The Haynes Ford Engine Overhaul Manual: The Haynes Automotive Repair Manual for Overhauling Ford V8 Engines 1850107637, 9781850107637

Citation preview

10320l|

FORD Engine Overhaul

Maiilial

•260 • 289 • 302 • 351 • 360 • 390 429 and 460 cubic inch V8 engines

Includes 255

400

3 I

^

•

428

•

•

Diagnosis •Oyeftiaur

•

Performance &

Economy

Modifications

Digitized by the Internet Archive in

2009

http://www.archive.org/details/haynesfordengineOOstyv

The Haynes

Ford Engine Overhaul Manual by Brian Styve and John H Haynes Member

of the Guild of Motoring Writers

The Haynes Automotive Repair Manual for overhauling Ford

V8 engines (5D4

-

10320) (1763)

,\550(:UT1CN

Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England

Haynes North America, 861 Lawrence Drive Newbury Park California

91320

USA

Inc

IVItlVCtK

Acknowledgements We are grateful for the

help and cooperation of the Ford Motor

Company

and certain illustrations. We also wish to thank Performance Automotive Wholesale (PAW) in Chatsworth, California who graciously supplied the parts needed to overhaul our two project engines. The Super Shops in Thousand Oaks, California allowed us to photograph the performance parts shown in Chapter 9. Machine shop work was done by American Engine in Oxnard, California, who also for assistance with technical information

supplied technical assistance.

©

Haynes North America, With permission from

J.

H.

Inc. Haynes & Co.

1991 Ltd.

A book in the Haynes Automotive Repair Manual Series Printed in the

USA

All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder

ISBN1 85010 763 7 Library of Congress Catalog Card

Number 91-71159

While every attempt is made to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

Contents Chapter

Introduction

1

How to What

is

use this repair manual an overhaul?

5 6

Engine identification

7

Parts interchangeability

11

Buying parts

12

Chapter 2

Tools and equipment

A place to work Tools and equipment Fasteners

13 16

64 70 70

Component disassembly Gasket sealing surfaces Hose removal tips Automotive chemicals and lubricants Safety

Chapter 3

71 71

first!

'

Diagnosing engine problems 79 80 80

General information Reading symptoms

Measuring

oil

consumption

81

Diagnostic checks is the engine worth rebuilding?

Chapter 4

96

Preparing for an overhaul

Preparing to remove the engine Removing the engine Removing the external engine components

Chapter 5

74

•

99 101

115

Overhauling the cylinder heads

Removing the

cylinder heads

Rebuilding the cylinder heads Inspecting the valve springs Assembling the heads Installing the heads Installing the valve train

127 129 141 143 144

146

Haynes Ford engine overhaul manual Chapter 6

Overhauling the engine block

Disassembly

1

Cleaning and inspection Machine shop procedures

Choosing piston rings and honing the cylinders Reassembly

Chapter 7

Reassembling and

installing the

engine

Introduction

Replacing the front transmission seal Assembling the engine Installing the engine Starting the engine Breaking in the engine

Chapter 8

187 187 190

206 208 209

Related repairs

Carburetor overhaul Distributor overhaul Fuel pump overhaul Starter overhaul Alternator overhaul

Chapter 9

47

156 170 174 175

211

213 216 218 223

Improving performance and economy

Introduction

Camshaft selection Exhaust modifications Ignition systems Intake manifolds Carburetors

work together Engine swaps Making

it

all

229 234 242 247 248 251

255 255

Introduction How to

use

this repair

manual

divided into Chapters. Each Chapter is sub-divided into which consist of consecutively numbered Paragraphs (usually referred to as "Steps", since they're normally part of a procedure). If the material is basically informative in nature, ratherthan a step- by-step

The manual

Sections,

is

some

of

procedure, the Paragraphs aren't numbered.

The first three Chapters contain material on preparing for an overhaul. The remaining Chapters cover the specifics of the overhaul procedure. Comprehensive Chapters covering tool selection and usage, safety and general shop practices have been included. The term "see illustration" (in parentheses), is used in the text to indicate that a photo or drawing has been included to make the information easier to understand (the old cliche "a picture is worth a thousand words" is

especially true

when

it

comes

to how-to procedures). Also, every at-

tempt made to position illustrations directly opposite the corresponding text to minimize confusion. The two types of illustrations used (photographs and line drawings) are referenced by a number preceding the capis

tion. Illustration

the Chapter

numbers denote Chapter and nurherical sequence within 3.4 means Chapter 3, illustration number four in order).

(i.e.,

The terms "Note", "Caution", and "Warning" are used throughout the purpose in mind - to attract the reader's attention. A "Note" simply provides information required to properly complete a procedure or information which will make the procedure easier to understand. A "Caution" outlines a special procedure or special steps which must be taken when completing the procedure where the Caution is

text with a specific

found. Failure to pay attention to a Caution can result in damage to the component being repaired or the tools being used. A "Warning" is included where personal injury can result if the instructions aren't followed exactly as described.

Even though extreme care has been taken during the preparation of this manual, neither the publisher nor the author can accept responsibility for any errors in, or omissions from, the information given.

Haynes Ford engine overhaul manual

What

is

an overhaul?

An engine overhaul involves restoring the internal parts to the specifications of a new engine. During an overhaul, the piston rings are replaced and the cylinder walls are reconditioned (rebored and/or honed). If a rebore is done, new pistons are required. The main bearings, connecting rod bearings and camshaft bearings are generally replaced with new ones and, if necessary, the crankshaft may be reground to restore the journals. Generally, the valves are serviced as well, since they're usually in lessthan-perfect condition at this point. While the engine is being overhauled, other components, such as the distributor, starter and alternator, can be rebuilt as well. The end result should be like a new engine that will give many thousands of trouble-free miles. Note: Critical cooling system components such as the hoses, drivebelts, thermostat and water pump MUST be replaced with new parts when an engine is overhauled. The radiator should be checked carefully to ensure that it isn't clogged or leaking; if in doubt, replace it with a new one. Also, always install a new oil pump when overhauling the engine - we recommend against rebuilt pumps. It's

not always easy to determine when, or

pletely overhauled, as a

number

of factors

if,

an engine should be com-

must be considered.

High mileage is not necessarily an indicationthatan overhaul is needed, while low mileage doesn't preclude the need for an overhaul. Frequency of servicing is probably the most important consideration. An engine that's had regular and frequent oil and filter changes, as well as other required maintenance, will most likely give manythousandsof miles of reliable service. Conversely, a neglected engine may require an overhaul very early in its life.

Excessive oil consumption is an indication that piston rings, valve seals and/or valve guides are in need of attention. Make sure that oil leaks aren't responsible before deciding that the rings and/or guides are bad. Perform

compression check (see Chapter 3) and have a leak-down test performed by an experienced tune-up mechanic to determine the extent of the work

a

required. If

the engine

is

making obvious knocking or rumbling noises, the conmay be at fault. Check the oil pressure

necting rod and/or main bearings

with a gauge installed

in place of the oil pressure sending unit or switch and compare it to the specifications for the particular engine (see the Haynes Automotive Repair Manuallor your vehicle). If it's extremely low (generally, less than 10 psi at idle), the bearings and/or oil

(see Chapter 3)

pump

are probably

worn

out.

Loss of power, rough running, excessive valve train noise and high fuel consumption rates may also point to the need for an overhaul, especially if they're all present at the same time. If a complete tune-up doesn't remedy the situation, major mechanical work is the only solution. Before beginning the engine overhaul, read through this entire manual scope and requirements of the job. Overhauling an engine isn't particularly difficult if you have the correct equipment; however, it is time consuming. Plan on the vehicle being tied up for a minimum of two weeks, especially if parts must betaken to an automotive

to familiarize yourself with the

machine shop for repair or reconditioning. Check on availability of parts and make sure that any necessary special tools and equipment are obtained in advance. Most work can be done with typical hand tools, al-

Introduction though

a

number of precision measuring

tools are required for inspecting

they must be replaced. Often an automotive machine shop will handle the inspection of parts and offer advice concerning reconditioning and replacement. parts to determine

if

Engine identifying just which engine you have is crucial because Ford engines which are very similar in appearance can be quite different in important details. Thefirst step of engine identification isto lookatthe Vehicle Identification Number (VIN), found on the left front door latch face or pillar and/ or at the left front corner of your dashboard, just inside the windshield (see illustration). On 1980 and earlier models, the first digit in the VIN denotes the model year and fifth isthe engine code (see illustrations). On 1981 and later models, the eighth digit is the engine code and the tenth digit denotes

the year (see illustration).

On 1 980 and

models, only the second digit of the year of production appears on the VIN so you have to know the decade of manufacture (0=1970, 1 = 1971 and so on). On 1981 and later models a letter code is used earlier

(see illustration).

Haynes Ford engine overhaul manual

Introduction

Haynes Ford engine overhaul manual ENGINE

ENGINE CID

CHANGE LEVEL

MODEL YEAR

429

o