REMOVAL & INSTALLATION
6 Cylinder Engines
See Figure 1
- Drain the cooling system and crankcase.
- Disconnect the upper radiator hose from the intake manifold and the lower hose from the water pump. On cars with an automatic transmission, disconnect the cooler lines from the radiator.
- Remove the radiator, fan and pulley, and engine drive belts. On models with air conditioning, remove the condenser retaining bolts and move the condenser forward. [cf2]Do not disconnect the refrigerant lines.
- On 170 and 200 cu in. engines, remove the cylinder front cover retaining bolts and front oil pan bolts and gently pry the cover away from the block. On 250 engines, it is necessary to remove the oil pan cover before removing the front cover.
- Remove the crankshaft pulley bolt, then use a puller to remove the vibration damper.
- Place a socket wrench on the crankshaft pulley bolt, and gently rotate the crankshaft in a clockwise direction until all slack is removed from the left side of the timing chain. Scribe a mark on the engine block parallel to the present position of the left side of the chain. Next, turn the crankshaft in a counterclockwise direction to remove all the slack from the right side of the chain. Force the left side of the chain outward with the fingers and measure the distance between the reference point and the present position of the chain. If the distance exceeds 1 / 2 inch, replace the chain and sprockets.
- Crank the engine until the timing marks are aligned as shown in the illustration. Remove the bolt, slide the sprocket and chain forward, and remove them as an assembly.
- Position the sprockets and chain on the engine, making sure that the timing marks are aligned.
- Reinstall the front cover, applying oil resistant sealer to the new gasket.
On 170 and 200 engines, trim away the exposed portion of the old oil pan gasket flush with the front of the engine block. Cut and position the required portion of a new gasket to the oil pan, applying sealer to both sides of it.
- On 250 engines, reinstall the oil pan.
- Install the fan, pulley and belts. Adjust the belt tension.
- Install the radiator, connect the radiator hoses and transmission cooling lines. If equipped with air conditioning, install the condenser.
- Fill the crankcase and cooling system. Start the engine and check for leaks.
See Figures 2 through 19
- Drain the cooling system, remove the air cleaner, disconnect the battery, and remove the oil dipstick.
- Disconnect the radiator hoses and remove the radiator.
- Disconnect the heater hose at the water pump. Slide the water pump bypass hose clamp toward the pump.
- Remove the fan, spacer, pulley, and drive belt.
- Loosen the generator mounting bolts at the generator. Remove the generator support bolt at the water pump. Remove the Thermactor pump from 428 CJ, 429 Super CJ, Boss 302, and Boss 429 engines. Next remove the water pump.
- Remove the pulley from the crankshaft pulley adapter. Remove the cap screw and washer from the front end of the crankshaft. Remove the crankshaft pulley adapter with a puller.
- Disconnect fuel pump outlet line at the pump. Remove fuel pump retaining bolts and lay the pump to the side.
- Remove the front cover attaching bolts. Remove the 2 oil pump bolts. On the 351 C engine, it is necessary to remove the oil pan before the front cover can be removed.
- Remove the crankshaft oil slinger if so equipped.
- Check the timing chain deflection, using the procedure outlined in step six of the six-cylinder cover and chain removal.
- Crank the engine until the sprocket timing marks are aligned as shown in valve timing illustration.
- Remove the crankshaft sprocket cap screw, washers, and fuel pump eccentric. Slide both sprockets and chain forward and off as an assembly.
- Position the sprockets and chain on the camshaft and crankshaft with both timing marks on a centerline. Install the fuel pump eccentric, washers and sprocket attaching bolt. Torque the sprocket attaching bolt to 30-35 ft. lbs.
- Install the crankshaft front oil slinger.
- Clean the front cover and mating surfaces of the old gasket material.
- Coat a new cover gasket with sealer and position it on the block.
On all except 351 C engines, trim away the exposed portion of the oil pan gasket flush with the cylinder block. Cut and position the required portion of a new gasket to the oil pan, applying sealer to both sides of it. On 351 C engines, after installing the cylinder front cover, install the oil pan using a new gasket.
- Install front cover, using a crank-shaft-to-cover alignment tool. Torque the attaching bolts to 12-15 ft. lbs.
- Install fuel pump, and tighten the attaching bolts to 23-28 ft. lbs. Connect the fuel pump outlet tube.
- Install the crankshaft pulley adapter and torque the attaching bolt to 70-90 ft. lbs. Install the crankshaft pulley.
- Install the water pump pulley, drive belt, spacer, and fan.
- Install the generator support bolt at the water pump. Tighten the generator mounting bolts. Adjust the drive belt tension. Install the Thermactor pump if so equipped.
- Install the radiator and connect all coolant and heater hoses. Connect the battery cables.
- Refill and bleed the cooling system.
- Start the engine and operate at fast idle to reach operating temperature.
- Check for leaks, install the air cleaner. Adjust the ignition timing and make all final adjustments.