258 - 232 AMC Engines

SIX CYLINDER ENGINE l-A-l
232-258 Cubic Inch Displacement

Page Page
ENGINE ASSEMBLY 1 Installation 12
Description 1 TIMING CHAIN COVER 12
Identification 1 Removal 13
Diagnosis G u i d e 2 Installation 13
Mounting 3 O i l Seal Replacement 13
Removal 3 TIMING CHAIN 14
Installation 4 Checking V a l v e Timing 14
LUBRICATION SYSTEM 4 Removal 14
Lubrication Circuit 4 Installation 14
Oil Filter 5 C A M S H A F T A N D BEARINGS 14
O i l Pump 5 Measuring C a m Lobe Lift 14
Oil Pressure Relief Valve 5 Removal 14
POSITIVE C R A N K C A S E V E N T I L A T I O N 6 Inspection 15
Air Inlet Filter 6 Installation 15
PCV V a l v e 6 OIL P A N 15
CYLINDER HEAD C O V E R A N D G A S K E T 6 Removal 15
Removal 6 Installation 15
Installation 7 OIL PUMP 15
ROCKER A R M A N D SHAFT ASSEMBLY 7 Removal 15
Removal and Disassembly 7 Disassembly a n d Inspection 16
Cleaning and Inspection 7 Assembly a n d Installation 16
Assembly and Installation 7 REAR M A I N BEARING OIL SEAL 16
VALVE S P R I N G A N D / O R V A L V E STEM OIL D E F L E C T O R . . 7 Removal and Installation 16
Removal a n d Testing 8 C O N N E C T I N G ROD BEARINGS 17
Installation 8 Removal a n d Inspection 17
INTAKE A N D E X H A U S T M A N I F O L D S 8 Measuring Bearing Clearance With Plastigage 17
Removal a n d Cleaning 8 Measuring Connecting Rod Journal With a Micrometer 17
Installation 8 Installation 18
CYLINDER HEAD A N D G A S K E T 8 C O N N E C T I N G ROD A N D P I S T O N ASSEMBLIES 18
Removal 9 Removal 18
Cleaning and Inspection 9 Cylinder Bore Conditioning 18
Installation 9 Pistons 18
CYLINDER H E A D R E C O N D I T I O N I N G 9 Piston Rings 18
Disassembly 9 Connecting Rods a n d Piston Pins 19
Cleaning a n d Inspection 10 Installation 20
Valve Refacing 10 C R A N K S H A F T M A I N BEARINGS 20
Valve Seat Refacing 10 Removal a n d Inspection 20
V a l v e Stem to G u i d e Clearance 10 Measuring Bearing Clearance With Plastigage 21
Assembly 10 Installation 21
HYDRAULIC V A L V E TAPPETS 10 CRANKSHAFT 21
Noise Diagnosis 11 Replacement 21
Removal and Disassembly 11 Checking End Play 21
Cleaning a n d Inspection 11 SHORT E N G I N E ASSEMBLY 21
Assembly and Testing 12 FLYWHEEL A N D STARTER R I N G G E A R ASSEMBLY 21
Installation 12 SPECIFICATIONS 22
V I B R A T I O N DAMPER 12 TOOLS 23
Removal 12
E N G I N E ASSEMBLY from the rear of the engine. The letter contained in the code
Seven two-piece main bearings are identifies the engine by cubic inch
Description used to support the crankshaft and the displacement, carburetor type and
The 232 and 258 C I D six cylinder camshaft is supported by four one- compression ratio.
engines incorporate an overhead valve piece line bored bearings. The letters used are coded as follows:
system in which the rocker arms oper- Comp.
ate on a common shaft. Code CID Carb. Ratio
Identification
The cylinders are numbered from A (Standard) 258 IV 8. 0: 1
front to rear with a firing o r d e r of The Engine C o d e is located on a B (Optional) 258 IV 7. 6: 1
1-5-3-6-2-4. The crankshaft rotates in machined surface of the block between E (Standard) 232 IV 8. 0: 1
a counterclockwise direction, viewed number two a n d three cylinders. F (Optional) 232 IV 7. 5: 1
l-A-2 SIX CYLINDER ENGINE
DIAGNOSIS GUIDE
Conditions and Probable Causes
Cannot Crank Engine
Electrical System
Trace circuits for faulty electrical
units.
Coolant Leak into Cylinder
Remove spark plugs to check for
coolant in cylinders. Crank with
plugs removed. Cylinder heads must
be removed to check gaskets, block,
and head for a source of coolant
leak. If permanent anti-freeze en-
tered engine, complete disassembly
will have to be accomplished.
Mechanical Seizure
Recondition.
Engine Will Crank Normally but

Will Not Start
Ignition System
Check spark plugs and secondary
circuit energy available at spark
plugs.
Fuel System
air horn for choke condition. If water

is present, clean out a n d substitute
with a supply of new fuel.
Ignition or V a l v e Timing
Check ignition and valve timing.
Engine Starts a n d Runs for

Short Periods O n l y
Fuel System
Check fuel pump and fuel lines from
fuel tank for intermittent or constant
restricting material or defect.
Ignition System
FIGURE 1 - Engine Code Check for leaky condenser and coil
Typical Location secondary. Check for faulty distribu-
tor contacts, ignition switch, and all
A l l engines built for sale in C a l i - FIGURE 2 — Engine Letter C o d e connecting wires including battery
fornia are painted " r e d . " All other connections.
engines are painted "blue. " l0WS:
Induction System
In the machining of cylinder blocks Single l e t t e r . . " B " Cylinder Check air leaks which may be too
and crankshafts, it is sometimes neces- bore — . 010" Oversize severe after choke enrichment is re-
sary to machine the cylinder bores to Single l e t t e r . . " M " Main duced.
. 010" oversize, and the crankshaft bearings —. 010" Undersize Exhaust System
main bearing journals or crank pins to Single l e t t e r . . " P " . . . . Connecting Check exhaust system for restrictions.
. 010" undersize. rod bearings —. 010" Undersize
These engines are marked with a Double l e t t e r s . . " P M " Main Engine Runs but Mis-fires at
single or two letter code (Fig. 2). and connecting rod bearings — Low Speed O n l y
The code is located on a boss di- . 010" Undersize
rectly above the oil filter. Single l e t t e r . . " C " Camshaft Fuel System
The letters used are coded as fol- block bores - . 010" Oversize Check for dirty passages and jets in
SIX CYLINDER E N G I N E l - A - 3
the idle circuit. Cooling System Exhaust System

Ignition System Thermostat not permitting proper Back pressure and leakage into the
Check spark plug heat range a n d operating temperature. intake system.
gap. Engine Resistance
Induction System Bearing a n d piston ring and piston
Mounting
Check for intake manifold air leaks. fit for oil clearance.
Check for air leaks from units con- Rolling Resistance of Vehicle Resilient rubber mounting cushions
nected to intake manifold. Brakes d r a g g i n g . Soft tires. Wheel support the engine and transmission at
Valves alignment. Wheel bearings. Clutch three points. A cushion is located at
Check for poor valve seating. or transmission slippage. each side on the center line of the en-
gine, (Fig. 3), with the rear supported
Engine Runs but Misses at A l l Speeds Engine Rough Running at Higher by a cushion between the transmission
Speeds extension housing a n d the rear sup-
Fuel System port crossmember. Removal or replace-
Dirt in carburetor or water in the Ignition System ment of a n y cushion may be accom-
fuel system. Spark plug g a p a n d heat range. plished by supporting the weight of
Ignition System Ignition timing. Distributor centrif- the engine or transmission at the area
Spark plugs, wiring, capacitor, coil, ugal and vacuum advance units. of the cushion.
and ignition system wiring. Ignition Coil polarity.
switch. Fuel System
Removal
Valves Improper fuel mixtures.
Poor valve seating — sticking valves. Fuel Induction System The engine is removed without the
Cooling System Severe air leaks into intake system. transmission a n d bell housing.
Coolant leak into intake sections or Valves and Camshaft On the Commando, W a g o n e e r a n d
cylinders. Sticky valves. Incorrect valve lift. Truck the hood must be removed. Mark
Camshaft the hinge locations at the hood panel
W o r n lobes on camshaft. Engine will not Respond to Fast Positive for alignment during installation. Re-
Opening of Throttle move the hood from the hinges.
Engine Rough Running at Low Speeds Remove the air cleaner assembly
Fuel System
and drain the cooling system.
Ignition System Carburetor accelerating circuits. Im-
Disconnect the upper a n d lower ra-
Spark plug g a p a n d heat range. proper fuel. Throttle linkage. Re-
diator hoses. If equipped with auto-
Secondary system wiring. Distributor strictions a n d dirty air cleaner.
matic transmission, disconnect the
points or capacitor. C a r b o n build-up on floor of intake
cooler lines from the radiator.
Fuel System manifold.
Idle circuits dirty. Choke sticking. A i r Ignition System N O T E : If vehicle is equipped with
leak below carburetor. Idle mixture C o i l capacity a n d polarity, spark a radiator shroud, it is necessary to
adjustment. plug condition, g a p , and heat separate the shroud from the radiator
Cooling System range. Ignition timing. Distributor to facilitate removal of the radiator
Coolant system leaks into intake condition. and engine fan.
valve ports or cylinder.
Valves
Poor valve seating.
Exhaust System
Exhaust leaks into intake passages.
Exhaust back pressure.
Engine Power Not Up to Normal
Valves
Valves not seating properly. Not
timed properly.
Rings
Rings w o r n , broken, not seating.
Fuel System
Air cleaner restricted. Power mixture
not proper.
Ignition System
Coil capacity, polarity, a n d distribu-
tor point spacing. Ignition timing.
Exhaust System
Restriction causing back pressure.
l-A-4 SIX CYLINDER E N G I N E
Remove the radiator. engine compartment a n d align with the upper a n d lower hoses. If equipped
Remove the engine fan. transmission bell housing (automatic with automatic transmission, connect
If so equipped, remove the power transmission) or clutch housing (manual the cooler lines.
steering pump and drive belt from the transmission). On manual transmissions, Fill the cooling system to the speci-
engine and place aside. Do not dis- make certain the clutch shaft is aligned fied level. Inspect the engine oil level
connect the power steering hoses. properly with the splines of the clutch a n d a d d oil as required.
If equipped with air conditioning, driven plate. Install the air cleaner assembly.
turn both service valves clockwise to Install the transmission bell housing Start the engine. Check all hose con-
the front seated position. to engine adapter plate bolts (auto- nections for leaks. Stop the engine.
Bleed the compressor refrigerant matic transmission) or the clutch hous- If removed, install a n d align the
charge by slowly loosening the service ing to engine bolts (manual transmis- hood assembly.
valve fittings. Disconnect the condenser sion). Tighten the bolts to the specified Install the transmission access cover,
and evaporator lines from the compres- torque. Remove the floor jack which floor mat a n d transfer case shift lever
sor. Disconnect the receiver outlet at was used to support the transmission. boot.
the disconnect coupling. Remove the If equipped with automatic trans-
condenser and receiver assembly. mission, align the marks previously
LUBRICATION SYSTEM
Disconnect all wires, lines, linkage made on the converter and flex plate,
and hoses which are connected to the install the converter to flex plate cap A full pressure type lubrication sys-
engine. screws and tighten to the specified tem is used, except for the piston pins,
Remove the oil filter. torque. which are lubricated through the con-
Remove both engine front support Install the two (2) engine adapter necting rod squirt holes a n d oil throw-
cushion to frame retaining nuts. plate inspection covers (automatic off.
Disconnect the exhaust pipe at the transmission) or the clutch housing Pressure is applied by a gear type,
support bracket and exhaust manifold. lower cover (manual transmission). positive pressure pump mounted on a
Support the weight of the engine Install the starter motor. boss adjacent to the number f o u r main
with a lifting device. Install the front support cushion and bearing location.
Remove the front support cushion bracket assemblies to the engine,
and bracket assemblies from the en- tighten the retaining bolts to the speci- Lubrication Circuit
gine. fied torque.
Remove the transfer case shift lever Lower the engine onto the frame O i l , drawn through the inlet screen
boot, floor mat (if so equipped) a n d supports, remove the lifting device and a n d tube to the inlet side of the oil
transmission access cover. install the front support cushion re- pump, is driven between the gears and
Remove the upper bolts securing taining nuts. Tighten the nuts to the pump b o d y to the pressure outlet por-
the transmission bell housing to the specified torque. tion of the o i ' pump where it is
engine adapter plate on vehicles Connect the exhaust pipe at the routed through an oil gallery to the
equipped with automatic transmission. support bracket and exhaust manifold inlet side of the full flow oil filter; and
If equipped with manual transmission, using a n e w seal, if required. on into the main oil gallery (Fig. 4 ) .
remove the upper bolts securing the Install the oil filter. Each main bearing and camshaft
clutch housing to the engine. bearing is lubricated by oil from the
Connect all wires, lines, linkage a n d
Remove the starter motor. main oil gallery.
hoses which were previously discon-
If equipped with automatic trans- Holes drilled in each connecting rod
nected from the engine.
mission, remove the two (2) engine journal direct lubrication to the con-
If removed, install the air condition-
adapter plate inspection covers. Mark necting rod bearings. O i l throw-off
ing condenser and receiver assembly.
the assembled position of the converter from each connecting rod bearing lu-
Connect the receiver outlet to the dis-
and flex plate a n d remove the con- bricates the cylinder walls and piston
connect coupling. Connect the con-
verter to flex plate cap screws. Remove pins.
denser and evaporator lines to the
the remaining bolts securing the trans- compressor. Purge the compressor of A small channel (squirt hole) lo-
mission bell housing to the engine air as outlined in the " A I R C O N D I - cated on the numbered side of the
adapter plate. T I O N I N G " section. connecting rods and caps allows oil to
If equipped with manual transmis- lubricate the camshaft lobes, tappets,
sion, remove the clutch housing lower CAUTION: Both service valves must piston pins a n d distributor drive gear.
cover and the remaining bolts securing be open before the air conditioning The hydraulic valve tappets are fed
the clutch housing to the engine. system is operated. directly from the main oil gallery.
Support the transmission with a floor Lubrication is supplied to the timing
jack. If removed, install the power steer- chain and gears from the front cam-
ing pump and drive belt, tighten the shaft bearing a n d returned to the
Remove the engine by pulling for-
belt to the specified tension. crankcase through a cavity under the
ward and upward.
Install the engine fan a n d tighten front main bearing cap.
the retaining bolts to the specified The oil supply for the rocker arms
Installation
torque. a n d push rods is obtained from the
Lower the engine slowly into the Install the radiator and connect the number three cam bearing location,
SIX CYLINDER E N G I N E l-A-5
incorporates a pressure relief valve

to regulate maximum pressure. Crank-
case oil enters the pump through a
pick-up tube and screen assembly
which is a press fit in the pump body
(Fig. 6).
FIGURE 4 — Lubrication Circuit FIGURE 6 — O i l Pump Components
where oil from the main lubrication

gallery is metered through a groove
in the camshaft bearing surface to a
gallery extending upwards to the cyl-
inder head gasket surface. At this
point, the cylinder head gasket forms
a seal joining the cylinder block gallery
with the adjoining gallery in the cyl-
inder head. Commencing at the num-
ber five rocker arm support, the oil
then flows into the rocker arm shaft
to supply lubrication to the rocker arm
and push rods.
Holes cast in the cylinder head re-
turn the oil to the crankcase through
the valve tappet area, which in turn
lubricates the tappets.
Oil Filter
A full flow oil filter, mounted on the
lower right hand side of the engine, is
accessible through the hood opening.
A by-pass valve, incorporated in the
filter mounting boss, provides a safety
factor in the event the filter becomes FIGURE 5 - O i l Filter Assembly
inoperative as a result of dirt or sludge
O p e r a t e engine at fast idle and O i l pump removal or replacement
accumulation. (Fig. 5. )
check for leaks. will not affect distributor timing as the
O i l Filter Removal Tool J-22700 will
distributor drive gear remains in mesh
facilitate removal of the oil filter.
O i l Pump with the camshaft gear.
A p p l y a thin film of oil to the new
filter gasket before installation. A positive displacement g e a r type
Install filter until gasket contacts the
O i l Pressure Relief Valve
oil pump is used and is driven by the
seat of the adapter. Then tighten se- distributor shaft, which in turn is driven The oil pressure relief valve is not
curely, by hand only. by a g e a r on the camshaft. The pump adjustable. A setting of 75 pounds
maximum pressure is built into the ten- along with the fuel-air mixture.
sion of the spring. The system will work effectively as
In the relief position, the valve per- long as all component parts are free
mits oil to by-pass through a passage from sludge a n d foreign material.
in the pump body to the inlet side of The oil filler cap, which is non-
the pump. vented, requires no service. The air
The oil pump pick-up tube a n d inlet filter and the P C V valve require
screen assembly is a press fit in the service at periodic mileage intervals.
oil pump body. The connecting hoses should be
cleaned or replaced whenever neces-
CAUTION: Do not disturb the posi-
sary.
tion of the tube assembly in the pump
body unless absolutely necessary.
Air Inlet Filter
In the event the tube is disturbed,
The wire gauze air inlet filter is
it must be replaced with a new tube
located within the air cleaner end of
assembly.
the moulded rubber hose which is con-
nected between the air cleaner and FIGURE 8 — Removing A i r Inlet Filter
POSITIVE CRANKCASE cylinder head cover. It must be cleaned
VENTILATION in kerosene at the mileage intervals
During periods of relatively high
manifold vacuum, such as during idle,
This system prevents crankcase recommended in the "Mechanical
the valve provides a reduced air flow
vapors from entering the atmosphere. Maintenance Schedule. "
since crankcase vapor pressure is low
During periods of relatively high
NOTE: The air inlet filter must be re- at this time and requires little venting.
manifold vacuum, such as idle or cruise
moved frorn inside the carburetor air The reduced air flow also assures a
speeds, crankcase vapors are drawn
cleaner hose prior to removing the hose. smooth idle (Fig. 9).
through the cylinder head cover a n d
The molded end of the air inlet hose
PCV valve into the intake manifold
will be damaged if the hose is pried out
where they are burned with the fuel-
with the filter in place (Fig. 8).
air mixture.
At this time, fresh air passing
through the inlet filter in the connecting
PCV Valve
hose between the air cleaner a n d cyl- The P C V valve is located in a rubber
inder head cover, is routed through the grommet toward the rear of the c y l - FIGURE 9 — Positive Crankcase
cylinder head cover to the crankcase inder head cover and is connected to Ventilation Flow-Valve
(Fig. 7). a hose through which manifold vac-
The P C V valve must be replaced at
the mileage intervals recommended in
the "Mechanical Maintenance Sched-
ule. " It should be cleaned a n d tested
at more frequent mileage intervals
when driving under adverse conditions.
A cleaned or replacement P C V valve
should always be tested with PCV
V a l v e Tester J-23111 to determine cor-
rect air flow rate (Refer to the "Emis-
sion C o n t r o l " section for a complete
test procedure).
CYLINDER HEAD C O V E R A N D
GASKET
Removal
Remove the air cleaner a n d the PCV
During periods of low manifold vacuum is routed from a fitting at the moulded hose.
uum, such as heavy acceleration, the intake manifold. Disconnect the fuel and distributor
flow is reversed. During periods of relatively low vacuum advance lines at the carbu-
Crankcase vapors are then drawn manifold vacuum, such as high speed retor, bend as required to allow re-
into the connecting hose between the or heavy acceleration, the valve pro- moval of the cylinder head cover.
air cleaner and cylinder head cover vides an increased air flow to vent the Disconnect all other hoses or lines
and through the air cleaner element high vapor pressure which develops attached to the cylinder head cover.
to the intake manifold to be burned in the crankcase. Remove the retaining screws and
SIX C Y L I N D E R E N G I N E l-A-7
separate the cylinder head cover and scored or worn, they should be re- the oil used for rocker arm lubrication
gasket from the engine. placed. If the shaft is plugged by from entering the combustion chamber
sludge which cannot be removed by through the valve guides. The oil de-
Installation cleaning, it should be replaced. flectors should be replaced whenever
valve service is performed or if the
Place the gasket on the cylinder IMPORTANT: Always check for ade-
rubber has become hard and brittle.
head cover flange making certain the quate oil supply through the oil passage
The valve spring is held in place
gasket tabs are positioned in the cut at number five (numbered from front
on the valve stem by a retainer and
out openings of the cover. to rear) rocker arm support whenever
a set of valve locks. The locks can be
Position the cylinder head cover a n d the rocker arms or shaft are worn due
removed only by compressing the valve
gasket on the engine. Install the retain- to oil starvation.
spring. Whenever valve springs are re-
ing screws and tighten to the specified
Inspect the push rod contact surface moved, they should be tested for
torque.
of each rocker arm. Replace the rocker correct tension a n d replaced if not
Connect the fuel a n d distributor vac-
arm as well as the mating push rod if within specifications.
uum advance lines to the carburetor.
excessively worn. V a l v e springs a n d oil deflectors can
Connect all other hoses or lines
Inspect the valve stem contact sur- be removed without removing the cyl-
which were previously disconnected
face of each rocker arm.
from the cylinder head cover.
Reface the contact surface if minor
Install the air cleaner and connect
pitting has occurred. Replace the
the PCV moulded hose.
rocker arm if it is deeply pitted.
ROCKER ARM AND SHAFT

Assembly and Installation
ASSEMBLY
Assemble the rocker arms, spacers,
Removal and Disassembly retainers, retaining bolts a n d oil de-
Remove the cylinder head cover and flector on the rocker arm shaft in the
gasket. same order as removed. If the correct
Loosen the retaining bolts from the order is not known, refer to the dis-
cylinder head and remove the rocker assembled view in Figure 10.
arm and shaft assembly, including the
NOTE: The oil holes of the rocker
retaining bolts.
arm shaft must face the cylinder head.
Remove the roll pin a n d spring
washer from one end of the rocker Use two rubber bands to hold the
arm shaft. rocker arms in position as shown in
Remove the rocker arms, spacers, Figure 11 a n d install the rocker arm
retainers, retaining bolts a n d oil de- a n d shaft assembly to the cylinder
flector and place on a bench in the head. Make certain the push rods are
same order as removed. correctly aligned with the rocker arms
before tightening the retaining bolts.
Cleaning and Inspection Work from the center of the rocker
arm shaft outward a n d tighten the
Clean all parts with a g o o d cleaning retaining bolts evenly until the speci-
solvent while retaining the order in fied torque is obtained.
which they were removed from the Install the cylinder head cover and
rocker arm shaft. Use compressed air gasket.
to clean out the oil passages in the
rocker arms and shaft.
VALVE SPRING AND/OR
Inspect each rocker arm mounting
VALVE STEM OIL DEFLECTOR
surface and the rocker arm shaft at
each rocker arm location. If the shaft Rubber valve stem oil deflectors are
or a n y rocker arms are excessively installed on each valve stem to prevent
l - A - 8 SIX CYLINDER E N G I N E
inder head. Refer to " C y l i n d e r Head tainer from the cylinder head. Remove surfaces of the intake manifold to
Reconditioning" for removal procedure the oil deflector if replacement is exhaust manifold a n d also between the
with the cylinder head removed. required. exhaust manifold a n d exhaust pipe.
Use V a l v e Spring Tester C-647 to
Removal and Testing test each removed valve spring for Removal and Cleaning
the specified tension values (Fig. 14).
Remove the cylinder head cover a n d Replace all valve springs which are Remove the air cleaner a n d carbu-
gasket. retor.
not within specifications.
Remove the rocker arm a n d shaft Disconnect the accelerator cable
assembly and the push rods. from the accelerator bellcrank.
Disconnect the PCV vacuum hose
N O T E : Push rods should be retained
from the intake manifold.
in the same order as removed.
Disconnect the distributor vacuum
Remove the spark plug from the hose and electrical wires at the TCS
cylinder which requires valve spring solenoid vacuum valve.
or oil deflector removal a n d install a If equipped with air conditioning,
14 mm. thread size air adapter in the disconnect the compressor a n d bracket
spark plug hole. assembly from the intake manifold.
Disconnect the exhaust pipe from
NOTE: The adapter can be made
the manifold flange.
from the body of a spark plug from
Remove the manifold attaching bolts,
which the porcelain has been removed
nuts a n d clamps; separate the intake
and an air hose connection fastened to
a n d exhaust manifold from the engine
the body of the spark plug.
as an assembly. Discard the gasket.
Connect an air hose to the adapter If either manifold is to be replaced,
and maintain at least 90 PSI in the separate the manifolds at the riser
cylinder to hold the valves against their area.
Installation
seats. Clean the mating surfaces of the
Use V a l v e Spring Remover a n d In- If removed, install the oil deflector manifolds a n d the cylinder head.
staller Tool J-21931 to compress the on the valve stem.
valve spring and allow removal of the Installation
IMPORTANT: The valve springs must
valve locks (Fig. 13). be installed with the close coiled end If separated, assemble the two mani-
facing the cylinder head. folds a n d finger tighten the retaining
nuts.
Install the valve spring a n d retainer.
Position a new intake manifold gas-
Compress the valve spring with V a l v e
ket on the cylinder head a n d install
Spring Remover and Installer T o o l
the manifold assembly. Tighten the
J-21931 a n d insert the valve locks.
manifold attaching bolts a n d nuts in
Release the spring tension a n d remove
the sequence shown in Figure 15.
the tool. T a p the valve spring from
Torque to specifications.
side to side with a light hammer to be
Install the flange gasket a n d connect
certain the spring is seated properly
the exhaust pipe to the exhaust mani-
at the cylinder head.
fold flange.
Disconnect the air hose and remove
Install the carburetor.
the air adapter from the spark plug
If removed, install the air condition-
hole. Install the spark plug.
ing compressor a n d bracket assembly
Install the rocker arm a n d shaft as-
to the intake manifold. Install the drive
sembly.
belt and tighten to the specified
Install the cylinder head cover a n d
tension.
gasket.
Connect the distributor vacuum hose
a n d electrical wires to the T C S sole-
INTAKE AND EXHAUST
noid vacuum valve.
MANIFOLDS
Connect the accelerator cable and
The intake and exhaust manifolds P C V hose.
are mounted externally on the left side Install the air cleaner.
of the engine a n d attached to the
CAUTION: Do not compress the valve
cylinder head. A gasket is used be- CYLINDER HEAD A N D GASKET
springs more than required to remove
tween the intake manifold and the
the valve locks, as the oil deflectors Removal
cylinder head, none is required for the
may be damaged-
exhaust manifold to cylinder head. An Drain the cooling system and dis-
Remove the valve spring a n d re- asbestos gasket is used at the mating connect the hoses at the thermostat
compound on head and block surfaces

or allow sealer to enter cylinder bores.
Install the cylinder head and bolts

to the block. Tighten the bolts to the
specified torque following the sequence
shown in Figure 16.
Connect the temperature sending
unit wire.
Install the ignition coil and bracket
assembly.
Install the spark plugs and connect
the spark plug wires.
Install the intake and exhaust mani-
fold assembly to the cylinder head.
Refer to "Intake and Exhaust Manifold
Installation" for the correct torque
tightening sequence.
Install the push rods in the order re-
moved.
FIGURE 15 — Intake Manifold Torque Sequence Install the rocker arm and shaft as-
sembly, tighten the retaining bolts to
housing. stem diameter. Replace the valves if the specified torque and install the
Remove the cylinder head cover and they are oversize as only standard cylinder head cover a n d gasket.
gasket, rocker arm a n d shaft assem- size valves are to be used with a Connect the hoses to the thermostat
bly, and the push rods. service replacement head. If the orig- housing and fill the cooling system to
inal valves are standard size, remove the specified level.
NOTE: Push rods should be retained
all carbon buildup a n d reface the
in the same order as removed.
valves as outlined under " V a l v e Re-
CYLINDER HEAD
Separate the intake a n d exhaust facing. " Install the valves in the cyl-
RECONDITIONING
manifold assembly from the cylinder inder head using new valve stem oil
head. deflectors. Transfer all attached com- The following procedures apply after
Disconnect the spark plug wires and ponents from the original head which the cylinder head has been removed
remove the spark plugs. are not included with the replacement from the engine.
Disconnect the temperature sending head.
unit wire, ignition coil and bracket as- A p p l y an even coat of "Perfect Disassembly
sembly from the cylinder head. S e a l " sealing compound, or equivalent,
Compress each valve spring with a
Remove the cylinder head bolts a n d to both sides of the new head gasket
" C " clamp type spring compressor tool
separate the cylinder head and gasket and position the gasket on the block
a n d remove the valve locks, retainers,
from the block. with the stamped word " T O P " facing
springs a n d valve stem oil deflectors.
upward.
Remove the valves one at a time
Cleaning and Inspection CAUTION: Do not apply sealing a n d place them in a rack in the same
Thoroughly clean the gasket surface
of the cylinder head and block to re-
move all dirt and gasket cement. Re-
move the carbon deposits from the
combustion chambers and the top of
each piston.
Use a straight e d g e and feeler
gauge to check the flatness of the
cylinder head and block mating sur-
faces. O u t of flatness must not exceed
. 001" over a 1" l e n g t h , . 003" over a
6" length a n d . 008" over the entire
length.
Installation
If the cylinder head is to be re-
placed and the original valves re-used,
remove the valves and measure the FIGURE 16 — Torque Tightening Sequence Chart
order as they were in the cylinder

head.
Cleaning and Inspection

Clean all carbon buildup from the
combustion chambers, valve ports,
v a l v e stems a n d heads.
Clean all dirt and gasket cement
from the cylinder head gasket surface.
Inspect for cracks in the combustion
chambers and valve ports. Inspect for
cracks in the gasket surface at each
coolant passage.
Inspect for burned or cracked v a l v e
heads. Inspect for damaged valve
stems.
Valve Refacing
Use a valve re-facing machine to
reface the intake a n d exhaust valves 68125
to the specified angle. Replace a n y FIGURE 18 - Checking Valve Seat FIGURE 19 — Checking Valve Guide
valve which is bent or w a r p e d . After Runout Clearance
refacing, at least 1I32" margin must re-
main or the valve must be replaced. Valve Stem to Guide Clearance
Examples of correct a n d incorrect C-3427 . 030"
valve refacing are shown in Figure 17. Valve stem to guide clearance may
IMPORTANT: Valve guides must be
be checked by two methods.
reamed in steps, starting with the. 003"
O n e method is to measure the valve
O. S. reamer and progressing to the size
stem diameter with a caliper microm-
required.
eter midway between the valve head
and tip and then select a pilot from
a valve refacing kit which fits snugly Assembly
in the valve guide bore.
Thoroughly clean the valve stems
C o r r e c t V a l v e Facing
NOTE: Make certain the valve stem and the valve guide bores.
No Margin
and guide bore are thoroughly cleaned Install each valve in the same valve
before measuring. guide from which it was removed.
Install a new valve stem oil deflec-
The valve stem to guide clearance
tor on each valve stem.
can be determined by subtracting the
Position each valve spring a n d re-
diameter of the valve stem from the
tainer on the cylinder head and com-
Incorrect V a l v e Facing 70723
size of the pilot selected.
press the valve spring with the com-
Another method is to use a dial in- pressor tool. Install the valve locks
FIGURE 1 7 - V a l v e Refacing dicator to measure the lateral move- and release the tool.
ment of the valve stem with the valve
T a p each valve spring from side to
installed in its guide and off the valve
The valve stem tip can be resurfaced side with a light hammer to be certain
seat (Figure 19).
and rechamfered when w o r n . How- the spring is seated p r o p e r l y at the
The valve guides are an integral
ever, never remove more t h a n . 010". cylinder head.
part of the cylinder head and are not
replaceable.
Valve Seat Refacing HYDRAULIC VALVE TAPPETS
Therefore, when the stem to guide
Install a pilot of the correct size in clearance is excessive, the valve guides The hydraulic valve tappet consists
the valve guide and reface the valve must be reamed to the next larger of a b o d y , plunger, plunger return
seat to the specified angle with a g o o d size so that proper clearance can be spring, c a p and lock ring (Fig. 20).
dressed stone. Remove only enough obtained. Oversize service valves are The tappet operates in a guide
metal to provide a smooth finish. available i n . 0 0 3 " , . 015" a n d . 030" bore which has an oil passage drilled
Narrowing stones should be used to sizes. into the adjoining main oil gallery.
obtain the specified seat widths when The following oversize valve guide W h e n the tappet is on the heel of
required. reamers may be used. the cam lobe, the plunger return spring
Control seat run-out to a maximum J - 6 0 4 2 - 1 . 003" indexes with an oil hole undercut in
o f . 0025" (Fig. 18). C-3430 . 015" the plunger a n d allows the oil supply
SIX CYLINDER E N G I N E 1-A-ll
Noise Diagnosis
A loud clicking noise is usually the
result of the plunger stuck below its
operating position or a check valve
held open. A light clicking noise at idle
is usually the result of excessive "leak-
d o w n " caused by wear or slight leak-
age at the check valve and its seat.
An intermittent noise is the result of
dirt or chips stopping the check valve
action or a lack of oil flow into the
b o d y . A general tappet noise is, in
most cases, due to a lack of oil
volume, pressure or cereation.
A clicking noise, upon starting the
engine, reducing in level and disap-
pearing after a short period of time is
normal. This noise is due to a slight
oil leak-down condition caused by
valve spring pressure exerted on the
Plunger
tappets.
Return
Spring An individual noisy tappet can read-
ily be located by placing one end of
a length of heater hose at the push
rod end of the rocker arm and the
FIGURE 20 - Hydraulic Tappet other end to the ear.
Assembly Sequence (Typical) The valve tappets should be cleaned
a n d serviced at time of engine over-
to be admitted through the tappet haul or whenever excessive noise exists.
body. O i l under pressure flows into
FIGURE 22 — Removing Valve Tappets
the body through the check valve
Removal and Disassembly with J-21884
assembly, maintaining the tappet fully
charged. (Fig. 21). This cycle of opera- Remove the cylinder head cover and
The inspection should include check-
tion occurs when the tappet leaks off gasket, rocker arm and shaft assembly,
ing for signs of scuffing on the barrel,
some oil during the normal valve open- push rods and the cylinder head and
and face of the tappet. Each tappet
ing events. Contact with the cam lobe gasket.
face should be inspected for wear as
causes tappet body movement, closing
NOTE-. The push rods should be re- shown in Figure 23. If the tappet face
the check valve and transmitting " z e r o -
tained in the same order as removed. is concave, the corresponding lobe on
lash" movement of the push rod to
the camshaft is worn and the replace-
open the intake or exhaust valve. Remove the tappets through the
ment of the camshaft and tappets is
push rod openings of the engine block
necessary.
with Hydraulic V a l v e Tappet Remover
If any components of a tappet as-
and Installer Tool J-21884 as shown
sembly are noticeably worn or dam-
in Figure 22.
a g e d , replace the entire assembly.
IMPORTANT: The tappets and all After cleaning and inspection, the
components must be retained in the tappet must be " l e a k - d o w n " tested to
same order as removed. insure its " z e r o l a s h " operating ability.
Valve Tappet Test O i l J-5268 should
Release the lock ring and remove the
be used for this test.
plunger cap, plunger assembly and
Figure 24 illustrates Tool J-5790
plunger return spring from the tappet
used to accurately test tappet "leak-
body.
down. " They may be tested by filling
the body with V a l v e Tappet Test O i l
Cleaning and Inspection
J-5268, installing the plunger return
Clean all components of the hydrau- spring, plunger assembly, and plunger
Charging Cycle Leak D o w n C y c l e lic tappet assembly in a g o o d cleaning cap. Do not install lock ring for test.
( V a l v e Closed) (Valve Open)
solvent to remove all varnish or gum Place a . 312"-. 313" diameter ball
deposits. bearing in the plunger cap. Place the
FIGURE 21 - Hydraulic Tappet A visual inspection of each tappet push rod on the ball bearing.
Operation C y c l e assembly is required. Adjust the tester gauge on the
Installation damper.
Remove the vibration damper retain-
Dip each tappet assembly in Engine
ing bolt a n d washers.
O i l Supplement a n d use Hydraulic
Use Vibration Damper Remover Tool
Valve Tappet Remover a n d Installer
J-21791 to remove the damper from
Tool J-21884 to install the assemblies
the crankshaft as shown in Figure 26.
in the same bores from which they
were removed.
Install the push rods in the same
order as removed.
Install the rocker arm a n d shaft
assembly a n d tighten the retaining
bolts to the specified torque.
Pour the remaining engine oil sup-
plement over the entire valve train
mechanism.
IMPORTANT: The E. O. S. must remain

in the engine for at least 1, 000 miles
but need not be drained until the next
scheduled oil change.
FIGURE 23 — Checking Tappet Face Install the cylinder head cover and
for Concave W e a r gasket.
FIGURE 26 — Removing Vibration
Damper Assembly with T o o l J-21791
VIBRATION DAMPER
The vibration damper (Fig. 25) is Installation

balanced independently and then re- A l i g n the key slot of the vibration
balanced as part of the complete damper with the crankshaft key and
crankshaft assembly. install the damper on the crankshaft.
Install the vibration damper retain-
ing bolt a n d washers, tighten to the
specified torque.
If removed, install the accessory
pulley a n d retaining c a p screws,
tighten the screws to the specified
torque.
Install the drive belt(s) and tighten
FIGURE 24 - Testing V a l v e Tappet
to the specified tension.
" L e a k - D o w n " with J-5790
TIMING CHAIN COVER

start position and allow the weighted
arm to "leak, d o w n " the tappet. The timing chain cover is provided
If the tappet leaks down rapidly or with a seal a n d oil slinger to prevent
collapses immediately, it must be re- FIGURE 25 — Vibration Damper oil leakage at the vibration damper
placed with a complete new tappet Assembly hub (Fig. 27).
assembly. A g o o d tappet will take
Do not attempt to duplicate original
approximately 20-110 seconds to
damper balance holes when installing
"leak-down" with a 50 lb. load travel
a service replacement.
o f . 125".
The vibration damper is not repair-
able a n d is serviced o n l y as a complete
Assembly and Testing assembly.
After testing the tappets, install the A loose vibration damper or dam-
lock rings to those which have passed age to the damper cushions may be
the test. Discard those which have misdiagnosed as engine bearing noise.
failed the test and replace with new FIGURE 27 — Timing Chain Cover
tappet assemblies. Removal
NOTE: Do not charge the tappet as- Remove the drive belt(s). It is important that the timing chain
semblies with engine oil as they will If so equipped, remove the three cover is properly aligned with the
charge themselves within 3 to 8 minutes retaining cap screws and separate the crankshaft to prevent eventual damage
of engine operation. accessory pulley from the vibration to the oil seal. The oil seal may be
replaced without removing the timing a n d remove the seal. Clean the timing Install the cover to block screws and
chain cover. chain cover, oil pan and cylinder block oil pan to cover screws, tighten the
gasket surfaces. screws to the specified torque.
Removal Remove the crankshaft oil seal from Remove the cover aligning tool,
the timing chain cover. place a new oil seal on the tool with
Remove the drive belt(s), engine fan
the seal lip facing the cover. Place a
and hub assembly, accessory pulley
Installation light film of "Perfect S e a l " on the out-
(if so equipped) and vibration damper.
side diameter of the seal. Insert the
Remove the oil pan to timing chain A p p l y "Perfect S e a l " sealing com-
draw screw from Tool J-9163 into the
cover screws and the cover to block pound, or equivalent, to both sides of
seal installing tool and press the seal
screws. a new timing cover gasket and position
into the cover until bottomed in seal
Raise the timing chain cover just the gasket on the cylinder block.
opening (Fig. 30). Remove the tools;
high enough to detach the retaining Cut off the same amount from the
apply a light film of engine oil on the
nibs of the oil pan neoprene seal from end tabs of a new oil pan seal as was
seal lip. Install the vibration damper
the bottom side of the cover. This must cut off the original seal. Coat the end
a n d tighten to the specified torque.
be done to prevent pulling the seal tabs of the seal generously with "Per-
end tabs a w a y from the tongues of the matex" N o . 2 and install the seal to
pulley.
oil pan gaskets which would cause an the oil pan.
Install the engine fan and hub as-
oil leak a n d necessitate removal of the Position the timing chain cover on
sembly.
oil pan to correct. the engine and place Timing Chain
Remove the timing chain cover a n d Cover Alignment Tool and Seal In-
gasket from the engine. staller J-22248 on the crankshaft a n d
Use a sharp knife or single edge in the seal opening of the cover (Fig.
29).
O i l Seal Replacement
razor blade to cut off the oil pan seal
end tabs flush with the front face of the Remove the drive belt(s), accessory
cylinder block as shown in Figure 28 pulley (if so equipped) a n d the vibra-
tion damper.
Use Timing Chain C o v e r O i l Seal
Remover Tool J-9256 to remove the
oil seal from the cover as shown in
Figure 31.
Place a new oil seal on Timing
Chain Cover Alignment Tool a n d Seal
Installer J-22248 with the seal lip
facing the cover. Place a light film of
"Perfect S e a l " on the outside diameter
of the seal.
Insert the draw screw from Tool
J-9163 into the seal installing tool and
press the seal into the cover until
bottomed in the seal opening.
FIGURE 29 — Aligning Timing Chain Remove the tools; apply a light film
FIGURE 28 — Cutting O i l Pan Front Cover of engine oil on the seal lip. Install the
Seal
vibration clamper and tighten to the CAMSHAFT A N D BEARINGS

specified torque.
The camshaft is supported by four
steel-shelled, Babbitt-lined bearings
pulley.
which have been pressed into the
block a n d line reamed. The camshaft
bearings are step bored, being larger
at the front bearing than at the rear,
TIMING CHAIN
to permit easy removal a n d installa-
installation of the timting chain with tion of the camshaft. A l l camshaft
the timing marks of the crankshaft and bearings are lubricated under pres-
camshaft sprockets properly aligned sure.
assures correct valve timing. A worn
N O T E ; It is not advisable to replace
timing chain will adversely affect valve
4501?
camshaft bearings unless equipped with
timing. If the timing chain deflects
special removing, installing and reaming
more than y2", it should be replaced.
tools.
FIGURE 32 - Place Marked Teeth
Checking Valve Timing on Center Line W h e n Installing Camshaft end p l a y is maintained by
Sprockets and Chain the load placed on the camshaft by
Remove the spark plugs and the
the oil pump a n d distributor drive
cylinder head cover and gasket. shaft sprocket and camshaft sprocket gear.
Rotate the crankshaft until N o . 6 with the timing marks aligned as The helical cut of the gear holds the
piston is at T D C on the compression shown in Figure 32. Install the assembly camshaft sprocket thrust face against
stroke. to the crankshaft and camshaft. Install the cylinder block face. Therefore,
Turn the crankshaft slowly counter- the camshaft sprocket retaining bolt camshaft end play is zero during en-
clockwise (viewed from front) until N o . and washer and tighten to the specified gine operation.
1 exhaust valve just begins to open. torque. To assure correct installation
Note the distance between the timing of the timing chain, locate the timing
mark on the vibration damper and the
Measuring Cam Lobe Lift
mark of the camshaft sprocket at
TDC mark on the degree scale of the approximately the one o'clock position. C a m lift is a function of camshaft
timing chain cover. This should place the timing mark of lobe dimensions.
Turn the crankshaft slowly clockwise the crankshaft sprocket where it meshes Cam lift may be checked with a dial
(viewed from the front) past T D C posi- with the chain (Fig. 33). Count the indicator.
tion until N o . 1 intake valve just be- number of pins between the timing To check cam lift, remove the cylin-
gins to open. Note the distance be- mark of both sprockets. There should der head cover and gasket, rocker
tween the timing mark on the vibration be 15 pins. arm assembly and spark plugs. Install
damper a n d the T D C mark on the de- a dial indicator on the end of the push
gree scale of the timing chain cover. rod as shown in Figure 34. A piece of
If the valve timing is correct, the rubber tubing may be used to secure
two distances will be equal. the dial indicator plunger to the push
rod.
Removal Rotate crankshaft until the cam lobe
base circle (push rod down) is under
Remove the drive belt(s), engine fan
the valve tappet. Set the dial indica-
and hub assembly, accessory pulley (if
tor to zero and rotate the crankshaft
so equipped), vibration damper and
to a point where maximum upward
timing chain cover. Remove the oil
movement of the push rod occurs.
seal from the timing chain cover.
Read the travel at the dial indicator.
Remove the camshaft sprocket re-
An excess of minus. 006" from the spec-
taining bolt and washer.
ified dimensions indicates a defective
Rotate the crankshaft until the " 0 "
cam.
timing mark on the crankshaft sprocket
65020
is closest to and in a centerline with the
timing pointer of the camshaft sprocket FIGURE 33 — Correct Timing Chain Removal
as shown in Figure 32. Installation
Drain the cooling system and remove
Remove the crankshaft sprocket,
the radiator. If equipped with air con-
camshaft sprocket and timing chain as
Install the timing chain cover a n d a ditioning, remove the condenser and
an assembly. Disassemble the chain
new oil seal. Install the vibration receiver assembly as a charged unit.
and sprockets.
damper, accessory pulley (if so Refer to the " A I R C O N D I T I O N I N G "
equipped), engine fan and hub as- section for detailed procedure.
Installation
sembly and the drive belt(s). Tighten Remove the cylinder head cover and
Assemble the timing chain, crank- the belt(s) to the specified tension. gasket, rocker arm and shaft assembly,
Inspect the distributor drive g e a r for OIL PAN

damage or excessive wear.
Inspect each cam lobe and the Removal
matching hydraulic v a l v e tappet for
Raise the vehicle and drain the
wear. If the face of the tappet(s) is
engine oil.
worn concave, the matching camshaft
Remove the starter motor.
lobe(s) is also worn, both the camshaft
On C J - 5 / C J - 6 a n d Commando,
and the tappet(s) must be replaced.
place a jack under the transmission
bell housing. Disconnect the engine
right support cushion bracket from the
Installation block a n d raise the engine to allow
sufficient clearance for oil pan re-
Lubricate the entire camshaft gener-
moval.
ously with Engine O i l Supplement and
Remove the oil p a n .
install carefully into the engine block.
Remove the oil pan front and rear
Assemble the timing chain, crank-
neoprene oil seals and the side gas-
shaft sprocket and camshaft sprocket
kets. Thoroughly clean the gasket sur-
with the timing marks aligned as shown
faces of the oil pan and engine block.
in Figure 32. Install the assembly to
Remove all sludge and dirt from the
the engine.
oil pan sump.
Install the timing chain cover and a
new oil seal.
Install the vibration damper. If re- Installation
moved, install the accessory pulley.
Install a new oil pan front seal to
Install the engine fan and hub as- the timing chain cover and apply a
sembly a n d the drive belt(s). Tighten generous amount of "Permatex" N o . 2,
the belt(s) to the specified tension. or equivalent, to the end tabs.
FIGURE 34 - Installation of Dial
Install the fuel pump. Cement new oil pan side gaskets
Indicator for Checking Cam Lobe Lift
Rotate the crankshaft until N o . 1 into position on the engine block and
piston is at T D C position on the com- apply a generous amount of "Perma-
push rods, cylinder head a n d gasket, pression stroke. Install the distributor t e x " N o . 2, or equivalent, to the gasket
and hydraulic valve tappets. so that the rotor is aligned with the ends.
N o . 1 terminal of the cap when fully C o a t the inside curved surface of a
NOTE: The push rods and tappets
seated on the block. Install the distri- new oil pan rear seal with soap and
should be retained in the same order
butor cap and spark plug wires. apply a generous amount of "Perma-
as removed.
Install the hydraulic valve tappets, t e x " N o . 2, or equivalent, to the gas-
Remove the drive belt(s), engine fan cylinder head and gasket, push rods, ket contacting surface of the seal end
a n d hub assembly, accessory pulley (if rocker arm and shaft assembly, and tabs.
so equipped), vibration damper and cylinder head cover a n d gasket.
Install the seal in the recess of the
timing chain cover. Remove the oil seal rear main bearing cap making certain
IMPORTANT: The hydraulic valve tap-
from the timing chain cover. it is fully seated.
pets and all valve train components
Remove the fuel pump and distribu- A p p l y engine oil to the oil pan
should be lubricated with Engine Oil
tor assembly (including spark plug contacting surface of the front and rear
Supplement during installation. The
wires). oil pan seals.
E. O. S. must remain in the engine for at
Rotate the crankshaft until the " 0 " Install the oil pan and tighten the
least 1, 000 miles but need not be
timing mark of the crankshaft sprocket drain plug securely.
drained until the next scheduled oil
is closest to a n d in a centerline with If disconnected, lower the engine
change.
the timing pointer of the camshaft and connect the right support cushion
sprocket as shown in Figure 32. If removed, install the air condition- bracket to the block. Remove the jack.
Remove the crankshaft sprocket, ing condenser and receiver assembly. Install the starter motor.
camshaft sprocket and timing chain as Refer to the " A I R C O N D I T I O N I N G " Lower the vehicle and use new oil
an assembly. section for procedure to purge the to fill the crankcase to the specified
Remove the front bumper or grille compressor of air. level.
as required and remove the camshaft.
CAUTION: Both service valves must
OIL PUMP
be open before the air conditioning
Inspection system is operated. Removal
Inspect the camshaft bearing jour- Install the radiator and fill the cool- Drain the engine oil and remove the
nals for an uneven w e a r pattern or ing system to the specified level. oil pan.
rough finish. Either condition will ne- If removed, install the front bumper Remove the oil pump retaining
cessitate camshaft replacement. or grille. screws and separate the oil pump a n d
1-A-16 SIX CYLINDER E N G I N E
gasket from the engine block. Install the idler shaft, idler g e a r a n d
drive g e a r assembly.
CAUTION: Do not disturb the position
of the oil pick-up tube and screen as- IMPORTANT: To ensure self-priming
sembly in the pump body. If the tube is of the oil pump, the pump must be
moved within the pump body, a new filled with "Petrolatum" prior to the in-
assembly must be installed to assure an stallation of the oil pump cover. (Do
air tight seal. not use grease of any type. )
Install the pump cover a n d new

Disassembly and Inspection gasket. Tighten the retaining screws to
Remove the cover retaining screws the specified torque.
and separate the cover and gasket
NOTE: Check for free operation prior
from the pump b o d y .
to installing the oil pump to the engine.
Measure the gear end clearance by
placing a straight edge across the Install the oil pump and a new gas-
gears and pump body. Select a feeler ket to the engine block. Tighten the
gauge which will fit snugly but freely retaining screws to the specified torque.
between the straight edge a n d the Install the oil pan using new gaskets
pump b o d y (Fig. 35). Refer to the and seals. Use new oil to fill the
Specifications pages for the correct crank case to the specified level.
clearance. FIGURE 36 — Measuring O i l Pump
G e a r to Body Clearance
REAR M A I N BEARING OIL SEAL
IMPORTANT: The oil pick-up tube
T h e rear main bearing crankshaft
must be moved to allow removal of the
seal consists of a two piece neoprene
relief valve; therefore, the pick-up tube
single lip seal to effectively seal the
assembly must be replaced upon instal-
rear of the crankshaft. Correct instal-
lation.
lation of the seal will assure leak free
engine operation (Fig. 38).
Assembly and Installation
If removed, install the oil pressure
relief valve, spring, retainer and cotter
pin.
If the position of the pick-up tube
in the pump b o d y has been disturbed,
a new pick-up tube assembly must be
installed.
FIGURE 35 — Measuring O i l Pump
G e a r End Clearance Prior to installing the new assembly,
place a light film of "Permatex" N o . 2,
If the g e a r end clearance is less than or equivalent, around the tube at the
specified, replace the oil pump as- joint. Using Tool J-21882 as shown in
FIGURE 38 - Rear Main O i l Seal
sembly. Figure 37, drive the tube into the body
and C a p Installation
Measure the gear to b o d y clearance making sure that the alignment of the
by inserting a feeler g a u g e between support bracket is correct during the
the gear tooth and the pump b o d y entire installing operation.
Removal and Installation
inner wall directly opposite the point
of gear mesh. Select a feeler gauge Drain the engine oil and remove the
which fits snugly but freely (Fig. 36). oil p a n .
Rotate the gears to check each tooth Remove the oil pan front and rear
in this manner. Refer to the Specifica- neoprene oil seals. Remove the oil pan
tions pages for the correct clearance. side gaskets. Thoroughly clean the
If the g e a r to body clearance is gasket surfaces of the oil pan and
more than specified, replace the idler engine block. Remove all sludge and
gear, idler shaft and drive gear assem- dirt from the oil pan sump.
bly. Remove the rear main bearing cap.
If required, the oil pressure relief Remove and discard the lower seal.
valve may be removed from the pump
IMPORTANT: To assure leak free op-
body for cleaning. Remove the cotter
eration, the upper and lower seal halves
pin and slide the spring retainer,
must be replaced in pairs.
spring and relief valve out of the
pump body. FIGURE 37 - Installing Pick-up Tube Clean the main bearing cap
thoroughly to remove all sealer. alloy precision type. of the connecting rod.
Loosen all remaining main bearing Each bearing is selective fit to its
NOTE: Do not mix bearing caps.
cap screws. respective journal to obtain the de-
Each connecting rod and its matching
W i t h a brass drift a n d hammer, tap sired operating clearance. In produc-
cop is stamped with the cylinder num-
the upper seal until sufficient seal is tion the select fit is obtained by using
ber on a machined surface which faces
protruding to permit pulling the seal various sized color coded bearing in-
the camshaft side of the engine block.
out completely. W i p e the seal surface serts as shown in the bearing fitting
of the crankshaft clean; then oil chart. Inspect the bearing inserts for ab-
lightly. W h e n required, different sized up- normal wear or damage. Bearing in-
Coat the block contacting surface of per and lower bearing inserts may be serts with either condition should be
the new upper seal with soap, and the used as a pair; therefore, a standard replaced.
lip of the seal with engine oil. Install size upper insert is sometimes used in W i p e the connecting rod journals
the upper seal into the engine block. combination with a . 001" undersize clean and use a micrometer to check
( U . S. ) lower insert. for an out of round condition. Refer to
CAUTION: The lip of the seal must
Service replacement bearing inserts specifications. If a n y rod journal is
face to the front of the engine.
are available as pairs in the following beyond specifications, it must be re-
Coat both sides of the new lower sizes: s t a n d a r d , . 001" U. S . , . 002" U. S., conditioned and fitted with new under-
seal end tabs with "Permatex" N o . 2 . 010" U. S. a n d . 012" U. S. The size is size bearing inserts.
or equivalent, being careful not to stamped on the back of the inserts.
apply sealer to the lip of the seal. The bearing fitting chart may be
Measuring Bearing Clearance
Coat the outer curved surface of utilized to select the bearing inserts re-
With Plastigage
the lower seal with soap and the lip quired to obtain the specified bearing
of the seal with engine oil. Install the clearance. W i p e the bearing inserts a n d rod
seal into the cap recess and seat it
firmly. C O N N E C T I N G ROD BEARING FITTING CHART
Place "Permatex" N o . 2, or equiva-
lent, on both chamfered edges of the Diameter Of Upper Color Lower Color
rear main bearing cap. Install the rear Rod Journal Bearing Code Bearing Code
main bearing c a p and inserts. Tighten 2. 0955"-2. 0948" Standard Yellow Standard Yellow
all main bearing cap screws to the
2. 0948"-2. 0941" Standard Yellow . 001 " U . S. Black
specified torque.
Install a new oil pan front seal to 2. 0941"-2. 0934" . 001" U. S. Black . 001" U. S. Black
the timing chain cover a n d apply a 2. 0855"-2. 0848" . 010" U. S. Red . 010" U. S. Red
generous amount of "Permatex" N o . 2,
or equivalent, to the end tabs.
Cement new oil pan side gaskets It may be necessary, in some in- journal clean. Place a strip of Plasti-
into position on the engine block and stances, to use different sized upper g a g e across the full width of the lower
a p p l y a generous amount of "Perma- a n d lower inserts to reduce clearance insert at the center of the bearing cap.
t e x " N o . 2, or equivalent, to the gasket b y . 0005" (54 thousandth"). The bear- Install the bearing cap to the con-
ends. ing insert nearest to standard should necting rod a n d tighten the retaining
C o a t the inside curved surface of a always be installed in the upper nuts to the specified torque.
new oil pan rear seal with soap and location. Remove the bearing cap and deter-
apply a generous amount of "Perma- mine the amount of clearance by
CAUTION: Never use bearing inserts
tex" N o . 2, or equivalent, to the gasket measuring the width of the compressed
with greater than. 001" difference in
contacting surface of the seal end Plastigage with the scale furnished as
size in pairs.
tabs. shown in Figure 39.
Install the seal in the recess of the Example
rear main bearing cap making certain
Correct Incorrect
it is fully seated.
Upper — Std. Upper — Std.
A p p l y engine oil to the oil pan
Lower - . 001" U . S . Lower - . 002" U . S .
contacting surface of the front and
rear oil p a n seals.
Removal and Inspection
Install the oil pan and tighten the
drain plug securely. Drain the engine oil a n d remove the FIGURE 39 — Checking Bearing
Use new oil to fill the crankcase to oil pan. Clearance with Plastigage
the specified level. Rotate the crankshaft as required
to position two pistons at a time at the
Measuring Connecting Rod
bottom of their stroke.
C O N N E C T I N G ROD BEARINGS Journal With A Micrometer
Remove the bearing caps a n d upper
The connecting rod bearings are and lower inserts. The upper insert can W i p e the connecting rod journal
steel-backed, sintered copper, lead be readily removed by spinning it out clean.
Use a micrometer, measure the maxi- with an inside micrometer or telescope Pistons are fitted to their respective
mum diameter of the rod journal. gauge from the top to the bottom of bores by measuring the inside diam-
Compare the reading obtained with the cylinders for taper. Check for an eter of the cylinder bore a n d the
the journal diameters listed in the bear- out of round condition by measuring diameter of the piston.
ing fitting chart a n d select the inserts across the cylinder bores at two points; Measure the cylinder bore inside
required to obtain the specified bear- parallel to the crankshaft and per- diameter at a point 2 5 /j 6 " below the
ing clearance. pendicular to the crankshaft. top of the bore.
If cylinder taper does not exceed Pistons are cam ground a n d , there-
Installation . 005" a n d out of round does not fore, must be measured at right angles
e x c e e d . 003", the cylinder bore may to the piston pin at the center line of
Lubricate the bearing surface of
be trued by honing. pin as shown in Figure 41.
each insert with clean engine oil. In-
If the cylinder taper or out of
stall the bearing inserts, c a p a n d re-
round condition exceeds these limits,
taining nuts. Tighten to the specified
the cylinder must be bored a n d then
torque.
honed for an oversize piston.
CAUTION: Care must be exercised When finish honing the cylinder
when rotating the crankshaft with bear- bores, move the hone up and down at
ing caps removed. Be sure the connect- sufficient speed to produce a uniform
ing rod bolts do not accidentally come cross hatch pattern on the cylinder
in contact with the rod journals and walls.
scratch the finish. Bearing failure would Prior to fitting pistons, the cylinder
result. bores should be scrubbed clean with a
hot water a n d detergent solution.
Install the oil pan using new gaskets Cover the connecting rod journals with
a n d seals. Tighten the drain plug se- clean cloths during the cleaning opera-
curely. tion.
Use new engine oil to fill the crank- After cleaning, apply light engine
case to the specified level. oil to the cylinder walls a n d then wipe
with a clean lint free cloth.
C O N N E C T I N G ROD A N D FIGURE 41 — Piston Measurements
PISTON ASSEMBLIES Pistons
The difference between cylinder
Removal Aluminum alloy "Autothermic" pis-
bore diameter and piston diameter
Remove the cylinder head cover a n d tons, steel reinforced for strength and
dimensions is the piston to bore clear-
gasket, rocker arm and shaft assembly, controlled expansion are used. The
ance.
push rods and the cylinder head a n d ring belt area provides for three pis-
gasket. ton rings, two compression a n d one oil
Piston Rings
Position the pistons one at a time control ring above the piston pin.
near the bottom of their stroke a n d The piston pin boss is "offset" from C a r b o n must be cleaned from all
use a ridge reamer to remove a n y the piston center line to place it ring grooves. The oil drain openings
ridge from the top end of the cylinder nearer the thrust side of the piston. in the oil ring grooves and pin boss
walls. To ensure correct installation of the must be cleared. C a r e must be exer-
Drain the engine oil a n d remove piston in the bore, a notch is cast cised not to remove metal from the
the oil pan. into the top perimeter of the piston grooves since this will change their
Remove the connecting rod bearing head. The notch must face forward as depth; nor from the lands since this
caps and inserts a n d retain in the same shown in Figure 40. will change the ring groove clearance
order as removed.
NOTE: Connecting rods and caps

are stamped with the number of the
cylinder to which they were assembled.
Remove the connecting rod a n d pis-

ton assemblies through the top of the
cylinder bores being careful that the
connecting rod bolts do not scratch the
connecting rod journals or cylinder
walls.
Cylinder Bore Conditioning

Inspect the cylinder bores for scor-
ing, taper, and out of round. Check FIGURE 40 — Pistons Correctly Positioned in Bores
and destroy ring to land seating. upon cleanliness during the honing
Side clearance between land and operation or when handling parts. The
compression rings should be as listed engine bearings and lubrication sys-
on the Specifications pages. tem must be protected from abrasives.
Roll the ring around the groove in Rigid type hones are not to be used
which it is to operate. It must fit freely to remove cylinder glaze as there is
at all points (Fig. 42). always a slight amount of taper in
cylinder walls after the engine has
been in service.
After removing the cylinder g l a z e ,
install the rings on the pistons. Install
the oil control rings first by following
the sequence shown in Figure 44. Com-
pression rings are marked to designate
top of ring. Typical compression ring
markings are shown in Figure 45. FIGURE 46 — Installing Compression
Rings on Piston Using Tool J-8028
FIGURE 42 - Checking Ring Side

Clearance
70726
Piston ring g a p or joint clearance is Cylinder

measured at the bottom of the cylinder Number
near the end of the ring travel area. Squirt Hole
To square the ring in the bore for
checking joint clearance, place the ring
in the bore, then, with an inverted
piston, push the ring down near the
lower end of ring travel area (Fig. 43).
FIGURE 47 — Connecting Rod
FIGURE 44 - O i l Control Ring
Numbering a n d Squirt Hole Location
Installation
blies to ensure true operation in the

cylinder bore.
Misaligned rods will cause uneven
FIGURE 45 — Typical Piston Ring piston and ring wear which will result
Markings in oil consumption. The connecting rod
Rings must be installed on the pis- should be inspected for a twisted or
tons with a ring installing tool to pre- bent condition.
vent distortion a n d ring breakage Assemble the connecting rods to the
(Fig. 46). pistons with the notch on the pistons
facing to the front of the engine and
the numbered side of the rods facing
Connecting Rods And
FIGURE 43 — Checking Ring G a p the camshaft.
Piston Pins
Clearance The piston pins are a press fit into
The connecting rods and caps are the connecting rod, thus requiring no
W h e n other than standard ring sizes stamped with the cylinder numbers in locking device.
are used, rings should be individually which they were assembled. Remove the piston pin with Piston Pin
fitted to their respective bores. The numbers are on the same ma- Remover J-21872 and an arbor press.
Removal of g l a z e from the cylinder chined surface as the squirt holes (Fig. Place the piston on the remover
wall for quicker ring seating can be 47). support J-21872-1 so that the pin will
accomplished by various methods. The numbered sides and the squirt enter the support when pressed out
W h e n an expanding type hone is holes must face the camshaft. with the piloted driver J-21872-3 (Fig.
used, do not use more than ten strokes Whenever new rings are installed 48).
(each stroke down and return) to re- or piston pins are replaced, it is To install the piston pin, place the
condition a cylinder wall. necessary to check the alignment of piston pin pilot in the support and in-
Successful ring installation depends the connecting rod and piston assem- sert the piston and connecting rod. This
#2 compression ring gap. The oil con- are available as pairs in the following
trol ring gaps are to be installed 90° sizes: s t a n d a r d , . 001" U. S . , . 002" U. S.,
from the spacer g a p with at least 30° . 010" U. S. and 012" U. S. The size
between each ring gap. is stamped on the back of the inserts.
Lubricate the piston and ring sur- The bearing fitting chart may be
faces with clean engine oil. utilized to select the bearing inserts re-
Use Piston Ring Compressor Tool quired to obtain the specified bearing
C-385 to install the connecting rod clearance.
a n d piston assemblies through the top It may be necessary, in some in-
of the cylinder bores being careful stances, to use different sized upper
that the connecting rod bolts do not and lower inserts to reduce clearance
scratch the connecting rod journals or b y . 0005" ( 1 / 2 thousandth"). The bear-
cylinder walls. ing insert nearest to standard should
always be installed in the upper lo-
NOTE: Lengths of rubber hose slipped
cation.
over the connecting rod bolts will afford
protection during installation. CAUTION: Never use bearing inserts
with greater than. 001" difference in
Install the connecting rod bearing
size in pairs.
caps and inserts in the same order as
removed. Tighten the retaining nuts to Example:
the specified torque.
Install the engine oil pan using new Correct Incorrect
gaskets and seals. Tighten the drain Upper — Std. U p p e r — Std.
65103
plug securely. Lower - . 001" U . S . Lower - . 002" U . S .
FIGURE 48 — Removing or Installing Install the cylinder head and new
Piston Pin gasket, push rods, rocker arm and shaft Removal and Inspection
assembly and cylinder head cover and
Drain the engine oil and remove the
aligns the piston and connecting rod gasket.
pan.
piston pin bores. Press the piston pin Use new oil to fill the crankcase to
Remove one main bearing cap and
into the connecting rod a n d piston as- the specified level.
insert.
sembly until the lower pilot enters the
Inspect the bearing insert for ab-
support and the index mark on the CRANKSHAFT MAIN BEARINGS
normal wear or damage. If either con-
pilot is located at the lower edge of
The main bearings are steelbacked, dition exists, both upper a n d lower
the gauge window of support
sintered copper, lead alloy precision inserts must be replaced. Refer to
J-21872-1. At this point, the connect-
type. "Measuring Bearing Clearance With
ing rod is centered on the piston pin.
Each bearing is selective fit to its Plastigage" to select the bearing in-
A plus or minus 1 / 3 2 " is allowed for
respective journal to obtain the desired serts required to obtain the specified
centering the piston pin to connecting
operating clearance. In production the bearing clearance.
rod.
select fit is obtained by using various Inspect the crankshaft main journal.
W h e n fitting the pin, with all parts
sized color coded bearing inserts as If it is damaged, it must be either re-
dry and free of nicks and burrs,
shown in the bearing fitting chart. conditioned or replaced. Refer to
the pin must not support its weight in a
W h e n required, different sized upper "Crankshaft. "
vertical position over its entire length
and lower bearing inserts may be used Remove the upper insert by loosen-
in either of the bores.
as a pair; therefore, a standard size ing all of the other bearing caps and
CAUTION: The piston pins must be a upper insert is sometimes used in com- inserting a small pin about l/2" long
tight press fit (2000 lb. ) into the con- bination with a. 001" undersize ( U . S. ) in the crankshaft oil hole. The head of
necting rod. lower insert. this pin should be large enough so that
Service replacement bearing inserts it will not fall into the oil hole, yet
Installation
After thoroughly cleaning the cylin-
der bores, apply a light film of clean CRANKSHAFT BEARING FITTING CHART
engine oil to the bores with a clean
lint free cloth. Diameter Of Upper Color Lower Color
Prior to installing the connecting rod Main Journal Bearing Code Bearing Code
and piston assemblies into the engine, 2. 5001 "-2. 4996" Standard Yellow Standard Yellow
arrange the piston ring gaps so that 2. 4996"-2. 4991" Yellow
Standard . 001" U. S. Black
the #1 compression ring g a p is 180°
2. 4991 "-2. 4986" . 001" U. S. Black . 001" U. S. Black
from the #2 compression ring gap
and the oil control ring spacer ex- 2. 4986"-2. 4981" . 001" U. S. Black . 002" U. S. Green
pander gap is at least 90° from the 2. 4901 "-2. 4896" . 010" U. S. Red . 010" U. S. Red
thinner than the thickness of the bear- Use new engine oil to fill the crank-
ing. case to the specified level.
With the pin in place, rotate the
shaft so that the upper bearing insert CRANKSHAFT
will rotate in the direction of its lo-
cating tongue. The crankshaft is counterweighted
Remove and inspect the remaining a n d balanced independently. The 232
bearings one at a time in the same C I D crankshaft has eight counter-
manner. weights and the 258 C I D crankshaft
has twelve counterweights. Both have
seven main bearings and six connect-
Measuring Bearing Clearance
ing rod journals.
With Plastigage
An oil slinger is provided at the
Support the weight of the crankshaft rear main journal inboard of the rear
with a jack placed under the counter- oil seal.
weight which is adjacent to the main The component parts of the crank-
bearing being checked. shaft assembly are individually bal-
anced; then the complete assembly is
IMPORTANT-. Check clearance of only
balanced as a unit.
one bearing at a time. All other bear-
ings must remain tightened. IMPORTANT: On automatic transmis-
sion equipped engines, the torque con- FIGURE 50 - Checking Crankshaft
Remove the main bearing cap and
verter and converter flexplate must be End Play
insert. Wipe the insert and the ex-
marked prior to removal and installed
posed portion of the crankshaft journal sembly consists of engine block, piston
in this position upon assembly.
clean. and rod assemblies, crankshaft, cam-
Place a strip of Plastigage across the Service replacement dampers, crankshaft, timing gears and chain.
full width of the bearing insert. Install shafts, flywheels, torque converters, Installation includes transfer of com-
the bearing cap and tighten the retain- and clutch components are balanced ponent parts from the original engine
ing bolts to the specified torque. individually a n d , therefore, may be including cleaning and torque tighten-
Remove the bearing cap and deter- replaced as required without rebalanc- ing as required.
mine the amount of clearance by ing the complete assembly.
measuring the width of the compressed IMPORTANT: Whenever installing a
Plastigage with the scale furnished as short engine assembly, always install a
Replacement
shown in Figure 49. new engine oil pump pick-up tube and
If the crankshaft is damaged to the screen assembly.
extent that reconditioning is not feas-
ible, it must be replaced. The engine FLYWHEEL AND STARTER
must be removed from the vehicle for RING GEAR ASSEMBLY
crankshaft replacement.
The starter ring gear can be re-
placed separately only on vehicles with
Checking End Play
manual transmission. The starter ring
The crankshaft end play is con- gear is welded to and balanced as
60291
trolled at the N o . 3 main bearing in- part of the converter flexplate on ve-
FIGURE 49 - Checking Main Bearing sert which is flanged for this purpose. hicles with automatic transmission.
Clearance With Plastigage To check this clearance, attach a To remove, place the flywheel on an
dial indicator to the crankcase a n d arbor press with steel blocks equally
pry the shaft fore and aft with a spaced under the gear and press the
Installation
screw driver (Fig. 50). flywheel through. The ring gear can
Lubricate the bearing surface of The crankshaft end play should be also be removed by breaking it with a
each insert with clean engine oil. as listed on the Specifications pages. chisel.
Loosen all main bearing caps and To install a new starter ring gear,
IMPORTANT: When replacing the
install the main bearing upper insert(s). apply heat to expand the inside diam-
thrust bearings, it is recommended to
Install the main bearing cap(s) a n d eter so that it can be pressed over the
pry the crankshaft fore end aft to align
lower insert(s). Tighten the retaining flywheel.
the thrust faces of the bearings.
bolts evenly to the specified torque. On manual transmission equipped
After installation, turn the crank- vehicles, the flywheel is balanced as
shaft by hand to check for free opera-
SHORT ENGINE ASSEMBLY
an individual component and also as
tion. A service replacement short engine part of the crankshaft assembly.
Install the oil pan using new gaskets assembly may be installed whenever Do not attempt to duplicate original
and seals. Tighten the drain plug the original engine block is damaged flywheel balance holes when installing
securely. beyond repair. The short engine as- a service replacement.
Core Hole Plugs (Coolant)
Front
FIGURE 51 - Rear Camshaft a n d

O i l Gallery Plugs FIGURE 52 - Core Hole Plug Location
SIX CYLINDER ENGINE SPECIFICATIONS

232 CID 258 CID
Type - OHV 6 Cyl. •
Bore
Stroke
Firing O r d e r
Displacement
Compression Ratio
Net Horsepower
Net Torque
Taxable Horsepower
Fuel
Cylinder Head a n d Block Flatness
VALVES
V a l v e Arrangement (Front to Rear)
Valve Stem Diameter
Valve Length
V a l v e G u i d e I. D. (Integral)
Stem to G u i d e Clearance
Intake Valve Face A n g l e
Intake Valve Seat A n g l e
Intake Valve Seat Width
Exhaust V a l v e Face A n g l e
Exhaust V a l v e Seat A n g l e
Exhaust V a l v e Seat Width
Valve Seat Run-out
V A L V E S P R I N G T E N S I O N (LBS. )
Closed
Open
INTAKE V A L V E T I M I N G
Opens
Closes
EXHAUST V A L V E T I M I N G
Opens
Closes (California)
Closes (Nationwide)
Valve Opening O v e r l a p
(California)
Valve Opening O v e r l a p
(Nationwide)
CAMSHAFT
Cam Lobe Lift
End Play
Bearing Clearance
Intake Duration
Exhaust Duration
(California)
Exhaust Duration (Nationwide)
Base Circle Run-Out
Tappet Clearance
PISTONS A N D R I N G S
Pistons to Bore Clearance
(Right Angle to Center
Line of Piston Pin)
Piston Ring G a p Clearance
Top and Center (Compression)
Bottom (Oil Control)
Piston Ring Side Clearance
# 1 Compression
#2 Compression
O i l Control
Piston Pin to Connecting Rod
Piston Pin to Piston
C R A N K S H A F T A N D BEARINGS
Main Bearing Journal Diameter
Main Bearing Journal Width
Main Bearing Clearance

Crankshaft End Play
Connecting Rod Journal Diameter
Connecting Rod Journal Width
Connecting Rod Bearing Clearance
Connecting Rod Side Clearance
Connecting Rod Journal Out of Round
OIL PUMP A N D LUBRICATING SYSTEM

O i l Pump Type
Normal Operating Pressure
@ 600 RPM
@ 1600 RPM or Higher
O i l Pressure Relief Maximum
G e a r to Body Clearance
G e a r End Clearance (Cover
a n d Gasket Removed)
O i l Filter
Engine O i l Capacity
T O R Q U E SPECIFICATIONS Cylinder Head C o v e r Screws 45-55 In. Lbs.

(Torque Values given in Foot Pounds Crankshaft Pulley to Damper 20-25
Unless Otherwise Specified) Clutch Housing Spacer to Block Screw 10-15
Alternator Adjusting Strap a n d W a t e r Pump to S t u d . 18-25 Clutch or Bell Housing
Alternator Bracket Bolt 18-35 Top 25-30
Alternator to Bracket Nut 30-35 Bottom 40-45
Camshaft Sprocket Screw 45-55 Distributor Clamp Bolt 10-15
Carburetor Hold-Down Nuts 12-15 Distributor Bracket Screw 10-15
Connecting Rod Nuts 26-30 Exhaust Manifold Bolts 20-25
Cylinder Head C a p Screws 80-85 Exhaust Pipe to Manifold Nuts 20-25
Fan and Spacer to Pulley Hub Bolt 15-25 Front Insulator to Frame Bracket Nut 25-30
Flex Plate to Converter 270 In. Lbs. Rear Insulator to Transmission Bolt 30-35
Flex Plate to Crankshaft 100-110 Insulator to Crossmember Locknut 25-30
Flywheel to Crankshaft Bolt 100-110 Insulator to Transmission 30-35
Front Cover to Block Screw 4-6 Rear Insulator to Crossmember Hex Nut 30-35
Fuel Pump Screws 15-17 Torque Reaction Bracket 25-30
Fuel Pump Clip to O i l Pan Bolt 5-8 O i l Pan Screws l/4"-20. 5-8
Fuel Pump Clip to T / C C o v e r Bolt 5-8 5/16"-18. 10-12
Ground Strap and Alternator Bracket 18-35 Rocker Arm Assy, to Head - Bolt 20-23
Ignition Coil Bolt 18-25 Spark Plugs 25-30
Intake Manifold to Head Bolt 20-25 Solenoid to Bracket Nut 18-25
Main Bearing C a p Screws 75-85 Starter Nut 30-35
Oil Pump; T. C. S. Solenoid Bracket and Accelerator C a b l e
Cover to Body Bolt 5-8 Bracket to Intake Manifold Bolt 18-25
Pump to Block Bolt 10-12 Timing Chain C o v e r Bolt 5-8
Mounting and Connecting Parts: Thermostat Housing 10-15
Engine Mounting Brackets to Engine Bolt 25-30 Vibration Damper Screw 50-60
Bracket to Plate Bracket to Crossmember Nut 30-50 W a t e r Pump to Block Bolt 10-15
•
J-22248
Timing C h a i n C o v e r
Alignment Tool and
Seal Installer
J-21832
O i l Pump Inlet
T u b e Installer
J-21872
Piston Pin Remover J-5790
a n d Installer H y d r a u l i c V a l v e Lifter
Tester
J-21931
V a l v e S p r i n g Remover
a n d Installer
J-22700
O i l Filter W r e n c h
J-5959-4 J-21791 C-647

" C " C l a m p and V i b r a t i o n Damper V a l v e a n d Clutch
Rod Extension Remover S p r i n g Tester 69009
FIGURE 53 - Engine Tools

258 - 232 AMC Engines

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SIX CYLINDER ENGINE l-A-l

232-258 Cubic Inch Displacement

Conditions and Probable Causes

Cannot Crank Engine

Engine Will Crank Normally but

air horn for choke condition. If water

Engine Starts a n d Runs for

the idle circuit. Cooling System Exhaust System

Engine Power Not Up to Normal

incorporates a pressure relief valve

FIGURE 4 — Lubrication Circuit FIGURE 6 — O i l Pump Components

where oil from the main lubrication

ROCKER ARM AND SHAFT

compound on head and block surfaces

Install the cylinder head and bolts

order as they were in the cylinder

Cleaning and Inspection

IMPORTANT: The E. O. S. must remain

The vibration damper (Fig. 25) is Installation

TIMING CHAIN COVER

vibration clamper and tighten to the CAMSHAFT A N D BEARINGS

Inspect the distributor drive g e a r for OIL PAN

Install the pump cover a n d new

NOTE: Connecting rods and caps

Remove the connecting rod a n d pis-

Cylinder Bore Conditioning

FIGURE 42 - Checking Ring Side

Piston ring g a p or joint clearance is Cylinder

blies to ensure true operation in the

Core Hole Plugs (Coolant)

FIGURE 51 - Rear Camshaft a n d

SIX CYLINDER ENGINE SPECIFICATIONS

Main Bearing Clearance

OIL PUMP A N D LUBRICATING SYSTEM

T O R Q U E SPECIFICATIONS Cylinder Head C o v e r Screws 45-55 In. Lbs.

J-5959-4 J-21791 C-647

FIGURE 53 - Engine Tools

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