Ford Falcon. Manual — part 105
303-00-10
Engine System — General Information
303-00-10
GENERAL PROCEDURES (Continued)
3. Verify the crankshaft journal clearance.
Crankshaft — Runout
For additional information, refer to
NOTE: Crankshaft main bearing journals must be
Specifications in the appropriate section in
within specifications before checking runout.
Group 303.
1. Use the Dial Indicator with Bracketry to measure
If it is out of specification, install new
the crankshaft runout.
components as necessary. Refer to the
For additional information, refer to
appropriate section in Group 303 for the
Specifications in the appropriate section in
procedure.
Group 303.
Rotate the crankshaft and subtract the lowest
dial indicator reading from the highest dial
indicator reading to figure the crankshaft
runout. If it is out of specification, install new
components as necessary. Refer to the
appropriate section in Group 303 for the
procedure.
Crankshaft — End Play
1. Measure the crankshaft end play. Use a Dial
Indicator with Bracketry to measure crankshaft
end play.
2. Position the crankshaft to the rear of the cylinder
block.
3. Zero the indicator.
Crankshaft — Connecting Rod Journal
4. Move the crankshaft to the front of the cylinder
Taper, Out of Round
block. Note and record the crankshaft end play.
1. Measure the crankshaft connecting rod journal
If crankshaft end play exceeds specifications,
diameters in two directions perpendicular to one
install a new crankshaft thrust washer (6334)
another at each end of the connecting rod journal.
or crankshaft thrust main bearing (6337).
The difference in the measurements from one end
Refer to the appropriate section in Group 303
to the other is the taper. Verify measurement is
for the procedure.
within the wear limit.
For additional information, refer to
Specifications in the appropriate section in
Group 303.
If it is out of specification, install new
components as necessary. Refer to the
appropriate section in Group 303 for the
procedure.
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303-00-11
Engine System — General Information
303-00-11
GENERAL PROCEDURES (Continued)
Cylinder Bore — Out-of-Round
1. Measure the cylinder bore in two directions. The
difference is the out-of-round. Verify the
out-of-round is within the wear limit and bore the
cylinder to the next oversize limit.
For additional information, refer to
Specifications in the appropriate section in
Group 303.
Cylinder Bore — Taper
1. Measure the cylinder bore at the top and bottom.
Verify the cylinder bore is within the wear limit.
The difference indicates the cylinder bore taper.
Bore the cylinder to the next oversize.
For additional information, refer to
Specifications in the appropriate section in
Group 303.
Piston — Inspection
CAUTION: Do not use a caustic cleaning
solution or a wire brush to clean the pistons or
damage can occur.
1. Clean and inspect the (2) ring lands, (4) skirts, (3)
pin bosses, and the (1) tops of the pistons. If wear
marks, scores or glazing is found on the piston
skirt, check for a bent or twisted connecting rod.
2. Use the Piston Ring Groove Cleaner to clean the
piston ring grooves.
Make sure the oil ring holes are clean.
Piston — Pin to Bore Diameter
WARNING: Cover the end of the pin bore with
a hand or shop rag when removing the retainer
ring, since it has a tendency to spring out. Wear
eye protection.
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303-00-12
Engine System — General Information
303-00-12
GENERAL PROCEDURES (Continued)
NOTE: Piston and piston pins are a matched set and
Piston — Ring End Gap
should not be interchanged. Measure the piston pin
1. Use a piston without rings to push a piston ring in
bore diameter in two directions on each side. Verify
a cylinder to the bottom of ring travel.
the diameter is within specification.
1. If it is out of specification, install new components
CAUTION: Use care when fitting piston
as necessary. Refer to the appropriate section in
rings to avoid possible damage to the piston
Group 303 for the procedure.
ring or the cylinder bore.
CAUTION: Piston rings should not be
transferred from one piston to another.
NOTE: Cylinder bore must be within specification
for taper and out-of-round.
Piston — Diameter
1. Measure the piston skirt diameter 90 degrees
from the piston pin at the points indicated. For
additional information, refer to Specifications in
the appropriate section in Group 303.
2. Use a feeler gauge to measure the top piston ring
end gap and the second piston ring end gap.
If it is out of specification, install new
components as necessary. Refer to the
For additional information, refer to
appropriate section in Group 303 for the
Specifications in the appropriate section in
procedure.
Group 303.
Piston — Ring-to-Groove Clearance
1. Inspect for a step in the grooves.
2. Measure the piston ring-to-groove clearance.
For additional information, refer to
Specifications in the appropriate section in
Group 303.
If out of specification, install new components
as necessary. Refer to the appropriate section
in Group 303 for the procedure.
Piston — to Cylinder Bore Clearance
1. Subtract the piston diameter from the cylinder
bore diameter to find the piston-to-cylinder bore
clearance. If the measurement is outside
specification, replace the piston, or machine the
cylinder block oversize and fit oversize pistons.
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303-00-13
Engine System — General Information
303-00-13
GENERAL PROCEDURES (Continued)
Piston — Pin Diameter
Connecting Rod — Bushing Diameter
1. Measure the piston pin diameter in two directions
1. Measure the inner diameter of the connecting rod
at the points shown. Verify the diameter is within
bushing, if equipped. Verify the diameter is within
specification.
specification.
For additional information, refer to
For additional information, refer to
Specifications in the appropriate section in
Specifications in the appropriate section in
Group 303.
Group 303.
If out of specification, install new components
If out of specification, install new components
as necessary. Refer to the appropriate section
as necessary. Refer to the appropriate section
in Group 303 for the procedure.
in Group 303 for the procedure.
Connecting Rod — Cleaning
Connecting Rod — Bend
1. Measure the connecting rod bend on a suitable
CAUTION: Do not use a caustic cleaning
alignment fixture. Follow the instructions of the
solution or damage to connecting rods can occur.
fixture manufacturer. Verify the bend
measurement is within specification.
Connecting Rod — Large End Bore
For additional information, refer to
1. Measure the bore in two directions. The difference
Specifications in the appropriate section in
is the connecting rod bore out-of-round. Verify the
Group 303.
out-of-round is within specification.
If out of specification, install new components
For additional information, refer to
as necessary. Refer to the appropriate section
Specifications in the appropriate section in
in Group 303 for the procedure.
Group 303.
If out of specification, install new components
as necessary. Refer to the appropriate section
in Group 303 for the procedure.
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