Valve Rocker Arm Cover, Rocker Arm And/Or Shaft Removal And Installation; Intake Manifold Removal And Installation; Exhaust Manifold Removal And Installation; Cylinder Head Removal And Installation - Ford VSG-411 Service Manual

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Basic Engine
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REMOVAL AND INSTALLATION
VALVE ROCKER ARM COVER, ROCKER ARM
AND/OR SHAFT
Removal
1. Remove the air cleaner from the carburetor.
2. Disconnect the spark plug leads, remove them from the clip on
the rocker cover and position aside.
3. Remove the rocker cover attaching screws, remove the rocker
cover and discard the gasket.
4. Remove the rocker arm shaft attaching bolts evenly and lift off
the rocker arm shaft assembly.
5. Remove the cotter pin from one end of the shaft and slip the
flat washer, crimped washer and second flat washer off the
shaft. The rocker arm shaft supports, rocker arms and springs
can now be removed from the shaft.
6. Remove the plugs from the rocker shaft ends by drilling a hole
in one plug. Insert a long rod through the drilled plug and
knock the opposite plug out of the shaft. Remove the drilled
plug in the same manner.
7. Clean the component parts of the shaft assembly in any suit-
able degreasing fluid.
FIG. 28 Front End of Rocker Shaft
Installation
1.
2.
Refit new plugs to the rocker shaft ends.
3.
4.
5.
6.
7.
8.
Assemble the rocker arm shaft. The bolt hole in the rocker
arm shaft support must be on the same side as the adjust-
ing screw in the rocker arm. The oil holes must point
downward and the flat on the shaft to the front of engine.
The rocker arms are right and left handed, the rocker
pads being inclined towards the support. Install the cotter
pins with the heads upwards and bend over the legs to secure.
Lubricate the valve stem tips, rocker arm pads and the push
rod ends with Lubriplate or equivalent. Position the rocker
shaft assembly on the cylinder head engaging the push rods
with the adjusting screws. Install and tighten the bolts evenly
to specifications.
Adjust the valve clearance to specifications.
Ensure that the mating surfaces on the cylinder head and
rocker cover are free from all traces of the old gasket material.
Position the rocker cover and gasket on the cylinder head and
secure with the attaching screws. Torque the screws to
specifications.
Locate the spark plug leads in the rocker cover clip and re-
connect them to their respective plugs.
Install the air cleaner.
INTAKE MANIFOLD
Removal
1. Partially drain the cooling system.
2. Remove the air cleaner.
3. Disconnect the throttle rod from the carburetor throttle lever.
4. Disconnect the fuel line and the distributor vacuum line from
the carburetor.
5. Disconnect the water outlet hose and the crankcase ventilation
hose from the intake manifold.
6. Remove the attaching nut and bolts and remove the intake
manifold.
7. Remove the gasket.
8. If a new manifold is to be installed, transfer all necessary
components to the new manifold.
Installation
1. Apply a water resistant sealer to both sides of the gasket
around the water port and position it on the cylinder head.
2. Install the intake manifold and tighten the nuts and bolts
evenly to specifications.
3. Connect the water hose and the crankcase ventilation hose to
the intake manifold.
4. Connect the distributor vacuum line and the fuel supply line to
the carburetor.
5. Connect the throttle rod.
6. Install the air cleaner.
7. Refill the cooling system with the recommended coolant.
EXHAUST MANIFOLD
Removal
1. Remove the exhaust pipe retaining nuts and exhaust
pipe.
2. Remove the eight exhaust manifold retaining nuts.
3. Remove the exhaust manifold.
4. Remove the four exhaust gaskets and discard them.
Installation
1. Install four new exhaust manifold gaskets onto the studs.
2. Install the exhaust manifold and torque the nuts to specifica-
tion in the sequence shown in Figure 28a.
3. Install the exhaust pipe and torque the retaining nuts to
specification.
L
e FRONT OF ENGINE
5 1 4
0
0
0
cl
0
0
0
cl
cl
0
0
0
8
3 2
L
FIG. 28a Exhaust Manifold Torque Sequence
7
0
0
cl
0
6
CYLINDER HEAD
Removal
1. Remove the air cleaner.
2. Disconnect the fuel line at the fuel pump and carburetor.
3. Drain the coolant.
4. Disconnect the spark plug leads, remove them from the clip
on the rocker cover and position out of the way.
5. Disconnect the water outlet and crankcase ventilation hoses at
the intake manifold.