AMC Rambler 1965 Operating manual

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INDEX
Technicql
Service
Mqnuql
, A-ericqn Motors Corporolion
iAulomolive Technicol Service
n 3280 South Clement Avenue
AM-65.4004
Milwoukee, Wisconsin 5320 1
TITHOGRAPHED IN U.S.A.
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ENGINE - 6 CYLINDER - L-Heod ond O.H.V;
195.6 Cubic Inch Displocement (
ENGINE - 6 CYLINDER _ O.H.V
232 Cul>ic lnch Displocement
COOLING
ELECTRICAL
FUEL _ CARBURETION _ EXHAUST (
(
TUNE-UP
(
CLUTCH
(
TRANSMISSION
(
OVERDRIVE
FLASH-O MATIC TRANSMISSION (
SHIFTING
BRAKES AND WHEELS _ HUBS AND DRUM (
REAR AXLE.PROPELLER SHAFT
FRONT SUSPENSION-STEERING GEAR (
(
WEATHER EYE
ALL SEASON AIR CONDITIONING (
HEAVY DUTY AND FLEET EQUIPMENT
BODY
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FOREWORD
The service proceduies ond specificotions contoined
in this monuol ore outlined for the I965 Rombler Amer-
icon Series.
The speciflcotions ond oc!lustments contoined in this
monuol were in effect ot the time of publicotion. Amer-
icon Motors reserves the right to discontinue models.
chonge speciflcotions or design, without notice or incur-
ring obligotion.
The brond nomes mentioned in this monuol ore to
be construed os ond/or their equivolent. They ore not
intended os odvertising moteriol but os specified type. {
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1ENGINE
I95.6 Cubic lnch L-Heqd qnd Overheqd Vqlve
aPoge
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.10
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- - :-., ?:MOVAL
- . ::.. 3ASKET INSTALLATION
: -' l:; -::D AND GASKET
:: _. _: ::',., SHAFT ASSEMBLY
- - '. : -: :- AND BEARINGS
PISTON PINS
CONNECTING RODS
CRANKSHAFT
REAR MAIN BEARING OIL SEALS . ..
VIBRATION DAMPER
STARTER RING GEAR
CLUTCH SHAFT PILOT BEARING . . .
LUBRICATION SYSTEM
OIL FILTER
POSITIVE CRANKCASE VENTILATION
SPECIFICATIONS . . .
DIAGNOSIS
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6 Cylinder L-Heod Engine
ENGINE IDENTIFICATION
he engine code number is locoted
:- c nochined surfoce on the upper
,e{: front corner of the dngine block.
The letter "A" included os port of
'Le number identifies the engine os the
'?5 6 Cu ln. 6 Cylinder L-Heod; letter
C" os the 195.6 Cu. ln. Overheod
' c '.e Engine (Fig. l). FIGURE 1 - Engine Code Number
Locolion - L-Heod Shown
6 Cylinder Overheod Volve Engine
Letter ldentificotion, Size of
Bore, Moin Beorings ond
Connecting Rod Beorings
ln the mochining of cylinder blocks
ond cronkshofts, it is sometimes neces-
sory to mochine the cylinder bores to
.0 10" oversize, ond the cronkshof;
moin beoring iournols or cronk pins tc
.010" undersize.
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These engines ore morked with o
three letter code, stomped below the
engine code number. The letters ore
decoded os follows'
First Letter Size of the Bore
Second Letter . . Size of the Moin
Beorings
Third Letter . Size of the Connecting
Rod Beorings
ENGINE
I95.6 Cubic lnch L-Heod ond Overheod Volve
compressor ond brocket ossembly ond
condensei.
Disconnect oll wiring, tubing, hoses
ond linkoge, which ore connected to
the body.
Disconnect exhoust pipe f rom ex-
houst monifold.
Support engine with lifting fixture.
Remove reor crossmember.
Disconnect front motor support
cushions from the engine.
Move engine forword ond upword
wh'ile supporting the propeller shoft.
ENGINE MOUNTING
Resilient rubber mounting cushions
support the engine ond tronsmission ot
three points. A cushion is locoted ot
eoch side on the center line of the en-
gine, with the reor supported by o
cushion between the tronsmission ex-
tension housing ond the reor engine
support crossmember. Removol or re-
plocement of ony cushion moy be oc-
complished by supporting the weight
of the engine or tronsmission ot the
oreo of the cushion.
Letter "4"
Letter "B"
Letter "C"
.. .. . Stondord
.0I 0" Undersize
, .010" Oversize
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FIGURE 2 - Engine Mounting
--O o
ENGINE REMOVAL
Remoyp hood ossembly; mork hinge
locotionrbn hood ponel to oid in os-
sembly.
Remove the bottery.
Droin the cooling system, engine ond
tronsmission lubricont.
Remove oir cleoner ond rodiotor
core. Where so equipped, remove the
power steering pump, oir conditioning
CYLINDER HEAD AND GASKET
Whenever o L-Heod engine cylinder
heod is removed, inspect the studs to
moke sure thot they ore tight in the en-
gine block. lf the studs ore removed,
they should be seoled with compound
upon replocement.
After thoroughly cleoning the top
surfoce of the block ond bottom sur-
foce of o cylinder heod, inspect eoch
for smooth flot surfoces with o stroight
edge.
Apply AM i?er{ect Seol" Seoling
Compound or equivolent to both sides
of the cylinder heod gosket.
Core must be used when plocing the
gosket over the studs on o L-Heod en-
gine to see thot the threods of the studs
do not domoge the gosket.
To focilitote Overheod Volve cyl-
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inder heod instollotion, o poir of guide
pins moy be fobricoted from cylinder
hecC cop screws by cutting off the
hexogon heod ond cutting o screw
i're. slot in the end.
- g"fen the cop screws or stud nuts
:? 'c 62 Foot Pounds of torque with o
-..'trJe wrench, following the sequence
s^:.r'n in Figures 3 ond 4. ln oll coses
-echeck lo torque specificotions with
=1."
ot normol operoting tempero-
Front
FIGURE3 * L Heod EngineCylinder
Heod Torque Tightening Sequence
1-17/32" 3-l 1-17 /32"
Stud Nut Type
FIGURE 4 - Overheod Volve Engine
Cylinder Heod Torque Tightening
Sequence ond Bolt Length Chort
ROCKER ARM AND SHAFT
ASSEMBLY
OverheodVolve Engine
The entire rocker orm ond volve os-
sembly is lubricoted by oil, under pres-
sure from the oil pressure gollery, di-
'ected through the opening provided
r rhe cylinder heod, then through the
:':-t rocker orm shoft".s0pport block.
- e 'ocker orm shoft is of one piece
:: ^s"r:ction. Therefore, the complete
,-:t' c-d rocker orm ossembly moy be
':-': . eC ofter the hold down bolts ore
":'':.:i
--: -::ker orms ore retoined on the
, -:'- . . r snop ring, thrust woshers,
r-l ..:.: ".:sher on eoch end of the
:rr:' =;,': 5 rllustrotes the ossembly
secr.e':3:i'he rocker orms on one
enc of':e s.c{i.
The:::<e- crm shoft must be in-
:': led '... 'i the rocker orm lubricoting
3 :c es locoted to the bottom of the
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ENGINE
195.6 Cubic lnch L-Heod ond Overheod Volve
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FIGURE 5 - Rocker Arm Shoft Assembly Sequence
(One End Shown)
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VALVES
Volve Adiustments
For peok performonce ond economy,
the volve cleoronce should be odiusted
every 8,000 to 12,000 miles (Figs.
6,7, 8 ond 9).
FIGURE 6 - L-Heod Volve Adiustment
(Cold Setting - lntoke, .016";
Exhoust, .01 8")
I nto ke
Exhoust
FIGURET-L-HeodVolve
Arrongement
FIGURE 8 - Overheod Volve
Adiustment with Engine "Hot" ond
Running, lntoke .012" - Exhoust.0l6"
Exhousl
FIGURE 9 - Overheod Volve
Arrongement
Volve Springs
Whenever volve springs ore re-
moved, they should be tested occord-
ing to the specificotions listed below
using o volve spring tester (Fig. I0).
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FIGURE l0 - Volve Spring Tester
Any spring not within the following
specificotions should be reploced.
L-Heod
Free Length
Volve Open
Volve Closed
25lzz"
75-82Lbs. @ 17|rc"
37-41 Lbs. @ 1y4"
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4
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Front
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Overheod Volve
Free Length 23h"
Volve Open I 15- l25 Lbs. @ 1 ?,r,r"
Volve Closed 65-70 Lbs. 62 lt3 rr"
It is not necessory to remove the c'vl-

inder heod in order to remove o volve
spring on the Overheod Volve Engine.
First remove ihe spork plug from the
cylinder thot requires o volve spring
replocement ond insert o 14 mm.
threod size odopter.
NOIE: Ihis odopler con be mode
from the body of o spork plug
from which the porceloin hos been
removed ond on oir hose connec-
tion threoded into the body of the
spork plug.
Mointoin oir pressure obove 90 Lbs.
in the cylinder while the volve spring is
being removed. The oir pressure will
hold the volve ogoinst the volve seot
so thot the volve lock ond the upper
retoiner con be removed (Fig. 11).
J_21931
FIGURE I I - Overheod Volve
Spring Removol
)-21073
FIGURE 12 - lnstolling Volve Lock -
l-Heod Engine
Volve Spring Position
When instolling volve springs, it is
importont thot the closely coiled end of
the spring be instolled toword the cyl-
inder heod os shown in Figure 13.
ENGINE
I95.6 Cubic lnch L-Heod ond Overheod Volve
Iocole
Close
Coils To
Cylinder
Heod
FIGURE l3 - Volve Spring Position
Volve Morgin
Correcl Volve Focing
lncorrecl Volve Focing
FIGURE l6 - Correct Volve Refocing
The L-Heod Engine exhoust ond
intoke volve seot ongle is 45o ond the
foce ongle is 44o The volve seot width
should be .078"-.093" for proper cool-
ing of the volve heods.
The Overheod Volve Engine exhoust
ond intoke volve seot ongle is 45o. The
exhoust foce ongle is 44tfo ond intoke
44o fhe volve seot width should be
.060"-,075" for proper cooling of the
volve heods.
lf the volve seot is too wide, it
should be norrowed by using the
proper ongle stones of l5o ot the top
ond 75" ot the bottom of the volve
seot.
Check the volve seot runout with on
occurote diol indicotor. The runout
should not exceed .0025" totol in-
dicotor reoding rFig. \7).
FIGURE I7 - Checking Volve Seot
Runout (Overheod Volve Design
Shown)
Volve Stem to Guide Cleoronce
Volve stem to guide cleoronce con
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FIGURE I4 - L-Heod Volve Assembly
Sequence
FIGURE l5 - Overheod Volve
Assembly Sequence
CAUI/ON: On the L-Heod Engine
moke sure that the springs ore
seofed in the counter bores of lhe
cylinder block to prevent excessive
weor on the valve slems ond vo/ve
guides.
Volve Refocing
It is importont when volves ore re-
foced thot lust enough metol be
ground off to cleon up the foce.
A heovy volve morgin oids in the
dissipotion of heot ond helps ovoid
volve worpoge (Fig. l6).
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ce a'a:.a: a ,' one of two common
r-e'!::: -a .l !e siem con be meos-
u-:r ,'. -- tr :r ce. micrometer ond
--: r, :: -::s',;.eC with colibroted
s -:: ied with volve grinding
=-- :: by tool componies. By
- -3 :-e d ometer of volve stem
rreosrred from the size of pilot se-
leaed ro snugly fit in volve guide, the
oil cleoronce con be computed.
A simple method for Overheod
Volne design is to diol indicote the
loterol movement, represenling volve
guide cleoronce, of the volve stem
with volve instolled in its guide os
*rown in Figure 18. The volve must be
ofi its seot.
FIGURE '18 - Checking Volve Guide
to Slem Cleoronce on Overheod
Volve Design
The L-Heod Engine volve stem to
guide cleoronce is .0025" to .004",
ond the Overheod Volve Engine,
.00.]5" to.004" intoke volves ond
.442" to.004" exhoust volves.
Reploce the guides when these cleor-
rnces ore exceeded. Check volve stem
: icmeters ond guides to determine
,.^e'her or not proper stem to guide
: ::'once exists.
' c re Stem Diometers ore:
ENGINE
195.6 Cubic lnch L-Heod ond Overheod Volve
ond instoll the L-Heod volve guides
(Fis. 19).
Ai time of instollotion, drive the
guides flush with the guide bore open-
ing in the block. The guides must be
reomed ofter instollotion.
)-21751+
FIGURE 20 - lnstolling Overheod
Volve Guides
Com Lift
L-Heod
Com lift is o function of the com
shoft lobe dimensions.
Com lifts moy be checked with the
use of o diol indicotor instolled on
the top of the volve os shown in Fig-
vre 21. The engine is shown without
studs for illustrotion purposes only. Re-
movol of studs is not necessory for
this operotion.
FIGURE 2l - Checking L-Heod
Com Lift
Volve losh should be odiusted to
zero before ottempting io check com
lobe lift.
Roiote the engine until com lobe
being checked hos the bosic circle
(opposite nose of com) under the volve
toppet. Set diol indicotor to zero. Ro-
tote engine to o point where moximum
upword movement of the volve occurs.
Reod the diol indicotor trovel. lt
should be .340" lor oll com lobes, in-
toke ond exhoust.
NOfE, frue volve lift is o resu/f
of com /obe dimension minus yolye
Iosh.
A defecttve com will resu/f in ex-
cess of minus .006" from the spe-
cified dimension.
Overheod Volve
Com lift moy be checked witL' '-=
use of o diol indicotor instoliec c- '::
of the volve rocker orm ca ,:- -:
screw (Fig. 22).
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.3407"-.3412"
.3407"-.34)2"
o lve a 11tt
.J+ I -.J+2
.340s"-.3415"
r,: --: --- !'L::,sl vo/ve sfem is
'tr::-:: ,---: :-'i' with its diom-
e':' :: -g .--: e- io lhe volve
::_
3. - 112q-O l s used lo remove
o
NOIE, Irue volve ltft is o '::
FIGURE '19 - lnstolling L-Heod
Volve Guide
The Overheod volve guides ore re-
moved with Tool J-l429-0\. Use Tool
J-2\7 54 for instollotion.
The guide must be instolled so thot
the top is locoted 23/e:" obove the sur-
foce of the lower spring seot.
Tool J-2 1754 when used ond driven
until bottomed estoblishes the required
23/a::" guide height (Fig. 20).
Volve guides musi be reomed ofler
insto llotion.

6
FIGURE 22 - Checking Overheod
Volve Com Lift
the cam lobe dimension, multi-
plied by lhe rocker orm rotio,
minus volve losh.
A defecfive com will resu/t in ex-
cess of minus .006" from lhe spe-
cilied dimensions.
To check for com lift the volve losh
should be odiusted to zero before ot-
tempting to check com lobe lift.
Rotote the engine until com lobe
being checked hos the bosic circle
(opposite nose of com) under the volve
toppet. Set diol indicotor to zero. Ro-
tote engine to o point where moximum
upword movement of push rod occurs.
Reod the diol indicotor trovel. lt
should be .262" for the intoke volve
com lobe, .263" exhoust volve com
lobe.
Volve Timing
Volve timing is determined by the
relotion between the sprocket on the
comshoft ond the sprocket on the
cronkshoft.
When instolling new ports, line up
the morked teeth, odiocent to eoch
other, on o center line drown through
the center of the comshoft ond the cen-
ter of the cronkshoft (Fig. 23).
FIGURE 23 - Ploce Morked Teeth
on Cenler Line When lnstolling
Sprockets ond Choin
ENGINE
I95.6 Cubic lnch L-Heod ond Overheod Volve
Before instolling the timing choin
cover, check the correct instollotion of
the timing choin; locote the morked
tooth on the comshoft sprocket ot op-
proximotely the one o'clock position.
This should ploce the morked tooth of
the cronkshoft sprocket where it be-
gins to mesh with the choin (Fig. 24).
FIGURE 24 - Correct Timing Choin
lnstollotion
Count the number of links between the
morked teeth of both sprockets. This
should be 9tl links or 19 pins. Eoch
link consists of two pins.
Volve timing moy olso be inspected
by locoting the No. 6 piston on T.D.C.
in flring position. Then set volves on
the No, 1 cylinder to .003" cleoronce.
Slowly rock the cronkshoft bock ond
forth.
lf timing is set properly, the exhoust
volve should open before the D.C.
mork on the vibrotion domper lines up
with the pointer. Note this distonce.
The intoke volve should open on equol
distonce o{ter the D.C. mork posses the
pointer.
lnloke Opens T.D.C Exhousl
Closes
Volve losh
..le"
lntqke Closes Exhoust Opens
FIGURE 25 - L-Heod Volve Timing
Diogrom
TIMING CHAIN COVER
The timing choin cover is provided
ko#n-r0 I
T.D.C
lntoke Opens Exhoust
Closes
Yolve losh
.o225"
lnloke Closes Exhoust Opens
FIGURE 26 - Overheod Volve Timing
Diogrom
with o rubber seol ond oil slinger to
prevent the leokoge of oil oround the
front cronkshoft pulley hub (Fig. 27).
Slinger
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FIGURE 27 -Iiming Choin Cover
To prevent domoge to this seol, it is
importont thot the cover be properly
oligned when instolling the vibrotion
domper. This is occomplished by leov-
ing the cover to block screws loose
until the vibrotion domper hos been
portiolly instolled. Then tighten the
cover screws.
The replocemert of 'he oil seol moy
be occomplished wrthoul the removol
of the timing choin cover by using
Tools J-9256 Remover ond J-9'l63 ln-
sto ller.
Figures 28 ond 29 show the engine
FIGURE 28 - Removing Timing Choin
Cover Oil Seol wirh )-9256
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1 20 30',
100 30
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; 3URE 29 - lnstolling Oil Seol
with J-9163
-:--:.ed {or illustrotion purposes only.
:- t me of instollotion opply o light
::: cotion of seoler to the outer diom-
=-:r of the oil seol, ond lubricote the
.nner diometer.
CAMSHAFT AND BEARINGS
The comshoft is supported by four
steel shelled, bobbitt-lined beorings
which hove been pressed into the block
ond line-reomed. The comshoft beor-
ings ore step-bored, being lorger ot
the front beoring thon ot the reor, to
permit eosy removol ond instollotion
of the comshoft. All comshoft beorings
ore lubricoted under pressure through
drilled golleries in the cylinder block.
Comshoft End Ploy
The cleoronce between the comshoft
thrust plote ond the comshoft sprocket
should be .004" to .008".
OIL PAN REMOVAL
Remove the front springs, ond then
support the weight of the front of the
acr.
Support the front of the engine from
::cve the engine comportmeni.
?enrove the engine support cushion
:-:ching nuts ot the engine mounting
ENGINE
I95.6 Cubic lnch l-Heod ond Overheod Volve
Droin the engine oil, turn cronkshoft
so number one piston is on uPstroke,
ond remove the oil pon.
OIL PAN GASKET
INSTALLATION
Cleon the gosket surf oces of the
cylinder block, timing choin cover
spocer, ond oil pon.
lnspect the oil pon gosket surfoce
for distortion ot the bolt holes; if nec-
essory peen the offected oreos to moin-
toin o smooth surfoce.
Apply gosket cement to the block,
timing choin spocer plote, ond the cor-
responding gosket surfoces.
lnstoll the oil pon reor rubber seol
into the mochined groove of the reor
moin com.
IIT4PORTANT: THE SEAL MUST BE
INSTALLED SO THAT THE RUB-
BER SIDE SEAL PORTION IS
PRESSED FIRMLY BETWEEN THE
CAP AND BLOCK. DO NOT USE
CEMENT ON THIS SEAL.
Position the oil pon gosket on the
cylinder block moking sure thot the
tongue portion of the cork gosket en-
goges into the groove of the rubber
pon seol.
Position the front gosket of the oil
pon on the spocer plote.
Position the oil pon to the block, in-
stolling o bolt on eoch side finger tight.
lnstoll the oil pon bolts which en-
ter through the timing choin cover;
tighten 8 to II Foot Pounds torque.
Instoll the remoining bolts; tighten
from the center in eoch direction 8 to
'I I Foot Pounds torque.
PISTONS
The piston ls o three ring type utiliz-
ing two compression rings ond o three
piece oil control ring.
The pistons ore ground, hoving o
lorger diometer meosured ot right on-
gles to the piston pin hole ond contoin
o steel strut for structurol strength ond
controlled exponsion. When operoting
temperoture is reoched, the piston ex-
ponds to flt the bore uniformlY ond
provide correct operoting cleoronce ot
oll points.
When instolling the piston ond con-
necting rod ossemblies, core must be
token to locote them correctly in the
7
engine block. The pistons ore morked
with o notch on their top perimefer.
They must be instolled with the notch
toword the front of the engine.
Fitting Pistons
Pistons ore fitted so thot eoch piston
will support its own weight in ony por-
tion of the cylinder with oll porls cleon
ond dry. Piston to bore cleoronce is
.0006" to .0012".
Before fitting the pistons, check the
cylinder bores for out of round or
topered condition. This check is mode
with o cylinder gouge or diol indicotor.
lf the bore is found to be out of round
in excess of .004", it should be irued
up by honing (rigid type).
lf cylinder toper exceeds .009", bore
must be trued up ond oversize pistons
ond rings used.
Piston Removol
Piston removol is occomplished from
the top of the engine. However, be-
fore removing the pistons, the ring
ridges in,ihe cylinder bores must be
removedr(Fig. 30).
FIGURE 30 - Ridge Reoming Prior
to Piston Removol
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o
ihe idler orm f rom the
r:- -. - 'Le front susPension cross-
-.^'..-:''cching bolts from the body
:'. '^' :-:ssrnember down to obtoin
...'i^.. t:- : i pon removol. Wood-
:- i.:::- : ::<s r-stolled between the
:':::-:-.3r cr^c ccdY side sill will os-
s:- - -clding ihe crossmember down.
Re,r ove the flywheel dust cover.
Foilure to remove the ridge,ot the
top of the cylinder bore will veiy often
result in piston ring breokoge ond
domoge to the piston groove lond.
oPISTON RINGS
A three ring piston is csej --=-;
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c-e iwo compression rings ond o three
o ece oil control ring.
Before ossembling the rings to the
piston, corbon must be cleoned from
ol ring grooves. The oil droin open-
lngs in the oil ring grooves must be
cleored. Core must be exercised not to
remove metol from the grooves since
this will chonge their depth; or from
the londs, since this will chonge the
ring groove cleoronce ond destroy ring
to lond seoting.
ENGINE
I95.6 Cubic lnch L-Heod ond Overheod Volve
Checking Ring GoP Cleoronce
Piston ring goP or loint cleoronce is
meosured in the bottom of the cylin-
der neor the end of the ring trovel
oreo (Fig.33).
t
2.771"
-L7U"
2.766"
2.756"
Diqmeter 'lst
ond 2nd Groove
Diomeler Third Groove
*r&
.091--8.
.080'\:
FIGURE 3l - Piston Meosurments -
Overheod Volve Piston Design Shown
Checking Ring Groove Cleqronce
Side cleoronce between lond ond
compression rings should be 002" to
.004". Roll the ring oround the groove
in which it is to oPerote. lt must fit
freely ot oll Points (Fig. 32)'
FIGURE 32 - Checking Ring Groove
Cleoronce
^-L-
FIGURE 33 - Checking Ring GoP
Cleqronce
Prior to instolling the Piston ond
connecting rod ossemblies into the en-
gine, the Piston ring goPs ore to be
orronged so thot the lf 'l compression
ring is 'l 80o from the Jf2 compression
ring gop. The oil control ring spocer
"*[ond"t goP is to be instolled ot
Ieost 90o from the ::2 comPression
ring gop. The oil control roil gops ore
to be instolled 90' from the sPocer
gop with ot leost 3Oo between eoch
roil gop.
FIGURE 34 - Gloze Removol
with Exponding TYPe Hone
Service Piston Ring Sets
For service ring replocement, follow
detoiled instructions enclosed in the
ring pockoge.
To squore the ring in the bore for
checking ioint cleoronce, ploce the
ring in the bore. Then, with o Piston'
prih th" ring down neor the lower
end of ring trovel oreo'
The comPression ring goP should be
.010" to .020".
When other thon stondord ring sizes
ore used, rings should be individuolly
fltted to their resPective bores'
Piston Ring lnstollotion
Removol of gloze from the cYlinder
woll for quicker ring seoting con be
occomplished by vorious methods' lf
the exponding tYPe hone, os shown in
Figure 34, is used, do not use more
thLn ten strokes (eoch stroke down
ond return) to recondition o cylinder
woll.
Successful ring instollotion depends
uoon cleonliness in hondling ports ond
while honing the cylinder wolls The
engine beorings ond lubricotion sys-
tem must be protected from obrosives'
Rigid tYPe hones ore not to be used
to remove cylinder gloze os there is
olwoys o slight omount of toPer in
cylinder wolls ofter the engine hos
been in service.
Rings must be instolled on the Pis-
tons with o ring instolling tool to pre-
vent distortion ond ring breokoge'
PISTON PINS
The piston Pins ore o Press fit into
the connecting rod, thus requiring no
locking device.
The piston pin is removed with Piston
Pin Remover J-21872 ond on orbor
oress.
The piston is Ploced on the remover
suooor; J-2187i'1 so thot the pin will
enter the suPPort when Pressed out
with the piloted driver J-2.l872-6 (FiS'
3s).
io instoll the piston pin, ploce the
piston pin pilot in the support o.nd-i1-
sert piston ond connecting rod' This
:lffi ff [:'Jr ;:1,.,"#?'''.ffi;:: €
into the connecting rod ond piston os-
sembly until the lower pilot enters the
.rooort ond the index mork on the
piiot is locoted ot the lower edge of
t
i
I
a
tr
::iilrr:l:{":irr
€
.1 88"
r
n
LI
\

FIGURE 35 - Removing Piston Pins
J-21872-1. At this point, the connecting
rod is centered on the piston pin. A
plus or minus 1/l:" is ollowed for cen-
tering the piston pin to connecting rod.
CAUI/ON: fhe pisfon pin must be
o tight press fil (200A#) into the
connecting rod.
The piston pin to piston pin bore
cleorqnce is .0003" to .0005" ot room
temperoture. When fltting the pin, with
cll ports dry ond free of nicks ond
currs, the pin must not support its
..,,eight in o verticol position over its
=r't re length in either of the bores.
CCNNECTING RODS
--e identi{lcotion knob on the con-
-=:' -g rod (Fig. 36) is instolled to the
t"--' -:t the engine.
ENGINE
195.6 Cubic lnch L-Heod ond Overheod Volve
The notch on the top perimeter of
the piston must be instolled to the front
of the engine.
Alwoys ossemble connecting rod
ond cops with the cylinder locotion
numbers ploced to the comshoft side of
the engine.
Connecting Rod Alignment
Whenever new rings ore instolled or
new piston pins ore reploced, it is nec-
essory to olign the connecting rods
ond pistons os ossemblies to insure true
operotion in the cylinder bore.
Misoligned rods will couse uneven
piston ond ring weor which will result
in oil consumption. The connecting rod
should be inspected for ony twisted or
bent condition os shown in Figures 37
ond 38.
FIGURE 37 - Checking Connecting
Rod Alignment for Twist
Connecting Rod Beorings
The connecting rod beorings ore the
steel-bocked bobbitt-lined precision
type ond ore instolled os poirs in the
connecting rod ond cop.
CAUIIONT Never fi/e o conneci-
ing rod or cop fo odiust beoring
cleoronce.
The cronk pin diometer is 2.0948"-
2.0955".
FIGURE 38 - Checking Connecting
Rod,Alignment for Bend
lf the beoring cleoronce is excessive,
the correct undersize beoring insert
(poir) should be instolled in the con-
necting rod.
The correct connecting rod beoring
cleoronce is .00 1" to .00.l5".
To determine the omount of beoring
cleoronce, ploce o piece of Plostigoge
in the beoring cop os shown in Figure
39. Tighten the cop to torque specifi-
cotions to compress the gouge.
FIGURE 39 - Plostigoge in Ploce
in Beoring Cop
Remove the beoring cop ond coli-
brote the width of the Plostigoge with
the scole furnished os shown in Figure
40.
FIGURE 40 - Meosuring the Width
of the Plostigoge with the Plostigoge
Scole
9t
e
%
O
.,.';.'.- S:rirt Hole
o
I3, :ier Lo:cr on Number to Cqmshofl
FIGURE 36 - Connecting Rod
ldentificolion
-

f-.
l0
Connecting Rod Beoring Cops
It is importont thot the connecting
rod beoring cop bolt nuts be drown
up to the correct torque of 27 to 30
Foot Pounds (dry).
Cronkshoft end thrust is controlled
ot the front moin beoring locotion. End
thrust cleoronce moy be corrected by
the replocement of the front moin
beoring liners. Correct cronkshoft end
thrust is .003" to .007".
The component ports of the cronk-
shoft ossembly ore individuolly bol-
onced, ond then the complete ossem-
bly is dynomicolly bolonced os o unit.
Replocement of flywheel or vibrotion
domper con be occomplished without
reboloncing the complete ossembly.
Cronkshoft Moin Beorings
Moin beorings ore of the precision
type hoving o steel bock with o bob-
bitt Iining. The beorings ore not od-
iustoble. Beoring cops should never be
flled to odiust cleoronce.
When either holf of o beoring re-
quires replocement, o complete set
should be insfolled. To reploce the up-
per holf of o beoring, remove the
beoring cop of the beoring to be re-
ploced. Then loosen oll of the other
beoring cops ond insert o smoll pin
FIGURE 4l - Moin Beoring Cop ldentificotion
ENGINE
195.6 Cubic lnch L-Heod ond Overheod Volve
obovt /2" long in the cronkshoft oil
hole. The heud of this pin should be
lorge enough so thot it will not foll
into the oil hole yet thinner thon the
thickness of the beoring (Fig. 42).
With the pin in ploce, rotote the
shoft so thot the upper holf of the
beoring will rotote in the direction of
ihe locoting tongue on the beoring.
Cronkshoft Moin Beoring
Cleoronce
The stondord cleoronce of .001" to
FIGURE 42 - Removing Moin Beoring
I nsert
.00,l5" con be occurotely checked .by
the use of Plostigoge.
NOIE, When checking bearing
clearonce, with the engine in such
o position that the beoring cops
support the weight of the cronk-
shoft ond flywheel, keep oll moin
beorings tight except ihe one be-
ing checked. Supporf the weight
of the cronkshoft with o jack.
Remove the beoring cop ond wipe
the oil from the beoring insert.
Ploce o piece of Plostigoge ocross
the full width of the beoring insert
(Fis. 39).
lnstoll the beoring cop ond tighten
66 to 70 Fool Pounds torque (dry).
Then remove the beoring cop ond with
the groduoted scole, which is printed
on the Plostigoge envelope, meosure
the width of the flottened Plostigoge
ot its widest point (Fig. 40). The num-
ber within the gr-oduotion indicotes the
cleoronce in thousondths of on inch.
lnstoll the prcper size beoring liners
(inserts) to bring the cleoronce to
stondord.
Moin Beoring Journol
Moin beoring iournols con be meos-
sured without removing the cronkshoft
from the engine block.
There ore vorious gouges for this
use, one of which is shown in Figure 43.
FIGURE 43 - Meosuring Moin
Beoring Journol
To operote this gouge, remove the
moin beoring cop ond ploce the gouge
ogoinst the cronkshoft. Then releose
the plunger so thot it is up ogoinst the
iournol ond lock the odiusting screw
in position. Remove the gouge core-
f ully ond double the micrometer reod-
ing to get the shoft diometer.
Alwoys check both ends of the iour-
nol to note the toper. Then rotote the
shoft 90 degrees ond meosure for out
of round.
The four moin beoring pournol di-
ometers ore 2.4793" to 2.4798". Ihe
cronk pins ore 2.0948" 2.0955".
Moin Beoring Cops
Moin beoring cops ore recessed into
the engine block ond line-reomed.
Therefore, it is not procticol to reploce
them in the field.
t
h
t
CRANKSHAFT
The cronkshoft is supported by four
moin beorings. The moin beoring cops
ore numbered to mointoin correct lo-
cotion. An orrow designotes the for-
word foce (Fig. 4l).
n
tt
U
(.

REAR MAIN BEARING OIL
SEATS
: -..'rnoin beoring cronkshoft
r s :.xrposed fo two hemp pock-
:^: r the block, the other in the
-: i'emp pocking is driven into
: ::e with Tool J-21309 (Fig. 44); ex-
:=ss pocking is cut off flush with the
:trp,
FIGURE 44 - lnstolling Cronkshoft
Oil Seol in Reor Moin Beoring
coP
Prior to ossembling the reor moin
beoring cop to the cylinder block, o
rhin film of AM "Perfect Seol" seoling
compound or equivolent must be op-
plied os illustroted in Figure 45.
FiGURE 45 - Applying Seoler ro Moin
Beoring Cop Prior to Assembly
, , -:' nstolling the upper cronkshoft
: ::: ::cking, the cronkshoft must
: - '=--.:: The upper seol is instolled
- : : - r" -3nner os the pocking in
'^:':r- --;- cop.The pocking is
:-.:- -': :r.e with Tool J-21309
:-r --: :l:.: -c cut flush with the
- r' - ; . -'t:.. .: ':e cop ond cylinder
ENGINE
195.6 Cubic lnch L-Heod ond Overheod Volve
T.D.C. 30
FIGURE 46 - lgnition Timing Morks
FTYWHEEL AND STARTER
RING GEAR
With the exception of the ring geor
os used with the outomotic tronsmis-
sion, which is welded to ond bolonced
os port of the torque converter ossem-
bly, the storter ring geor con be re-
ploced by plocing the flywheel in on
orbor press with steel blocks equolly
spoced oround the geor.
To instoll the storter ring geor, first
heot it to expond the inside diometer
so thot it con be pressed over the fly-
wheel.
CLUTCH SHAFT PILOT BEARING
The pilot beoring for the clutch shoft
is locoted ot the center of the reor end
of the cronkshoft. This is on oil im-
pregnoted bronze beoring. lt is pressed
into the end of the cronkshoft. This
beoring does not require ony lubrico-
tion ofter ossembly. When ossembled
in service, it is odvisoble to ploce o
smoll omount of high melting point
greose on the end of the clutch shoft
os it is instolled into the beoring. Beor-
ings being instolled must be of the
correct size.
LUBRICATION SYSTEM
The lubricotion system is the full
pressure type except to the piston pins.
Pressure is supplied by o geor driv-
en, geor type, positive pressure pump.
I'l
The oil pump (Fig. 47) is mounted
on the outside of the engine block on
the right side.
CAUIION, Alwoys mointain o
tight connecfion bef ween the oil
pump inlet tube ond oil inlet hole
Iocoted on lhe right side ot the
bottom of the cylinder block.
Oil Pressure Relief Volve
The oil pressure relief volve consists
of o plunger, spring, ond retoiner lo-
coted in the oil pump cover.
The oil pressure relief volve is not
od justoble. A setting of 60 pounds
pressure is built into the tension of the
spring (Fig. 4Z).
Lubricotion Circuit
The oil pump through displocement,
couses otmospheric pressure to force
oil from the oil pon reservoir, through
the oil inlet tube ond screen ossembly
into the low pressure side of the oil
PUMP.
The rototing pump geors corry the
oil between the geor teeth ond pump
body to the dischorge or pressure side,
then through the full flow oil fllter to
the moin oil gollery.
The oil pressure relief volve which
mointoins correct pressure under voried
conditions is locoted in the oil pump
cover.
When the oil pressure reoches 60
P.S.l., os determined by the plunger
spring, the resultont force couses the
plunger to move ogoinst the spring.
When the plunger trovels o given dis-
lonce o possoge is uncovered which
reroutes oil bock to the low pressure
side of the pump geors, thus conlrolling
the oil pressure in the moin oil gollery.
Possoges ore drilled from the right
side of the engine through the moin oil
gollery, ot the moin beoring webs in
the cylinder block to eoch of the four
cronkshoft ond comshoft beoring sto-
tions. Oil under pressure through these
possoges lubricotes the cronkshoft
moin beorings ond comshoft beorings.
Oil from the front comshoft beorings rs
metered to the timing choin ossembly,
ond bock to the oil pon below tl'e
f ront moin beoring cop. The drillec
possoges in the cronkshoft direc: c
from the moin beorings to the c.c-<-
pins to lubricote f he conrec' -: -:.:
beorings.
I
e
o
O
I
'' B,qATiCN DAMPER
-: o-ji a- ll-a:: is rci crijs5l-
oble, ond ports connot be serviced
seporotely (Fig. 46).
Tighten vibrotion domper retoining
screw 70 to 80 Foot Pounds torque.
lgnition timing ond T.D.C. morks ore
milled into the vibrotion domper pul-
l"y.

12 ENGINE
195.6 Cubic lnch L-Heod ond Overheod Volve
Filler Adopter
heod to return the oil to the toppet
ond push rod chomber where it lubri-
cotes the push rod seot of the volve
toppets. The oil in the push roo ond
toppet chomber droins bock to the oil
pon through openings in the cylinder
block.
CAUIION' When instolling a new
oil pump, or pump hos been dis-
ossembled, the pump musl be
primed by removing relief volve
plunger and filhng pump with oil.
fhis musl be done before slorling
engine.
OIL FILTER
A full flow oil fllter mounted on the
lower right hond side of the engine is
occessible through the hood opening.
A byposs vo lve incorporoted in the
filter odoptor provides o sofety foctor
in the event the fllter becomes inoper-
otive os o result of dirt or sludge oc-
cumulotion.
Oil filter Removol Tool J-9614 will
focilitote removol ot recommended
mileoge intervols listed in Figure 51.
Apply o thin film of oil to the new
fllter gosket before instollotion.
lnstoll filter until gosket contocts the
seot of the odoptor then lighten se-
curely by hond only.
Operote engine ot fost idle ond
check for leoks.
One odditionol quort of oil is re-
quired when o fllter unit is reploced.
Comshoft
Fronl Moin Beoring
r
It
Filter
I-J
Lock Ring
Geor
Thrust Wosher
Pump Body
Gosket e
Drive Geor
Drive Shoft
ler Shoft
ldler Geor
Y %d"l:*"''"n
Prunser @w Spocer
FIGURE 47 - O't Pump Assembly
lnlel Tube
FIGURE 48 - Intermittent Rocker,Arm
Lubricotion Circuit
I+
Pump Cover t
The connecting rod upper cop sec-
tions ore drilled with o squirt hole
(TOWARD THE CAMSHAFT). These
squirt holes ot low engine R.P.M. sup-
ply lubricotion to the comshoft lobes,
tqppets, oil pump ond distributor drive
geors. Oil throw off from the connect-
ing rod beorings supply lubricotion
to the cylinder wolls, pistons, rings,
ond pins.
oil to the flot mochined surfoce on top,
then to eoch push rod, volve stem ond
spring.
Holes ore provided in the cylinder
Oil Supply to Oil Filter
Oil Supply to Rocker Arm Assembly
t
]
L
Moin Oil Gollery
Overheod Volve Engine
lnlermittent lubricotion to the volve
troin is controlled by metering the flow
by volume through the front comshoft
beoring. This is occomplished by o
groove in the front comshoft iournol
which indexes the moin oil supply to
ihe comshoft beoring to o drilled pos-
soge ot the right front of the cronk-
cose. From this externol opening, the
oil is routed through o fitting ond tube
ossembly through the drilled possoges
in the cylinder heod, front rocker orm
support block ond into the hollow
rocker orm shoft (Fig. 48).
Eoch rocker orm is drilled to convey

I3 I
a
FIGURE 49 - L-Heod Lubricotion System
ENGINE
195.6 Cubic lnch L-Heod ond Overheod Volve
FIGURE 5l - Mileoge Chort
ber is controlled by o metered hole in
the oil filler cop.
NOIE, Ihe cylinder heod cover
on engines eguipped with single
throot corburelor ore nof venfed
lo olmosphere.
Overheod volve engines equipped
with Duol Throot Corburetors ond L-
Heod engines ore equipped with o
flow-volve in the vocuum line con-
nected to the intoke monifold. The
flow volve vories lhe oir flow through
FIGURE 50 - Overheod Volve Lubricotion System
e Q) Q) (-)
t
the cronkcose ond engine volve chom-
ber (Fig. 54 ond 55)
The system will work effectively os
long os oll component ports ore cleon
ond free from sludge ond corbon.
The volve, connecting pipes, hoses,
ond oil filler cop must be inspected ot
intervols not exceeding 8,000 miles. lt
moy be necessory to inspect ond
cleon the system more frequently un-
der odverse driving ond/ or weother
conditions.
To check ihe operotion of the sys-
tem, the hose connecting the volve
ond volve toppet cover should be dis-
connected. With the engine operoting,
o vocuum should be felt ot the end of
the hose. lf no vocuum is present, lhe
volve ond hoses should be removed
ond couse of restriction determined.
The inner chomber of the volve
should be checked to see thot it con
be moved freely. This moy be occom-
plished by inserting o stiff wire into
the volve body crnd observing whether
or not the plunger con be reodily
moved.
The volve moy be cleoned by sook-
ing in o relioble corburetor cleoning
solution or reploced.
Smoke or vopor from the oil flller
cop indicotes on inoperotive ventilo-
tion system.
FIGURE 52 - Typicol Positive
Cronkcose Ventilotion Flow-Vo lve
POSITIVE CRANKCASE
VENTILATION
Positive cronkcose ventilotion is oc-
complished by utilizing the vocuum
creoted in the intoke monifold to drow
cleon oir through the cronkcose ond
volve chomber.
The cronkcose ventilotion system on
overheod volve engines equipped with
Single Throot Corburetor is connected
to the corburetor oir cleoner. Air flow
through the cronkcose ond volve chom-
ENGINE OIL DRAIN EVERY
4000
MILES
EVERY
2000
MILES
EVERY
1000
MILES
Fovoroble Conditions-
(Over l0 miles overoge
per trip) X
Summer
(Over 32oF. overoge.)
Less thon l0 miles
overoge per trip.
X
Winter
(Below 32"F. overoge)
Less thon l0 miles
overoge per trip.
X
Predominontly Dusty
Driving Conditions. X
Chonge Oil Filter (every 2000
miles in Predominontly Dusty
Driving Conditions.) X
e
j
t.
_L
+Bl

r14
FIGURE 53 - Positive Cronkcose
Venlilotion System - Overheod
Volve - Single Throot Corburetor
TORQUE SPECIFICATIONS
Recommended
Torque in
Description Fool Pounds
Comsho{t Sprocket Screw . .. . 50-55
Comshoft Thrust Plote Screw . . 21-25
Corburetor Hold Down Nuts . . l2-l5
Connecting Rod Bolt Nut ..,.27-30
Cronkshoft Beoring Cop Screw 66-70
Cylinder Heod Cover Screw (OHV) 3-5
Cylinder Heod Cop Screw or
Srud Nur ....58-62
No. of Cylinders
Bore
Stroke
Displocement
Compression Rotio
Broke Horsepower
W/AC Only
Torq uo
W/AC Only
Toxoble Horsepower
Corburetor
Single Throot
Duol Throot
Fuel
ENGINE
I95.6 Cubic lnch L-Heod ond Overheod Volve
FIGURE 54 - Positive Crqnkcose
Ventilotion System - Overheod
Volve - Duol Throot Corburetor
Distributor Clomp Screw ..... 10-15
Exhoust Monifold Clomp Nuts . 20-25
Exhoust Monifold (OHV)
End Flonge Nuts.. .. 8-l0
Center Flonge Nuts . 20-25
Flywheel to Cronkshoft Screw 'l 00-l l0
Fuel Pump Screw . 15-17
lntoke Monifold Cover Screw (OHV)
'ly:" . . 15-20
ll+".,. ....,..8-]l
Oil Pon Screw . ....... 8-1l
Oil Pump Attoching Screw . ... 20-25
SporkPlug ....25-30
ENGINE SPECIFICATIONS
L-Heod
FIGURE 55 - Position Cronkcose
Ventilolion System - L-Heod Engine
Timing Cose Cover
Cop Screw ...8-12
Timing Cose Cover Spocer Screw l5- l7
Engine Side Plote
Stud Nur . . 30-40 lnch Lbs.
Rocker Arm Shoft Support
Screws (OHV) . .... 25-30
Vibrotion Domper Retoining
Screw. ..... 70-80
Woter Pump to Block Screw . . . 8-12
All torque volues ore given in Foot
Pounds unless otherwise specified. All
ports ore ossumed to be dry.
Overheod Volve
8.7,1
12s @ 4200
R.P.M.
r 38 @ 4s00
R.P.M.
180 Lbs. Ft. @
1600 R.P.M.
185 Lbs. Ft. @
1800 R.P.M.
Holley 1909
Corter WCD
e
t
8.0, l
90 ot 3800
R.P.M.
I 60 Lbs. Ft. ot
1600 R.P.M.
6
31r""
411 +/t
i95.6 Cu. ln
23.4
Corter R.B.S
Reg ulor
c
*

\
t
I
?
Volves
lntoke Volve Lift
lntoke Volve Stem
Stondord Diometer
lntoke Volve Foce Angle
lntoke Volve Seot Angle
lntoke Volve Seot Width
lntoke Volve Spring Tension
Free Length
Volve Open
Volve Closed
lntoke Volve Stem to
Guide Cleoronce
lntoke Guide l.D.
Exhoust Volve Lift
Exhoust Volve Stem
Stondord Diometer
Exhoust Volve Foce Angle
Exhoust Volve Seot Angle
Exhoust Volve Seot Width
Exhoust Volve Spring Tension
Free Length
Volve Open
Volve Closed
Exhoust Volve Stem to
Guide Cleoronce
Exhoust Guide l.D.
Volve Timing
lntoke
Opens
Closes
Volve Adiustment
Set Cold
I nto ke
Ex ho ust
At Normol Operoting
Temperoture
lntoke
Exho ust
PISTONS AND RINGS
Piston to Bore Cleoronce
Top Lond
Skirt Top
Skirt Bottom
! stcn Ring Gop Cleoronce
-1-op
l-":rn tSteel Roil)
I .--- r g Side Cleoronce
:3
l:-:- S'eel Roil)
I .- - I ^--.i"^ ROd
P s-c- r ^ ro Pistcn
ENGINE
195.6 Cubic lnch L-Heod ond Overheod Volve
ENGINE SPECIFICATIONS
L-Heod
340"
.3407" - .3412" 440
45"
.078" - .093"
25laz"
75-82 Lbs. ot
17|rc"
37-41 Lbs. ot
131+"
.0025" - .004"
3433" -.3443"
.340"
.3407" - .3412"
440 45"
.078" - .093"
251.32"
75-82 Lbs. ot
17hc"
37-41 Lbs. ot
13I+"
.002s" - .004"
.3433" - .3443"
15
Overheod Volve
262"
.34l|" - .342"
060" - .07s"
z"/g
I l5-125 Lbs. ot
171rc"
65-70 Lbs. ot
1rBlrc"
.0015"-.004"
.343s" - .344s"
.263"
3405" - .3415"
441J2"
.060" -.075"
2Ys"
I l5-.l25 Lbs. ot
I 7/ro
65-70 Lbs.
l73lr."
.002" - .004"
3435" - .3445"
ot
10" B.T.D.C.
58" A.B.D.C. 2440
Durotion 12" 30'B.T.D.C.
5lo 30'A.B.D.C. 244'
Durotion
.016"
.0.l8"
.012"
.016"
.017" - .019,,
.0006" - .0017"
.4006" -.0012,,
.010" -.020"
.o10" - .020"
.0r 5" - .055"
.002" - .004"
.002" - .004,,
.000"-.005"
Press Fit (2000 Lbs.)
.0003" - .0005" Cleoronce
in Piston Pin Bore ot Room
Temperoture i
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ENGINE
I95.6 Cubic Inch L-Heod ond Overheod Volve
ENGINE SPECIFICATIONS
L-Heod Overheod Volve t
CRANKSHAFT AND BEARINGS
Moin Beoring Diometer
Moin Beoring Cleoronce
Moin Beoring Cop Torque
Cronkshoft End ploy
Cronkshoft End Thrust
Connecting Rod Beoring Diometer
Connecting Rod Beoring Cleoronce
Connecting Rod Cop Torque
Connecting Rod Side Cleoronce
Comshoft
Comshoft End Ploy
Comshoft Beoring
Cleoronce
OIL PUMP AND LUBRICATION
SYSTEM
Oil Pump Type
Normol Oil Pressure
Oil Pressure Releose
Geor to Body Cleoronce
Geor End Cleoronce
: re'
:^; .e Oil RefillCopocity
DIAGNOSIS GUIDE
Conditions qnd
Proboble Couse
Cornot Cronk Engine
i ::-- :cl System
-'::e Circuit for Storting
i::':ce Foulty Electricol Units.
Coclont Leok into Cylinders
ie.-ove Spork plugs to Check for
3::lont in Cylinders. Cronk with
) rgs Removed. Cylinder Heods
'viusf be Removed to Check Goskets,
3lock, ond Heod for o Source of
Coolont Leok. lf permonent Anti-
Freeze Entered Engine, Complete
Disossembly will Hove to be Accom-
p lished.
\/echonicol Seizure
Recondilion.
Engine will Cronk Normolly but will
not Slort
: "ition System
Check Spork plug ond Secondory
Circuit Energy Avoiloble ot Spork
P lug.
Euel System
Check Corburetor for Fuel Supply
ond Air Horn for Choke Condition
2.4793" - 2.4798"
.001 ,, - .001s,,
66-20 Ft. Lbs.
.003,,-.007,,
Front Moin Beoring
2.0948" - 2.095s,,
.001" -.0015,,
27-30 Ft. Lbs.
.005,'- .015"
004" - .008,,
001" - .003,,
Geor
r 3 P.S i :, 600 RPM
60 P S.t
.0c05, _ A025"
.000" - aa4,,
(Geors Abcve Body)
Fu ll F lcw
4 Qts. ^co ACditionol
quorl ,rri+l f lter
chc nge
lf Fuel is Present, Cleon out Fuel ond
Substitute oS Known to be Good Sup-
ply of Fuel. Woter moy Hove En-
tered System.
lgnition or Volve iiniing
_ Check lgnition ond Volve Timing.
Exhoust Sysiem
Check Exhoust System for Severe
.Restriction.
Engine Storts ond Runs for Short
Periods Only
Fuel System
Check Fuel pump ond Fuel Lines
from Fuel Tonk for lntermittent or
Constonl Restricting Mqteriol or De-
fect.
lgnition System
Check for Leoky Condenser ond
Coil .Secondory. Check for Foulty
Distributor Contocts. lgnition Switch,
ond oll Connecting Wires including
Bottery Connections.
lnduction System
Check Air Leoks which moy be too
Severe ofter Choke Enrichment is
Reduced.
Exhoust System
Check Exhoust System for Restric_
tions.
t
(. I
-EF
a
Engine Runs but Mis-Fires ot
Low Speed Only
Fuei S;,:+em
Che:k fc: Dirty Possoges ond Jets
rn'i'3 3i3 Speed Circuit.
lgniticr S,,,s.eo
Check Sc:'< Dlug Hecf Ronge ond
Gop
lnductjcn Si,s-e-
Check io'l-ic<e r,i:rilolci Air Leoks.
Check fc. . . leoks f .om Units Con-
nected lc --oke Mcn;fold, such os
Fuel Pump, Pcwer Brokes, Wind-
shield !',/ioe.s, erc.
Exhoust Syslern
Exhoust System Hot Spot Areos in
Cylinde- Heod for Leokoge of Ex_
houst Gos into lntoke Chombers.
Volves
Check for Poor lntoke Volve Seots
ond Also for lnsufficient Volve Cleor_
once.
'Engine Runs but Misses ot oll Speeds
Fuel System
Dirt in Corburetor or Woter in the
Fuel System.
lgnition System
Spork Plugs, Wiring, Copocitor. Coil,
ond lgnition System Wiring, or lg_
I

nition Switch. Bottery Connections.
Volves
Poor Volve Seoting - Sticking Volves
Cooling System
Coolont Leok into lntoke Sections or
Cylinders.
Comshoft
Worn Lobes on Comshoft.
Engine Rough Running ot Low Speeds
lgnition System
Spork Plug Gop ond Heot Ronge.
Secondory System Wiring. Distribu-
tor Points or Copocitor.
Fuel System
ldle Circuits Dirty. Choke Honging.
Air Leok below Corburetor. ldle
Mixture Adjustment.
lnduction System
Air Leoks into lnduction System.
Cooling System
Coolont System Leoks into lntoke
Volve Port or Cylinder.
Volves
Poor Volve Seot. Volve Adiustments.
Exhoust System
Exhoust Leoks into lntoke Possoges.
Exhoust Bock Pressure.
Engine Power not up to Normol
Volves
Volves Adiusted too Tight. Not Seot-
ing Properly. Nol Timed Properly.
Rings
Rings Worn, Broken, not Seoting.
Oil Viscosity.
Fuel System
Fuel Woshing Cylinder Wolls. Air
Cleoner Restricted. Power Mixture
not Proper.
lgnition System
Coil Copocity, Polority, ond Distrib-
utor Contoct Spocing. lgnition Tim-
ing.
Exhoust System
Restriction Cousing Bock Pressure.
ENGINE
I95.6 Cubic lnch L-Heod ond Overheod Volve
Cooling System
Thermostot not Permitting Proper
Operoting Temperoture.
Cronking Resistonce or Engine
Friction
Beoring ond Piston Ring ond Piston
Fit for Oil Cleoronce.
Rolling Resistonce of Cor
Brokes Drogging. Soft Tires. Wheel
Alignment. Wheel Beorings. Clutch
or Tronsmission Slippoge.
Engine Rough Running ot Higher
Speeds
lgnition Syslem
Spork Plug Gop ond Heot Ronge.
lgnition Timing. Distributor Centrif-
ugol ond Vocuum Advonce Units.
Coil Polority.
Fuel System
lmproper Fuel Mixtures. Cleon Cor-
buretor ond Adiust. Cleon oir Cleon-
er. Distribution.
lnduction System
Severe Air Leoks into lntoke System.
Volves ond Comshoft
Sticky Volves. lncorrect Comshoft
Lift ond Timing,
Cronkshoft ond Components
Unbolonce in Cronkshoft. Too Greot
o Vorionce in Piston or Connecting
Rod Weights.
Cor will not Respond to Fost Positive
Opening of Throttle
Fuel System
Corburetor Acceleroting Circuits. lm-
proper Fuel. Throtlle Linkoge.
Induction System
Restrictions ond Dirty Air Cleoner.
lgnition System
Coil Copocity ond Polority, Spork
Plug Condition, Gop, ond Heol
Ronge. lgnition Timing. Distribution
Condition.
Exhoust Syster
17
Bock Pressures ond Leokoge into the
lntoke System.
Tronsmission Slippoge
See Tronsmission Section for Couses
of Slippoge, etc.
Clutch Slippoge
Pressure Plote Springs Weok. Driven
Clutch Plote Worn.
Poor Fuel Economy
Fuel System
High Fuel Pressure. Corburetor Coli-
brotion. Choke Honging. Pump Pull-
Over.
Leoks ot Fuel Line Connection
Repoir or Reploce os Needed.
Thermostot (Engine Operoting
Temperotures Below Normol)
Check Thermostot.
Cleon or Reploce.
lgnition System
Spork Plug Condition, Gop, ond
Heot Ronge. Secondory Copocity
ond Polority. Distributor Advonce
Mechonism. lgnition Timing.
Volves
Volve Adiustment ond Seoting.
Volve Timing.
lnduction System
,flirty Air Clegner, Restricted P.C.
I Volve. ,:t:'
Exhoust System i.
Restrictions in Exhoust System.
Engine Friction
Piston, Rings, Beorings Fitted too
Tishtly.
Oil Viscosity
Oil too Heovy for Existing Tempero-
tu re.
Rolling Resistonce of Cor
Brokes Drogging. Tires too Soft.
Wheels Out of Alignment. Wheel
Beorings too Tight.
Slippoge in Power Line
Pressure Plote Springs Weok. Driven
Clutch Plote Worn.
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l8 ENGINE
195.6 Cubic lnch L-Heod ond Overheod Volve
r:Er[m
)-21872
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J-9256
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)-21309
J-9 t 63
J-2 1 309
J-8056
J-21931
J-92s6
J-21881
J-9r63
J-9614
J-8056
)-9611
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J-21881
J-21791
)-21073
tuw ilffiF
exryef*Hr "-
J-8520
)-5959-1
ReorMoin Beoring Oil Seol lnstoller
Volve ond Clutch Spring Tester
Volve Spring Remover ond lnstoller (OHV)
Timing Choin Cover Oil Seol Remover
Cylinder Heod Stud Nut Wrench
Timing Choin Cover Oil Seol lnstoller
Oil Filter Removing Tool
M
1t@
J-21751
)-1129-Ol
J-21872 Piston Pin Remover ond lnstoller
J-21073 Volve Keeper lnstolling Tool (L-Heod)
J-21791 Vibrotion Domper Removing Tool
J-8520 Diol lndicotor (0- I " .001 Groduotion)
J-n754 Volve Guide lnstolling Tool (OHV)
J-5959-4 Diol lndicotor Clomp ond Rod
)-\429-01 Volve Guide lnstolling ond Removing Tool (L-Heod)
FIGURE 56-Engine Tools
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Letter No Subiect
TECHN ICAL SERVICE LETTER REFERENCE
Dote Chonges informotion on Poge No
t
:,.: :
S,i":i
rdltli
'ffi )-21931