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Part ONE
POWER PLANT
Chapter
I
General Engine Repair
Section
Page
1
2
3
4
5
6
7
8
9
Trouble Shooting .................................................................... .
5
8
10
15
15
21
22
26
27
29
Engine Tune-Up ..................................................................... .
Engine Removal and Installation ....................................................... .
Intake and Exhaust Manifolds ......................................................... .
Rocker Mechanism, Cylinder Head, Valves, Valve Lash Adjustment, and Valve Timing .......... .
Camshaft Sprocket, Camshaft, and Camshaft Bearings ...................................... .
Flywheel, Crankshaft, Main Bearings, and Connecting Rod Bearings ........................... .
Oil Pan, Oil Filter, and Oil Pump and Pressure Relief Valve ................................. .
Cylinder Block, Pistons, Piston Rings, and Connecting Rods ................................. .
10
Exhaust System ..................................................................... .
Trouble shooting, tune-up, inspection, and repair
procedures, applicable to all engines, are given in
this chapter. For the removal and installation of en-
gine components, refer to the chapter covering the
specific engine.
Inasmuch as a determination of the basic cause
of engine trouble should precede any repair work, the
trouble shooting section is presented first. Many de-
fects in engine performance can be attributed directly
to a maladjustment of one part or a combination of
several parts; therefore, general engine tune-up logi-
cally follows the trouble shooting section, and pre-
cedes the actual repair work.
I. TROUBLE SHOOTING
Trouble shooting is the application of a definite pro-
cedure, in a logical sequence, to locate and eliminate
the cause of trouble in a particular system or unit. It
should be borne in mind, when trouble shooting, to first
look for the obvious causes of trouble such as an empty
gas tank, a wet or cold engine, loose or disconnected
wiring, or any other such item that may cause a tem-
porary defect.
The various factors affecting power plant operation
are outlined in this section.
a. Engine.
Poor engine performance can be attributed to the
engine or to forces on the vehicle that tend to retard its
motion. An example of a retarding force is dragging
brakes which causes the engine to work harder and
results in poor engine performance.
Engine performance depends on proper fuel distribu-
tion, correctly timed ignition, normal uniform compres-
sion, properly regulated flow of the fuel-air mixture to
the cylinders, and unobstructed flow of exhaust gases.
Engine trouble symptoms are discussed under sepa-
rate headings with instructions on what to do to correct
5
these conditions and regain good engine performance.
(1) ENGINE WILL NOT CRANK. If starter does
not turn the engine over, or turns it over too slowly to
start, the fault is likely to be in the battery or the
starter. Perform the following checks in the order listed,
until the cause of the trouble is determined:
(a) CHECK THE BATTERY. Try the horn or lights.
If they do not operate properly, test the battery, then
recharge it, or replace it, as necessary.
(b) CHECK THE BATTERY CABLES. Check for loose
or corroded connections at the starter, solenoid, battery,
and ground. Clean, tighten, or replace them as necessary.
( c) CHECK THE SOLENOID CIRCUIT. The solenoid
surfaces seldom become so badly burned that they will
prevent the starter from cranking the engine. However,
other wiring may
be
at fault. Repair as necessary. (Refer
to the Electrical System Section).
( d) CHECK THE STARTER OR STARTER DRIVE. If the
above components are not at fault, the trouble is
probably in the starter or starter drive. If the starter is
running, but not engaging the flywheel, remove the
starter and make the necessary repairs to the starter
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