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.

G37839 en

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.

G37843 en

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.

G37843 en

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.

G37876 en