l-39
BASIC ENGINE
1-39
REMOVAL AND INSTALLATION (Continued)
Installation
1. Oil the camshaft journals and apply Ford
Polyethylene grease DOAZ-19584-A or
equivalent to the cam lobes. Carefully slide
the camshaft into position.
2. Install camshaft thrust plate. Check
camshaft end play. If end play is excessive,
replace the camshaft thrust plate.
3. Install timing chain, sprockets, oil slinger and
cylinder front cover as detailed under Cylin-
der Front Cover and Timing Chain.
4. Clean the tappets externally. Lubricate the
tappets and tappet bores with engine oil be-
fore installing them. Lubricate the push rod
ends with Ford Polyethylene grease
DOAZ-19584-A or equivalent. Install the
valve tappets and push rods in their original
positions.
5. Install intake manifold and carburetor, fol-
lowing the procedure under Intake Manifold.
6. Rotate the crankshaft damper until No. 1
piston is at TDC at the end of compression
stroke. Position the distributor in the block
with the rotor at No. 1 firing position and
points just starting to open. Install the hold
down clamp.
7. Apply Ford Polyethylene grease
DOAZ-19584-A or equivalent to valve stem
tips. Position rocker arms over push rods
and tighten bolts following the procedure un-
der Valve Rocker Arm Installation. Adjust
valve clearance if necessary.
8. Clean the valve rocker arm covers and cylin-
der head gasket surfaces. Apply oil-resistant
sealer to one side of the new cover gaskets.
Lay the cemented side of gaskets in place in
the covers.
9. Position the covers on the cylinder heads
and make sure that gaskets seat evenly. In-
stall cover attaching bolts and tighten to
specifications. Two minutes later, tighten
bolts to same specifications.
10. Connect the radiator upper hose.
11. Connect the fuel line to the carburetor.
12. Install the coil and bracket assembly to in-
take manifold.
13. Install the throttle linkage.
14. Engage engine wiring harness in clips on
left cylinder head and connect all wire termi-
nals. Connect PCV valve and hose to right
valve rocker arm cover.
15. Install the distributor cap and connect the
coil and spark plug wires.
16. Place the water pump pulley and drive belts
in position. Position the fan assembly to
water pump shaft and install and tighten the
attaching screws to specification.
17. Adjust the tension of drive belts to specifica-
tions and tighten attaching screws.
18. Fill and bleed the cooling system. Run en-
gine at fast idle and check for leaks.
19. Adjust the ignition timing and connect dis-
tributor vacuum line.
20. Check and adjust the carburetor idle speed
and mixture as required after engine tem-
perature has stabilized. Adjust transmission
linkage, if necessary. Install the air cleaner
and intake duct.
CORE PLUGS
Removal
To remove a large core plug, drill a 12.70mm (l/2-
inch) hole in the center of the plug and remove with
an impact Slide Hammer T59L-100-B, T50T-100-A
or equivalent, or pry it out with a large drift punch. On
a small core plug, drill a 6.35mm (1/4=inch) hole in the
center of the plug and pry it out with a small pin
punch. Clean and inspect the plug bore.
Prior to installing a core plug the plug bore
should be inspected for any damage that would
interfere with the proper sealing of the plug. If
the bore is damaged it will be necessary to true
the surface by boring for the next specified over-
size plug.
Oversize (OS) plugs are identified by the OS
stamped in the flat located on the cup side of the
plug
.
Coat the plug and/or bore lightly with an oil-
resistant (oil galley) or water-resistant (cooling
jacket) sealer and install it following the pro-
cedure for cup type or expansion type below:
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