FORD V8 ENGINES 209. the treated area, the block is cracked and should be replaced.

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1 FORD V8 ENGINES 209 Cylinder block Core plug Strike here with hammer Drift 8 the treated area, the block is cracked and should be replaced. 3. Check flatness of the cylinder block deck. Place an accurate straightedge on the block. If there is any gap between the block and straightedge, measure it with a feeler gauge. Measure from end to end and from comer to comer. 4. Measure the cylinder bores with a bore gauge (Figure 74) as described under Piston Clearance Check in this chapter. If the cylinders exceed maximum tolerances, they must be rebored. Reboring is also necessary if the cylinder walls are badly scuffed or scored. Before boring, install all main bearing caps and tighten the cap bolts to specifications in Table 2. CORE PLUGS Check the condition of all core plugs in the block (Figure 73) and cylinder head whenever the engine is out of the boat for service. If any signs of leakage or corrosion are found around one plug, replace them all. Removal/Installation CAUTION Do not drive core plugs into the engine casting. It will be impossible to retrieve them and they can restrict coolant circulation, resulting in serious engine damage, 1. Tap the bottom edge of the core plug with a hammer and drift. Use several sharp blows to push the bottom of the plug inward, tilting the top out (Figure 75).

2 210 CHAPTER EIGHT 2. Grip the top of the plug with pliers. Pull the plug from its bore (Figure 76) and discard. 3. Clean the plug bore thoroughly to remove all traces of the old sealer. 4. Apply a light coat of Loctite Stud N' Bearing mount or equivalent to the plug bore. \ Pliers 5. Install the new core plug with an appropriate size driver or socket. The sharp edge of the plug should be at least 0.02 in. inside the lead-in chamfer. General specifications Piston displacement Bore Stroke Horsepower rating Cylinder numbering (front to rear) Starboard bank Port bank Firing order All others Cylinder bore Diameter Out-of-round Taper Thrust side Relief side Piston clearance Table 1 ENGINE $IPECIFICATION (302 AND 351 CID) 4,949 cc (302 cu. in.) 5,752 cc (351 cu. in.) 4.00 in in in. 175, 190 hp 235 hp in in. max in. max in. max. (continued) in.

3 FORD V8 ENGINES 211 Table 1 ENGINE SPECIFICATION (302 AND 351 CID) (continued) Piston rings Compression rings Side clearance Width Gap ON ring Side clearance Gap Piston pin Diameter Clearance Fit in rod Crankshaft Main journal diameter Journal taper Journal out-of-round Main bearing clearance No. 1 No. 2-5 (all) End play Connecting rod journal diameter Journal taper Journal out-of-round Rod bearing clearance Rod side clearance Camshaft Lobe lift (intake) Lobe lift (exhaust) Journal diameter No. 1 No. 2 No. 3 No. 4 No. 5 Runout Cylinder head Gasket surface flatness in in in. Snug in in in. Interference in in in in in in in in in In in in in in in in in in in in in. max in. any 6 in. or in. overall max. (continued)

4 212 CHAPTER EIGHT Table 1 ENGINE SPECIFICATION (302 AND 351 CID) (continued) Valve system Lifter Rocker arm ratio Face angle (intake and exhaust) Seat angle (intake and exhaust) Seat runout (all) Head diameter Intake Exhaust Stem clearance Intake Exhaust Valve springs Free length Pressure Closed Open Closed Open Installed height Oil pump Outer race to housing clearance Rotor end play Drive shaft to housing bearing clearance Relief valve clearance Hydraulic 1.6: in. max in in in in in in in in in in in in. 1 21/ /32 in. 1 13/ /32 in in in in in.

5 FORD V8 ENGINES 213 Table 2 TIGHTENING TORQUES Fastener ft.-lb. Adapter housing to spacer nut Alternator pivot bolt Camshaft Sprocket Thrust plate Crankshaft damper Carburetor Connecting rod cap nuts Cylinder head Step 1 Step 2 Step 3 Distributor hold-down bolt Engine block spacer bolt Exhaust manifold Flywheel Front cover Front mount Fuel pump Intake manifold Main bearing cap bolt Oil pan screw 1 and and Oil drain plug Oil pump Oil pump cover Oil pump pickup tube Rocker arm cover Rocker arm stud nut* Spark plugs Thermostat housing Water pump Water pump pulley screw SO * After nut contacts shoulder.

Fig. 6: Assembling Piston & Rod. NOTE: Notch must face forward Toyota Starlet CRANKSHAFT MAIN BEARINGS

Fig. 6: Assembling Piston & Rod. NOTE: Notch must face forward Toyota Starlet CRANKSHAFT MAIN BEARINGS connecting rods are marked for reassembly. 3. Thoroughly clean and inspect all components. Coat pin with engine oil and heat piston to 158-176 F (70-80 C). Pin should push fit with thumb pressure through