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PART
8-1-GENERAl
ENGINE SERVICE
8-15
another cut. Repeat the procedure
until the proper fit is obtained.
Check the piston pin for fit in the
respective rod or rod bushing.
CYLINDER BLOCK
Refinishing
CyUnder
WaDs.
Hon-
ing is :recommended for refinishing
cylinder walls only when the walls
have minor imperfections, such as
light scuffs and scratches or for fit-
ting pistons to the specified clear-
ance. The grade of hone to be used
is determined by the amount of
metal to be
removed.
Follow the in-
structions of the hone manufacturer.
If coarse stones are used to start
the honing operation, leave enough
material
so
that all hone marks can
be removed with the finishing hone
which is used to obtain the proper
piston clearance.
Cylinder walls that are severely
marred and/ or worn beyond the
specified limits should be refinished.
Before any cylinder is refinished, all
main bearing caps must be in place
and tightened to the proper torque
so
that the crankshaft bearing bores-
will not become distorted from thtil
refinishing operation.
Refinish only the cylinder or cyl-
inders that require it. All plsto4S are
the same weight, both standard and
ovenlze; therefore, various sizes of
plstous can be used without upset-
ting engine balance.
Refinish the cylinder with
the
most
wear first to determine the
maximum oversize. If the cylinder
will
not clean up when refinished
for
the maximum oversize piston
recommended,
replace the cylinder
block.
Refinish
the
cylinder to within ap-
proximately
0.0015 inch of the re-
quired oversize diameter. This
will
allow enough stock for the final step
of honing
so
that the correct surface
finish and pattern
are
obtained. Use
clean sharp hones of No. 180-220
grit for this operation.
For the proper
.
use
of the re-
finishing
equipment, follow the in-
structions
of the manufacturer.
Only
experienced penonnel should be .._
lowed to perform
this
won.
After the final operation in either
of the two refinishing methods de-
scribed and prior to checking the
piston
fit, thoroughly clean and oil
the cylinder walls, following the
procedure in Section 3. Check the
piston fit, following the procedure
in this section and Section 3. Mark
EJ
CLEANING AND INSPECTION
The cleaning and inspection pro-
cedures in this section are for a
complete engine overhaul; therefore,
for partial engine overhaul or parts
replacement, follow the pertinent
cleaning or inspection procedure.
INTAKE MANIFOLD
CLEANING
Remove all gasket material from
the machined surfaces of the mani-
fold. Clean the manifold in a suit-
able solvent and dry it with corn-
pressed air.
INSPECTION
Inspect the manifold for cracks,
damaged gasket surfaces, or other
defects that would make it unfit for
further service. Replace all studs
that are stripped or otherwise dam-
aged. Remove all fiilngs and foreign
matter that may have entered the
manifold as a result of repaln.
EXHAUST MANIFOLDS
CLEANING
Remove all gasket material from
the manifolds. Make sure the auto-
matic choke air inlet and outlet
hold (right exhaust manifold on
302 V-8 engines)
are
completeiy
open
and the cover
does not leak.
Blow out
the automatic choke air
heat tube
with compressed air.
INSPECTION
Inspect the
cylinder head
joining
flanges
of the exhaust manifold(s)
for
evidence of exhaust gas leaks.
Inspect the manifold(s) for cracks,
damaged
gasket surfaces, or other
defects
that
would make them unfit
for further
service.
VALVE ROCKER ARM
AND/OR SHAn ASSEMBLY
CLEANING
Clean
all the parts thoroughly.
Make
sure all oil passages are open.
On
ball
stud rocker arms, make
sure the
oil passage in the push rod
end
of
the
rocker arm is open. •
INSPECTION
On
rocker
arm shaft assemblies,
check
the
clearance between each
rocker
arm and the shaft by check-
ing the ID
of the rocker arm bore
and the
OD of the shaft.
If
the clear.
ance
between any rocker arm and
the shaft
exceeds the wear limit, re-
the pistons to correspond to the
cylinders in which they are to be
installed.
When the refinishing of
all cylinders that require it has been
completed and all pistons are fitted,
thoroughly clean the entire block
and oil the cylinder walls following
the procedure under Cylinder Block
Cleaning
on
page
8·f9
FLYWHEEL RING GEAR-
MANUAL-SHIFf
TRANSMISSIONS
To
replace
a defective
ring
gear,
heat
the
defective ring gear with a
blow torch on
the
engine side of the
gear, and knock
it
off the flywheel.
Do
not hit the flywheel when remov-
Ing the ring gear.
Heat the new
ring
gear evenly
until the gear expands enough to
slip onto the flywheel. Make sure
the gear
is
seated properly against
the shoulder.
Do
not heat any por-
tion of
the
gear to a tempenture
higher
than
500°F. If this Umlt II
exceeded,
the
temper will be re-
'moved froiD the ring gear teeth.
place the shaft and/ or the
rocker
arm. Inspect the
·
s haft and the rocker
arm bore for nicks, scratches, scores
or scuffs.
Inspect
the pad at the valve end
of the rocker arm for indications of
scuffing or abnormal
wear.
If
the
pad is grooved,
replace
the .rocker
arm.
Do
not attempt to
true
this
1111'·
face by grinding.
On ball stud rocker arms, check
the
rocker arm and fulcrum seat
for
excessive wear, cracks,
nicks
or
burrs. Check the rocker arm stud
.and nut for
.stripped
or broken
threads.
PUSH RODS
CLEANING
On a V
-8 Engine, clean
the push
rods
in
a
suitable
solvent. Blow out
the oil passage in the push
rods
with compressed air.
INSPECTION
Check the ends of the
push rods
for nicks, grooves,
roughness
or ex-
cessive wear.
The push
rods
can be visually
checked for straightness while they
are installed in
the
engine by rotat-
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