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SIX CYLINDER ENGINE 232-258 Cubic Inch Displacement

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SIX CYLINDER ENGINE 232-258 Cubic Inch Displacement 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 Guide 2 Installation 13 Mounting 3 Oil Seal Replacement 13 Removal 3 TIMING CHAIN 14 Installation 4 Checking Valve Timing 14 LUBRICATION SYSTEM 4 Removal 14 Lubrication Circuit 4 Installation 14 Oil Filter 5 CAMSHAFT AND BEARINGS 14 Oil Pump 5 Measuring Cam Lobe Lift 14 Oil Pressure Relief Valve 5 Removal 14 POSITIVE CRANKCASE VENTILATION 6 Inspection 15 Air Inlet Filter 6 Installation 15 PCV Valve 6 OIL PAN 15 CYLINDER HEAD COVER AND GASKET 6 Removal 15 Removal 6 Installation 15 Installation 7 OIL PUMP 15 ROCKER ARM AND SHAFT ASSEMBLY 7 Removal 15 Removal and Disassembly 7 Disassembly and Inspection 16 Cleaning and Inspection 7 Assembly and Installation 16 Assembly and Installation 7 REAR MAIN BEARING OIL SEAL 16 VALVE SPRING AND/OR VALVE STEM OIL DEFLECTOR.. 7 Removal and Installation 16 Removal and Testing 8 CONNECTING ROD BEARINGS 17 Installation 8 Removal and Inspection 17 INTAKE AND EXHAUST MANIFOLDS 8 Measuring Bearing Clearance With Plastigage 17 Removal and Cleaning 8 Measuring Connecting Rod Journal With a Micrometer 17 Installation 8 Installation 18 CYLINDER HEAD AND GASKET 8 CONNECTING ROD AND PISTON ASSEMBLIES 18 Removal 9 Removal 18 Cleaning and Inspection 9 Cylinder Bore Conditioning 18 Installation 9 Pistons 18 CYLINDER HEAD RECONDITIONING 9 Piston Rings 18 Disassembly 9 Connecting Rods and Piston Pins 19 Cleaning and Inspection 10 Installation 20 Valve Refacing 10 CRANKSHAFT MAIN BEARINGS 20 Valve Seat Refacing 10 Removal and Inspection 20 Valve Stem to Guide Clearance 10 Measuring Bearing Clearance With Plastigage 21 Assembly 10 Installation 21 HYDRAULIC VALVE TAPPETS 10 CRANKSHAFT 21 Noise Diagnosis 11 Replacement 21 Removal and Disassembly 11 Checking End Play 21 Cleaning and Inspection 11 SHORT ENGINE ASSEMBLY 21 Assembly and Testing 12 FLYWHEEL AND STARTER RING GEAR ASSEMBLY 21 Installation 12 SPECIFICATIONS 22 VIBRATION DAMPER 12 TOOLS 23 Removal 12 ENGINE 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 CID 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 order of The Engine Code 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 and three cylinders. F (Optional) 232 IV 7. 5: 1 l-A-2 SIX CYLINDER ENGINE 232-258 Cubic Inch Displacement 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 and substitute with a supply of new fuel. Ignition or Valve Timing Check ignition and valve timing. Engine Starts and Runs for Short Periods Only 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 All engines built for sale in Cali­ FIGURE 2 — Engine Letter Code connecting wires including battery fornia are painted "red. " All other connections. engines are painted "blue. " l0WS: Induction System In the machining of cylinder blocks Single letter.. "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 letter.. "M" Main duced. 010" oversize, and the crankshaft bearings —. 010" Undersize Exhaust System main bearing journals or crank pins to Single letter.. "P".... Connecting Check exhaust system for restrictions. 010" undersize. rod bearings —. 010" Undersize These engines are marked with a Double letters.. "PM" Main Engine Runs but Mis-fires at single or two letter code (Fig. 2). and connecting rod bearings — Low Speed Only The code is located on a boss di­ . 010" Undersize rectly above the oil filter. Single letter.. "C" Camshaft Fuel System The letters used are coded as fol- block bores -. 010" Oversize Check for dirty passages and jets in SIX CYLINDER ENGINE l-A-3 232-258 Cubic Inch Displacement the idle circuit. Cooling System Exhaust System Ignition System Thermostat not permitting proper Back pressure and leakage into the Check spark plug heat range and operating temperature. intake system. gap. Engine Resistance Induction System Bearing and 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 dragging. 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 All Speeds Engine Rough Running at Higher by a cushion between the transmission Speeds extension housing and the rear sup­ Fuel System port crossmember. Removal or replace­ Dirt in carburetor or water in the Ignition System ment of any cushion may be accom­ fuel system. Spark plug gap and 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 and bell housing. Coolant leak into intake sections or Valves and Camshaft On the Commando, Wagoneer and cylinders. Sticky valves. Incorrect valve lift. Truck the hood must be removed. Mark Camshaft the hinge locations at the hood panel Worn 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 and lower ra­ Spark plug gap and heat range. proper fuel. Throttle linkage. Re­ diator hoses. If equipped with auto­ Secondary system wiring. Distributor strictions and dirty air cleaner. matic transmission, disconnect the points or capacitor. Carbon build-up on floor of intake cooler lines from the radiator. Fuel System manifold. Idle circuits dirty. Choke sticking. Air Ignition System NOTE: If vehicle is equipped with leak below carburetor. Idle mixture Coil capacity and polarity, spark a radiator shroud, it is necessary to adjustment. plug condition, gap, 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 worn, broken, not seating. Fuel System Air cleaner restricted. Power mixture not proper. Ignition System Coil capacity, polarity, and distribu­ tor point spacing. Ignition timing. Exhaust System Restriction causing back pressure. l-A-4 SIX CYLINDER ENGINE 232-258 Cubic Inch Displacement Remove the radiator. engine compartment and align with the upper and 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 and add 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 and 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 and transfer case shift lever sor. Disconnect the receiver outlet at was used to support the transmission.
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