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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