for
2. Disconnect oil filler pipe hose from left rocker arm the cover removal and installation.
cover.
2. Remove the applicable spark plug and bring the
3. Remove the PCV valve from the right rocker arm piston to the top of the bore to prevent accidental
cover if so equipped. loss of the valve into the cylinder.
4. Disconnect the spark plug wires from the spark 3. Remove the valve rocker arm fulcrum bolts, fulcrum
plugs by grasping, twisting and pulling the moulded seats, valve rocker arms and push rods from the
cap by using Tool No. T74P-6666-A or equivalent. applicable cylinder. Remove the exhaust valve stem
Remove wires and bracket assembly from the rocker cap.
arm cover attaching stud and position out of the
way. 4. lnstall an air line with an adapter in the spark plug
hole and apply air pressure to the cylinder (Fig. 15).
5. Remove vacuum harness to amplifier on R.H. cover Failure of the air pressure to hold the valve(s) in the
and vacuum harness and electrical connector to closed position is an indication of valve seat
vacuum solenoid on L.H. rocker cover, if so damage and requires removal of the cylinder head.
equipped.
5. lnstall the fulcrum bolt and position the compressor
6. Disconnect evaporative canister hoses from the tool T70P-6049-A or equivalent as shown in Fig.
tube harness on the chassis and position out of the 15. Compress the valve spring and remove the
way. retainer locks, spring retainer, sleeve and valve
7. Disconnect the thermactor air supply hose at the spring.
air pump and move aside. 6. Remove and discard the valve stem seal (Fig. 16).
8. Remove rocker arm cover(s).
7. lf air pressure has forced the piston to the
9. Remove the valve rocker arm bolt, fulcrum seat and bottom of the cylinder, any removal of air
rocker arm (Fig. 14). pressure will allow the valve(s) to fall into the
lnstallation cylinder. A rubber band, tape or string
l. Apply Ford Polyethylene Grease (DOAZ-19584-A) wrapped around the end of the valve stem will
or equivalent to the top of the valve stem, the prevent this condition and will still allow
fulcrum seat and socket. enough travel to check the valva for binds.
2. lnstall the fulcum guide, valve rocker arm, fulcrum 8. lnspect the valve stem for damage. Rota te the valve
seat and bolt. Tighten to specifications. and check the valve stem tip for eccentric
movement during rotation. Move the valve up and
3. Clean and inspect gasket surfaces. lnspect the
down through normal travel in the valve guide and
gasket sealing surface for damages and distortion
check the stem for binds. lf the valve has been
due to overtightening of the bolt. Repair and
damaged, it will be necessary to remove the
straighten as required. Place the new gaskets in the
cylinder head for repairs as outlined in Part
covers, making sure that the tabs of the gasket
21-01, General Gasolina Engine Service.
engage the notches provided in the cover.
4. Position the cover(s) on the cylinder head(s). lnstall lnstallation
the bolts and tighten to specifications. Two minutes l. lf the condition of the valve proved satisfactory,
later, tighten the ~olts to the sorne specifications. lubricate the valve stem with engine oil of quality
5. Reconnect vacuum harness to amplifier on RH cover rec~mmended in the owner's manual. Hold the
and vacuum harness and electrical connector to valve in the closed position and apply a ir pressure
vacuum solenoid on LH rocker cover, if so equipped, within the cylinder.
the rocker arm cover. 2. lnstall a new valve stem seal (Fig. 16) using a 5/8-
6. Connect spark plug wires and bracket assembly to inch deep wall socket and a light hammer or mallet
attaching stud on rocker arm cover and connect to drive the seal onto the valve stem. Place the
wires at spark plugs. spring in position over the valve and install the
21-21-17 4.2L (255 CID) V-8, 5.0L (302 CID) V-8 and 5.8L (351 CID) W-V-8 Engines 21-21-17
5. Turn off the air and remove the air line and
adapter. lnstall the spark plug and connect the
spark plug wire.
6. Clean and install the rocker arm cover.
INTAKE MANIFOLD
The intake manifold assemblies are shown in Figs.
17 and 18.
Removal
l. Drain the cooling system. Remove the air cleaner
and intake duct assembly, including the crankc~se
ventilation hose.
2. Disconnect the accelerator cable and speed control
linkage (if so equipped) from the carburetor.
Remove the accelerator cable bracket. Disconnect
the automatic transmission kickdown rod at the
carburetor (if so equipped). Disconnect the electric
choke and carburetor solenoid wires, if so
equipped.
3. Disconnect the high-tension lead and wires from the
coi l.
4. Disconnect the spark plug wires from the spark
plugs by grasping, twisting and pulling the moulded
cap using Tool No. T74P-6666-A or equivalent.
Remove the wires and bracket assembly from the
rocker arm cover attaching stud. Remove the
FIG. 15 Compressing Valve Spring-ln Chassis distributor cap and spark plug wires as an
assembly.
5. Remove the carburetor fuel inlet line.
6. Disconnect the distributor vacuum hoses from the
distributor. Remove the distributor hold down bolt
and remove the distributor. Disconnect evaporative
hoses.
7. Disconnect the radiator upper hose from the
coolant outlet housing, and the water temperature
sending unit wire at the sending unit. Remove the
heater hose from the intake manifold.
8. loosen the clamp on the water pump by-pass hose
at the coolant outlet housing and slide the hose off
the outlet housing.
9. Disconnect the crankcase vent hose at the valve
rocker arm cover.
1O. Remove the intake manifold and carburetor as an
assembly. lt may be necessary to pry the intake
manifold away from the cylinder heads.
Remove the intake manifold gaskets and
seals. Discard the intake manifold attaching
FIG. 16 Removing or lnstalling Valve Stem Seal bolt sealing washers.
11. lf the manifold assembly is to be disassembled,
identify all vacuum hoses before disconnecting
them. Remove the coolant outlet housing gasket
valve spring retainer and sleeve. Compress the
and thermostat. Remove the ignition coil,
valve spring and install the valve spring retainer
temperature sending unit, carburetor, spacer, (on
locks. Remove the compressor tool and fulcrum bolt.
EEC engines remove EGR cooler and related parts)
3. Lubricate the push red ends with Ford Polyethylene gasket, vacuum fitting, accelerator retracting
Grease (DOAZ-19584-A) or equivalent and install spring bracket and choke cable bracket.
the push red. Apply Ford Polyethylene Grease
(DOAZ-1 9584-A) or equivalent to the tip of the lnstallation
valve stem. lnstall the exhaust valve stem cap. l. lf the intake manifold assembly was disassembled,
4. Apply Ford Polyethylene Grease (DOAZ-19584-A) install the temperature sending unit (threads coated
or equivalent to the rocker arms and fulcrum. lnstall with electrical conductive sealer), ignition coil,
the valve rocker arms, fulcrum and fulcrum bolts. carburetor, spacer, (on EEC engine install EGR
Tighten to specifications. cooler and related parts) gaskets, vacuum fitting,
21-21-18 4.2L (255 CID) V-8, 5.0L (302 CID) V-8 and 5.8L (351 CID) W-V-8 Engines 21-21-18
PHENOLI C
CAABUAE TOASPACEA
9A589
SEAL - 9A425
~
___ j 1
1 /
SEALING
WASHEFl
INT AK E
MAN 1FOLD - 9424
SEA L 9A4 24
~
COOLANl OUTLET IWUS ING - 8594
accelerator retrading spring bracket and choke Seal, B5A-19554-A or equivalent, and position it
cable bracket. Position the thermostat in the on the coolant outlet housing. lnstall the coolant
coolant outlet housing. Coat the thermostat gasket outlet housing. Connect all vacuum hoses.
with water-res istant sealer such as Ford Perfect 2. Clean the mating surfaces of the intake manifold,
cylinder heads and cylinder block using a solvent
such as Ford Spot Remover (87 A-19521-A) or
equivalent. Apply a 1/8 inch bead of RTV sealer,
(D6AZ-19562-B or equivalent) at the points shown
in Fig. 19.
3. Apply a 1116 inch bead of RTV sealer to the o uter
end of each intake manifold seal for the full width
LOCA T OA PI N
" '~
END SEAL
IA EF EAEN CE)
_r::t------:...-~ 9 A425
1/ 16" D I A . BEAD DGA Z -19562-A
lOA Bl SEA LEA 14-S E-AL EN OSI
of the seal (4 places). See Fig. 19. NOTE: This 9. Rotate the crankshaft damper until the No. 1 pistan
sealer sets-up in 15 minutes, so it is important is on TDC at the end of the compression stroke.
that assembly be completed promptly. Do not lnstall the distributor following the procedure in
drip any sealer into the engine valley. Position Part 23-01 for breakerless ignition systems.
the seals on the cylinder block and new gaskets on 1O. lnstall the distributor cap. Connect the spark plug
the cylinder heads with the gaskets interlocked with wires and bracket assembly to attaching stud on
the seal tabs. Be sure the hales in the gaskets are rocker arm cover and connect the wires to the plugs.
aligned with the hales in the cylinder heads. 11. Connect crankcase vent hose. Connect the high-
4. Carefully lower the intake manifold into position on tension lead and coil wires.
the cylinder block and cylinder heads. After the 12. Connect accelerator cable and accelerator cable
intake manifold is in place, run a finger around bracket. Connect speed control cable, if so
the seal area to make sure the seals are in equipped. Connect the choke cable. Connect
plac•. lf the seals are not in place, remove the electric choke and carburetor wires, if so equipped.
intake manifold and position the seals. Connect the automatic transmission kickdown rod
5. Be sure the hales in the manifold gaskets and at the carburetor (if so equipped). Reconnect
manifold are in alignment. lnstall the intake evaporative canister hoses.
manifold attaching nuts and bolts. Tighten the nuts 13. Fill and bleed the cooling system.
and bolts in two steps (Fig. 20). Tighten all nuts and WARNING: Do not operate the engine with
bolts in sequence to specifications. the hood open until the fan has been first
examined for possible cracks and separation.
-1 4: Start the engine and check and adjust the ignition
timing. Connect the distributor vacuum hoses to the
distributor.
15. Qperate the engine at fast idle and check all hose
connections and gaskets for leaks. Operate the
engine until engine temperatures hove stabilized
and adjust the engine idle speed and idle fuel
mixture to specifications on engine decal. Re-
tighten the intake manifold bolts to specifications.
16. Adjust the transmission throttle linkage. lnstall the
air cleaner and intake duct assembly, including the
closed crankcase ventilation hose.
TAPPET
Befare replacing a hydraulic tappet for noisy
operation, be sure the noise is not caused by improperly
adjusted valve to rocker arm clearance or by worn
rocker arms or push rods.
Removal
l. Remove the intake manifold and related parts
following procedures given in lntake Manifold
Removal in this Port.
2. Disconnect thermactor air supply hose at the air
pump and place it out of the way.
3. Remove the valve rocker arm cover, then loasen the
valve rocker arm fulcrum bolts (Fig. 14) and rotate
A1658-1G
the rocker arms to the side.
FIG. 20 lntake Manifold Bolts Tightening 4. Remove the valve push rods in sequence so that
Sequence they can be installed in their original positions.
5. Using Tool T?Ol-6500-A or equivalent shown in Fig.
After completing the remaining assembly 21, re move the tappets and place them in a rack
steps, operate the engine until it reaches so that they can be installed in their original bares.
normal operating temperatura, then re-tighten lf necessary to disassemble a tappet, refer to
the manifold nuts and bolts in sequence to Tappet Disassembly and Assembly in this Port.
specifications. lnstallation
6. lnstall the water pump by-pass hose on the coolant
outlet housing. Slide the clamp into position and Tappets and bares are to be lubricated with engine
tighten the clamp. oil of the quality recommended in the owner's manual
befare installation.
7. Connect the radiator upper hose. lnstall the heater l. Clean the externa! surfaces and install the tappets
hose and connect the hose to the intake manifold. in the bares from which they were removed, using
8. lnstall the carburetor fuel inlet line. Tool T?Ol-6500-A or equivalent. lf a new tappet(s)
21-21-20 4.2L (255 CID) V-8, 5.0L (302 CID) V-8 and 5.8L (351 CID) W-V-8 Engines 21-21-20
A4995-1B
F-100-F-250, BRONCO
Disconnect the thermactor air supply hoses at the
FIG. 21 Removing Valve Tappet check valves and plug the check valve.
is being installed, check the new tappet(s) for a free
fit in the bore in which it is to be installed. lubi-icate
the tappet(s) and bore(s) with recommended quality
engine oil before inserting the tappet.
2. lubricate the ends of the push rods with Ford
Polyethylene Grease (DOAZ-19584-A) or
equivalent and install the push rods in their original
positions. Apply Ford Polyethylene Grease (DOAZ-
19584-A) or equivalent to .the valve stem tip.
3. lubricate the rocker arms and fulcrum seats with
Ford Polyethylene Grease (DOAZ-19584-A) or
equivalent and position the rocker arms over the FIG. 22 Removing Valve Push Rods
push rods. Tighten rocker arm fulcrum bolts to
specification.
6. Remove the exhaust valve stem caps.
4. lnstall the valve rocker arm covers.
5. Reconnect thermactor air supply hose. 7. lnstall the cylinder head holding fixtures. Remove
the cylinder head attaching bolts and lift the
6. lnstall the intake manifold following instructions cylinder head off the block. Remove and discard
given under lntake Manifold lnstallation in this Port. the cylinder head gasket.
CYLINDER HEADS lnstallation
l. Clean the cylinder head, intake manifold, valve
lf a cylinder head is to be replaced, follow the
rocker arm cover and cylinder head gasket
procedures under Cylinder Head Disassembly and
surfaces. lf the cylinder head was removed for a
Assembly in this Part, and transfer all valves, springs,
cylinder head gasket replacement, check t~e
spark plugs, etc., to the new cylinder head. Clean and
flatness of the cylinder head and block gasket
inspect all parts, reface the valves (refer to Part 21-01,
surfa.c es (refer to Part 21-01, General Gasoline
General Gasoline Engine Service) and check all
Engine Service).
assembly clearances before assembling the new or used
parts to the new cylinder head. 2. A specially treated composition gasket is used. Do
not apply sealer to a composition gasket.
Removal Position the new cylinder head gasket over
l. Remove the intake manifold and carburetor as an the cylinder dowels on the block. Position the
assembly, following the procedure under lntake cylinder head on the block and install the
Manifold Removal in this Port. attaching bolts . .Remove the holding fixtures.
21-21-21 4.2L (255 CID) V-8, 5.0L (302 CID) V-8 and 5.8L (351 CID) W-V-8 Engines 21-21-21
3. The cylinder head bolts are tightened in three the check valve and connect the thermactor air
progressive steps. Tighten all the bolts in sequence supply hose.
(Fig. 23) to specifications. When cylinder head bolts
hove been tightened following this procedure, it is EXHAUST MANIFOLD$
not necessary to re-tighten the bolts after extended
operation. However, the bolts may be checked and Removal
re-tightened if desired. l. Remove a ir cleaner and intake duct assembly,
including the crankcase ventilation hose.
2. Remove bolts attaching the air cleaner inlet duct
(F-1 00-F-250, Bronco).
3. Disconnect muffler inlet pipes.
4. Remove attaching bolts and flat washers. On the
left hand exhaust manifold remove oil dipstick tube
assembly and speed control bracket, if so
equipped, then remove the exhaust manifold.
lnstallation
A1594-1B l. Clean the mating surfaces of the exhaust
FIG. 23 Cylinder Head Bolt Tightening Sequence manifold(s) and cylinder head(s). Clean the
mounting flange of the exhaust manifold(s) and
muffler inlet pipe(s).
4. Clean the push rods in a suitable solvent. Blow out
the oil passage in the push rod with compressed air. 2. Position the exhaust manifold(s) on the cylinder
Check the ends of the push rods for nicks, grooves, head(s) and install attaching bolts and flat washers.-r
roughness or excessive wear. Visually check the On the left hand exhaust manifold install oil
push rods for straightness or check push rod runout dipstick tube assembly and the speed control
with a dial indicator (refer to Part 21-01, General bracket, if so equipped. Working from the center
Gasoline Engine Service). lf runout exceeds the to the ends, tighten the bolts to specifications.
maximum limit at any point, discard the rod. Do 3. Place a new gasket(s) on the muffler inlet pipe(s).
not attempt to straighten push rods. Position the muffler inlet pipe(s) into the manifold(s).
5. Lubricate the end of the push rods with Ford lnstall and tighten the attaching nuts to
Polyethylene Grease (DOAZ-19584-A) or specifications (refer to Part 26-01, General Exhaust
equivalent and install them in their original System Service).
positions. Apply Ford Polyethylene Grease (DOAZ- 4. Position the a ir cleaner inlet duct (F-1 00 vehicles
19584-A) or equivalent to the valve stem tips. only). lnstall and tighten attaching bolts to
lnstall the exhaust valve stem cap. specifications.
6. Lubricate the rocker arms and fulcrum seats with 5. lnstall a ir cleaner and intake duct assembly,
Ford Polyethylene Grease (DOAZ-19584-A) or including the crankcase ventilation hose.
equivalent, then install the rocker arms.
7. Position a new gasket(s) on the muffler inlet pipe(s). WATER PUMP
Connect the exhaust manifold(s) at the muffler inlet
pipe(s). Tighten the nuts to specifications (refer to F-1 00-F-250/BRONCO
Part 26-01, General Exhaust System Service). Removal
8. lf the right cylinder head was removed, swing the l. Drain the cooling system. Refer to Part 27-02,
air pump into position and install the alternator General Cooling System Service.
attaching bolt and spacer, ignition coil (E-l 00-E-
250) and air cleaner inlet duct on the right cylinder 2. Remove the bolts securing the fan shroud to the
head. Adjust the drive belt tension to specifications. radiator, if so equipped. Position the shroud over
the fan.
lf the left cylinder head was removed, install the
3. Disconnect the radiator lower hose, heater hose
air conditioning compressor bracket, if so
equipped, at the front of the cylinder head. lnstall and by-pass hose at the water pump. Remove the
the oil dipstick and tube assembly and speed drive belts, fan, fan spacer and pulley.
control bracket, if so equipped. Remove the fan shroud, if so equipped.
9. Clean the valve rocker arm cover and cylinder head 4. Loasen the alternator pivot bolt and bolt attaching
gasket surfaces. Place the new gaskets in the covers, the alternator adjusting arm to water pump.
making sure that the tabs of the gasket engage the 5. Remove the bolts securing the water pump to
notches provided in the cover. lnstall the valve cylinder front cover. Remove the water pump.
rocker arm cover(s).
lnstallation
10. lnstall the intake manifold and related parts,
following the procedure under lntake Manifold Before a water pump is re-installed, check it for
lnstallation in this Port. damage. lf it is damaged, replace it. ·
11. lnstall the thermactor air supply manifold at the l. Remove all gasket material from the mounting
rear of the cylinder heads and reconnect. The a ir surfaces of the cylinder front cover and water
supply hose to the air pump (F-100/F-150) unplug pump.
21-21-22 4.2L (255 CID) V-8, 5.0L (302 CID) V-8 and 5.8L (351 CID) W-V-8 Engines 21-21-22
2. Position a new gasket, coated on both sides with CYLINDER FRONT COVER ANO TIMING
sealer such as Ford Perfect Seal B5A-19554-A, on CHAl N
the cylinder front cover; then, install the puinp.
F-1 00-F-250/BRONCO
3. lnstall the attaching bolts and tighten to
specifications. Removal
4. lnstall the alternator pivot bolt and bolt attaching , l. Refer to Water Pump Removal in this Part. Perform
the alternator adjusting arm to the water pump. all steps except removal of the pump. Leave it
5. Position the fan shroud over the water pump, if so attached to the front cover.
equipped. lnstall the pulley, spacer and fan. lnstall 2. Remove the crankshaft pulley from the crankshaft
and adjust the drive belts to the specified belt vibration damper. Remove the damper attaching
tension (refer to specifications at end of this Part). bolt and washer. lnstall the puller on the crankshaft
Connect the radiator hose, heater hose and by-pass vibration damper (Fig. 24) and remove the vibration
hose. damper.
lnstall the fan shroud bolts, if so equipped.
6. Fill and bleed the cooling system (refer to Part 27-
02, General Cooling System Service). Operate the
engine until normal operating temperatures have
been reached and check for leaks.
E-1 00-E-350
Removal
1. Remove the air cleaner and intake duct assembly,
including the crankcase ventilation hose.
2. Drain the cooling system. Refer to Part 27-02,
General Cooling System Service.
3. Disconnect the radiator upper hose at the engine
a nd lower hose a t the radiator. Remove the radiator
attaching bolts and nuts. Remove the radiator (refer
to Part 27-04, Radiators).
4. Remove drive belts, fan, spacer and water pump
pulley. A3248 · 1C
TIMING MARKS
A2731 -1B A2732-1B
E-1 00-E-250
Removal
l. Drain radiator. Remove radiator (Part 27-04,
Radiators). lf so equipped, remove AC idler pulley
and bracket and remove belt (refer to Part 36-65,
E-100-E-350 Air Conditioning System).
2. Remove upper radiator hose. Remove fan and
shroud as an assembly. Raise vehicle on hoist.
3. loasen thermactor and alternator and remove drive
belt.
4. Disconnect radiator lower hose at water pump.
Disconnect fuelline at fuel pump and remove pump.
lower vehicle on hoist.
5. Remove by-pass hose. lf so equipped, remove
power steering belt. Remove water pump pulley
and disconnect heater hose at pump.
6. lf so equipped, remove AC compressor upper
FIG. 28 Aligning Cylinder Front Cover bracket. Remove power steering pump mount frc;>m
AC compressor and water pump.
the seal and to the front of the crankshaft for 7. Remove crankshaft pulley. Remove crankshaft
damper installation. vibration damper using tool T58P-6316-D (Fig. 44).
Remove oil pan to front cover bolts. Remove front
11. line up the crankshaft vibration damper keyway
cover and water pump as an assembly.
with the key on the crankshaft. lnstall the vibration
damper on the crankshaft (Fig . 29). lnstall the 8. Discard the cylinder front cover gasket.
capscrew and washer. Tighten the screw to 9. Check the timing chain deflection using the
specifications. lnstall the crankshaft pulley. procedure given in Part 21-01, General Gasoline
Engine Service. lf deflection exceeds specifications
listed at the end of this Part, replace the chaín and
sprockets.
1O. Crank the engine until the timing. marks on the
sprockets are positioned as shown in Fig. 25.
11. Remove the camshaft sprocket capscrew, washers
and fu el pump eccentric. Slide both .sprockets and
the timing chain forward, and remove them as an
assembly (Fig. 26).
12. Clean front cover, fuel pump and damper. lubricate
seal. Clean gasket surface at pan and trim gasket.
Clean front cover gasket surface at block.
lnstallation
l. Position the sprockets and timing chain on the
camshaft (Fig. 26). Be sure the timing marks on the
sprockets are positioned as shown in Fig. 25.
2. lnstall the fuel pump eccentric, washers and
camshaft sprocket capscrew. Tighten the sprocket
FIG. 29 lnstalling Crankshaft Vibration Damper capscrew to specifications.
3. Replace oil seal in front cover. Position gasket to
12. lubricate the fuel pump lever with recommended front cover. Apply RTV silicone sealer 06AZ-19562-
quality engine oil and install the fuel pump using B or equivalent to oil pan and cylinder block
a new gasket. Connect the fuel pump outlet pipe. junction. Cut pan gasket, then position to pan and
front cover.
13. Complete the remaining operations given under
4. lnstall front cover . lnstall fuel pump. lnstall
Water Pump lnstallation.
crankshaft vibration damper (Fig. 30). lnstall
14. Fill and bleed the cooling system. Refer to Part 27- crankshaft pulley and water pump.
02, General Cooling System Service. 5. lf so ·equipped, install power steering pump. lnstall
15. Operate the engine at fast idle and check the by-pass hose and connect heater hose.
coolant level and· check for oil leaks. Check and 6. lf so equipped, install AC c~mpressor upper
adjust the ignition t iming to specifica tions on bracket. lnstall water pump pulley. lf so equipped,
engine decal. position power steering belt.
16. lnstall the air cleaner and intake duct assembly, 7. Position alternator belt. Position thermactor pump
including the crankcase ventilation hose. belt. lnstall fan and shroud.
21-21-25 4.2L (255 CID) V-8, 5.0L (302 CID) V-8 and 5.8L (351 CID) W-V-8 Engines 21-21-25
CAMSHAFT
The camshaft and related parts are shown in Fig. 32.
FRON T
COVER Removal
SEA L
REMOVER l. On E-l 00-E-350 vehicles only, remove the grille.
2. Drain the cooling system (refer to Part 27-02,
A576 5- 1A
General Cooling Systems Service). Disconnect the
FIG. 30 Removing Front Crankshaft Seal radiator upper and lower hoses. Disconnect the
transmission oil cooler lines, if so equipped. Remove
lnstallation the radiator (Refer to Part 27-04, Radiators).
l. Coat a new front cover plate oil seal with lubriplate 3. Remove the cylinder front cover and the timing
or equivalent and place it onto the front oil seal chain, following the procedure under Cylinder Front
alignment and installation sleeve as shown in Fig. Cover and Timing Chain Removal in this Port.
31. Place the sleeve and seal onto the end of the 4. Remove the intake manifold and carburetor as an
crankshaft and push it toward the engine until the assembly, following the procedures under lntake
seal starts into the front cover. Manifold Removal in this Port.
21-21-26 4.2l (255 CID) V-8, 5.0l (302 CID) V-8 and 5.8l (351 CID) W-V-8 Engines 21-21-26
4. lnstall the intake manifold and related parts by l. Coat the threads of the flywheel attaching bolts
following the steps under lntake Manifold with oil-resistant sealer (EOAZ-19554-A or
lnstallation in this Part. equivalent). Position the flywheel on the crankshaft
5. Replace the crankshaft front oil seal. lnstall the flange. lnstall and tighten the bolts in sequence
timing chain, cylinder front cover and related parts, across from each other to specifications.
21-21-27 4.2L (255 CID) V-8, 5.0L (302 CID) V-8 and 5.8L (351 CID) W-V-8 Engines 21-21-27
NEEDL E ROLLER
BE A R I NG
1
IRON COLLAR
NO TE . IRON COLLAR AN O NEED L E
RO LLER BEAR I NG ARE ONf
ASS EM B LY ANO CANNOT Hl
REPL AC ED I N OI V ID UALI Y. C29 6 1·1B
OIL PAN
F-1 00-F-250/BRONCO
Removal
l. Remove the oil dipstick (on pan entry models only).
2. Remove the bolts attaching the fan shroud to the
radiator and position the shroud over the fan.
3. Remove the nuts and lockwashers attaching the
engine support insulators to the chassis bracket.
4. lf equipped with an automatic transmission,
disconnect the oil cooler line at the left side of the
radiator.
5. Raise the engine and place wood blocks under the
engine supports.
6. Drain the crankcase.
01 L PAIII GASK ET A2 876-1A
7. Remove the oil pan attaching bolts and lower the
oil pan onto the crossmember. FIG. 36 Oil Pan Gaskets and Seals lnstalled
8. Remove the two bolts attaching the oil pump pick-
up tube to the oil pump. Remove nut attaching oil E-1 00-E-350
pump pickup tube to the number 3 main bearing Removal
cap stud. Lower the pick-up tube and screen into
the oil pan. l. Open hood and disconnect battery. Open door and
remove engine cover. Remove air cleaner. Drain
9. Remove the oil pan from the vehicle. cooling system (refer to Part 27-02, General
lnstallation Cooling System Service).
l. Clean oil pan, inlet tube and gasket surfaces. 2. lf so equipped, loasen power steering pump and
lnspect the gasket sealing surface for. damages and remove belt. Remove power steering pump from
distortion due to overtightening of the bolts. Repair mount and position out of way. lf so equipped,
and straighten as required. remove A/C compressor retainers and position
2. Position a new oil pan gasket and seals to the compressor out of way.
cylinder block (Fig. 36). 3. Disconnect radiator upper hose. Remove fan shroud
bolts and oil filler tube. Remove oil dipstick to
3. Position the oil pick-up tube and screen to the oil
exhaust manifold bolt. Raise vehicle on hoist.
pump, and install the lower attaching bolt and
gasket loosely. lnstall nut attaching to number 3 4. Remove splash shield under alternator. lf so
main bearing cap stud. equipped, disconnect transmission cooier lines at
radiator. Disconnect radiator lower hose.
4. Place the oil pan on the crossmember. lnstall the
upper pick-up tube bolt. Tighten the pick-up tube 5. Disconnect fuelline at pump. Remove engine mount
bolts to specifications. nuts. Drain crankcase. Remove the dipstic'k tube
from oil pan. Disconnect muffler inlet pipe from
5. Position the oil pan to the cylinder block and install
manifolds.
the attaching bolts. Tighten to specifications.
6. lf so equipped, remove automatic transmission
6. Raise the engine and remove the wood blocks.
dipstick and tube. Disconnect manual linkage at
Lower the engine and install the insulator-to-chassis
transmission. Remove center driveshaft support and
bracket nuts and washers . Tighten the nuts to
remove driveshaft from transmission.
specifications.
7. Place a transmission jack under the oil pan and
7. lf equipped with an automatic transmission,
insert a wooden block between the pan and jack.
connect the oil cooler line at the radiator.
The engine and transmission assembly will
8. lnstall the fan shroud attaching bolts. pivot around the rear engine mount. The
9. Fill the crankcase with the proper grade and engine assembly must be raised four inches
quantity of engine oil. lnstall the oil dipstick. Start measured from the front motor mounts. The
the engine and operate it until it reaches normal engine must remain centered in the engine
operating temperature, then check for leaks. compartment to obtain this much lift.
21-21-29 4.2L (255 CID) V-8, 5.0L (302 CID) V-8 and 5.8L (351 CID) W-V-8 Engines 21 -21 -29
3. Position transmission jack, raise engine, remove FIG. 37 Oil Pump and lnlet Tube
wood blocks, lower engine and remove jack. lnstall
front insulator attaching nuts and tighten to lnstallation
specifications. l. Prime the oil pump by the inlet port with engine oil.
4. lnstall driveshaft. Connect manual linkage at Rotate the pump shaft to distribute the oil within
transmission. lnstall muffler inlet pipe. Tighten nuts the pump body.
to Specification to Part 26-01 , General Exhaust 2. Position the intermediate drive shaft into the
System Service . lnstall tra ns mission filler tube . distributor socket. With the shaft firmly seated in
Connect radiator lower hose . the distributor socket, the stop on the shaft should
5. lf so equipped, connect transmissio n cooler lines to touch the roof of the crankcase. Remove the shaft
radi a tor. Co n nec t fu el li ne t o pu mp . lnst a ll a nd position the stop as necessary.
alternator splash shield. Lower vehicle on hoist. 3. With the stop properly positioned, insert the
6. lnstall radiator shroud a nd con nect radiator upper intermediate drive shaft into the oil pump. lnstall
hose. lf so equipped, insta ll power steeri ng pump. the pump and shaft as an assembly. Do not
Position power steering be lt and adju st be lt tension. attempt to force the pump into position if it will
lnstall bolt attaching d ipstick tub e to exhaust not seat readily. The drive shaft hex may be
manifold. misaligned with the distributor shaft. To align,
7. lf so equipped, install A/ C compressor (refe r to Part rotate the intermediate drive shaft into a new
36-65, E- l 00-E-350 Air Condition in g System . position. Tighten the oil pump attaching screws to
Position A/ C belt and adjust belt tension following specifications.
Specifications at the end of thi s Port. 4. Clean and install the oil pump inlet tube and screen
8. lnstall oil filler tube and install a ir cleaner. Fill assembly.
crankcase and cooling system (refer to Part 27-02, 5. lnstall the oil pan and related parts as outlined
General Cooling System Service). under Oil Pan lnstallation.
9. Connect battery. Start e ngine and check for leaks.
lnstall engine cover. Close hood and door. CRANKSHAFT REAR OIL SEAL
Replacement of a crankshaft rear oil seal because
OIL PUMP of oil leaka ge requires replacement of both the upper
and lower seals . Refer to Crankshaft Rear Oil Seal
Removal Replacement in Part 21 -01, General Gasoline Engine
NOTE: On E-100-E-250 5.0L (302 C10) V-8 Engine Service for special replacement procedures.
vehicles the oil pump and oil pan must be removed
and installed together. Refer to the E-100-E-250 MAIN BEARING
Oil Pan Removal and lnstallation procedures in The main bearing inserts are selective fit. Refer to
this Part. the procedures under Fitting Main and Connecting Rod
F-100-F-250 ANO BRONCO Bearings in Part 21-01, General Gasoline Engine
Service.
l. Remove the oil pan and related parts as outlined
under Oil Pan Removal. Removal
2. Remove the oil pump inlet tube and screen l. Drain the crankcase. Remove the oil level dipstick.
assembly. Remove the oil pan and related parts, following the
3. Remove the oil pump attaching bolts (Fig. 37), and procedure under Oil Pan Removal in this Port.
remove the oil pump gasket and intermediate drive 2. Remove the oil pump inlet tube assembly and the
shaft. oil pump.
21-21-30 4.2L (255 CID) V-8, 5.0l (302 CID) V-8 and 5.8l (351 CID) W -V-8 Engines 21-21-30
3. Replace one bearing at a time, leaving the other Connecting Rod Bearings in Port 21-01, General
bearings securely fastened. Remove the main Gosoline Engine Service.
bearing cap to which new bearings are to be 6. lf the beoring is being reploced on journol number
installed. 1, 2 or 4, opply o coot of engine oil of the quolity
4. lnsert the upper bearing removal tool (Tool 6331) recommended in the owner's manual to the journal
or equivalent in the oil hole in the crankshaft (Fig. ond beorings and install the beoring cap. Tighten
38). the cap bolts to specifications.
7. lf the reor moin beoring is to be reploced, remove
the rear moin oil seol retaining pin from the lower
bearing cap seal groove. The pin is not used with
the split, lip-type seal.
Cleon the oil seal groove with o brush and
salven t.
8. lnstall the lower seol in the reor main bearing cap
with the undercut side of the seol toword the
FRONT of the engine (Fig. 36). Allow the seal to
protrude approximately 3/8 inch above the porting
surfoce to mate with the upper seal when the cap
is installed.
9. Refer to Port 21-01, General Gosoline Engine
Service for speciol instructions in applying RTV
sealer to the reor moin beoring cap. lubricate the
journol with engine oil of the quality recommended
in the owner's manual and install the reor moin
beoring cap. Tighten the cap bolts to specificotions.
1O. lf the thrust bearing cap (No. 3 main bearing) has
been removed, install it os follows:
FIG. 38 Removing or lnstalling Upper Main
lubricate the journal with engine oil of the qual-
Bearing lnsert
ity recommended in the owner's manual and install
the thrust bearing cap with the bolts finger tight.
5. Rotate the crankshaft in the direction of engine Pry the crankshaft forward against the thrust sur-
rotation to force the bearing out of the block. face of the upper half of the bearing (Fig . 39) .
6. Clean each crankshaft journal. lnspect the journals Hold the crankshaft capto the rear. This will align
and thrust faces (thrust bearing) for nicks, burrs or the thrust surfaces of both halves of the bearing.
bearing pick-up that would cause premature Retain the forword pressure on the crankshaft.
bearing wear. Tighten the cap bolts to specifications (Fig . 39) .
7. lf the rear main bearing is being replaced, remove 11. Cleon the oil pump inlet tube screen. Prime the oil
and discard the rear oil seal from the beoring cap. pump by filling the inlet opening with oil ond
8. Remove the block holf of the rear oil seol following rototing the pump shoft until oil emerges from the
the procedures given under Cronkshoft Reor Oil outlet opening. lnstall the oil pump and inlet tube
Seal Removal, Port 21-01, General Gosoline assembly.
Engine Service. 12. Position the oil pon goskets on the oil pon. Position
the oil pan front seal on the cylinder front cover.
lnstallation Position the oil pon rear seol on the reor moin
l. lf the rear main beoring is being reploced, cleon beoring cap. lnstall the oil pon ond reloted parts,
the reor oil seol groove in the block with o brush following the procedure under Oil Pon lnstallation
ond solvent. in this section. lnstall the oil level dipstick.
2. lnstoll the block half of the rear oil seal following 13. Fill the cronkcose. Stort the engine and check for
the procedures given under Crankshaft Reor Oil oil pressure. Operote the engine at fost idle ond
Seol lnstollotion, Port 21-01, General Gosoline check for oil leaks.
Engine Service.
3. To install an upper main beoring, place the plain CONNECTING ROO BEARINGS
end of the beoring over the shoft on the locking The connecting rod bearings ore selective fit. Refer
tong side of the block ond partiolly install the to the procedures under Fitting Moin ond Connecting
bearing so that Tool 6331 or equivalent can be Rod Beorings in Part 21-01, General Gasoline Engine
inserted in the oil hale in the cronkshoft (Fig. 38). Service.
With Tool 6331 or equivolent in the hole in the
crankshaft, rotate the crankshoft in the opposite Removal
direction of engine rotation until the beoring seots l. Droin the cronkcose: Remove the oil level dipstick.
itself. Remove the tool. Remove the oil pan and reloted parts, following the
4. lnstall the bearing cap. procedure under Oil Pon Removal.
5. Select fit the beoring for proper clearance, 2 . Remove the oil pump inlet tube assembly and the
following the procedures under Fitting Moin ond oil pump.
21-21-31 4.2L (255 CID) V-8, 5.0L (302 CID) V-8 and 5.8L (351 CID) W-V-8 Engines 21-21-31
HOLD
CR ANKSHA FT
FO RWARD
THRUST BEARING
3. Turn the crankshaft until the connecting rod to PISTONS ANO CONNECTING RODS
which new bearings are to be fitted is down.
Remove the connecting rod cap. Remove the Removal
bearing inserts from the rod and cap. l. Drain the cooling system and the crankcase .
Remove the intake manifold, cylinder heads, oil pan
1nsta llation and oil pump, following the procedures in this
l. Be sure the bearing inserts and the bearing bore section.
in the connecting rod and cap are clean. Foreign 2. Remove any ridges and/ or deposits from the upper
material under the inserts will distort the bearing end of the cylinder bores as follows.
and cause a failure.
Turn the crankshaft until the pistan to be removed
2. Clean the crankshaft journal. is at the bottom of its travel, then place a cloth on
3. lnstall the bearing inserts in the connecting rod and the pistan head to collect the cuttings. Remove the
cap with the tangs fitting in the slots provided. cylinder ridge with a ridge cutter. Follow the
4. Pull the connecting rod assembly down firmly on the instructions furnished by the tool manufacturers.
crankshaft journal. . Never cut lnto the ring travel area in excess of
5. Select fit the bearing, following procedures under .794 mm (1/32 inch) when removlng ridges.
Fitting Main and Connecting Rod Bearings in Part 3. Make sure all connecting rod caps are marked so
21-0 l, General Gasoline Engine Service. that they can be installed in their original positions.
6. After the bearing has been fitted, clean and apply 4. Turn the crankshaft until the connecting rod being
a coat of engine oil of the quality recommended removed is down.
in the owner's manual to the journal and bearings. 5. Remove the connecting rod nuts and cap.
lnstall the connecting rod cap. Tighten the nuts to 6. Push the connecting rod and pistan assembly out
specifications. the top of the cylinder with the handle end of a
7. Repeat the procedure for the remaining connecting hammer . Avoid damage to the crankshaft
rods that require new bearings. journal or the cylinder wall when removing the
8. Clean the oil pump inlet tube screen. Prime the oil piston and rod.
pump by filling the inlet opening with oil and 7. Remove the bearing inserts from the co'lnecting rod
rotating the pump shaft until oil emerges from the and caps.
outlet opening. lnstall the oil pump and inlet tube 8. lnstall the cap on the connecting rod from which it
assembly. was removed.
9. Position the oil pan gaskets on the cylinder block.
Position the oil pan front seal on the cylinder block lnstallation
front cover and interlock the seal with the gaskets. l. lf new pistan rings are to be installed, remove the
Position the oil pan rear seal on the rear main cylinder wall glaze. Follow the instructions of the
bearing cap and interlock the seal with the gaskets. tool manufacturer.
lnstall the oil pan and related parts, following the 2. Oil the piston rings, pistons and cylinder walls with
procedure under Oil Pan lnstallation in this Port. recommended quality engine oil. Be sure to install
lnstall the oil level dipstick. the pistons in the same cylinders from which
1O. Fill thé crankcase with engine oil of the quality and they were fitted. The connecting rod and bearing
quantity recommended in the owners manual. Start caps are numbered from 1 to 4 in the right bank
the engine and check for oil pressure. Operate the and from 5 to 8 in the left bank, beginning at the
engine at fast idle and check for oil leaks. front of the engine. The numbers on the connecting
21-21-32 4.2l (255 CID) V-8, 5.0l (302 CID) V-8 and 5.8l (351 CID) W-V-8 Engines 21-21-32
rod and bearing cap must be on the same side when 5. Check the cle~tance of each bearing, following the
installed in the cylinder bore. lf a connecting rod procedure under Fitting Main and Connecting Rod
is ever transferred from one block or cylinder to Bearings in Part 21-01, General Gasoline Engine
another, new bearings should be fitted and the Service.
connecting rod should be numbered to correspond 6. After the bearings hove been fitted, apply a light
with the new cylinder number. coat of recommended engine oil to the journals and
When installing the pistan and cannecting bearings.
rad assembly, the largest chamfer at the 7. Turn the crankshaft throw to the bottom of its
bearing end af the rad shauld be pasitianed stroke. Push the piston all the way down until the
tawards the crank pin thrust face af the connecting rod bearing seats on the crankshaft
crankshaft. journal.
3. Make sure the ring gaps (oil ring spacer-A, oil ring- 8. lnstall the connecting rod cap. Tighten the nuts to
8, compression ring-C) are properly spaced around specifications.
the circumference of the piston, (Fig. 40).
9. After the piston and connecting rod assemblies
hove been installed, check the side clearance
OIL R I NG SPACER between the connecting rods on each shaft journal
01 L R ING OILRING
(Fig. 42).
SEGMENT SEGMENT
\
o
~
1
1
/ PIN BORE \
PI ST ON 'í:_ (..._
COMPRESSION f11NG
FRONT
t (0
COMPRESSION R I NG
A2811 · 1B
CRANKSHAFT
The crankshaft and related parts are shown in (Fig.
43).
Removal
l. With the engine removed from the vehicle and
placed in a work stand, disconnect the spark plug
wires at the spark plugs and remove (using Tooi-
T7 4P-6666-A or equivalent) the wires and bracket
assembly from the attaching stud on the valve
rocker arm covers. Disconnect the coil to distributor
high-tension lead at the coil. Remove the distributor
cap and spark plug wires asan assembly. Remove
the spark plugs to allow easy rotation of the
crankshaft. FIG. 44 Crankshaft Vibration Damper
2. Remove the fuel pump and oil filter. Slide the water Removai-E-1 O~E-350
pump by-pass hose clamp toward the water pump.
Remove the alternator and mounting brackets. Service, then remove the timing chain and sprockets
3. Remove the crankshaft pulley from the crankshaft by following steps under Cylinder Front Cover and
vibration damper. Remove the capscrew and Timing Chain Removal.
washer fro~ the ·e nd of the crankshaft. lnstall the 6. lnvert the engine on the work stand. Remove the
puller (univtt~al puller, Tool T58P-6316-D or clutch pressure plate and disc (manual-shift
equivalent) ~n the crankshaft vibration damper transmission). Remove the flywheel and engine rear
(Figs. 25 or 44) and remove the damper. cover plate. Remove the oil pan and gasket.
4. Remove the cylinder front cover and water pump Remove the oil pump.
as an assembly. 7. Make sure all bearing caps (main and
5. Check the timing chain deflection following connecting rod) are marked so that they can
procedures in Part 21-01, General Gasoline Engine be installed in their original locations. Turn the
CRANKSHAFT
- 6303 - - - - - - - - - .
CRANKSHAFTSPROCKET
- 6306
A2878-2F
crankshaft until the connecting rod from which the 14. lnstall the thrust bearing cap with the bolts finger-
cap is being removed is down, and remove the tight.
bearing cap. Push the connecting rod and piston 15. Pry the crankshaft forward against the thrust
assembly up into the cylinder. Repeat this surface of the upper half of the bearing (FJg. 39).
procedure until all the connecting rod bearing caps
16. Hold the crankshaft forward and pry the thrust
are removed.
bearing cap to the rear. This will align the thrust
8. Remove the main bearing caps. surfaces of both halves of the bearing.
9. Carefully lift the crankshaft out of the block so that 17. Retain the forward pressure on the crankshaft.
the thrust bearing surfaces are not damaged. Tighten the cap bolts to specification.
Handle the crankshaft with cara to avoid 18. Force the crankshaft toward the rear of the engine.
possible fracture or damage to the finished
surfaces. 19. Check the crankshaft end play (refer to Part 21-01 ,
General Gasoline Engine Service).
To refinish journals, dress minor imperfections,
etc., refer to Part 21-01, General Gasoline Engine 20. lnstall new bearing inserts in the connecting rods
Service. and caps. Check the clearance of each bearing,
following the procedure under Fitting Main and
lnstallation Connecting Rod Bearings in Part 21-01, General
l. Remove rear journal oil seal from the block and rear Gasoline Engine Service.
main bearing cap. 21. After the connecting rod bearings hove been fitted,
2. Remove ~he main bearing inserts from the block and apply a light coat of recommended quality engine
bearing caps. oil to the journals and bearings.
3. Remove the connecting rod bearing inserts from the 22. Turn the crankshaft throw to the bottom of its
connecting rods and caps. stroke. Push the piston all the way down until the
rod bearing seats on the crankshaft journal.
4. lf the crankshaft main bearing journals hove been
refinished to a definite undersize, install the correct 23. lnstall the connecting rod cap. Tighten the nuts to
undersize bearings. Be sure the bearing inserts and specifications.
bearing bores are clean. Foreign material under the 24. After the piston and connecting rod assemblies
inserts will distort the bearing and cause a failure. hove been installed, check the s ide clearance
between the connecting rods on each connecting
5. Place the upper main bearing inserts in position in
rod crankshaft journal (Fig. 42) following
bores with the tang fitting in the slot provided.
Specifications listed at the end of this Port.
6. lnstall the lower main bearing inserts in the bearing 25. lnstall the timing chain and sprockets, cylinder front
caps. cover and crankshaft pulley and adapter, following
7. Clean the rear journal oil seal groove and the steps under Cylinder Front Cover and Timing Chain
mating surfaces of the block and rear main bearing lnstallation.
cap with Ford Spot Remover (8 7 A- 19 521-A) or 26. Coat the threads of the flywheel attaching bolts
equivalen t. Refer to Part 21-01, General Gasoline with oil-resistant sealer (EOAZ-19554-A or
Engine Service for special instructions in seal equivalent). Position the flywheel on the crankshaft
replacement. Remove the rear oil seal retainer pin flange. lnstall and tighten the bolts to
from the rear main bearing cap seal groove. The specifications.
pin is not used with the split, lip-type seal.
On a flywheel for manual-shift transmission, use
8. Dip the lip-type seal halves in clean engine oil. Tool T75L-6392-A or equivalent to locate the clutch
lnstall the seals in the bearing cap and block with disc. lnstall the pressure plate. Tighten the
the undercut side of the seal toward the FRONT of attaching bolts to Specifications.
the engine as shown in Part 21 -01, General
27. Clean the oil pan, oil pump and oil pump screen.
Gasoline Engine Service.
Prime the oil pump by filling the inlet port with
9. Carefully lower the crankshaft into place. Be engine oil and rotating the pump shaft to distribute
careful not to damage the bearing surfaces. oil within the housing. lnstall the oil pump and oil
10. Check the clearance of each main bearing by pan by following the procedures under Oil Pan and
following the procedure under Fitting Main and Oil Pump lnstallation in this Port.
Connecting Rod Bearings in Part 21-01, General 28. lnstall the oil filter, fuel pump and connect the fuel
Gasoline Engine Service. lines. lnstall the alternator, shield and mounting
11. After the bearings hove been fitted refer to Part bracket.
21-01 for special instructions in applying RTV seale'r 29. lnstall the spark plugs, distributor cap and spark
(D6AZ- 19 562-8 or equivalent) to the rear ma in plug wires. Connect the spark plug wires and high-
bearing cap. tension lead.
12. Apply engine oil of the quality recommended in the 30. lnstall the engine in the vehicle.
owner's manual to the journals and bearings.
13. lnstall all the bearing caps, except the thrust
CAMSHAFT BEARINGS
bearing cap (No. 3 bearing). Be sure that the Camshaft bearings are available prefinished to size
main bearing caps are installed in their for standard and 0.015 inch undersize journal
original locations. Tighten the bearing cap bolts diameters. The bearings are not interchangeable from
to specifications. one bore to another.
21-21-35 4.2L (255 CID) V-8, 5.0L (302 CID) V-8 and 5.8L (351 CID) W-V-8 Engines 21-21-35
Removal
l. Remove the camshaft, flywheel and crankshaft,
following the appropriate procedures in this Port.
Push the pistons to the top of the cylinders.
2. Remove the camshaft rear bearing bore plug as
detailed in Part 21-01 , General Gasoline Engine
Service Remove the camshaft bearings (Fig. 45).
3. Select the proper size expanding collet and back-
up nut and assemble on the expanding mandrel.
With the expanding collet collapsed, install the
collet assembly in the camshaft bearing, and
tighten the back-up nut on the expanding mandrel
until the collet fits the camshaft bearing.
4. Assemble the puller screw and extension (if
necessary) as shown and install on the expanding
mandrel. Wrap a cloth around the threads of the
puller screw to protect the front bearing or journal.
Tighten the pulling nut agciinst the thrust bearing
and pulling plate to remove the camshaft bearing.
Be sure to hold a wrench on the ·end of th.e puller FIG. 46 Camshaft Frant Bearing Replacement
screw to prevent it from turning.
5. Repeat the procedure for each bearing. To remove OIL FILTER
the front bearing, install the puller screw from the
rear of the cylinder block. The oil filter assembly is shown in Fig. 47.
lnstallation Removal
l. Position the new bearings at the bearing bores l. Position a drip pan under the oil filter.
with the oil holes aligned and press them in place 2. Unscrew the filter from the adapter fitting using an
with the Tool T65l-6250-A or equivalent shown in oil filter wrench and clean the adapter fitting.
(F ig. 45). Be sure to center the pulling plate and
puller screw to avoid damage to the bearing . On E-l 00--E-250 equipped with power steering,
Failure to use the correct expanding collet can be sure the wheels are fully to the right before
cause severe bearing damage. Be sure the front removing the filter. Then unscrew the filter from the
bearing is installed the specified distance below adapter fitting, turn it horizontal and let the excess
the front face of the cylinder block (Fig. 46). oil drain off. Slide the oil filter towards the rear of
the vehicle and remove as shown in Fig. 47. Sorne
2. lnstall a new rear ~earing bore plug. effort may be required to slide the oil filter between
3. lnstall the camshaft, crankshaft, flywheel and the engine crossmember and power steering hoses.
related parts, following the appropriate
procedures, except do not check connecting rod lnstallation
and main bearing clearances as a part of Camshaft l. Coat the gasket on a new filter with recommended
Bearing Replacement. lnstall the engine in the quality engine oil. Place the new filter in position
vehicle. on the adapter fitting.
DETAILB
PULLING NUT
\ ~
DETAlL 1,20R 3
BACK -UP NUT
~ t'l -1"'\=
DETAIL6 DR 7
PULLER SCREW
CAMSHAFT BEARING
I LOOSEI ..-------~
l cAMSHAFT BEAR I NG SE T I
EXTENS ION
A281 3 ·2 B
A3704-1C
l
procedures.
TAPPET
The interna! parts of each hydraulic tappet LOCK RIN G
V
e 1 ""'1"" '""'"
(<'3frtt¡¡
~L.
BOD Y
plunger and spring. 4. Place the plunger spring, and then the plunger
(open end up) into the tappet body.
3. Carefully remove the plunger spring, the check
valve retainer and the check valve spring and valve
1
5. Position the metering valve (disc) in the plunger 1
from the plunger. and then place the push rod cup in the plunger.
Assembly 6. Depress the plunger and position the closed end
1
2. Place the check valve (disc or ball check) in position lock ring.
over the oil hole on the bottom of the plunger. Set 7. Use the tappet leakdown tester (Part 21-01 1
the check valve spring on top of the check valve General Gasoline Engine Service) to fill the tappets
(disc or ball check). with test fluid.
21-21-37 4.2L (255 CID) V-8, 5.0L (302 CID) V-8 and 5.8L (351 CID) W-V-8 Engines 21-21-37
EXHAUST
,--, VA L VE
/ A - - STEM CAP
¡
~ 1
/ tó.,¡! - 6550
O IL SEAL
- 6571
------~
¡, ,_,
/
EXHAUST
VAL VE -
6506
IN T AKE
VA L VE -
6507
A3307·1B
3. Drill a small hole and insert a self-threading sheet connecting rod with the indentation in the
metal screw of the proper diameter into the oil pi1ton . po1itioned a1 1hown in Fig. 55.
pressure relief valve chamber cap and pull the cap On replacement connecting rods, install the
out of the chamber. Remove the spring and plunger. large-chamfered side of the connecting rod bearing
Assembly bore towards the crankshaft cheek; facing towards
front of engine on the right bank rods, and facing
The oil pump assembly is shown in Fig. 52. towards rear of engine on left bank rods.
2. Start the piston pin in the pistan and connecting
rod (this may require a very light tap with a mallet).
Using an Arbor Press and Tool T68P-6135-A or
equivalent, press the pistan pin through the pisten
and connecting rod until the pin is centered in the
pistan (Fig. 53).
3. Check the end gap of all pis ton rings (Part 21 -01,
General Gasoline Engine Service). lt must be within
specifications listed at the end of this Port. Follow
the instructions contained on the pistan ring
package and install the pistan rings.
4. Check the ring side clearance (refer to Specification
at the end of this Part) of the compression rings with
a feeler gauge inserted between the ring and its
lower land (Part 21 -01, General Gasoline Engine
Service). The gauge should slide freely around the
A 2535- B entire ring circumference without binding. Any wear
that occurs will form a step at the inner portien of
FIG. 52 Oil Pump-Di1assembled the lower land . lf the lower land1 have high
1tep1, the pi1ton 1hould be replaced.
l. Clean, inspect and oil all parts thoroughly.
2. lnstall the oil pressure relief valve plunger, spring 5. Be sure the bearing inserts and the bearing bore
and a new cap. in the connecting rod and cap are clean. Foreign
material under the inserts will distort the bearing
3. lnstall the outer roce and the inner rotor and shaft and cause a failure. lnstall the bearing inserts in the
assembly. Be 1ure the dimple (identification connecting rod and cap with the tangs fitting in the
mark) on the outer race i1 facing the 1ame 1ide slots provided.
a1 the identification mark on the rotor. The
inner rotor and 1haft and the outer race are
1erviced a1 an assembly. One part 1hould not CYLINDER ASSEMBL Y-( 6009)
be replaced without replacing the other. lnstall
the cover and tighten the cover attaching bolts to Disassembly
specifications. l. Mount the old engine in a work stand and remove
4. lnstall the attaching bolts. all parts not furnished with the new cylinder
assembly; following the procedures given in the
PISTONS AND CONNECTING RODS Removal and lnstallation section of this Port.
Disassembly 2. Remove the old cylinder assembly from the work
l. Remove the bearing inserts from the connecting rod stand.
and cap. Assembly
2. Mark the pistons to ássure assembly with the same
l. Clean the gasket and seal surfaces of all
rod and installation in the same cylinders from
serviceable parts and assemblies.
wh ich they were removed.
3. Using an Arbor press and the tool T68P-6135-A or 2. Position the new cylinder assembly in a work stand.
equivalent shown in Fig . 53, press the pistan pin 3. Transfer all serviceable parts removed from the old
from the pistan and connecting rod . Remove the cylinder assembly, following the procedures given
pistan rings. in the Removal and lnstallation section of this Port.
Assembly 4. Check all assembly clearances followi ng
The pistan, connecting rod and related parts are Specifications listed at the end of this Part, and
shown in Fig. 54. Check the fit of a new pistan in the correct as necessary.
cylinder bore befare assembling the pistan and pistan
pin to the connecting rod. CYLINDER BLOCK-(6010)
The pistan pin bore of a connecting rod and the
diameter of the pistan pin must be within specifications Before replacing a cylinder block, determine if it is
listed at the end of this Port. repairable. lf so, make the necessary repairs, following
l. Apply a light coat of recommended quality engine the procedures given in Part 21-01 , General Gasoline
oil SE to all parts. Auemble the pi1ton to the Engine Service.
21-21-39 4.2l (255 CID) V-8, 5.0l (302 CID) V-8 and 5.8l (351 CID) W-V-8 Engines 21-21-39
PISTON PIN
~""'" "'"'
RECEIVING
TUBE
PRESS
1
IN PI ST O N PIN FOR MAKE CER T AIN
PIN REMOVAL PI STON FLOAT S
RE~~~~~~~ _ __
ADAPTER
CU P
PI ST ON PIN
REMOV ER/ INSTA L LE R A 580 1-2A
UPPER
g?NM:RESSION -~ ;r
LOWER
COMPRESSION
Disassembly
l. Completely disassemble the old engine, following
the procedures given in the Removal and
~ 6148 2.
lnstallation section of this Port.
Remember to ridge-ream the cylinder bares befare
6 106
~ OI ! RING
~ ASSEMB L Y
removing pistan assemblies.
Assembly
l. Clean the gasket and seal surfaces of all
serviceable parts and assemblies.
PISTON ' 2. Position the new cylinder block in a work stand.
PIN 3. Transfer all serviceable parts removed from the old
6135 cylinder block, following the procedures given in the
Removal and lnstallation section of this Port.
4. Check all assembly clearances following
Specifications listed at the end of this Part, and
BOLT correct as necessary.
6214 - - --!T
.0 BEAR ING
INSERTS
CAP
NU T
6212 - - - -
A2B72 l B
A3706· 1C
SPECIFICATIONS
GENERAL SPECIFICATIONS
5 OL (302 CID ) -8 3416 .3423 3411 -. 3418 1 3566- 3U3 561 - 3568 3/ 16 3/23 3 /lÍ- 3/ 18
5 8L (351 CID ) W-V-8 1
CAMSHAH
---- ·---- -,------·:--- -- ·-·--~--- ·-· - ·- - --·--- ·-
Engine
Lobe Lift 0 Camshaft ~nd Play Camshafl dournal lo
lntake Exhaust End Play Wear limil Bearing Clearance 0
-
.._ __ -- --- ·---
4 2L (255 CID) V~
5.8L (351 CID ) W-V-8 .2600 .2600 .001 -.007 009 .001 -. 003
-
0 Maxrmum allowable IIft loss .005
0 Servrce hmit - .006 rnaximum
CAMSHAFi ORIVE
l
No . 1 No . 2 No. 3 No. 4 No . 5 No. 1 No . 2 No . 3 No . 4 No . 5 location (0 Maximum
---~---- -
CYLINOEA BLOCK
-
Main Bearing Oistributor Shaft
Cylinder Bore Head Gasket Head Gasket Tappet Bore
Engine Bore Bearing Bore
Oiameter 0 Surface Flatness Surface Finish Oiameter
Diameter 0 Oiameter
- - - - - - - - -· 003 in any 6 in . RMS
4.21 (255 CID) V-8 3.6800-3 6835 2. 4412-2 4420 .4525-. 4541 8752-.8767
.006 overall 60-150
.003 in any 6 rn . RMS
5 01 (302 CID) V-8 4.0004-4 0052 2.4412-2.4420 .4525-.4541 .8752- .8767
----- .006
.003 rn
overall
any 6 in .
60-150
RMS
5 8L (351 CID) W-V-8 4.0000 -4 0048 3 1922-3 1930 5155-. 5170 8752-.8767
.006 overall 60-150
0 Maximum out -of-round - · 001 5. Serv rce hmit - .005 . Max1mum taper service limit - .01 O. Cyhnder bore surface frni sh - RMS 18-38 . Bore ta pes service limit - .01 O
0 Crankshaft to rear tace of block runout. TIA maxrmum .005
Main and
Main Bearing Main Bearing Main Bearing Main Bearing Main Bearing
Thrust Bearing Aod Bearing
Engine Journal Journal Runout Thrust Face Runoul Journal Taper Thrust Face Finish
Journal Length Journal Finish
Diameter 0 TIA Maximum G: TIA Maximum Maximum Per lnch RMS Maximum
RMS Maximum
- 1
4.2L (255 CI D) V-8
2.2482-2.2490 002 .001 .0005 1 137-1 139 12 25 Front-- 20 Rear
5.0L (302 CID) V-8
5.8L (351 CID) W-V-8 2.9994 ·3.0002 1 137-1.139 12 25 Front- - 20 Rear
- -002 .001 .0005
0 Maximum out-of-round - 0006 .
0 Service hm1t - 005 CA4958-28
21-21-43 4.2l (255 CID) V-8, 5.0l (302 CID) V-8 and 5.8l (351 CID) W-V-8 Engines 21-21-43
CRANKSHAFT BEARINGS
CONNECTING ROO
Connecting Rod Alignment Rod lo CrankshaH
Piston Pin Bore Rod Bearing Rod Length
Engine Maximum Total Dlfference Assembled
or Bushing 1.0. Bore I.D. (i) Center to Center
Twist 0 Bend f!) Side Clearance 0
PISTO N
4.2L (255 CID) V-<3 3.6784-3 .6790 3.6798-3 .6804 3.6812-3.6818 0018- 0026 .9123- .9126 080- 081 .080-. 081 .188-.189
5.0L (302 CID) V-<3 3.9984-3.9990 3.996-4 .000 4 0008-4 .0014 0018- 0026 .9123- .9126 .080-. 081 080- .081 .188-.189
5.8L (351 CID) W V-8 3' 9978-3 ' 9984 3.9990-3 ' 9996 4.0002-4 0008 .0018- ' 0026 .9124- .9127 080- 081 080- 081 .188-.189
(i) Measured at the pistan pin bore centerline at 90' to the pin .
PISTON PIN
PISTON RINGS
Englne
Rlng Wldth Compresslon Slde Clearance Compression 0 Rlng Gap Compression
Top Bottom Top Bollom 011 Top Bollo m Oil <!.J
Rellel Valve
Sprlng Pressure Drlveshalt lo Rellel Valve lo Rotor Assembly Outer Race lo Englne 011 Capaclty
Englne
Lbs.@ Houslng Clearance Houslng ctearance End Clearance Houslng Clearance Qts . - u.s. 0
Specllled Length
4.2L (255 CID) V.f.i
5.0L (302 CID) V-8 10.1>-12.2 @ 1.74 .0015- .0030 .0015-.0030 .004 Maximum .001 - 01 3 5
5.8L (351 CID) V-8 18.2-20.2 @ 2.49 .0015-.0030 .0015-.0030 .004 Maximum .001- 003 5
0 Add 1 qt. when replacing filler .
Englne Stallc Pressure (PSI) 0 Volume Flow- Mlnlmum 0 0 Eccentric Total Lilt- lnches
TOROUE LIMITS- 4.2L (255 CID) V-8 - 5.0L (302 CID) V-8- 5.8L (351 CID) W-V-8
NOTE: All values in N•m (ft-lbs). unless otherwise noted . Oil threads with engine oil unless the threads require oil or water-resistan! sealer. The standard torque limits listed below
are applicable for all functions not listed in the special torque chart.
1/4-20 5/16-18 9116-18
8-12 (6-9) 17-24 (12-18) 116-162 (85-120)
Pipe Threada
118-27 1/4-18 3/8-18
7-11 (5-8) 17-24 (12-18) 30-44 (22-33)
Torque
ltem
N•m (11-lba)
Camshaft Sprocket - Gear to Camshaft 55-61 (40-45)
Camshaft Thrust Plate lo Cylinder Block 13-16 ( 9-12)
Connecting Rod Nut- 4.2L (255 CID) V-8/5.0L (302 CID) V-8 26-32 (19-24)
- 5.8L (351 CID) W-V-8 55-61 (40-45)
Cylinder Front Cover 17-24 (12-18)
Cylinder Head Bolts (:)Q)
Damper lo Crankshaft 95-122 (70-90)
EGR Valve lo Carburetor Spacer or lntake Manifold 17-24 (12-18)
Fuel Pump to Cylinder Block or Front Cover 26-36 (19-27)
Aywheel lo Crankshaft 102-115 (75-85)
Main Bearing Cap Bolts- 4.2L (255 CID) V-8/5.0L (302 CID) V-8 82-94 (60-70)
~ 5.8L (351 CID) W-V-8 129-142 (95-105)
Manifold lo Cylinder Head - lntake 32-33 (23-25)
Manifold lo Cylinder Head - Exhaust 25-32 (18-24)
lntake Manifold Vacuum Fittings - Aluminum 8-13 ( 6-10)
-Casi lron 32-37 (23-28)
lntake Manifold Pipe Fittings - Aluminum 17-24 (12-18)
-Casi lron
- 32-37 (23-28)
Oil lnlet Tube lo Main Bearing Cap 30-43 (22-32)
Thermactor Pump Bracket lo Cylinder Block 44-67 (30-45)
Carburetor Mounting Stud 7-13 ( 5-10)
Distributor Clamp Down 24-32 (17-25)
Oil Filler lnsert lo Cylinder Block!Adaptor 28-40 (20-30)
1/2 turn alter gasket
Oil Filler lo Adaptor or Cylinder Block contacts sealing surface -
oiled asket
Oil lnlet Tube Pump 14-20 (10-15)
Oil Pan Drain Plug 21-33 (15-25)
Oil Pan lo Cylinder Block 13-14 ( 9-11)
Oil Pump lo Cylinder Block 30-43 (22-32)
Pulley lo Damper Bol! 48-67 (35-50)
Rocker Arm Stud/Bolt to Cylinder Head 25-33 (18-25)
Spark Plug lo Cylinder Head 14-20 (10-15)
Valve Rocker Arm Cover 4-6 ( 3-5 )
Water Outlet Housing 13-16 ( 9-12)
Water Pump lo Block!Front Cover 17-24 (12-18)
Alternator Bracket lo Cylinder Block - Bol! 17-24 (12-18)
Alternator Adjusting Arm to Alternator Bol! 33-60 (24-40)
Thermactor Pump Pivot Bol! 30-43 (22-32)
Thermactor Pump Adjusting Arm lo Pump 30-43 (22-32)
Thermactor Pump Pulley lo Pump Hub 17-24 (150-220 in-lbs)
Fuel Filler lo Carburetor 10-11 (80-100 in-lbs)
Carburetor Attaching Nuts 17-20 (12-15)
0 4.2L (255 CID) V-8/5.0L (302 CID) V-8 - Torque in steps : first lo 75-88 N•m (55-65 11-lbs.) then lo 88-97 Nom (65-72 11-lbs .)
<D 5.8L (351 CID) W-V-8- Torque in steps: first lo 115 N•m (85 11-lbs.) then lo 129 N•m (95 11-lbs.) , final lo 143-151 N•m (105-112 ft-lbs .) CA4961-2B ,
21-21-46 4.2L (255 CID) V-8, 5.0L (302 CID) V-8 and 5.8L (351 CID) W-V-8 Engines 21-21-46
f "-SIIOLE- AOJU$1 AP U WITH l i'VIIO $ MI$$10 N ANO ~¡t, $1 IOl[ C AI.I IN SPE CIH[ Q
POSlli()N O P' EGR 1/ .0. l\lf •N O PUAGE W•CUV M 1-!()Sf Al A
CV A8 1D1..( - A0JUST AP¡,j Wlll'l TAANSMISSIO N IN SP[ Cifi(Q M(IO( oUIO 4 l l Yo\C
W M t'IOSfSCONN( Cl (Q 1/[H!Ct( I,IU$1 8[ lt.l ~f lrol l"'l r.IU "' oUolll lf "'T AJA TUoi P
UU.TUA( WH(N 4 0JUS TING 4 C OH CU RB 101.(
A6501 -2A
. . . ..