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    AMC - 304 & 360 V8 engine manual

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    AMC 304-360 V8 engine manual

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    AMC - 304 & 360 V8 engine manual

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    © All Rights Reserved
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    4K views21 pages

    AMC 304-360 V8 Engine Manual

    Uploaded by

    ducatiss900
    AMC - 304 & 360 V8 engine manual

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
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    V-8 ENGINE 13-1 304-360 Cubic Inch Displacement Poge ENGINE IDENTIFICATION DIAGNOSIS. GUIDE (GINE REMOVAL ENGINE INSTALLATION. ENGINE MOUNTING INTAKE MANIFOLD CYLINDER HEAD AND GASKET ROCKER ARM ASSEMBLY VALVES Valve Springs Volve Refocing Valve Stem to Guide Clearance Hydraulic Valve Toppers Com Lif TIMING CHAIN COVER CAMSHAFT IDENTIFICATION Volve Timing Sectional View of Engine Assembly ENGINE IDENTIFICATION OL PAN REMOVAL PISTONS Piston Pins PISTON RINGS. CONNECTING RODS CRANKSHAFT Main Bearings Cronkshoft End Ploy REAR MAIN BEARING OIL SEALS 3 VIBRATION DAMPER ‘ “4 STARTER RING GEAR 15 LUBRICATION SYSTEM 18 OIL FILTER 16 POSITIVE CRANKCASE VENTILATION 16 SPECIFICATIONS 7 TOOLS 21 FIGURE 1 — Engine Code Location The letters are coded as follows: Comp. Code CID. Carb, Ratio H 3 8a) N 0 8S To further identify the engine by external inspection, the cubic inch die placement is cast into the cylinder Block on both banks between the first ‘ond second core plug location. Engines bullt for sole in California ‘re pointed red, cl others are painted a in the machining of cylinder blocks cond crankshofts, tis sometimes neces: sary to machine the cylinder bores to 010” oversize, and the crankshaft main beoring journals or connecting rod journals to .010" undersae. These The letter contained in the code engines have a code stamped adjacent The Engine Code is locoted on © identifies the engine by cuble inch to the Engine Code on the tag attached ‘og whichis cttached tothe right bank displacement, carburetor type ond to the right bonk cylinder head cover. cylinder head cover (Fig. 1) compression rato, code is used. 18-2 The letters ore decoded os follows: Single letter “8” .... Cyl. bore 010" ‘Oversize Single letter “M” .... Main bearings 010" Undersize Single letter “P’ .... Connecting Rod bearings O10" Undersize Double letters “PM” .... Main and connecting tod bearings 010" Undersize Single letter “C" .... Camshaft block bores 010” Oversize DIAGNOSIS GUIDE Conditions and Probable Causes ‘Cannot Crank Engine Electrical System Trace circuits for faulty electrical nits. Coolant Leak into Cylinder Remove spork plugs to check for coolant in cylinders. Crank with plugs removed. Cylinder heads must bbe removed to chack gaskets, block, ‘ond head for the source of coolant eck. If permanent ont-freeze ‘entered engine, complete disassem- ‘by will have to be eccomplished, Mechanical Seizure Recondition Engine Will Cronk Normally but Will Not Star Ignition System ‘Check spark plugs and secondary revit energy evcilable ot spark plugs. Fuel System Check carburetor for fuel supply ond tir horn for choke condition. If water 's present, clean cut and substitute © known good supply of fuel. Ignition or Valve Timing (Check ignition and valve timing, Engine Rough Running ot Higher Speeds Ignition System Spork log gap ond heot ronge. Ignition timing. Distributor contrite. gal ond voevem odvanes unis. Coil Polarity. V-8 ENGINE 304.360 Cubie Inch Displacement Fuel System Improper fuel mixtures Fuel Induction System Severe air leaks into intake system. Sticky valves, Inocrect valve lift Engine Will Not Respond to Fest Positive Opening of Throttle Fuel System Corburetor accelerating circuits, Im proper fuel. Throttle linkage. Fuel Induction System Restrictions ond dirty ole cleaner. Carbon build-up on floor of intake manifold Ignition System Coll capacity ond polarity. Spork plug condition, gap, ond heat range, ignition timing. Distributor condition. Exhoust Sysiem Bock pressure ond leckage into the intake system. Stuck heat control valve, Engine Storts and Runs for ‘Short Periods Only Fuel System Check fuel pump ond fuel lines from fuel tonk for intermittent or constant restricting material or de- fect. Ignition System ‘Check for leaky condenser end coil secondary. Check for foulty distribu tor contocts, ignition resistonce wire, ignition switch, and all connecting wires including bettery connections. Induction System ‘Check oir leaks which may be too severe after choke enrichment is re- duced. Exhoust System ond heat riser ‘Check exhaust system for restrictions. Engine Runs but Misses ot Low Speed Only Feel System ‘Check for dirty possoges ond jets in the idle cicuit. Ignition System Check spork plog heat range and gp. Induction System Check for intoke manifold cir leaks. Check for cir leoks from units con= nected to intoke menifold, such as poner brokes and cutomatic trans Valves Check for poor valve seating. Engine Runs but Misses ot All Speeds Fuel System Dirt in carburetor oF woter in the fuel system. Ignition System, Spark plugs, wiring, eapeciter, coll, ‘ond ignition system wiring. Ignition ‘switch or ignition resistance wire. Valves Poor valve seating — sticking valves Cooling System ‘Coolant leak into intake sections or oylinders Comshaft ‘Worn labes en camshaft. Engine Rough Runring ot Low Speeds Jgniton System Spark plug gop ond heat rang Secondary system wiring, distribu. tor points or eapector. Fuel Systm Idle ereus dity. Choke sticking. Air Teak below carburetor, Idle mixture just. Cooling Sysom Coolant system lecks into. intake valve port or cylinder Velves Paar valve seating Exhoust System Exhaust leaks into intoke possages Exhoust back pressure. Engine Power Not Up to Normal Volves Valves not seoting properly. Net timed propery. Rings Rings worn, broken, not seating, Fuel System ‘it cleaner restricted. Power mixture not proper. Ignition System all capacity, polarity, and distribu. tor point spacing. Ignition timing. Exhous System Restriction causing back pressure, Cooling System. ‘Thermostat not permitting proper ‘operating temperature Engine resistance, bearing end pis- ton fit for oil clearance. Rolling Resistance of Cor Brakes dragging. Soft tires. Wheel ligament. Wheel bearings. Clutch fr fronsmision slippage. ENGINE REMOVAL ‘The engine is removed without the transmission and bell housing. (On the Commando, Wagoneer and Truck, the hood must be removed. Mark the hinge locations ot the hood ponel for cligrment during installation Remove the hood from the hinges. Remove the cir cleaner assembly. Drain the cooling system ond dis- connect the upper ond lower radiator hoses. IF equipped with automatic tronsmission, disconnect the cooler lines from the radiator. NOTE: If vehicle is equipped with o ‘odiator shroud, it is necessary to sep ‘arate the shroud from the radiator 19 feciltate removal and installation of the todiotor ond engine fan Remove the radioter. Remove the engine fan, IF so equipped, remove the power steering pump ond bracket ossembly cond the drive belt from the engine ond ploce aside, Do not disconnect the ower steering hoses. If equipped with ir conditioning, turn both service volves clockwise to the front sected postion, Bleed the com- pressor refrigerant chorge by slowly loosening the service valve fitings. Dis- connect the condenser ond evoporoter lines from the compressor. Disconnect the receiver outlet at the disconnect coupling. Remove the condenser and receiver assembly. (On C1-5/C1-8 ond Commando re move the battery and tray. ‘On the Wogoneer and Truck, re move the chorcool conister from the Frewell Disconnect oll wites, lines, linkege cond hoses which are connected to the engine. IF equipped with ovtomotic trans: mission, disconnect the transmission filler tube brocket from the right cyin- der head, Do not remove the filler tobe from the transmission, Remove both engine front support cushion to frome retoining nuts, Support the weight of the engine with ¢ lifting device. (On C1.5/C1.6 ond Commando, re: V-8 ENGINE 904-360 Cubic Inch Displacement ‘move the transfer case shit lever boot, floor mat (if so equipped) ond trons: Remove the upper bolts securing the transmission bell housing to the engine ‘edopter plate on vehicles equipped with automatic transmission. if equipped with manual transmission, remove the upper bolts securing the clutch housing to the engine. Disconnect the exhaust pipes ot the ‘exhaust manifolds and support bracket. Remove the starter motor. Suppo the transmission with @ oor jock, If equipped with automatic transe mission, remove the two engine odop- ter plate inspection covers. Mark the ‘ossombled postion of the converter ond flex plote end remove the converter to flex plote cop screws. Re- move the remaining bolts securing the tronsmission bell housing to the engine edopter plote, IF equipped with monval tronsmise sion, remove the clutch housing lower cover and the remoining belts securing the clutch housing tothe engine. Remove the engine by pulling up- ward and forward, NOTE: If equipped with power brokes, core must be token to avoid damaging the power unit while remov- ing the engine. ENGINE INSTALLATION Lower the engine slowly into the engine compartment and clign with the transmission bell housing (automatic transmission) or clutch houting (manual transmission). On manual transmission, make certain the clutch shaft is cligned properly with the splines of the eluteh driven plete, Install the tronsmission bell housing 0 engine adapter plate bolts (auto- matic transmission) or the clutch hour ing to engine bolts (manval transmis. sion) Tighton the bolts to the specified torque. Remove the floor jack which was used fo support the tronsmission. If equipped with automatic trane mission, lign the marks previously made on the converter and flex plate, Install the converer to flex pote cop screws ond tighten to the specified torque. Install the two engine adapter plate Inspection covers (outomatie transmis- 18-3 sion) or the clutch housing lower cover (rmonval transmission Install the storter meter. Lower the engine onto the frome -upports, remove the lifting device and insll the front support cushion re- faining nuts. Tighten the nuts to the specified torque, Connect the exhaust pipes ot the exhaust manifolds ond support bracket, Hf disconnected, connect the trons- mission filler tube bracket to the right cylinder head. If removed, install the charcoal con- ister tothe firewall If removed, install the bottery ond troy. Connect all wires, lines, linkoge ond hoses which ware previously discon- rected from the engine. If removed, install the cir condition- ing condenser ond receiver assembly. Connect the receiver outlet to the dis. connect coupling, Connect the con- denser and evaporator lines to the compressor. Purge the compressor of cir as outlined in the “AIR CONDI- TIONING" section, CAUTION: Both service valves must ‘be open before the air conditioning syste it operated. If removed, install the power steer. ing pump and bracket cssombly and the drive bel, tighten the belt 10 the specified tension, Install the engine fon ond tighten the reteining bolts to the specified torque. Install the radiotor and connect the upper ond lower hoses. IF equipped with outomatie trenemision, connect the cooler lines, Fill the cooling system to the speci- fed level, Install the air cleaner assembly. Stor the engine. Check ll con- nections for leaks. Stop the engine. | removed, install ond align the hood essembly. |f removed, Install the transmission cccess cover, floor mat ond transfer cate shift lever boot. ENGINE MOUNTING Resilient rubber mounting cushions suppor the engine ond transmission at three points, A cushion is located ot ‘each side on the center line of the engine with the reor supported by @ 1B—4 ccuthion between the transmission ex: tension housing ond the engine rear support crossmember Removal or replacement of ony ‘cushion moy be occomplished by sup potting the weight of the engine or fronsmission at the oreo of the cush- ion (Fig, 21 INTAKE MANIFOLD The cast iron intake manifold is de- signed to completely enclose and seal the toppet oreo between the two cylinder heods. The intake monifeld contains coolant passoges, @ cronkcase ventilotor passage, exhaust crossover passage ond induction system passages to uniformly distribute the fuel ond oir mixture to the combustion chamber of each cylinder. A one piece metal gos ket is used 10 secl the intake mani {old to the cylinder heads end block. It also serves os an cll splosh baffle. The left bore(s) of the carburetor supply fuel-cir mixture through pos- soges in the intoke manifold to. num- bers 1, 7, 4 ond 6 cylinder intoke pots, The right bore supplies 3, 5, 2 ‘ond 8. Removal Removal of the intake manifold re- quires draining the coolant from the radiator core and disconnecting the tached components from the mani= fold os required Instollotion When installing the intake manifold, alwoys ue © new goskst ond seals. The moting surfaces must be clean cond free of burrs. Asply “Perfect Seat” Compound, Port Number 8990973, to both sides of the metal gosker ond the rubber tend seols. Position the gosket in ploce ‘ond align the two locators at the rear of the gosket into the loccting holes in the rear of the cylinder hecds. Hold the gosker in ploce ot the recr while aligning the front locators. Install the two end seals ond opply "Perfect Seal” to the seal ends, Install the in- toke morifold end tighten the bolts ceverly tothe specified torque, CYLINDER HEAD AND GASKET ‘After thoroughly cleaning the gos- V-8 ENGINE 304.360 Cubic Ineh Displacement FIGURE 2 — Engine Front Mounting — Typical All Series ket surface of the block ond cylinder CAUTION: De net opply sealing heed, inspect each for @ smooth end compound en head ond block eurfocoe fot surface with o straight edge. or allow seoler to enter cylinder. Either surface must not hove more : ne" The cylinder head cop screws must ‘hon 008" moximum, 002" In 6° be ightaned in two stop following the 001" in 1” out of fotness. “he cylinder block hos two locating “O4veNE® Oulined in Figure 3. dowels on each bank to assis in align CAUTION: The threcds of the bolts ing the cylinder head ond gasket dur- must be wire brushed priar to installa ing installation tion a: dit will oft the torque reod- NOTE: The 304 CID engine utilizes "9% ‘an cluminum coated embossed steel Iniiolly tighten the screws evenly to ‘gasket end the 360 CID engine utilizes 80 Foot Pounds, then tighten to the fon oluminum cooled laminated steel specified torque. Refer to the Speci. ‘and asbeztot gasket. Neither type ges: cotions poges, ket requires retorqueing. Apply ¢ thin even coat of “Perfect ROCKS ARM ASSEHBLY’ Seal” Sealing Compound, or equiva- Individvelly mounted rocker arms lent to both sides of the cylinder head consisting of @ rocker orm retaining gaskets. stud, rocker orm pivot ball, rocker The gasket is marked “TOP.” form, and retaining nut operate each ® g® dep ©pD ® FIGURE 3 — Cylinder Head Bolt Torque Tightening Sequence Chart ca valve os shown in Figure 8, The rocker orm retaining studs are threcded into the cylinder head. The threads are designed to cause an inter- ference ft; therefore, care must be token that roplecement studs are in- stalled until the hexagon head is fush with the cylinder heed ond then tight. ‘ened to the specified torque, IMPORTANT: Prior to installing rocker form studs the threads must be lub cated with high pressure or Molyaizul fide grease Port No, 6992356. The push rods ore hollow ond serve 5 cil galleries to lubricate each in- dividvel rocker arm assembly. Prior to Insallotion, the push rods should be leaned thoroughly and inspected for weer and deposits which moy restrict the flow of ell tothe rocker arm assem. blies. CAUTION: All volve train compo ‘ents must be replaced in their original locations ond operating positions. (Fig. 4) The push rods also serve os guides to mointoin correct rocker orm to valve om relationship, therefore, o pattern fn the push rods, where they contact the cylinder heed, i normal ‘When installing the rocker arm re taining stud nuts, #t i important that they are bottomed ond tightened to the specified torque. Lubrication t9 each indvidvel rocker form assembly is supplied by the cor responding hydraulic valve toppet ig. 5) ‘A metering system located in each toppet consists of © stepped lower surface on the push rod cap thet con- tocts @ fat plate cousing a restriction The restriction meters the amount of cil flow through the push rod cop, hallow push rod and the upper valve train components A loss of lubrication to the rocker V-8 ENGINE 304.360 Cubie Inch Displacement orm assembly could be coued by @ restricted or plugged push rod or 0 defective hydraulic topper \rieation Supply fo Push Red FIGURE 5 — Hydraulic Teppet Wdentificetion| VALVES Velve Springs Whenever valve springs ore re moved, they should be tested accord. ing 10 specticaions. Use Valve Soring Teser Tool C647 and replocs oll spring not within speceatons Fig. 8) FIGURE 6 — Valve Spring Testor C67 The valve spring retainer assembly serves the purpose of holding the valve cond spring together. The hal conical shaped volve locks con be removed ofter compressing the spring, a oo FIGURE 4 — Valve Train Components in Operational Order — One Bank Shown 18-5 CAUTION: Do not over comoress the valve springs at domage 10 the oil deflector moy occur. It Is not necessary to remove the gylinder head in order to remove o valve spring. Remove the spark plug from the cylinder thet requires @ valve spring replacement ond insert a 14 nm, threod size edepter. NOTE: The adopter con be mode from the body of & spork plug from which the porcelain hae been removed cond on ir hose connection threaded inte the body ofthe sparkplug Maintain cir pressure cbove 90 PS! inthe cylinder while the valve spring is Boing removed. The air pressure will hold the valve egainst the valve sect $0 that the valve lock and the Upper retainer can be removed (Fig 8). IMPORTANT: The velve springs must be installed with the close coiled end focing the cylinder head. Velve Refacing The intoke volves ore faced too 29° angle and the exhaust valves to 0 414° angle. Volves may be refaced until romaining margin ie downto "as": then the valve must be replaced The valve stom tip con be resurfaced ‘ond rechamfered when worn. How: lever, never remove more than 010”. Correct end incorrect valve refacing is shown in Figure 10. Refoce the valve seats to the follow. ing specifications: Intake ses eeese +. 30° Exhoust : + 45° Volve Seat Width Intake. Exhaust 2. (040"-.060" Norrowing stones should be used to ebioin the proper seot widths when required, Control seat run-out to © maximum ‘of 0025". (Fig. 11) The vale stem to guide clearance 1s 001" to .008” for Both intake ond coxhovst volves. Volve stem to guide clearance may bbe checked by two common methods, FIGURE 7 — Valve Arrangement FIGURE 8 — Valve Spring Removal and Installation with Tool J-22534 fone is by meosuring the vale sem ‘ond guide. The valve stem con be measured with @ caliper micrometer fond the guide meosured with a call broted pilot supplied with valve grind- ing equipment or by tool companies By subtrocting the diometer of the valve stem from the size of the pilot selected to snugly ft inthe valve guide, the oil clecronce can be computed. NOTE: The exhaust valve stem is tapered .0005"-001" with its diometer being smaller o the valve head. Valve guide clearance may elso be checked by using © diol indicator t0 meczure the loteral movement of the valve stem with the voe installed in is guide and of the valve seat (Figure 1, V-8 ENGINE 304-360 Cubic Inch Displacement eshowrt ae FIGURE 9 — Valve, Push Rod, ond Toppet Assembly Sequence alee Marin No Margin FIGURE 10 — Correct Valve Refacing FIGURE 11 — Checking Volve Seat Runout FIGURE 12 — Checking Valve Stem to Guide Clearance The valve guides ore on integral port of the cylinder head and cre not replaceable. Therefore, when the stom to guide cleorance is excessive, the valve guides must be reamed to the next larger size s0 that proper clearance can be ob- tained. Oversize service valves ore available in .003", .015" ond 030" The following oversize valve guide reamers may be used. 46042-1003" C3430 ois” 6347 1930" IMPORTANT: Valve guides must be reomed in steps. Storting withthe .003 (OS. reamer and progressing tothe size required, Hydraulic Valve Tappets The hydraulic volve topper consists of @ body, plunger, plunger return spring, check valve ossembly, meter- ing disc, plunger cap, ond lock ring (Fig. 13) The toppet operates in @ guide bore fond receives oil under pressure from the adjoining oil gallery. FIGURE 13 — Hydraulic Toppet ‘Assembly (Typical) When the toppet is on the heel of the cam lobe, the plunger return spring Indexes on oil hele undercut in the plunger and ollows the oil supply fo be odmitted through the body. Oil under pressure flows body through the check valve ossem- bbly mointcining the toppet fully charged (Fig. 14). This cycle of opero- tion eccurs when the toppet leaks of some oll during the normal volve ‘opening events. Contact with the com lobe causes toppet body movement, closing the check valve and tronsmit= ting “zero-lash” movement of the push rod to open the intake or exhoust vole. NOTE: Oi! under pressure in the plunger also flows through the meter- ing disc, plunger cop, ond hollow push rod to the rocker orm assembly. ‘The valve toppets should be cleaned fond serviced ot time of engine over- haul or whenever excessive noise exists When removing the tappets they rust be kept in on order that will en- sure replacement in thelr respective operoting bores. Keep each hydraulic toppet component group by itself dur- ing dscssembly os all components are V-8 ENGINE 304-960 Cubie Inch Displacement N74 Chersing Crete aah Down Cyle (Wake loved) (aie Open FIGURE 14 — Hydraulic Tappet Operation Cycle select fited in manufacturing. Only complete teppet assemblies ore sup- plied for service replacements, ‘The hydraulic toppet components should be cleaned ino solvent to re- move all varnish or gum deposits, A visual inspection of each tappet 's necessary, This inspection should in- clude inspecting for signs of seufing fon the barrel and face of the toppet. Each toppet face should be inspected for wear as shown in Figure 1S. If # toppet face is concave the correspond: Ing lobe on the camshaft is worn, ond the replacement of the comshait and toppers ie necessary. FIGURE 15 — Checking Teppet Face for Concave Wear 18-7 After clegning end inspecting the toppet must be “leak-dowa" tested to ensure its "zero-lash” operating ability. Valve Topper Test Oil; J-5286 should ‘bo used for this tee Figure 16 illustrates. Tool 45790 used to occurotely test toppet “leak down’ by filling the body with Valve Toppet Test Oil, J5286 ond then in- stalling the plunger return spring, plunger ossembly, metering disc, ond plunger ep. Do not install snap ring fortes Place @ .312".313" diameter boll bearing in the plunger cap. Ploce the tester push rod on the ball bearing. ‘Adjust the tester gauge on the stort position ond ellow the weighted orm 10 “eck down” toppet FIGURE 16 — Testing Volve Toppet “"Leak-Down' with 15790 Ifthe toppet leaks down rapidly or collopses immedistely, it must be re- pleced with « complote new toppet fossembly. The normal tappet will take ‘opproximetely 20-110 seconds to "leak-dows using Velve Toppet Test Oil, 4.5286 with © 50 Ib. locd, travel of 125". After testing toppets, they should be pre-lubricated ond assem bled in the engine without on cil charge. They will normally chorge themselves in 3 to 8 minutes of engine ration. IMPORTANT: Prelubvicole now com- shofl, toppets ond valve froin compo- nests with Engine Oil Supplement, and pour remainder of contents into crank cose. The EOS. must remain in the engine for ot last 1000 miles and need ‘ot be drained until the next oil change interval, 18-8 Toppet Noise A loud clicking noise is usvally the result of the plunger stuck below its ‘operating position or a check valve held open. A light clicking noize ot idle is uswolly the result of excessive “leak down’ caused by wear or slight leak ‘age ct the check valve ond its sect. ‘An intermittent noise isthe result of ditto chips stopping the check valve ‘action or @ leck of cil flow into the body. A general toppet noise is, in most cases, due to a lack of oil volume, pressure or oration A clicking noise, upen sterting the engine, reducing in level ond disap- peering after @ short period of time 's norm. This noise is due to @ alight cil leok-down condition caused by valve spring pressure exerted on the toppets Com Lift Com lift is o function of comshat lobe dimensions Com lift may be checked with the use of @ dial indicator instlled on the end of the push rod (Fig. 17) FIGURE 17 — Installation of Die! Indicator for Checking Valve Timing or Cam Lit To check cam lit, ramove the rocker ‘orm ossembly and install o dial indi- cotor in position, A piece of rubber tubing may be used to secure the dial Indicator plunger to the push rod. Rotote the cranksheft until the com lobe bese circle (push rod down) is under the valve toppet. Set the dial Indicator ot ero ond rotate the crank- shoft to © point where maximum up. ‘ward movement of the push rod occurs. Read the travel ct the dial indicator. Refer to Specifcotions for correct di- mensions. Y-8 ENGINE 904-360 Cubie Inch Displacement ‘An excess of minus .006" from the specified dimensions indicates 6 defec- TIMING CHAIN COVER ‘The timing chain cover is 0 die cast- Ing incorporating on cil zeal at the vibration damper hub. The cronkshaft front oll seal is in tolled from the back side of the cover, therefore, it is necessary to re- move the cover when replacement of the seal is required. Prior to removing the cover, drain the cocling system and remove lower radiator hose and by-pass hose from cover. Remove distributor, fuel pump, clternotor drive belts, fon ond hub cssembly, accessory dtive pulley ond vibration domper using J-21791 Puller. Fig. 35). NOTE: I is not necessary to discon- ect power steering hose: or discharge the cir conditioning system if $0 ‘equipped. Remove the units from theit ‘mounting locations and place aside. Remove the two front oil pon bolts fond the 8, *Yke" hexagon head bolts retaining the cover to cylinder block Remove the cover by pulling forword antl free of the locating dowel pins Remove the original seal. Cleon the seal bore and gasket surface of the Prior to insollotion of the replace- ment seal, place « light film of “Per- fect Seat” or equivalent to the outer surface and « film of “Lubriplate” or ‘equivelent on the seal lips, Timing Chain Cover Ol Seal Drive the seal into cover bore with Seal Installer Tool 4-22533 until sec! Contacts outer lange of cover (Fig. 19). FIGURE 19 — Instolling Timing CChain Cover Oil Seal with J-22533 Prior to installation of the cover, re- move the lower dowel pin from the cylinder block IMPORTANT: The dowel pin is re- quired for correct cover lignment ond must be either reused or @ replacement dowel installed alter the cover is in position Using © sharp knife or rozor blode, cut the ell pan gosket flush with the gylinder block on both sides of the oil pan, FIGURE 18 — Discssembled View. Timing Chain Cover Assembly Cut corresponding pieces of gosket from the replocemert oil pan gosket set. Cement the gasket 10 the cover. Install the replacement front “Neo. rene” oil pan seal into the cover and clign the cork gasket tobs with the pon seal. Apply @ strip of “Permatex 322” or equivalent to both cut-off oil pan goskels ot the oil pan to cylinder block location. Place the cover into position, install the oil pon bolts into the cover. NOTE: The 8, *Je® cover bolts ore of diferont lengths and must be inealled in the some location from which they wore eriginally removed. Tighten evenly and slowly until cover cligns with the upper dowel. The cover should now be in the correct position Install the lower dowel through the cover and deve dowel into correspond. 9 hole in the cylinder block. Install the cover to cylinder bleck bole. Tighten to the specified torque. ‘Adjust ignition timing to specifica. tion, check engine for oll or coolant leaks. CAMSHAFT IDENTIFICATION Comshalts have no paint markings ‘except for those installed in California engines. The California camshafis are identified by blue paint marke between the number 4 and 5 camshaft becrings, ‘Camshaft and Bearings The comshott is supported by five seel-shelled, Babbit-lined beorings which hove been pressed into the Bleck and line reomed. The comehatt beorings are step bored, being larger ct the front bearing thon at the rear 10 permit easy removal and instollo- tion of the camshaft. All camshoft beorings ere lubricated under pres The oll lubrication is supplied through connecting drilled passages from the right bank tappet oil gollery. Comshoft il clearence is 001" 10 003", CComshaft cam heels should not run- cut over 001" on bose circle when gouged between two adjacent cam. shaft bearings Camshaft End Ploy Comshatt end ploy is meintoined by V-8 ENGINE 204-360 Cubie Inch Displacement the load placed on the camshaft by the cil pump and distributor drive gear. The helical cut of the gecr holds the camshaft sprocket thrust fece against the cylinder block foce. Therefore, camshaft end play is zer0 during en- sine operation. Camshaft Removal Disconneet battery cable, Disconnect transmission cooler lines ct radiator if so equipped. Drain radiator ond both banks of the cylinder block Remove lower hose at radiater, by: pass hose ot pump, thermostat housing fond radiator. Remove distributer, wires, and coll from menifold Remove intake manifold os on os sembly. Remove cylinder head covers, rocker forms, and push rods Remove hydraulic valve toppets Refer to “Hydraulic Toppers.” NOTE: It is not necessory fo dizcone rect power steering hoses er discharge the sir conditioning system if 30 equipped. Remove the units rom their mounting locations and place exe. Remove fon and hub assembly, fuel pump, ond heater hose ot water pump. Remove cltemctor ond bracket os con assembly; move aside, do not die eeonnect wiring Remove crankshaft pulley ond damper, ond lower radiator hose ot woter pump, Remove timing choin cover, a torcil pump drive geor, fuel pump ‘eccentrie, sprockets ond chain, (On Ch5/CI-S and Commando, re- move the hood catch support. Remove camshaft carefully to pre- vent domoge to comshaft bearings ‘When assembling, refer to "Timing Chain Cover" for timing chain and cover insolation procedure. ‘Adjust belt tension to specifications, fill cacling system to correct level and check for possible leaks, IMPORTANT; Pro-lubricote new com- shaft, toppats and valve troin compo- rents with Engine Oil Supplement, ond pour remainder of contents into cronk- cose. The EOS. must remain in the en- gine for ot leat! 1000 miles and need 18-9 ‘ot be removed until the next ol chenge interval. Valve Timing The correct valve timing is estab- Ished by the ‘elation between the sprocket on the camshaft ond the sprocket on the crankshaft, To obtain the correct vse timing, index the “O” marks on camshaft end cronkshatt sprockets on a line drown vericelly through the center line of each shaft (Fig. 20) FIGURE 20 — Properly installed Timing Chain Assembly To check the assembly, rotate the crankshaft until the timing marke on camshaft sprocket is on 0 horizontal | line ot the 3 e‘clock postion, Begin count of pins with the pin thot aligns directly ocross from comshott sprocket timing mack. There should be 20 pins down to the crankshaft sprocket timing mark, The crankshaft sprocket timing rmork must be between the twentieth ‘ond twenty-first pins. (Fig. 21) To make an external check of valve timing, remove the cylinder head cov- ers ond spark plugs, Crank the engine until No, 6 piston is on TDC. on com- pression stroke. This places No. I piston ‘on T.D.C, on the exhaust stroke valve ‘overlap position. Rotate the crankshaft counterclockwise 90° (viewed from front). | 18-10 FIGURE 21 — Link Count Position Install dial indicator on the No. 1 Intake volve rocker arm push rod end. Set dial indicator to zero. Cronk the engine slowly in the direction of rotation (clockwise) until the dial indi ator reads .020", ot this point, the rrilled timing mark on the vibration domper should be in line with the TDC. er zero marking on the timing chain cover. If the mark is more than "from TDC in ether direction, remove the i ing chain cover ond inspect timing hain instllation, A.wemn timing chain will adversely ‘offect vale timing. If the choin dex fects more than 4", it should be re- placed. (lL PAN REMOVAL Remove starter. Drain cl, remove pon, PISTONS. Aluminum clloy “Autothermic” Pis- tons, steel reinforced for strength ond controlled exponsion cre used, The ring belt crea provides for three piston rings, two compression and one oil con- trol ring above the piston pin. The pistons are removed from the top of cylinder bore efter removing ring ridge. ‘The piston pin boss is “ofzet” from the piston centerline to place it nearer V-8 ENGINE 304-360 Cubie Inch Displacement the thrust side of the pion. To ine sure proper installation of the piston in the bore, notches ore cast in the piston top. These notches must face 0 the front of the engine. istons can be identified by measur- ing the piston diameter, which differs in eoth case. However, the pistons can be more readily identified by the Jeep port number, which is stamped ‘on the outside of the piston skirts Piston Fit Pistons are fitted to their respective bores by measuring the inside diom- ter ofthe cylinder bore and the diam- eter of the piston, Pistons are com ground and, there- fore must be measured ot right an- gles and ot the centerline tothe piston pin os shown in Figure 22. ing 420" Otome SER te ond tod some seer 3339" Diameter 3329" Sed Croow 2420" Ocomtar ‘SGRE tar ond Groowe |__ 3495" Diameter E25" Sed Coors acne Paton be ‘Thr Ave fr Fiing FIGURE 22 — Piston Measurements The difference between bore diam. eter and piston diameter dimensions is the piston to bore clearance. The piston to bore clearance specifi- cations are listed on the Specifications. Poses. Piston Pins The piston pins ore a press fit (2000 Ibs) into the connecting red, thus re- quiring no locking device. The piston pin Is removed with a a piston pin remover end an arbor press. Use Too! 4.21872, ‘The piston is placed on the remover support s0 that the pin will enter the support when pressed out with the piloted driver (Fig. 23) 3 Site i Taare FIGURE 23 — Removing or Installing Piston Pin J-21872 Shown To install the piston pin, ploce the piston pin pilot in the support ond in- sett piston ond connecting rod, This aligns the piston ond connecting rod Piston pin bores, Press the piston pin Into the connecting rod and piston as sembly until the lower pilot enters the support and the index mark on the pilot is located ot the lower edge of the gauge window. At this point, the connecting rod is centered on the piston pin. A plus or minus Ya” is cllowed for centering the piston pin 12 connecting rod. The piston pin to piston pin bore dlearanee is 0003" to .0005" at room tompercture. When fitting the pin, with all pans dry and free of nicks and burrs, the pin must not support its weight in a vertical position over as entire length in either of the bores Cylinder Bores Inspect cylinder bores for scoring, ‘oper, and out of round, The cylinder bores are checked with on inside mi- crometer or telescope gauge from the top to the bottom for taper and from parallel to the connecting rod journals to right angles to the connecting rod Fpurnols for out of round. If cylinder toper does not exceed 005" and out of round does not ex: ved .003", the cylinder bore may be frued by honing Prior to fitting pistons, the trued bores must be measured for size. This ameter measurement should be token Die" from the top of the cylinder bere, PISTON RINGS Checking Ring Side Clearance Before ossombling the rings to the piston, carbon must be cleaned from all ring grooves. The oil drain open ings in the oil ring grooves ond pin bess must olio be cleared. Care must be exercized not to remove matal from the ring grooves since thet will change the depth; nor from the lands since thot will change the ring groove clear- ‘once ond destroy ring to land secting. Side clearence between lond ond piston ring should be os listed on the ‘Specifications poges. Rall the ring around the groove in which tis t0 operate. it must fit freely ot all points (Fig. 24). FIGURE 24 — Checking Ring Side Clearance Checking Ring Gop Clearance Piston ring gop or joint clearance is measured ot the bottom of the eylin- der near the end of the ring travel V-8 ENGINE 304-360 Cubic Inch Displacement cree (Fig. 25). To square the ring in the bore for checking joint clearance, piloce the ring in the bore. Then with fon inverted piston, push the ring down near the lower end of the ring trovel oreo. FIGURE 25 — Checking Ring Gop Clearance When other thon standard ring sizes 1 used, rings should be individually fitted to their respective bores to obtain the specified gop clearance, Ring Installation Removal of gleze from the cylinder wall for quicker ring seating can be ‘accomplished by various methods. When an expanding type hone is used, do not use more than ten strokes (each stroke down ond return) to reeandition 2 cylinder wall Successful ring installation depends upon cleanliness during the honing ‘operation or when handling ports, The engine bearings and lubrication sys tem must be protected from abrasives. Rigid type hones are not to be used to remove cylinder glaze as there is bways @ slight omount of toper in gylinder walls cfter the engine hos been in sorvice. ‘After removing the cylinder gloze, install the rings on the pistons, Install the oil control rings first. Compression rings ore marked to designate top of ring. Typical compression ring mork- Inge ere thown in Figure 26, BR RA FIGURE 26 — Typical Piston Ring Markings 18-11 Compression rings must be installed fon the pistons with @ ing intaling tool to. prevent distortion ond ring breakage (Fig. 27) FIGURE 27 — Installing Compression Rings Ring Gop Positioning Prior t0 installing the piston ond connecting rod ossomblies into the en- gine, the piston ring gaps are to be forranged so that the 1 compression ring is 180° from the 3:2 compression ring gop. The cil control ring spacer expander gap ie to be installed ot least 90° from the 22 compression ring gop. The oll contral rail gops cre to be instolled 90° from the expander .g9p with ct least 30° between exch rail gop (Fig. 28), Crlnder Number — Qutbeord Suet Hola Inboord FIGURE 28 — Piston Ring Sequence 1B=12 Y-8 ENGINE 304-360 Cubic Inch Displacement CONNECTING RODS Connecting Rod Alignment the op fe torque specctions to compress the gauge. Remove the bear. The connecting rods ore stomped Whenever new rings are installed for bartany SaliSeae the veut cre With the cylinder numbers in which or piston pins ere replaced, its neces- 2, C0P ond calibrate the width of th Plesigoge wih the tele rsa thy er ene Te nnbur oe S10 age he clan che Rigag® wth he itd opposite the squirt holes ond face connecting rods ond pistons, os assem- the outside of the cylinder in which lies, to ensure true operation in the tayo bas oyna Soe Tha comeing rod aut tle nM rads wl coi ssn cited tuciehe Siniesee gaemautac enema aoe Bet cea Rosceche re Mim cowering cd tit i cro feud Ue egecad e iwinkewiecss Sas bearing cap (Fig. 29). FIGURE 31 — Checking Bearing Connecting Rod Bearings Clearance with Plastigage i ech Sesme ts jonni esl egper Nc Te win onfr den Dae ace ees Lr bets wc Buses, neon sae es i cmeeceie Eees se ee el Peis Sh bere tant, saad os mm To obtoin this select ft, the vse of ard, should always be instolled in the witcecly tl weet ccd te, seal spon peste rosa oe, itn er ing ad, CAUTION, Nee lo cercig wou 10. identify bearing insert sizes os '00 & CoP fo odust bearing cleo Zom't’ he CANEING HS aterte the Coneciog tod eng HOUR 27 —comesing od BREN ran onNES pa caters eres Nanton ond Squrtutacston Sacer Steet sam nr Chm the donee the amare a sits te tig cilend GEE ea Meee ET apo hee cc ek i Se ed i clear US mate teeth aed Som Se E teael eee eer the front of the engine (Fig. 28). Cylin Specifications pages. der munber thous ford the at- «CAUTION. Never use. bering i Se of he eyndr wich hey ore get Na ni , eles "ON Thegam OP SF Checking Connecting Rod ‘The cylinders are numbered from . Journal Diameter Using a front to rear 1,3,5,7 in the left bonk Exomp! Micrometer 288 in he rg bk Cones _— Pe a tho comedy toh ere mauied Upped. Upper ole garage te pide side by side on eoch connecting rod Lawer—001" US. Lower—oo2" us. jamie leumel omer, the fellow. janpol Sas doseace nce oak tha chy may eo te he € feeler gouge es shown in Figure 30 Connecing rod beorings ore ave. fauest bearing Age ble in pairs from service in stondard, (OMEN) $9 arte ot the specified olf or" US, 002" US, DIO" US, oak ous To determine the amount of bearing CRANKSHAFT ciecrocs ples lcs of Platigngs The crenakit ls exunerveiyied ‘on the bearing cop insert. Then tighten end balanced independently. CONNECTING ROD BEARING FITTING CHART [_ Diometer OF Upper Color [tower | Color Rod Journal Bearing Code | Bearing | Code 2.0955"2.0948" Stendard | Yellow | Standard | Yellow 2.094872.0941" Stondord | Yellow | 00'S. | Black FIGURE 20 — Checking Connecting 2.0941"-2.0984" or"US. | Block | oor"us. | Black Rod Side Clearance (20557-2.0848" OPUS, Red | o10"us. | Red There ore five main beorings ond four connecting rod journals. The end thrust is controlled by the number three moin bearing The rear main bearing cil seal Is protected from excessive oil by o slinger which i mochined os part of the eronkshaft ‘The component parts of the crank: shot osembly ore individually bal: ‘onced, and then the complete assembly is bolenced 8 ¢ unit, IMPORTANT: On ovtomatic transmis: son equipped engines, the torque con- verter and converter fexplate must be ‘marked priar 10 removal and instelled inthis position upon ossembly Service replacement dampers, eranke shatts, flywheels, torque converters, explotes ond clutch components are balanced individually ond, therefore, moy be replaced without rebalancing the complete ossembly, Crankshaft Main Bearings Main bearings are of the precision type having © steel back with o sin- tered copper lead alloy beoring mo- terial Each beoring is selec ft to the main bearing journal to obtain the desired ‘operating clearance. To obtcin this select ft, the uso of individually sized upper and lower bearing inserts is necessary. In preduetion, color coding is used to identify bearing insert sizes os shown in the CRANKSHAFT BEARING FITTING CHART. When required, two different sizes fore used in pairs, Therefore, it is pos sible to have a standard bearing insert fond © .001” US. bearing inser used 08 6 pair. CAUTION: Never use beoring ine V-8 ENGINE 304-360 Cubie Inch Displacement serts with greater thon 001" diference in sizo in pois Exomple: Correct Incorrect Upper—Std. Upper—Std. Lower=001" US. Lower—002" US, Mein bearings are available in pairs from service in standard, .001” US., 002" US., .010" US, ond 012" US. ‘The correct undersize and/or stond- ‘ord bearing inserts should be installed to cbtoin the specified bearing clear- ‘The bearing insert, nearest to stond= ‘rd, should clwoys be installed in the upper location. CAUTION: Never fle @ main bearing cop to adjust bearing cleoronce. The main bearing journal diameters core listed on the Specifications pages. To reploce the upper half of o becr- ing, remove the bearing cop of the becring to be replaced, Then loosen oll of the other bearing caps ond in- sett @ small pin about ¥4" long in the crankshaft oil hole, The head of this pin should be large enough so that it will not fall into the oll hole, yet thin- rer than the thickness of the beoring. With the pin in ploce, rotate the shaft so thet the upper beoring insert will rotote in the direction of the lo- tongue on the bearing Crankshaft Main Bearing Clearance Main bearing clearance may be ac- curctely checked by the use of Plost- 090. NOTE: whon checking becring cleor- cence, with the engine in such © position that the beoring cops support. the weight of the cronkshalt ond Aywheel, CRANKSHAFT BEARING FITTING CHART Diameter OF Upper ‘Color | tower | Color Main Journal Bearing Code | Bearing | Code 27489" 27484" Stendard__| Yellow | Stondard | Yellow 27484"27679" ‘Stondard | Yellow | 001" US. | Block 2779-2767 orus. | Block | oor~us. | Block 27a E2746" oovus. | Black | o0z"us | Red 27389-27386" O1OUS. | Red | O10" US. | Groen 18-13 keep oll the main bearings tight exceot the one being checked. Support the weight of the cronkshatt with a jack. Remove the besting cap ond wipe the oil from the bearing inser Place @ piace of Plastigage across the full with of the bearing insert Install the bearing cap ond tighten to the specified torque. Then remove the becring cop and with the gradu. ted scale, which is printed on the plastigage envelope, measure the Width of the flattened Plastigage ot is widest point. The number within the gradvotion indicates the clearance in thousandths of an inch (Fig. 22). Instll the proper size bering inserts to bring the clearance to specications. FIGURE 32 — Checking Main Bearing Clearance With Plastigage Checking Main Bearing Journal Using a Micrometer If @ micrometer is used to determine journal diameter, the CRANKSHAFT BEARING FITTING CHART may be used f0 selec the correct bearing ine serts (upper ond lower) to arrive of the specified oll clearance. Crankshaft End Ploy The crankshot end play is conrlled by the No. 3 main bearing inser which ie fanged fer thi purpose. IMPORTANT: When replacing the No. 3 beering inserts pry the crank toh fore ond aft 10 align the thrust faces of tho Bearings. Tighten cap bots 10 the specified torque To check this dleorance, atoch dial indicator to the cronkease ond Pry the shaft fore ond alt with Ecrowdrver (ig. 3) REAR MAIN BEARING OIL SEALS The rear main beating area utilizes V-8 ENGINE 304-360 Cubie inch Displacement cylinder block; coat the end of each ‘gasket tongue, joint of the tongue ond front neoprene seal with “Permatex” #2 or equivalent before instolling, Coat cil pan reer seal with soop. Place into the recess of the rear main ‘cop moking certain that the seal is firmly and evenly seated, Install the oil pan, VIBRATION DAMPER The vibration damper is balanced independently and then rebalanced os part of the complete crankshaft os sembly Do not attempt to duplicate balance holes present in original damper when installing o replocement damper. Figure 35 illustrates — vibration sae demper removal with Tool J-21791 FIGURE 33 — Checking Crankshaft End Play = Sr, [poten all remaining main bearing Sa Pp With © Bross deft and hammer, top the upper seal until sufiient seal

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